enpac oil user's guide

Enpac OilUser’s Guide

Your manual for using thedigital Contam Alert®,

ferrous Contam Alert®,digital Visc Alert®,

Enpac Oil,and the Oil Sensor Interface

withEnlube™ Proaction® Manager,

EMONITOR Odyssey®,or Enshare™

Entek IRD International Corporation

P/N 45805

Copyright Notice

Copyright © 2000 by Entek IRD International CorporationAll Rights ReservedFirst Edition 2000Printed in the U.S.A.

This Manual is supplied to the User under license, subject to recall by Entek IRD International Corporation at any time, and the Manual at all times remains the property of Entek IRD International Corporation. The information contained in this Manual is considered confidential. No part of this Manual is to be copied or reproduced or transmitted in any form whatever (including orally or by electronic transmission), nor is any information in this Manual to be disclosed in any form whatever (including orally or by electronic transmission) to anyone other than an authorized representative of the User’s employer who also shall agree not to disclose same, without express prior written consent of Entek IRD International Corporation.

Trademarks

EMONITOR Odyssey, Proaction, digital CONTAM ALERT, ferrous CONTAM ALERT, and digital VISC ALERT, Entek, and IRD are registered trademarks of Entek IRD International Corporation.Enshare, Enlube and Lube Link are trademarks of Entek IRD International Corporation.Millipore is a registered trademark of Millipore Corporation. Microsoft, MS-DOS, and Windows are registered trademarks of Microsoft Corporation.All other product names are registered trademarks of their respective owners.

Entek IRD International Corporation1700 Edison Dr.Milford, OH 45150-2729

Contents

Enpac Oil User’s Guide iii

Table of Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Overview of the Host Software and the Oil Analysis System . . . . . . . . . . . . . . . . . . .2

Using this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Using the Online Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2. The Enpac Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Overview of the Enpac Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Parts of the Enpac Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Data Collector Diagram and Key Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . .12Data Collector Hardware Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Strap Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Enpac Oil Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Battery Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Checking Battery Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Inserting or Removing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Basic Enpac Oil Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Powering On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Adjusting the Screen Contrast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Making Selections in the Data Collector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Displaying the Operating System Version Number . . . . . . . . . . . . . . . . . . . . . .19Resetting the Data Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Bootloader Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Loading the Enpac Oil Operating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Setting the Date and Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Enpac Oil Menus and Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24dCA Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Communicate with PC Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24View Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Using Memory Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Types of Memory Card Used with Enpac Oil. . . . . . . . . . . . . . . . . . . . . . . . . . .26Inserting and Removing a Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

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3. The digital CONTAM-ALERT (dCA). . . . . . . . . . . . . . . . . . . . 27Overview of the dCA (digital CONTAM-ALERT) . . . . . . . . . . . . . . . . . . . . . . . . . 28

Safety Warnings for the dCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28dCA Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Understanding How the dCA Sensor Works . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Connecting the dCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Configuring the dCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Setting Screen Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Setting Screen Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Setting Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Setting Result Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Setting Particle Size Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Techniques for Collecting Data with the dCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Probing On with the dCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Priming the dCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Assembling the dCA Sensor with Sensor Screen . . . . . . . . . . . . . . . . . . . . . . . 35

Maintaining the dCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Backflushing the dCA Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Cleaning dCA Sensor Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Changing Screen Sizes or Changing Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Calibrating the dCA Sensor Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Seal Compatibility with Specific Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Replacing the Sensor Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Diluting High Viscosity Fluids to Test with the dCA. . . . . . . . . . . . . . . . . . . . . . . . 44

4. The ferrous CONTAM-ALERT (fCA) . . . . . . . . . . . . . . . . . . . 47Overview of the ferrous CONTAM-ALERT (fCA) . . . . . . . . . . . . . . . . . . . . . . . . . 48

Understanding How the fCA Sensor Works . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Connecting the fCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Maintaining the fCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Cleaning the fCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Verifying the fCA Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Replacing the fCA Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Flushing the fCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Collecting a Ferrogram for Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Diluting High Viscosity Fluids to Test with the fCA . . . . . . . . . . . . . . . . . . . . . . . . 54

5. The digital VISC-ALERT (dVA) . . . . . . . . . . . . . . . . . . . . . . . 55Overview of the digital VISC-ALERT (dVA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Safety Warnings for the dVA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56dVA Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Understanding How the dVA Sensor Works . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Connecting the dVA Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58Probing On with the dVA Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Assembling the dVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Priming the dVA Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Configuring the dVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Entering the Probe Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Calibrating the Probe for Low Viscosity Fluids . . . . . . . . . . . . . . . . . . . . . . . . .61Calibrating the Probe for High Viscosity Fluids. . . . . . . . . . . . . . . . . . . . . . . . .63Setting the Default Units and Projected Temperature. . . . . . . . . . . . . . . . . . . . .65Entering New Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Maintaining the dVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Backflushing the dVA Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Seal Compatibility with Specific Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69Replacing the Sensor Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Comparing Test Results to New Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .72

6. Equipment for Sampling and Testing . . . . . . . . . . . . . . . . . 75Overview of Equipment for Sampling and Testing . . . . . . . . . . . . . . . . . . . . . . . . . .76

Proper Sampling Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76Choosing Sample Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78When to Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79Sampling Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80Other Sampling References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Preparing Test Port Valves for Sampling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Collecting Fluid Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83Overview of Collecting Fluid Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83Collecting a Bottled Sample from a 5–500 psi Line . . . . . . . . . . . . . . . . . . . . . .84Collecting a Bottled Sample from a 500–3000 psi Line . . . . . . . . . . . . . . . . . . .85Agitating the Bottled Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Using the High Pressure Sampler II (HPS II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Using the Portable Pressure Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Using the Bench-Top Apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

7. Setting Up Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . 93Overview of Setting Up Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Measurement Definition Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94Measurement Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94Measurement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95Measurement Input Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Setting Up the Lubricant Specifications and Categories . . . . . . . . . . . . . . . . . . . . . .97Adding Lubricants to the Lubricant Library . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Using the Viscosity Calculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99Setting Up Categories for Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

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Setting Up Measurement Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Setting Up Measurement Definitions for the dCA for Particle Count . . . . . . . 102Setting Up Measurement Definitions with the fCA for Ferrous Count . . . . . . 103Setting Up Measurement Definitions with the dVA for Viscosity . . . . . . . . . 103

Setting Up Alarms, Lists, and Inspection Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . 104Alarms and the Data Collector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Lists and the Data Collector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Inspection Codes and the Data Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8. Loading and Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Overview of Loading and Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Setting Up for Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Preparing the Host Software for Communication . . . . . . . . . . . . . . . . . . . . . . 109Setting Up the Data Collector for Communication . . . . . . . . . . . . . . . . . . . . . 111Selecting the Correct Communication Settings in the Enpac Oil . . . . . . . . . . 111Connecting the Data Collector and Computer . . . . . . . . . . . . . . . . . . . . . . . . . 112

Loading Lists to the Data Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Preparing the Data Collector for Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Deleting or Resetting Lists in the Data Collector . . . . . . . . . . . . . . . . . . . . . . 113Selecting the List(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Loading Lists to the Data Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Displaying the Data Collector Driver Version Number. . . . . . . . . . . . . . . . . . 115

Unloading a List from the Data Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Preparing the Data Collector for Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . 116Unloading a List in the Host Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Unloading Unscheduled Data from the Data Collector . . . . . . . . . . . . . . . . . . 117Automatically Printing Reports after Unloading . . . . . . . . . . . . . . . . . . . . . . . 117

Transferring Individual Files from your Computer to the Enpac Oil . . . . . . . . . . . 118Downloading and Installing Microsoft ActiveSync. . . . . . . . . . . . . . . . . . . . . 118Connecting to the Enpac Oil using ActiveSync. . . . . . . . . . . . . . . . . . . . . . . . 119Transferring Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

9. Collecting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Overview of Collecting Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Preparing for Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Collecting List Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Using the dCA to Collect List Data for Particle Count . . . . . . . . . . . . . . . . . . 126Using the fCA to Collect List Data for Ferrous Count . . . . . . . . . . . . . . . . . . 129Using the dVA to Collect List Data for Viscosity . . . . . . . . . . . . . . . . . . . . . . 132Entering Inspection Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Moving through a List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135Skipping Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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Collecting Unscheduled Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136Using the dCA to Collect Unscheduled Particle Count Data . . . . . . . . . . . . . .137Using the fCA to Collect Unscheduled Ferrous Count Data. . . . . . . . . . . . . . .139Using the dVA to Collect Unscheduled Viscosity Data . . . . . . . . . . . . . . . . . .141Storing Unscheduled Data in the Host Software. . . . . . . . . . . . . . . . . . . . . . . .143

Reviewing Collected Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

10. Using Lube Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Overview of Lube Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Setting Up Lube Link Data Collection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146Choosing the Default File Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147Choosing the Export Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147Inserting New Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148Setting Up a Lab Stand for Lube Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Configuring the dCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151Setting Screen Size and Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152Setting Screen Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153Setting Particle Count Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

Configuring the dVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154Entering the Probe Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154Calibrating the Probe for Low or High Viscosity Fluids . . . . . . . . . . . . . . . . .154Setting the Default Viscosity Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158Entering New Oil Specifications in the Lubricant Library . . . . . . . . . . . . . . . .158

Connecting to the Oil Sensor Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160Connector Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160Setting the Computer Communications Port. . . . . . . . . . . . . . . . . . . . . . . . . . .161

Collecting dCA Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162

Collecting dCA/fCA Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

Collecting dVA Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166Comparing Test Results to New Oil Specifications . . . . . . . . . . . . . . . . . . . . .168Troubleshooting Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

Viewing Particle Count and Ferrous Count Data . . . . . . . . . . . . . . . . . . . . . . . . . . .170Setting Default Display Units for Particle Count . . . . . . . . . . . . . . . . . . . . . . .171Setting Plot Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172Viewing Plots of Particle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173Printing Plots of Particle Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

Viewing Viscosity Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174Setting Default Display Units for Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . .174

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175Setting Up Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177Generating Reports on Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182Printing Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

Table of Contents

viii Enpac Oil User’s Guide

Exporting and Importing Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183Selecting Units for Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184Exporting Data to the Host Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184Importing Data into Host Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186Setting Up Automatic Import. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187Exporting Data to Excel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189Data Collector INI File Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Frequently Asked Questions and Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192Setting Up Measurement Definitions in the Host Software. . . . . . . . . . . . . . . 192Loading Lists to the Enpac Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Collecting Data with the Enpac Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194Unloading Data from the Enpac Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Abbreviations, Prefixes, and Letter Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . 224Cleanliness Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Terms and Conditions

Enpac Oil User’s Guide ix

ENTEK IRD INTERNATIONAL CORPORATION GENERAL TERMS AND CONDITIONS

1. CONTRACT. When Customer accepts a Quotation from Entek IRD International Corporation or an affiliate (the entity issuing the quotation being "Entek IRD") by issuance of a purchase order or otherwise and Entek IRD accepts the order, Customer is deemed to have agreed to all the Terms and Conditions contained herein. Unless otherwise approved in writing, the acceptance of Entek IRD is expressly conditioned upon Customer accepting these Terms and Conditions, and any different or additional terms and conditions contained in Customer's order or related documents are expressly objected to by Entek IRD and not binding upon it. Entek IRD reserves the right to accept or reject all orders received by it and all orders may only be accepted at the contracting office of Entek IRD located in Ohio. Entek IRD may accept in writing, by commencement of performance or otherwise.

2. QUOTATIONS. All quotations expire automatically thirty days from date of quotation or earlier by notice from Entek IRD. Unless otherwise noted in writing by Entek IRD, all prices are F.O.B. the place of origin for domestic shipments and Ex Works (as defined in INCOTERMS 1990) for international shipments; and risk of loss in transit is on Customer. Prices do not include any applicable taxes, however designated, levied or based upon the goods or services being quoted. Customer agrees to pay all such taxes or provide acceptable evidence of exemption therefrom.

3. TIMING. All delivery/shipping and service dates stated by Entek IRD are approximate dates only and estimated in good faith to the best of Entek IRD's ability and are dependent upon Entek IRD's prompt receipt of all necessary information from Customer. Time shall not be deemed to be of the essence in Entek IRD's performance of this agreement, and no penalty clause of any description in any specification or order will be effective unless specifically approved in writing by an authorized officer of Entek IRD. In any event delivery/shipping and service dates are always quoted subject to unavoidable delays due to causes beyond Entek IRD's control including but not limited to strikes, casualty, war, acts of God, systems failure or government action.

4. TERMS. Payment terms for domestic orders are net 10 days from date of invoice, unless otherwise provided in the quotation. For international orders, Entek IRD reserves the right to specify prepayment, letter of credit, or payment net 10 days from the date of invoice. Each shipment shall be considered a separate and independent transaction and payment must be made accordingly. If the financial condition or credit of Customer at any time in the judgment of Entek IRD, does not warrant shipment of goods ordered, Entek IRD may at its option require full payment prior to shipment or refuse to ship and terminate any order outstanding without liability to Entek IRD. If any sum is not paid by Customer when due, Entek IRD shall not be obligated to continue performance. If any amount is not paid when due, to the extent permitted by law a late fee of 1% per month (or any part thereof) shall be charged on past due amounts until paid.

5. CONFIDENTIALITY. If Customer data comes into Entek IRD's possession, Entek IRD shall use the same level of care to maintain the confidentiality of that data which Entek IRD uses for its own confidential information. Subject thereto, Entek IRD may use data in its possession to compile and maintain commercial machinery information databases in which the origin of specific data is not identifiable by users. Such databases shall be the sole property of Entek IRD.

6. CANCELLATION. Once accepted by Entek IRD, an order is not subject to cancellation in whole or in part by Customer without Entek IRD's prior written consent. Any such cancellation shall be subject to a cancellation charge as determined by Entek IRD to cover any loss that may be incurred by Entek IRD as a result of such cancellation, including without limitation a 25% restocking charge for standard products.


x Enpac Oil User’s Guide

7. CUSTOMER RESPONSIBILITIES. Customer shall be solely responsible for the accuracy and adequacy of the information provided to Entek IRD, and Entek IRD shall not be liable for any damages resulting from the loss, disclosure or inaccuracy of such information. Customer shall, for those contracts which include on-site installation, have the installation site prepared at its expense prior to the scheduled installation date to enable Entek IRD to promptly deliver and commence installation. The products are not for use in or with any nuclear facility, unless the Quotation expressly permits such use; and Customer shall indemnify and hold Entek IRD harmless from all liability (including such liability resulting from Entek IRD's negligence) arising out of such improper use. Customer shall not send or use the products outside the United States except in compliance with all applicable law, including U.S. export regulations and restrictions.

8. SOFTWARE AND SERVICES DOCUMENTS. If any computer software, whether incorporated into a piece of equipment ("firmware"),or provided separately, and related user documentation in any medium (collectively referred to as "Software") are included in the contract, the terms of the Entek IRD Standard Software License Agreement shall govern the contract with respect to Software. If any services other than oil analysis services are included in the contract, the Entek IRD Standard Field Engineering Services Terms and Conditions shall govern such services. Those documents are available to Customer upon request, and Customer is responsible to obtain and read the Standard Software License Agreement and the Standard Field Engineering Services Terms and Conditions.

9. LIMITED WARRANTIES AND REMEDIES. A. Entek IRD warrants to Customer (and not anyone else) that (i) all products manufactured by Entek IRD shall be free of defects in materials and workmanship under normal conditions for a period of one (1) year from the date of shipment (except that items with limited life such as batteries and lamps are warranted for 90 days from date of shipment) and that (ii) services will be free from defects in workmanship under normal conditions, for 90 days from performance. With respect to performance related in any way to the passage of time to the year 2000 and beyond, or the occurrence of a leap year, Entek IRD does not make any representation or warranty; Entek IRD has issued a Year 2000 readiness disclosure statement, which is available to Customer upon request.

B. With respect to any Entek IRD product or service that fails to satisfy the limited warranty provisions in this Section, as Customer's exclusive remedy, and at Entek IRD's option, Entek IRD will repair or replace the product or refund its purchase price or refund the purchase price of the service, provided that any defect is brought to the attention of Entek IRD within the warranty period. To qualify for this warranty concerning a product Customer must return the defective product to Entek IRD's designated facility freight prepaid, and after repair or replacement Entek IRD will return the product freight prepaid; or, if in Entek IRD's opinion the product is impractical to ship, Customer shall be charged for labor, transportation and subsistence expenses for the service representative(s) providing the warranty work at Customer's site. Entek IRD alone will be authorized to furnish or arrange for repairs or replacements.

C. The above limited warranties do not apply, and no warranty, either express or implied, shall be applicable, (a) to damage resulting from accident, alteration, misuse or abuse, harmful conditions, systems failure or Act of God; (b) if the product is not installed, operated and maintained according to procedures recommended by Entek IRD; or (c) if the Entek IRD serial number is obliterated. In no case shall the limited warranty extend to defects in materials, components, or services furnished by third parties or to the repair or installation of the product performed by third parties. The above warranties do not extend to any products sold "as-is" or "as-inspected;" no warranties, either express or implied, are made with respect to such products.

D. Entek IRD makes no representations or warranties to Customer, or anyone else, with respect to products manufactured by a third party. Any warranties of the third party manufacturers shall run directly to Customer to the extent permitted by law and Entek IRD shall have no liability therefor.


Enpac Oil User’s Guide xi

E. The limited warranties in this Section constitute Entek IRD's entire warranty as to the products and services provided hereunder. ENTEK IRD HEREBY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING CONFORMITY TO ANY REPRESENTATION OR DESCRIPTION AND INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSES WHATSOEVER.

10. EXCLUSIVE REMEDIES AND LIABILITY LIMITATION. THE REMEDIES PROVIDED HEREIN ARE CUSTOMER'S SOLE AND EXCLUSIVE REMEDIES, AND ENTEK IRD'S EXCLUSIVE LIABILITY WHETHER ARISING IN CONTRACT, TORT (INCLUDING NEGLIGENCE), STRICT LIABILITY OR ANY OTHER LEGAL THEORY. CUSTOMER AGREES THAT NO OTHER REMEDY (INCLUDING, BUT NOT LIMITED TO, INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOST PROFITS, LOST SALES, LOST PRODUCTION, OVERHEAD, LABOR, INJURY TO PERSON OR PROPERTY, OR ANY OTHER INCIDENTAL LOSS) SHALL BE AVAILABLE TO CUSTOMER. THIS ALLOCATION OF RISK IS REFLECTED IN THE PRICES OF THE PRODUCTS AND SERVICES. ENTEK IRD'S MAXIMUM LIABILITY HEREUNDER ARISING FROM ANY CAUSE WHATSOEVER SHALL BE LIMITED TO THE PURCHASE PRICE OF THE PRODUCTS AND SERVICES IN QUESTION. Any suit related to this Agreement, on any legal theory, must be commenced within one year after the cause of action accrues.

11. TITLE AND LIEN RIGHTS. Each product shall remain personal property regardless of how it is affixed to Customer's real property and Entek IRD reserves a purchase money security interest in the product until the purchase price has been fully paid. Customer agrees to execute, and hereby appoints Entek IRD as its attorney-in-fact to execute on Customer's behalf, any documents requested by Entek IRD which are necessary for attachment and perfection of its security interest. If Customer defaults, Entek IRD shall have all the rights of a secured creditor under the Uniform Commercial Code as enacted in Ohio.

12. OTHER TERMS. These terms and conditions and any issue, claim or dispute arising hereunder shall be interpreted under and governed in all respects by the internal laws of the State of Ohio, and not by the 1980 U.N. Convention on the International Sale of Goods. These terms and conditions and the written quotation to which they relate constitute the entire contract between the parties, and supersede all other oral or written statements of any kind whatsoever made by the parties or their representatives. Waiver by Entek IRD of strict compliance with any one or more of these Terms and Conditions is not to be considered a continuing waiver or a waiver of any other term or condition. No statement purporting to modify any of these terms or conditions shall be binding unless expressly agreed to in writing signed by an officer of Entek IRD and by Customer.


xii Enpac Oil User’s Guide

ENTEK IRD INTERNATIONAL CORPORATIONSTANDARD SOFTWARE LICENSE AGREEMENT

1. LICENSE: This License Agreement ("Agreement") sets forth the terms and conditions on which software owned by or licensed to Entek IRD International Corporation ("Entek IRD"), whether incorporated into a piece of equipment (i.e. "firmware") or provided separately, together with related user documentation in any medium and hardware security keys (together referred to as "Software"), are licensed to a customer ("Customer"). Each entity that has licensed to Entek IRD any Software that is being licensed to Customer hereunder, including Oracle Corporation, is a third party beneficiary of this Agreement, to the extent permitted by law. Upon Customer's use of or payment for the Software, Customer is deemed to have agreed to all the terms and conditions contained in this Agreement. Any different or additional terms and conditions contained in Customer's order or other documents are expressly objected to by Entek IRD and not binding upon it.

A. Entek IRD grants Customer a non-exclusive and non-transferable license to use each Software program furnished hereunder solely for Customer's internal use and subject to the following limitations: If the Software provided is for a single-user system as identified in the quotation, Customer may use the Software only on a single computer. If the Software provided is for a local area network (LAN) multi-user system as identified in the quotation, Customer may install the Software on a single database server and may access the Software only from other network clients located at the same site. If the Software provided is for a wide area network (WAN) multi-user system as identified in the quotation, Customer may install the Software on a single database server and may access the Software only from network clients at the same site and at the number of remote sites for which Customer purchases licenses. If the Software provided is for a multi-user system as identified in the quotation, the Customer may use the Software with a single database server, and the Software may be accessed only by the number of concurrent users for which Customer purchases concurrent user licenses. TurboMonitor software may be installed only on a single computer per license. If any Software requires a security key for access, Customer may use only security keys purchased from Entek IRD.

B. Customer acknowledges that the Software and related documentation including all versions, corrections, enhancements and improvements thereto, include confidential data and know-how which are claimed as trade secrets or other proprietary information by Entek IRD and/or its suppliers. Use of the Software is restricted to object code. Without prior written consent of Entek IRD, Customer shall not do, or permit or assist others to do any of the following: (i) allow the Software, related documentation or any portion thereof in any form to be used by any person or entity other than Customer's employees or agents, and then only to the extent necessary in the scope of their employment or agency; (ii) copy or otherwise reproduce, disassemble, decompile, reverse engineer, modify, update, translate, transform into other form, or enhance the Software; or (iii) disclose or permit access to the Software to any person or entity, except to the extent necessary to facilitate the permissible use thereof as set forth in (i) above. Entek IRD is under no obligation to furnish source code for any Software program.


Enpac Oil User’s Guide xiii

C. Customer shall not assign or otherwise transfer the license to the Software granted herein except to a successor in interest to the entire business in which the Software is used, and then only if the assignee or transferee agrees in writing to be bound by the terms hereof. Timesharing and rental of the Software is prohibited. Customer warrants that all persons having access to the Software will observe and perform the obligations set forth in this document. Customer understands and agrees that the Software is an unpublished work and agrees that the existence of any copyright notice shall not be construed as an admission or presumption that publication has occurred. Customer acknowledges, notwithstanding the license granted herein, that all intellectual property rights in the Software are and shall continue to be exclusively owned by Entek IRD and/or its suppliers. The Software is "commercial computer software" for purposes of licenses to any divisions or agencies of the U.S. Federal Government. Customer shall not send or use the Software outside the United States except in compliance with all applicable law, including U.S. export regulations and restrictions. Entek IRD may enter Customer's premises during normal business hours to verify Customer's compliance with the terms of this license. Customer may not publish the results of any benchmark test run on the Software.

