Rev.15 OilView

Reference Manual
OilView
AMS Suite: Machinery Health Manager
In-Shop Oil Analysis and Laboratory
Information Management System
CSI Part # 97381 Rev. 15
Copyright
2012 by Emerson Process Management.
All rights reserved.
No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into
any language in any form by any means without the written
permission of Emerson Process Management.
Disclaimer
This manual is provided for informational purposes.
EMERSON PROCESS MANAGEMENT MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE. Emerson Process Management
shall not be liable for errors, omissions, or inconsistencies
that may be contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Information in this document
is subject to change without notice and does not represent a
commitment on the part of Emerson Process Management.
The information in this manual is not all-inclusive and
cannot cover all unique situations.
Product Support
Should you have any comments on this documentation or
questions concerning the Agreement on the following
pages, please contact Emerson Process Managements
Product Support Department.
The Americas and Canada
Emerson Process Management
835 Innovation Drive
Knoxville, TN 37932 USA
Phone: 865-675-4274
FAX: 865-218-1416
mhm.custserv@emersonprocess.com
Europe and Middle East
Emerson Process Management
Research Park Inerleuvenlaan 50 Leuven 3001 Belgium
Phone: 32/16/74/.14.71
UK 441516779418
FAX: 32/16/74.14.19
emacust@emersonprocess.com
Asia Pacific
Emerson Process Management Asia Pacific Pte Ltd
1 Pandan Crescent
Singapore 128461
Phone: 65.67708706
FAX: 65.67708006
MHM-TechSupport@AP.EmersonProcess.com
Worldwide Web:
http://www.MHM.AssetWeb.com
AMS Machinery Manager Reference Manual
This document was written, illustrated, and produced by
Emerson Process Managements Engineering Publications
Group on Power Macintosh workstations using Adobe
FrameMaker, Adobe PhotoShop, and Macromedia FreeHand. Printed copies are produced using the Xerox
DocuTech publishing system.
Trademarks and Servicemarks
Emerson Process Management logo; Infranalysis; InfraRoute; MachineView; MotorView; Nspectr; OilView
(Japan); AMS Machinery Manager; Reliability-Based
Maintenance, and logo; are registered trademarks of
Emerson Process Management.
PeakVue; RBMview; AMS Machinery Manager (Australia,
China, Japan); RBMwizard; Reliability-Based Maintenance (Venezuela); SonicScan; SST; VibPro; and VibView
are pending trademarks of Emerson Process Management.
Lubricant Profile and Trivector are registered servicemarks
of Emerson Process Management.
RBM; AMS Machinery Manager (China); ReliabilityBased Maintenance (Venezuela); and design are pending
servicemarks of Emerson Process Management.
Adobe is a trademark and FrameMaker and PhotoShop are
registered trademarks of Adobe Systems, Inc. Power Macintosh is a trademark of Apple Computer, Inc. Macromedia
is a registered trademark and FreeHand is a trademark of
Macromedia, Inc. Xerox and DocuTech are trademarks of
Xerox Corporation.
All other brand or product names are trademarks or registered trademarks of their respective companies.
License Agreement
IMPORTANT: CAREFULLY READ ALL THE
TERMS AND CONDITIONS OF THIS AGREEMENT BEFORE OPENING THE PACKAGE OR
PROCEEDING WITH INSTALLATION. OPENING
THE PACKAGE OR COMPLETING THE INSTALLATION INDICATES YOUR ACCEPTANCE OF
THE TERMS AND CONDITIONS CONTAINED
IN THIS AGREEMENT.
IF YOU DO NOT AGREE TO THE TERMS AND
CONDITIONS CONTAINED IN THIS AGREEMENT, CANCEL ANY INSTALLATION AND
PROMPTLY RETURN THIS PRODUCT AND THE
ASSOCIATED DOCUMENTATION TO CSI, AND
YOUR MONEY WILL BE REFUNDED. NO
REFUNDS WILL BE GIVEN FOR PRODUCTS
WITH DAMAGED OR MISSING COMPONENTS.
Definition of Software
As used herein, software refers to any computer program
contained on any medium. Software includes downloadable
firmware for use in devices such as analyzers or MotorStatus units and it includes computer programs executable on
computers or computer networks.
Software License
You have the non-exclusive right to use this software on
only one device at a time. You may back-up the software for
archival purposes. For network systems, you have the nonexclusive right to install this software on only one server.
Read/write access is limited to the number of concurrent use
licenses purchased. The number of guest-only accesses is up
to a maximum of 250.
CSI grants you a non-exclusive right to use the Software
solely for your own internal data processing operations on
the CSI designated supported operating platform for up to
any applicable maximum number of licensed users. You
may not relicense the Software or use the Software for third
party training, commercial time sharing, rental, or service
bureau use. Client may not use the Software in, as, or with
an ASP (Application Service Provider).
Software Updates
CSI agrees to provide you, at no charge except for media,
preparation and shipping charges, for one (1) year from the
date of purchase, all updates to the software made at the sole
discretion of CSI. Should you purchase a software support
agreement for the next succeeding year following the first
year from the date of purchase, and thereafter on an annual
basis, and if CSI is still providing support, you may purchase the same, annually, at the then existing rate.
Updates/Upgrades
Upon receipt of new CSI software replacing older CSI software, you have 30 days to install and test the new CSI software on the same or a different device. At the end of the 30day test period, you must both remove and return the new
CSI software or remove the older CSI software.
Ownership
The licensed software and all derivatives are the sole property of Computational Systems, Inc. You may not disassemble, decompile, reverse engineer or otherwise translate the
licensed program. You may not distribute copies of the program or documentation, in whole or in part, to another party.
You may not in any way distort, or otherwise modify the
program or any part of the documentation without prior
written consent from CSI.
Transfer
You may transfer the software and license to another party
only with the written consent of CSI and only if the other
party agrees to accept the terms and conditions of this
Agreement. If you transfer the program, you must transfer
the documentation and any backup copies or transfer only
the documentation and destroy any backup copies.
Copyright
The software and documentation are copyrighted. All rights
are reserved.
Termination
If you commit a material breach of this Agreement, Emerson may terminate the Agreement by written notice.
Virus Disclaimer
CSI uses the latest virus checking technologies to test all its
software. However, since no antivirus system is 100% reliable, we strongly advise that you use an anti-virus system in
which you have confidence to verify the software is virus-
free. CSI makes no representations or warranties to the

effect that the licensed software is virus-free.
NO WARRANTY
THE PROGRAM IS PROVIDED "AS-IS" WITHOUT ANY WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING BUT NOT LIMITED TO
ANY WARRANTIES OR MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY AND REMEDIES
IN NO EVENT WILL CSI BE LIABLE TO YOU

OR ANY THIRD PARTY FOR ANY DAMAGES,
INCLUDING ANY LOST PROFITS, LOST SAVINGS, OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE
USE OR THE INABILITY TO USE THIS PROGRAM.
THE LICENSEE'S SOLE AND EXCLUSIVE REMEDY IN THE EVENT OF A DEFECT
IN WORKMANSHIP OR MATERIAL IS
EXPRESSLY LIMITED TO THE REPLACEMENT
OF THE CD OR OTHER MEDIA. IN NO EVENT
WILL CSI'S LIABILITY EXCEED THE PURCHASE PRICE OF THE PRODUCT.
Export Restrictions
You agree to comply fully with all laws, regulations,
decrees and orders of the Unites States of America that
restrict or prohibit the exportation (or re-exportation) of
technical data and/or the direct product of it to other countries, including, without limitation, the U.S. Export Administration Regulations.
U.S. Government Rights
When provided to the U.S. government, the computer software and related materials and documentation are provided
subject to the same license rights as those enumerated
above.
Hardware Technical Help

1. Please have the number of the current version of your
firmware ready when you call. The version of the
firmware in Emerson Process Managements CSI
21XX series, and other analyzers appears on the
power-up screen that is displayed when the analyzer is
turned on.
2. If you have a problem, explain the exact nature of your
problem. For example, what are the error messages?
When do they occur? Know what you were doing
when the problem occurred. For example, what mode
were you in? What steps did you go through? Try to
determine before you call whether the problem is
repeatable.
Hardware Repair
Emerson Process Management repairs and updates its hardware products free for one year from the date of purchase.
This service warranty includes hardware improvement,
modification, correction, recalibration, update, and maintenance for normal wear. This service warranty excludes
repair of damage from misuse, abuse, neglect, carelessness,
or modification performed by anyone other than Emerson
Process Management.
After the one year service warranty expires, warranty coverage may be extended through the purchase of a support
agreement. If a product is no longer covered by warranty or
support, each return of a Emerson Process Management
hardware product is subject to a minimum service fee. If the
cost of repair exceeds this minimum fee, we will call you
with an estimate before performing any work. Contact
Emerson Process Managements Product Support Department for information concerning the current rates.
Obsolete Hardware
Although Emerson Process Management will honor all
contractual agreements and will make every effort to ensure
that its software packages are backward compatible, to
take advantage of advances in newer hardware platforms
and to keep our programs reasonably small, Emerson Process Management reserves the right to discontinue support
for old or out-of-date hardware items.
Software Technical Help

1. Please have the number of the current version of your
software ready when you call. The version number for
software operating under Windows is displayed by
selecting About under the Help menu bar item.
2. If you have a problem, explain the exact nature of your
problem. For example, what are the error messages?
(If possible, make a printout of the error message.)
When do they occur? Know what you were doing
when the problem occurred. For example, what mode
were you in? What steps did you go through? Try to
determine before you call whether the problem is
repeatable.
3. Please be at your computer when you call. We can
serve you better when we can work through the
problem together.
Software Technical Support
Emerson Process Management provides technical support
through the following for those under support agreement:
Telephone assistance and communication via the
Internet.
Mass updates that are released during that time.
Interim updates upon request. Please contact Emerson
Process Management Product Support for more
information.
Returning Items
1. Call Product Support (see page 2) to obtain a return
authorization number. Please write it clearly and
prominently on the outside of the shipping container.
2. If returning for credit, return all accessories originally
shipped with the item(s). Include cables, software
CDs, manuals, etc.
3. Enclose a note that describes the reason(s) you are
returning the item(s).
4. Insure your package for return shipment. Shipping
costs and any losses during shipment are your
responsibility. COD packages cannot be accepted and
will be returned unopened.
Contents
Chapter 1 Introduction
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OilView Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrostatic Discharge or Other Harsh Environments. . . . . . . . . . . . . . . . . . . . . . 1-3
On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
OilView System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Trivector Laboratory Data Import. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
License Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
OilView Software Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Drop down menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Toolbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Database Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Change Marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Right Mouse Click Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
Translations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
Severity Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
File Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
Licenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
DB Level Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
Lab Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-39
Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40
E-mail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-41
Text Shortcuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
Chapter 2 OilView Database Options

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Test and Display Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Internal Working Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Internal Process Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
External Working Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Oil Wetted Bearing Parts (P1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Analysis Parameter Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Database Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
AP Sets and AL Sets (Folder icon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
CSI Default Oil AP Set (AP Set icon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
AP Sets Secondary Tabs and Information Window. . . . . . . . . . . . . . . . . . . . . . . 2-32
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Current Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Chapter 3 OilView Reporting

Trend Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Sample Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
TriVector Plot Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Observations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ISO Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
NAS Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
5100 Data Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
5200 Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Viscosity Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Summary Report Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Print Preview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Chapter 4 Importing Data From the Laboratory

Import Lab E-mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Laboratory Imports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Database Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Statistics Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Chapter 5 OilView Analyzer Models 5100, 5100-1, and 5100-2

Software Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Verify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Calibrate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Test Data Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Calibration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Test Time Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Calibration Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
OilView AnalyzerInitial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
System Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
Sensor Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
An Example Testing Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
Analyzer Model Test Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30
Dilution Of Viscous Samples (OilView Analyzer). . . . . . . . . . . . . . . . . . . . . . .5-31
Synthetic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32
OilView Analyzer Usage Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33
Chapter 6 Digital Viscometer Model 51DV and Model 52DV

Digital Viscometer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Using the Digital Viscometer With the OilView Analyzer. . . . . . . . . . . . . . . . . . 6-3
Alternate OilView Analyzer Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Using the Digital Viscometer With a Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Calibrating the Digital Viscometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Existing Digital Viscometer Users. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
New Digital Viscometer Users. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Verify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Plot ASTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Using the Digital Viscometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Chapter 7 The OilView Particle Counter - Model 51PC

OilView Particle Counter Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Particle Counter Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Running a Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Particle Counter Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Alternative Testing Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Test ISO Plot and Test NAS Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
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
Chapter 8 The OilView Ferrous Wear Monitor - Model 51FW

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

Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Sample/Atlas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Atlas Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
Analyst tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
The OilView Analyzers And Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13
Using the Model 51WD Wear Debris Patch Maker. . . . . . . . . . . . . . . . . . . . . . .9-17
Using the Model 51SM Shop Microscope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21
Chapter 10 The Model 5200 Trivector Analyzer

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Instrument Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
Scale Configuration (may be skipped if scale has already been configured) . .10-6
Scale Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8
Model VIR-400 only: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9
Scale Functional Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
Save Scale Model Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16
Volumetric Dilution For Test 2 and Test 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-28
Dilution By Weight For Test 2 and Test 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-29
Making WDA Filter Patches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-29
Reference Oil Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-37
Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40
Test 2 Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40
Test 3 ISO Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-42
Test 3 NAS Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-45
Calibration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-47
Calibrate Overall Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-49
Test 1 Calibration & Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-51
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-51
Preparation for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-52
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-54
Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-57
11
Test 2 Calibration & Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59
Preparation for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-62
Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-65
Test 3 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-67
Test 3 Particle Counter Calibration Overview. . . . . . . . . . . . . . . . . . . . . . . . . . .10-67
Test 3 Preliminary Instrument Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-73
Test 3 Sizing Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-76
Test 3 Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-79
Test 3 Diluent/Clean Fluid Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-83
Test 3 Coincidence Error Limit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-86
Test 3 Flow Rate Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-91
Test 3 Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-94
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-98
Chapter 11 Laboratory Information Management System (LIMS)

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
12
Chapter 12 OilviewLite
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1
Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
Databases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
Adding a Sample and Running a Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3
Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4
Alarm Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5
Reference Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6
Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7
Appendix A Using the OilView Analyzer

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

Applying the OilView Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Plot Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
OilLife Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Chemical Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Contaminant Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
Ferromagnetic Index (Fe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
Large Contaminant Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13
Dielectric Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13
Appendix C The Original Frequency Units Data Plot

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

Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
13
OilView Instrument Directory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Setting up OilView File Locations for Terminal Server or Citrix AMS Machinery Manager
ClientsD-6
Setting up OilView File Locations for Workstation A using AMS Machinery Manager Local
Client AD-7
Setting up OilView File Locations for Workstation B using AMS Machinery Manager Local
Client BD-8
Setting up OilView for Terminal Server or Citrix. . . . . . . . . . . . . . . . . . . . . . . . . D-9
Setting up OilView Local Client . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Appendix E Extended NAS Table

Appendix F Addendum
Models 5100-1 and 5100-2 OilView Analyzer CE Addendum . . . . . . . . . . . .F-1
Explanation of Symbols:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Electrical Specifications:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Environmental Specifications:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Index
14
Chapter
Introduction
How To Use This Manual

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.
Note
This manual covers the OilView Analyzer Model 5100-1 and

Model 5100-2; however, some described functions and features are
applicable only to the particular model.
1-1
Manual Conventions
These conventions are used throughout this manual to call attention to the adjacent text:
Note
The Note paragraph indicates special comments or instructions.
Caution!
The Caution paragraph alerts you to actions that could have an

effect on the equipment or the collected data.
Warning!
The Warning paragraph warns you of actions that could cause

serious injury or death.
1-2
Introduction
OilView Disclaimer
The OilView instrumentation and software aids the user in diagnosing oil lubricating and
machine wear problems. Because of the complexities of real-world problems, there are no
claims or guarantees that OilView will correctly solve all of the problems encountered.
Questionable results should be sent to a reputable oil analysis laboratory for a more 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.
Electrostatic Discharge or Other Harsh Environments

In unusually harsh operating environments, operation of this product may require reset and/
or restart of the function in progress. This user 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.
1-3
On-Line Help System

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.
1-4
Introduction
OilView System
The OilView system includes oil analysis software used in conjunction with an oil laboratory, a minilab, or both. This manual describes the operation of the OilView software, lab
communications devices, and OilView minilab instruments.
There are three license/configurations of the OilView system. Depending on which software license you purchased, you may have one or more of the following configurations
enabled.
Minilab instruments
Laboratory Information Management System (LIMS) and Data I/O
Wear Debris Analysis
Trivector Laboratory Data Import

The Trivector Laboratory Data Import configuration is used by the CSI lab customer who
only wants to view CSI lab data without the possibility of adding, editing, or performing
further analysis on the data. This 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.
License Configurations
The Minilab Instruments and Data Edit/Entry configuration is used to operate any of the
CSI OilView products including any or all of the 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.
OilView System
1-5
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
1-6
Introduction
The following table shows which tabs are activated by the three license categories. The Trivector Lab Import does not require a license.
OilView
Software
Tabs
Trend Info
OilView System
Users
Manual
Chapter
Activated categories
Trivector
Minilab
Lab Import Instruments
LIMS &
Data I/O
WDA
yes
yes
yes
yes
Sample Info 3
yes
yes
yes
yes
Assign Ref
yes
yes
yes
yes
Point Info
yes
yes
yes
yes
AP Sets
yes
yes
yes
yes
AL Sets
yes
yes
yes
yes
LIMS
n/a
no
no
yes
no
Data I/O
Only CSI
no
All Labs
no
5100
no
yes
no
no
5xDV
no
yes
no
no
51PC
no
yes
no
no
51FW
no
yes
no
no
5200
n/a
no
yes
no
no
WDA
no
no
no
yes
Expert
n/a
n/a
n/a
n/a
n/a
Setup
yes
yes
yes
yes
1-7
OilView Software Menu Structure
The primary tabs are used to select the group of functions that you wish to perform, and
then the secondary tabs are used to select options within the selected function
The front row of the primary tabs is the active row. If you click on the tabs on the back row,
the back row will be brought to the front and become the active row.
1-8
Introduction
Drop down menus

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

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

Tutorial runs the online tutorial.
Print Certification Test prints the OilView certification test.
About displays the current software version number and build date.
1-9
Toolbar
The toolbar icons are as follows (from left to right):
Open Database switches databases.

Print Prints the currently selected report.
Print Preview Previews the currently selected report.
Help Opens the on-line help system.
Save Grid Save grids to a CSV file for importing into spreadsheets
Report List Selects a report for printing.
Graphics Save Saves the graphics from a data plot to RBMView
RBMView Opens RBMView
1-10
Introduction
Database Tree
The OilView database is a part of the hierarchical database system used in all modules of
the AMS Machinery Manager system as shown in the following illustration.
1-11
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.
1-12
Introduction
Note
Although other types of data may be visible on the database tree,

OilView will only display oil points.
Change Marks
Whenever an oil sample has been updated, the database tree places change marks on the
left side of the window beside the sample and the associated measurement point, piece of
equipment, and area.
1-13
Right Mouse Click Functions

The right mouse button can be used to perform the following functions from within the
database tree:
Click On the Database Icon
Add Customer Allows addition of a customer level. Areas can be dragged and dropped
for one customer to another. Initially all areas fall under the Unknown Customer.
Find Sample # A search facility to find a specific sample.
Recalculate Alarms Should one change alarm limits then you have the ability to re-calculate
Update Point Baseline Alarms can have a baseline relative to the median at each point.
This option updates the point baseline for all points in the database.
Clear Mark - clears the change marks for each piece of equipment, measurement point,
and oil sample under all Areas.
Schedule Schedule sampling for every point in the database. See scheduling, chapter 2.
Clear Marks - clears all of the change marks for each piece of equipment, measurement
point, and oil sample under all Areas.
Print/Preview
Point Labels Create sample bottle labels for the entire database.
Sample Summary Sample summary report for entire database.
1-14
Introduction
Parameter Exception A report similar to the parameter exception report created using
the 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.
Click on the Customer Icon
Add Area Add a new area to the database.

Edit Customer Edit customer details. Detailed customer information can be edited in the
LIMS Module.
Delete Customer Delete a customer from the database.
1-15
Print/Preview
the AMS Machinery Manager reporting module. This report has been customized for oil
data giving more detailed information.
Setup information.
Customer Details
The customer details are described in the Laboratory Information Management System
(LIMS) on page 11-1.
1-16
Introduction
Click On the Area Icon
10
Add Equipment - allows you to add a new piece of equipment to the current area.
Edit Area - allows you to change the ID and/or the name of the clicked on area.
Delete Area - allows you to delete an area provided there is only oil points under the area.
If there are any other technology points under the area then the only way to delete the area
is using the database utility program.
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.
point, and oil sample under the selected Area.
1-17
Print/Preview
the AMS Machinery Manager reporting module. This report has been customized for oil
data giving more detailed information.
Setup information.
1-18
Introduction
Alarm Details
11
This screen shows the severity contribution from all technologies.

Alarm Display Options
12
You can set the following preferences:
1-19
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.
Note
The icons on the database tree are only available if you have purchased RBMview Full.
Alarm Tree Filters
13
1-20
Introduction
This box displays the different technologies. Those technologies with check marks in the
boxes beside them will be the ones with active Alarm Tree Filters. You can turn on the filters for an entire technology category by checking in the box beside the category head of a
technology. For example, you can check Periodic Vibration and it will turn on all the analysis types under that Technology category. Or you can check those individual analysis
types you want filtered.
By default, the tree will show the status for all technologies that the user has purchased.
However, applications may set a filter to limit the number of technologies for which status
is displayed. For example, OilView may choose to set a filter to only display Oil Technology statuses.
You can also click on the box beside Use these filters for all programs to turn on the filters
for all the technologies. Doing so changes the dialog box heading to Global Alarm Tree
Filters.
Click On the Equipment Icon
14
Add Point - allows you to add a new measurement point to the current piece of equipment.
(See Measurement Point Information on page 2-17.)
Edit Equipment -allows you to change the ID and/or the name of the clicked on equipment.
1-21
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.
Print/Preview
Sample Labels Print Sample labels.
Setup information.
1-22
Introduction
Click On the Measurement Point Icon
15
Add Sample - allows you to add a new sample to the current measurement point.
Edit Point allows you to edit the clicked on measurement point.
Delete Point - deletes the clicked on measurement point.
Copy Point - allows you to copy the current measurement point so that it can be pasted
(duplicated) into another piece of equipment.
Clear Marks - clears all of the change marks for every oil sample under the selected piece
measurement point.
1-23
Print/Preview
Setup information.
1-24
Introduction
The Add Sample option pops up a form in which you enter the sample data and number.
You also have the opportunity to record the observations that have been recorded when the
sample was collected.
16
Click On the Sample Icon
17
1-25
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
Setup information.
Sample Labels create a sample label.
Drag and Drop Sample
Sample data can be dragged to another point or another point or another sample. First, click
and hold the left mouse button on the sample. Next, move the highlight data to another
point or sample. Finally, release the mouse button.
Note
If the sample is dropped on a point, then the sample will be added

to the point. However, if the sample is dropped on another sample,
then the data will be merged.
1-26
Introduction
Copy for Ref DB
This enables one to copy an oil sample from the User database into the Oil Reference database. Select the sample, then right click on the mouse, and then go to the Ref(erence) Database where you will be able to paste it into the correct location.
1-27
Setup Menus
The Setup menus includes functions to specify operating characteristics of the OilView
hardware and software.
Communication Ports
This function specifies the OilView and LIMS accessories that will be used with this software, and to assign the OilView Analyzer and computer ports for these accessories.
18
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.
1-28
Introduction
You will observe that there are several other general purpose laboratory instruments in the
list. These instruments can be connected to the LIMS system for automatic data import.
You are limited first off to the number of comm ports available on your computer (up to a
maximum of 8) and secondly to the number of LIMS instrument link licenses you have
purchased.
19
The OilView Analyzer Type area is used to specify which Model 5100 or 5200 is to be
used with this software. Click the appropriate box beside the Model 5100 version or 5200
you will be using. You cannot connect both a 5100 and a 5200 simultaneously to your computer.
The OilView Analyzer port area is also used to specify which OilView equipment is connected to the Model 5100 or 5200 ports. For example, if the Model 5XDV is connected to
port 4 on the Model 5100, check the box beside 5XDV under the Port 4 column.
Note
Comm 1 is the serial port number 1 (or letter A) on the computer;

Comm 2 is the serial port number 2 (or letter B) on the computer.
The Port numbers refer to the ports on the Model 5100-1 or Model
5100-2. See System Setup on page 5-21 for OilView Analyzer
port assignments.
Refresh Comm Port Status
This button is used to check the computers Comm Port Status to see if the ports are available. If a ports status is unavailable, then either it is not configured in the operating
system or some other application program is using it.
Setup Menus
1-29
System
This window allows the system administrator to set the security status of data editing and
data entry within the OilView software.
The remaining functions are not used in the normal operation of the OilView software.
They are tools that you may need to use when communicating with CSIs customer support
20
Error Tracing
These options are for use only when working with CSIs Customer Support and you are
resolving a problem.
Test Modes
Diagnostics Enable Minilab instrument diagnostics. These features are used for diagnosing problems in conjunction with CSI customer support.
Add Sample With Start - When a new test is started with any of the Minilab instruments,
you are automatically prompted to enter a new sample number. When this box is checked,
if the sample already exists then it is used; otherwise, a new sample is added.
1-30
Introduction
Verbose More detailed errors and warnings.

Data Collection Mode Used in a WAN installation (see Appendix D).
Data Analysis Mode Used in a WAN installation (see Appendix D).
Diagnostics and Verbose are only used when working with CSIs Customer Support and
you are resolving a problem.
Data Edit/Entry
This function is used to change the security level in the OilView software located on the
current computer.
Read Only - When this box is checked, the software is in the Read Only user mode. The
user is allowed to download data into the OilView database, and the ability to view and
print plots and reports. However, changing information and/or data in the OilView database
is not permitted.
Advanced User - This option places the software in the Advanced user mode and
allows the administrator of the OilView software to set up or edit areas and equipment,
measurement points, and other technical information. When this option is selected, the
grayed out primary tabs that are not available to the read only user are now accessible.
Miscellaneous
Pause on Daily Tip If you do not have time to read the daily tip this option will pause
the software for you.
Mini-Lab Demo Mode Switches the software into demo mode whereby the running
of the MiniLab instruments can be simulated without actually having them connect to the
computer.
Display ISO 11171 counts By default particle counts are displayed with ISO 4406
standard. This option enables the new ISO 11171 standard. If selected, old data is automatically converted to the this standard. The 5200 Trivector Analyzer can be calibrated in
either standard.
Let lab alarm levels override user alarms on import By default when importing lab
data the lab severity is stored with the user severity, which is calculated based on alarm
limits. This option disables the calculation of user severity based on stored alarm limits and
instead sets the user severity equal to the severity imported from the lab. This is essential if
the alarm limits have not been correctly set up.
Setup Menus
1-31
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).
Rename Log File
This function allows you to rename the current log file. This feature can be used, for
example, to create multiple log files during a software troubleshooting session.
Clear Log File
This function clears the existing log file and begins writing new data.
LIMS
Lab Options Reserved for the CSI Trivector lab.

Display Customer Level The customer level in the RBM database groups areas under
a given customer. This option is activated here.
1-32
Introduction
Print lab label @ login This option activates the automatic printing of lab labels one at
a time as samples are logged into the LIMS batch system. You need a label printer to use
this option.
Export 0-5 Severities Used to export the old 0-5 severities to be compatible with OilView 4.60 and earlier. This is a global setting and therefore applies to all data exported. The
new 1-100 severities used in OilView 4.70 are only compatible with OilView 4.61 (latest
patch) and OilView 4.70.
Trend Plots
All Data plot all data on trend plots.