D. If Customer data comes into Entek IRD's possession, Entek IRD shall use the same level of care to maintain the confidentiality of that data which Entek IRD uses for its own confidential information. Subject thereto, Entek IRD may use data in its possession to compile and maintain commercial machinery information databases in which the origin of specific data is not identifiable by users. Such databases shall be the sole property of Entek IRD.

2. LIMITED WARRANTIES.

A. Entek IRD warrants to Customer (and not anyone else) that all Entek IRD Software supplied by Entek IRD shall perform in substantial conformance with the specifications provided by Entek IRD in the product manual of such Software for a period of one year from the date of shipment. With respect to performance related in any way to the passage of time to the year 2000 and beyond, or the occurrence of a leap year, Entek IRD does not make any representation or warranty; Entek IRD has issued a Year 2000 readiness disclosure statement, which is available to Customer upon request. Entek IRD does not warrant that the operation of the CPU or Software will be uninterrupted or error free. Entek IRD makes no representation or warranty, either express or implied, with regard to the Software's suitability, capacity, or performance in relation to Customer's specifications or needs. Entek IRD warrants that the Software does not contain computer viruses when shipped. It is Customer's responsibility to preserve the integrity of its computer systems and to conduct virus checks of all Software before it is installed, and this warranty concerning computer viruses expires when the Software is installed.

B. With respect to any Entek IRD Software which fails to satisfy the limited warranty provisions in this Agreement, as Customer's exclusive remedy, and at Entek IRD's option, Entek IRD agrees to repair or replace such defective item without charge, or Entek IRD's sales price therefor shall be refunded upon return of the defective product to Entek IRD, provided that any defect in the Software is brought to the attention of Entek IRD within the warranty period; Entek IRD alone will be authorized to furnish or arrange for repairs or replacements, or to refund Entek IRD's sales price, within the terms of this limited warranty.

C. The above limited warranties do not apply, and no warranty, either express or implied, shall be applicable, (a) to damage resulting from accident, alteration, misuse or abuse, harmful conditions or Act of God; (b) if the product is not installed, operated and maintained according to procedures recommended by Entek IRD; or (c) if any modifications whatsoever to the Software are made by anyone except Entek IRD. In no case shall the limited warranty extend to defects in materials, components, or services furnished by third parties or to the repair or installation of the product performed by third parties.


xiv Enpac Oil User’s Guide

D. The limited warranties in this Section constitute Entek IRD's entire warranty as to the Software provided hereunder. ENTEK IRD AND EACH LICENSOR OF ENTEK IRD HEREBY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING CONFORMITY TO ANY REPRESENTATION OR DESCRIPTION AND INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSES WHATSOEVER.

3. PATENT AND COPYRIGHT INDEMNITY. Entek IRD will at its expense, defend Customer against any claim that any Entek IRD Software furnished under this Agreement infringes a United States patent or copyright. Entek IRD will pay all costs, damages and attorney's fees that a court finally awards as a result of such claim. To qualify for such defense and payment, Customer must 1) give Entek IRD prompt written notice of any such claim, and 2) allow Entek IRD to control, and fully cooperate with Entek IRD in, the defense and all related settlement negotiations.

Customer agrees that if the operation of the Entek IRD Software becomes, or Entek IRD believes is likely to become, the subject of such a claim, Customer will permit Entek IRD at its option and expense, either to secure the right for Customer to continue using the Entek IRD Software or to replace or modify it so that it becomes non-infringing. However, if neither of the foregoing alternatives is available on terms which are reasonable in Entek IRD's judgment, Customer will return the Entek IRD Software upon Entek IRD's written request. Entek IRD will grant Customer a credit for any Entek IRD Software whose total charges are fully paid, as Customer's sole remedy and Entek IRD shall have no other liabilities therefor.

Entek IRD shall have no obligation with respect to any such claim based upon Customer modification of any Software or its combination, operation or use with apparatus, data or programs not furnished by Entek IRD or in other than the specified operating environment. This Section states Entek IRD's entire obligation to Customer regarding infringement or the like.

4. EXCLUSIVE REMEDIES AND LIABILITY LIMITATION. THE REMEDIES PROVIDED HEREIN ARE CUSTOMER'S SOLE AND EXCLUSIVE REMEDIES, AND ENTEK IRD'S EXCLUSIVE LIABILITY WHETHER ARISING IN CONTRACT, TORT (INCLUDING NEGLIGENCE), STRICT LIABILITY OR ANY OTHER LEGAL THEORY. CUSTOMER AGREES THAT NO OTHER REMEDY (INCLUDING, BUT NOT LIMITED TO, INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR LOST PROFITS, LOST SALES, LOST PRODUCTION, OVERHEAD, LABOR, INJURY TO PERSON OR PROPERTY, OR ANY OTHER INCIDENTAL LOSS) SHALL BE AVAILABLE TO CUSTOMER. THIS ALLOCATION OF RISK IS REFLECTED IN THE PRICE OF THE SOFTWARE. ENTEK IRD'S MAXIMUM LIABILITY HEREUNDER ARISING FROM ANY CAUSE WHATSOEVER SHALL BE LIMITED TO THE PURCHASE PRICE OF THE SOFTWARE IN QUESTION. Any suit related to this Agreement, on any legal theory, must be commenced within one year after the cause of action accrues.

5. SOFTWARE LICENSE TERM. The Software license granted hereunder shall be effective until terminated. Customer may terminate the license at any time by returning to Entek IRD the Software and related documentation together with all copies, modifications, and merged portions in any form. Entek IRD may terminate this license if Customer breaches any term of this license. This license will terminate automatically when Customer ceases to use the Software, except for temporary periods not exceeding one year. When the license terminates no refund shall be made by Entek IRD, and Customer shall at its expense return to Entek IRD the Software and all related keys and documentation together with all copies, modifications, and merged portions in any form. Upon termination Customer must discontinue use and destroy or return to Entek IRD all copies of the Software and all documentation.

6. MAINTENANCE AND SERVICE. Entek IRD has no obligation, except as otherwise expressly stated in the Quotation or herein, to provide service, support, technical assistance, updates or training.


Enpac Oil User’s Guide xv

7. MISCELLANEOUS. Entek IRD may enter Customer's premises from time to time during business hours and conduct such inspections as Entek IRD deems appropriate to verify Customer's compliance with this Agreement. This Agreement, any written quotation to which it relates and the General Terms and Conditions of Entek IRD constitute the entire contract between the parties with respect to the Software, and supersede all other oral or written statements of any kind whatsoever made by the parties or their representatives. No statement purporting to modify any of these terms or conditions shall be binding unless expressly agreed to in writing signed by an officer of Entek IRD and by Customer. These terms and conditions and any issue, claim or dispute arising hereunder shall be interpreted under and governed in all respects by the internal laws of the State of Ohio, and the state and federal courts of Clermont County, Ohio shall have exclusive jurisdiction and venue over all disputes related to this Agreement or relationship. Waiver by Entek IRD of strict compliance with any one or more of these Terms and Conditions is not to be considered a continuing waiver or a waiver of any other term or condition.


xvi Enpac Oil User’s Guide

Enpac Oil User’s Guide 1

Chapter 1

1. Introduction

This chapter introduces you to using the Enpac Oil and Oil Sensor Interface with the dCA, the fCA, the dVA, and with EMONITOR

Odyssey®, Enshare™, or Enlube™ Proaction® Manager. It also describes the Online Help System and Customer Support.

Overview of the Host Software and the Oil Analysis System ................ 2

Using this Manual ................................................................................. 2

Using the Online Help System............................................................... 4

Customer Support.................................................................................. 5

2 Enpac Oil User’s Guide

Chapter 1 - Introduction

Overview of the Host Software and the Oil Analysis SystemThe Enpac Oil is a Windows CE-based data collector for collecting and analyzing the amount of particulate matter, ferrous matter, or viscosity levels in a fluid sample. The combination of this data collector with Entek host software provides a complete package for predictive maintenance using oil or hydraulic fluid analysis. The host software can be Enshare, EMONITOR Odyssey, or Enlube Proaction Manager.

This manual covers using the Enpac Oil or Oil Sensor Interface with three different sensors:

z the digital CONTAM-ALERT® (dCA)

z the ferrous CONTAM-ALERT® (fCA)

z the digital VISC-ALERT® (dVA)

A predictive maintenance program helps you decide when equipment needs to be serviced or replaced. Fluid analysis can help you determine general equipment health. The Enpac Oil can perform fluid analysis by determining the concentration of specific sizes of particles or viscosity levels in lubricant or hydraulic fluid for analysis.

With the combination of the host software and the Enpac Oil, you can complete your data collection and oil analysis on site by learning how to:

z Create lists of measurement definitions.

z Load lists from the host software into the Enpac Oil.

z Collect list data using the dCA sensor, the fCA sensor, or the dVA sensor

z View collected data with the Enpac Oil.

z Unload collected data into your host software database.

This chapter walks you through this manual and the Online Help System, and offers information on Customer Support services.

Using this ManualThis Guide is intended for people using the host software and the oil analysis system sensors coupled with the Enpac Oil. This manual contains step-by-step instructions for using the Enpac Oil with the host software and serves as a reference and troubleshooting guide with sections about the Enpac Oil, Oil Sensor Interface, the dCA sensor, the fCA sensor, the dVA sensor, and frequently asked questions.

OrganizationTo help you navigate through this manual, it is organized in chapters based on these tasks and topics:

Chapter 1 “Introduction” contains an overview of this manual and the Online Help System. It also contains information about the host software and using Entek Customer Support Services.

Chapter 2 “The Enpac Oil” describes the Enpac Oil data collector in detail, including battery information and how to load the operating system.

Using this Manual


Chapter 3 “The digital CONTAM-ALERT (dCA)” covers the basic operations of the dCA sensor, including important safety information.

Chapter 4 “The ferrous CONTAM-ALERT (fCA)” contains information about the fCA sensor and how to use it with the Enpac Oil and dCA.

Chapter 5 “The digital VISC-ALERT (dVA)” describes using the dVA to obtain viscosity information and how you can compare your measurements to new oil specifications.

Chapter 6 “Equipment for Sampling and Testing” describes other equipment used for collecting fluid samples and testing samples, such as the High Pressure Sampler II, the Portable Pressure Chamber, and the bench-top apparatus.

Chapter 7 “Setting Up Measurements” describes setting up measurement definitions in the host software for use with the Enpac Oil data collector. It also covers lists, inspection codes, and alarms.

Chapter 8 “Loading and Unloading” describes loading and unloading lists with the Enpac Oil data collector.

Chapter 9 “Collecting Data” contains all the tasks associated with collecting data, including collecting samples and using the Enpac Oil to collect list data.

Chapter 10 “Using Lube Link” contains all the information about the LubeLink software package and interfacing with the dCA, fCA, and dVA using the LubeLink software application.

The Appendix contains information about the INI files for the dCA and dVA and a Frequently Asked Questions section.

The Glossary contains definitions of terms used frequently in this manual.



Document ConventionsThere are several document conventions used in this Guide, including the following:

z The data collector is referred to as the Enpac Oil or the data collector throughout this User’s Guide. EMONITOR Odyssey, Enshare, and Enlube PM software is referred to as the host software in this User’s Guide.

z Keys that you press on the Enpac Oil are shown within angle brackets in <ALL CAPS>. The enter key is shown as <ENTER>.

z Keys on your computer keyboard are shown in boldface. The Shift key is shown as Shift and the Enter key is shown as Enter. Sometimes keys are used in combination. Ctrl+F1 means hold down the Control key and press the F1 key.

z Menu names in the Enpac Oil are capitalized as they appear in the title on the Enpac Oil display. For example, the main menu on the Enpac Oil is referred to as the Main Menu. A display is called a menu if it allows you to make choices by selecting a number.

z Menu names and commands from the host software menus have the first letter of the word capitalized. Selections and choices in the host software dialog boxes are in boldface. For example, “Choose OK in the dialog box.”

WARNING: A warning indicates potential bodily harm or damage to equipment.

Caution: A caution indicates potential loss of data.

Note: A note indicates additional information which may be helpful.

For definitions of other terms, see the Glossary at the end of this manual.

Using the Online Help SystemThe host software includes a complete Online Help System. This Online Help System allows you to get help for commands, terms, and tasks quickly without opening a manual. The Online Help System is context sensitive, which means that you can get help that applies to whatever you are doing at that moment. In addition, the host software includes an online tutorial to help you get started using the software.

The Online Help System includes both help for the host software and for the Enpac Oil. The main host software online help describes commands, dialog boxes, procedures, and windows. The Enpac Oil online help displays topics describing the operation and maintenance of this data collector.

You access the main host software online help by pressing the F1 key to display context sensitive help in a Help window. The topic in the Help window depends on the current state of the system. For instance, if you highlight a command, or open a dialog box, the help explains that command or dialog box.

You access the dCA/fCA/dVA Online Help by selecting DCA from the Help menu in the host software window.

Customer Support


OrganizationThe Online Help System consists of topics. Each topic contains information on a specific command, term, or task. Hypertext links the topics so you can look up additional information, such as definitions of terms in the topic. Once you press F1 to open the Help window, you can easily move around in the Online Help System to get more information by using the hypertext links.

Customer SupportIf you are under warranty or have an active ESAFE Agreement, Entek IRD provides a variety of Customer Support services. In the United States you can reach the Technical Support Hotline by dialing 1-800-ENTEKIRD (1-800-368-3547) Monday through Friday 8:00 a.m.–5:00 p.m. eastern time. Limited extended support for users in the mountain and Pacific time zones is available until 7:00 p.m. eastern time. You can send a fax detailing your questions or comments 24 hours a day by dialing (513) 576-4213. Please address the fax to the Customer Support department. You can also reach Entek IRD from your computer.

z Send questions to [email protected]

z Send suggestions and comments to [email protected]

z Visit our web site at http://www.entek.com

For support outside of the United States, please contact your local Entek representative or the nearest Entek IRD office. If your local support representative is not available, please contact the U.S. Customer Support department. You can display the worldwide Customer Support phone numbers by choosing the About command from the Help menu in the host software.


Chapter 2

2. The Enpac Oil

This chapter describes the Enpac Oil data collector in detail and covers the basic operations of the data collector. It includes the following sections:

Overview of the Enpac Oil .................................................................... 8

Parts of the Enpac Oil ......................................................................... 12

Enpac Oil Battery Pack....................................................................... 15

Basic Enpac Oil Operations................................................................ 17

Enpac Oil Menus and Screens............................................................. 24

Using Memory Cards .......................................................................... 25


Chapter 2 - The Enpac Oil

Overview of the Enpac OilThe Enpac Oil is a Windows® CE based data collector that a allows you to collect oil analysis data using the digtal Contam-Alert® (dCA), ferrous Contam-Alert® (fCA), or digital Visc-Alert® (dVA). You can unload these measurements to your software program for analysis. You can collect data for sample locations defined in a list, or unscheduled measurements not associated with a list. The Enpac Oil is also called the data collector in this User’s Guide.

This chapter discusses the basic operations of the Enpac Oil, including how to:

z Check and remove the batteries.

z Power the data collector on and off.

z Reset the data collector.

z Go through the screens and make selections.

Product Specifications

Enclosure

Product Feature Specification

Size 8 in. x 5 in. x 2 in. (200mm x 130mm x 50mm)

Weight Less than 700g (1.5 lbs.)

Case Material: 80% ABS and 20% Polycarbonate plasticHand strap either side of unit

Viewable Display 1/8 VGA: 240 x 160 backlit LCD, 2.24 in. x 1.49 in. (57mm x 38mm) viewable

Keypad 1 ENTER key, 1 ESCAPE key, 4 function keys, 4 cursor keys, and a numeric keypad (with . and +/-) On/Off keyAll keys are glow in the dark luminescent

Overview of the Enpac Oil


Connector Panel

Battery/Power

Performance


PC Comms RS232 – 9-way D Type (Plug)IrDA Window (not currently used)

Other I/O 7-pin Fisher:Power in/battery charge


Battery option Rechargeable Lithium Ion Pack

Power gauge Yes

Capacity 1350 mA/hr

Life 6 hours

Charging In the unit or via an external chargerUnit can be powered indefinitely via external DC supply

Oil Sensor Interface Power

When red light is on, power is going to the Oil Sensor Interface


Operating System Windows CE V2.x

Processor Types Philips PR31700DSP processor: Motorola DSP56303

OS Storage(for WinCE and Applications)

8 Mbytes FLASH

Disk (for applications and user data)

4 Mbytes FLASH

Internal RAM 16 Mbytes

PC Card support Type I or II PCMCIA cards (SRAM, ATA and Linear Flash Memory, and VGA Cards) See “Types of Memory Card Used with Enpac Oil” on page 26 for details.

Operating systemand Application S/W upgrades

Via RS232Via PCMCIA card



Environmental

I/O and Communications

System

Loading Options

Approval/Certification

Safety Information

Avoid WaterThe Enpac Oil has been designed to be splash and dust resistant. However, avoid direct contact with water, wet surfaces, or condensing humidity. Keep this instrument away from wet locations such as sinks, laundry, wet basements, and swimming pools, etc. If the instrument is subjected to these conditions adverse operation may result. Allow the instrument to dry thoroughly before operation. In addition, avoid opening the PCMCIA card door in locations where ingress of water or other contaminants may occur.


Sealing IP65 standard (with PC card slot)

Drop Test 6 ft. 6 in. (2 meters)

Temperature Range Operating: -10 to +60 °C (14 to 140 °F)Storage: -40 to +80 °C (-40 to 176 °F)

Humidity Operating: 0 to 95% Relative Humidity


Serial Comms RS-232 serial port; up to 115k baud

Infrared IrDA interface (not currently used)


Download and Upload from PC RS-232 transfer – indicates data transfer when connected to PC

Off Route/Pre-Defined Mode All measurement options available

Review Mode Yes

Memory Options Copy a single dCA route to and from PCMCIA memory card. A single dVA route can also occupy the same card at the same time. See “Types of Memory Card Used with Enpac Oil” on page 26.


EMC/ESD CE

Overview of the Enpac Oil


Avoid DamageTo avoid costly damage or injury, place the instrument on a solid stable surface when not in use, and do not place any heavy objects on it. Use only accessories recommended by Entek, and use a damp, clean cloth for cleaning. Do not use cleaning fluids, abrasives, or aerosols. They could enter the unit, causing damage, fire, or electrical shock. These substances may also mar the finish of your instrument.

Keep liquids and foreign objects away from your instrument. Never operate your instrument if any liquid or foreign object has entered it. Do not enter any other object other than recommended PCMCIA type cards into the PCMCIA opening. Electrical shock could result, causing fire or shock hazards as well as damage to the instrument.



Parts of the Enpac OilThis section includes a diagram of the data collector showing the hardware connections.

Data Collector Diagram and Key DefinitionsThe following is a diagram of the Enpac Oil data collector showing the display and keys used for operation.

<Enter> KeyThe <Enter> key is the yellow key on the right-hand side of the Enpac Oil. Pressing this key starts collecting data for the current point, or accepts the current measurement. The <Enter> key is also used as a selector or “Forward” key.

<Escape> KeyThe <Escape> key allows you to move back one menu item or cancel out of a dialog box. This key can also be thought of as a “Back” key.

Function keysBelow the display are four function keys referred throughout this manual as <F1>,< F2>, <F3>, and <F4>. The function keys change depending on the current state of the data collector. The data collector displays the current function of the keys in the display above the key. When no text appears above a function key, the key is inactive in the current window.

ArrowKeys

NumericKeys

Function Key sF1 - F4

On/OffSwitch

Decimal Key

+/- Key

Enter KeyEscape Key

Parts of the Enpac Oil


Arrow keysThe arrow keys are located below the function keys. Use the <Up> and <Down> arrow keys to move up and down the display. Use the <Enter> key to open the menu.

<On/Off> keyThe <On/Off> key turns the data collector on and off. To turn the data collector off, press and hold the <On/Off> key for about two seconds.

Decimal keyThe Decimal (<.>) key allows you to check the battery life of the battery in the data collector, or enter a decimal point in a numeric field.

Data Collector Hardware ConnectorsThis section discusses the data collector hardware connections for communications and data collection. This diagram shows the top view of the Enpac Oil. Each connector is labeled below.

Power/TrigThis socket connects the Enpac Oil to a power adapter. The pin assignment for the trigger is shown in the illustration above.

The external power adapter can be used to charge the internal battery. This can be connected via the Power socket on the top of the Enpac Oil. Only the provided transformer may be used. Any other supply may cause permanent damage to the data collector.

PIN POWER/TRIG PIN RS232

1 MIC-IN + 1

2 SPEAKER + 2 TXD-OUT

3 SPEAKER - 3 RXD-IN

4 DGND 4 DTR-OUT

5 EXT-DC-IN 5 GND

6 EXT-TRIG-IN 6 N/C

7 +5V-TACHO-OUT 7 CTS-IN

8 RTS-OUT

9 +5V



IrDA InterfaceThe IrDA interface allows the Enpac Oil to transfer data to another IrDA device. When the two infrared transmitters/receivers are aligned and activated, you can use the infrared beam to transfer data back and forth between the Enpac Oil and your computer.

Note: The Enpac Oil does not currently use the IrDA interface.

RS-232 InterfaceData is transferred between the Enpac Oil and your computer over an RS-232 interface. The RS-232 interface is provided via a 9-way (Plug) D-connector on the top of the Enpac Oil. The pin assignments are shown below. The interface operates with a hardware handshake.

Pin Signal I/O

1 CD Carrier Detect Not Connected

2 RD Receive Data Output

3 TD Transmit Data Input

4 DTR Data Terminal Ready Output

5 GND Ground

6 DSR Data Set Ready Not Connected

7 CTS RTS Request To Send Input

8 CTS Clear To Send Output

9 RI Ring Indicator Not Connected

Enpac Oil Battery Pack


Strap AttachmentThe strap can be fitted to either the left or right side of the Enpac Oil. Follow these steps to connect the strap to the Enpac Oil:

1. Feed the ends of the strap through the top and bottom corner pillars as shown in the illustration below.

2. Loop the ends of the strap through the buckles and adjust tightness to suit.

Enpac Oil Battery Pack The Enpac Oil can be powered either from its own internal Lithium Ion battery or using the main adapter plugged into the Power/Trig connector at the top panel of the instrument and to an appropriate supply outlet. It also has an internal backup battery which maintains the system settings should the battery become discharged or removed while the unit is not being powered by an external DC supply.

This section discusses checking the battery level information, and removing the battery pack from the data collector. Note that the Enpac Oil battery pack is located on the underside of the Enpac Oil.



Battery Capacity

Checking Battery LifeYou can check the battery life of the battery in the data collector by following these steps.