Last plot the last N samples on trend plots. You select the number of samples.
Start Date Plot all sample data after the start date on trend plots.
Translations
21
Setup Menus
1-33
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.
Severity Codes
During the diagnosis process there are five levels of severity ranging from normal to
extreme. Default terms for these levels are provided; however, you may use this window to
specify your own terminology. You may also select to use only 3 severity levels.
22
Note
When renaming the severity codes with this option, the actual
levels are not changed, only the name associated with the particular severity code.
Severity is ranked from 0 = Normal to a value between 1 - 100 as shown above.
1-34
Introduction
File Locations
This window shows the hard drive location of the calibration files for the instruments that
make up the OilView MiniLab system. The displayed default locations are set up during
the original software installation. However, this window can be used to change the file locations if desired.
23
You may type in the file location manually, or you may use the browse button (on the right
side of the field next to the appropriate instrument) to search through the hard drive directories and select a location. After you have finished making the changes, click on the Save
button, or click the Cancel button to revert to the original settings.
Note
These file locations should be adequate unless multiple users at a

site will share mini-lab instruments. Contact CSIs Customer Support for information in this case.
Setup Menus
1-35
Lab Export/Import
This file location is used to archive data import files when importing data using the E-mail
option. After the data has been imported from the E-mail then it is automatically archived
in this directory.
PC Configuration
This file location is used to store setup configuration information such as which RS232
ports are being used by the various instruments. It is important to set this location to your
local drive in a multi-user network installation as this information is specific to a particular
PC.
Licenses
The Activate/Release buttons allow you to use a license and then release it to another user,
if required. The default check box marks those licenses that are automatically activated
when the OilView program is started.
24
1-36
Introduction
DB Level Names
The Database Level Names options enable you to globally substitute other descriptive
names used in the hierarchical database structure and the reference oil database.
Caution!
CSI recommends that you do not use a keyword to replace another

keyword. For example, Equipment should not be substituted for
Area.
25
If you decide not to keep the new names you have selected, click on the Restore Default
Level Names button to restore the names to factory setting.
Setup Menus
1-37
Labels
Use this function to set up the dimensions of the labels being used to label sample bottles.
The labels identify the sample and are used on sample bottles.
26
Label Fields
Select the required fields to be printed on the sample label.

Label Printer
Select the appropriate printer. Labels can either be printed form sheets or single labels
depending on the printer selected. This enables printing labels on a specific printer rather
than the system default printer.
Default labels
Select a default label size.
1-38
Introduction
Lab Labels
The lab labels identify the sample and are used during the testing phase in the laboratory.
27
Label Fields
The test matrix lists the tests to be performed based on the Point Setup.
Label printer
Select the appropriate printer. Labels can either be printed form sheets or single labels
depending on the printer selected. This enables printing labels on a specific printer rather
than the system default printer.
Default Labels
Select a default label size.
Setup Menus
1-39
Reports
The Name and address appearing on several reports may be customized as shown below.
You may also use your own logo by specifying the location of a bitmap of your logo.
28
Report Colors - This sliding color level is used to tone down the colors on trend plots or
on printed reports.
1-40
Introduction
E-mail
29
The Laboratory Information Management System (LIMS) requires an internet connection

for E-mailing data and reports. Additionally, the Data I/O section also requires an internet
connection to download data directly using E-mail.
For these two options to work you need to establish a direct link to the internet using the
Simple Mail Transfer Protocol (SMTP) to send E-mail and the Post Office Protocol
(POP3) to receive E-mail. These are fairly 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.
Select Fax Printer
The LIMS enables the automatic faxing of reports. this is enabled by setting up a fax printer.
Setup Menus
1-41
Text Shortcuts
30
When typing an observation or action message, you can use shortcuts that automatically
enter phrases into your message. This is done by first setting up the shortcuts. You do this
by selecting the Text Shortcuts secondary tab at the bottom of the screen. Next, click on the
first box under the Shortcut column and type in your shortcut letter, number, symbol or
combination of letter, number, and symbol. The shortcut can be from one to six characters
long.
Now, when typing in an observation or action, type the / key, then the shortcut character
or characters, and then press the Enter key. The observation or action text associated with
that shortcut appears in the observation or action dialog area.
1-42
Introduction
Chapter
OilView Database Options
Reference Database
Many of the minilab measurements result from comparing new or reference oil tests with
similar tests on used oil samples. The OilView Analyzer, Digital Viscometer, and Particle
Counter all use Reference Oil test data. The OilView 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.
2-1
Assign Reference
The Assign Ref and Ref Info tabs are used to add and edit reference oil information. The
Assign Ref title is applied to this tab when the user is in the User Database because the
primary purpose is to assign references to points and samples on the User Database. The
assign reference function is disabled when switching to the Reference Database.
When using the Assign Ref tab in the User Database, a Reference Database tree is displayed in the middle of the screen alongside the User Database. The focus automatically
appears on the oil sample from the Reference Database tree in the display center which is
assigned, if any, to the Measurement Point or Sample highlighted on the User Database tree
in the display on the left.
2-2
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.
Assign Reference Special Functions

The same reference oil may be assigned to multiple samples and points in the user database
when the oil is used in more than one piece of equipment. If the oil supplier or oil type for
one piece of equipment is changed, then the new oil can be assigned as a reference to that
one point as described above.
Superseding References at the Point Level
Sometimes, however, an oil supplier is replaced and the user may wish to re-assign references for all pieces of equipment which had previously used an old supplier. In this case,
the historical data samples must keep the old reference oil. However, all new samples added
to the point should use the new reference oil. Instead of manually assigning the new reference oil to each point, the software allows the old reference oil to be superseded by the new
reference oil on every point in the current user database where the old oil was assigned.
After adding the new reference oil and saving its data, the user simply uses the mouse to
drag the new reference oil sample and drop it onto the old reference oil sample in the Assign
Ref, center Ref DB tree.
Drag and Drop
New reference oil can be copied to another point on the Ref DB tree. First, click and hold
the left mouse button on the new reference oil. Next, move the highlight data to another
point. Finally, release the mouse button. You will be prompted with a message to continue.
2-3
Superseding References at the Point and Sample Levels
A somewhat different situation arises when the user has merged old oil databases and has
duplicate reference samples. In this case, the user wishes to supersede not only the references assigned at the point level for future samples, but also the references assigned at the
sample level. This allows only one of the duplicate references to be assigned and the other
duplicate references may be deleted. In order to perform this operation, the user must first
right-mouse click at the top level of the reference database tree on the Assign Ref tab, and
then choose the Enable Global Supersede and Lock DB menu item. After this, dragging
and dropping a reference oil sample will assign the dragged reference oil to all samples and
points where the old reference was previously assigned. After completing the global supersede function, the user must right-mouse click at the top level again to Enable Default
Supersede and Unlock DB.
Expand Entire Tree
Another feature available by right-mouse clicking at the top level of the reference DB tree
on the Assign Ref tab is to expand and collapse the entire tree.
Show Ref Samples used by this Database
The last feature available by right-mouse clicking at the top level of the 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.
Reference Info
Reference Info Tabs
2-4
Data Available
The Data Available tab is a display of the instruments and tests for which reference oil information has been stored on a specific reference oil sample. These displays are for information only and cannot be edited.
2-5
Data
The Data tab is a single column of reference oil parameters and associated measurement
values. This tab is only available when you are on the sample level of the Reference Database tree. This list is similar to the data tabs under Trend Info on the User Database with
these key differences: only one sample is displayed no trend information, and there are no
alarms applied to reference oil data. An Advanced user can edit any of the fields in this list.
2-6
Oil Type
The Oil Type tab is only available when viewing the oil designator (e.g., measurement
point) level of the Reference Oil Database (Advanced user mode). Check off the one base
stock field that describes the reference oil. If synthetic is selected as the base stock, then
select the type of synthetic oil base stock from the lower list. This lower list is grayed out
unless synthetic is checked in the upper list.
2-7
Properties
The Properties tab is only available when viewing the oil designator (e.g., measurement
point) level of the Reference Oil database (Advanced user mode). Select one or more properties for the reference oil. This information typically is included with specification information from the oil supplier.
2-8
Purpose
The Purpose tab is only available when viewing the oil designator (e.g., measurement
point) level of the Reference Oil Database (Advanced user mode). Select one or more functional purposes for the reference oil. This information typically is included with specification information from the oil supplier.
2-9
5x00/51PC
The upper selection of this section is only available when viewing the oil designator (e.g.,
measurement point) level of the Reference Oil Database (Advanced user mode). It is used
to identify the relative additive 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.
2-10
Stat Plot
Stat Plot: Histogaph
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.
2-11
Statistic Data
Stat Plot: Data
This displays the data used to create the histogram plot and is used to identify these data
points that appear to be incorrectly assigned.
2-12
Adding a Reference Oil

To add an oil to the reference database first select the Ref DB (Reference Database) tab and
then add the Supplier, Brand and Oil Description to the database. This is the same as adding
Area, Equipment and Point. At the Oil description level (equivalent to Point) use the Ref
Info Tab (equivalent to Point Info) to enter the required information as described above.
This is much easier than entering and editing this information at the Assign Ref tab,
although it is still useful when in the User DB and assigning references.
The next step is to add a sample and run the necessary tests. Lab data can be imported in a
similar way to the user database. Most of the functionality available for the user database is
also available for the Reference database.
2-13
Note
Any data also may be entered manually by typing it into the

Sample Info/Data Spreadsheet. For example, Digital 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.
2-14
Database Queries
Note
This option requires a license to the LIMS module.
10
To query the database, select the Q Database Queries tab. Right mouse click on the Customer Query option and select either Customer Sample Query or Generate Schedule.
2-15
Customer Query
11
Select the Cust ID (Customer Identification) or Cust Desc (Customer Description) from the
drop down menus. You may also select various reporting conditions as show and a start and
an end date. Press the Start button to run the query.
The results of a query are shown as a list similar to the LIMS (Laboratory Information Management System) Batch Info display. You have full access to all the reporting options for
the list as detailed in the LIMS module.
Generate Schedule
12
This menu option generates a list of samples that are due based on the 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.
2-16
Measurement Point Information

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.
13
General Information
Point ID - The Point ID is a three-character designator you select to tell the difference
between all of the points on a piece of equipment (the Point ID designation must be
unique for each point within the current machine). Normally you will want to use a consistent method for 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.
2-17
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 2-29). 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 2-29 for
more information.
2-18
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.
14
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 2-37 for more information.
Note
When specifying a new piece of equipment, you will probably

want to begin using a pre-defined Analysis Parameter and Alarm
Limit set for the first three months. Then after getting some experience with alarming in your plant, you can increase or decrease
alarm limits so that approximately 10% of your equipment is in the
highest alarm level and another 10% is in the second alarm level.
2-19
Schedule
15
Setup sampling schedule by right mouse click on appropriate date. You should setup the
schedule for at least one year in advance, although you can setup for as far in the future as
you want.
Note
Printing of sample labels for due samples is done on the Q (Database Queries) tab.
Criticality - is the relative impact of a failure of this equipment on overall plant operation. This function enables you to specify one of five levels of criticalness for this piece of
equipment.
2-20
Test and Display Filter

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.
16
Criticality - is the relative impact of a failure of this equipment on overall plant operation. This function enables you to specify one of five levels of criticalness for this piece of
equipment.
Many of the more than 90 parameters in the Analysis Parameter set are used for reference
and are not important in every report. By using this filter, you can limit the number of
parameters displayed to those of greatest interest. If at any time you want to view the data,
simply check the box or clear the check.
The filter is organized by measurement device. This way you can turn off the display of
blank information when you are not conducting particular tests on a point. Later, if you
begin collecting these data, simply turn the display back on.
2-21
Internal Working Environment

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

low
<500 psig
medium
<2000 psig
high
>2000 psig
Oil Temperature - The measured temperature of the oil.

Separator - The type of water/oil separator that the piece of equipment uses.
Oil Change - describes the basis that is used to decide when to do an oil change.
Coolant - Indicate whether coolant is used and if so, what type.
Filter
Category - Select either filtered or not filtered category.
2-22
Actual - If known, enter the actual filter specification in terms of micron size and beta ratio.
Oil Capacity
Estimate - Enter the approximate oil capacity of the system.

Actual - If known, enter the actual oil capacity of the system.
Breather - Indicate if there is a breather on the oil compartment.
Usage Units
These units are used to specify the volume of the oil compartment as well as the units used
when entering the amount of oil added when a new sample is taken.
2-23
Internal Process Material
18
General - If it is possible for process contamination of the oil, identify if this can cause the
oil to become chemically neutral, acidic, caustic, or unknown.
Gas - If the processed material is a gas, enter the kind.
Liquid - If the processed material is a liquid, enter the kind.
Solid - If the processed material is a solid, enter the kind.
Transformer - If the piece of equipment is a transformer, indicate the rated features.
2-24
External Working Environment
19
Type - Indicate how corrosive the external environment is.

Lube System - Specify whether the system is opened or closed.
External Temperature - Indicate the ambient temperature:
hot
greater than 140 F (60 C)
temperate
40 F (5 C) to 140 F (60 C)
cold
less than 40 F (5 C)
Humidity - Indicate the ambient, relative humidity:
dry
less than 40%
moderate
40% to 80%
very humid
80% to 95%
wet
100%
2-25
Particulate - Indicate if the area contains abrasives that may be problematic.
Oil Wetted Bearing Parts (P1)
20
Bearings - Indicate if bearings are used in the system.

Speed - Enter the speed range of the piece of equipment.
Sleeve (Conformal) - Indicate what type of conformal sleeves (if any) are used.
Roller Cage - If a roller cage is in the bearing, indicate its material.
Other - Select any other elements that may be present in the oil system.
2-26
Oil Wetted Parts (P2)
21
Gears - Enter the composition of any gears.

Seals - Enter the composition of any seals.
Cylinders/Pistons/Rings - Enter the composition of any of these components.
Shafts/Slides/Cams - Enter the composition of any of these components.
2-27
Oil Wetted Parts (P3)
22
Turbine Blades - Enter the composition of any turbine blades.

Oil Pump - Enter the composition of an oil pump.
Other Parts - Enter the composition of any other parts as required.
2-28
Analysis Parameter Sets

Database Tree
The analysis parameter (AP) sets that are available for the database are represented as icons
at the bottom of the database tree. To expand and view the sets, click the plus box beside
the folder AP Sets and AL Sets.
23
AP Sets and AL Sets (Folder icon)

Add AP Set
To add a new analysis parameter set, right mouse click on the folder icon and select Add
AP Set from the pop-up menu. You can then edit the current view and profile setup as
required for the new set.
24
2-29
Delete Unused Alarms
This option removes all un-used AL Sets from the database. This not only frees up space in
the database for new AL Sets (there is a limit of 512), it also makes it a lot easier to view the
statistics for each AL Set as the only AL Sets available are those that are actually used. CSI
therefore recommends that you use this option to clear-out all the un-used AL Sets.
Set Default Alarm Type
This option automatically sets the Ref and Point alarm type for each reference parameter in
all the AL Sets.
Update Statistics
Exports all the parameter data for generating statistical information. You must first set both
the correct alarm type and which are to be alarmed. Also, you must update the Point Baseline.
Update Alarm Baseline
Once the statistics have been exported, you must them update the AL Set baseline. This is
necessary if you have set an alarm to use the AL Set baseline.
Add User Alarm
To add a new user alarm to an individual analysis parameter set, right mouse click on an
individual AP Set icon from the list under a folder icon. Then pop-up menu. You can then
edit the current view and profile setup as required for the new set.
2-30
CSI Default Oil AP Set (AP Set icon)

Edit AP Desc
First, right mouse click on an individual AP Set icon from the list under a folder icon to
bring up the option box with Edit AP Desc in it. Then from the list, select Edit AP Desc.
25
Use this option to edit the AP Set Description and to add/edit the AP Set ID code. This ID
is used to export AP Sets and then import them to the correct location within a database.
This is the same principal as the Area, Equipment, and Point ID.
The other options are explained under Alarms on page 2-37.
Other selections in this menu box include:
Add User Alarm Add a new alarm limit (AL) set.

Delete AP Delete an AP Set and all its associated AL Sets. The software first checks to
ensure that neither the AP set nor any of the AL sets are 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.
Additional Drag and Drop feature
You can supercede an AP Set with another by dragging and dropping onto another AP Set.
Parameters will be added to the target AP Set so that data is not lost. All points using the
old AP Set will be converted to the New AP Set.
2-31
AP Sets Secondary Tabs and Information Window

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.
26
The second column is the units associated with each analysis parameter set. The third,
fourth, and fifth columns are the primary functional category for each of these parameters.
Those listed under Wear, Chemistry, and Contamination directly contribute to the
respective dimension of the Trivector and show up on the respective tabs within Trend Info.
The minilab and lab columns indicate which parameters are associated with OilView
minilab instruments and which come from oil laboratories.
2-32
The Plot column is used to mark, with a Yes, for those parameters for which a trend
plot will appear on the Trend Info tab. If you mark No then the plot will not appear,
although the data will be stored and easily viewed at a later time.
The Alarm column is used to mark those parameters for which there are alarm limit
values. Many of the analysis parameter values are for reference or human interpretation and
should not be subjected to alarms, so you can turn alarming off by simply marking No as
desired. You will notice that all of the oil lab parameters begin with default No for alarm
indications. The reason is that the lab should give an overall interpretation of their results
which overrides individual alarms.
The Manual column is used to mark those parameters that appear on the manual data
entry form in the LIMS module.
The Digits column shows the number of display digits for each parameter and may be
set from 0 to 4.
The Import Units column is used to specify the units for the import of lab data.
Profile Setup
Profile Setup is a list of all the parameters in the analysis parameter set. Editing of this list
will permanently change the analysis parameter set and is not recommended except when
absolutely necessary. The Update Changes button must be clicked in order to actually save
the new parameters.
2-33
The grayed out Tests in the AP Set box is for information only. It shows which tests or
instruments are included in the parameters from the analysis parameter set.
27
Update Changes This writes any changes made to an AP Set back into the database.
Highlight Used Parameters The Drag and Drop feature enables the merging of AP
Sets. This may result in more than 96 parameters in which case it is presented. This feature
enables you to see which parameters in an AP Set actually have data. Those parameters that
do not have data can be removed (deleted) from the AP Set making room for additional
parameters that can be merged from another AP Set.
A Few Words about Drag and Drop. Drag and drop enables more than the merging
of two AP Sets. In addition, the AL Sets from the AP Set being dragged and dropped are
also added to the AL Sets of the target AP Sets. Also, an AL Set may also be dragged and
dropped or copied from one AP Set to another. In the process all data is automatically
updated. This can be a slow process and there is a progress bar showing status of the merge
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.
2-34
Report Group Setup
This screen is used to setup the parameters and trend plots that appear on the Sample
Trend report. The Table column is used to mark those parameters that appear in the table
on the report and the Plot column is used to mark those parameters for which a trend plot
is provided. There is a maximum of 6 trend plots and 70 parameters on a report. The different groups enable you to define different combinations of parameters and plots for different types of equipment. For example, you could have one group for engines and another
for gearboxes. The specific group used is defined at the Point level.
28
2-35
Statistics
29
This shows the coverage weeks between an alert severity happening (i.e.,
severity of 1) where 0 implies normal. This can be referred to as Mean Time
Between Alerts (MTBA). Best results depend on alarm limits being correct and
uniformly applied to the statistics. The Recalculate option is useful in achieving
this. Once this has been done, it is also necessary to Update 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.
2-36
Alarms
To view the Alarm Limit (AL) sets within an analysis parameter set, click the checkbox
beside the analysis parameter name.
30
Add User Alarm Set
To add a new alarm set, use a right mouse click on the folder icon and select Add Alarm
Set from the pop-up menu. You can then edit the current values as required for the new set.
Edit AP Set Desc.
Edit AP Set description and AP Set ID code.

Delete AP
Delete an AP Set and all its associated AL Sets. The software first checks to ensure that neither the AP set nor any of the AL sets are currently being used. If they are the user cannot
delete the AP Set.
Add CSI Default Alarm
Add a selected default AL Set from a list of default AL Sets. To add a new alarm set, use a
right mouse click on the folder icon and select Add CSI Default Alarm Set from the popup 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.
Alarms
2-37
Generate Default Alarm Sets
Generate a complete set of CSI default AL Sets. This function (also accessed with a right
mouse click on the folder icon) will create ALL the default alarm sets for each of the equipment categories listed in the Point Setup. CSI recommends that you do not use this function
but rather only create those you require using the previous option.
31
Show Used AL Sets
The used AL Sets are highlighted. This is useful for reviewing only those AL Sets that are
used.
Additional Drag and Drop feature (not shown on menu)
You can supersede an AP Set with another by dragging and dropping onto another AP Set.
Parameters will be added to the target AP Set so that data is not lost. All points using the old
AP Set will be converted to the New AP Set.
2-38
Current Alarms
This table shows the current alarms assigned to the Alarm Limits (AL) set. The alarm
threshold value fields can be edited, if required.
32
Base Type - This column specifies if the alarm values are relative to zero or to the oil reference value. A good example of this is viscosity where one is interested in how much the
viscosity has changed relative to the reference oil viscosity.
The baseline can also be relative to the AL Set Baseline, Point Baseline, or Point Baseline
if here is no reference value (Ref or Pnt).
Delta Type - This column specifies whether the alarm value is an absolute value or in percent of the reference value.
Alarm Type - This column specifies whether the alarm value is up (greater than), down
(Less than) or both Up and Down relative to the base type.
Alarms
2-39
Base Type
Delta Type
Alarm Type
Zero
Value
ABS Value
Up
Oil Ref.
AL Base
Pnt Base
Ref or Pnt
Value
Percent
Up
Down
Up and Down
Disabled
AL Base
This column shows the AL Set baseline value.

Statistics
The statistical information must be created by first exporting all the data into a special database using the Data I/O tab as shown below.
33
2-40
This option is automatically activated from the AP and AL Set popup menu button Update
Statistics.
This table shows the average, minimum, maximum, count and standard deviation of the set
of samples to which this AL Set has been assigned in the database. This information is
useful for establishing alarm limits.
34
The annual average values for each parameter as calculated based on a simple average, or
on the 80%, 90%, 95%, or 98% percentile values. This information is used to establish
whether the oil analysis program is having a beneficial impact on the equipment, and is
based on a steady decline in contamination and wear.
Alarms
2-41
Right mouse button click on a particular parameter to display a histogram over time.
Histogram over time
Histogram Plot
This is an extremely useful statistical plot for setting alarm limits. The x-axis plots the
parameter values and the y-axis the percentage of samples for each parameter value. The
basic concept in establishing alarm limits is that a maintenance department can only handle
a certain percentage of problems at any one time. Therefore, one typically assigns the
extreme alarm limit at 95% (i.e. put only those samples whose parameter values fall in the
top 5% into this category). Similarly the next alarm limit down is set at 90% (top 10%), then
at 80% (top 20%) and the lowest alarm limit at 70% (top 30%).
The vertical bars representing the alarm limit values can be dragged with the mouse to the
desired value. Once all the alarm limit positions have been set then press the Save
Changes button and the alarm limit value will be automatically written back to the AL Set.
Using this method one can easily and reliably set the alarm limits for all the parameters.
There should be at least 100 samples in the statistics before one can reliably use this method
to set the alarm limits. The more samples the better. Remember to update the statistics at
regular intervals to ensure you are using the latest samples collected.
2-42
Baseline Adjusted Plot
35
Set/Save All - automatically sets all alarm limits.

Set Alarm Limits - automatically sets alarm limits for selected parameters.
Save Changes - save manual changes by dragging vertical alarm limit lines, and then
pressing the Save Changes button.
Note
Sometimes the plot has several bumps that are difficult to interpret. This is most often when a Reference baseline is being applied.
Alarms
2-43
Raw Data Plot
36
The raw data plot ignores any reference or other baseline and only plots the raw data. This
is useful for diagnosing the source of obscure plots. Most often these plots with bumps
are due to incorrect references being applied.
The solid vertical line shows the mean value and the dashed vertical line one standard deviation from the mean value.
2-44
Raw Data
37
To further diagnose obscure plots the raw data itself can be viewed here to find the specific
data that is causing inconsistent plots. Using this information you can then usually correct
the problem much as fixing an incorrect oil reference.
One way of minimizing these sorts of issues is to run the Point Configuration Summary
report, which is designed to find incorrect oil reference and other Point Setup issues.
Alarms
2-45
Scatter Plot
38
The scatter plot is used to see if there is a correlation between any two parameters. Simply
select the appropriate two parameters from the X and Y drop down lists and then press the
Plot button.
If the two parameters correlate well, they will fall on a relatively straight line unlike the one
shown here. The slope and intercept of the best fit line are shown on the display together
with the correlation coefficient. A correlation coefficient of 1 represents a perfect 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.
2-46
Alarm Templates
39
The standard alarms have been established from a large base of data from many customers.
Alarm limits can be copied into an existencing AL Set by selecting the AL Set, the appropriate standard AL Sets, the appropriate standard AL Set and then pressing the <<< button.
Alarms
2-47
Alarm Analysis
40
The LIMS license is required in order to access the Alarm Analysis tab. This data is used
to assist with analysis of alarms. For the case shown, 15 samples use this alarm set with 6
samples in alarm. There is 1 sample with a severe alarm caused by only 1 parameter. That
parameter is Manganese.
2-48
Alarm Analysis
41
Alarms
2-49
The LIMS license is required in order to access the Alarm List tab. This tab is useful for
quickly checking and changing configuration information. Lines can be sorted by clicking
a caption at the top of the column. Additional sort criteria may be entered in the text boxes
at the top. Columns can be hidden and made visible by clicking the buttons at the top. The
Type ID, AL Set, RefID, TCLs, and Report Group (Grp) can all be modified from this
screen.
42
2-50
Sequential items may be changed by selecting the desired value and dragging down the list.
43
You may also select Ref oils from a drop down list on the Ref Oil Desc field.
Alarms
2-51
2-52
Chapter
OilView Reporting
Trend Information
The Trend Info tab is used to view and edit historical data and alarm status for all samples
stored on a given point.
All Data, Minilab Data, and Lab Data Tabs
These three data tabs display stored data in a table format. The first column of the table lists
the analysis parameters within the AP Set. This list is filtered to include only those which
are part of the minilab or lab on the respective tabs.
3-1
Note
You can limit the number of parameters displayed using the Test
and Display Filter option on the Point Info tab.
The second column includes reference oil data or statistical data for the sample. Click on
the top of the second column to toggle through the options which include Mean, Standard
Deviation, Median, Point Baseline, and Oil Reference. The number of samples included in
the running statistical 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.
3-2
OilView Reporting
Any of the values or blank spaces on the data tabs can be edited by typing in the desired
value. However this alone will not update the overall Trivector status (wear, contamination,
and chemical status). After typing in or editing data, you should right-mouse-click on the
appropriate sample on the tree and select Recalculate Alarms. This must be repeated for
each separate sample that is edited.
Wear, Contamination, and Chemical Plots
The three plot tabs display data in trend graphs with separate tabs for wear, contamination
and chemistry related parameters. The horizontal lines on the trend plots represent alarm
levels. The vertical bars represent 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.
3-3
Detailed Parameter Plots
Right Mouse click on a parameter description in the grid or on a trend plot and you will get
a detailed trend plot for that parameter. You can select what additional information to 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.
3-4
OilView Reporting
Sample Information
The Sample Info tab is used to view graphs, observations, and notes for individual oil samples. This tab can be used with either the User Database or the Reference Database.
TriVector Plot Data

The TriVector plot combines multiple test results into one graph. It consists of three mutually perpendicular axis extending from a common origin. The results of an oil test are categorized to fit into one of three evaluation areas: wear, contamination, or chemistry. Each
axis represents one of these 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.
Sample Information
3-5
Analyze
This automatically analyzes Minilab data and generates Observations and Actions. It does
not use laboratory or any non-minilab data.
Reviewed
This button is used in conjunction with the LIMS.

Schedule
Once a sample has been diagnosed and if another sample is required, then you can go
directly to the schedule for the Point and schedule another sample.
ABC
The Spell check button checks the spelling in the Diagnostic message.
The shape of the TriVector plot is also helpful because it lets you quickly identify areas of
concern. For example, a sample with normal wear and contamination readings but very bad
lube chemistry would appear as below.
3-6
OilView Reporting
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.
Observations Block
The Observations block provides the opportunity to annotate the sample with noteworthy
observations. To add an observation, use a right mouse click on the intended row and select
the appropriate observation from the pull-down list.
Sample Information
3-7
Selecting an observation automatically adds one or more items to the Actions block. If any
of these is not what you want reported you may delete any item.
The fields under Observations and Actions can only be filled using the pull-down lists. You
cannot type any entries into these fields.
Sample diagnosis is your text description of the status and recommendation for this sample.
Observations
This list of selectable observations serves as a sample record for non-trendable information.
3-8
OilView Reporting
Notes
The Notes tab allows you to add free form text to the sample data and sample diagnosis.
10
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.
Sample Information
3-9
Data
The Data tab shows all the parameter data for the selected sample divided into Wear, Contamination and Chemistry. This grid is similar to the Grid on the Trend Info Tab enabling
data entry and edit.
11
3-10
OilView Reporting
ISO Count
The ISO 4406 plot is a representation of size distribution and concentration for particles in
oil. Each graph has two lines. One line is for the sample data, and the other is for the target
cleanliness level (as set on the Point Information, Equipment tab).
12
Sample Information
3-11
NAS Count
The NAS cleanliness code (NAS 1638) was developed by the Aerospace Industries Association of America, and is similar to ISO 4406 in that it 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.
NAS
1638
Class
3-12
Number of particles per 100 ml

range
5 to 15
15 to 25
25 to 50
50 to 100
> 100
00
125
22
250
44
500
88
16
1000
178
32
2000
356
63
11
4000
712
126
22
8000
1425
253
45
16000
2800
506
90
16
32000
5700
1012
180
32
64000
11400
2000
360
64
128000
22800
4100
720
128
10
256000
45600
8100
1440
256
11
512000
91200
16200
2800
512
12
1000000
182000
32400
5800
1024
OilView Reporting
13
PPM Plot
14
Sample Information
3-13
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.
Note
The particle PPM is calculated by volume whereas the typical PPM

is PPM by weight. To convert PPM by volume to PPM by weight,
you must multiply by density. If one assumes that all the particles
were the same size then one would multiply the PPM by volume
by 7 to get the PPM by weight of all the particles in the oil sample.
Because it is difficult t know what type of particles are being
counted we report the PPM by volume which is an accurate measure.
3-14
OilView Reporting
5100 Data Plot

The 5100 Data Plot shows the time resolved dielectric measurement graph for new and reference oil test data. For a detailed explanation of how to understand these plots, see
Appendix B.
15
Sample Information
3-15
5200 Plot
The 5200 Plot shows a time resolved plot of dielectric as particles settle on the detector grid.
The first part of the plot shows two curves that are 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.
16
The shapes of these curves are used to determine the contamination and ferrous indices as
well as the presence of large ferrous and non-ferrous particles. The water content is also estimated from these curves.
3-16
OilView Reporting
Viscosity Plot
The Viscosity Plot shows how viscosity changes with temperature for both the reference
and used oil samples. This plot is used to determine what 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.
17
Sample Information
3-17
Reports
This option, accessed by clicking on the Print Preview button, is used to preview reports
generated by the OilView program.
Sample Trend Report
18
This is the most typical report generated. The parameters in the grid (spread sheet) and e
parameters plotted are selected in the Report Groups setup in the AP Set module. This gives
the user the flexibility to customize this report for different types of equipment such as
hydraulics, gearboxes, etc. Each point has its run report group assigned to it.
The logo and address can be customized on this report.
3-18
OilView Reporting
Note
You can zoom in on the preview window by double-clicking the

left mouse button. To move the zoomed image within the window,
click the left mouse button (and hold) and drag the mouse. You can
zoom out by double-clicking the right mouse button.
Standard Sample Report
19
This report is used to give more detailed sample information including alarm limits and
diagnostics comments for each sample. It is typically used for reporting on historical examples.
Reports
3-19
Sample Trend Vib Analyst
20
Parameters and graphs have been selected to highlight wear problems. The contents can be
customized on the Report Group sub tab of the AP Set tab. A summary of the wear debris
analysis is included if available.
3-20
OilView Reporting
Sample Reports
21
This report is linked to the report groups in the same way as the Sample Trend report. It only
shows the data from a single sample but also lists the observations and actions. The report
also has a detailed lot such as the ISO plot shown above. Other versions of the report show
the NAS plot, particle count PPM plot, WDA image, and the 5100 / 5200 data plots.
Reports
3-21
Summary Report Options
22
The range of summary reports is controlled by the position on the database tree, e.g., Database, Customer, Area Equipment, and Point and by the above selections.
Sample Summary Report
23
This report shows the Area, Equipment, Point, Sample Date, Sample ID, and then the
Wear, Contamination, and Chemistry severities.
3-22
OilView Reporting
If the sample has observations and actions assigned to it, the report will also show the category into which they fall. For example, Inspection Day, Clean, Oil, Flush, Mechanical,
Sampling, and Other. This information helps create a clear idea of the typical problems
occurring in the plant.
Parameter Exception Report
24
This report is a customized version for oil analysis of the exception report created by the
AMS Machinery Manager reporting module. It details the Area, Equipment, Point, Sample
Date, and Sample ID together with the parameter in alarm, color coded for severity, along
with the actual alarm limits.
Reports
3-23
Point Configuration Summary Report
25
This report checks to see if each Point in the database has been correctly set up. For each
point it shows the Equipment Type, AP Set, AL Set, Reference Oil, and the number of 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.
3-24
OilView Reporting
Alarm Setup Exception Report
26
This report does a detailed check on the alarm limit used at each point, looking specifically
for inconsistencies in the alarm limits. Examples would be all of the alarm limits set to zero,
or that they do not progress from small to high values for higher severity.
Use the alarm limit statistical options to correctly set alarm limits. This will give the most
consistent and reliable results.
Reports
3-25
Oil Usage Report
27
This report shows the oil added per year for each point. It then summarizes the oil used per
year for each oil type.
Schedule Summary Report
28
3-26
OilView Reporting
This report shows the sampling schedule for each point for an entire year. If samples have
already been collected, their status (severity) is shown.
This report is useful to see that sampling has been scheduled and to see that samples have
actually been processed in the past.
Reports
3-27
Print Preview
The Print Preview window is controlled with the following buttons:
29
Graphics save - adds the current image to the problem area in RBMview.
View case history - launches the RBMview program.
Save to File - Save the current report to a .pdf file.
3-28
OilView Reporting
Chapter
Importing Data From the Laboratory
Import Lab E-mail
Logon - Press this button to log onto your E-mail system. You must setup your E-mail connection in the Setup E-mail Tab before you can connect. Once you have logged onto the
E-mail then this button will change to Logoff so that you can disconnect once you have
completed importing data.
Import - Once logged-on the system will search for all E-mail messages whose subject
contains the phrase Lab Data. This enables the system to distinguish E-mail messages
containing lab data file attachments from other E-mail messages. A list of these E-mail
messages is then displayed. To import the data from each E-mail simply click on the E-mail
message to select it and then press the Import button.
4-1
Once the data has been imported the attached file containing the data is automatically
archived in the Lab Export/Import directory which is setup under File Locations on the
Setup tab. The E-mail message is then automatically deleted. If for some reason you need
to re-import that data then use the Import Lab File tab to import the data from the file in
this location.
Delete - Use this button to manually delete an E-mail message.
Cancel - This button stops an import before it is complete. There may be a short delay
before the import stops.
Lab File Type - See next section for details.
Import Into - See next section for details.
4-2
Laboratory Imports
This tab is used to import lab data from oil laboratories including the CSI Trivector Lab.
Before using this function, you must have already obtained the file to be imported the
internet, an E-mail, a floppy disk, etc. The CSI Trivector Lab will E-mail the data file to
you.
Lab Type - These are the currently supported download formats. If your oil laboratory is
not represented, CSI can provide them with a specification for the Generic file format.
When importing the data from the CSI Trivector lab the CSI Trivector lab format must be
selected.
Data File - allows you to browse the computers storage media (hard drives, floppy
disk, etc.) to find the file that is to be imported.
Import Into - This option either selects the current database (fastest) or all the databases in
the RBMadmin group.
Start - Click on the Start button to begin the import process.
4-3
Database Export
This tab is used to export data from the CSI 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.
4-4
A/E/P with Cust (.zip). This option includes the customer level in the
export.
DB Structure. This option exports only the database structure down to the
point level without any sample information. This is useful for duplicating
database structures.
AP & AL Sets. this option exports AP and AL Set data. You must first
assign AP and AL Set IDs because they are used to identify the AP and
AL Sets when importing.
Note
When exporting sample data using the A/E/P option, the 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.
4-5
Statistics Export
This tab is used to export data for the Alarm Limit statistics option.
4-6
Chapter
OilView Analyzer Models 5100, 5100-1, and 5100-2
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.
5-1
The OilView Analyzer test is an immediate, on-site test that will detect abnormal conditions. If the OilView Analyzer test indicates a problem, you may choose to send a sample
to an industrial fluid analysis lab for a more detailed analysis and for expert advice. When
using the CSI Trivector 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 by-products in crankcase oils, including carbon soot and emulsion sludge.
When used as a screening tool for the preceding conditions, The OilView Analyzer provides you with immediate and nearly cost-free results.
5-2
Software Setup
Test
This menu is used to test used oil samples with the Model 5100 and to test reference oil
samples. Select either the user database or the reference 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 5-14) or verify (see Verify on page 5-13) each sensor that is
going to be used that day.
Software Setup
5-3
Now you are ready to choose from the following test options and begin a test on either port
of the Model 5100-2, or on the left port of the Model 5100 or Model 5100-1. The following
table outlines four different selectable test sequences used with the OilView Analyzer. In
order to get meaningful trend information, you should select one option and then use it consistently.
5-4
Test Sequences and Test Options for the OilView Analyzer.

Model 5100 test options
Undiluted
testing for
all
parameters
Testing for
Testing
Diluted
wear and
for oil
testing for
chemistry contaminati
all
on only
only
parameters
double clean
sensor grid
40 sec
40 sec
40 sec
40 sec
avoid cross
contamination
short test for

dielectric and
oil chemistry
n/a
10 sec
10 sec
n/a
fingerprint
oil and
measure
chemistry
save data
n/a
10 sec
10 sec
n/a
open sample
and add solvent
n/a
30 sec
n/a
30 sec
drops
viscosity to
<20 cSt
full test
250 to 1200
sec
250 sec
n/a
250 sec
measures
contaminants
and ferrous
save data
10 sec
10 sec
n/a
10 sec
view wear
debris
60 sec
60 sec
n/a
60 sec
total time
360 to 1310
sec
410 sec
60 sec.
340 sec
Model 5100
test sequence
Software Setup
Comments
see ferrous,
non-ferrous,
and water
5-5
Testing Profiles for Minilab.

5100
Neat
Full
Test
Test time*
Short
Test
<1
Diluted
Full
Test
51FW
51PC 5xDV 51SM
<1
Test
time*
<1
Incoming lubes
Pump oils
10
Compressor
oils
10
Engine oils
turbine oils
10
Gear oils
10
Hydraulic
fluids
10
Transformer
oils
Greases
R
R
11
R
R = recommended
O = optional
* = typical time in minutes
The Undiluted Testing For All Parameters option is good for oils less than 46 cSt. The full
test time for oils less than 46 cSt will be either 250 or 500 seconds. Although not recommended, this option can be used for oils greater than 46 cSt. Using the full test with high
viscosity oils may take up to 1200 seconds and the results will not be as sensitive as they
would if the same samples were tested using the preferred diluted testing option which
would take much less time.
The Diluted Testing For All Parameters option is good for all oils in any viscosity range
(see Dilution Of Viscous Samples (OilView Analyzer) on page 5-31). The dilution effectively allows all of the measurable wear particles to get to the sensor during the 250 second
test interval, while only a small portion of the particles have enough time to get to the sensor
without dilutioneven though the test interval is much longer.
5-6
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.
Software Setup
5-7
Oil Compatibility Chart
The following table lists various oils that can and cannot be tested using the Model 5100series OilView Analyzer.
Oil Type
5-8
5100 Grid
Type
(Gasket)
5100 test
method
Calibration
Fluids
Dedicated
grid?
Dilute
with
kerosene
?
Mineral oil
Regular
(Red)
Most oils
A&B
No
Yes
Polyalphaolephin
(PAO)
Regular
(Red)
Most oils
A&B
No
Yes
Synthetic
Regular
hydrocarbon (SHC) (Red)
Most oils
A&B
No
Yes
Polyol ester (POE)
Regular
(Red)
Most oils
B&C
Yes
Yes
Diester
Regular
(Red)
Most oils
B&C
Yes
Yes
Polyalkalene glycol
(PAG)
Regular
(Red)
Most oils
B&C
Yes
Yes
Perfluorinated ether Regular

(PFE)
(Red)
Heavy
synthetic
B&C
Yes
No
Phosphate ester
(PhE)
Special
(Black)
Heavy
synthetic
B&C
Yes
Yes
Transformer oils
Regular
(Red)
Ultraclean
A&B
Yes
n/a
Liquid hydrocarbon Regular

fuels
(Red)
Ultraclean
A&B
Yes
n/a
Bunker fuels
Most oils
A&B
Yes
Yes
Water/oil emulsions n/a
None
n/a
n/a
n/a
Fluids with
dielectric > 16.0
None
n/a
n/a
n/a
Regular
(Red)
n/a
Note
If kerosene does not dissolve a specific type of oil then consider

using another solvent. However, make sure that the solvent has a
dielectric value of less than 16. Most alcohols, for example, have a
dielectric value of greater= than 16.
Since the sensor grid has no sensitivity above a dielectric value of 16, high dielectric fluids
cannot be tested. For reference, most mineral oils have a dielectric of 2 to 3, most synthetics
have a dielectric of 2 to 7, water has a dielectric of 78, and conductive materials like metals
have infinite 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 5-31). Some users prefer to use other hydrocarbon
solvents such as hexane or heptane.
Warning!
Consult your industrial hygiene department, be aware of flammability characteristics and skin contact restrictions for solvents and
oils.
Software Setup
5-9
Click To Change Grid Color
This selection assures that the correct calibration is applied to the sensor being used.
Available For Test Seconds To Go
This box informs you of the status of tests. Available for test indicates that there is not a test
in progress. xxx seconds to go indicates the amount of time remaining until the test will
be completed on a test port. (This status updates once every few seconds.) At the end of the
Model 5100-1 or Model 5100-2 test interval, the status will show Reading test data.
It normally takes three or four seconds to read all of the raw data from the OilView Analyzer, and during this interval other software operations will be delayed. Otherwise, you are
free to move about the software and use other functions while a Model 5100-1 or Model
5100-2 test is running in the background.
Long Test
The Long Test is a full-length test performed by the OilView Analyzer. This test will take
from 250 to 1200 seconds depending on the viscosity of the oil and the test option. A long
test consists of 500 cycles through a three-step measurement sequence:
measure dielectric with electromagnet off,
measure dielectric with electomagnet north, and
measure dielectric with electromagnet south.
Altogether, a full test consists of 1500 dielectric measurements and two temperature measurements (at the beginning and end of each test). The OilView software uses these raw
data to calculate dielectric and index values.
5-10
Short Test
The Short Test is a relatively fast test for a single dielectric value with the electromagnet in
the off position. This test option only measures the 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.
Start
The Start button begins a test sequence.

Cancel
The Cancel button aborts a test sequence in process.

Ref
Reference oil information appears in the Ref window. Included in this window are the
date that the reference oil was tested, its viscosity, and the dielectric for the reference oil.
Date
This is the date of the reference oil test.

Viscosity
The viscosity value is obtained from the reference oil database and is used to determine the
time period for either Enhanced Particle Sensitivity or Reduced Particle Sensitivity test
options. If this value is missing or incorrect, it can be edited in the reference oil database.
Displayed Test Results
Immediately following a 5100 test, the results are automatically extracted from the analyzer
and displayed in the test results block. The two ports are independent, so one port might
have results displayed while the other port is either idle or still running a test. The displayed
results will remain until the data is either saved or cancelled.
If you want to see a data plot before saving these results, click on the Test Data Plot. (This
will not affect the buffered data.) The red flag on the 5100 tab is your reminder that you
need to come back to the Test tab to choose between the save or cancel option.
Software Setup
5-11
Use the Sample Info tab to view the data plot after the results are stored.
Keep in mind that results are saved to the sample that was highlighted at the start of the test,
which may not be the same as the sample highlighted at the end of the test. By the time the
test is over and the results are saved, you may already be on an entirely different point. The
point and sample information for a data set are displayed with the data.
Critical
Sometimes the results show Critical. The OilView analyzer measures dielectric values
between 1 and 16. Many fluids such as water and coolant have dielectric constants much
higher than 16. Also, metal particles can short the capacitance of the sensor grid causing the
sensor to report a value exceeding 16. If the dielectric value is greater than 16 at the end of
an 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.
Is This a Diluted Sample?
A Long Test performed on a sample with short test data will bring up the message Is this
a diluted sample? This prompt is included for the frequent case where you have run a Short
Test to get Dielectric and Chemical Index measurements in preparation for a diluted sample
test. After clicking on Yes, the analyzer will begin a 250 second test.
Diluted sample tests are intended to measure Contaminant, Ferrous, and Large Contaminant. The Chemical and Dielectric measurements are retained from previously stored Short
Test of unmixed oil, prior to dilution. When the long test results are saved, the results of the
long and short test are automatically merged.
Note
Never dilute the reference oil. Chemical comparisons between the

reference and the used oil must both be measured on unmixed,
undiluted oils.
5-12
Verify
Verification testing quickly confirms whether a sensors calibration is still within a recommended range. It is used for two reasons: to provide you with information to decide whether
to extend the time period that a sensors calibration remains valid, and to double-check test
results before taking a strong action based on the advice of the OilView Analyzer.
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.
Software Setup
5-13
Calibrate
The Calibrate Tab and Verify Tab for the OilView Analyzer are similar in operation and
function. They both use CSI-supplied calibration fluids having a known dielectric to establish the basis for comparison to all 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.
5-14
Note
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.
Cleaning Process
Clean the sensor by carefully wiping the sensing grid dry using a soft tissue paper and a circular (twisting) motion. The grid has been wiped clean when it no longer stains or wets successive clean pieces of tissue. Do not use a water-based cleaner or an abrasive material to
clean the grid. Do not allow water-contaminated oil to stand on the grid after a test.
Cleaning the sensor grid.
Software Setup
5-15
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 51002, 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.
Cross-section of sensor grid.
5-16
Note
Repeat this process for each calibration fluid, following the

instructions in the software.
Grids
The first software step in calibration or verification testing is to select the grid color from the
selection list. This menu does not default to the last color used which addresses a common
error when calibratinginadvertently selecting the wrong grid color. You must select the
grid color before doing anything else on this menu tab.
Start and Cancel
These selections are similar to regular Model 5100 testing except that the Calibration fluid
is poured into the sensor rather than screwing a bottle onto the sensor. This prevents contamination caused by reuse of the CSI-supplied calibration fluids.
Special Notice
It is especially important to thoroughly clean the sensor before calibrating or verifying. The
effects of cross contamination during calibration will affect all of the measurements made
until the next calibration. Be sure to clean the grid at least two times using the same calibration fluid that is to be tested. You must wipe the sensor surface completely dry using tissue
paper during each cleaning operation.
Keep in mind that Fluids A, B, and C are very different in dielectric; each one must be completely removed before continuing with the next 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.)
Starting new calibration
Since you may be calibrating or verifying multiple sensor grids, the sequence is repetitive.
At the beginning or end of the sequence the dialog box will state that you are starting a new
calibration or verification. At this point you should verify grid color and dielectric values
for calibration fluids listed on the Calibration Settings tab.
Continue.. cancel
Continue through the sequence, following the instructions in the dialog box. You will be
asked to clean the sensor grid and then fill the sensor well with two calibration fluids
sequentially. Calibration Fluids A and B are used for normal oils and Fluids B and C are
used for higher dielectric oils.
Software Setup
5-17
While you are testing calibration oils, other tabs will be grayed out because they are not
available for use. These will return to normal appearance after calibration or verification is
completed.
Frequency for calibration fluids is too close.
This warning indicates a common problem. You may have forgotten to switch fluids or the
grid may not have been cleaned properly.
Test Data Plot

This tab is used to view the OilView Analyzer data plots corresponding to the left and right
test ports before the data has been saved. Use the 5100 Data Plot on the Sample Info
tab to view plots after the data has been saved.
Calibration Settings
Test Information
Three test options are available to the OilView Analyzer user. These settings remain in
effect constantly until they are changed.
5-18
Test Time Options

There are three test time options. CSI recommends using the enhanced particle sensitivity
option unless there is a reason not to.
Regular 500 Second Test
This is the oldest of the OilView Analyzer test options. CSI only recommends using this
test time option when testing viscous oils that would otherwise require longer than 500 seconds to test.
Enhanced Particle Sensitivity
This is the CSI recommended test option. This option enables viscosity-based test times
ranging from 250 seconds to 1200 seconds. When you follow the suggested procedures
and dilute any samples over 48 cSt, the test time for diluted samples is 250 seconds regardless of the undiluted viscosity. Diluted test results are much more sensitive than neat oil test
results since dilution enables more particles to settle onto the sensor.
Calibration Information
Before calibrating or verifying sensor grids, the grid type and calibration oil properties must
be selected. These properties are reported on the labels of CSI-supplied calibration fluids.
Grid Type
There are two calibration ranges: normal and high. Normal calibration is done using CSI
supplied Fluids A and B for oils in the range of 2.1 to 3.2 dielectric. High calibration is done
using CSI supplied Fluids B and C for oils having dielectric values above 4.0.
Be aware also that there are two grid types: Phosphate Ester and non-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.)
Calibration Fluid Dielectric
The dielectric constant (also called permittivity) for the calibration Fluids A, B, and C are
copied from the CSI-supplied bottle and entered into these fields. If you are not using any
high dielectric oils, there is no need to enter any value in for Fluid C.
Software Setup
5-19
Calibration Out Of Date Warning
You may specify the out-of-date warning interval. This setting defaults to one day (the CSI
recommended calibration interval). This interval can usually be lengthened with experience.
Diagnostics
The diagnostics tab is only to be used under the direction of CSI Customer Support when
troubleshooting potential problems.
5-20
OilView AnalyzerInitial Setup

System Setup
To set up the OilView Analyzer system, place the OilView Analyzer and the computer
with which it is to be used on a flat, horizontal surface. Using the provided interface cable,
connect the OilView Analyzers Port 1 to the computer's COM1 or COM2 serial communication (RS232) port.
Note
Ports 2, 3, and 4 are available only on the Model 5100-1 and 51002. The earlier Model 5100 does not contain these ports.
Note
If port 2 of the Model 5100-1 or 5100-2 is not being used by either

the Digital Viscometer or the Ferrous Wear Monitor, then the Auxiliary Port connector key should be plugged into port 2.
5-21
Caution!
Port 2 is a 15-pin, high-density Sub-D port intended to provide

both power and serial communication to either the Digital Viscometer or the Ferrous Wear Monitor. Use caution when inserting the
15-pin cable into Port 2 as it is possible to force the connector
upside 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 5-25.
Caution!
The sensing grid should never be exposed directly to water.
Note
Because the OilView Analyzer is extremely sensitive to moisture,

it should be used indoors where humidity and temperature are relatively constant. For best results, the humidity should be low and
the temperature should be nearly constant.
5-22
Note
The OilView Analyzer should be turned on before use, allowed to

warm up for a few minutes, and should not be turned off until after
all tests have been stored to the database system. Before analyzing
oils, the OilView Analyzer should be operated through one entire
Full Test sequence to preheat the electromagnet.
Note
OilView initializes the serial port where the analyzer is defined. If

the computer mouse is connected to that port, the mouse will not
work.
Note
If necessary, the fuse (next to the power connector) can be replaced

with a standard 2-amp fuse.
5-23
Sensor Curing
When the OilView Analyzer is first unpacked, it will be necessary to cure the sensing
grid. As delivered, the grid may contain air in the interstitial space between fibres in the substrate. It is necessary to cure the grid by allowing a clean oil to stand in the sensor for a
few hours. The oil will 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.
Caution!
Never expose a new sensor to water or water contaminated oil

before it is cured.
Phosphate Ester
When testing phosphate ester oils on the OilView Analyzer, you must use a special phosphate ester sensor grid. (You can recognize this type of sensor grid because the threaded
rubber material is black.) In addition, you must cure the sensor by applying a bottle of clean
phosphate ester oil to the sensor for 24 hours. Failure to follow this procedure will result in
an unstable chemical index as the grid reaches equilibrium with the phosphate ester.
Caution!
Do not use kerosene, mineral oil or CSI-supplied Calibration

Fluid A on the phosphate ester sensor gridthe black seal material on the grid is not compatible.
Caution!
Do not use phosphate ester oil or CSI-supplied Calibration Fluid

C on normal sensors that have the red rubber seal. These fluids are
not compatible with the seal*.
*Phosphate ester oil and the CSI-supplied Calibration Fluid C are corrosive type fluids and
if used on the normal sensor grids (which have a red rubber seal) they would damage the seal.
CSI has special grids to use with the Phosphate ester oil and the CSI-supplied Calibration
Fluid C.
5-24
An Example Testing Session

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 AnalyzerInitial Setup on page 5-21).
Before beginning the test:
1Connect 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 5-21 for port location). Connect the other
end of the cable to the computers COM1 or COM2 serial communication
(RS232) port.
2After 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.
3Turn the OilView Analyzer on. The analyzer should sound a three-tone
output and display the OilView copyright message on its LCD screen.
5-25
Typical Test Procedure
To test an oil sample with the OilView Analyzer system:

1 Inspect the sensor. If necessary, wipe grid clean (see Step 7).
2 Vigorously shake the sample bottle after making sure that the cap is
screwed on tightly. This must be done to ensure that the contaminants are
evenly dispersed in the sample. The bottle should be shaken 15 seconds
or until no sediment can be seen on the bottom of the bottle after it has
been inverted. In extreme cases, it may be necessary to stir the sediment
from the bottom of the bottle using a clean plastic or glass rod before
shaking.
10
5-26
Note
This procedure describes shaking the sample bottle and then

screwing on the sensor. Some users prefer to shake the sample after
the sensor has been screwed onto the bottle. Either method is
acceptable as long as the sample is vigorously shaken just before
the test.
3Once the sample has been shaken, screw the sensor to the bottle.
11
4Plug 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.
5-27
12
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.
5-28
Note
The test is time dependentstart the test as soon as the sensor is

plugged into the OilView Analyzer. Do not allow the sample to
stand on the analyzer for an extended period of time before starting
the test. If necessary, shake the bottle again before starting the test.
6As 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.
7The grid should be double cleaned after each test. Carefully wipe the
sensing grid clean and dry with a soft tissue paper inserted into the bottle
opening using a circular (twisting) motion. The grid has been wiped clean
and dry when it no longer stains or wets successive clean pieces of tissue.
Do not use a water-based cleaner or an abrasive material to clean the grid.
Do not allow water-contaminated oil to stand on the grid after a test. Be
sure to apply a few drops of the next lubricant to be tested on the grid and
wipe clean and dry before testing (see Cleaning the sensor grid. on page
5-15).
Caution!
The sensing grid should never be directly exposed to water.
Caution!
Prolonged exposure to salt water or acid may damage the sensor

grid.
5-29
Analyzer Model Test Differences

Model 5100
When testing with the Model 5100, do not attempt to use the computer for any other task
while the test is runningdata may become corrupted or lost.
Model 5100-1 or 5100-2 OilView Analyzer
When testing with either the Model 5100-1 or 5100-2, the computer initiates the tests and
reads the data after a test has been completed. You can 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.
5-30
Dilution Of Viscous Samples (OilView Analyzer)