1. Turn the Enpac Oil on.

2. Choose [4] Utilities on the Main Menu.

3. Choose [4] Battery Status from the Utilities Main Menu. The display reports the status

Mode State Life Expectancy

Bootloader Backup battery only 30 days typical

Main and backup battery 280 days typical

CE Operation(Windows CE)

Idle (main battery) 19 hours typical

Constantly capturing data

14 hours minimum

Off Backup battery only(main battery removed)

4 days typical

Main and backup battery 37 days typical

DC Power Bootloader mode current

5.5mA @ 12V

CE mode current 5.5mA @ 12V

Off mode current 6.5mA @ 12V

Main Battery Max. Charge Current

1.10 Amps

Main Battery Charge Time

70% full 1Hr 15mins to 1Hr 45mins

Charging with the Enpac Oil Charger

100% 3Hrs 30mins to 4Hrs 30min

Basic Enpac Oil Operations


in percent life of the Internal Battery.

4. Choose <F4> OK to return to the Utilties Main Menu.

Inserting or Removing the BatteryAccess to the main battery pack is obtained by removing two screws on the plate located on the underside of the data collector using a flat head screwdriver.

The main battery is removed by sliding the cell to the left and lifting it out from the data collector. The battery is inserted into the data collector by following this process in reverse order.

Note: The Enpac Oil has a safety switch positioned under the plate of the battery compartment. When you remove this cover, the data collector shuts down (as if the <On/Of> key was pressed.)

Basic Enpac Oil OperationsThis section covers many basic operations for the data collector, including powering up and down, changing your display contrast, resetting the data collector, and setting the time.

Powering On and OffThe <On/Of> key powers the data collector on and off. A single press of the key turns the data collector on. To power off the data collector, press the <On/Of> key for about two seconds. The Enpac Oil resumes operation at the last screen you viewed when you turn the data collector off.



Adjusting the Screen ContrastThe Enpac Oil allows you to change the screen contrast using a few button presses. This allows you to lighten or darken the screen depending on your preferences. You can adjust the contrast from any screen. To do so, follow these steps.

1. Turn the Enpac Oil on by pressing the power button.

2. Hold the right arrow button down.

3. To darken the screen contrast, press <F3> repeatedly. To lighten the screen contrast, press <F1> repeatedly.

3. Release the right arrow button when the contrast settings are satisfactory.

Making Selections in the Data CollectorThere are different types of displays used with the Enpac Oil. The method for making selections depends on the display:

z Menu – Allows you to select a single function from a list of functions. An example is the Main Menu. See “Enpac Oil Menus and Screens” on page 24.

z Dialog box screens – Allow you to make selections for settings and measurement parameters.

Making selections in a menu1. Use the <Up> and <Down> arrow keys or press the numeric keys to choose the desired

function.

2. Press the <Enter> key to activate the chosen function.

Making selections in a dialog box1. Use the <Up> and <Down> arrow keys to select the desired field.

2. Select the choice using the <Up> and <Down> arrow keys, or type in the value using the numeric key pad.

3. Press the <F4> key or <Enter> key to choose OK and save the selection.

Entering letter or numeric characters1. To enter a number, simply press the number on the keypad once.

2. To enter a letter, choose the number key that contains the letter and press twice for the first letter. For example, to type an “A,” press the <2> key twice.



Displaying the Operating System Version Number1. To view the operating system version number, go to the Main Menu and choose [4]

Utilities.

2. Next, choose [6] About Enpac Oil.

3. The About screen displays the version number of the data collector.

Resetting the Data CollectorYou should reset the Enpac Oil only if the data collector is “locked up” and not responding to any key presses. To reset the Enpac Oil, you press the reset switch located behind the main battery access panel at the rear of the data collector. This can only be pressed using a 1/16th inch diameter pin or a straightened paper clip. Detailed steps are outlined below.

Caution: Resetting the Enpac Oil in this manner deletes all files from the system.

HardwareReset



To reset the data collector, follow these steps:

1. Using a flat head screwdriver, remove the two screws on the battery access panel located at the rear of the data collector.

2. Remove the battery access panel.

3. Press the reset switch using a 1/16th inch diameter pin or a straightened paper clip.

4. Press the <On/Of> key to turn the data collector on. The data collector will power up in the Bootloader Configuration screen. See “Bootloader Configuration Screen” on page 20 for more information.

Bootloader Configuration ScreenThe Windows CE Bootloader screen appears after you reset the Enpac Oil. This screen allows you to reinitialize Windows CE, or load an operating system to the data collector, either through a serial connection or using the PCMCIA drive.

The Bootloader screen displays the unique unit id of the data collector and also provides you with the following three options:

1. Run Windows CE – The data collector reinitializes the Windows CE operating system and turns the Enpac Oil off. After you choose this option, you must press the <On/Of> key to turn the Enpac Oil on.

2. Load OS Image via RS232 – Allows you to load an operating system through a serial connection. See “Loading the Enpac Oil Operating System” on page 20.

3. Load OS Image via PCMCIA – Allows you load an operating system from a PCMCIA card inserted in the data collector. See “Loading the Enpac Oil Operating System” on page 20.

To choose any of these options, press the respective number on the numeric key pad button.

Loading the Enpac Oil Operating SystemThe Enpac Oil uses the Bootloader Configuration screen to transfer the operating system files from your computer to your Enpac Oil, either through a serial connection or directly using the PCMCIA card. This procedure describes how to use a serial connection. The same sequence occurs when you use the PCMCIA card. Refer to “Bootloader Configuration Screen” on page 20 for a more information on the Bootloader Configuration screen.



Using the RS232 optionTo load the operating system using a serial connection, follow these steps:

1. Using a flat head screwdriver, remove the two screws on the battery access panel located at the rear of the data collector.

2. Remove the battery access panel.


Caution: Resetting the Enpac Oil by pressing the reset key deletes all files from the system. If you have any route data in the box, it will be deleted if you use this reset method.

4. Press the <On/Of> key to power the data collector on. The data collector will power up in the Bootloader Configuration screen.

5. Connect the Enpac Oil to the computer with a RS-232 serial cable.

6. Insert the Enpac CD-ROM disk into your CD-ROM drive of your computer.

7. Double-click the WinSerDL.exe file. You need to run this file to load the Enpac operating system. The WinSerDL dialog box appears.

8. From the File menu, choose Open.

9. Select the operating system file from the list. This file has an .out extension. Note that the file name is dependent on the version of the operating system. For example, version 107of the operating system has the file name “v107.out.”



10. Choose Open. Make sure the name of the file you are loading appears in the title of the WinSerDL dialog box as illustrated below.

11. Press <2> on the data collector’s numeric keypad to start the transfer.

12. In the WinSerDL dialog box, choose Start Download. A progress bar displays in the dialog box indicating the progress of the transfer as illustrated below. A message also displays at the bottom of the Enpac screen. This process will take time, so please be patient while the download progresses.

13. When the message “Transfer complete” displays on the Enpac screen, disconnect the Enpac to the computer.

14. Press the <On/Of> key for two seconds to power the data collector off.

15. Press the <On/Of> key to power the data collector on. The data collector powers up and starts the specific operating system that was loaded.

Using the PCMCIA option1. Insert the PCMCIA card containing the Operating System into the slot.

2. Using a flat head screwdriver, remove the two screws on the battery access panel located at the rear of the data collector.Remove the battery access panel.


Caution: Resetting the Enpac Oil by pressing the reset key deletes all files from the system. If you have any route data saved, it will be deleted if you use this reset method.



4. Press the <On/Of> key to power the data collector on. The data collector will power up in the Bootloader Configuration screen.

5. Press the <3> key. The image begins to load.

Setting the Date and TimeThe Enpac Oil keeps the current date and time even when powered off. However, there may be times when you need to change these settings, such as after reloading the operating system. To do so, follow these steps.

1. From the Main Menu, choose Utilities by pressing the arrow keys to select it then pressing <Enter>.

2. Choose Set Up System Time by pressing the arrow keys to select it then pressing <Enter>. The following dialog box appears.

3. Use the arrow keys to move between fields, and type the value into the dialog box, or use the up and down arrow keys to set the date and time.

4. When you are finished entering the time and date, press <F4> (OK).



Enpac Oil Menus and ScreensThis section provides an overview of common menus and screens in the Enpac Oil. Each menu has a primary use.

z The Main Menu is the starting point for most instructions in this manual.

z The dCA Menu is the starting point for testing with the dCA sensor. The Enpac Oil has main menus for each sensor.

z The Communicate with PC screen facilitates downloading and uploading data to the host software when connected to a computer.

z The Result menu screen allows you to review previously collected data points.

Main MenuThe Main Menu is the first menu shown when the Enpac Oil is turned on. It is the starting point for many tasks, including functions of testing with the dCA, fCA, or dVA. You can usually return to this menu by pressing <Escape> repeatedly until it appears.

dCA Main MenuThe dCA Main Menu is the menu shown when you select [1] dCA Only in the Main Menu. It is the starting point for all functions using the dCA sensor, including testing either from a loaded list or unscheduled points, viewing data, connecting to a computer, configuring the sensor, or using utilities related to the Enpac Oil. You can usually return to this menu by pressing <Escape> repeatedly until it is the menu shown on the screen.

Communicate with PC ScreenChoosing [4] Load/Unload Route from the dCA or dVA Main Menu brings up the Communicate with PC screen.

Using Memory Cards


The Communicate with PC screen allows communication between the Enpac Oil and the host software.

The Status message tells you the state of the connection between the data collector and the computer. The Status message in the example above is “Gathering Data.”

View Data ScreenThe View Data screen allows you to review data taken at each point. If you have not saved any results, the Enpac Oil displays a message stating, “The PCM.DAT file does not contain data or does not exist.”

The Enpac Oil lists the available records on the Result menu screen, organized by machine name. It shows up to two measurements on the screen at once. Choose <F1> Previous and <F2> Next to review the data points.

Using Memory CardsThe Enpac Oil can store program information and collected data on memory cards. The Enpac Oil uses both type I and type II PCMCIA cards (Personal Computer Memory Card International Association). These cards are an industry standard storage media designed to be a rugged replacement for floppy disks in portable computer systems. PCMCIA memory cards are quite durable and cannot be damaged by electromagnetic fields. However, you should avoid exposing the cards to direct sunlight, extreme temperature, or excessive moisture.

This section provides a list of memory cards that can be used with the Enpac Oil. It also tells you how to install and remove memory cards.



Types of Memory Card Used with Enpac OilThe following types of cards may be used with Enpac Oil :

Other generic SRAM/FLASH and ATA cards can be used with the Enpac Oil if a standard Windows CE driver is available for their class. Check with the card manufacturer to find out if a Windows CE driver is available.

Inserting and Removing a Memory CardYou load the Enpac Oil memory card into the data collector through a door in the bottom of the Enpac Oil. The memory card can be inserted while the Enpac Oil is powered on or off. With the bottom of the Enpac Oil facing you, open the door by pressing down on both latches simultaneously and pulling the door towards you. Once the door is open, turn the memory card so the logo side of the card is facing you and insert the memory card into the slot. The end with the sockets fits into the data collector.

Note: If the memory card has not been formatted or not formatted to the correct standard, the Enpac Oil will open a dialog box asking if you wish to format the card. Press <Enter> to format the card so it can be used in the Enpac Oil.

Caution: Formatting the card deletes everything on the card.

To remove a memory card, open the door at the bottom of the Enpac Oil. Press the release button and gently work the card out of its slot.

Type Models Tested Manufacturer

3.3V/5V SRAM 2MB1 & 2 MB

CentennialMitsubishi

3.3V/5V FLASH 2MB Series II Linear Mitsubishi

ATA (external hard disk) 85MB ATA Scandisk


Chapter 3

3. The digital CONTAM-ALERT (dCA)

This chapter describes the dCA sensor in detail and covers the basic operations of the sensor. It includes the following sections:

Overview of the dCA (digital CONTAM-ALERT) ............................... 28

Connecting the dCA............................................................................. 30

Configuring the dCA ........................................................................... 31

Maintaining the dCA ........................................................................... 36

Diluting High Viscosity Fluids to Test with the dCA........................... 44


Chapter 3 - The digital CONTAM-ALERT (dCA)

Overview of the dCA (digital CONTAM-ALERT)The dCA sensor is the portable contaminant monitoring instrument used with the Enpac Oil. It is suited for a variety of applications and can be used either in the field or in the lab. Using patented pore-blockage technology, the dCA yields fast, accurate particle counts that can be uploaded to the host software for data analysis.

This section contains safety and precautionary measures to consider when using the dCA sensor. Also, it describes the dCA sensor in detail, offering suggestions on maintenance and care for the instrument.

Included in this section is a description of the main components of the sensor and assembly instructions. This description includes the dCA sensor screens as well as how to change settings for the dCA using the data collector. For specific information on sampling with the dCA sensor, see “Probing On with the dCA” on page 34. For information on equipment used with the dCA, see Chapter 6 “Equipment for Sampling and Testing”.

Safety Warnings for the dCA

WARNING: Failure to follow proper procedures can lead to injury. Review these safety warnings before attempting to collect data. Never compromise your personal safety for data collection.

As with all precision instrumentation, you should handle the dCA sensor and Enpac Oil with care. Dropping the sensor on a hard surface can cause misalignment or internal damage which affects the accuracy of test results. To ensure your safety and to prevent mishandling of the sensor, follow these warnings.

1. Do not use the dCA sensor on life dependent systems. The sensor is a tool intended to provide assistance in maintenance procedures. It is not intended for use on life dependent systems.

2. Do not point the dCA sensor at any person while backflushing or discharging fluid.

3. Do not drop the dCA sensor. Dropping the sensor on a hard surface can cause misalignment or internal damage which affects the accuracy of test results.

4. Do not attach the dCA sensor to valves with pressures above 150 psi (10.34 bars). For pressures between 150 psi and 3000 psi (206.84 bars), use the High Pressure Sampler II (HPS II). See “Using the High Pressure Sampler II (HPS II)” on page 87 for more information.

5. Do not attach the High Pressure Sampler II (HPS II) to valves with pressures above 3000 psi (206.84 bars). If the pressure at the test valve exceeds 3500 psi(241.3 bars), locate and use another point for your test port where the pressure is below this limit.

6. Do not stand behind or block the dCA sensor during testing. Use caution at all times when working around or with high pressure systems (above 150 psi, or 10.34 bars). Do not turn the knob to increase the pressure of the HPS II and do not block the backflush knob of the dCA when performing a test.

Overview of the dCA (digital CONTAM-ALERT)


dCA Operating SpecificationsThe following table contains the dCA sensor specifications, including temperature and physical limitations as well as storage guidelines.

This chart shows the viscosity ranges at 100°F for each screen size.

Pressure at valve

30–150 psi (2.07–10.34 bars) Pressure should always remain constant and within this range during a test.

Pressure at valve with High Pressure Sampler II

150–3000 psi (10.34–206.84 bars) Pressure should always remain constant and within this range during a test.

Temperature of sample fluid

Maximum 190ºF (88ºC)

Sample fluid viscosity range

50–1000 SSU at 100°F (10–230 cSt) for the 10 micron screen. See table below for additional screen sizes.

dCA storage temperature

-40ºF to 158ºF (-40ºC to 70ºC)

Contaminant concentration sensitivity

5–28000 particles greater than 10 microns per milliliter (ml),equivalent to ISO 11/8 to ISO 24/21

Fluid compatibility

All fluids compatible with standard Viton seals. EP and other seals are available by special order.



Understanding How the dCA Sensor WorksThe sensor uses a flow decay principle to determine the concentrations of specific particle sizes in a fluid sample. When fluid enters the sensor, the flow rate is measured at extremely small time intervals as the piston moves in response to fluid entering the bore area. As fluid enters the assembly, the piston is slowly pushed upward. As the solid particles in the fluid block the pores in the sensor screen, the flow rate of the fluid is reduced. The dCA sensor measures this rate and generates flow decay curves based on that rate.

Different particle size distributions and concentrations generate distinct flow decay curves. When the Enpac Oil monitors the piston’s movement, it also checks to see if it has enough data to make an evaluation. When the Enpac Oil receives enough data, it begins analyzing the data and returns a representative particle count.

Unlike optical particle counting, this process does not require fluid dilution and is not generally affected by the presence of non-solid impurities such as air, water, or carbon soot in the fluid. Because of its unique technology, the dCA sensor can measure solid contamination levels in a great variety of fluids.

Connecting the dCAThe Enpac Oil connects to the PC port on the Oil Sensor Interface, then you connect the dCA to the dCA port on the Oil Sensor Interface. When power is going to the Oil Sensor Interface, the red light on the Enpac Oil lights up and stays on while powering the interface.

1. Insert the 25-pin plug at the end of the dCA sensor cable in the dCA connector on the Oil Sensor Interface.

2. Tighten the thumbscrews located on either side of the connector to secure the dCA cable to the Oil Sensor Interface.

3. Insert one end of the serial cable into the PC connector at the bottom of the Oil Sensor Interface. Plug the other end into the COM port on the top of the Enpac Oil.

Connect the dCA here

Connect the Enpac Oil serial cable here

Configuring the dCA


Configuring the dCABefore you begin testing with the dCA, you must configure it. Choose [5] Configure dCA at the dCA main menu. There are several options available to you. This section explains each configuration option.

Setting Screen Size1. Return to the Enpac Oil Main Menu by pressing <Escape> if necessary.

2. Choose [1] dCA Only. The dCA Main Menu appears.

3. Choose [5] Configure dCA. The dCA Configuration menu appears.

4. Choose [1] Screen Size. The Screen Size screen appears.

5. Enter the number representing the correct sensor screen size according to the color of the sensor screen, which is in the table below. For example, if your sensor screen is silver, choose 5µ Screen and press <F4>. The Enpac Oil enters the change and returns to the previous screen.

Color Screen size

silver 5 micron screen

gold 10 micron screen

black 15 micron screen



Setting Screen Calibration1. Return to the Enpac Oil Main Menu by pressing <Escape> if necessary.


3. Choose [5] Configure dCA. The Configure dCA menu appears.

4. Choose [2] Screen Number. The Change Screen Calibration dialog appears.

5. Enter the calibration number engraved on the flat side of the screen. Make sure your cursor is next to the correct sensor screen size.

6. Press the down arrow to move down one row. Press <F4> to accept changes to the calibration number. The Enpac Oil saves the change and returns to the previous screen.

Note: For information about the Calibration Validation Program see “Calibrating the dCA Sensor Screens” on page 39.

Setting Fluid Type1. Return to the Enpac Oil Main Menu by pressing <Escape> if necessary.



4. Choose [3] Fluid Type. The Fluid Type screen appears.

5. Choose Hydraulic or Lubrication, representing the type of fluid you are testing. Choose OK to save the change and return to the previous screen.

Setting Result CodesYou can set result codes after you collect data. If you would like to see your results and target values on the Enpac Oil in ISO units instead of particle counts, you must change the result code.

1. Return to the Enpac Oil Main Menu by pressing <Escape> if necessary.



Techniques for Collecting Data with the dCA


4. Choose [4] Result Code. The Result Code screen appears.

5. Use the arrow keys to choose Particles or ISO or NAS, representing the type of units you are using.

6. Choose OK by pressing <F4>. The Enpac Oil saves the change and returns to the previous screen.

Setting Particle Size DistributionYou can display particle size distribution while you are viewing data using the Enpac Oil. If you would like to view the data in different particle sizes, you can set the particle size distribution by following these steps.

1. From the dCA Main Menu, choose [5] Configure dCA. The Configure dCA menu appears.

2. Choose [5] Particle Size. The Particle Size screen appears.

3. Press the arrow keys to move through the sizes.

4. When you reach your selection, press the number keys to change the particle size.

5. Press <F4> to accept your changes.

Techniques for Collecting Data with the dCAOnce you have completed all the configuration procedures, you are ready to take sample data. Here are a few hints about probing on with the dCA sensor for consistent data and safety in using the system. If you need more information about test port valves, see “Preparing Test Port Valves for Sampling” on page 81.



Probing On with the dCA

WARNING: Failure to follow proper procedures can lead to injury or damage to the dCA sensor.

z Wait for the message to appear on the Enpac Oil that signals that you can begin collecting data.

z Grasp the dCA sensor by the barrel and attach it to the test port valve by pressing firmly to get a quick, positive connection. Continue to press down with the sensor while tightening its lock-on sleeve.

z Make sure to completely tighten the sleeve before relaxing pressure on the sensor.

z Do not block, handle, push, or pull the backflush knob of the sensor while testing. When the sensor is connected to the test port valve, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor.

Priming the dCA Before you attempt to test any fluid with the dCA sensor, be sure that the internal surfaces have been coated with the test fluid. Priming the sensor with lubricant or hydraulic fluid wets the internal surfaces which improves operation and allows for greater accuracy in testing the fluid. To prime the dCA, simply probe on to the test port for about 1 or 2 seconds. Detach the dCA, and expel the fluid by backflushing the dCA. For more detail on backflushing, see “Backflushing the dCA Sensor” on page 36.

Note: You may not have to do this every time you begin collecting data, but if you are not sure which fluid was used previously, you should prime the dCA sensor with the test fluid before use.

test port valve

flow

lock on sleeve

sensor

Techniques for Collecting Data with the dCA


Assembling the dCA Sensor with Sensor ScreenYou may need to disassemble the dCA sensor in order to replace or change the sensor screen, or to read the calibration number. To do so, follow these steps.

Note: You must enter the calibration number on the sensor screen in your Enpac Oil in order for your data to be accurate. See “Configuring the dCA” on page 31.

1. Grip the large knurl and unscrew the probe-on body of the dCA. Turn it counter clockwise until you can remove it completely. Make sure that the small o-ring does not fall out.

2. While holding the sensor vertically with the backflush knob pointing down, place the screen in the probe so the engraved calibration number is visible. There are three different sizes of dCA sensor screens. The color coding is outlined in the following table. Write down the calibration number and color of screen for future reference.

3. Thread the probe body back into the sensor and hand-tighten.

small o-ring

large knurl

insert sensor screen here

backflush knob

Color Screen size






Maintaining the dCAThis section discusses the maintenance procedures needed to maintain your dCA and continue to get consistent results. The maintenance of the dCA also includes properly backflushing the sensor every time you collect data. In addition, this section includes information about cleaning the dCA sensor screens as well as calibration validation for the sensor screens.

Backflushing the dCA SensorProperly backflushing the dCA sensor clears the sensor screen of built-up hard particle contamination. It is critical that you backflush the sensor screen following each sample test. Backflush to clear the screen, then backwash to expel the remaining fluid. If you are backflushing manually, follow these steps.

1. Once the backflush knob stops moving, disconnect the dCA sensor from the valve.

2. Push down on the backflush knob, expelling at least 10 drops of fluid. The knob will require firm, steady pressure to backflush the fluid through the screen.

3. Turn the large knurled probe body approximately one-half turn counterclockwise and expel the remaining fluid, which should now flow easily. This is called backwashing the fluid. Merely backwashing the fluid will not clear the screen.

4. Tighten the probe body by hand after all the fluid is expelled. The sensor is now ready for another test.

If you are backflushing using the lab apparatus, follow these steps.

1. Once the backflush knob stops moving, disconnect the dCA sensor from the valve.

2. Attach the sensor to the automatic backflushing rig with the probe on the bottom of the fixture.

3. Turn the knob located behind the backflushing rig to the FLUSH position. The backflush piston pneumatically pushes the sensor knob, backflushing the sensor.