The OilView Analyzers contamination and ferrous indexes are dependent on magnetic
and gravitational forces moving contaminants and debris through the oil onto the sensing
grid. When an oil is very thick (viscous), this process is very slow. Consequently, viscous
oils such as gear oils should be diluted or cut with a petroleum solvent such as kerosene
or diesel fuel before testing. Dilution is the recommended method for testing thick oils (see
table below). However, if dilution is not practical, then thicker oils can be tested for longer
test durations using enhanced particle sensitivity (see Test Time Options on page 5-19
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.
Sample Viscosity/(ISO NUM) @
40 degrees C
Kerosene
(to be added)
<48 cSt (ISO < 48)
None
>48 cSt (ISO > 48)
Dilute 1:1
The viscosity of the undiluted sample should be determined with the optional Model 51DV
Digital Viscometer. If this test shows a viscosity of less than 48 centistokes (cSt), dilution is
not necessary. If the viscosity is greater than 48 cSt, the oil should be diluted by adding kerosene to the oil sample. This can be done by filling the sample bottle slightly over 1/3 full
with oil, adding an equal amount of kerosene, and leaving the rest empty to allow for easy
mixing when shaking the sample.
When an oil is diluted prior to a test, it is wise to record that fact in the test comment line.
Dilution Of Viscous Samples (OilView Analyzer)
5-31
The recommended procedure for testing high viscosity oils is:

1 Perform a Short Test to measure the chemical index on an undiluted
sample,
2 store test results (chemical information) on the sample,
3 open sample bottle, add solvent, replace grid, shake, and run full test on
diluted sample,
4 store test results (contaminant, ferrous, and large contaminant
information) on same sample as step 2 above.
Note
For information on diluting samples to be used with the OilView

Particle Counter, see Dilution Of Viscous Samples (OilView Analyzer) on page 5-31.
Warning!
Consult your industrial hygiene department, be aware of flammability characteristics and skin contact restrictions for solvents and
oils.
Synthetic Oils
The OilView Analyzer can be used to test most synthetic lubricants. Extra care should be
taken in cleaning the grid when changing between mineral oils and synthetic lubricants. See
Oil Compatibility Chart on page 5-8 for additional information regarding testing synthetics with OilView instrumentation.
5-32
OilView Analyzer Usage Tips

Procedural consistency and proper techniques are the best way to achieve reliable results
from your OilView analyzer. The following list of 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.
Double-Clean the Grid
Clean the grid two times to prevent cross contamination. CSI recommends that in addition
to wiping the grid after a test, you should apply a small amount of the next oil to be tested
onto the surface of the grid, and 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.
Verify Calibration
After initially calibrating your grids using CSI-supplied calibration fluids, regularly verify
the calibration using the 5100 Verification Test. This quick test will indicate whether or not
a grid needs to be recalibrated.
Synthetic Oils
Since synthetic lubricants such as phosphate ester, polyol ester, or diester have vastly different properties from typical mineral oils, extra precautions are necessary to clean away
any residual of the synthetic before resuming tests with mineral oils, or vice versa. You
must dedicate a sensor grid for the sole purpose of testing each generic class of synthetic
lubricants that you use. Once again it is important to do final cleaning using the next oil
to wipe away any residual surface film on the grid surface and to wipe the sensor dry using
tissue paper between cleaning steps.
Start-Up Support
Start-up support is a good way to get off on the right foot. Allow CSI 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.
OilView Analyzer Usage Tips
5-33
5-34
Chapter
Digital Viscometer Model 51DV and Model 52DV
CSIs Model 51DV and 52DV Digital Viscometer (referred to in this manual as the Model
5xDV) can be used to rapidly measure the viscosity of lubricants and other fluids that have
a 40C viscosity of from 20 cSt to 680 cSt.
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.
Warning!
For safety reasons, the OilView Digital Viscometer should never

be applied to a highly flammable hydrocarbon liquid such as gasoline.
6-1
Note
The well must be cleaned of previously tested fluid before each

new measurement. Old fluid can be poured out of the unit by tilting
it and allowing the fluid to flow into a disposable receptacle. Take
care to ensure that the steel ball does not fall out of the well and be
accidentally discarded. Alternatively, you may place a paper towel
into the well and allow it to absorb the old fluid, or use the syringe
to remove the fluid.
6-2
Digital Viscometer Setup

Using the Digital Viscometer With the OilView Analyzer
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 5-21 for more information on cable connections). Allow both the
OilView Analyzer and the Digital Viscometer to warm up for an hour before using.
Caution!
Exercise care when inserting the Digital Viscometers 15-pin connector into the OilView Analyzers port 2it is possible to force
the connector upside down.
6-3
Alternate OilView Analyzer Port

Using the optional viscometer power supply, the digital viscometer can be connected to
port 3 or 4 of the OilView Analyzer as shown below. This frees port 2 for use with the
Model 51FW ferrous wear monitor.
6-4
Using the Digital Viscometer With a Computer

An optional power supply package allows the Digital Viscometer to be used with a computer without using the OilView Analyzer as shown below.
6-5
Calibrating the Digital Viscometer

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

If you have already used CSIs Digital Viscometer with an earlier version of OilView Software, you may or may not need to recalibrate your unit. If your current Model 5xDV test
options with the previous software are set as Single Power (recommended) Default, then
you can start with your existing DVCAL_H.DEF file. Find this file in your previous CSI
program directory and copy it into the Model 5xDV directory as selected in the Setup tabs
File Locations. Then when you exit and re-enter the OilView software and select the 5xDV
tab, the program will ask you if you wish to convert the older DVCAL_H.DEF file to the
new format. Answer Yes.
You then may recalibrate with your own laboratory-tested oils1 or a selection of CSI-supplied calibration oils (recommended). If you are supplying your own oils, you will need to
know their 40C and 100C viscosities and the viscosity index as provided by an oil analysis laboratory. The calibration procedure is described on the next page.
New Digital Viscometer Users

If you are a new user of the Digital Viscometer, you have two additional steps before you
begin the calibration process. First, you must copy a file from a disk that was provided with
the Digital Viscometer to your hard drive. Copy the DVCAL_H.DEF file into the Instruments subdirectory.
Second, you must tell the OilView software that you are adding a Digital Viscometer (see
Setup Menus on page 1-28). You are now read to begin the calibration procedure.
1. ISO 14, 32, 68, 100, 137, 220, 460, and 680
6-6
Calibration Procedure
Note
Make sure your Digital Viscometer is plugged in and warmed up

for one hour prior to starting a calibration. When calibrating, start
with the highest viscosity oil and progress to the lowest viscosity
oil.
Enter the Name, 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 CSIsupplied Digital Viscometer calibration fluids. If you are using your own oils for calibration, these numbers will have to be provided by an oil analysis laboratory.
Note
The viscosity index value is for reference only. If this field is left
blank, it will not affect your measurements.
Calibration Oil Description - Enter a unique name or title to identify the fluid being used
for calibration.
6-7
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.
Start Calibration
This function button starts the calibration for the highlighted oil entry.
Delete Calibration
This function can be used to delete the highlighted calibration oil.

Default Calibration
The Default Calibration function can be used to identify the highlighted oil (with an
asterisk) as the typical viscosity/temperature profile that will be used to compute the 40C
viscosity value when tests are performed on unknown oils or when the 100C value has not
been entered.
Cancel Calibration
This function aborts a calibration run in progress. Any new fluid data entered will be lost
after aborting and leaving the Calibration tab.
6-8
Calibration Continued
The digital viscometer should be calibrated with at least eight fluid samples representing the
range of viscosity of the fluids that will be tested. CSI 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.
Note
When calibrating, start with the highest viscosity oil and progress
to the lowest viscosity oil.
After clicking on the Start button, a window will follow asking you to prepare the viscosity
standard for testing. Make sure that the sample well and steel ball are clean, and place
enough of the fluid into the well to fill it to the vertical rim as shown below. Then, place the
steel ball into the well (if it is not already there). Click the OK button to begin the calibration
procedure.
A progress bar will be displayed showing the test progress as the ball rotates. The progress
will display Finished at the end of the run. You may then save the results by clicking on
the Save button, or discard the results by clicking on the Cancel button.
Remove the ball from the cup using the magnetic ball retriever. Then remove the ball from
the retriever to prevent the ball from becoming magnetized. Discard the oil and clean the
cup and ball bearing before the next test.
6-9
Note
Do not pour the calibration fluid back into the original bottle.
To test the next calibration oil, enter the data and select the Start button to repeat the same
process described above. When you are finished with the last calibration oil, your calibration table will display the oils you tested from highest to lowest viscosity.
Highlight one of the oils in the calibration table and choose the Default (*) button to select
it as the default reference. This default will be used if no reference oil is chosen for a point
or if the chosen reference oil doesnt include a 100C viscosity.
Note
CSI strongly recommends that the default reference be changed as

needed to match, as closely as possible, the 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.
Plot Cal
The Plot Cal tab displays the calibration curve of the full viscosity range tested. Each oil
used in your calibration is identified by a marker on the graph.
6-10
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.
Verify
Use the Verify tab function to verify the measurement accuracy of the Model 5xDV. Select
the calibration oil you are using from the list, and then click on the Start button. The results
and percent deviation are displayed at the end of the test.
6-11
Plot ASTM
This tab displays an ASTM plot of calibration oil viscosity versus temperature.
10
Note
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.
6-12
Using the Digital Viscometer

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.
11
Whenever possible, assign a reference oil to the displayed point prior to running the Digital
Viscometer test. Best results will be achieved if you provide both the 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,
Using the Digital Viscometer
6-13
if neither the 40C nor 100C viscosity is defined on the reference on the
point,
if a default reference is not defined on the point.
To select the default calibration, select the 5xDV Calibrate tab, highlight the desired oil, and
then click the Default Calibration button to place the asterisk (*) next to the default calibration.
Note
If a reference oil is not specified for a point, it is very important to

choose a default calibration with a viscosity index similar to the oil
you will be testing.
Note
If both the 40C and 100C values are not specified on the point,
the Digital Viscometer will use the viscosity/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.
6-14
Viscosity
Viscosity determination is important for several reasons (viscosity can be measured with
the OilView Digital Viscometer; see Chapter 6). The first and most important reason is to
detect misapplication of lubricant such as when a 32 cSt oil is accidentally used in a 68 cSt
application. Viscosity is the only practical way to find this misapplication of perfectly good
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.
Viscosity
6-15
6-16
Chapter
The OilView Particle Counter - Model 51PC
The CSI Model 51PC Particle Counter is a laser-based optical particle counter enabling
direct particle measurements and size distribution from 2 microns upwards. The particle
counter is an essential tool for monitoring clean oil systems such as turbines, hydraulics,
high-speed compressors, or where life extension of equipment is an important consideration.
The particle counter features ISO and NAS cleanliness outputs, in-line 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
7-1
OilView Particle Counter Setup

Connect the provided interface cable to the 9-pin connector located on the right side of the
particle counter and connect the other end of the interface cable into port 3 or 4 on the OilView Analyzer. Alternatively, the particle counters interface cable can be plugged directly
into the computer's COM1 or COM2 serial communication (RS232) port.
Connect the power supplys output cable into the power connector located on the right side
of the particle counter. Plug the power supplys AC cable into a standard 110/220 VAC
outlet.
7-2
Computer Connection
The Model 51PC can also be connected directly to the computers COM port via the 9-pin
communications cable. Plug the one end of the cable into the Model 51PCs Communication port and the other end into the 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.
OilView Particle Counter Setup
7-3
Particle Counter Component Locations
7-4
Running a Test
Before starting the testing procedure:
Attach a CO2 cartridge or plant air to the pressure regulator and turn the
pressure regulator knob to the HI position (reading > 2 kgf/cm2).
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).
Running a Test
7-5
Note
When using plant air, the plant air adapter must be used between
the plant air hose and the regulator. If plant air is used, instrument
air (air that passes through a filter and a dryer) should be used.
Unfiltered air may add contaminants to the sample.
7-6
Particle Counter Test Procedure

1Place the sample fluid in a clean sample bottle. For maximum accuracy,
use a certified super-clean sample bottle in accordance with ISO 37221.
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.
Caution!
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.
2Unscrew 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.)
1. Hydraulic Fluid PowerFluid Sample ContainersQualifying and Controlling

Cleaning Methods ISO 3722, International Organization for Standardization,
Stockholm, Sweden
Running a Test
7-7
Note
Be sure not to pour the sample directly into the sample cup. The
sample bottle should contain enough of the test fluid to equal the
flush volume plus three test volumes. In addition, an extra amount
should be included to ensure that the tube does not draw air when
the fluid reaches the bottom of the bottle.
7-8
Note
The OilView software will notify you if it has been more than 24
hours since the last flush cycle.
3Turn the sample cup clockwise back onto the particle counter, tightening
until a hard stop is felt.
4Ensure 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.)
Running a Test
7-9
Note
The default values for flow rate, test volume, and flush volume are
taken from the PC reference oil (see Assign Reference on page
2-2).
5 At this point you have the option of specifying whether dilution is being
used. Check on the Diluted Sample box of the Test Control area if dilution
is to be used. Leave the box unchecked if dilution is not being used.
7-10
Note
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.
Recommended Particle Counter Settings For Diluted Sample.
Flush
Volume
ml
Flow Rate
ml/min
50
25
Test Volume
ml
Minimum Total
Sample Volume
50 ml
6Make sure that a drain container is positioned beneath the drain tube.
10
7Select Start from the 51PC Test tab. When the test begins, turn the drain/
fill valve knob when requested to do so.
Running a Test
7-11
11
7-12
Problems
Inadequate pressure
Flow rate is too high for viscosity of sample. Try diluting the sample.
The CO2 cartridge is almost empty. Check the pressure regulator indicator and ensure that the reading is greater than 2 kgf/cm2.
Pressure regulator is not opened to the HI position. Adjust regulator.
Plant air pressure is too low. You may need to increase air pressure to 100
psi or more.
The sensor is dirty and needs to be cleaned (see Sensor Cleaning on
page 7-33).
On Power Up
When the particle counter is powered up, two short beeps should be heard and the LED
next to the power supply connector should turn green. If the LED remains red, some fluid
may be in the cylinder from a previous test and must be drained by starting a test and turning
the Drain/Fill valve knob to the drain position. If there is no audible beep and/or the LED
does not come on, check all power supply connections.
Running a Test
7-13
Alternative Testing Method

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.
Particle Counter Settings For Undiluted Sample (not recommended).
Fluid
Viscosity
7-14
Flush
Volume
ml
Flow Rate
ml/minute
Test Volume
ml
Minimum Total
Sample Volume
1-90 cSt
50
25
50 ml
91-160 cSt
20
25
50 ml
160-300 cSt
10
25
50 ml
Test Results
12
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 44062 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.
2. Hydraulic Fluid PowerFluidsMethod for Coding Level of Contamination by

Solid Particles, ISO 4406, International Organization for Standardization, Stockholm, Sweden
Test Results
7-15
ISO 4406 Cleanliness Code Levels

Particle Count Range (per
ml)
ISO Code
7-16
Minimum
(Included)
Maximum
(Excluded)
0.01
0.02
0.02
0.04
0.04
0.08
0.08
0.16
0.16
0.32
0.32
0.64
0.64
1.3
1.3
2.5
2.5
5.0
Particle Count Range (per

ml)
ISO Code
Test Results
Minimum
(Included)
Maximum
(Excluded)
10
5.0
10
11
10
20
12
20
40
13
40
80
14
80
160
15
160
320
16
320
640
17
640
1300
18
1300
2500
19
2500
5000
20
5000
10000
21
10000
20000
22
20000
40000
23
40000
80000
24
80000
160000
25
160000
320000
26
320000
640000
27
640000
1300000
28
1300000
2500000
7-17
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.
NAS
1638
Class
Number of particles per 100 mL

range
5 to 15
15 to 25
25 to 50
50 to 100
> 100
00
125
22
250
44
500
88
16
1000
178
32
2000
356
63
11
4000
712
126
22
8000
1425
253
45
16000
2800
506
90
16
32000
5700
1012
180
32
64000
11400
2000
360
64
128000
22800
4100
720
128
10
256000
45600
8100
1440
256
11
512000
91200
16200
2800
512
12
1000000
182000
32400
5800
1024
Lube Quality - This is a measure of fluid degradation as detected by the colorimetric and
dielectric sensors. This measurement correlates with the analyzer Chemical index.
Dielectric Constant - A measure of the dielectric permittivity of the fluid (i.e., the insulating quality). This will increase as the lubricant becomes degraded by oxidation or acidity.
7-18
Dielectric Index - Reports the change in dielectric constant as an index relative to the reference oil; for which 0.0 is good and 10.00 or more (depending on the alarm setting) is deteriorated lube oil.
Color - A measure of the fluid color. In general, color changes from amber to reddish brown
as oil is degraded. Clear to amber oil has a color value of zero. The value increases as the
red/brown color darkens.
Light Absorbance - A measure of the total optical absorbance of the oil over a range of
optical wavelengths. Directly related to total contamination and degradation of the oil.
ISO Recommended Cleanliness Levels
Component type
Test Results
Fluid classification
ISO code
Servo valves
17/14/11
Vane and piston pumps/motors
19/16/13
Directional and pressure control valves
19/16/13
Gear pumps/motors
20/17/14
Flow control valves and cylinders
21/18/15
Aircraft test stands
16/13/10
Injection molding
19/16/13
Metal working
20/17/14 - 19/16/13
Mobile equipment
21/18/15 - 19/16/13
New unused oil
21/18/15
7-19
Test ISO Plot and Test NAS Plot

The Test ISO and Test NAS plots are graphs of the test data before it has been stored to the
sample in the database. These plots are for viewing 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).
13
7-20
Diluent Test
The Diluent Test tab is used when testing the contamination of particle counter diluents.
These results are used when you test diluted samples. The OilView software automatically
subtracts the counts associated with diluent so that accurate counts for the oil sample can be
computed.
To run a diluted sample test, complete the fields for diluent data: 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.
14
Settings
Use these fields to adjust the flow rate, flush volume, and test volume for the Model 51PC
regular test.
CSI recommends always using the 50 ml/minute flow rate as this is the rate used to calibrate
the sensor. Normally, you will want to select 25 ml flush volume and 5 ml test volume.
Keep in mind that the total sample consumed equals the flush volume plus three times the
test volume.
Test Results
7-21
Sample Preparation
The OilView Particle Counter uses advanced laser technology to count individual particles
down to 2 micrometers in size as they pass through the laser window. These measurements
are naturally sensitive to settling of the particles in the sample bottle and are adversely
affected by air bubbles or water droplets in the oil. Each of these points is addressed separately below.
It is important for particles to be evenly distributed in the sample just prior to testing on the
OilView Particle Counter. A very good way to do this without entrapping air bubbles in the
sample is to use an ultrasonic bath. After thoroughly shaking the sample, tightly seal the
caps on sample bottles and place them in an ultrasonic bath3. 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 Scientific4, can be used in
conjunction with an ultrasonic bath to speed up the removal of entrained air. After initially
removing the majority of air from the sample with an ultrasonic bath, loosen the caps to the
sample bottles and place them in a vacuum chamber for a few minutes to remove the
remaining small air bubbles.
Note
Do not put shaken samples of undiluted oil directly into a vacuum

chamber or foaming may occur.
When this process is complete, tighten the lids to the sample bottles and place them back
into the ultrasonic bath. The ultrasonic bath will keep the particles suspended until you are
ready to perform the test. Be sure to dry the water off the outside of the bottle before opening
and inserting it into the sample cup for particle counter testing.
3. CSI (1-423-675-2110) Parent part number A5101A1.

4. Fisher Scientific (1-800-766-7000) Vacuum Desiccator, Fisher No. 08-642-7. Vacuum Pump, Fisher No. 01-092-25 (115 V AC).
7-22
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:
1Flush the Model 51PC particle counter with the mixed solvent.
2Run a particle counter test on the mixed solvent and store the results as
the diluent.
3Weigh, to the nearest 0.1 gram, an appropriate amount of the sample in a
tared sample bottle. Record and tare the weight.
Note
An appropriate amount of the sample can be anywhere between

one to twenty grams of sample depending upon contamination.
4Add approximately 50 grams of the mixed solvent to the tared sample
bottle. Record the mixed solvent weight to the nearest 0.1 gram.
5Shake the sample and mixed solvent vigorously for at least thirty seconds.
6Degas the sample solution in the ultrasonic bath and optional vacuum
chamber.
7Perform a particle count following the particle counter diluent test
procedure and save the results.
Note
The mixed solvent is proven to be effective on samples with up to

17% water content.
Sample Preparation
7-23
Sample bottle in an ultrasonic bath.
7-24
Dilution of Model 51PC Samples

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.)
Recommended Dilution Ratios.
Dilution ratio for excess contamination:
10:1
Dilution ratio for dark samples:
10:1
Dilution ratio for high viscosity:
1:1
The diluent that is used should be one which is completely soluble with the oil sample.
After mixing the two, there should be no evidence of haziness or layers floating in fluid
this would indicate a mixture as opposed to a solution.
Kerosene makes a very good diluent for mineral-oil-base stocks and nearly all synthetic
lubricants. For typical industrial applications, commercial K1 kerosene will suffice for
flushing to clean the sensor. You can filter commercial K1 kerosene yourself to use for 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.
7-25
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.
7-26
Dilution Ratios
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.
7-27
Measuring by Weight
To measure amounts by weight, use a scale to measure tare weight of the sample, then measure the tare weight of the diluent added to the sample.
1 Turn on the power to the scale, and verify that the scale reads zero (0.0).
15
2 Place the empty bottle on the scale, then select the tare option on the
scale. Effectively, now the empty bottle weights 0.0 gram.
16
7-28
17
3Place the sample bottle on the scale to measure the weight of the sample
(in grams). Write the sample weight on the bottle label.
18
7-29
4 Select the tare option again to make the bottle and sample equal 0.0 gram.
19
5 Add an approximate amount of the diluent. For a 1:1 dilution ratio, add
about the same weight of diluent as the sample. For a 10:1 dilution ratio,
add ten times as much diluent as the sample.
7-30
20
6Write the weight of the diluent on the label along with the weight of the
sample.
21
7-31
7 When testing diluted samples using the OilView Particle Counter, check
the Diluted Sample box under Test Control.
22
8 Then enter the diluent weight and the sample weight in the cells in the
Test Control table.
Measuring By Volume
To measure the amounts by volume, fill with sample to a pre-measured line on the bottle
and then add diluent to a second pre-measured line on the same bottle. The actual particle
counts for the diluent (already stored in memory) will be used by applying the rule of mixtures for the most accurate calculation of particle counts on diluted samples.
7-32
Sensor Cleaning
The internal particle counter sensor does not have to be cleaned very often; however, inadequate pressure problems or laser calibration failure after flushing indicates that the sensor
needs to be cleaned.
The included cleaning brush may be inserted slowly into the sample pick-up tube with a
rotating motion until it stops (approximately one inch of the brush handle remaining below
the sample tube; see illustration on next page).
Flush completely with approximately 200 ml of kerosene or similar light mineral oil for
final cleaning. Check particle counts for repeatability and reasonableness to determine
effectiveness and completeness of sensor cleaning. (The software performs some basic
checks during the Flush Only test.)
Sensor Cleaning
7-33
Note
The laser windows in the Model 51PC are made of sapphire and
cannot normally be damaged with the bristles of the supplied wire
brush.
7-34
23
Sensor Cleaning
7-35
Supplemental OilView Particle Counter Procedures

Flush Till Clean
At the start and finish of each OilView Particle Counter testing day as well as between
sample batches, you will be prompted to flush the sensor with kerosene until an acceptable
particle count is achieved. (A batch is defined as a collection of used oil samples of the same
type, for example the same reference oil.)
Use the sensor flushing option to automatically select 100 ml/min flow rate, 35 ml flush,
and 5 ml test. The particle counter will reinstate the previously set flow, flush, and test
values after flushing. The software will suggest 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.
Sample Types
Certain types of oil samples should not be tested on the OilView Particle Counter. Do not
test an oil unless it readily dissolves in the flushing solvent being used. This is critical
because you will need to flush 100% of this oil out of the system before introducing a different oil type into the particle counter. For instance, if kerosene is used to flush the sensor
clean between batches, then PAO (poly alpha olefin) is likely to be the only synthetic lubricant that can be tested, since other synthetics will not dissolve in kerosene.
Caution!
Do not test per fluorinated ethers (for example, Krytox or Fomblin) since there is no solvent that chemically dissolves this PTFEbased synthetic material.
To prevent excessive flushing time, do not test used diesel engine oils that are black from
soot. Note that all of these types of samples are able to be tested on the OilView Analyzer
even though they cannot be tested using the OilView Particle Counter.
Finally, although it will not damage the particle counter, water/oil emulsions cannot be adequately tested because the water droplets may give false particle counts.
7-36
Screening Samples
Screen certain samples with the OilView Analyzer prior to testing on the OilView Particle
Counter. You may want to use the OilView Analyzer first before using the OilView Particle Counter to test certain samples. This can minimize the time spent flushing the laser
particle counter sensor.
Note
If you intend to screen the sample as described, you should split the
oil sample so that the Model 5100 test does not 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.
Batching Similar Oil Samples
Prior to beginning a test with the OilView Particle Counter, the software will check to see
if the last reference oil is the same as the present default reference oil. If it is the same, or if
the last test was the flush sequence, the test will proceed as normal (50 ml/min flow, 25 ml
flush, 5 ml test; or 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.
7-37
Intelligent Software
The OilView software will evaluate the test results for indications of common problems
and provide messages as appropriate. These helpful suggestions include automatic evaluation of dirty sensor, excessive contamination requiring dilution, or excessive viscosity
requiring dilution.
Sensor Cleaning
When the sensor does not come clean with multiple kerosene flushing, use the wire brush
supplied with the particle counter to clean the sensor (see Sensor Cleaning on page 7-33).
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.
Kerosene
Clean kerosene can be purchased from Fisher Scientific5 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.
5. Fisher Scientific (1-800-766-7000) Odorless kerosene, Fisher No. K10-4.
7-38
Chapter
The OilView Ferrous Wear Monitor - Model 51FW
Introduction
The Model 51FW Ferrous Wear Monitor is a single-purpose analyzer that rapidly tests
lubricants and greases for ferrous wear particles.
The Model 51FW uses a magnetometer to sense (through the plastic of an unopened
sample bottle) the change in permeability due to the presence of a lubricant or grease contaminated with ferromagnetic particles. Because viscosity does not affect the measurement,
the Ferrous Wear Monitor is ideally suited for measuring viscous oils, such as gear lubes
and greases, without dilution.
Also, because the Model 51FW does not depend on optical properties, it can easily be used
on opaque and/or soot loaded oils without any special preparation.
8-1
Note
The Model 51FW does not detect lube degradation. Sufficient

quantities of non-ferrous particles can be detected and will generate a non-ferrous particles message in the status area.
Standard Equipment
The Model 51FW is available for stand-alone operation or as an accessory to either the
Model 5100-1, 5100-2, or 5200.
The stand-alone system consists of:
The Ferrous Wear Monitor instrument
Power supply and cable
15-pin to 9-pin female cable
Reference standard
Software
Users manual
The accessory system consists of:
The Ferrous Wear Monitor instrument
15-pin to 15-pin female cable
Reference standard
Caution!
The cables provided with the Model 51FW are custom engineered
and cannot be substituted with a standard serial cable.
8-2
Software Setup
The OilView software must be informed that you will be using a Model 51FW. Click the
Setup tab on the main menu and check the appropriate checkbox to specify the port where
the Model 51FW is connected. When finished, click on the Save Changes button.
Model 51FW connected to Port 2 of the Model 5100.
Software Setup
8-3
Model 51FW connected to Comm 1 on the computer.
8-4
Cables And Connections

There are two ways to connect the Ferrous Wear Monitor depending on whether it is to be
connected to an OilView Analyzer or directly to a computer.
Connection to OilView Analyzer Port
The Ferrous Wear Monitor Model 51FW can be connected to port 2 on the OilView Analyzer Model 5100-1 or 5100-2 via the supplied 15-pin to 15-pin cable. Plug one end of the
cable into the Model 51FWs Communication port and the other end into the Model 5100s
port 2. This cable also supplies power to the Ferrous Wear Monitor.
8-5
Computer Connection
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.
8-6
Alternate OilView Analyzer Port
Using the power supply, the Ferrous Wear Monitor can be connected to port 3 or 4 of the
OilView Analyzer with the 15-pin to 9-pin communications cable; freeing port 2 for use
with the Digital Viscometer.
Power Switch
The Ferrous Wear Monitor uses a three-way power switch. Operation is shown in the following illustration.
Caution!
The 51FW uses an internally generated magnetic field and sense

coil. External fields from some electronic devices or computer
monitors may interfere with the 51FW and cause erratic readings.
Large metal objects may have a similar effect. Move the 51FW
away from these objects.
8-7
Calibrating the Ferrous Wear Monitor

Before testing any samples, the Ferrous Wear Monitor Model 51FW must be calibrated
(with the provided calibration standard) using the following procedure. Calibration is quick
and should be performed on a daily basis.
Empty/Clean Calibration
When testing with the Model51FW, it is possible for a clean, empty sample bottle to cause
a slight reading by itself. This is due to the composition of the plastic used to make the
sample bottles. To account for this, a clean, empty sample bottle should be tested. The bottle
should be the same type as those used for collecting routine samples. If you change the type
of bottle you use, simply use the new bottle the next time you calibrate your unit.
When a standard calibration test is run, the result of the empty bottle test is automatically
subtracted from the standard calibration test results. This zeros-out the reading from the
empty bottle.
Select the 51FW tab on the top of the main menu, then click the Calibrate Empty tab. (Note
the date of the last calibration in the upper-right corner of the window.)
8-8
Note
The 51FW uses an optical sensor in the black ring on top to sense
bottle placement. Some empty bottles may not be sensed; therefore, you may need to add tape around the bottom of the bottle.
Click the Start button to begin the calibration procedure, the 51FW 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.
Standard Calibration
After completing the Empty/Clean calibration, select the 51FW Standard Calibration
option located under the Calibrations option of the Setup menu. Repeat the same test procedures using the CSI-supplied calibration standard.
The following section, Taking Calibration Readings, provides greater detail on testing
and the prompts given in the User Action box.
Taking Calibration Readings

The 51FW Calibration Standard needs no special preparation to be measuredsimply
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.
Note
Bad readings are commonly caused by slow placement of the

sample or movement of the sample before the measurement has
been completed.
Calibrating the Ferrous Wear Monitor
8-9
You will be asked to place and remove the Calibration Standard until the software records
three good readings. Upon completion of the calibration procedure, the test status will show
finished and you should click the Save button to store the results.
Note
An excessive range message indicates an inconsistency between

the three bottle placement readings. This is most commonly caused
by the standard being placed off-center from the red sensing area.
Note
Although not required, CSI recommends that the Model 51FW be

calibrated daily. The 51FW index value for tests run using the calibration standard should equal 100 (5). Any fluctuations in the
electromagnetic readings will be zeroed out when the 51FW is calibrated.
Note
Although not required, CSI recommends that the Model 51FW be

calibrated daily. During calibration, the raw results for the calibration standard typically will be in the 300 to 400 range. Then, when
the calibration standard is re-tested under the 51FW Test tab, the
software scales the raw results so the 51FW index value should
equal 100 (5). The number on the calibration standard bottle is
simply a reference index as compared against a gold standard at
CSI. Any fluctuations in the electromagnetic readings will be
zeroed out when the 51FW is calibrated.
8-10
Testing Samples With the Ferrous Wear Monitor

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.
8-11
After pressing a key, the OilView software will average the three readings and display the
result.
Note
Data taken from a regular Ferrous Wear Monitor test may not be
stored to a reference file.
Screening
The sample screening tab is used to screen samples without saving the results to the database. This is also a good place to verify your calibration. Three readings are averaged per
sample. Pressing he Next button starts a new set of readings.
Diagnostics and Raw Data

The 51FW Diagnostics and Raw Data tabs display information which is mainly useful to
CSI Customer Support for trouble-shooting problems. These tabs are normally grayed out,
but may be enabled through the main Setup / System / Diagnostics check box.
The 51FW Raw Data plot is sometimes useful to see why bad readings are occurring. A
good raw data plot for the calibration standard is shown below. The raw data plot shows 40
measurements that were taken before, during, and after bottle placement. The plot should
be relatively flat before and after bottle placement and show a steep rise in the middle as the
bottle is placed. A more gradual upward slope in the middle indicates the bottle was placed
too slowly. Bumps in the plot that occur before or after bottle placement usually indicate
slow bottle placement or bottle movement (including bouncing or sliding) after placement.
8-12
Note
Ripples in the plot could indicate electromagnetic interference

resulting from the 51FWs being too close to another electronic
device.
8-13
8-14
Chapter
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 9-13, discusses wear mechanisms and how
the OilView analyzers and microscopes assess wear.
Although you do not have to capture images to do wear debris analysis, it is helpful to use
a CCD camera with video capture to bring live images into the image window. The 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.
9-1
Video Camera
Recommended Specifications
Minimum System Requirements
1/3" Color CCD
Camera
470 TV lines horizontal resolution
Power Supply
768 (H) x 494 (V) effective pixels
Video Cable Assembly
525 line/60 Hz 2:1 interlace scanning

system
C-Mount Adapter Ring
NTSC or PAL video output

Small size for mounting on microscope
Video Frame Grabber

Recommended Specifications
Minimum System Requirements
Composite NTSC, PAL, or S-Video input Intel Pentium computer or greater

24/16/15 bit RGB video digitizing
8 MB RAM (ideally 16 MB or more)
640 x 480 NTSC (768 x 576 PAL)

digitizing resolution
MS Windows NT or Windows 95 or later
30 frames/sec, 60 fields/sec
TWAIN Video Capture Software

Interface
Full bandwidth PCI bus mastering read

and write (up to 132 MB/sec)
One available PCI 32-bit bus master
expansion slot
Interpolated scaling in X and Y directions
Digital control of offset, gain, brightness,
contrast, hue, and saturation
The CSI Model 51CV Wear Debris Image Capture Kit includes a camera and video frame
grabber card. Refer to the camera and capture card manuals for installation and setup
instructions.
9-2
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.
9-3
In effect wear debris analysis introduces another level below the sample level on the User
Database treethe image level.
9-4
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.
Sample
The Sample tab is used to analyze and document this analysis for each individual image as
well as the overall oil sample. These features on the screen pertain to the image and to the
sample.
Feature
Image
Photograph with tool bar
Image Caption
Image Note
Sample
Wear Debris Analysis Sample Diagnosis
Analysis Grid with 5 Groups
9-5
Sizes range from Fine <6u, to Small 6-14u, to Med 14-40u, to Large 40-100u, to
Huge >100u.
The photograph taken through the microscope is captured using the Capture button. Otherwise, photographs are imported using the Add File button.
Note
When capturing an image with the 51CV Image Capture Kit,

verify the Input Type setting is SVideo. Save this setting.
Once the image is captured or added to the sample, additional images are sequentially
appended and can be scrolled through using the left and right arrow buttons.
Each image can be given a caption and note. These notes and captions remain associated
with the image and are not passed on to the sample record.
Notes added to the wear debris analysis Sample Diagnosis field are copied to the sample
record under the Sample Info tab. These notes apply to any or all images for a given sample.
The wear debris analysis grid includes five pages. Each page represents an analysis of a different group of particles. To do this analysis you can select one item from each column for
each group which most closely describes the group.
9-6
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.
9-7
Measuring Image Size and Particle Density
Before you can measure the size of particles in the captured image, you must calibrate the
microscope capture system.
Note
You must enter the magnification and zoom settings on he microscope when the image is captured.
To measure the particle size, first click on the Measure (particle size and set rectangle for
counting particles) button. Next, position the cursor near the particle, press the left mouse
button, and then draw a rectangle around the particle. The size of the particle is shown in
the popup dialog box.
Counting Particles
To measure the particle density (particles per square millimeter), first press the Measure
button and then draw a rectangle around the region 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.
9-8
Sample/Atlas
This screen is used to compare images from the wear debris analysis Atlas with sample
images and to import analysis results accompanying the atlas image over to a selected
group in the sample image.
The left photograph is functionally the same as it is on the Sample screen, except that you
cannot edit the caption, notes, or select through the wear debris analysis grid.
The right photograph is one from the atlas. If no atlas image is present then you may scroll
through the tree on the lower right to select and view until you see one that looks like the
sample image.
The Show Analysis button displays the WDA matrix settings for the selected atlas image.
Once you have found an image that has features you want ported over to the wear debris
analysis, select one of the five groups on the lower left and then select the <<< button. This
automatically replaces entries in that analysis group with those from the atlas image.
Go back to the Sample tab to edit these entries to exactly fit your analysis of the sample.
9-9
Atlas Setup
The Atlas tab is much like the Sample tab except that it is used to add or edit the wear debris
analysis Atlas. You must be an advanced user to edit the atlas.
The tree on the upper left is used to select the image to be viewed, and the note field below
the tree contains information relevant to this image.
The wear debris analysis grid below the image represents the most obvious group of particles in the atlas image. There is only one group of particles represented in this grid.
To add images to the atlas, first use a right mouse click on a tree folder and select the Add
Child Folder option. Then use either the Add file or Capture buttons below the photograph
to add an image to the folder. These work the same as they do for the Sample images.
9-10
Analyst tab
The Analyst tab displays multiple sample images simultaneously for easier classification
and diagnosis.
9-11
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.
9-12
The OilView Analyzers And Wear

Wear is the (unwanted) removal of material from a surface. In lubricated machinery,
abnormal wear results from one or more of three general mechanisms: abrasion, fatigue, or
adhesion.
Severe Abrasive Wear
Severe abrasive wear is the removal of surface material through the cutting action of relatively harder particles against a relatively softer surface. Grinding, sanding, and polishing
processes are all examples of intentional abrasive wear.
Abrasive wear occurs in lubricated systems primarily through 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.
Fatigue Wear
Fatigue wear is caused by cyclic loading of metal surfaces. This wear eventually results in
micro-cracks in the surface which causes separation of metal from the surface as the cracks
spread. Metal surfaces exposed to cyclic loading often fail from fatigue. The time to failure
decreases with increasing load and increasing cyclic load frequency. This implies that high
loads from sharp surfaces can cause both abrasive and fatigue wear in rolling elements.
Common machine parts subject to fatigue failure include gear teeth, roller element 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.
9-13
In many cases, fatigue wear will not have a solution other than planning to replace the worn
part. In the short term, corrosion influences and secondary abrasive wear from fatigue wear
particles should be minimized by changing the oil and filter. In addition, vibration analysis
should be performed on the machine to determine if the system is being subjected to 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.
Adhesive Wear
Adhesive wear is caused by metal to metal contact in the absence of an oxide or lubricant
film. The mechanism involves bonding at the atomic level between clean opposing metal
surfaces. Wear debris produced by adhesion is often referred to as rubbing or sliding wear.
The size of the wear particles produced is generally dependent on the roughness of the
opposing surfaces. Finely finished metal surfaces produce very fine wear debris particles.
Mild adhesive (rubbing or sliding) wear is normal in many machine types.
Sliding wear particle sizes may decrease over time as opposing surfaces polish one another.
This is the case during break-in of newly aligned or machined bearing surfaces.
Abnormal adhesive wear is usually a result of an inadequate oil film, or increased surface
roughness. The OilView Analyzer sensor grids and Ferrous Wear Monitor are only 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.
Testing For Ferrous Wear with the 5100
When the OilView Analyzers or Ferrous Wear Monitor are used to screen for ferrous wear,
the most important things to look for are increasing 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.
9-14
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.
9-15
Allow the oil to drain into the bottle and remove the bottle from the grid. Place the grid back
on the analyzer and attach the microscope. Initiate an OilView Analyzer test to cycle the
analyzers electromagnet. You can then observe ferrous particles as they are rotated
through three distinct angular positions each second.
Note
To classify particles, see the CSI Wear Particle Atlas.

If the residue moves with the magnet, the material is ferromagnetic. If individual particles
can be resolved with the naked eye under a bright light, they are probably 40 microns or
larger along their smallest dimension and are evidence of abnormal wear of a ferrous surface. If the particles are chunky or plate-like, fatigue wear is likely. If the particles appear
to be long narrow strips or have a spiral appearance, cutting (severe abrasive) wear is likely.
An alternative method is to submerge a white magnet in the oil, lightly rinse it with solvent,
and look for magnetic particles adhering to the magnet. The magnetic particles will tend to
follow the lines of magnetic flux and will concentrate on the corners of the magnet.
9-16
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.
Using the Model 51WD Wear Debris Patch Maker

The Model 51WD Wear Debris Patch Maker is a complete, standalone system, including
vacuum pump and waster container, for preparing wear debris filter patches. See the diagrams below for setting up the system and assembling the patch holder.
The patch maker offers these features:
Separation of large particles from smaller particles using stacked filter
patches.
Magnetic separation of ferrous particles from non-ferrous particles on
separate patches.
Easy clean-up and disposal of waste oil.
Preparation
Select the pore size(s) for the filter patch(es) based upon the estimated or measured particle
size range. Standard filter patch pore sizes are 3 micron and 8 micron. Other pore sizes
ranging from 0.8 micron to 30 micron are readily available and may be used. A few tests
will quickly reveal what pore sizes tend to plug and which ones yield meaningful specimens. The goal is to produce wear debris analysis patches with particles distributed so they
can be easily viewed with a microscope.
Assemble the filter into the patch maker including all O-rings and screens according to the
diagram.
9-17
Patch Making
All samples must be diluted before they are put into the patch maker. A very small amount
of actual sample is required. About 2 ml of sample should be used consistently, unless a
sample is extremely clean or extremely dirty. Shake the sample thoroughly and then extract
2 ml using a clean pipette. Add this to a clean mixing bottle or beaker, and then add 10 to
20 ml of solvent (lamp oil will suffice). The diluted sample will filter and clean-up more
easily as well.
Shake the diluted sample and then pour it into the patch maker chamber. Press the vacuum
pump foot pedal to run the pump and suck the sample through the patch. Pour additional
solvent into the chamber while vacuuming to wash the particles through the plumbing and
to clean the oil residue off of the filter patch. Continue running the pump and suck air
through the patch to help dry it.
Remove the filter patch(es) from the holder and allow them to dry. After they have dried,
glue them onto the backing in the filter storage container so they will stay flat for microscopic viewing.
Dual Filter Sizes
You can separate large particles from smaller particles using stacked filter patches. For
example, if the sample is highly contaminated you may choose to use a 30 micron filter
above a 10 micron filter. Keep in mind that the small pore size filter is most often the one
that is plugged from excess contamination.
9-18
Ferrous / Non-Ferrous Separation
If you wish to view ferrous and non-ferrous particles on separate patches, then use the
sheathed magnet to extract ferrous particles from the diluted sample mixture before ever
adding it to the patch maker chamber. After removing the ferrous particles, you can pour
the remaining diluted sample into the chamber and prepare the non-ferrous patch. Remove
the non-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.
10
9-19
11
9-20
Using the Model 51SM Shop Microscope

The Model 51SM shop microscope can be set on the top of the OilView Analyzer directly
over the sensor grid as shown in the following 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.
Model 51SM using oblique lighting.
Model 51SM using through-lens lighting.
9-21
Through-lens lighting can be used when viewing particles where the oil film has been
removed; however, oblique lighting is best when viewing particles in an oil film. (An oil
film clouds the image when using through-lens lighting.)
Keep in mind that the process of removing the oil film with solvents will also remove most
of the non-ferrous particles. Therefore, oblique lighting can be used first to view both 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.
Model 52LM Lab Microscope
Refer to the manual which came with your microscope for setup and operation instructions.
9-22
Model 52ZM Stereoscopic Zoom Microscope
The 52ZM Stereo Zoom Microscope provides three-dimensional viewing of wear debris
particles. Continuous zoom magnification allows samples to be quickly searched at low
power and then zoomed in to a higher magnifiction. See the illustration below and the
microscope manual for setup and operation.
12
9-23
9-24
Chapter
10
The Model 5200 Trivector Analyzer
Introduction
The Model 5200 Trivector Analyzer is a complete minilab-in-a-box. It combines the
Model 5100 type system with a particle counter and wear debris analysis system in a single
unit, giving enhanced performance. The scale can be used for accurately measuring the
dilution of oil samples.
The right-hand chamber (Test 1) is used to measure the dielectric of the neat oil and, with
the aid of a reference oil, produce the chemical index. The center chamber (Test 2) is used
to measure the contamination and ferrous indices of a diluted oil sample, and the tower
arrangement (Test 3) is the particle counter. The mechanical assembly on the front panel is
a filter patch maker that works in conjunction with the diluted oil in the Test 2 chamber.
10-1
Instrument Overview
The front panel of the instrument is replicated in the software interface, and the instrument
can largely be operated from either interface aside from certain mechanical operations.
The interface is divided into three tests. Test 1 measures the dielectric of the neat oil, Test 2
the contamination and ferrous indices, and Test 3 the particle counts. In addition, the diluted
oil from the Test 2 chamber can be filtered through the patch maker to create wear debris
filter patches.
The front panel has a series of colored LEDs that are used to indicate the status of each test.
In general, a flashing LED indicates the next action that you should take. The four push buttons are used to control the tests and weighing sequence of the scale. Associated with these
buttons are four check boxes that are used to turn on (checked) the test or scale. This enables
you to only use those tests required for a particular oil sample.
The Trivector status of the oil sample is also displayed on the front panel using red, yellow,
and green LEDs.
10-2
The 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.
Front view of the Model 5200.
Initial Setup
The 5200 must be connected to a computer for starting and controlling the test sequences
and for collecting the test results. Also, the analyzer comes complete with a waste container
system including a vacuum pump. The communications cables and plumbing must be connected before the instrument can be operated.
Instrument Overview
10-3
Cable Connections
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.
Caution!
Before making any cable or power connections, turn off the power
to the unit by toggling the power switch on the rear panel to the off
position.
Caution!
The 5xDV communications port is a 15-pin, high-density sub-D

connector which provides both power and serial communications.
Use caution when inserting the 15-pin cable into this port as it is
possible to force the connector upside down damaging the cable
and the port connector. Always make sure the power is off before
connecting this cable.
Note
The power supply cable connector is keyed and labeled on the top
position.
Software Setup
After verifying the cable connections, go to the Setup/Comm Ports software screen and
configure the ports as described in Chapter 1.
Electronic Scale
The analyzer system includes an electronic scale which is used for accurately weighing
dilution ratios. The scale comes with its own DC power supply which is unique and should
not be used on any other instrument. The scale also uses batteries, but its power supply
should be used to keep it out of power saver mode.
Connect the scale to its port on the back of the 5200 using a 9-pin, RS232 cable.
10-4
Note
The null modem communications adapter must be connected inline with the cable to the electronic scale (Model VIR-400 only).
Caution!
Do not apply excessive force to the weighing surface of the scale.

Doing so will overload and damage the weighing mechanism. If
the scale must be packaged or stored, then remove the plastic and
metal trays, and store them separately. Also, protect the weighing
posts that protrude from the top of the scale.
Instrument Overview
10-5
Scale Configuration (may be skipped if scale has already been configured)

Note
There are two different scale models with slightly different keypad
interfaces. The keys for the newer, VIC-511 VICON model (CSI
P/N 93030) are described below with the older, VIR-400 model
(CSI P/N 93035) keys listed in parentheses.
1. To gain access to the balance internal menu system, start with balance
turned off.
2 Now briefly press the ON/OFF (ON/MEMORY) key and immediately
(and briefly) press the ZERO (TARE/PRINT) key on the scales keypad.
You should see a 1 toward the left side of the LCD display. This is the
left segment value.
3. There are three segment values on the display: left, center and right. Four
categories need to be set-up for the scales, the Baud Rate, Parity, Stop
Bits, and Handshake. Use the F (TARE/PRINT) key repeatedly to
increment the segment values. Use the ENTER (CAL/MODE) key to
switch from one segment position to another.
4. Once a category has been set up with correct values, PRESS & HOLD
the ENTER (CAL/MODE) key until o or > is displayed in the lower
right of the right-segment display. This indicates the category values have
been stored.
5. Now repeat Steps 3 and 4 for the remaining set-up categories in the table.
6. To finalize and save ALL revised parameter settings, press and hold the
ZERO (TARE/PRINT) key until the balance resets (balance displays all
zeros). Now all of your new settings will be balance defaults at startup.
10-6
Segment Position
Category
Left
Center
Right
Baud Rate
Parity
5* or 2*
Stop Bits
2** or 1**
Handshake
* Parity = 5 for VICON model; or 2 for VIR-400 model

** Stop Bits = 2 for VICON model; or 1 for VIR-400 model
Instrument Overview
10-7
Scale Calibration
1. Place the scale in a stable environment free from vibration and air
currents.
2. Remove all objects from the scale tray top, power on the scale, and allow
it to warm up a few minutes.
3. Press the ZERO (TARE/PRINT) key briefly to re-zero the scale. The
scale should display a stable 0.0 g reading.
4. Model VIC-511 (VICON):
a. Press the CAL key briefly. The preset calibration weight will be
displayed.
b. Press the F key repeatedly until the 100g calibration weight is
displayed.
c. Press the ENTER key to confirm the weight and start calibration.
CAL will be displayed followed by the calibration weight
flashing on the display.
d. Place the 100g calibration weight on the balance.
e. If successful, the readout will stop flashing.
f. Remove the calibration weight and the display should return to
0.0g.
g. Calibration is complete.
10-8
Model VIR-400 only:

a. If the Units arrow points to a different unit than grams, then press the
CAL/MODE key repeatedly until the arrow moves to the gram position.
b.Press and hold the CAL/MODE key until +200.0 appears on the display.
c. Gently place the 200 gram calibration weight onto the center of the tray
top.
d.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.
e. When internal calibration is complete, the unit will beep, the display will
blink, and the + sign will re-appear with the correct weight displayed.
f.
Remove the calibration weight and press the TARE/PRINT key briefly
to reset the scale to zero.
Error Codes
The following error codes may be displayed during scale operation of the VIR-400 model.
Error Code
L
H
E-02
E-10
E-30
E-54
Triangle
Meaning
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 that you not exceed the
maximum load capacity of 600 grams for this scale. If
exceeded, damage to the scale may occur.
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.
Turn the unit off and back on to clear stored Memory value.
Electronic malfunction. Return the unit for evaluation.
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.
(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.
The following error codes may be displayed on the VIC-511 model scale:
Instrument Overview
10-9
Error Code
No segments appear
oL
UL
disErr
calErr
appErr
PrtErr
Bal.Err
Sep.Err
10-10
Meaning
No power available - check the power supply; plug in the
AC adapter. Battery is drained; Replace battery.
The load exceeds the balance capacity ; unload the
balance.
Weighing pan not in place. Place the weighing pan on
the balance.
Display overflow: Reduce load on the balance. Value
cannot be shown.
Calibration parameter not met; e.g.: Calibrate only when
zero is displayed
Balance not zeroed Press (ZERO) to tare the balance
Balance is loaded; unload the balance
Weight is too light or increase the weight on the balance;
there is no sample on the balance
Data interface for printing is blocked; Contact customer
service center
Balance/scale loaded when power was turned on or
defective. Unload balance/scale before switching or
contact Acculab customer service.
Balance/scale defective. Contact Acculab customer
service.
Scale Functional Test

Verify correct balance setup and functionality by doing the following:
1.Connect the serial COMM cable from the scale to the 5200 / 52PC Port 4.
For the Model VIR-400 only, include the Null modem adapter on the
COMM port at back of the scale. The VIC-511 VICON model should
have its RS232 adapter (CSI P/N 93038) with attached cable already
installed in the bottom of the scale.
2.Power on the scale and select the ZERO (TARE/PRINT) button. The
scale should display 0.0 if no object is on the scale.
3.From the 5200/Diagnostics/Misc Diag/Balance tab, select the
appropriate scale model type. Then select the Read button. With no
object on the scale, it should display on the computer screen the same
value that is shown on the scale LCD display. If the software displays an
error or no weight, then re-check cable connections then repeat Scale
Configuration, Step B, and re-test.
4.Now repeat Step 3 with the scale calibration weight on the scale. The scale
should read between 99.5 and 100.5 grams with the 100 gram weight or
between 199 and 201 grams for the 200 gram weight.
5.If the scale passes both Steps 3 and 4, it is set up and working.
Save Scale Model Type

1.Go to the 5200/Diagnostics/Diag Settings tab in the software.
2.Under the Dilution / Scale frame, select the correct Scale Type model for
the scale being used with the 5200.
3.Click the Save button to save this setting to the 5200.
Instrument Overview
10-11
Waste Container System
The waste container system provides a means for automatically removing waste oils and
cleaning the 5200 after each test. The vacuum pump is used to vacuum the waste from the
Test 1 and Test 2 sensors. It also provides vacuum degassing of air bubbles from the syringe
for Test 3. The vacuum line is not connected to the Test 3 sample port. This port may be
flushed by manually squirting a syringe full of solvent into the sample port. Test 3 uses a
direct drain line into the waste container. Refer to the assembly diagrams below for setting
up the waste system.
Warning!
The vacuum pump is not explosion-proof. It must not be used in

the presence of flammable liquids or gases. Adequate ventilation
of its exhaust is required.
Vacuum Relief Valve
Once a vacuum has been applied to the system, the pump will hold this vacuum until the
system has been fully vented, even after the pump stops running. The vacuum is released
slowly from the flasks as air enters one of the 5200s test ports. This release usually takes
several seconds. In some cases, the vacuum may need to be released more quickly,
depending upon the next operation to be performed by the user. For example, a vacuum
should not be applied to Test 1 during its test as this may introduce air 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.
10-12
Note
The vacuum pump will not restart when the system is already
holding a vacuum. If the foot pedal is pressed, and the pump does
not run, then the system is already under vacuum, and additional
vacuum from the pump should not be required until the vacuum is
released.
3
Instrument Overview
10-13
Hardware/Software Startup
Turn on the power to the analyzer using the switch in the rear. On power-up, the analyzer
should sound one initial beep, pause, and then sound two more beeps. It is best to powerup 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.
Note
Any communications errors must be resolved before using the

instrument.
10-14
Rear view of analyzer.
Side view.
Instrument Overview
10-15
Test Procedure
The 5200 Trivector Analyzer has a simple 1-2-3 step operation yielding automatic chemistry, contamination, and wear measurements in about 5 minutes. When appropriate, a
fourth step is added to extract particulate debris on filter patch(es) for detailed microscopic
wear debris analysis. The steps below outline the testing sequence:
Front view of the Model 5200.
Test 1, chemistry. Fill 10 ml syringe with neat, undiluted oil. Insert syringe tip and
inject into hole at bottom, run test, and then flush/clean with solvent.
10-16
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.
Sampling
When collecting used oil samples, collect approximately 2/3 of a sample bottle of oil. This
will be sufficient for running the digital viscometer test and all 5200 tests. Do not fill the
bottle to the top. Full bottles are not easily mixed by hand shaking. If you need more oil for
other tests, consider collecting a second sample bottle.
Viscosity
Use the OilView Digital Viscometer to measure the viscosity of the undiluted oil sample.
You may want to test viscosity on all samples in the batch before beginning 5200 tests.
Always run the viscosity test on the undiluted oil before the 5200 tests.
Solvent Selection
Before testing any oil samples, test that the cleaning solvent easily dissolves with that oil
type. To test this, add equal amounts of oil and solvent to a clear bottle, shake, and watch.
If the fluid comes clear in 10 or 15 seconds then you are okay to begin testing. If the mixture
stays milky, cloudy, or separated into layers, STOP. Find another solvent that easily dissolves in that oil before testing it in the Trivector Analyzer. The table below provides a general guideline of solubility for different oil types.
Table 10 - 1. Oil and Solvent Solubility: Y=Yes, N=No
Original Ultra
Pure
Dielectri Lamp
Oil Class
Lamp
c
Oil or
Kerosene Oil
Mineral 2.1 - 2.4 Y
Y
Oil
Instrument Overview
Original
Lam Oil Toluene Hexane Fluid A Fluid B Fluid C
+ Fluid B
Y
Most
industrial
lubricants
10-17
Table 10 - 1. Oil and Solvent Solubility: Y=Yes, N=No