4. Once the backflush cycle is complete, turn the knob to the RETRACT position. If the knob does not return all the way (leaving more than 1/8 inch of rod shaft showing), use the backwash procedure described in step 3 of the manual backflush procedure.

5. Remove the probe body from the backflushing rig after all the fluid is expelled. The sensor is now ready for another test.

Cleaning dCA Sensor ScreensYou should remove the sensor screen at the end of each work day, clean it, and store it in the protective case. Directions for cleaning screens follow, including how to clean very contaminated screens and screens contaminated on both sides.

Caution: The suggested solvents require careful handling and storage. Check with your company’s safety officer for handling and storage advice or instruction. Always practice the proper safety measures with these solvents.

Always store the screen in the provided plastic case when not in use to avoid ambient comtamination. Avoid unnecessary handling and try not to drop it onto unclean surfaces such as the floor.

Maintaining the dCA


Dry the sensor screen thoroughly before placing it back into the plastic container. Some solvents, such as Methyl Ethyl Ketone (MEK), can dissolve the plastic storage container.

1. Remove the screen from the dCA sensor by rotating the large knurl counterclockwise until it is released. See “Assembling the dCA Sensor with Sensor Screen” on page 35.

2. Place the screen in a clean bottle filled with an acceptable solvent. Acceptable solvents include Methyl Ethyl Ketone (MEK), Dichloroflouroethane, and 1,1,1 Trichlorethylene.

Note: If you are using Isopropyl Alcohol (IPA) to clean screens you may experience problems. This solvent has been found to cause some hydraulic fluids to gum up on the screen, making cleaning difficult. If you are using IPA, and cannot locate an acceptable solvent, continue to use it until you find an acceptable solvent. Do not let your screens soak in IPA, instead, clean the screen by agitating it, and promptly remove the screen. Clean the screen with IPA only when absolutely necessary, and call Customer Support if you experience problems.

3. Agitate the bottle using an ultrasonic bath or paint shaker, or by hand for 15 minutes. Ultrasonic bath is the recommended method. For very contaminated screens, agitate for no less than one hour.

4. Remove the screen from the solvent.

5. Let screen air dry until all solvent has evaporated. Do not use shop air to dry the screen.

6. View the screen under a microscope (if available) to check for contamination.

7. Reinsert the screen into the dCA sensor. Wet the screen with the fluid being tested before running an actual test. For very contaminated screens, run a test with a fluid of known particle count such as calibration fluid to test for accuracy and repeat the cleaning procedure if the screen still gives you high readings.

To clean screens contaminated on both sidesIf you are experiencing problems backflushing, the screen may be contaminated on both sides. This can happen when changing from a high micron screen to a low micron screen, for example, changing from a 15 micron to a 10 micron screen. If this is the case, clean the screen as directed above with the following additions.

1. Flush the dCA sensor several times with superclean fluid (defined as fluid containing fewer than 10 particles > 10 microns per mL of fluid) or Flushing Fluid.

2. If contamination is still present on the screen, remove the screen and fill the dCA with a superclean fluid or Flushing Fluid.

3. Reinsert the screen, and backflush the superclean fluid through the screen.

4. Repeat with screen inserted upside down (calibration number not showing).

5. Remove the screen and inspect it under a microscope (if available) for contamination.

6. If contamination still exists, repeat the cleaning process from step 1.



Changing Screen Sizes or Changing FluidsIf you change from a smaller screen pore size to a larger screen pore size you should have no problems with larger particles blocking the screen. However, if you want to go from a larger pore size to a smaller pore size, you must clean the screen to prevent the remaining particles inside the dCA from plugging the screens. Also, if you are changing testing fluids from hydraulic or lube oil to water glycols, particles that the larger screen would allow through would be backflushed onto the back of the smaller sensor screen. If the screen is clogged on the back with these larger particles it can impede fluid flow through the screen during normal testing.

To eliminate these problems, prepare the dCA sensor for a screen change by performing the following steps.

1. Remove the larger size sensor screen, and clean using the screen cleaning procedure. See “Cleaning dCA Sensor Screens” on page 36.

2. Clean the smaller size sensor screen using the same procedure.

3. With no screen in the dCA, flush the dCA with superclean fluid or Entek flushing fluid by probing onto the pressure chamber for about 3 seconds and backflushing into a waste container. Allow the piston to rise a full stroke.

Note: Superclean fluid is defined as fluid containing fewer than 10 particles greater than 10 microns per mL of fluid.

4. Repeat the superclean flush two or three times.

5. Place the smaller size cleaned screen in the dCA. Make sure you check all the configuration data in the Enpac Oil. See “Configuring the dCA” on page 31. You can now take data with the smaller size sensor screen.

Maintaining the dCA


Calibrating the dCA Sensor ScreensThe calibration validation program allows you to change the calibration number on your dCA sensor screens based on the repeatability of your testing. The Enpac Oil then adjusts its readings based on the calibration number. You should perform calibration validation testing monthly, and return the results to Entek if your calibration is unsatisfactory.

Note: You must enter the calibration number on the sensor screen in your Enpac Oil in order for your data to be accurate. See “Configuring the dCA” on page 31.

1. Flush your dCA sensor and all fluid lines with a clean fluid (defined as fluid containing fewer than 100 particles > 10 microns per mL of fluid) or use Flushing Fluid.

2. Shake the calibration validation fluid vigorously for a minimum of five minutes to homogeneously suspend all particles. If a paint shaker is not available, manually shake vigorously, occasionally hitting the bottle against the palm of your hand.

3. Place the calibration fluid bottle into the pressure chamber, replace the lid, and pressurize to approximately 60 psi (4.14 bars).

4. Flush any old fluid out of the test port by probing on for 1–2 seconds using a flushing bottle or a flushing tube.

5. With the Enpac Oil turned off, probe the sensor onto the chamber, allow the plunger to rise 1/4 inch, backflush into the backflush chamber, and repeat one time.

6. Turn on the Enpac Oil and check the configuration. It should be set to test particles > 10 micron, and hydraulic fluid, and the correct screen size and calibration number should be used. See “Configuring the dCA” on page 31.

7. Run a test on the calibration fluid and record your results on the calibration form provided by the manufacturer.

8. Repeat step 7 without delay until you have completed and recorded three valid tests.

9. Average the results of the three tests, and record your average.

10. Calculate the percentage difference from the control count.

11. Determine if your percentage difference results are satisfactory or unsatisfactory.

z If your percentage difference is within +/- 10% of the Control, check the box next to Calibration Satisfactory.

z If your percentage difference is outside +/- 10% of the Control, check the box next to Calibration Unsatisfactory, and call Customer Support. A representative can work with you to bring your results within an acceptable calibration limit.

12. Fax results to Entek at (513) 576-4213, or mail them to Entek, 1700 Edison Dr., Milford, OH 45150. Be sure to send it to the attention of Customer Support.

average of three tests control count–control count

---------------------------------------------------------------------------------------- 100× percentage difference=



Calibration VerificationCOMPANY: _________________________________________________________

CONTACT:__________________________________________________________

PHONE: __________________________ FAX:_____________________________

SCREEN CALIBRATION #:____________________________________________

SCREEN SIZE: ______________________________________________________

ENTEK CONTROL #: ________________________________________________

PLEASE CHECK ONE:

__ Calibration Satisfactory (Average WITHIN +/- 10 % of Control Count)

__ Calibration Unsatisfactory (Average OUTSIDE +/- 10 % of Control Count)

DATE TESTED:____________________ TESTING BY:______________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

PLEASE FAX OR MAIL COMPLETED FORM TO ENTEK

ATTN: Customer Support1700 Edison Drive Milford, OH 45150Fax: 513-576-4213

Particle Micron

Size

(1) Control Count

Particles per mL

Test #1

Particles per mL

Test #2

Particles per mL

Test #3

(2) Average of Tests

Percentage Difference

(2) - (1) / (1) x 100

__ 5 µ__ 10 µ__ 15 µ

Maintaining the dCA


To calculate a new calibration numberIf your test results are outside of the acceptable range but results are repeatable, you can calculate and change the calibration number of the screen. This procedure allows you to use the screen and obtain accurate results.

1. If test results were outside +/- 10% of the Control Count (i.e. calibration is unsatisfactory), take six more tests and record your 10 micron results.

2. Eliminate the highest and lowest readings, and average the four remaining “good tests.”

3. Compute percentage difference again as shown below.

4. If the results are still outside of the +/- 10% of the control count, determine whether or not your results are repeatable. Do this by computing the following:

5. If the repeatability factor is less than 10%, go on to the next step. If the repeatability factor is greater than 10%, call Customer Support for assistance.

6. If the results are repeatable but still outside the acceptable +/- 10% of the control count, recalibrate the screen using the following calculations:

7. Enter the new calibration number into the Enpac Oil. See “Setting Screen Calibration” on page 32 for instructions.

average of four tests control count–control count

-------------------------------------------------------------------------------------- 100× new percentage difference=

highest count of four tests lowest count of four good tests–average of four good tests

---------------------------------------------------------------------------------------------------------------------------------------------- repeatability factor=

average of four testsscreen calibration number-------------------------------------------------------------- 100× adjusted average=

control countadjusted average---------------------------------------- 100× new calibration number=



Seal Compatibility with Specific FluidsThis chart lists the known seal compatibilities with certain fluids. Be sure to use seals that are compatible with the fluids you are testing. The following codes are used for the chart:R=RecommendS=SatisfactoryM=MarginalU=UnsatisfactoryI=Insufficient data

Fluid Name Military Spec Trade Names/Numbers Color EP Viton

Water Glycol n/an/aMIL-H22072n/an/an/an/a

Houghto-Safe 600 SeriesHoughto-Safe 500 SeriesHoughto-Safe 271Ucon HydrolubeUcon M1CelluguardSafety Fluid 200

redredredyellow or redyellowredbright pink

RRRRRRR

RRRRRRR

Water/Oil Emulsion n/an/an/an/a

Houghto-Safe 5000 seriesFRIrus 902Pyrogard C&Dd

whitecreamyellowpale yellow

UUUU

RRRR

Water-Soluble Oil n/a water-soluble oil milky - R

Water-Fresh n/a fresh water clear R R

Water-Salt n/a salt water clear R R

Phosphate Ester n/aMIL-H-19547Bn/an/an/an/an/an/an/an/an/an/a

Houghto-Safe 1000 seriesHoughto-Safe 1120Pydraul F-9, 150, 625FyrquelShell SFR B.C.D.Pyrogard 42,43,53,55,190,600Skydrol 500ASkydrol 7000Pydraul 312, 135 (2)Pydraul ACPydraul 60Pyrogard 210 (3)

greengreencloudy bluelt. greenaqua greenpale yellowpurplegreenblue greencloudy bluecloudy blueyellow

RRSRRRRRMSRM

RRRRRR/SUURRUR

Diester Chlorinated Hydrocarbon

MIL-H-7808n/a

Lube Oil-AircraftAroclor 1200 Series (1)

amberclear

US

RR

Silicate Ester n/aMLO-8200MIL-8515MIL-H-8446B

OS-45 Type 4Oronite 8200Oronite 8515Brayco 846

clearclearclearredbrown

SUUU

RRRR

Kerosene n/a Kerosene clear U R

Jet Fuel MIL-J-5624 JP-3,4,5 (RP-1) lt. straw U R

Diesel Fuel n/a Diesel Fuel clear U R

Gasoline n/a Gasoline various U R

Petroleum Base MIL-H-6083 Preservative Oil red U R

Maintaining the dCA


Replacing the Sensor SealsYou need regular maintenance of the sensor seals to ensure consistent results. The schedule for replacing the seals depends on many factors. The wear on the seals is dependent on the type of seal, fluids being tested, how often the sensor is used, and the cleaning method used. If you use the unit daily, we recommend replacing the seals every 12–18 months.

One of the most common problems with seals is fluid incompatibility. You must choose a seal that is compatible with the fluids you test. To confirm seal compatibility, see “Seal Compatibility with Specific Fluids” on page 42.

To replace the seals in your dCA sensor, follow these steps.

1. Use the attached drawing to identify and carefully remove the old seals by pulling them off. Do not cut the old seals off, as cutting may score the sensor and cause testing problems.

2. Using the following diagram, match the new seals with their respective locations by matching the part numbers printed on the protective bags.

#1 (small black seal)#2 (small black seal underneath sensor screen, dCA only)#3 (larger black seal below screw threads)

#4 (black inner seal)#5 (blue outer seal)

Part numbers for Viton seals:1 = Part # 1305-0102 = Part # 1305-011 (dCA only)3 = Part # 1305-0154 = Part # 1305-0185 = Part # 1668-016



3. Replace each seal as follows:

Seal #1: Seal number 1 is located on the sensor probe assembly. Unthread and remove the sensor probe assembly, and pull off the o-ring mounted on it. Carefully pull the new o-ring down over the sensor probe assembly, taking care not to cut the o-ring on the metal edges of the probe assembly. The seal should fit snugly into a groove on the sensor probe body.

Seal #2: (Note that Seal #2 is not used in the dVA.) Seal number 2 is located inside the barrel cap, and rests on top of the sensor screen when the sensor is held in an upright position. Replace this seal by removing the sensor probe assembly and the sensor screen, and dropping the seal into the inverted sensor. Replace the screen and the sensor probe assembly to help fit seal down into the opening.

Seal #3: Seal number 3 is the barrel cap seal. Unthread the barrel cap from the barrel and remove the old seal by pulling it up and over the threads. Pull the new seal on, taking care not to cut the seal on the threading. Re-attach the barrel cap to the barrel and hand-tighten only.

Seals #4 and #5: Seal numbers 4 and 5 fit onto the piston inside the sensor barrel. These seals are very crucial, so take special care to install them correctly. Pull the backflush knob out to its full stroke. Remove the old seals by unthreading the sensor barrel from the transducer at the seam that joins the barrel to the barrel adapter (the 1" section of the barrel attached to the transducer). After unthreading the barrel, gently pull it off of the piston. The blue teflon seal and the black o-ring underneath it can both be removed by gently pulling them off of the piston. To install new seals, first pull the black o-ring #4 into position in the groove on the piston. Then gently stretch the blue seal over the piston to fit on top of the black o-ring. Massage the blue seal into place with your fingers, gently compressing it down into the groove. After working the seal into the groove, attempt to thread the barrel back onto the piston. Do not force the barrel over the seals. If the barrel does not thread on, continue to compress the seal down into the groove. You do not need to grease or lube the seals in any way to insert them into the barrel. Continue to alternately massage the seal and thread it on the barrel until the piston fits into the barrel.

4. Discard old seals, and run a test with the dCA or dVA to assure that all seals are placed correctly. Any incorrect placements inside the sensor causes problems with test results.

Diluting High Viscosity Fluids to Test with the dCAThe symptoms of problems caused by very high viscosity fluids are extremely slow flow through the dCA, accompanied by erratic readings and/or invalid test results. If these types of problems occur with a low or medium viscosity fluid you may want to call Customer Support.

If you get unusual test results even though the dCA has been cleaned and flushed, it may be necessary to dilute the test fluid. You should only need to dilute the fluid if it has a very high viscosity.

Diluting High Viscosity Fluids to Test with the dCA


The viscosity limits for using the dCA are as shown in the table below:

Follow this procedure to dilute high viscosity fluids for testing.

1. Select a solvent for dilution. We recommend a clean MIL-H-5606.

2. Pour the dilution fluid into a sample bottle. Agitate the sample bottle for several minutes by hand or with a paint shaker. Put the sample bottle in a pressure chamber.

3. Prime the dCA sensor with the dilution fluid by probing on for a few seconds and then backflushing.

4. Run three baseline tests on the dilution fluid, and record the average of your results. Name this average BASELINE. Make sure your results are within 10% of each other.

5. In a clean sample bottle, create a 50-50 mix of the viscous sample and baseline dilution fluid using approximately 40 mL of each fluid. Agitate the sample bottle for several minutes by hand or with a paint shaker.

6. Put the diluted sample bottle in the pressure chamber.

7. Prime the dCA sensor with the diluted sample fluid by probing on for a few seconds and then backflushing.

8. Run three consecutive tests on the diluted sample. Name these results DILUTED SAMPLE. Make sure your results are within 10% of each other.

9. To find the correct particle counts for the original undiluted fluid, use this calculation:

(DILUTED SAMPLE x 2) - BASELINE = Original undiluted particle count.


Chapter 4

4. The ferrous CONTAM-ALERT (fCA)

This chapter describes the fCA sensor in detail and covers the basic operations of the sensor. It includes the following sections:

Overview of the ferrous CONTAM-ALERT (fCA) ............................... 48

Connecting the fCA ............................................................................. 49

Maintaining the fCA ............................................................................ 49

Collecting a Ferrogram for Analysis .................................................. 52

Diluting High Viscosity Fluids to Test with the fCA............................ 54


Chapter 4 - The ferrous CONTAM-ALERT (fCA)

Overview of the ferrous CONTAM-ALERT (fCA)The ferrous CONTAM-ALERT (fCA) provides a method for checking for ferro-magnetic particulate in hydraulic and lubricating fluids. While the dCA measures cumulative hard particle contamination levels, the fCA goes one step further by identifying how much of that total particle count is ferro-magnetic material. Ferro-magnetic particulate causes most component wear, so ferrous particle count is a strong indicator of component failures in progress.

This chapter discusses the basic operations of the fCA, including how to:

z Maintain and care for the fCA sensor.

z Connect the fCA sensor to the Enpac Oil and dCA.

z Collect a ferrogram for analysis.

z Dilute a high viscosity sample.

Understanding How the fCA Sensor WorksThe fCA works in conjunction with the dCA and Enpac Oil to yield wear-related particle counts. After using the dCA to measure total particle counts, you put the fCA accessory onto the test port and re-attach the dCA to the top of the fCA. By performing a second test with the dCA through the fCA, you obtain particle counts for only those particles made of ferrous material.

The fCA operates using a proprietary technology that magnetizes the fluid during testing, allowing only those particles that are non-ferrous in nature to be tested by the dCA. The software then calculates the difference between the first, cumulative particle count test and the test with the fCA to obtain a ferrous particle count. In 4–6 minutes, the dCA and fCA can provide both an accurate total particle count and ferrous particle count, making these particle counts valuable for an oil analysis program.

The fCA provides a way for the dCA user to attribute increasing particle counts to either an increase in ferrous particulate which is indicative of wear, or an increase in silica, dirt or other particulate which indicates other types of system problems. When used online, or when testing bottle samples, this first check for wear can mean the difference between planned, controllable maintenance costs, and unplanned, disastrous, and expensive downtime.

Connecting the fCA


Connecting the fCAYou connect the fCA directly to the test port, then connect the dCA sensor to the top of the fCA. Connect the fCA by probing on and threading the lock-on sleeve into place. Then, connect the dCA to the port on the top of the fCA. This diagram shows the connection locations on the fCA.

The dCA then has to be connected to the Oil Sensor Interface, and then the Enpac Oil also must be connected to the Oil Sensor Interface.

Maintaining the fCAThis section discusses the recommended maintenance on your fCA in order to consistently obtain accurate results.

Caution: Solvents require careful handling and storage. Check with your company’s safety officer for handling and storage advice or instruction. Always practice the proper safety measures with these solvents.



Cleaning the fCAWe recommend that you flush your fCA unit every other week with 100 mL of a Viton-compatible solvent or Entek Flushing Fluid using the bench-top apparatus or the portable pressure chamber. To do so, follow these steps.

1. Place the Flushing Fluid in the pressure chamber and pressurize it to 60 psi (4.14 bars).

2. Turn the fCA knob to Flush.

3. Probe on to the test port of the pressure chamber for 20 seconds, or long enough to allow 100 mL of the Flushing Fluid to go through the fCA. Performing this flush regularly ensures optimal accuracy from your fCA unit.

Verifying the fCA ResultsIf you need to verify that your fCA is functioning properly, you can obtain fluid with a known ferrous content in order to compare your results with the appropriate amounts. The fCA calibration fluid is used as a quality assurance tool. It simply verifies that the fCA is working properly. To order this fluid, contact your Entek sales representative.

Replacing the fCA BatteryThe indicator lights on the front of the fCA are run with a 9V battery. If the indicator lights stop working, you may need to replace the battery. To do so, follow these steps.

1. Turn the fCA knob to the OFF position.

2. Using a coin or slotted screwdriver, turn the screw located on the bottom of the fCA counterclockwise until the screw comes out.

3. Carefully pry the battery out of the fCA case. It may be a tight fit but you should be able to work it out of the case.

4. Replace with a new 9 V battery, matching the positive and negative indicators.

5. Close the battery lid and screw it to the case.

Maintaining the fCA


Flushing the fCAThe fCA makes use of a magnetic media in the separation zone, which is in the upper area near the test port. The media must be flushed and reused, so it is important to make sure it is clean before running a test. If the media is not clean, particles from a prior test may be released during testing and cause unusual readings. To flush the fCA, follow these steps.

1. Obtain a bottle of clean fluid, such as Entek Flushing Fluid. Shake the bottle vigorously for at least 5 minutes before placing it in the pressure chamber.

2. Place the bottle in the pressure chamber and pressurize it to 60 psi (4.14 bars).

3. Turn on the Enpac Oil and check the configuration. It should be set to test particles > 10 micron, and hydraulic fluid, and the correct screen size and calibration number should be used. See “Configuring the dCA” on page 31.

Run a dCA test on the fluid to determine the particle count. This is the baseline particle count.

4. Place the fCA on the sample chamber. Turn the knob to the FLUSH position. Flush about 5–10 mL through the fCA.

Note: You can flush the fCA either with a bottle or the lab apparatus.

5. Run a dCA test with the fCA on the pressure chamber, still in the FLUSH position. The particle count should be close to the baseline particle count. If it is higher than the baseline particle count, the magnetic media in the fCA is not clean and requires more flushing.

6. Repeat procedure until the particle count is close to baseline. When it is clean, it is ready to be used in a regular fCA test.



Collecting a Ferrogram for AnalysisKeep Millipore® membranes sealed except when removing to avoid contamination. Also, be careful about accidently pulling membrane and waxed paper together, because it will cause problems when backflushing.

You can use a special syringe, syringe adapter, and membrane holder with the fCA to collect a wear particle sample for microscopy viewing and analysis. To do so, follow these steps.

1. Run standard particle count tests with the dCA either on-line or with the dCA lab apparatus to obtain regular particle count information.

2. After obtaining two consecutive valid test results with the dCA and saving the data, choose [1] Run fCA test.

3. Probe the fCA onto the test port, and thread the lock-in sleeve into place.

4. Turn the dial to the OFF position. Flush 5–10 mL of oil sample through the fCA and into a waste oil container.

5. Turn the fCA dial to the TEST position, and probe the dCA onto the test port on the top of the fCA for 2–3 seconds to prime the dCA sensor. Backflush the dCA sensor.

6. Run test with the dCA and fCA combination to get two consecutive valid readings (within +/– 10% of each other). Save this test data if you want to view it later.

7. With the fCA still in the TEST position, detach the fCA from the test port. Detach the dCA from the top of the fCA. Thread the syringe adapter onto the top fCA test port on the top of the fCA.

8. Fill the syringe with 20 mL clean solvent that is compatible with Viton seals by placing the tip into a container of solvent or fluid, and pulling up on the tops metal ring until the desired amount of fluid is drawn into the syringe.

Collecting a Ferrogram for Analysis


9. Put one Millipore Membrane paper disc into the membrane holder. Attach the membrane holder to the test port, and attach the fCA to the membrane holder. The assembly should look like this.

10. Turn the fCA to the FLUSH position. Quickly flush the 20 mL of solvent through the syringe adapter, the fCA and the membrane and into a waste bottle or flask.

11. Carefully remove the paper disc from the holder and allow it to air dry.

12. Flush 20–30 mL of oil through the fCA. Ensure that the dial on the fCA is in the OFF position before running another test or storing the fCA.

13. Allow the membrane to dry.

14. Place the membrane under a microscope to view ferrous particulate.



Diluting High Viscosity Fluids to Test with the fCAThe symptoms of problems caused by very high viscosity fluids are extremely slow flow through the dCA, accompanied by erratic readings and/or invalid test results. If these types of problems occur with a low or medium viscosity fluid you may want to call Customer Support.

If you get unusual test results even though the fCA has been cleaned and flushed, it may be necessary to dilute the test fluid. You should only need to dilute the fluid if it has a very high viscosity.

The viscosity limits for using the fCA are as follows:

z If you are using a 10 micron screen in the dCA, you cannot use a fluid with a viscosity greater than 420 cSt@40ºC.

z If you are using a 15 micron screen in the dCA, you cannot use a fluid with a viscosity greater than 680 cSt@40ºC.

Follow this procedure to dilute high viscosity fluids for testing.

1. Select a solvent for dilution. A Viton-compatible solvent should be used, such as trichlorethylene or dichlorofluoroethane (commonly used as a contact cleaner).

2. Agitate the fluid sample bottle for several minutes, then pour out sample fluid until approximately 60 mL of sample fluid remains in the bottle.

3. Decant the solvent from the top of the solvent container with a syringe, if possible, to make sure it is clean solvent. The container should be undisturbed for several minutes before decanting.

4. Add about 20 mL of solvent to the fluid sample. The total sample volume should now be about 80 mL. Agitate vigorously by hand or with a paint shaker for several minutes.

5. Follow regular fCA testing procedure for total particle count and ferrous particle count.

6. To find the correct particle counts for the original undiluted fluid, multiply the total particle count and ferrous particle counts by 1.33.


Chapter 5

5. The digital VISC-ALERT (dVA)

This chapter describes the dVA sensor in detail and covers the basic operations of the sensor. It includes the following sections:

Overview of the digital VISC-ALERT (dVA) ....................................... 56

Configuring the dVA............................................................................ 60

Maintaining the dVA............................................................................ 68

Comparing Test Results to New Oil Specifications ............................. 72


Chapter 5 - The digital VISC-ALERT (dVA)

Overview of the digital VISC-ALERT (dVA)This chapter discusses the basic operations of the digital VISC-ALERT (dVA), including how to:

z Use the dVA sensor safely

z Attach the dVA sensor to the Enpac Oil

z Maintain and care for the dVA sensor

z Configure the dVA sensor

Safety Warnings for the dVAOnce this product is received and opened, you and your company accept all responsibility for the product and its use, unless the product is damaged due to mishandling during shipping or a manufacturing defect is present.

As with all precision instruments, the dVA parts need to be handled with care. Dropping the dVA sensor on a hard surface can cause misalignment or internal damage, which in turn affects the accuracy of test results.


To ensure your safety and to prevent mishandling of the sensor, follow these warnings.

1. Do not use the dVA sensor on life dependent systems. The sensor is a tool intended to provide assistance in maintenance procedures. It is not intended for use on life dependent systems.

2. Do not point the dVA sensor at any person while backflushing or discharging fluid.

3. Do not drop the dVA sensor. Dropping the sensor on a hard surface can cause misalignment or internal damage which affects the accuracy of test results.

4. Do not attach the dVA sensor to valves with pressures above 100 psi (6.89 bars).

5. Do not stand behind or block the dVA sensor during testing. Do not block the backflush knob of the dVA when performing a test.

Overview of the digital VISC-ALERT (dVA)


dVA Operating SpecificationsNote: The reason for having the upper limit in cP instead of cSt is the cSt upper limit is determined

by dividing the cP viscosity value by the specific gravity entered by the user. To determine your upper limit in cSt, divide 9999 by the test specific gravity and the result will be the upper cSt limit.

Understanding How the dVA Sensor WorksThe dVA sensor is made up of three main components, the dVA probe assembly, the piston assembly, and the linear encoder.

The dVA employs the principle of a capillary viscometer, measuring fluid flow per unit time at a given pressure drop through a capillary of known dimensions, to obtain absolute viscosity.

The test fluid sample is run on the laboratory apparatus to provide pressure and flow. The hand-held dVA sensor measures the flow rate through the capillary in the dVA probe assembly by capturing fluid flow in the piston assembly and measuring the flow rate with the linear encoder.

The dVA is easily calibrated to ASTM velocity standards or other fluids of known viscosity. Kinematic viscosity can be determined by entering the fluids specific gravity and can be provided in Saybolt Universal Seconds (SSU or SUS), centistokes, or ISO viscosity units.

Pressure at valve

30–100 psi (2.07–6.89 bars) Pressure should always remain constant and dVA Sensor within this range during a test.

Temperature of sample fluid

Maximum 190ºF (88ºC)

Sample fluid viscosity range

Standard low viscosity probe 5 to 460 cStHigh viscosity probe 460 cSt to 9999 cP (See note above)

dVA storage temperature

-40ºF to 158ºF (-40ºC to 70ºC)

Fluid compatibility

All fluids compatible with standard Viton seals. EP and other seals are available by special order.



Connecting the dVA SensorThe Enpac Oil connects to the Oil Sensor Interface. You connect the dVA to the Oil Sensor Interface.

1. Insert the 25-pin plug at the end of the dVA sensor cable in the dVA connector on the Oil Sensor Interface.

2. Tighten the thumbscrews located on either side of the connector to secure the dVA cable to the Oil Sensor Interface.

3. Insert one end of the serial cable into the PC connector at the bottom of the Oil Sensor Interface. Plug the other end into the COM port on the top of the Enpac Oil.

Connecting the dVA Sensor


Probing On with the dVA Sensor


Here are a few hints about probing on with the dVA sensor for consistent data and safety in using the system.

It is recommended that you use the dVA with the lab stand for best results.

z Grasp the dVA sensor by the barrel and attach it to the valve by pressing firmly to get a quick, positive connection. Continue to press down with the sensor while tightening its lock-on sleeve.

z Make sure to completely tighten the sleeve before relaxing pressure on the sensor.

z Do not block, handle, push, or pull the backflush knob of the sensor while testing. When the sensor is connected to the test port valve, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor.

Assembling the dVARecord the calibration number that is inscribed on the large end of the probe. Thread the dVA probe onto the end of the dVA sensor. Attach the 25-pin sensor cable to the top of the Enpac Oil and tighten the two thumbscrews on either side of it.

Priming the dVA SensorBefore you attempt to test any fluid with the dVA sensor, be sure that the internal surfaces have been coated with the test fluid. Priming the sensor with lubricant or hydraulic fluid wets the internal surfaces which improves operation and allows for greater accuracy in testing the fluid. To prime the dVA, simply probe on to the test port for about 1 or 2 seconds. Detach the dVA, and expel the fluid by backflushing the dVA. For more detail on backflushing, see “Backflushing the dVA Sensor” on page 68.

Note: You may not have to do this every time you begin collecting data, but if you are not sure which fluid was used previously, you should prime the dVA sensor with the test fluid before use.



Configuring the dVABefore you begin testing with the dVA, you must configure it. Choose [6] Configure dVA at the dVA main menu. There are several options available to you. This section goes through each selection.

Entering the Probe Serial NumberThe probe serial number is used to match the sensor with a calibration file. This number must be input for accurate results. To enter the probe serial number, follow these steps.


2. Choose [3] dVA. The dVA Main Menu appears.

3. Choose [6] Configure dVA. The Configure dVA menu appears.

4. Choose [1] Probe Number. The dVA Probe screen appears.

5. Unscrew the probe tip from the dVA tube. The serial number is located on the base of the probe tip, inscribed in the metal.

6. Enter the serial number (up to four characters) of the probe you are going to test. The serial number is used to match the sensor with a calibration file. Do not include any letters at the beginning of the number when entering it.

7. Press <Enter> to save your changes or <Escape> to leave the information as it was and return to the Configure dVA screen.

Configuring the dVA


Calibrating the Probe for Low Viscosity FluidsTo calibrate the probe for your testing, you enter specific values, including specific gravity and viscosity at 40°C for the dVA probe. Low viscosity range is from 1 cSt to 460 cSt. High viscosity range is from 460 cSt to 9999 cP.




4. Choose [2] Calibrate. The following screen appears.



5. Choose Low Viscosity to bring up the Calibrate screen. Low viscosity range is from 1 cSt to 460 cSt. High viscosity range is from 460 cSt to 9999 cP.

Note: The reason for having the upper limit in cP instead of cSt is the cSt upper limit is determined by dividing the cP viscosity value by the specific gravity you enter. To determine your upper limit in cSt, divide 9999 by the test specific gravity and the result is the upper cSt limit.

If the test viscosity limit of 9999 cP is exceeded, the Enpac Oil displays an error message and the test viscosity value is not displayed or stored.

6. Choose Lower Range, Middle Range, or Higher Range.

7. After choosing the range at the Calibrate dVA screen for low viscosity fluids, enter the specific gravity and viscosity for the calibration oil. Type the specific gravity number and press <Enter>. Type the viscosity value and press <Enter>.

8. Press <Enter> to return to Calibrate dVA screen.

Configuring the dVA


Calibrating the Probe for High Viscosity FluidsTo calibrate the probe for your testing, you enter specific values, including specific gravity and viscosity at 40°C for the dVA probe. Low viscosity range is from 1 cSt to 460 cSt. High viscosity range is from 460 cSt to 9999 cP. If you have a high viscosity probe tip, use it for these tests. If you do not have a high viscosity probe tip, you can use the low viscosity probe tip, provided you choose the low viscosity menu item in step 5.



3. Choose [6] Configure dVA. The dVA Configure menu appears.

4. Choose [2] Calibrate. The Calibration screen appears.

5. Choose High Viscosity and press <F4> OK. Low viscosity range is from 1 cSt to 460 cSt. High viscosity range is from 460 cSt to 9999 cP.

Note: There are two probe tip types, one for low viscosity and one for high viscosity. If you are using the low viscosity probe tip, choose the low option at this screen.

The Calibration oil screen appears.



Note: The reason for having the upper limit in cP instead of cSt is the cSt upper limit is determined by dividing the cP viscosity value by the specific gravity you enter. To determine your upper limit in cSt, divide 9999 by the test specific gravity and the result is the upper cSt limit.

If the test viscosity limit of 9999 cP is exceeded, the Enpac Oil displays an error message and the test viscosity value is not displayed or stored.

6. After choosing the range, enter the specific gravity and viscosity for the calibration oil. Type the specific gravity value and press <Enter>. Type the viscosity value and press <Enter>.

7. Enter the temperature of the calibration sample.

8. Enter the pressure of the calibration sample.

9. The viscosity test cycle begins. For more information about data collection, See “Using the dVA to Collect Unscheduled Viscosity Data” on page 141.

10. After the data has been gathered, a new calibration value is calculated and can be used.

Configuring the dVA


Setting the Default Units and Projected TemperatureYou can choose cP, cSt, or SUS for the default display units. You can also select the temperature at which the Enpac Oil projects the viscosity value. Your choices are 40°C, 100°C, or entering another temperature. For example, if you want the Enpac Oil to project the viscosity value at room temperature, enter 25°C for the projected temperature. Follow these steps to set the default units and projected temperature.



3. Choose [6] Configure dVA. The dVA Configure Menu appears.

4. Choose [3] Default Units. The Default Units menu appears.

5. Choose Viscosity or Projected Temperature, then choose OK.

6. Select the units you want to use, then choose OK.

Entering New Oil SpecificationsFor unscheduled measurements, you can enter and save new oil specifications to use for comparing your viscosity results to a known value. For example, you may want to observe how your oil viscosity values change over a month’s use. You can enter the new oil specifications and compare the month-old oil to those specifications. For more information about the comparison, see “Comparing Test Results to New Oil Specifications” on page 72.



To enter new oil specifications, gather the information from your oil supplier and enter it by following these steps.




4. Choose [3] Default Units. The Default Units screen appears.

5. Choose New Oil Specs. The New Oil Specs screen appears.

6. To enter new oil specifications, choose New Oil by pressing <F2>. The Oil Type [New] screen appears.

Configuring the dVA


7. Select New Record and press <Enter>. The Oil Input screen appears.

8. Using the new oil information, enter the fluid name, specific gravity, viscosity at 40 °C, and viscosity at 100 °C. This information should be available from your oil supplier. Press the arrow keys to move from field to field.

9. Press <Enter> or <Escape> when you are finished entering information. The list of the available oil specs appears.

10. Use the arrow keys to make your selection, then press <F4> OK. A summary of the oil specs appears for you to accept.

11. To use this oil data, choose <F4> Accept. The selected Oil Spec becomes the new default and you return to the dVA Configure Menu.



Maintaining the dVAThis section discusses maintaining your dVA to ensure optimal results and accurate use of the dVA sensor.

Backflushing the dVA SensorProperly backflushing the dVA sensor clears the capillary tube of any potential contamination. It is critical that you backflush the sensor following each sample test. If you are backflushing manually, follow these steps.

1. Once the backflush knob stops moving, disconnect the dVA sensor from the valve.

2. Push on the backflush knob until it goes all the way down.

3. The sensor is now ready for another test.

If you are backflushing using the lab apparatus, follow these steps.

1. Once the backflush knob stops moving, disconnect the dVA sensor from the valve.

2. Attach the sensor to the automatic backflushing rig with the probe on the bottom of the fixture.

3. Turn the knob located behind the backflushing rig to the FLUSH position. The backflush piston pneumatically pushes the sensor knob, backflushing the sensor.

4. Once the backflush cycle is complete, turn the knob to the RETRACT position.

5. Remove the probe body from the backflushing rig after all the fluid is expelled. The sensor is now ready for another test.

Maintaining the dVA


Seal Compatibility with Specific FluidsThis chart lists the known seal compatibilities with certain fluids. Be sure to use seals that are compatible with the fluids you are testing. The following codes are used for the chart:R=RecommendS=SatisfactoryM=MarginalU=UnsatisfactoryI=Insufficient data

Fluid Name Military Spec Trade Names/Numbers Color EP Viton

Water Glycol n/an/aMIL-H22072n/an/an/an/a

Houghto-Safe 600 SeriesHoughto-Safe 500 SeriesHoughto-Safe 271Ucon HydrolubeUcon M1CelluguardSafety Fluid 200

redredredyellow or redyellowredbright pink

RRRRRRR

RRRRRRR

Water/Oil Emulsion n/an/an/an/a

Houghto-Safe 5000 seriesFRIrus 902Pyrogard C&Dd

whitecreamyellowpale yellow

UUUU

RRRR

Water-Soluble Oil n/a water-soluble oil milky - R

Water-Fresh n/a fresh water clear R R

Water-Salt n/a salt water clear R R

Phosphate Ester n/aMIL-H-19547Bn/an/an/an/an/an/an/an/an/an/a

Houghto-Safe 1000 seriesHoughto-Safe 1120Pydraul F-9, 150, 625FyrquelShell SFR B.C.D.Pyrogard 42,43,53,55,190,600Skydrol 500ASkydrol 7000Pydraul 312, 135 (2)Pydraul ACPydraul 60Pyrogard 210 (3)

greengreencloudy bluelt. greenaqua greenpale yellowpurplegreenblue greencloudy bluecloudy blueyellow

RRSRRRRRMSRM

RRRRRR/SUURRUR

Diester Chlorinated Hydrocarbon

MIL-H-7808n/a

Lube Oil-AircraftAroclor 1200 Series (1)

amberclear

US

RR

Silicate Ester n/aMLO-8200MIL-8515MIL-H-8446B

OS-45 Type 4Oronite 8200Oronite 8515Brayco 846

clearclearclearredbrown

SUUU

RRRR

Kerosene n/a Kerosene clear U R

Jet Fuel MIL-J-5624 JP-3,4,5 (RP-1) lt. straw U R

Diesel Fuel n/a Diesel Fuel clear U R

Gasoline n/a Gasoline various U R

Petroleum Base MIL-H-6083 Preservative Oil red U R



Replacing the Sensor SealsYou need regular maintenance of the sensor seals to ensure consistent results. The schedule for replacing the seals depends on many factors. The wear on the seals is dependant on the type of seal, fluids being tested, how often the sensor is used, and the cleaning method used. If you use the unit daily, we recommend replacing the seals every 12–18 months.

One of the most common problems with seals is fluid incompatibility. You must choose a seal that is compatible with the fluids you test. To confirm seal compatibility, see “Seal Compatibility with Specific Fluids” on page 69.

To replace the seals in your dVA sensor, follow these steps.

1. Use the attached drawing to identify and carefully remove the old seals by pulling them off. Do not cut the old seals off, as cutting may score the sensor and cause testing problems.

2. Using the following diagram, match the new seals with their respective locations by matching the part numbers printed on the protective bags.

#1 (small black seal)

#2 (larger black seal below screw threads)

#3 (black inner seal)#4 (blue outer seal)

Part numbers for Viton seals:1 = Part # 1305-0102 = Part # 1305-0153 = Part # 1305-0184 = Part # 1668-016

Maintaining the dVA


3. Replace each seal as follows:

Seal #1: Seal number 1 is located on the sensor probe assembly. Unthread and remove the sensor probe assembly, and pull off the o-ring mounted on it. Carefully pull the new o-ring down over the sensor probe assembly, taking care not to cut the o-ring on the metal edges of the probe assembly. The seal should fit snugly into a groove on the sensor probe body.

Seal #2: (Note that Seal #2 is not used in the dVA.) Seal number 2 is located inside the barrel cap, and rests on top of the sensor screen when the sensor is held in an upright position. Replace this seal by removing the sensor probe assembly and the sensor screen, and dropping the seal into the inverted sensor. Replace the screen and the sensor probe assembly to help fit seal down into the opening.

Seal #3: Seal number 3 is the barrel cap seal. Unthread the barrel cap from the barrel and remove the old seal by pulling it up and over the threads. Pull the new seal on, taking care not to cut the seal on the threading. Re-attach the barrel cap to the barrel and hand-tighten only.

Seals #4 and #5: Seal numbers 4 and 5 fit onto the piston inside the sensor barrel. These seals are very crucial, so take special care to install them correctly. Pull the backflush knob out to its full stroke. Remove the old seals by unthreading the sensor barrel from the transducer at the seam that joins the barrel to the barrel adapter (the 1" section of the barrel attached to the transducer). After unthreading the barrel, gently pull it off of the piston. The blue teflon seal and the black o-ring underneath it can both be removed by gently pulling them off of the piston. To install new seals, first pull the black o-ring #4 into position in the groove on the piston. Then gently stretch the blue seal over the piston to fit on top of the black o-ring. Massage the blue seal into place with your fingers, gently compressing it down into the groove. After working the seal into the groove, attempt to thread the barrel back onto the piston. Do not force the barrel over the seals. If the barrel does not thread on, continue to compress the seal down into the groove. You do not need to grease or lube the seals in any way to insert them into the barrel. Continue to alternately massage the seal and thread it on the barrel until the piston fits into the barrel.

4. Discard old seals, and run a test with the dCA or dVA to assure that all seals are placed correctly. Any incorrect placements inside the sensor causes problems with test results.



Comparing Test Results to New Oil SpecificationsThe dVA program in the Enpac Oil allows you to compare your viscosity test results to an oil specification. The program compares the tested viscosity to what the viscosity should be for your oil at the test temperature. The program also indicates the percentage difference from the oil specification viscosity value. The results indicate the tested oil is lower than specification with a minus sign (e.g. -7.6%). Test viscosities that are higher than specification are indicated by a positive number (e.g. 10.5%).

Note: This procedure is for unscheduled measurements. You can also compare list measurements to oil specifications if you enter the specifications in the host software. See “Setting Up Measurement Definitions with the dVA for Viscosity” on page 103.

1. After you press [1] Low Visc Test or [2] High Visc Test to begin a viscosity test at the dVA Main Menu, the program asks you if you want to compare your test result to the oil specs.

2. Use the arrow keys to highlight Yes, then press <Enter> to compare to an oil spec you can choose. The New Oil Specs screen appears, with the most recently created oil specification displayed.

3. You may accept the oil specifications that appear by choosing Accept. Press <Enter> or <F4. OK to use the one displayed.

If you decide to create a different oil than is on the screen, choose New Oil. The Oil Type [New] screen appears. If you want to enter a new record, see “Entering New Oil Specifications” on page 65.

Comparing Test Results to New Oil Specifications


4. Next, enter the temperature of the sample and press <Enter> or <F4> OK.

5. Enter the pressure of the sample and press <Enter> or <F4> OK.

6. If you have chosen the dVA test results to be in centistokes or Saybolt Universal Seconds, the Test Sample screen appears and ask for the specific gravity of the fluid. The program uses the specific gravity to convert the viscosity measurement from absolute viscosity (cP) to kinematic viscosity (cSt or SUS).

7. The viscosity test cycle begins. For more information about data collection, See “Using the dVA to Collect Unscheduled Viscosity Data” on page 141.


Chapter 6

6. Equipment for Sampling and Testing

This chapter describes collecting fluid and the equipment used for testing. It covers the basic operations of preparing test ports, collecting fluid with the Samplyzer bottles, regulating pressure with the High Pressure Sampler, and using the bench-top apparatus. It includes the following sections:

Overview of Equipment for Sampling and Testing .............................. 76

Preparing Test Port Valves for Sampling ............................................ 81

Collecting Fluid Samples .................................................................... 83

Using the High Pressure Sampler II (HPS II) ..................................... 87

Using the Portable Pressure Chamber................................................ 88

Using the Bench-Top Apparatus.......................................................... 88


Chapter 6 - Equipment for Sampling and Testing

Overview of Equipment for Sampling and TestingThis chapter discusses the basic operations related to oil analysis. Additional equipment is available for collecting samples and running tests. There are several tasks related to these activities, including preparing test ports, collecting fluid with the Samplyzer bottles, regulating pressure with the High Pressure Sampler, and using the bench-top apparatus. Each section offers more detail about these tasks.

Proper Sampling TechniquesGarbage in - is garbage out! If the sample is not good, then good testing equipment, quick turnaround time and conclusive results are not beneficial. Good oil sampling is dependent upon location, hardware and procedure. The sample bottle and its cleanliness level must also be take into consideration when performing oil analysis. The objective is to maximize the data intensity, minimize any data disturbance and perform oil analysis at the proper frequency. This session will provide you with the very best oil sampling procedures and techniques. A basic education of oil analysis and the importance of proper oil sampling will also be discussed.