Original Ultra
Pure
Dielectri Lamp
Oil Class
Lamp
c
Oil or
Kerosene Oil
PAO
2.1 - 2.4 Y
Y
Original
Lam Oil Toluene Hexane Fluid A Fluid B Fluid C
+ Fluid B
Y
Diester
POE +
PAG
3.4 - 4.3 Y
4.6 - 4.8 Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
PAG
6.6 - 7.3 N
PhE
6.0 - 7.1 ?
Synthetic
Hydrocarbon
Diester
Polyol
Ester +
Polyalkylene
Glycol
Polyalkylene
Glycol
Phosphat
e Ester
Warning!
Both Toluene and Isopropyl Alcohol have flash points below room
temperature. They require an explosion proof vacuum pump.
Software Test Setup
The software provides instructions and the hardware flashes appropriate LEDs to automatically lead the user through the test sequence. However, before pressing the Start button to
begin testing, check the following:
1 Select the correct sample on the database tree. If the sample is not there,
then add the sample to the correct Area, Equipment, and Point.
2 Normally all three 5200 tests are run by default. If some tests are not
required for a particular sample, then un-check the test-enable boxes next
to the test icons for the non-required tests.
3 When diluting by weight using the scale, make sure the scale-enable
checkbox is checked. Also, select the additional dilution for Test 3 as
needed.You will be directed to the scale at the appropriate time during the
test.
4 Press the Start button in the software. This will initiate the testing
sequence. Now simply follow the instructions and the flashing LED.
10-18
Test 1, Chemistry
Use this test to accurately measure the dielectric of the neat, undiluted oil sample, and
generate the chemical index. You may also use this test to establish a reference dielectric for
a new reference sample on the Ref DB tree.
1Thoroughly shake the sample bottle to get a homogeneous mixture.
2Use 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.
3Place 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.
Instrument Overview
10-19
Note
To obtain more accurate results for high dielectric oils, first prime
the sensor with 5 to 10 ml of the undiluted sample.
4 Press the button next to the flashing Test 1 LED. The test will take
approximately 5 seconds. The LED will change to solid red after the
results have been automatically read and saved to the database.
5 When the LED changes to a flashing yellow color, this means that it is
time to clean Test 1. This may occur immediately after Test 1, if it is the
only test in the sequence, or at some later time if other tests are being run.
6 Flush Test 1. Remove and discard the syringe. Use the foot pedal to run
the vacuum pump to evacuate the oil from the Test 1 chamber. You may
push thick oils out of the sensor using a syringe filled with solvent.
7 Clean Test 1. Pour lamp oil or other solvent into the chamber to flush out
the oil. Do this for 5 to 10 seconds, and then, without pouring any
additional solvent, just vacuum air through the chamber to dry it.
8 Perform a clean check. Press the Test 1 button next to the flashing yellow
LED, and the software will take a reading. If not sufficiently clean, you
may try vacuuming more air and pressing the button again. If this fails,
then clean by flushing with more solvent and vacuuming air, then repeat
the clean check.
9 When the chamber is sufficiently clean, you will be directed to the next
test to clean, or to wait for Test 2 to complete.
Test 2, Wear and Contamination
Use this test to detect water and metal debris that settle out of the oil onto the sensor at the
bottom of the chamber. The patented, time-resolved dielectric measurement is sensitive to
water, iron, and other metal particles in the oil. All oil samples are diluted approximately
1:1 with solvent (see Table 1) before filling the Test 2 chamber with approximately 20 ml
of diluted oil. Dilution reduces the viscosity of industrial oils having a viscosity range of 32
to 680 cSt down to a very low range of 10 to 20 cSt. This allows the particles to settle during
the test time. Dilution also makes cleaning easy and cross-contamination unlikely.
10-20
Note
If subsequent Test 3 particle counting is to be run on the sample,

then the representative particle count for the diluent must be saved
first using the Calibrate/Test 3 Diluent/Clean Fluid Calibration
procedure described later in this chapter.
Note
If testing a new reference oil sample, refer to the section on reference oil tests.
After completing any required, undiluted oil tests (for example, viscosity and Test 1 chemistry tests), follow these Test 2 procedures:
1Determine 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.
2Dilute the sample approximately 1:1 in its original sample bottle, using
the appropriate solvent (see Solvent Selection information above).
3Replace the lid on the sample bottle and shake vigorously until the Test 2
LED flashes green indicating the sample may be added.
4Open 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.
Instrument Overview
10-21
Note
High dielectric oils such as PAGs or Phosphate Esters require

priming of the sensor grid. The software will check the Test 1
dielectric and the reference dielectric. If either value is above a
threshold, the software will prompt the user to prime the Test 2
sensor grid with a few ml of the diluted sample. After 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.
Caution!
Never touch the Test 2 sensor grid with a hard object! Doing so
may permanently damage the sensor.
9 Perform a clean check. Press the Test 2 button next to the flashing yellow
LED, and the software will take a reading. If not sufficiently clean, you
may try further drying and press the button again. If this fails, then clean
by flushing with more solvent and vacuuming air, then repeat the clean
check.
10-22
Manual Clean Check
Tests 1 and 2 include a manual clean check button (the C button on the display next to the
test icon) that may be used before starting a test to make sure the sensor has been left clean.
This will perform a short test and display the dielectric value of the clean sensor. A dry
sensor will have a dielectric close to 1.00. However, a slightly wet sensor could read 1.20
or higher. The software will display a message indicating the pass/fail status.
Test 3, Particle Counts
Use this test to count particles and determine particle size distributions in eight different size
ranges. This is a laser optical particle counter. Air 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.
Instrument Overview
10-23
The following table summarizes the water masking solvent options:

Table 10 - 2. Patented Particle Counting Water Masking Options
Solvents
Isopropyl
DOWANOL
Toluene
Ratio (Diluted
Alcohol
DPnB
(Fp 50F)
Water Masking
sample to
Application
(Fp 54F)
(*Fp 205F)
Available from
Solvent Mixture
Available from masking fluid)**
Available from
chemical supply
chemical supply
chemical supply
Mask 1
100%
Add until clear Particle count
with water-in-oil
Mask 2
75%
25%
1:2
Particle count
with water-in-oil
Mask 3
25%
75%
1:2
Particle counting
diluent for waterglycol hydraulics
*Fp = Flash point
**These solvent blends are added to the already diluted 1:1 sample from Test 2.
Warning!
Both Toluene and Isopropyl Alcohol have flash points below room
temperature. They require an explosion proof vacuum pump.
5200 Back-Flushing Procedures
Current 5200 Analyzers have back-flush capabilities for Tests 1 and 3. This is to aid in
cleaning large debris that becomes lodged in either of these 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.
10-24
Test 3 Back-Flushing Procedure

1Remove the cap from the Test 3 back-flush fitting.
2Move the Test 3 drain line from the normal drain fitting to the back-flush
fitting.
3Place the cap on the normal drain fitting.
4Place the end of the Test 3 drain tubing into a container of clean diluent.
5Insert a syringe into the Test 3 sample port, and pull the plunger up to
back-flush clean diluent.
Dowanol Statement
Dowanol DPnB is a clear colorless solvent produced by the Dow 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.
Instrument Overview
10-25
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
10-26
place.
12 Press the Test 3 button next to the flashing green LED. The LED should
stop flashing, and the stepper motor arm will come down and drive the
syringe plunger at a constant rate. The first 10 ml pushed through the
syringe is flush volume, the next 15 ml are counted as the fluid goes
through the laser sensor, and approximately 5 ml are left in the syringe at
the end and can be discarded.
13 At the end of the test, the Test 3 LED will change from green to red
indicating that the data has been automatically saved to the database. The
motor will reverse and return the arm to the top, home position.
Note
Test 3 itself is not cleaned because the initial 10 ml of the diluted

sample is used to flush the laser detector. Additional cleaning
should be performed at the end of the day by 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.
Instrument Overview
10-27
Volumetric Dilution For Test 2 and Test 3

Note
The scale checkbox must be cleared to use this method.

CSI recommends that for Test 2, you dilute 1 to 1; in other words, equal parts of oil and solvent (usually lamp oil). Using a clean, empty sample bottle, place two equally spaced
marks on the bottle using a marker pen. After thoroughly shaking the oil sample, pour in
the used oil up to the first mark and then add solvent up to the second mark. Thoroughly
shake to mix the oil and solvent.
The on-screen text boxes next to the sample bottle icons are automatically filled with 10 for
the icon representing a bottle with only oil in it, and 20 for the icon representing oil and solvent. This gives a dilution of 1:1. The second entry being the total fluid present (i.e. oil plus
solvent).
If further dilution is required for Test 3 because the sample is particularly dirty, you must
click on the check box next to the bottom sample bottle icon to indicate that further dilution
is required. You have a choice between diluents for the Test 3 additional dilution step.
Double-click on the bottom sample bottle icon to toggle between diluent types. The water
masking bottle icon will display half blue. Then enter 40 into the bottom text box to establish an additional 1 to 1 dilution. After pouring off the required 20ml into the Test 2
chamber, pour off more of the diluted oil into the waste beaker until you reach the first mark
and then add additional solvent up to the second mark. This will give a final 1 to 3 dilution.
10-28
Dilution By Weight For Test 2 and Test 3

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

If an empty bottle has not been previously weighed, you will be prompted to place an
empty bottle on the scale. Once the empty bottle is on the scale, press the button on the front
panel next to the scale icon to automatically record the weight of the empty bottle. (Do not
use the buttons on the scale.) If you must re-weigh an empty bottle, double click on the
empty bottle icon to set the empty bottle weight to zero.
CSI recommends that you dilute 1 to 1; in other words, equal parts of oil and solvent (usually lamp oil) for Test 2. Using a clean, empty sample bottle, place two equally spaced
marks on the bottle using a marker pen. After thoroughly shaking the oil sample, pour in
the used oil up to the first mark, and then place the half-filled sample on the scale and press
the weigh button. Now add solvent up to the second mark and re-weigh the bottle containing oil and solvent. Thoroughly shake the bottle to mix the oil and solvent before
pouring it into the Test 2 chamber.
The on-screen text boxes next to the sample bottle icons are automatically filled with
weights of the empty bottle, bottle with oil only, and bottle plus oil and solvent.
If further dilution is required for Test 3 because the sample is particularly dirty, you must
click on the check box next to the bottom sample bottle icon to indicate that further dilution
is required. Double click the bottle icon to choose which additional diluent will be used.
Move the mouse pointer to the bottle for a second to see which diluent is currently selected.
After pouring off the required 20ml into the Test 2 chamber, pour off more of the diluted oil
into the waste beaker until you reach the first mark and re-weigh the sample as directed by
the flashing LED. Now add additional solvent up to the second mark and re-weigh as
directed. The dilution ratio is automatically calculated from the recorded weights.
Making WDA Filter Patches

The wear debris filter patch maker is connected between the Test 2 chamber and the drain.
Therefore, as the diluted oil sample is drained from the Test 2 chamber, it passes through
the filter patch maker. To create a filter patch you must open the filter patch maker and insert
a filter patch before cleaning the chamber using the vacuum pump.
Instrument Overview
10-29
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 nonferrous 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.
10-30
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.
Instrument Overview
10-31
Reference Oil Tests

When testing new reference oils in the reference oil database for the 5200, only the Test 1
dielectric is absolutely required in order to calculate the Chemical Index. However, as an
additional option for more accurate 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.
10-32
Note
The optional Test 2 reference water test requires an additional 50

to 100 ml of the undiluted reference oil. Also, a variable speed drill
with a stirring paddle attachment, plus a lab stand, is required for
mixing water with the reference oil.
Reference Test 1 and 2, Standard
When the Ref DB tab is selected for the reference database, the 5200 Test screen is slightly
different than usual. First, Test 3 Particle Counts are 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.
Instrument Overview
10-33
Reference Test 2 with Water
After running the standard Test 1 and 2 on the reference oil, the optional water test may be
run. Each oil has its own additive package, or lack thereof, which affects how the oil keeps
water in solution. The purpose of the reference water test is to measure how the timeresolved 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.
10-34
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 re-test. If this is the case, start with a new, undiluted sample and
follow the instructions for number of drops of water and volume, then
repeat Steps 3 through 8. Note that, if requested to use one drop per 100
ml of oil, then enter 0.5 drops per 50 ml in the software for Step 3.
9.If the software does not prompt to re-test the oil, then the data is okay.
Instrument Overview
10-35
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.
10-36
Results
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.
Test 1 Chemistry
Dielectric The dielectric of the oil is a basic property and changes with oxidation, nitration, and moisture content. Different oil types have different dielectrics as well. The Test 1
sensor measures the dielectric of a small volume of the sample between two electrical
plates.
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.
Results
10-37
Test 2 Wear / Contamination
The Test 2 sensor measures dielectric properties of contaminants in the oil. The Test 2
sensor uses gravity and an electromagnetic field to concentrate and move particles on the
surface of the sensor grid during the test. See the Test 2 Plot example later to better illustrate
the following indices.
Contamination Index This index is based upon the change in apparent dielectric
resulting from non-ferrous contaminants settling onto the sensor grid over the test time.
Water has the largest affect on the contamination index, but other non-ferrous metals affect
it as well. The contamination index is calculated by scaling the total dielectric change
during the test.
Non-Ferrous Index This index is the same as the Contamination Index.
Ferrous 1 Index This index is a measure of the delta dielectric resulting from the ferrous
particles standing up and lying down on the sensor grid. An internal electromagnet changes
states during the first part of Test 2 to produce this effect.
Ferrous 2 Index During the second part of Test 2, a different electromagnetic field
sequence is used to sweep the settled iron outside of the sensing area. The resulting change
in dielectric is scaled to give the Ferrous 2 Index.
Large Ferrous As the particles settle onto the grid and the electromagnet changes states,
large ferrous particles or ferrous chains of particles will sometimes cause abrupt spikes in
the data plot. The Large Ferrous indicator is a count of these spikes.
Large Non-Ferrous Spikes which occur while the ferrous particles are standing up are
treated as Large Non-Ferrous indicators.
Water Droplets As water droplets settle onto the sensing grid, they cause abrupt changes
in dielectric too. However, these changes last for at least a few test cycles, and are thus distinguishable from other contaminant spikes.
Estimated % Water As mentioned before, water has the largest effect on the contaminant index. Water will settle onto the sensor grid differently for different oil types and additive levels. Water also affects the Test 1 Chemical Index.
Test 3 Contamination
Test 3 uses a laser-based particle counter to simultaneously count and size particles in eight
different size ranges as the fluid is forced through the sensor at a constant flow rate.
10-38
The particle count table shows the individual particle counts per milliliter for each of the
size ranges. The displayed sizes are either the older ISO 4402 calibration-based sizes (i.e. 2,
5, 15 m, etc.) or the newer ISO 11171 sizes (i.e. 4, 6, 14 m(c), etc.). The size display
mode is selectable under Setup / System by checking or un-checking the Display ISO
11171 counts box. A micron (m) is one millionth of a meter. There are 25.4 m per thousandth of an inch (per mil). The m(c) notation is used by the new ISO 11171 standard
to denote the new sizing method. For more information on these two particle counting standards, refer to the Test 3 Calibration 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.
Results
10-39
Plots
Test 2 Plot
The Test 2 plot shows a time resolved plot of dielectric as particles settle on the detector
grid. The first part of the plot shows two curves that are produced by alternating a magnet
sequence that alternately stands up and lays down ferrous particles. If there are no ferrous
particles present then these two curves fall on top of each other. The second part of the plot
shows a decrease in dielectric as the ferrous particles are swept off the grid. If there are no
ferrous particles present, then the curve becomes a continuation of the first part. If there are
large particles present, then spikes appear on these curves.
10-40
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.
10
Plots
10-41
Test 3 ISO Plot

The ISO 4406 plot is a representation of size distribution and concentration for particles in
oil. The graph has two lines. One line is for the sample data, and the other is for the target
cleanliness level (as set on the Point Information, Equipment tab). Cumulative counts are
displayed on the left vertical axis whereas ISO codes are displayed on the right vertical axis.
The size axis displays either the old or new particle sizes based upon the current ISO 11171
display mode.
11
10-42
ISO 4406 Cleanliness Code Levels

Particle Count Range (per ml)
ISO Code
Plots
Up to and
including
More than
0.01
0.02
0.02
0.04
0.04
0.08
0.08
0.16
0.16
0.32
0.32
0.64
0.64
1.3
1.3
2.5
2.5
5.0
10
5.0
10
10-43
Particle Count Range (per ml)

ISO Code
10-44
Up to and
including
More than
11
10
20
12
20
40
13
40
80
14
80
160
15
160
320
16
320
640
17
640
1300
18
1300
2500
19
2500
5000
20
5000
10000
21
10000
20000
22
20000
40000
23
40000
80000
24
80000
160000
25
160000
320000
26
320000
640000
27
640000
1300000
28
1300000
2500000
>28
2500000
Test 3 NAS Plot

The NAS cleanliness code (NAS 1638) was developed by the Aerospace Industries Association of America, and is similar to ISO 4406 in that it 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.
NAS
1638
Class
Plots
Number of particles per 100 ml

range
5 to 15
15 to 25
25 to 50
50 to 100
> 100
00
125
22
250
44
500
88
16
1000
178
32
2000
356
63
11
4000
712
126
22
8000
1425
253
45
16000
2800
506
90
16
32000
5700
1012
180
32
64000
11400
2000
360
64
128000
22800
4100
720
128
10
256000
45600
8100
1440
256
11
512000
91200
16200
2800
512
12
1000000
182000
32400
5800
1024
10-45
12
The NAS plot shows the number of particles in each of the six specified size ranges. It also
shows the resulting NAS code profile. You will notice from this example that the >100
particle size category is closest to the NAS profile. So this category is the one that actually
determines the NAS value.
10-46
Calibration Overview
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.
Verification Versus Calibration
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.
Calibration Overview
10-47
New Calibration
If a verification shows large percent errors, then first check to make sure the procedure is
being followed correctly and that the correct fluids are being used. Repeat the verification
on the fluid in question. If the fluid still fails the verification test, then re-calibration is
required.
Each calibration screen in the software contains a New button. This button is used to
erase all of the calibration data for the current test screen in preparation for a new test. For
example, if two or more fluids fail Test 1 Verification, then go to the Test 1 Calibration tab
and click the New button to start a completely new Test 1 Calibration. If only one fluid fails
the verification, then do not use the New button. Simply re-calibrate with the failing fluid
as described under Test 1 Calibration below.
Restore Latest
Each calibration screen contains a Restore Latest button which is used to restore the most
recently saved calibration data for that test. This function may be used to restore the latest
calibration data after viewing an older, 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.
Save Changes
Each calibration screen also contains a Save Changes button which saves changes to the
hardware and to the calibration database. This button is initially grayed out and becomes
active after changes have been made to the data. In order to save time, the user should wait
until all fluid samples for a particular test have been tested before clicking the Save button.
If you forget to save the changes, the software will prompt you to save when you try to
switch tabs.
10-48
Calibrate Overall Tab

The 5200 Calibrate, Overall tab shows current hardware information plus historical calibrations for all tests. This tab also allows previous calibration data to be restored for individual
tests or for all tests.
Current Hardware Info
The software reads the 5200 hardware during initialization to get the 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.
Historical Calibrations
The historical calibration data table lists all past and present calibrations that have been
saved in the calibration database. The calibrations are sorted in the table by serial number,
test type, and date. This table serves as a log of all calibration activity for the unit. Also, if it
ever becomes necessary to restore a previous calibration, then this is the place to do it.
The current calibration database path name is displayed above the table. The button
may be used to browse for and switch calibration databases. However, normally only the
default A5200cal.mdb calibration database should be used.
Read Test(s) This command button is used to restore previous calibrations. First 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.
Calibrate Overall Tab
10-49
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.
10-50
Test 1 Calibration & Verification

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 and B. This section describes the calibration procedure
and the clean check procedure.
Procedure
Perform the calibration procedure and clean check procedure with fluid A and fluid B in
the following sequence, A B A B.
1. On the Calibration screen, enter fluid A information in the first and third
rows. See the figure below for example.
2. Enter fluid B information in the second and fourth rows.
3. Calibrate with fluid A. Flush and perform clean check.
4. Calibrate with fluid B. Flush and perform clean check.
7. Save the results.
10-51
Test 1 Calibration screen
13
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 clean 10ml syringes for each of the calibration fluids. Also prepare and label clean
100ml sample bottles for the fluids. Pour approximately 75 ml of each calibration fluid and
cleaning solvent into the appropriately labeled bottles.
Caution!
Never use the wrong syringe with the wrong calibration fluid
bottle.
10-52
Initial Clean Check
An initial test is required to record a clean sensor value. Perform the following steps:
1Turn the valve on the instrument so the arrow points to the LED at the
right of the valve, Test 1 position.
2Draw 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.
3Remove the syringe and use the foot pedal to run the vacuum until all of
the fluid runs through the tubing to the waste container.
4Press the C Clean Check button on the screen next to the Test 1 icon.
After about five seconds, the dielectric (if available) and frequency value
will be displayed.
Note
During re-calibration, the calculated dielectric will not always be

available or accurate because it is derived from the 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.
10-53
Calibration
The response of the sensor to the two 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 up 10ml of the calibration fluid, using its
dedicated syringe, from the sample bottle. Insert the syringe tip into the
hole at the bottom of the Test 1 chamber, and squirt the fluid into the
sensor. Remove the syringe and run the vacuum to flush this initial sample
out of the sensor. DO NOT chase this with solvent.
3 Highlight the Freq 1 cell in the calibration table for the fluid to be tested.
4 Click the Start Calibration button. The software will prompt you to squirt
10ml into the Test 1 sensor.
5 Draw up 10ml using the correct syringe and calibration fluid. With the
syringe tip pointing upward, push the plunger in enough to express any air
bubbles in the tip of the syringe.
6 Now place the tip of the syringe into the hole at the bottom of the Test 1
chamber and slowly squirt the oil into the sensor. Any air bubbles
introduced into the line will cause a false reduced dielectric reading.
Leave the syringe in the chamber until after the reading.
7 Press the Test 1 button beside the flashing LED on the instruments Front
Panel.
8 The test will finish in about 5 seconds and display the frequency.
9 Remove the syringe and vacuum the sample out of the sensor.
10 The software will highlight the Freq 2 cell for the second test using the
same calibration fluid. Repeat steps 4-9 above.
11 The software will highlight the Freq 3 cell for the third test using the same
calibration fluid. Repeat steps 4-9 above.
10-54
Note
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.
Note
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.
10-55
Note
You may want to wait and do the verification before repeating any
of the calibrations as it may give you a better idea of which fluid is
truly out of calibration range.
If all calibration data looks good, you must select the Save Changes button to save the calibration data. It takes several seconds for the data to be written to the analyzer.
10-56
Verification
Immediately after calibration, follow this procedure to verify that the calibration data is
good and repeatable. Verify the data periodically, preferably using at least two calibration
fluids to ensure the sensor is still calibrated.
Test 1 Verification screen
14
10-57
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.
10-58