When a decision has been made to invest in an oil analysis program, whether it is laboratory or on-site screening, one element remains the same - sampling. The on-line sample or bottle sample must be representative of what is happening in the machinery and within the oil itself. If the sample is not truly representative, at best it will provide worthless information and at worst it can be misleading and hazardous. Proper oil sampling is not impossible and does not have to be difficult. Once a procedure using the best fluid sampling methods is implemented, sampling becomes routine and testing gains accuracy.

Obtaining a valid oil sample begins with selecting the critical machines to be tested and identifying an appropriate oil sample location. This sample location should allow for future samples to be obtained from the same place. The need for consistency in numerous samples leads to the need for permanent sampling points. There can be more than one recommended place and method for removing a fluid sample, depending upon the analysis program and the expected results. Most people will agree that live zone sampling is the best location for any system when possible. Try not to sample from dead pipe legs or hose ends, this provides little information and is usually not accurate. A sample port should be located in a turbulent zone such as an elbow where fluid changes direction and becomes mixed. Sampling downstream of bearings, cylinders, gears, pumps, and actuators provides information from the "work" environment of the system is a primary sampling point. When all of the criteria (ISO cleanliness) can be met downstream of "work" equipment, then by default the cleanliness must be met before the "work" equipment. Locate the sample port in a low-pressure return line ahead of any filters or centrifuges, so that information is not removed from the fluid sample. If a filter is operating correctly, it will remove data from the fluid sample. Many times there is even a pressure gauge on the filter head that can be removed and replaced with a "T" and a sample port along with a gauge can be installed in its place. This sample type represents oil that is circulating and will not miss contaminants being removed by filters from other locations. The accepted procedure for extracting samples from dynamic fluid lines is ISO Standard 4021.

Proper Sampling Techniques


Fig. 1. - Locating Primary and Secondary Sampling Points

An alternate location would be installing a sample port at the mid-oil level in the reservoir, above any high concentrations of sludge; avoiding any drain-ports and drop tube sampling whenever possible. Drain ports and drain port taps do not promote an accurate oil sample, they tend to contain the sediment from the bottom of the reservoir. If a sample from the drain must be taken then do not just remove the drain plug to obtain a sample. The best drain port sampling would be to install test port with a stainless steel tube that goes mid way into the reservoir below the low oil level, then use a vacuum sampling technique to remove the fluid sample. This keeps the sediment away from the test port. Drop down tubing is very difficult to control for accuracy and repeatability. Drop tube vacuum sampling is good in some bearing, bath lubricated, gear and hydraulic systems. When drop down tubing is necessary, try to get as close to the return line in a circulating system as possible. Stay away from walls and keep a mid-point between oil level and the bottom of the tank. Use a rod or weight to achieve a consistent measured standoff from the bottom sludge layer. This sample location should not contain high quantities of water that can be found at the oil surface, or sludge that often congregates in the bottom of the reservoir.

Options for sampling splash-lubricated gears would be to install a sampling port with a permanent tube that bends down into the reservoir below the low oil level. This port would be installed into the outer housing in an accessable location. If a fitting/nut already exists then only drill and tapping would be necessary. If this sample port is not an option then the drain port vacuum sampling will again be necessary. Another location would be to install quick disconnects into the housing to attach to a portable filter cart. This Beta cart will allow for a non-circulating system to become a circulating system, thus obtaining a live sample. This setup is more common on a hydraulic system and less desirable in most others. Since the filter cart is mobile, it may be used on various systems with only the adoption of two quick disconnects (inlet and outlet).



All permanent sample points should be identified with a small metal tag or a color-coded identifier. This tagging eliminates the chance of sampling from the wrong sample port. Usually, more than one sample port or more than one sample location is possible on a machine. Installing more than one sample port provides diagnostic information and better failure root cause analysis if necessary. Sample from the primary sample port on a routine basis and then use the secondary sample ports for a more thorough diagnosis. The goal in oil analysis sampling is to be accurate, consistent and simple.

Choosing Sample BottlesThe bottle used for sampling plays a major role in oil sampling. Any bottle used should be at least 100-120 milliliter (4-5 ounces) and be made of one of the following: polyethylene-an opaque plastic, PET plastic- which is a clear, transparent plastic or clear glass laboratory type. Bottles can have a cleanliness rating. The cleanliness levels are Clean - < 100 particles > 10 microns per milliliter of fluid, Super Clean - < 10 particles > 10 microns per milliliter of fluid and Ultra Clean - < 1 particle > 10 microns per milliliter of fluid. Refer to ISO 3722 for bottle cleanliness guidelines. The problem with this guideline is that it ignores the actual technique by which the bottles are cleaned. A Required Cleanliness Level (RCL) is specified into this standard. The RCL indicates that two orders of magnitude separate the sample bottle cleanliness from the expected fluid sample. This RCL becomes a greater focus when deciding upon bottle cleanliness. Again consistency is a prime objective. Once a bottle type is selected, it is best to maintain that same bottle type and vendor. If a sample bottle vendor is changed there is the chance of interfering with oil analysis trending due to the change in the bottles and not a change in the machine or oil makeup. The polyethylene or PET bottles are preferred. The PET bottles have the advantage of being clear, so that a simple visual observation and comparison can be preformed on lubricating fluids. Damaging contaminants are too small to be seen with the naked eye, but change in color and fluid-water separation is visible.

Typical sample bottle showing Ullage

Proper Sampling Techniques


The most dangerous particles are typically between five and twenty microns in size. The naked eye can only see about 40 - 80 microns, under ideal conditions. If any particles were visible in the sample bottle to the naked eye, this would indicate a definite problem within the system. Plastic bottles can not be reused for oil analysis purposes - they are disposable only. The glass bottles can be cleaned under laboratory conditions and reused. Glass bottles are clear, can be cleaned to Ultra Clean rating and resuspend particles well, but they are also expensive and break easily, therefore a safety hazard. Glass bottles are difficult to handle around heavy machinery and are recommended for laboratory use. Note that some sample containers are not compatible with synthetic lubricants and they may soften or dissolve.

Once the bottle type is selected, the goal should be at least a Clean rating with the RCL at two orders of magnitude between the bottle and sample fluid. The bottles should always be shipped with the caps attached. The bottles should not be opened until the fluid is to be filled into the bottle. The best sampling is done without removing the cap when taking a fluid sample. This can be achieved by using a 'Samplyzer' style bottle. This bottle has a short hose and plastic port attached to the bottle cap that will connect with a Minimess port and then can be disposed of by pulling the hose out of the cap and closing the holes with a plug. The newest clean oil sampling technique is the plastic bag. In a clean air environment, simply place the capped sample bottle into a zip-close bag and close it. All the bagged bottles should then be placed into a larger zipped bag with a sampling device (vampire pump) before going out into the plant. Enclosing the bottles and sampling device prevent any dirt from accumulating. When the test port has been flushed, remove the bottle cap without opening the zipped bag. Pull the plastic bag taunt around the open bottle and tread onto the vacuum sampling device. The plastic bag must be thin enough for the plastic tubing to puncture through. If using the 'Samplyzer' style bottle, a vent hole may need to be made by puncturing the bag with a small hole. When the bottle is only three-quarters full, remove the sampling device and re-attach the lid from inside the zipped bag. When the lid is firmly attached the bottle may be removed and clearly labeled. It is amazing how much airborne and surface dirt is prevented from entering the sample bottle through this inexpensive and simple step. This technique permits a clean, valid sample to be obtained in a dirty environment using dirty hands. It may seem a little awkward the first few times, but the people that have implemented this procedure are very pleased with the results. Once again the possible variables in contaminating the oil sample have been removed. ASTM has a written procedure called "Practice for Manual Sampling of Petroleum and Petroleum Products", method D 4057.

When to Sample The best time for fluid sampling is when the machine is operating. Live zone sampling while the machine is "on the run". The optimum sample is when the fluid makeup is homogenous through out the system, and then it should not matter where the fluid sample is taken. Allow the machine to come up to running speed and temperature, do not sample immediately after start up. It is not advisable to take fluid samples just after topping up or adding to the in-service fluid. Keep the in-service hours on oil recorded and the sampling time between oil changes the same. Consistency is a large factor in having a successful oil analysis program. Due to all of the information that must be gathered and stored it is very prevalent that a good database software package be installed and maintained.



Sampling frequency is dependent upon many variables. Each of these variables must be considered before defining sampling frequency. Some of the environmental factors that must be considered are: severe environment (high dust), severe moisture, high load, high pressure system, high speeds, high operating temperature, shock or severe duty cycle and chemical/radiation contamination. Another factor that must always be taken into consideration is the economic penalty of failure if there is any. Consider any safety risk that may be involved, repair costs, downtime costs and machine mission criticality (how dependent is the process upon this machine running?). When assessing the machine, the age of the equipment becomes a factor. New machines have a frequent "Infant mortality" rate requiring more sampling in the beginning. As the machine ages again the probability for failure will increase. The age of the fluid itself is a factor. The older a fluid becomes the worse it degrades at a faster rate. The final consideration is the target cleanliness level itself. What target is trying to be achieved and how tight is this target? I believe that it is very easy to get an "A" in a glass, but it is very difficult to maintain that "A". This is true with cleanliness levels the tighter the margin between the target and in-service or new fluids the more frequently sampling and testing will be required. The final decision upon sample frequency will usually depend upon budget spending money and personnel. If you do not have the money or the people, it will not matter how good your sample locations or techniques are.

The timeliness in getting the oil sample analyzed is just as important as taking the actual oil sample out of the operating machine. The oil sample must be immediately sent off to the laboratory, either on-site or outside. Time is of the essence! Do not wait weeks or even days. The turn around time for test results should be within 24 hours after receiving the sample for analysis.

Sampling ConclusionsThe omni-present goal is to improve decision effectiveness through accurate oil analysis. Accurate sampling and good testing denotes information that leads to the improved quality of maintenance and operations decisions. With out accurate sampling, the test results provide worthless information, creating a detriment instead of a benefit. The key factor becomes consistency. With a good written procedure, education and good hardware, proper oil sampling can be cost effective and informative.

Other Sampling ReferencesEntek IRD, Oil Analysis Course Workbook, 1998.

Fitch, E.C., Fluid Contamination Control, 1988.

Fitch, Jim, Practicing Oil Analysis, "Clean Oil Sampling", July/August 1998.

Hendrick, P., The South African Institute of Tribology, "Industrial Oil in Service", September 1991.

Mayo, Jerry, "The Benefits of Proactive Fluid Condition Control", May 1997.

Practicing Oil Analysis, "Putting On-Site Oil Analysis to Work", September/October 1998

Troyer, Drew and Holly Borden, "Streamlining Oil Analysis with Field Testing", P/PM Technology, April 1994.

BS5540, Part 3: 1978, "Methods of Bottling Fluid Samples", BSI.

Preparing Test Port Valves for Sampling


ISO 3722: 1976, "Hydraulic Fluid Power - Fluid sample containers - Qualifying and controlling cleaning methods.", ISO

ISO 4021: 1992, "Hydraulic Fluid Power - particle contamination analysis - Extraction of fluid samples from lines of an operating system.", ISO

Preparing Test Port Valves for SamplingThis section offers explanations about sampling and methods for getting ready to test dynamic fluid samples using a test port valve.

There are two types of fluid sampling: static and dynamic. Static sampling refers to extracting a fluid sample from a reservoir or dead zone where there is only slight fluid movement. Static fluids contain contaminant concentration gradients, in which moisture and solid particles segregate into layers due to gravity. Therefore, samples taken from different depths within the static container can yield different results.

Dynamic sampling refers to extracting a sample where there is extensive fluid movement. This is the best method of obtaining a representative sample from a hydraulic system. Dynamic sampling, however, requires that sampling valves be installed at critical points in the system. Usually the improved accuracy justifies the expense and effort involved in installing test port valves.

Both ball valves and probe-on valves are acceptable valve types. However, probe-on valves are easier to install, require much less fluid for flushing, and are less expensive than ball valves.

After selecting the type of fluid sampling and valve type, you must select a location for the test port valve. There are several valve location options for monitoring equipment, including pump effluent monitoring, component monitoring, and return line monitoring.

Pump effluent monitoring is important because the pump is most prone to contaminant failure in a hydraulic system. Fluid from this sampling point contains a combination of contaminants: those entering from the reservoir, those sloughing off the suction strainer, those desorbed (captured then released) from the intake filter, and those generated by the pump itself (wear and cavitation debris, and corrosion products).

Component monitoring includes samples taken downstream of component parts, including actuators, bearings, engines and gear systems. These samples can give information on hose fibers, corrosion, filter desorption, and wear debris generation, which helps identify ailing components and unusually high ingression points.

Return line monitoring is used when only one sample location can be selected. Make sure you sample upstream of any filters fitted to the return line. The return line fluid contains all the contaminants that the system just experienced, including those contaminants ingested and generated by the system. When samples are taken and analyzed frequently, you can effectively monitor overall system health. The only exception is when a high-efficiency pressure line filter is employed that may cover the signs of an ailing pump.



Once the primary and secondary sample ports have been identified, the actual test port must be selected. The options for pressurized lines are as follows: Minimess, portable Minimess, ball/needle valve or quick disconnect. The Minimess test port with a dust cap is a very valuable tool. The simple feature of a dust cap can eliminate external dirt from the sampling port. The Minimess port can be used with a probe-on style bottle or for on-line sampling. A flat face (male) quick disconnect can be installed and then a female quick connect with a Minimess can be attached when a bottle sample is needed.

Quick connects can be used in high-pressure systems when a needle or ball valve is attached with a helical coil to reduce the pressure. Quick connects can also be used with portable filter carts. These carts are mobile and can circulate fluids from the system in off-line mode, or filter oils in the case of new oil transfer.

Fig. 2 - Optimal sampling point location.

The best test ports have some kind of cap on them so they are not open to the environment. A very important part of sampling is the flushing of the test port before actually obtaining a sample. The test port size must be taken into consideration. A minimum of five times its capacity must be flushed through the tubing and test port. Once the flushing is finished, then a valid sample can be taken from that test port. A valid sample consists of filling the bottle approximately 70% full. Do not fill the bottle completely; allow room for the fluid sample to be properly agitated. Since the flushing time and volume can vary from individual to individual, it is best to make this a written procedure with explicit guidelines as to the volume of fluid that is to be flushed before getting an oil sample.

Collecting Fluid Samples


Collecting Fluid SamplesThis section discusses the steps to obtain a fluid sample and several methods to prepare a sample for testing with the oil analysis sensors. There are many variables involved in sampling and testing fluids, including the method of sampling, the pressure of the system, and the site of data acquisition. High pressure systems require special handling, and bottled samples can either be tested in a portable pressure chamber or with a bench-top apparatus. Each of these different situations is described in this section. Diagrams are included in the overview section.

Overview of Collecting Fluid SamplesThere are two methods for collecting a fluid sample. You can collect the sample directly with the sensor, or you can collect a bottled sample for later analysis.

When collecting samples directly, you attach the sensor to a low pressure line (5–120 psi) by probing on to a prepared test port. See “Probing On with the dCA” on page 34. On a high pressure line (120–3000 psi), you attach the High Pressure Sampler II to regulate the pressure, then probe on to the HPS II port with the sensor. See “Using the High Pressure Sampler II (HPS II)” on page 87. If you are not collecting bottled samples, you may want to skip directly to “Preparing for Data Collection” on page 125.

When collecting bottled samples, attach a Samplyzer bottle directly to a low pressure line (5–500 psi). For a high pressure line (500–3000 psi), attach the bottle to the HPS II once the pressure is regulated. See “Collecting a Bottled Sample from a 5–500 psi Line” on page 84. If you have an Entek Beta Plus filter cart, you can collect a bottled sample from the port on the cart itself, which allows for another type of off-line sampling.

Caution: Note that you can collect a bottled sample from a line up to 500 psi. The sensors should only be used from 5–120 psi without using the HPS II.

You place bottled samples into a pressure chamber and attach the dCA sensor to the test port on top, drawing the fluid up from the bottle into the dCA sensor. You can use the portable pressure chamber for testing bottled samples in the field. See “Using the Portable Pressure Chamber” on page 88. You can use a bench-top apparatus for multiple bottled samples for ease of collection and analysis. See “Using the Bench-Top Apparatus” on page 88.

The following diagram is designed to help you navigate through the process. Page references are located next to each stage.



Collecting a Bottled Sample from a 5–500 psi LineBottled samples allow you to remove a sample directly from a line, then carry it with you for testing with a portable pressure chamber or bench-top apparatus. Specially-equipped Samplyzer bottles are used to probe on and collect fluid from a test port. Samplyzer bottles include a probe tip for collecting samples online. You can obtain these bottles from Entek.

Note: Do not open a sample bottle until you are ready to take a test. Be careful not to allow accidental entry of environmental contaminants into the sample fluid.

1. Remove the test port cap. Be sure that the line pressure is between 5 and 500 psi. If it is higher than 500 psi, see “Collecting a Bottled Sample from a 500–3000 psi Line” on page 85.

2. If dirt is visible, wipe off the outside area with a clean rag.

3. Use a probe-on Samplyzer bottle to flush out at least 30 mL of fluid. Discard the fluid properly.

HPS II

dCAorfCAordVA

dCAorfCAordVA

Low pressure line (5 - 150 psi)

High pressure line (150 - 3500 psi)

test port test port

HPS II

FOR A BOTTLED SAMPLE

Samplyzer Bottle

Samplyzer Bottle

Bench-top ApparatusPortable Pressure Chamber

dCAorfCAordVA

OR

dCAorfCAordVA

High pressure line (500 - 3500 psi)

Low pressure line (5 - 500 psi)

test port test port

page 87 page 34page 85

page 88

page 84

page 88

Collecting Fluid Samples


4. Obtain a clean Samplyzer bottle and open the vent hole on the cap.

5. Attach the probe end of the sampling tube to the test port. Fluid enters the bottle. Allow the bottle to fill up to the Fill line, which is about 75% full. Make sure you leave ullage at the top of the bottle to allow for re-agitation of the bottle prior to testing.

6. Pull the tube from the valve to disconnect it.

7. Remove the tube from the bottle and quickly seal both holes in the bottle with the snap cover provided.

Collecting a Bottled Sample from a 500–3000 psi Line You use your High Pressure Sampler II to obtain a bottle sample from a higher pressure line. The exact adjustment of your HPS II may vary depending on your configuration. The most important aspect of using the HPS II is checking the pressure and adjusting it to a pressure at which you can probe on to the HPS II safely.


FILL RANGE

test port valve

Samplyzer bottle

vent hole

sampling tube

snap cover

flow

probe end



WARNING: Failure to follow proper procedures can lead to injury. Take precautions when operating around any high pressure fluids as they can be dangerous.

1. Check the pressure at the test port with a gauge to make sure it is less than 3000 psi.

2. Make sure that the regulator on the HPS II is fully off or decreased (turned all the way counterclockwise) before using the HPS II.

3. Thread the bottom of the HPS II directly onto the test port valve on the system.

4. Adjust the HPS II to 60 psi by turning the regulator clockwise slowly (increase) and reading the gauge attached to the HPS II.

5. Flush the test port on the HPS II into a waste container or flushing bottle for 5–10 seconds.

6. Obtain a clean Samplyzer bottle and open the vent hole on the cap.

7. Attach the probe end of the sampling tube to the HPS II. Fluid enters the bottle. Allow the bottle to fill up to the Fill line, which is about 75% full. Make sure you leave ullage at the top of the bottle to allow for re-agitation of the bottle prior to testing.

8. Pull the sampling tube off to disconnect it from the HPS II.

9. Remove the tube from the bottle and quickly seal both holes in the bottle with the snap cover provided.

10. When the sample collection is complete, turn the HPS II completely off by turning it all the way counterclockwise (decrease).

11. Bleed the remaining pressure in the HPS II off into a waste container or flushing bottle. The remaining amount should be less than 2–3 mL.

12. Remove the HPS II from the test port.

Note: Refer also to ISO standard 4021 NFPA/T2.9.1-1972 or ANSI/B93.19M-1972, “Extraction of Fluid Samples from Lines of an Operating System,” and ANSI standard B93.44-1978, “Method for Extracting Fluid Samples from a Reservoir of an Operating Hydraulic Fluid Power System.”

INCREASE

DE C R EA SE

FILL RANGE

Samplyzer bottle

High Pressure Sampler II

test port valve

flow

probe end

sampling tube

gauge

Using the High Pressure Sampler II (HPS II)


Agitating the Bottled SampleShake the calibration validation fluid vigorously for a minimum of five minutes to homogeneously suspend all particles. If a paint shaker is not available, manually shake vigorously, occasionally hitting the bottle against the palm of your hand. Agitation is extremely important to the accuracy of the oil analysis instruments. Unless you can suspend the particles or mix the fluid properly to simulate the true fluid environment, you cannot expect to get consistent or accurate readings.

Using the High Pressure Sampler II (HPS II)The High Pressure Sampler II (HPS II) can be used when the pressure level at the test port on the hydraulic or lubrication system is 120–3000 psi. The exact adjustment of your HPS II may vary depending on your configuration. The most important aspect of using the HPS II is checking the pressure and adjusting it to a pressure at which you can probe on to the HPS II safely.

WARNING: You must read this section carefully before performing a high pressure test, as the information is crucial to the safe operation of the HPS II. Take precautions when operating around any high pressure fluids as they can be dangerous.

1. Check the pressure at the test port with a gauge to make sure it is less than 3000 psi.

2. Make sure that the regulator on the HPS II is fully off or decreased (turned all the way counterclockwise).

3. Thread the bottom of the HPS II directly onto the test port valve on the system.

4. Adjust the HPS II to 60 psi by turning the regulator clockwise slowly (increase) and reading the gauge attached to the HPS II.

5. Flush the test port on the HPS II into a waste container or flushing bottle for 5–10 seconds.

6. Attach the sensor to the HPS II and run the test as described in Chapter 9 “Collecting Data”.

flow

test port valve

INCREASE

DEC RE ASE

High Pressure Sampler II

gauge

regulator



7. When the tests are complete, turn the HPS II completely off by turning the regulator all the way counterclockwise (decrease).

8. Bleed the remaining pressure off into a waste container or flushing bottle. The remaining amount should be less than 2–3 mL.

9. Remove the HPS II from the test port.

Using the Portable Pressure ChamberThe portable pressure chamber is designed for occasional, single-bottle testing of hydraulic and lubricant fluid. If more frequent testing is required, a bench-top apparatus can assist in providing faster sample processing. See “Using the Bench-Top Apparatus” on page 88. In order to pressurize the portable pressure chamber you will need an air supply with pressure between 40 psi and 80 psi or a hand-operated air pump and a pressure gauge.


1. Open the pressure chamber by unscrewing and removing the lid.

2. Shake the bottled fluid sample vigorously for a minimum of five minutes to homogeneously suspend all particles. If a paint shaker is not available, manually shake vigorously, occasionally hitting the bottle against the palm of your hand.

3. Open the sample bottle and place the bottle inside the pressure chamber.

Note: Do not pour the sample fluid directly into the pressure chamber.

4. Hand-tighten the pressure chamber lid, making sure that the plastic tube on the bottom of the pressure chamber lid goes into the bottle sample.

5. Pressurize the chamber to a minimum of 40–50 psi by using the hand pump or air supply hose. You can check the pressure by probing on to the test port on the chamber with a pressure gauge.

6. Flush the test port located on top of the chamber lid by connecting a flushing bottle and letting the fluid flow for approximately one second. This cleans the plastic tube inside the chamber and prepares it for a test.

7. Probe on to the top of the pressure chamber with the sensor and follow the instructions for “Collecting List Data” on page 126. You can backflush the fluid in the sensor into a waste container or flushing bottle.

Using the Bench-Top ApparatusYou can use the bench-top apparatus for quickly processing multiple samples. One of the functions of the bench-top apparatus is to provide air pressure to run tests with the sensor on bottle samples. The air pressure also allows you to automatically backflush the sensor. The waste oil line directs the backflushed fluid to a waste oil container.

Because the unit has two pressure chambers, two sensors can be used at the same time or one chamber can be used for flushing or drawing up clean fluid while the other is used for testing.

The bench-top apparatus requires an air supply with pressure between 80 psi and 120 psi.

Using the Bench-Top Apparatus


Release any water from the bench-top apparatus air line filter once a month. You can release the water by gently pushing or pulling the black rubber hose at the bottom of the filter.

Note: Do not open a sample bottle until you are ready to take a test. Be careful not to allow accidental entry of environmental contaminants into the sample fluid. After collecting a bottled sample, you must shake it before you can perform your tests in the lab using the bench-top apparatus. See “Agitating the Bottled Sample” on page 87.

The general specifications of the bench-top apparatus follow.

Recommended Supply Air Pressure

80–120 psi

Recommended Pressure Regulator Setting

60 psi for the dCA and fCA50 psi for the dVA

Maximum Pressure for Pressure Chambers

Maximum 120 psi

Supply Air Filter Rating

5 microns

Fluid Compatibility

Standard unit can test all fluids compatible with standard Viton seals. An EPR version of the unit is also available.



The following diagram shows the basic parts of the bench-top apparatus. Follow the instructions below to use the bench-top apparatus.

1. Place the loose end of the disposal hose into a waste oil container. The disposal hose is rolled up and attached to the back of the bench-top apparatus.

2. Attach the air supply to the air filter quick-connect fitting on the back of the bench-top apparatus.

3. Adjust the pressure regulator to between 80 and 120 psi, which is recommended for higher viscosity fluids. The higher the pressure, the shorter the test cycle.

4. Depressurize the pressure chambers by making sure the pressure control knob points upwards to the RELEASE position.

Note: To speed up your test time, use one pressure chamber exclusively for tests and one for flushing the sensor with clean fluid.

PRESSURE

pressure chambers

p ressure regulator

flushing hose

pressure control knobs

backflush stand

backflush knobPRESSUREREGULATOR

RETRACT

FLUSH

RELEASE RELEASE

pressure gauge

pressure hose

Enpac holder

Using the Bench-Top Apparatus


5. Open the pressure chamber by unscrewing and removing the lid.

6. Shake the bottled fluid sample vigorously for a minimum of five minutes to homogeneously suspend all particles. If a paint shaker is not available, manually shake vigorously, occasionally hitting the bottle against the palm of your hand.

7. Open the sample bottle and place the bottle inside the chamber. Do not pour the sample fluid directly into the pressure chamber.

8. Hand-tighten the pressure chamber lid, making sure that the plastic tube on the bottom of the pressure chamber lid goes into the bottle sample.

9. Pressurize the chamber by turning the pressure control knob located behind the pressure chamber counterclockwise until the arrow on the knob points down to the PRESSURE position.

10. Flush the test port located on top of the chamber lid by connecting the flushing hose and letting the fluid flow for approximately one second. This clears the plastic tube inside the chamber and prepares it for a test.

11. Probe on to the top of the pressure chamber and follow the instructions for your particular sensor. See “Collecting List Data” on page 126.

12. When the measurement is collected, backflush the sensor fluid into the test port on the backflush stand. Backflush the sensor by disconnecting it from the test port and placing it in the automatic backflushing rig with the black knob up. The sensor connects to the backflush valve through the opening on the bottom of the fixture.

13. Turn the backflush knob, located behind the backflushing rig, to the FLUSH position. The backflush piston pneumatically pushes the sensor knob, backflushing the sensor.

14. After backflushing, turn the backflush knob to the RETRACT position. If the knob does not return all the way (more than 1/8" of rod shaft showing), use the backwash procedure. See “Backflushing the dCA Sensor” on page 36.


Chapter 7

7. Setting Up Measurements

This chapter describes setting up measurement definitions in Enlube™ Proaction® Manager (Enlube PM), or EMONITOR Odyssey, or Enshare, for use with the oil analysis system. It includes the following sections:

Overview of Setting Up Measurements ............................................... 94

Measurement Definition Options ........................................................ 94

Setting Up Measurement Definitions................................................. 101

Setting Up Alarms, Lists, and Inspection Codes ............................... 104


Chapter 7 - Setting Up Measurements

Overview of Setting Up MeasurementsThe topics in this chapter describe setting up measurement definitions in the host software when using the dCA, fCA, or dVA.

This section discusses process measurements and the units used for oil analysis to help you set up measurements in the host software. The topics discussed also include setting up alarms and lists, and how to use inspection codes. For more general information about measurement definitions, alarms, lists, and inspection codes, refer to the printed or online host software User’s Guide.

Measurement Definition Options These topics describe the available selections for setting up measurement definitions. You determine these selections with the Set Active Collectors command from the Tools menu in the host software.

Note: Unlike the fCA, the dVA is separate from the dCA in the host software. You may want to choose the dVA as the active collector if that is your only sensor.

Note: If no data collectors are active, the selections that appear in the Measurement Definition pane are the ones available to ALL data collectors. If only the dCA is active, then only the valid choices for the dCA appear in the lists. If the dCA and other data collectors are active at the same time, you see the selections that are common to all data collectors that are active. Therefore, you may not see all the selections available for the dCA.

Measurement Types The host software and the oil analysis systems support only the process measurement definition type. Process measurements are also called process points, and are single measurements that indicate the general condition of the process or equipment. Each reading of particle count or viscosity using the dCA or dVA is a single measurement.

The active collectors you select with the Set Active Collectors command from the Tools menu determine which measurement types are available to you. If you have active collectors selected that do not support process measurements, the process measurement type may not be available to you.

Measurement Definition Options


Measurement Units The host software and the Enpac Oil support many different measurement units. The measurement units defined for the Enpac Oil include both ISO and NAS code, percent ferrous, ferrous particle counts, particle counts for certain particle sizes, and viscosity. This section discusses the different measurement units for the Enpac Oil.

In oil analysis, the ISO code is a convenient method for representing particle counts and is used by most oil analysis laboratories and maintenance organizations. Tables assign codes based on number of particles per milliliter. The table used for ISO codes shows that as the ISO numbers get higher the contamination levels double. Therefore an oil with an ISO Code of 17/14 is twice as dirty as an oil with an ISO Code of 16/13.

Another cleanliness code used as a measurement unit in the host software is NAS code, a National Aerospace Society cleanliness code developed in 1964. It represents cleanliness values over a range of particle sizes.

Particle counts are also used as a measure. Particle counts are based on the concentration of particles greater than or equal to a certain size, measured in microns.



In the host software, there are several choices for specifying measurement units you wish to use. The following table defines each unit.

Note: Particle counts in excess of 50 microns may not maintain consistency between readings due to limitations of the dCA sensor. Therefore, data analysis using the measurement types PC>=50, PC>=100, NAS 50-100, and NAS>100 may not yield consistent results.

Measurement Input TypeThe following input types are used with EMONITOR Odyssey or Enshare.

z Hydraulic 5 - Use with 5 micron sensor screen when testing hydraulic fluid.



z Lubricant 5 - Use with 5 micron sensor screen when testing lubricant fluid.

z Lubricant 10 - Use with10 micron sensor screen when testing lubricant fluid.

z Lubricant 15 - Use with 15 micron sensor screen when testing lubricant fluid.

Input types are not needed for the dVA.

UNITS Measurement represents

PC>=2 count of particles greater than or equal to 2 microns









ISO - 2 ISO cleanliness values for particles greater than 2 microns



NAS 5-15 NAS cleanliness values for particles ranging from 5 to 15 microns




NAS > 100 NAS cleanliness values for particles greater than 100 microns

FP > 10um count of ferrous particles greater than 10 microns

% Ferrous percent of ferrous particles as a function of total particle count

cSt@40C kinematic viscosity in centistokes

cP@25C absolute viscosity in centipoise

Setting Up the Lubricant Specifications and Categories


Setting Up the Lubricant Specifications and CategoriesIn the host software, a lubricant library is available to you so that you can enter information from the manufacturer and compare collected values to the new oil specifications when using the dVA and the Enpac Oil or Oil Sensor Interface. For viscosity measurements, the lubricant library must be set up correctly and the correct Category must be used in order for the measurement definitions to load and unload correctly. This section shows you how to set up your lubricant library and categories so that viscosity measurements can be compared to new oil specifications in the dVA.

When you set up a new Lubricant Specification, it automatically creates a new Category. You can choose that category when you set up your measurement locations. This shows an example using the demo database.

The viscosity information for that lubricant is loaded to the dVA for comparison to the test oil. This is an improved method over entering the information in the Description column, which was used with previous versions of EMONITOR Odyssey and Enshare.

The valid ranges for each viscosity value are as follows:

Specific Gravity 0.500–1.200 You can enter decimal places in this field. The values that are loaded to the Enpac Oil are rounded to three decimal places.

cSt@40C 1–5000 cSt You can enter decimal places in this field. The values that are loaded to the Enpac Oil contain five characters, including the decimal. So, if you enter 456.123, the value loaded to the Enpac Oil is: 456.12.

cSt@100C 1–the cSt@40C value If you try to enter a number that is higher than the cSt@40C value, an error message appears. You can enter decimal places in this field. The values that are loaded to the Enpac Oil contain five characters, including the decimal. So, if you enter 456.123, the value loaded to the Enpac Oil is: 456.12.

The viscosity ranges for the dVA fall into two ranges, low and high. The low range is from 0 to 460 cSt. The high range is from 460 cSt to 9999 cP. The reason for having the upper limit in cP instead of cSt is the cSt upper limit is determined by dividing the cP viscosity value by the specific gravity you enter. To determine your upper limit in cSt, divide 9999 by the test specific gravity and the result is the upper cSt limit.



Adding Lubricants to the Lubricant LibraryYou should gather all the new oil specifications for viscosity for each of your lubricants from the manufacturers, then enter it in the lubricant library. Here are the steps for adding new lubricant specifications to the lubricant library.

1. From the Setup menu, choose Lubricants .

2. To define a new Lubricant Specification, choose New. The following dialog box appears.

3. Enter the Name of the lubricant, the cSt@40C, the cSt@100C, and the Specific Gravity . These are the required fields, and these fields are loaded to the Enpac Oil to compare to tested values with the dVA. To use these specifications, choose the lubricant name in the Category column when you set up the measurements. Press F1 for a description of all the fields in the dialog box.

4. When you have entered all needed information, choose OK . The new lubricant will be added to the list of lubricant specifications.

Setting Up the Lubricant Specifications and Categories


Using the Viscosity CalculatorYou can use the viscosity calculator to determine the viscosity of the lubricant at any given temperature based on the specific gravity, cSt@40C and cSt@100C values. To use the viscosity calculator, follow these steps.

1. From the Setup menu, choose Lubricants .

2. Choose New or Edit to open the dialog box that contains the viscosity calculator. The following dialog box appears. The viscosity calculator is located at the bottom of the dialog box.



3. Enter the cSt@40C value, the cSt@100C value, and the Specific Gravity value.

4. Under Viscosity calculator, enter the target temperature for which you want to know the viscosity.

5. Choose Calculate. The viscosity value appears next to the cSt label as shown below.

Setting Up Categories for AlarmsYou can use either the lubricant description or a category to set up alarm levels in the host software. These alarm levels can be applied for all measurement locations that use a particular category.

Category variables allow you to have much greater control over alarms in the host software. These variables allow you to change the level of one or more alarms for an entire equipment category by changing the value of the variable only once.

For example, assume that you have set up constant alarms for process measurement definitions for thirty identical gearboxes. Initially, you decide to use a value of 400 PC >=10 for your warning alarm, and 450 PC>=10 for your danger alarm. Assume you use the same Gearbox category for all locations for the gearboxes.

After using the host software for several months, you discover that the constant alarm levels are too high. You decide to adjust them to set the warning alarm at 350 PC>=10 and the danger alarm at 400 PC>=10. If you did not use category variables, you would have to change the alarm levels for each of the magnitude constant alarms for each gearbox. This could take a significant amount of time.

Suppose, instead, you used the category variable LO ALARM1 for the warning alarm value, and HI ALARM1 for the danger alarm value. You could then simply change the values for the category variables LO ALARM1 and HI ALARM1 in the Gearbox category for matching Units (PC>=10 units). The host software then automatically changes all alarms in that category that use the LO ALARM1 and HI ALARM1 category variables for measurement definitions with that unit.

Setting Up Measurement Definitions


It is important to note that you must use the correct units for the category when changing category variables. The host software only changes alarms for measurement definitions in that category that match the units.

To set the value for a category variableHint: The easiest way to edit a category variable is to right-click the category in the location pane

and choose Edit . You can also right-click the alarm definition in the alarm pane and choose Category.

1. From the Setup menu choose the Category command.

2. Select the category, and then choose Edit . If you need to create a new category, or add a new unit, refer to your host software manual.

3. Enter the category variables for the first unit in the Category Variables table in the Edit Category dialog box. You only need to fill in the category variables you will be using in the host software. However, if you use a category variable in an alarm and do not give it a value, the host software ignores the alarm.

4. Choose Next Unit and repeat step 3 for each unit in the category.

There are two things to note about category variables:

z The value of a category variable depends on the combination of category you select for the location, and the unit you select for the measurement definition.

z You do not have to choose the Generate Alarm Statistics command from the Tools menu after you change the value of a category variable. The category variables are not part of the alarm statistics generated by the host software.

Setting Up Measurement Definitions The topics in this section describe setting up measurement definitions in the host software for this data collector. This section describes the way the host software works with your data collector for process measurement definitions. For more general information on setting up measurement definitions, consult the printed or online User’s Guide.

Enter the categoryvariable values for

the currentunit

Choose Next Unitto edit categoryvariables for the

next unit



Because the Enpac Oil is used solely for oil analysis, process measurements are the applicable choice for measurement definition. Each reading of particle count, ferrous count, or viscosity using the Enpac Oil is a single measurement.

Setting Up Measurement Definitions for the dCA for Particle CountThe following figure shows typical process measurement definitions for the Enpac Oil using the dCA sensor to measure particle count. It shows a portion of a Measurement Definition pane in the host software with three common measurement units:

z ISO - 5 with a 10 micron sensor screen for testing lubricant fluid


z PC>=10 using a 10 micron screen for testing lubricant fluid.

Each measurement definition represents a single point in your list. When the collection specification and location match for a particular measurement definition, the Enpac Oil will collect data only once. The host software then calculates each point in the correct units.

Other common measurement definitions include:

z ISO - 5 with a 10 micron sensor screen for testing hydraulic fluid


z PC >=10 with a 10 micron sensor screen for testing hydraulic fluid

z PC >=15 with a 10 micron sensor screen for testing lubricant fluid




The following figure shows the Collection Specification dialog box which corresponds to the COLLECTION column in the Measurement Definition pane.

Note: The host software does not automatically include a 5 micron collection specification for lubricant or hydraulic fluid. If you would like to create a collection specification for 5 micron particle size counts on lubricant fluid, choose Copy and change the name and sensor option to Lubricant 5 u. See the printed or online User’s Guide for more detailed instructions.

Setting Up Measurement Definitions


The sensor specifications are:

Setting Up Measurement Definitions with the fCA for Ferrous Count The following figure shows typical process measurement definitions for the Enpac Oil using the fCA sensor so that you can measure ferrous particle count. Because the fCA measurement is in addition to the dCA measurement, the host software treats the measurement as an add-on to the dCA measurement with the same collection specification.

This example shows a portion of a Measurement Definition pane in the host software with two common measurement units:

z FP > 10 um with a 10 micron sensor screen testing lubricant fluid

z % Ferrous with a 10 micron sensor screen testing lubricant fluid

Each measurement definition represents a single point in your list. When the collection specification and location match for a particular measurement definition, the Enpac Oil collects data only once. The host software then calculates each point in the correct units.

Setting Up Measurement Definitions with the dVA for ViscosityThe following figure shows typical process measurement definitions for the Enpac Oil using the dVA sensor to measure viscosity. It shows a portion of a measurement definition pane in host software with three common measurement units:

z cSt@40C - kinematic viscosity in centistokes testing lubricant fluid

z cP@25C - absolute viscosity in centipoise testing lubricant fluid

Note: Unlike the fCA, the dVA is separate from the dCA in host software. You may want to choose the dVA as the active collector if that is your primary sensor.

Each measurement definition represents a single point in your list. When the collection specification and location match for a particular measurement definition, the Enpac Oil collects data only once. The host software then calculates each point in the correct units.

Name Base Unit Units DC Offset

Lubricant 10 u none none N/A

Lubricant 15 u none none N/A

Hydraulic 10 u none none N/A

Hydraulic 15 u none none N/A



With dVA measurements, you can compare clean oil specifications to your measurements. The host software can do this for you if you add the oil specification to the Lubricant Library. To do so, follow these steps.

1. In the host software, choose Lubricant Library from the Setup menu.

2. Enter a name for the lubricant. Enter the viscosity and specific gravity values for the lubricant.

The valid ranges for each value are:

Specific Gravity 0.500–1.200Viscosity at 40 1–5000 cStViscosity at 100 must be less than the “Viscosity at 40” value in cSt

Note: The V100 value must be less than the V40 value. If you enter any of the values incorrectly, the host software loads the default values. The default values are 0.85 for specific gravity, 60 cSt for V40, and 9 cSt for V100.

Setting Up Alarms, Lists, and Inspection CodesThe topics in this section describe the way the host software loads alarms and lists and how it handles inspection codes in the Enpac Oil. The alarms, or target values, are included with the list of measurement definitions. This topic lists the unique characteristics of the Enpac Oil that you need to know when setting up and collecting data. For more information on alarms, lists, and inspection codes, see the printed or online User’s Guide.

Alarms and the Data CollectorThis topic lists the unique characteristics of the Enpac Oil that you may need to know when setting up and collecting data.

Alarms in the host software are represented as target values in the Enpac Oil. An example of the displayed target value is shown below.

If your data is above the alarm value set in the host software, the Enpac Oil displays a message asking if you would like to run an fCA test in addition to your dCA test.

If you wish to collect fCA data at this point, choose Yes. You can collect the fCA data, then return to your regular list.

Setting Up Alarms, Lists, and Inspection Codes


Selecting alarms to load to the Enpac Oilz Set Trigger to Yes in the Alarm spreadsheet pane to activate an alarm so it loads to the

data collector with a measurement definition.

z Only one alarm is downloaded per measurement definition, so if you set Trigger to Yes for more than one alarm, the host software chooses the most restrictive alarm.

Supported alarms with the Enpac OilMany data collectors cannot handle the complexity of alarms available in the host software. The Enpac Oil allows you to use a single alarm per process measurement definition. You can set up multiple alarms in the host software to help you monitor your data. The Enpac Oil only loads the most severe alarm.

The host software does two things when loading and unloading lists with alarms:

1. Simplifies the alarms using the most conservative combination to create an alarm within the ability of the data collector. This means that the data collector may indicate that a measurement exceeds an alarm when in fact the measurement is not in alarm.

2. Tests the measurements against the alarms when you unload the data collector. This means that the host software always accurately indicates when a measurement is in alarm, regardless of the number or complexity of the alarm(s). This is true for all active alarms, regardless of their trigger status.

Lists and the Data CollectorThe host software and the Enpac Oil support loading lists of measurement definitions, called routes in the Enpac Oil. The order of measurements in the list is the same in the Enpac Oil as it is in the host software. You can only load one list at a time to the data collector.

Note: Because the dCA and dVA are separate drivers, you must set up separate lists for each sensor type. A list can be for the dCA, or for the fCA/dCA, or for the dVA.

Loading listsNote: A list is called a route in the Enpac Oil.

You can load one list at a time to the data collector. However, if you select more than one list in the Load/Unload dialog box, the host software combines the two lists and asks you to save it under a new list name. The Enpac Oil can store up to 200 points from a list. You must delete the list in the Enpac Oil before you can load a new list.

Deleting listsThe data collector automatically deletes the list once it is uploaded to the host software. The Enpac Oil displays a screen to ask you “Was dCA data unload successful (Y/N)?” Pressing <Y> to answer yes deletes the list data. Pressing <N> to answer no allows you to return to view the data on the Enpac Oil again without deleting the data file.

Note: Before pressing <Y> for yes, you can run an unload report in the host software to verify that the unload was successful, or simply check a few measurements in your data history archive. See your online or printed User’s Guide for more information.

You can also manually delete the data file. See “Deleting or Resetting Lists in the Data Collector” on page 113.



Inspection Codes and the Data CollectorYou can use the Enpac Oil to record inspection codes by entering them in the Comments section as you collect data.The comment section appears after you have saved sample data. You can enter up to 17 characters in this field, then press <ENTER>. The comments section is unloaded with your data and the host software saves it as an inspection code.

However, the inspection codes in the host software are not loaded to the data collector when you load a list. Instead, you can carry a written record of your inspection codes with you on your route. You can then use the letter keys to enter information in the comment section.

For example, if you detect an abnormal noise from a machine while taking an oil sample, you may want to record that in the comments section as an inspection code. You can use the letter keys on the Enpac Oil to type ABNORMAL TEMP.

Inspection codes also appear as text on your trend plots in the host software. The host software displays exactly what was typed in the Enpac Oil.

Comment section


Chapter 8

8. Loading and Unloading

This chapter describes loading and unloading operations with the host software and the Enpac Oil data collector. It includes the following sections:

Overview of Loading and Unloading ................................................ 108

Setting Up for Communication.......................................................... 109

Loading Lists to the Data Collector ................................................... 113

Unloading a List from the Data Collector ......................................... 116

Transferring Individual Files from your Computer to the Enpac Oil 118


Chapter 8 - Loading and Unloading

Overview of Loading and UnloadingThe topics in this chapter describe using the Enpac Oil with the host software for loading and unloading lists. It covers information about setting up to load and unload your data collector. These tasks require setting communication options in both the host software and the data collector. Topics include:

z Setting communication options

z Connecting the data collector and the computer

z Loading lists to the data collector, including preparing the data collector and selecting load options

z Unloading data from the data collector, including preparing the data collector and selecting the unload options

You perform all the above functions from the Load/Unload dialog box in the host software. To display the Load/Unload dialog box, choose the Load/Unload command from the Tools menu.

For all connections with the Enpac Oil, you must use the COM cable that comes with the Enpac Oil. This cable is specially designed for communications with the Enpac Oil.