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 and B. This section describes the
calibration procedure and the clean check procedure.
Procedure
Perform the calibration procedure and clean check procedure with fluid A and fluid B in
the following sequence, A B A B.
1. On the Calibration screen, enter fluid A information in the first and third
rows. See the figure below for example.
2. Enter fluid B information in the second and fourth rows.
7. Save the results.
10-59
Test 2 Calibration screen
15
Calibration of the Test 2 Grid will follow a procedure very similar to the Test 1 process
except that more cleaning is involved. When you test your used oils, they will all be diluted
with a solvent. However, for the purpose of a calibration and/or a verification we use Neat
oil (undiluted) on the flat sensor surface with the grid traces. The sensor circuit board has
pores in it which allow fluid to collect in them and this can vary the capacitance of the
sensor. Thorough cleaning becomes very important to avoid cross contamination during
this process. Please take every effort to follow this procedure as thoroughly as possible.
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.
10-60
Initial Clean Check
An initial test is required to record a clean sensor value. Perform the following steps:
1Turn the valve on the instrument counter-clockwise so the arrow points to
the filter port LED at the left, Test 2 position.
2Use 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.
4Press the C Clean Check button on the screen next to the Test 2 icon.
After about ten seconds, the dielectric (if available) and frequency value
will be displayed.
Note
During re-calibration, the calculated dielectric will not always be

available or accurate because it is derived from the calibration
itself. The frequency value, however, should stay relatively the
same for the clean sensor.
10-61
Calibration
The response of the sensor to the calibration fluids must be measured to establish the calibration line. Repeat the following steps for each calibration fluid:
1 Clean the sensor by flushing with solvent and vacuum the solvent out of
the sensor. Perform the initial clean check using the Clean Check button.
If necessary, continue cleaning with solvent and/or vacuuming/drying to
flush fluid off of the sensor. Keep in mind that the cleaner and more
consistent the cleanliness level between each different fluid tested, then
the more reliable your next test will be.
2 Use the flip top calibration fluid bottle and squirt about 5ml (about half an
inch deep on the sensor) of the fluid onto the sensor at the bottom of the
Test 2 chamber opening. Try not to get the fluid onto the sides of the
chamber as this will need to be cleaned when changing to a different fluid.
3 Flush this initial preparation of the fluid out, but do not chase it with the
solvent. Use a clean cotton-tipped swab and gently wipe the surface with
what is left of the vacuumed calibration fluid.
4 Highlight the Freq 1 cell in the calibration table for the fluid to be tested.
5 Click the Start Calibration button. The software will prompt you to squirt
5ml of the calibration fluid into the Test 2 sensor.
6 Squirt an additional 5ml of the calibration fluid onto the grid.
7 Press the Test 2 button beside the flashing LED on the instruments Front
Panel.
8 The test will finish in about 10 seconds and display the frequency.
9 Vacuum the fluid sample out of the sensor, again do not chase it with the
solvent.
10 The software will highlight the Freq 2 cell for the second test using the
same calibration fluid. Repeat steps 4-9 above.
11 The software will highlight the Freq 3 cell for the third test using the same
calibration fluid. Repeat steps 4-9 above.
10-62
Note
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 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 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 cottontipped swab for final drying.
14 Push the button beside the flashing yellow Test 2 LED. The software will
check whether the Test 2 sensor is clean. You may need to use more
solvent or you may just need to pull more air through the sensor for drying
purposes. Repeat this step until the sensor passes Clean test.
Note
If this is the first calibration fluid of a new calibration then the

dielectric calculation will not be available and only the clean frequency will be displayed.
Repeat steps 2 to 14 for the remaining calibration fluids. The software will average the
results each time and then plot the average on the graph.
As each fluid is tested, the software will display the Fit % Error for each fluid. The plot is a
best-fit line through all points. Therefore the percent error is a calculation of the deviation
of each fluid point (Avg F) from the best-fit line. If the software pops up a warning message
that the error is 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.
10-63
Note
You may want to wait and do the verification before repeating any
of the calibrations as it may give you a better idea of which fluid is
truly out of calibration range.
If all calibration data looks good, you must select the Save Changes button to save the calibration data.It takes several seconds for the data to be written to the analyzer.
10-64
Verification
Immediately after calibration, follow this procedure to verify that the calibration data is
good and repeatable. Verify the data periodically, preferably using at least two calibration
fluids to ensure the sensor is still calibrated.
Test 2 Verification screen
16
10-65
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.
10-66
Test 3 Calibration
Test 3 Particle Counter Calibration Overview
The 5200 Particle Counter has been calibrated by CSI prior to shipping. You can re-calibrate the particle counter yourself using calibration fluid available from CSI. The recommended interval for calibration is at least once per year, or more frequently if the
Verification test indicates a need to do so.
17
Particle Counter Calibration Standards
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.
Test 3 Calibration
10-67
The 5200 Particle Counter calibration software supports both the older ISO 4402 standard
and the newer ISO 11171 standard for calibration of automatic particle counters.
The actual sizing calibration and verification parts of the two standards are very similar procedurally. The procedures differ by the fact that they use different calibration fluids and
measure different size ranges. The older ISO 4402 uses AC Fine Test Dust (ACFTD) as a
calibration fluid whereas the newer ISO 11171 uses NIST Medium Test Dust (MTD) and
Ultrafine Test Dust (UFTD). When ISO 11171 was created, the standards committee
decided that the original ISO 4402 ACFTD particle sizes were measured incorrectly. Thus,
the new ISO 11171 particle sizes are not the same as the older ISO 4402 sizes. The table
below shows the relationship between the old and new particle sizes.
ACFTD size (ISO 4402:1991), m
*NIST (ISO 11171) size, m(c)
0.8
4.2
4.6
4.3
6.4
10.25
10
15
13.6
15.5
14
23.4
20
25
21.2
40
31.7
50
38
52 - 55
40
70 - 75
48
100
54
*Note that the newer ISO 11171 particle sizes are always designated as m(c).
10-68
ISO Codes
Since the particle sizes were re-defined, the ISO 4406 standard for coding contamination
levels was revised. The older ISO 4406:1987 standard used a two-part code for contamination levels representing >5 m / >15 m. Industry extended this standard to a three-part
code of >2 m / >5 m / >15 m.
ISO 4406:1999(E) replaces the first edition, and defines a three-part code for particle count
contamination levels where the codes are for >4 m(c) / >6 m(c) / >14 m(c).
Note that the new >6 m(c) and >14 m(c) ISO codes line up fairly closely with the older
>5 m and >15 m codes. Thus, target cleanliness level (TCL) codes should stay about the
same for these sizes. However, the older >2 m code does not really match the newer >4
m(c) code. If a 2m TCL has been assigned to a machine previously, then it will need to
be adjusted upward under the new coding system for higher expected contamination levels
at the smaller particle size.
Fluid Requirements
Each part of the calibration procedure has its own fluid requirements. The factory standard
calibration uses about 400 ml total of Partistan 2806 fluid, which contains NIST Medium
Test Dust (MTD), for both calibration and verification. In addition, super clean fluid is used.
Refer to the individual test sections below for exact fluid requirements. As mentioned
above, additional tests and fluid volumes are required for full compliance with the ISO
11171 standard. Contact CSI for more information on this special calibration service.
Cleanliness Guidelines
The majority of particle sizes being counted are not visible to the naked eye. Thus the user
must take proper precautions to make sure extraneous contamination does not get into the
containers or calibration samples:
All calibrations must be performed in a dust-free environment.
Sample bottles and lids should be certified clean or cleaned in accordance
with ISO 3722. Keep the bottles tightly sealed until ready for use.
The syringes must be kept sealed in the original factory packaging until
ready to use. Do not handle the outside of the syringe or lay the syringe
down on a contaminated surface prior to use.
If dust has accumulated on the outside of the calibration fluid bottles
during storage, then clean it off with a lint-free cloth before use.
Never re-use bottles or syringes, or recycle calibration fluids. Any contamination tends to accumulate from prior use.
Test 3 Calibration
10-69
General Sample Preparation
These procedures apply to all calibration tests, and are listed here so they do not have to be
duplicated in the following sections.
Proper sample preparation is very important in order to get homogenous samples and good,
repeatable results. Particles must always be re-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.
10-70
Syringe Sampling and Degassing
After shaking the sample, follow these steps to draw the sample and run each test:
1.Insert a clean syringe into the sample bottle and draw the fluid into the
syringe to the last marking or slightly over. Ignore any air bubbles in the
syringe at this point.
2. Remove the syringe from the sample bottle and completely extend the
plunger, pulling air into the syringe, until the plunger reaches the built-in
stop.
3. Insert the brass spacer around the syringe plunger in preparation for
degassing.
4. Insert the syringe tip into the luer fitting, degas port on the top of the
tower for a snug fit.
5. Turn the 5200 vacuum control valve to the degas position, and operate
the vacuum pump by depressing the foot pedal. A wave of air bubbles
will begin to rise in the syringe. Try to not pull too much of the fluid into
the luer fitting. Once you create a vacuum, you may release the vacuum
pump pedal and the vacuum will be maintained. Therefore, air bubbles
will continue to be pulled from the sample in the syringe.
6. After the wave of air bubbles has moved to the top of the syringe (usually
no longer than 30 seconds), remove the syringe from the degas fitting.
The bubbles on the surface should mostly disappear as the vacuum is
released.
7. Remove the brass, plunger spacer from the syringe, then tilt the syringe
upward so the air pocket is directly under the tip. Slowly rock the plunger
and push it forward to expel the air pocket and most of the remaining air
bubbles. The plunger should return to almost the original fluid volume. It
will be a little less since some air volume was removed.
8.Press the Test 3 button next to the flashing yellow LED once to let the
software know that degassing is complete.
9.Insert the tip of the syringe into the Test 3 sample input port and push the
syringe body back into the retainer clip. Any air bubbles which were left
near the syringe tip should rise to the top of the syringe and will not be
counted. Push the Test 3 button again, and the flashing green LED should
turn solid green, and the motor arm will begin moving downward.
10. Wait for the motor to continue pushing the sample into the sensor. About
five ml of sample will be left in the syringe at the end and can be discarded
Test 3 Calibration
10-71
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.
10-72
Test 3 Preliminary Instrument Check
18
The Test 3 calibration, Preliminary Check tab contains the first set of tests run as part of the
factory standard calibration. These tests consist of a noise level check, volume calibration,
and verification. These tests only need to be repeated following repair or readjustment of
the particle counter. If a new batch of syringes is received, then the volume calibration may
need to be repeated.
Noise Level
The laser sensor outputs a signal proportional to particle size each time a particle flows by
the sensor. The bigger the particle, the higher the signal output is. The signal also contains
some background noise. The smallest particle size of interest must create a signal that is at
least 1.5 times the noise level.
10-73
The Noise Level test automatically increments the channel voltage settings for each particle
size until all channels read zero counts with clean fluid under no-flow conditions. Run the
test as follows:
1. Pour approximately 75 ml of super clean fluid into a clean sample bottle.
2. Use a clean syringe to draw up 30 ml of fluid and manually squirt the
entire contents into the Test 3 sample input port. This serves to flush the
sensor.
3. Use a new, clean syringe and draw up another 30 ml of clean fluid. Squirt
all but the last 5 ml into the Test 3 sample port and do not remove the
syringe from the port.
4. Click the Start button next to the noise level table in the software. The
software will begin cycling through the eight size channels, incrementing
the channel voltage settings (Pot, mV in the table), and taking noise
count readings at each setting.
5. When all channels read zero noise counts, the software will take several
repeated readings to make sure there is no more noise. The noise level is
then recorded as the previous Max, mV voltage setting which had noise
counts. This voltage level is then used to calculate the minimum channel
setting for the volume calibration test below.
Volume Calibration
The volume calibration is used to enter the dimensions of the syringe, and to verify the
sample volume and count repeatability with flow.
First use a metric ruler to measure the dimensions of the syringe as 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.
10-74
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.
10-75
Test 3 Sizing Calibration
19
The Test 3 sizing calibration is performed as part of the factory standard calibration. The
purpose of this calibration is to establish calibration curve data which correlates sensor
output signal levels to particle sizes. The sizing calibration needs to be repeated following
repair or readjustment of the particle counter, or at least on an annual basis.
The 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.
10-76
To begin a new calibration:

1. Navigate to the sizing calibration screen by selecting 5200 / Calibrate /
Test 3 / Calibration.
2. Click New to erase the previous calibration data. The "Enter New PC Cal
Fluid Info" dialog appears.
3. Select the fluid type from the drop-down list.
4. Enter the manufacturer, lot number, and dust concentration in the boxes
provided.
5. Click "Conc. Table" to display a concentration table to help you identify
the closest matching value based on counts. For example, for MTD fluid,
the concentration table shows 587 counts for 10 micron size range
corresponds to 3.2 mg/L.
6. Click OK to save the fluid information.
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).
5. Insert the syringe into the sample port and push the Test 3 button twice to
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.
Test 3 Sizing Calibration
10-77
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.
10-78
Test 3 Verification
20
The Test 3 verification is performed as part of the factory standard calibration. The purpose
of verification is to verify particle counting accuracy using size channel voltage settings 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.
Test 3 Verification
10-79
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.
To begin the verification test:
1. Navigate to the sizing verification screen by selecting 5200 / Calibrate /
Test 3 / Verification.
2. Click New to erase the previous verification data. The "Enter New PC
Cal Fluid Info" dialog appears.
3. Select the fluid type from the drop-down list.
4. Enter the manufacturer, lot number, and dust concentration in the boxes
provided.
5. Click "Conc. Table" to display a concentration table to help you identify
the closest matching value based on counts. For example, for MTD fluid,
the concentration table shows 587 counts for 10 micron size range
corresponds to 3.2 mg/L.
6. Click OK to save the fluid information.
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.
Now, 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.
10-80
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.
3. 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.
position. The software will update the sample counts, AvgCnt, %Err,
CoV%, and Rng% in the table. See the descriptions below for these
calculations.
6. 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.
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.
Sample n Each syringe sample is counted as three sub-samples. The detailed sub-sample
count data may be displayed by double-clicking on the sample header in the table. The
average counts per ml of these three sub-sample counts is displayed in the table in the
sample column.
Rng% percent range of the sub-sample count data within a given sample. The software
checks the percent range for count repeatability within the sample.
As each sample is tested, the software updates the table and plots average counts versus particle size. The plot should be a smooth curve. A verification data report is also available.
Test 3 Verification
10-81
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.
10-82
Test 3 Diluent/Clean Fluid Calibration
21
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.
Note
Clean fluid tests are very sensitive to any contamination. Thus, the
procedures below must be followed as closely as possible to get
accurate, repeatable results.
10-83
Note
Uncertified diluents should be filtered through a 0.8 micron or

smaller filter before being used for both the clean fluid test and for
normal diluted sample tests. The clean diluent particle counts
should be a small percentage of the used oil counts in order to minimize errors when testing the diluted sample. The OilView 51SF
Solvent Filtration device may be used for this purpose.
Begin by preparing the samples. Always keep clean lids on the bottles to prevent dust from
getting into them. Do not open each syringe until right before use. If not using a solvent filtration device, then shake the larger clean fluid / diluent bottle thoroughly to re-suspend any
particles. Fill one certified clean bottle with 100 ml of clean fluid to be used as an initial
flush. Then prepare three identical samples of the clean fluid / diluent by pouring 40 ml into
each of three clean sample bottles.
Use the left half of the table for a super clean fluid test or a standard diluent test, and use the
right side for a masking diluent test.
10-84
Follow these steps to perform the test:

1.Open a new syringe and draw up 30 ml of clean fluid from the 100 ml
flush bottle. Insert the syringe into the Test 3 sample port and manually
squirt all of the fluid into the sensor. Repeat this with two more 30 ml
flushes to clean the sensor.
2.Click on the appropriate side of the table on Count1 to select it as the first
sample to be tested.
3.Click the Start button in the software to start the test.
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.
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, and
%Range in the table.
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.
8.Repeat Steps 3 to 7 above until all samples have been tested.
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.
As each sample is tested, the software updates the table and plots average counts 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.
10-85
Test 3 Coincidence Error Limit Test
22
The Test 3 Coincidence Error Limit test establishes what concentration of particles causes
the sensor to start undercounting particles. The error is a result of the physical dimensions
of the sensing volume as well as the 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.
10-86
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:
23
where
Ct is the theoretical concentration limit as specified by CSI, in particles per
ml, or in mg/l of dust;
Vsis the final volume of the diluted sample, in ml;
L is the dilution percentage of the concentration limit, i.e. 10%, 20%, etc.;
Cais 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
24
10-87
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 dropdown 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.
10-88
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.
4.Click the Start button in the software to start the test.
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).
7.Insert the syringe into the sample port and push the Test 3 button twice to
start the test.
8.Wait for the test to complete and for the motor arm to return to the home
position. The software will update the sample counts, Avg/ml, Rng%, Xt/
ml, and Err% in the table. See the descriptions below for these
calculations.
9.The software will automatically select and highlight the next higher
concentrated dilution to be tested.
The following results are displayed in the coincidence limit data table:
Count n/ml Each syringe sample is counted as three sub-samples. These are the individual counts per sub-sample.
Avg/ml Average counts per ml of the three sub-counts.
Rng% percent range of the sub-sample count data within a given sample. The software
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.
10-89
As each sample is tested, the software updates the table and plots average counts versus dust
concentration. After the 0% to 40% samples have been tested, the software computes a
best-fit line equation for these sample counts. The theoretical counts are calculated from this
line equation, 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.
10-90
Test 3 Flow Rate Limits
25
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.
11171 calibration standard. ISO Ultrafine Test Dust (UFTD) fluid is used to establish the
upper and lower flow rate limits. Identical samples are prepared and tested at flow rates
ranging from 10 ml/min up to 80 ml/min in 10 ml/min increments.
First prepare nine identical samples of 1.00 mg/l of ISO UFTD fluid. Make sure the UFTD
fluid bottle is well shaken before pouring 40 ml into each of the nine clean sample bottles.
Cap each bottle with a clean lid.
10-91
Run the test from the 5200 / Calibrate / Test 3 / Flow Rate screen. First click the New button
to erase the previous data. Next select the fluid type from the drop-down list. Then enter the
manufacturer, lot number, and dust 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.
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.
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 software
10-92
%Err The percent error of the average counts versus the average counts at the working
flow rate of 50 ml/min.
As each sample is tested, the software updates the table and plots average counts versus
flow rate. The plot should be a smooth curve. After all flow rates have been tested, the software examines the data above and below the working flow rate. The upper and lower flow
rate limits are calculated to be where the average counts differ by + or - 5% from the
working flow rate counts. These limits are plotted with vertical bars. The particle counter
should always be operated within these flow rate limits. A flow rate limits data report is
available.
After all flow rates have been successfully tested, click the Save Changes button to save all
results. The save operation will take several seconds as the data is written back to the hardware.
10-93
Test 3 Resolution
26
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.
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:
10-94
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.
Test 3 Resolution
10-95
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.
3. 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.
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 software
StdDev Apparent standard deviation in microns of left and right side counts.
10-96
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.
Test 3 Resolution
10-97
Diagnostics
The 5200 Diagnostics tab is used mainly by CSI Customer Support to help trouble-shoot
hardware/software problems over the phone. However, the default test settings are also
stored under the Diagnostics tab. Some of these settings may be changed by the customer.
For example, one setting is used to enable or disable the scale every time the software is
entered.
By default, the Diagnostics tab is disabled and grayed out. It may be enabled by going to
the main Setup function and then choosing the System minor tab. The Diagnostics enable
checkbox is in the Test Modes frame.
From the 5200 / Diagnostics tab, select the Diag Settings tab, toward the left center of the
window, to get to the default settings.
27
10-98
Only the settings described below should be changed by the user:
Neat Oil Test 1, Neat Test Enable checkbox This is the default enable/disable for
Test 1 each time the software is started.
Wear Test 2, Wear Test Enable checkbox This is the default enable/disable for Test
2 each time the software is started.
Wear Test 2, Manual Start Dielectric This is the neat oil, threshold dielectric value,
above which the software will prompt for Test 2 to be 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.
Diagnostics
10-99
10-100
Chapter
11
Laboratory Information Management System (LIMS)
Introduction
Keeping track of oil samples as they are processed can be difficult. Normally, only a subset
of machines in an oil analysis program are sampled at one time. The oil analysis technician
must search the database for the machines and sampling points before each test is 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.
11-1
The LIMS (Lab Information Management System) solves the problem by allowing samples to be grouped into batches for testing, analysis, and reporting. Samples remain linked
to the master database so that data, 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.
11-2
Assign Samples
The first step is to organize the samples to be tested into groups or batches according to similar oils, test profiles, customers, or whatever is most 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.
Assign Samples
11-3
The next step is to log the samples into the batch. This process involves identifying the Point
in your database using the right-hand database tree.
Once the relevant point has been highlighted, use the Add button to 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.
11-4
You can print Lab sample labels for all samples in a batch, or for multiple batches,
depending on the level in the LIMS database tree (selected from the right mouse button
pop-up menu).
The lab labels are used internally with the lab as is the lab # printed on it, as well as which
tests are to be performed on the sample. This information is derived the Point setup for the
sample. (Set Lab Labels on the Setup tab.)
Assign Samples tab

From the user database tree, you can use the Assign Samples tab to add Customers, Area,
Equipment and Points. This avoids the necessity of either using Dbase or moving back to
the user DB in OilView, both of which are time consuming.
Database Level
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.
Assign Samples
11-5
Now, locate the LIMS category and click to place a check mark in the box
beside the Display Customer Level selection.
Finally, click on the LIMS button at the top of the screen to return to the
LIMS window.
If not enable, Add Area will be the option appearing in the dialog box.
Customer Level
For this option to be visible, the Display Customer Level must be enabled. If not enabled,
you will not see this dialog box. To have the 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.
11-6
Area Level
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.
Find Sample ID Find a sample.
Add Equipment Add equipment level to the database.
Edit Area Edit area details.
Equipment Level
10
Assign Samples
11-7
Add Point Add a point to the database.

Edit Equipment Edit equipment details.
Point Level
11
Add Sample Add a sample to the database.

Edit Point Edit point details.
Sample Level
12
Edit Sample Edit sample details.
11-8
Batch Types
The LIMS database tree has two types of batches. The top-most batch folder are for those
samples that you have logged in. Below this batch is another batch folder entitled
Imported Batches.
This batch type is automatically created when you import sample data using the Data I/O
option. This is extremely useful in that it groups together in batches all samples that are
imported at any one time so that you can easily find the individual samples without having
to search through the user databases. It also enables you to generate reports for all the samples at once as we will discuss in the next section.
Assign Samples
11-9
Batch Information
This is the display that will be used most frequently. It shows the progress of each sample
as activities are completed. As each test is run, that 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.
13
11-10
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.
14
On the extreme right of the grid are date columns reflecting the date on which each process
was completed. The analyst and reviewer user IDs are also recorded with each sample.
Batch Information
11-11
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.
15
Depending on which of the flags are set on the options specified for reporting, you can then
generate a variety of reports for printing and automatic E-mailing. You can also export the
data for importing at a remote site using the report results menu option shown below.
16
Before any reports can be generated, each Area and/or Equipment level in your database
must have at least one customer assigned to it. Each customer has an address that is printed
on the report, and a profile specifying the kinds of reports that customer requires. These
details are described later in this section of the manual.
11-12
Result Options
The Result Options tab serves two purposes: to establish the conditions under which reports
can be generated, and to override the normal reporting process.
The General Options region is used to set the conditions for generating reports based on
the flags that are set as each sample is processed. For each of the flags shown, you can
specify Ignore, Checked, or Unchecked.
Reports will be generated only for those samples in the batch that match these conditions.
The actual reports that are generated depend on the 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.
17
The section Report Override Options is used to generate ad hoc reports that will ignore
or override the specific setup for each customer assigned to the sample. The options here
are the same as those in the customer report profile that will be described in the next section.
Result Options
11-13
If Duplicate File Name
Each day data and reports are temporarily exported into each contacts sub-directory where
they are assembled. A temporary file with the days date is created to store this information.
The section If Duplicate File Name is used to specify the action to be taken if a report or
data for the contact is generated more than once per day. By default new reports and data
are appended to the existing file. These files can also be manually renamed or automatically
renamed.
11-14
Contacts
This tab is used to create a contact address book and reporting profile for each contact. The
Add New, Delete, and Update buttons are used to manage this list. The E-mail address can
be used to automatically E-mail reports to contacts.
These e-mailed reports can be viewed and printed.
18
To generate a specific report, the severity level at which that report will be created must be
set. The lowest severity level is Normal implying that the report will always be generated.
If the severity level is set higher, then reports will only be created if the severity for the
sample is greater than or equal to that level.
The Fax reports operate in the same manner. You must setup a fax printer to enable automatic faxing of reports. (See E-mail/Fax tab in ten Setup tab.)
Contacts
11-15
The check boxes are used to specify which form the reports are to be sent. To automatically
E-mail a report directly to a contact, check the E-mail box and the Format pdf (Adobe
Acrobat) box.
In a network environment, it may be more convenient to place the reports in a directory that
the contact can access. To use this method, check the Directory box instead of the Email box. The directory is specified in the Contact Sub-directory text box.
Each customer is required to have a unique sub-directory that is used as a working directory
by the software.
11-16
Assign Contacts
Once the contact list has been created, the next step is to assign contacts to the user databases so that contact-specific reports can be generated. 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.
19
To assign a contact to either of these levels, select the relevant node on the database tree and
then select the contact from the bottom list. Use the Add button to assign the contact.
Assign Contacts
11-17
Data Export
Note
CSI makes the following distinction between customers and contacts. Customers own the data in a database and only they can
import the data, whereas contacts receive reports either by email 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 e-mail option then the data remains
in the sub-directory and can be accessed directly from a WAN. The data format defaults to
the Area, Equipment, Point (AEP) format. The alternative uses the Unit ID format.
The data export setup only applies to the Area level. You must specify the customers 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.
11-18
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.
20
At each Area level of the database you must enter the database name to which the data is
being sent (In general this will be different from the current database.) as well as the 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.
Assign Contacts
11-19
Manual Entry
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.
21
11-20
Serial Communications
The CSI Minilab instruments are automatically linked to the LIMS system. Other instruments such as a spectrometer or FTIR instrument can be linked directly into the LIMS
system via a RS232 communication link. Each of these instruments require a special driver
that is connected to the RS232 port in the Setup Module. Contact CSI for specific information on your lab instruments.
22
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.
Serial Communications
11-21
LIMS Management Reports

Contact Statistics and Lab Statistic reports are available from the drop down menu and will
process samples based on the tree location.
23
From the drop down menu, select either Contact Statistics or Lab Statistics.
24
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.
11-22
Then the preview of Contact Statistics report appears.
Contact Statistics report
LIMS Management Reports
11-23
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.
Lab Statistics report
11-24
Chapter
12
OilviewLite
Introduction
The OilviewLite software package is designed to operate the new Model 5200 Trivector
Analyzer, Model 52DV Digital Viscometer, and the Model 51FW Ferrous Wear Monitor.
This software is completely independent of AMS Machinery Manager and has a simple
Microsoft Access database for storing the sample data. This data can be exported into either
the CSI generic file (for import into OilView when you upgrade to the full-featured
system), or into a comma separated value (csv) file for import into spreadsheets such as
Excel.
12-1
The software is divided into two main areas. On the left-hand side is a list of the samples in
the database. The right-hand side has a series of tabs that allow access to Setup, Alarm Sets,
Reference Oils, Data, Model 51FW, Model 52DV, and the Model 5200 Analyzer. The top
of the screen displays the current reference oil and alarm set.
Setup
The first step in using the software is to configure the communication port for the Model
5200 Analyzer and then the ports for the Model 51FW and Model 52DV. These latter two
instruments can either be plugged into the auxiliary ports on the Model 5200 or directly into
serial COM ports on the computer.
Each instrument requires a path to their calibration and configuration files that are typically
in the same directory as the OilviewLite application.
Databases
By default the last-used database will be automatically opened when you start the 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.
12-2
OilviewLite
Adding a Sample and Running a Test

To add a new sample, press the Add New Sample button above the sample list. You then
assign an Alarm Set and Reference Oil to the sample. The next step is to select the test to
be run (Models 5200, 52DV, 51FW) and proceed as described elsewhere in this manual for
each instrument.
Adding a Sample and Running a Test
12-3
Reporting
OilviewLite has a single report that can either be sent directly to the printer or previewed
using the Print and Preview buttons on the toolbar. The report is for the selected (highlighted) sample and shows the results for each parameter along with the reference oil data
and alarm limit values.
12-4
OilviewLite
Alarm Sets
The alarm limits are categorized into Alarm Sets. You can add new alarm sets using the
Add Alarm Set menu option under the Setup Menu option. Alarm sets can be deleted from
the Edit Menu. The alarms for each of the parameters are divided into five levels (4 values),
each of which you can set.
To connect an alarm set to a sample, first select the sample with a mouse click, select the
required alarm set, and then make a right-button mouse click. The message box shown
below will prompt you to either click the OK button if this is correct, or click the Cancel
button to select a different alarm set.
The selected alarm set for each sample is displayed at the top of the screen.
Alarm Sets
12-5
Reference Oils
Each reference oil requires such information as dielectric, and viscosity at 40C and 100C.
This information is acquired by sending a clean, unused oil sample to a laboratory for analysis. This information must then be entered manually for each reference oil. To add a new
reference oil, use the Add Reference Oil menu option under the Setup Menu option. Reference oils can be deleted from the Edit menu.
To connect a reference set to a sample, first select the sample with a mouse click, select the
required reference set, and then make a right-button mouse click.The message box shown
below will prompt you to either click OK if this is correct or Cancel and select a different
reference oil.
The selected reference oil for each sample is displayed at the top of the screen.
12-6
OilviewLite
Data
The Data tab shows the test results for each sample in a spreadsheet. As each instrument is
run, the data is automatically entered into the database and displayed in this spreadsheet.
Scroll horizontally to see all of the data.
Data
12-7
12-8
OilviewLite
Appendix
Using the OilView Analyzer
Where To Use the OilView Analyzer

The OilView Analyzer detects degraded lubricating oil or abnormal wear in lubricated
machinery. However, many lubricating oil applications are unique with respect to both oil
properties and the machinery in which they are used. The following paragraphs discuss
appropriate OilView Analyzer applications. (See also Testing Profiles for Minilab. on
page 5-6.)
Engine Crankcase Oils
The OilView Analyzer can be used to test crankcase (motor) oils used in reciprocating
engines. It is an excellent tool for monitoring oil condition in diesel, gas, and gasoline
engines. It has a special value with respect to diesel engines where soot makes any visual
determination of oil quality or debris content difficult.
The OilView Analyzer is sensitive to oxidationa common mode of oil failure in modern
engines. It is sensitive to soot loading in diesels, and will also detect abnormal wear of ferrous parts. The OilView Analyzer is very sensitive to the presence of either coolant or water
in the oil. Oils taken from engines fueled with liquid hydrocarbons (diesel or gasoline)
should also be screened for viscosity reduction resulting from fuel dilution. Viscosity is
measured with a viscometer such as the Model 51DV Digital Viscometer.
Turbine and Pump Oils
Oils used in steam turbines and water pumps are prone to contamination with water. In
these oils, the OilView Analyzer will detect water 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.
A-1
Gear Oils
The OilView Analyzer is an excellent tool for monitoring the condition of gear oils. It will
detect water and ferrous wear debris. Large chips resulting from fatigue wear of gear
teeth are very easily detected.
Bearing Lubricating Oils
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.
Hydraulic Oils
The OilView Analyzer can also be used to screen for water and ferrous debris in nonconductive hydraulic fluids. However, OilView Analyzer testing of fluids used in precise
hydraulic systems should always be accompanied by subsequent laser particle counter
tests.
Compressor Oils
Mineral and synthetic oils used in compressors can be tested for moisture contamination,
oil breakdown, and mechanical wear. It is normally important to degas the used oil samples
taken from refrigerant compressors prior to testing them regardless of what instrumentation
is being used. Most often it is normal for the used lubricant to contain significant amounts
of refrigerant such as ammonia, CFC, or R134A. The ammonia in particular has a significant effect on the OilView Analyzer sensor since ammonia has a high dielectric just like
water.
A-2
Electrical Insulating Oils
A special test option can be selected (see Oil Compatibility Chart on page 5-8) to test
transformer oils using the OilView Analyzer. This screening test evaluates the oil quality
and moisture contamination for electrical insulating oils commonly used in transformers
and oil filled circuit breakers (OCBs). The OilView screening test does not replace the need
for dissolved gas analysis to detect partial discharge in high voltage transformers.
Fuel Testing
The OilView Analyzer can be used to test fuel oils such as #2 diesel for 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.
A-3
Collecting Oil Samples

The key factor in any oil and machine condition monitoring program is consistency in collecting samples. Any oil monitoring program will 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.
Warning!
Hot oil may cause severe burns, and used oil should never be allowed to
remain on your skin or clothing. Consequently, be extremely cautious when
sampling oil from a hot or pressurized system.
Never handle very hot oil with a plastic bottle, as the bottle may melt or
deform. Use an intermediate, clean metal container to cool the oil, if necessary. If a metal 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 roomtemperature oils.
A-4
Warning!
Follow standard practice procedures for health and safety as established by

your safety department when collecting oil samples or handling new and
used lube oils, hydraulic fluid, and transformer oils.
A-5
Sampling Hints
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.
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.
A-6
Take samples just after the equipment has been shut down or, when it is safe, while
the equipment is operating. This is most important with less viscous oils as large
particles and water will settle out of the oil rapidly. It is extremely important to be
consistent with respect to when as well as where you sample.
Carefully label each sample bottle. The label should minimally identify the oil type,
the machine from the which the oil was taken, and the date on which the sample
was taken. If a sample is diluted prior to testing, the label should reflect that fact. A
sample taken from an unknown source has little value. Mislabeling of samples may
lead to unnecessary maintenance actions.
Over time, some contaminants will agglomerate and cling to the bottle walls, 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.
A-7
A-8
Appendix
Understanding the OilView Analyzer Data
Applying the OilView Analyzer

For clean, fresh oils, all OilView Analyzer index values should be at or near zero.
Increasing values indicate increasing levels of degradation or 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.
B-1
OilView Analyzer Model 5100 Detection Limits
Propert
y
Indexe
s
Lubricant Type
Minimum Detectable Limit
Lube Degradation
Oxidation
OL, LC
Most Lubricants
<<10% by FTIR (OL, Chl)
Soot
OL, Chl
Heavy duty diesel
0.4% by TGA
Lube System Contamination
Water
OL,
Cont, LC
Hydraulic
<0.005% (OL and Cont)

0.06% (LC-Droplets)
Water
OL, Chl,
Cont, LC
Heavy Duty Diesel
<0.2% (OL, Chl, Cont)

1% to 5% (LC Droplets; Water droplet formation
begins when lubricant plus additive is saturated.
Water
OL, Chl,
Cont, LC
Stern Tube Oil (used to lubricate the bearing at the

aft end of a marine drive shaft.)
<0.2% (OL, Chl, Cont)

>15% (LC-Droplets)
Water
OL, Chl
Polyol Alkaline Glycol (synthetic lubricant used in

R-134a refrigerant compressors)
<0.04% (OL, Chl)
Water
OL, Chl,
Cont, LC
Polyol Ester (synthetic lubricant used in R134a

refrigerant compressors.)
0.04% (Cont)
0.08% (OL
0.32% (Chl)
0.64% (LC-Droplets)
Water
OL, Chl
Perfluorinated Ether (synthetic lubricant used in

hard vacuum pumps)
<0.02% (Chl)
0.05% (OL)
Glycol
OL, Chl
Heavy Duty Diesel
<0.2%
Mechanical Wear
Iron
Fe, Cont,
LC
All
1 ppm >5 (Fe)

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

<1 ppm >40 (LC-Nonfer)
Tin
Cont, LC
All
50 ppm >5 (Cont)

<1ppm >40 (LC-Nonfer)
B-2
Propert
y
Indexe
s
Lead
Cont
Lubricant Type
All
Minimum Detectable Limit

50 ppm >5 (Cont; Instead of affecting the
contaminate index, it may cause a chemical index
response due to chemical oxidation of the lead
particles. The process of oxidation makes them
electrically nonconductive.)
Legend:
OL the OilLife index.
Chl the chemical index.
Cont the contaminant index.

Fe the ferrous index.
LC qualitative large ferrous or large non-ferrous or droplets.
Results Display
The OilView results display is a time plot that represents the change in dielectric properties
caused by contaminants forced onto the sensor during the time of the test. The Y axis represents changes in the dielectric properties of the oil while the X axis represents 500 test
magnetic oscillations during the test.*
Note
It is important to note that a thorough understanding of the OilView 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).
B-3
If a reference file is available for the current data, the bottom line on the plot will display the
magnet off state from the reference oil measurement. The three remaining lines on the
plot show the measurements for the oil being tested: a magnet off state, and two magnet
on states.
1
Plot Examples
In an oil with no ferromagnetic debris and without insoluble contaminants, these lines
should overlay one another and be nearly horizontal. The figure below is an OilView Analyzer plot taken from a clean, fresh turbine oil.
Clean oil plot.
B-4
The figure below is an OilView Analyzer plot of a used pump oil containing ferrous debris.
Note the divergence of the two upper magnetic lines from the lower nonmagnetic or
base line. This indicates ferromagnetic particles in the oil.
Oil with ferrous wear debris.
B-5
The figure below was taken with a fresh turbine oil containing 0.13% water. Note that all
three lines overlay indicating no significant ferromagnetic content. However, all lines have
a steep upward slope, rising more than half a point in 500 seconds. This indicates a significant non-ferromagnetic contaminant content. In this case there was also at least one small
droplet of free water as indicated by the small spike which occurred at about 260 seconds
into the test.
Fresh turbine oil containing 0.13% water.
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.
Oil contaminated with large, nonferrous conductive particles.
B-6
These spikes are caused by the large copper particles settling on the grid.
In an extreme case involving free water or large metal chips, you may see a sudden upward
jump of the plot with no return to a lower value. This will be accompanied by the display
of the word Critical on the results screen. Shake the bottle and repeat the test. If the pattern
is repeated, you have a serious lubrication problem involving either severe wear or free
water in the oil. In this case, Fe and large Fe values cannot be reported. However, if the plot
reveals a divergence of the magnet-off line and the magnet-on lines, ferrous debris is probably present.
Critical oil sample with free water droplets or

large metal chips that have electrically shorted the grid.
B-7
Test Results
More information can be obtained from oil testing when test results are trended over time.
Lubricant degradation is rarely linear over time. Typically, a petroleum-based lubricating
oil contains additives which protect and enhance the lubricating qualities of the base oil.
The oil will degrade slowly over time until one or more components of the additive
package are exhausted. After that point, the oil will rapidly degrade.
The time to additive exhaustion varies with oil type, the machine type, and changes in the
operating environment. In well-sealed, low-temperature applications, a lubricating oil may
last for years. In extreme reciprocating engine applications, an oil will degrade after only a
few hundred hours of use. Consequently, once you have a knowledge of the normal trend
of oil degradation in a specific case, abnormal conditions can be detected.
The OilView Analyzer test results are quantitatively reported in three numerical indexes
and two indicators which are discussed in the following sections.
B-8
OilLife Index
The OilLife Index reports on the overall condition of the lubricant, considering both lube
degradation and system contamination.
When the OilLife index is near zero, the lubricant is in good shape. An increase in the 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.
Note
The OilLife, Chemical and Contaminant Indexes are a direct measure of the
difference in dielectric permittivity between new and used oils when the
measurements are made at the end of the respective tests. A 0.10 increase in
ending dielectric yields an index of 10.0.
Test Results
B-9
Chemical Index
An increase in this index indicates that the oil is increasingly able to support electrical conduction due to the presence of polar molecules and/or ions. These conditions typically will
lead to increased wear and corrosion.
The most common causes of an increase in this index include:
thermally accelerated oxidation and nitration,
soot loading,
the formation of acids from combustion blowby in engines, and
increased moisture content.
This index should be trended over time. Normally, it will be zero. If it is non-zero, the oil is
becoming corrosive and frequent testing is in order. If the value continues to rise, it is probable that the oil additive package is exhausted or a contaminant is entering the system.
Before condemning the oil, be sure to check that the oil was being compared to the proper
reference oil. If desired, perform a Verification Test to make sure that the OilView Analyzer sensor has not been damaged. SeeVerify on page 5-13.
If, after verification, a second test gives the same results as the first, consider changing the
oil or sending a sample to an oil lab.
The following conditions will cause an increase in the chemical index:
corrosive products of high-temperature oil oxidation and nitration,
acids formed from combustion by-products such as sulfuric acid in diesel engines,
presence of dispersed water or coolant,
high levels of very fine, suspended particles such as soot, dust, road salt, or fine wear
debris.
Note
Remember that a reference sample must be assigned to the sample in order

to obtain a chemical index. If a reference is not available, the chemical index
will not be given.
B-10
Contaminant Index
This index is a measure of the level of oil-insoluble contaminants in the oil as opposed to
changes in the bulk oil chemistry. Some common contaminants include water, glycol 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.
Test Results
B-11
Ferromagnetic Index (Fe)

The ferromagnetic index is sensitive to conductive, ferromagnetic particles. It increases linearly with both particle size and concentration. The index is primarily sensitive to recent,
severe wear of oil-wetted steel and iron parts, because the surfaces of such particles are
likely to be conductive. It is an indicator of the condition of the lubricated system. In general, higher index values correspond to higher wear rates.
This index should be near zero. Any positive value indicates ferromagnetic debris. Higher
values indicate increasing concentrations and/or particle size. The graphic analog to this
reading is the divergence of the magnetic lines on the plot from the base nonmagnetic
line. In the event that an oil contains ferrous debris, the magnetic lines on the plot will
diverge from the base line. If the particles are large and have just been formed (highly 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 9-13.
B-12
Large Contaminant Indicator

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

indicate a serious problem.
Dielectric Number
This field reports the permittivity or dielectric constant, which, like boiling point, melting
point, viscosity, and refractive index, is a fundamental property of a material. Simply put,
dielectric constant measures the resistive, or nonconductive properties of the oil. 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.
Test Results
B-13
B-14
Appendix
The Original Frequency Units Data Plot
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.
Understanding the Frequency Units Data Plot

The OilView Data Plot displays a time plot that represents the change in dielectric properties caused by contaminants forced onto the sensor during the time of the test. The Y axis
represents a percent change in electrical properties of the oil measured by the OilView Analyzer that falls as 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).
C-1
Original Frequency Units Data Plot Examples

In an oil with no ferromagnetic debris and without insoluble contaminants, these lines
should overlay one another and be nearly horizontal. The figure below is an OilView Analyzer plot taken from a clean, fresh turbine oil.
Clean oil plot.
C-2
The figure below is an OilView Analyzer plot of a used pump oil containing ferrous debris.
Note the divergence of the two lower magnetic lines from the upper nonmagnetic or
base line. This indicates ferromagnetic 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.
Oil with ferrous wear debris.
C-3
The figure below was taken with a fresh turbine oil containing 0.13% water. Note that all
three lines overlay indicating no significant ferromagnetic 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.
Fresh turbine oil containing 0.13% water.
C-4
The figure below is a data plot from a test sample contaminated with large copper particles.
Note the shape of this plot as compared to the two previous plots; the presence of downward spikes with all three magnet lines running together.
Oil contaminated with large, nonferrous conductive particles.
C-5
In an extreme case involving free water or large metal chips, you may see a sudden downward jump of the plot with no return to a higher value. This will be accompanied by the display of the word Critical on the results screen. Shake the bottle and repeat the test. If the
pattern is repeated, you have a serious lubrication problem involving either severe wear or
free water in the oil. In this case, Fe and large Fe values cannot be reported. However, if the
plot reveals a divergence of the magnet-off line and the magnet-on lines, ferrous debris is
probably present.
Critical oil sample with free water droplets and large metal chips.
C-6
Appendix
WAN Setup for OilView
Communications
The main issue when installing OilView software and minilab instruments in a WAN environment is the RS232 communication between the software and hardware. Unlike the
2120 type instruments where data is simply dumped back to the RBM database after the
instruments have been run, the OilView software and Minilab hardware should be
regarded as a single unit, as the software controls the operation of the hardware while the
test is in progress. This means that it is not possible to operate the minilab instruments using
Thin Path, as time delays over the WAN make this totally unreliable. Furthermore, the
wear debris image capture can only work with a direct connection between the PC image
capture card and video camera attached to the microscope.
D-1
The other issue with a WAN installation is the slowness of the MS Access databases. One
way to overcome this issue is to use terminal server or Citrix in which case AMS
Machinery Manager is running over a LAN (between The AMS Machinery Manager
server and the AMS Machinery Manager client installed on the computer running Terminal Server or Citrix) and only display information and mouse and keyboard entries are
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.
D-2
The basic mode of operation is therefore to use the AMS Machinery Manager Local Client
on each workstation to run the minilab instruments and capture the data. Analysis features
will be disabled in this case. The user then swaps to terminal server or Citrix to run the other
version of OilView which allows analysis but disables access to the minilab instruments.
D-3
OilView Instrument Directory Setup

This directory appears under the Custdata directory and is used to store calibration and
setup information for the minilab instruments. There must be a separate directory for each
set of instruments connect to a particular PC workstation. If we assume that we have two
workstations A and B using minilab instruments then we require the following directory
structure, containing the files listed below.
The only exception to this is the 5200 which uses a common calibration file, a5200cal.mdb.
This is so because the 5200 hardware has a readable serial number that is used to identify
the correct calibration data in the a5200cal.mdb database. Furthermore, this database is
only accessed when the 5200 is being calibrated; under normal operation the calibration
data is read directly from the hardware.
\Custdata\Instrmnt\
a52caldm.def
a52calHW.def
a5200cal.mdb
example.zip
olv5200.cfg
olvcfg.cfg
parms.mdb
Wdatlas.mdb
\Custdata\Instrmnt\A\
anDemoR0.cfg
anDemoR1.cfg
anDemoT0.cfg
anDemoT1.cfg
dvcal_d.def
D-4
dvcal_demo.def
dvcal_dm.def
dvcal_h.def
olv51dv.cfg
olv51fw.cfg
olv51pc.cfg
olv5100.cfg
olvcfg.cfg
olvwda.cfg
WDACalLM.jpg
WDACalZM.jpg
\Custdata\Instrmnt\B\
anDemoR0.cfg
anDemoR1.cfg
anDemoT0.cfg
anDemoT1.cfg
dvcal_d.def
dvcal_demo.def
dvcal_dm.def
dvcal_h.def
olv51dv.cfg
olv51fw.cfg
olv51pc.cfg
olv5100.cfg
olvcfg.cfg
olvwda.cfg
D-5
WDACalLM.jpg
WDACalZM.jpg
After creating these directories and placing the correct calibration files in each directory, the
OilView file location setup must be changed. These locations are stored in the local PC registry, as they are user independent and specific to the PC, and therefore the user requires
administrative rights to change them.
Setting up OilView File Locations for Terminal Server or Citrix AMS

Machinery Manager Clients
All instances of OilView running under terminal server or Citrix use the same Instrmnt
directory.
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\
D-6
Setting up OilView File Locations for Workstation A using AMS Machinery

Manager Local Client A
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\A\
D-7
Setting up OilView File Locations for Workstation B using AMS Machinery

Manager Local Client B
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\A\
D-8
Setting up OilView for Terminal Server or Citrix

Check the Data Analysis Mode as shown below. This will disable access to the minilab
instruments. Wear Debris is enabled, but image capture is disabled.
D-9
Setting up OilView Local Client

Check the Data Collection Mode and Disable RBMview connection as shown below.
You must restart OilView for the second option to take effect. This will disable access to
the analysis options in OilView but will enable the minilab instruments and image capture.
Summary
The 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.
D-10
Appendix
Extended NAS Table
The NAS 1638 standard ends at 12. CSI has extended this table to better serve industrial
applications.
NAS
1638
Class
Number of particles per 100 ml. range

5 to 15
15 to 25
25 to 50
50 to 100
>100
13
2048000
364800
64800
11520
2048
14
4096000
729600
129600
23040
4096
15
8192000
1459200
259200
46080
8192
16
16384000
2918400
518400
92160
16384
17
32768000
5836800
1036800
184320
32768
18
65536000
11673600
2073600
368640
65536
E-1
E-2
Appendix
Addendum
Models 5100-1 and 5100-2 OilView Analyzer CE Addendum

Usage Notes:
Warning!
If the analyzer is not used in the manner specified either here or in the
accompanying users manual, then the safety protection provided by the
equipment may be impaired.
1 The analyzer must be connected to a safety ground by means of the safety ground
pin in the power plug.
2 Do not cover or block the ventilation slots on the analyzer
3 The power disconnect device for the analyzer is the power cord. When installing the
unit, be sure that the power cord is accessible for easy disconnection.
4 The analyzer is designed such that oil normally will not enter the unit in the case of
a spill. However, all spills should be wiped up as soon as possible. If it is suspected
that oil has entered the unit, then the unit should be returned to the factory for degreasing of internal wiring insulation.
F-1
Explanation of Symbols:
Protective Conductor Terminal
Alternating Current
Caution (refer to accompanying

documents)
Electrical Specifications:
Input Line Voltage Range: 100-240 VAC +/- 10%
Frequency Range: 47-63 Hz
Power Rating:Maximum 40W continuous output w/convection cooling
Fuse:250V 1.6A (IEC Code: T) 5 X 20 mm
Environmental Specifications:
Environment:Indoor use only
Operating Temperature: 0 degrees C to 5o degrees C
Storage Temperature: -25 degrees C to +85 degrees C
Relative Humidity: 5% to 80% non-condensing
Over Voltage (IEC 1010-1): Category II
Pollution (IEC 1010-1):Degree 2
CSI P/N 97379 Rev.
F-2
Index
Numerics
5200 Back-Flushing Procedures 10-24
A
abrasive wear 9-13
accessories, ports 1-28, 5-21
additives B-8, B-11
adhesive wear 9-14
Alarm Details 1-19
Alarms
Alarm Analysis 2-48
Alarm Limit (AL) sets 2-37
Baseline Adjusted Plot 2-43
CSI Default Alarm 2-37
Current Alarms 2-39
Default Alarm Sets 2-38
Histogram Plot 2-42
Raw Data 2-45
Raw Data Plot 2-44
Scatter Plot 2-46
Standard Alarm 2-47
Statistics 2-40
An Example testing Session
Analyzer Model Test Differences 5-30
Typical Test Procedure 5-26
Add User Alarm 2-30
Current Views 2-32
Edit AP Desc 2-31
Profile Setup 2-33
Report Group Setup 2-35
Set Default Alarm Type 2-30
Statistics 2-36
Update Alarm Baseline 2-30

Update Statistics 2-30
applications-OilView Analyzer A-1
assign contacts 11-17
ASTM plot 6-12
B
batch information 11-10
bearings A-2
babbit A-2
roller element A-2
sleeve A-2
C
Calibration Procedure 6-7
Existing Digital Viscometer Users 6-6
new user of the Digital Viscometer 6-6
Plot ASTM 6-12
Verify 6-11
Calibration
5200 Diagnostics 10-98
calibration
ferrous wear monitor 8-8 to 8-10
change marks 1-13
chemical index B-10
CO2 cartridge 7-5
color measurement
particle counter 7-19
combustion by-products 5-2
communication ports 5-21, 7-2
contacts 11-15
contaminant index B-11
I-1
contaminants B-4, C-2

large B-13
minimum B-1
corrosion B-10
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-1
digital viscometer
calibration 6-6 to 6-12
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 5-31
particle counter 7-11, 7-25
Dilution Of Viscous Samples 5-31
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 5-33
drain plug A-6
I-2
E
E-mail 1-41
Import Lab 4-1
Laboratory Information Management System
1-41
engines A-1
enhanced particle sensitivity 5-31
F
fatigue wear 9-13
ferromagnetic B-4, B-5, C-2, C-3
ferromagnetic index B-12
ferrous wear 9-14
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 9-13, A-4, A-6
free water A-1, B-6, C-4
frequency units test method
data plot C-1 to C-6
fuel A-3
fuse 5-23
G
gear A-2
H
hardware setup
ferrous wear monitor 8-5 to 8-7
oilview analyzer 5-21
particle counter 7-2 to 7-3

humidity 5-22
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 1-39
sample bottle label 1-38
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 2-3
Drag and Drop Sample 1-26
License Configurations 1-5
lighting, microscope 9-22
M
Alarm Limit Set 2-19
Analysis Parameter Set 2-18
Description 2-17
Equipment Type 2-19
External Working Environment 2-25
Filter 2-22
General 2-17
Internal Process Material 2-24
Internal Working Environment 2-22
Lab Unit ID 2-18
Lubrication System, Units 2-18
Oil Capacity 2-23
Oil Wetted Bearing Parts (P1) 2-26
Oil Wetted Parts (P2) 2-27
Oil Wetted Parts (P3) 2-28
Point ID 2-17
Report Group 2-18
Report Language 2-18
Schedule 2-20
Target Cleanliness 2-18
Test and Disply Filter 2-21
Usage Units 2-18, 2-23
microscope 9-14 to 9-22
model 51SM 9-21
N
NAS 7-18
nitration 5-2
O
oil
bearing A-2
collecting samples A-4 to A-7
crankcase A-1
gears A-2
hydraulic A-2
pump A-1
turbine A-1
Oil Tests
reference 10-32
OilLife index B-9
OilView Analyzer
usage tips 5-33
I-3
OilView Analyzer - Initial Setup 5-21

sensor curing 5-24
system setup 5-21
OilView Analyzer Usage Tips 5-33
Double-Clean the Grid 5-33
Verify Calibration 5-33
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 10-47
oxidation 5-2, A-1
P
particle counter
sample dilution 7-25
sensor cleaning 7-33, 7-38
setup 7-2
phosphate ester 5-24
plant air adapter 7-6
plot B-3 to B-7
lines B-4
Plot Cal 6-10
plots
trivector 3-5
pressure regulator 7-5
pumps A-1
I-4
R
Ref Samples used in Database 2-4
reference
file B-11
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 5-21, 5-25, 7-2
Running a Test 7-5
Alternative Testing Method 7-14
Particle Counter Test Procedure 7-7
Problems 7-13
S
sample 1-38
sample bottle 5-26, A-6, A-7
label A-7
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 2-20
sensor curing 5-24
sensor grid
cleaning 5-16
curing 5-24
double cleaning 5-33
phosphate ester 5-24
using 5-26 to 5-29
setup, operating characteristics 1-28 to 1-38
shop microscope 9-21
Software Menu Structure 1-8
Software Setup 5-3
Calibrate Tab 5-14
Calibration Information 5-19
Calibration Settings 5-18
Diagnostics 5-20
Test 5-3
Test Data Plot tab 5-18
Test Time Options 5-19
verification testing 5-13
specific gravity 6-8
spectroscopy 9-13
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-6
Superseding References 2-3
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 5-32, 5-33, 7-36
T
tare weight 7-28 to 7-32
test 5-25 to 5-29
results B-8 to B-13
Test esults 7-15
test options
high viscosity oils 5-32
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 10-32
Text Shortcuts 1-42
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 10-29
Initial Setup 10-3
Instrument Overview 10-2
Making WDA Filter Patches 10-29
Plots 10-40
Test 2 Plot 10-40
Test 3 ISO Plot 10-42
Test 3 NAS Plot 10-45
Results 10-37
Test 2 Wear / Contamination 10-38
Test 3 Contamination 10-38
Test 1 Calibration & Verification 10-51
Calibration 10-54
Initial Clean Check 10-53
Verification 10-57
Test 2 Calibration & Verification 10-59
Calibration 10-62
I-5
Preparation for Calibration 10-60

Verification 10-65
Test 3 Calibration 10-67

Test 3 Coincidence Error Limit Test 10-86
Test 3 Diluent/Clean Fluid Calibration 10-83
Test 3 Particle Counter Calibration Overview
10-67
Test 3 Sizing Calibration 10-76
Test 3 Verification 10-79
Test Procedure 10-16
Volumetric Dilution For Test 2 and Test 3 10-28
trivector plot 3-5
turbines A-1
U
ultrasonic bath 7-7, 7-22
Using the Digital Viscometer 6-13
V
vacuum chamber 7-22
verification test
OilView Analyzer 5-13
viscometer 5-31
Viscosity 6-15
viscosity
adhesive wear 9-14
dilution 5-31
fuel dilution A-1
viscosity index 6-8
viscosity index value 6-7
W
water 9-17, A-1
contaminant index B-11
corrosion index B-10
droplets B-13
example plot B-6, B-7, C-4, C-6
hydraulic oil 5-2
I-6
sampling location A-6

WDA Filter Patch 10-29
wear 9-13 to 9-17
Wear Debris Analysis 9-1
Analyst tab 9-11
Atlas Setup 9-10
Model 51SM Microscope 9-21
Model 52LM Lab Microscope 9-22
Model 52ZM Stereoscopic Zoom Microscope
9-23
OilView Analyzers And Wear 9-13
Sample 9-5
Sample/Atlas 9-9
Using the Model 51WD Wear Debris Patch
Maker 9-17
Video Camera 9-2
Video Frame Grabber 9-2
wear particles 5-2, B-12

Rev.15 OilView

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rev.15 OilView

Uploaded by

Copyright:

Available Formats

Reference Manual

CSI Part # 97381 Rev. 15

free. CSI makes no representations or warranties to the

THE PROGRAM IS PROVIDED "AS-IS" WITHOUT ANY WARRANTIES, EXPRESS OR

LIMITATION OF LIABILITY AND REMEDIES

IN NO EVENT WILL CSI BE LIABLE TO YOU

Hardware Technical Help

Software Technical Help

Chapter 2 OilView Database Options

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

Chapter 3 OilView Reporting

Chapter 4 Importing Data From the Laboratory

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

Chapter 6 Digital Viscometer Model 51DV and Model 52DV

Plot ASTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Chapter 7 The OilView Particle Counter - Model 51PC

Chapter 8 The OilView Ferrous Wear Monitor - Model 51FW

Chapter 9 Wear Debris Analysis

Chapter 10 The Model 5200 Trivector Analyzer

Test 2 Calibration & Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59

Chapter 11 Laboratory Information Management System (LIMS)

Appendix A Using the OilView Analyzer

Appendix B Understanding the OilView Analyzer Data

Appendix C The Original Frequency Units Data Plot

Appendix D WAN Setup for OilView

OilView Instrument Directory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Appendix E Extended NAS Table

How To Use This Manual

This manual covers the OilView Analyzer Model 5100-1 and

The Note paragraph indicates special comments or instructions.

The Caution paragraph alerts you to actions that could have an

The Warning paragraph warns you of actions that could cause

Electrostatic Discharge or Other Harsh Environments

On-Line Help System

Trivector Laboratory Data Import

OilView Software Menu Structure

Drop down menus

Open Database Switches to another database.

Help accesses the online help system.

OilView Software Menu Structure

Open Database switches databases.

OilView Software Menu Structure

Although other types of data may be visible on the database tree,

OilView Software Menu Structure

Right Mouse Click Functions

Add Area Add a new area to the database.

OilView Software Menu Structure

Click On the Area Icon

OilView Software Menu Structure

This screen shows the severity contribution from all technologies.

You can set the following preferences:

OilView Software Menu Structure

OilView Software Menu Structure

Click On the Measurement Point Icon

OilView Software Menu Structure

Click On the Sample Icon

OilView Software Menu Structure

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

Copy for Ref DB

OilView Software Menu Structure

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

Verbose More detailed errors and warnings.

Lab Options Reserved for the CSI Trivector lab.