For information on collecting data with your data collector, see Chapter 9 “Collecting Data”. For more information about loading lists and the Load/Unload dialog box, see the printed or online User’s Guide.

Setting Up for Communication


Setting Up for CommunicationThe topics in this section lead you through setting up for communication both in the host software and in your data collector. These steps include preparing the host software for communication, selecting the dCA as the data collector, setting up the Enpac Oil for communication, and finally, connecting the data collector and the computer.

Many of the steps in this section are completed through the Load/Unload dialog box. You use the Set Up Collector button and Set Up Computer button to set up the Enpac Oil and computer for communication.

Preparing the Host Software for CommunicationTo prepare the host software for communication with the Enpac Oil, you select the computer communication options, then select the data collector communication options.

To set up the host software for communicationOnce you select the communication options, you should not have to change them again unless you change your computer hardware.

Or click1. Choose the Load/Unload command from the Tools menu.

The Load/Unload dialog box appears.

2. Choose the large Set Up Computer button in the Load/Unload dialog box. The Set Up Computer dialog box appears.

3. Select the correct COM port for your Communications Device.

4. Choose OK to close the Set Up Computer dialog box.

To select the current data collectorYou can have several active data collectors in the host software, but only one current data collector at a time. Before you can communicate with a data collector, you must select it as the current data collector.



An icon of the dCA or dVA indicates whether the selected driver is the dCA or the dVA. The dCA and dVA are separate route files on the Enpac Oil. Make sure that the correct name appears below the Set Up Collector button.

Note: Because the dCA and dVA are different drivers, you must create and load different lists for each type of sensor.

If you need to select the current collector, follow these steps to make the correct sensor the current data collector.



2. Choose the large Set Up Collector button in the Load/Unload dialog box. The Set Up Data Collectors dialog box appears.

3. The word Yes appears in the Current column next to the name of the current data collector. Select the current data collector, the dCA or the dVA, by doing either one of the following:

z Double click in the Current column for the desired data collector to change the value to Yes. The previously selected collector automatically changes to No.

z Use the arrow keys to move the spreadsheet cursor to the Current column for the desired data collector. Press Enter to change the value to Yes. The previously selected collector automatically changes to No.

4. Choose OK to close the Set Up Data Collectors dialog box.

To select the correct communication settings in the host software



2. Make sure an icon of the Enpac Oil appears in the Set Up Collector button and the correct sensor is below the button, such as [dCA] or [dVA]. If not, see “Preparing the Host Software for Communication” on page 109.

3. Choose the Set Up Collector button. The Set Up Data Collectors dialog box appears.

4. Select the Baud column in the DCA row to set the Baud rate to the same rate you selected in the Enpac Oil. See “Selecting the Correct Communication Settings in the Enpac Oil” on page 111 if you need to check or change the baud rate in the Enpac Oil.

5. Select the Protocol column to set the Protocol to N81 by choosing N81 from the pull down menu.

6. Choose OK to close the Set Up Data Collectors dialog box.

Setting Up for Communication


Setting Up the Data Collector for CommunicationThe baud rate set in the host software must match the baud rate set in the data collector in order to communicate properly. This section describes how to check and change the baud rate in the Enpac Oil. You must set these options if any of the following are true:

z This is the first time you are using the Enpac Oil with the host software.

z Someone reloads the Enpac Oil operating system.

z Someone changes the baud rate.

Selecting the Correct Communication Settings in the Enpac Oil1. Turn the data collector on. Press <Escape> until you return to the Enpac Oil Main

Menu if necessary.

2. Choose [1] dCA Only from the Enpac Oil Main Menu. The dCA Main Menu appears.

3. Choose [6] Utilities.

4. Choose [3] Set Up Baud Rate. Use the arrow keys to select the baud rate you want. For example, press the down arrow for a baud rate of 38400, if 19200 is selected.

5. Choose <F4> OK to save the baud rate change.



Connecting the Data Collector and ComputerIn order to load and unload data from the Enpac Oil, you connect the Enpac Oil to a COM communication port in the back of your computer. Use the communications cable supplied with the Enpac Oil, which can be extended with a standard RS-232-C cable.

1. Locate the COM serial port on the back of your computer and insert the connector into it. Tighten the thumbscrews to ensure a reliable connection.

2. Insert the other end of the cable into the port on the Enpac Oil and tighten the thumbscrews. Consult the diagram if needed.

The following is a diagram of the hardware connection:

Loading Lists to the Data Collector


Loading Lists to the Data CollectorAfter you connect the data collector to the computer, you can load a list to the data collector by selecting the load options, selecting the list, and clicking on the Load button in the host software.

For more information on loading lists, load options, and the Load/Unload dialog box, see the printed or online User’s Guide.

Preparing the Data Collector for LoadingThe menu choice you make for loading and unloading the data collector depends on the type of sensor you will use.

1. Make sure you have correctly connected the data collector to the computer. See “Connecting the Data Collector and Computer” on page 112.

2. Turn the data collector on.

3. Press <Escape> to return to the Main Menu if necessary.

4. Choose the sensor type you will use for the list. If you are loading a list for the dCA, choose [1] dCA Only. If you are loading a list for the fCA, choose [2] dCA - fCA. If you are loading a list for the dVA, choose [3] dVA. The main menu for that sensor appears.

5. Choose Connect to PC by pressing the correct number key. The Communications screen appears.

The data collector is ready to receive a list. See “Loading Lists to the Data Collector” on page 114 to load a list. If you wish to cancel, press <Escape>.

Deleting or Resetting Lists in the Data CollectorIf data already exists in the data collector but you do not need it anymore, you can erase the data manually. If you are trying to load a new list with another list already loaded to the Enpac Oil, you must erase the old data first. You may either unload or delete the data. Check to make sure that you no longer need the data before deleting it. To delete just the data, but keep the list, you can reset the list.



Caution: Deleting and resetting the list erases the existing data. Be sure that you no longer need the data before deleting it.

1. Turn the data collector on. Press <Escape> until you return to the Main Menu if necessary.

2. Choose [1] dCA Only or [3] dVA from the Main Menu, depending on which type of data you want to delete. The dCA or dVA Main Menu appears.

3. Choose [6] Utilities from the Main Menu. The Utilities Menu appears.

4. To reset the list, clearing the data but keeping the list, choose [1] Reset dCA List. To delete the list and the data, choose [2] Delete dCA List from the Utilities Menu. A warning screen appears.

5. Choose Yes to delete the data or the list.

Note: Note that dCA data and fCA data are combined, so if you delete dCA data you are also deleting fCA data.

Selecting the List(s)The host software and the Enpac Oil support loading one list at a time, but the host software can combine lists so you may select more than one list to load.

The data collector has a storage capacity of 200 measurement definitions in a list. If a single or combined list has more than 200 total data points you might not be able to load the list.

Note that you cannot load a list if there is already a list in the Enpac Oil. If you want to reload a list, you must first delete the list in the data collector. See “Deleting or Resetting Lists in the Data Collector” on page 113.

Note: Because the dCA and dVA lists are separate files, you must create and load separate lists for each type of sensor.

Selected lists appear in inverse text. If you select more than one list, then try to load it, the host software combines the two lists and asks you to save it with a new list name.

Loading Lists to the Data CollectorAfter connecting the Enpac Oil and computer, selecting the correct communication settings, and selecting one or more lists, you are ready to load the data collector. Follow these steps to load your selected lists.

Note: It may take some time for the host software to build load files for large lists. You can save time by using Quickload lists and using the Update Quickload Files command from the Tools menu to build the load files when you are not using the computer. For more information on Quickload lists, see the printed or online User’s Guide.

Loading Lists to the Data Collector




2. Make sure the data collector and the host software are ready to communicate by checking the Enpac Oil display for the Communication screen. If not, see “Preparing the Data Collector for Unloading” on page 116.

3. Select the desired list or lists. If you choose more than one list, the host software asks if you want to combine the lists and saves the lists under a new list name.

4. Choose the Load button in the Load/Unload dialog box.

The following series of events occurs.

The host software builds the load file and shows a progress bar. See the note above if you want to use Quickload lists to save time during the build process. To stop the process, choose the Abort button.

The host software loads the file into the data collector and a second progress bar appears, telling you that it is loading file 1 of 1.

5. When the load is complete, the Enpac Oil displays a status message and the progress bar closes in the host software.

6. Choose Close to close the Load/Unload dialog box.

Displaying the Data Collector Driver Version NumberThe data collector driver is the software that allows the host software to communicate with the Enpac Oil. You can display the data collector driver version number in the host software with the following steps:



2. Make sure the correct data collector appears in the Load / Unload dialog box. If not, see “Preparing the Host Software for Communication” on page 109.

3. Choose the D.C. Functions button in the Options group in the Load / Unload dialog box.

4. Choose the About Data Collector Driver button in the Data Collector Functions dialog box. This displays the driver version number.

5. Choose OK to close the dialog box.

6. Choose Close to close the Data Collector Functions dialog box.

Note: See “Displaying the Operating System Version Number” on page 19 for information on displaying the data collector software version number.



Unloading a List from the Data CollectorOnce you collect list data you can unload it for storage in your host software database by connecting the Enpac Oil and computer and transferring the information. You can unload unscheduled measurements to your host software database at the same time. You can automatically print reports after unloading data from the data collector.

For more information on unloading lists, unload options, and the Load/Unload dialog box, see the printed or online User’s Guide.

Preparing the Data Collector for UnloadingThe menu choice you make for loading and unloading the data collector depends on the type of sensor you use to collect data.

1. Make sure you have correctly connected the data collector to the computer. See “Connecting the Data Collector and Computer” on page 112.

2. Turn the data collector on.

3. Press <Escape> to return to the Enpac Oil Main Menu if necessary.

4. Choose the menu for the sensor type you will use for the list. If you are loading a list for the dCA, choose [1] dCA Only. If you are loading a list for the fCA, choose [2] dCA - fCA. If you are loading a list for the dVA, choose [3] dVA. The main menu for that sensor appears.

5. Choose Connect to PC by pressing the correct number key.

6. The data collector is ready to unload a list. See “Unloading a List in the Host Software” on page 116 to load a list. To cancel, press <Escape> or choose <F2> “Abort.”

Unloading a List in the Host Software



2. Select the desired list. See “Selecting the List(s)” on page 114.

Unloading a List from the Data Collector


3. Choose the Unload button in the Load/Unload dialog box.

The following series of events occurs.

The host software unloads the file from the data collector and shows a progress bar, telling you that it is unloading the file and updating the database.

When the unload is complete, the Enpac Oil displays Status: COMPLETE and the progress bar closes in the host software. The Enpac Oil asks that you confirm that the data unload was successful so that it can delete the list and data file.

4. Before choosing Yes, you can run an unload report in the host software to verify that the unload was successful, or simply check a few measurements in your data history archive by selecting the Data History view in the host software. See your online or printed User’s Guide for more information if needed.

5. Choose Yes if the data was unloaded successfully. Choose No if not, or if you want to view the data on the Enpac Oil again. If you choose No, the data collector does not delete the list. See “Deleting or Resetting Lists in the Data Collector” on page 113 for information on deleting lists in the data collector.

Unloading Unscheduled Data from the Data CollectorUnscheduled measurements are any measurements that are not part of a list. You unload unscheduled measurements from the Load/Unload dialog box.

Note: You must unload unscheduled measurements with a list.

Make sure you have set up the host software to unload the unscheduled measurements automatically when unloading a list.

1. Choose the Unload Options button in the Load/Unload dialog box. The Unload Options dialog box appears.

2. Select the Also Unload Unscheduled Measurements checkbox.


Automatically Printing Reports after UnloadingYou can select reports to automatically send to a printer after unloading data from the Enpac Oil. The reports contain information on the list of measurements unloaded. See the printed or online User’s Guide for more information on printing reports and plots.



2. Make sure the correct data collector appears in the Load/Unload dialog box. If not, see “Preparing the Host Software for Communication” on page 109.

3. Choose the Unload Options button in the Load/Unload dialog box.

4. Select the Auto Reports on Unload checkbox.

5. Select the reports you want the host software to run automatically after unloading data.




Transferring Individual Files from your Computer to the Enpac OilIndividual files can be transferred between the Enpac Oil and a personal computer using Windows CE Services. This transfer is accomplished through the serial port of the personal computer and the communication port on the Enpac Oil.

Sometimes you need to transfer the dVA calibration file from your computer to the Enpac Oil. You can transfer that file using this procedure. Microsoft ActiveSync allows you to connect to the Enpac Oil and view the files contained there.

Downloading and Installing Microsoft ActiveSyncMicrosoft’s mobile device program that allows for file sharing across a serial connection is called ActiveSync. It is available at http://www.microsoft.com/mobile/downloads/files/as-dl.asp?.

If you are running Internet Explorer 4.0 or later1. Download the ActiveSync setup software (3.3 MB) to your PC.

2. Select Run this program from its current location and click OK .

3. Follow the instructions on the screen.

All other browsers1. Download the ActiveSync setup software (3.9 MB) to your PC.

2. Select Save this program to disk and click OK .

3. Store the ActiveSync download file to a new empty folder, creating the new folder and opening it as necessary. Remember the location of the new folder. Click Save.

4. Go to the location where you saved the ActiveSync download file on your computer and double-click the file to unpack all the ActiveSync setup files.

5. Double-click the Setup.exe file and follow the instructions on the screen.

Transferring Individual Files from your Computer to the Enpac Oil


Connecting to the Enpac Oil using ActiveSync1. Double-click the ActiveSync icon in the task bar.

2. From the File menu, choose Connection Settings.

3. Select Allow serial cable or infrared connection to this COM port, then choose the COM port you are connected to from the drop down list. Choose OK .

Note: You must clear this check box when you are loading and unloading using the host software. Otherwise, ActiveSync will always try to connect first.



4. Turn the Enpac Oil on. From the Main Menu, choose [4] Utilities.

5. From the Utilities Main Menu, choose [5] Connect to CE Service. This step is not absolutely necessary because most menu screens allow you to connect using CE services. However, certain dialog boxes may be minimized which effectively causes the Enpac Oil to appear to be locked up.

6. Connect the Enpac Oil to the computer using the serial cable. After a small delay, the ActiveSync icon turns green to indicate it is connecting to the Enpac Oil. When the connection is complete, the New Partnership dialog box appears, as shown below.

7. Choose No, then choose Next.

Transferring Individual Files from your Computer to the Enpac Oil


8. You are now connected to the Enpac Oil as indicated by ActiveSync and the Enpac Oil screen. Now you can transfer files between the computer and the Enpac Oil.

Note: If the connection is dropped by the Enpac Oil due to the unit turning off, you must unplug the serial cable on the Enpac Oil then plug it back in to reconnect.

Transferring Files1. After connecting successfully to the Enpac Oil, go to ActiveSync on your computer.

From the File menu, choose Explore. An Explorer window labeled “Mobile Device” appears, displaying the contents of the Enpac Oil.

2. You can right-click on a file on your hard drive and choose Copy, then paste it into the “Mobile Device” Explorer window.

3. When you have completed all file transfers, press <Escape> on the Enpac Oil and the ActiveSync window will disconnect.

4. Be sure to clear the Allow serial cable or infrared connection to this COM port checkbox in the Connection Settings dialog box in order to load and unload using the host software. Otherwise, ActiveSync will attempt to connect to the Enpac Oil whenever it is plugged into that COM port.


Chapter 9

9. Collecting Data

This chapter includes all the tasks associated with collecting data using the Enpac Oil. This chapter includes the following sections:

Overview of Collecting Data............................................................. 124

Preparing for Data Collection .......................................................... 125

Collecting List Data .......................................................................... 126

Collecting Unscheduled Data ........................................................... 136

Reviewing Collected Data ................................................................. 144


Chapter 9 - Collecting Data

Overview of Collecting Data

WARNING: Failure to follow proper procedures can lead to injury. Review safety warnings before attempting to collect samples or data. Never compromise your personal safety for data collection.

This chapter describes the process of data collection using the Enpac Oil with the attached sensors. To collect data you need a fluid sample. There are several methods for obtaining a fluid sample. Once the sample is prepared, you can attach the sensor to the proper port and collect data. See Chapter 6 “Equipment for Sampling and Testing.” for more detailed information about sampling and testing with the additional apparatus.

To organize your data collection, you can load a list to the data collector using the host software. The Enpac Oil allows you to collect data for points in a list and for unscheduled data (points not defined in a list). Once you collect your list data, you can review the data using the Enpac Oil data display functions and print a report using the Enpac Oil printer.

This chapter covers tasks associated with collecting data. These topics include:

z Collecting data using the Enpac Oil with the dCA

z Showing data in alarm when it exceeds the target value

z Collecting data using the Enpac Oil with the fCA and dCA

z Collecting data using the Enpac Oil with the dVA

z Printing reports after collecting data

When you are finished collecting data, you can unload the data into your computer database files using the host software. See Chapter 8 “Loading and Unloading” for more detailed information about loading a list to the data collector and unloading your data.

Preparing for Data Collection


Preparing for Data CollectionThis section includes tasks you should do every time you collect data, including checking the settings and batteries before taking data. Some of these instructions are found in Chapter 2 “The Enpac Oil.” The items include:

1. Check the batteries in the Enpac Oil. See “Checking Battery Life” on page 16.

2. Check the date and time settings in the data collector. See “Setting the Date and Time” on page 23.

3. Check the settings for the sensor. See “Configuring the dCA” on page 31 for the dCA sensor, and see “Configuring the dVA” on page 60 for the dVA sensor.

Before testing a sample with a dCA sensor, you should always check the Enpac Oil settings for screen size, calibration, and fluid type. Changing these items affects how the data collector analyzes the sample. For example, if you test hydraulic fluid, but the sensor is set for lubrication fluid, your test results will not be accurate. For more details on sensor screen calibration for the dCA sensor, refer to “Calibrating the dCA Sensor Screens” on page 39.

The fCA sensor does not require specific set up in the Enpac Oil because it is an addition to the dCA sensor. You may want to check dCA settings before collecting ferrous data.

Before testing with a dVA sensor, you should check settings for probe number and viscosity ranges. The default units do not affect the data collection process. For more details on configuring the dVA settings, see “Configuring the dVA” on page 60.

Result codes and particle size distribution are two other settings that you might want to check before collecting data. However, these do not affect how the Enpac Oil acquires the data, only how it is reported, so you can change these settings before or after you collect data. You may want to change these while you view the data as well. See “Reviewing Collected Data” on page 144 for more information about viewing data in the Enpac Oil.



Collecting List DataUsing the host software, you can load a list to the data collector to organize your data collection, then collect data for the measurements in the list. Once you have prepared the Enpac Oil and the selected sensor, you are ready to collect data from the sample.

If you need more information about preparing test port valves, refer to “Preparing Test Port Valves for Sampling” on page 81.

You may want to review some of the additional devices used when testing bottled samples. For more information about using the portable pressure chamber, see “Using the Portable Pressure Chamber” on page 88. For more information about using the bench-top apparatus, see “Using the Bench-Top Apparatus” on page 88.

Using the dCA to Collect List Data for Particle CountThe dCA (digital CONTAM-ALERT) tests for particles in fluids, giving a hard particle contamination level in the units selected in the list. For more general information about the dCA, see Chapter 3 “The digital CONTAM-ALERT (dCA).”

To collect list data, you load the Enpac Oil with a list and attach the correct sensor. You probe on to the test port when the TEST CYCLE screen appears.

1. Turn the data collector on. Press <Escape> until you return to the Enpac Oil Main Menu if necessary.


Collecting List Data


3. Choose [2] Route Sample from the dCA Main Menu. The Route Menu appears.

Note: If there is no list loaded in the Enpac Oil, the message “No dCA Route” appears. You must load a list to the data collector before you can collect data using the Route Sample option. See “Loading Lists to the Data Collector” on page 114.

4. Choose <F2> Run Test. The Communications screen appears.

5. Probe on to the test port valve with the dCA sensor. See “Probing On with the dCA” on page 34 for tips. Once connected, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor.

6. When the dCA test is complete, the backflush knob stops moving, and the Enpac Oil begins analyzing the data. Backflush the sensor while the Enpac Oil analyzes the data. See “Backflushing the dCA Sensor” on page 36.

When the data analysis is complete, the Enpac Oil displays the results.

Test results appear in ISO code, NAS code, or > 10 um (number of particles greater than 5, 10, or 15 microns, depending on your Enpac Oil settings. For more details on changing these settings, see “Configuring the dCA” on page 31.

7. To ensure accurate test results, always perform a minimum of two tests and compare the results. Choose <F2> Run Test to perform more tests, repeating steps 4–6.

Note: If the two results vary by more than 10%, perform a third test. If the third result varies by more than 10% in relation to both previous results, you may need to clean the sensor screen. If the third result does not vary more than 5% from one of the previous results, consider the two closest to each other as the correct results and ignore the other result. The result which is farthest from the other two may have occurred due to incorrect operation of the dCA sensor, such as inconsistencies in holding the sensor at the test port valve, or residual contamination in the machine fluid lines.



8. Once you have completed tests with satisfactory results, choose Save. The Save Result screen appears. You can enter a Comment if needed.

9. Choose Save Average if you want to save the average of both results.

10. If your data is above the alarm value set in the host software, the Enpac Oil displays a message that states that it exceeds the target levels.

z If you do not want to do an fCA test at this time, choose No to continue testing with the dCA.

z If you want to perform an fCA test, choose Yes. See “Using the fCA to Collect List Data for Ferrous Count” on page 129.

11. After you save your result, the cursor appears in the Comments field. Enter any comments and press <Enter>. You can enter up to 17 characters. These comments are stored as inspection codes in the host software. See “Entering Inspection Codes” on page 134 for more information.

12. Continue with the route, repeating steps 3–11 until the Enpac Oil screen states, “User route complete!” Press any key to continue and follow instructions for backflushing the sensor. To unload your data to the host software, see Chapter 8 “Loading and Unloading.”



Using the fCA to Collect List Data for Ferrous CountThe fCA (ferrous CONTAM-ALERT) tests for ferro-magnetic particles in hydraulic and lubricant fluids. It is used as an attachment to the dCA. While the dCA measures cumulative hard particle contamination, the fCA identifies how much of that total particle count is ferro-magnetic material. See Chapter 4 “The ferrous CONTAM-ALERT (fCA).” for more general information on the fCA.


2. Choose [2] dCA - fCA from the Enpac Oil Main Menu. The fCA Main Menu appears.

3. Choose [2] Route Sample from the dCA - fCA Main Menu. The Route Menu appears.



Note: If there is no list loaded in the Enpac Oil, the message “No dCA Route” appears. You must load a list to the data collector before you can collect data using the Route Sample option. See “Loading Lists to the Data Collector” on page 114.

4. Choose Run Test by pressing <F2>. The Communications screen appears, and you have 10 seconds to connect the sensor to the test port valve.



7. Take two averages, repeating steps 3–6. After you finish the tests, the fCA OPTION screen appears. Choose Yes.

8. Next, the Save Result screen appears. Choose Save Avg.

9. Next, the Run fCA Test screen appears. Choose Run Test.

10. Probe onto the test port with the fCA. Attach the dCA sensor to the fCA. See “Connecting the fCA” on page 49. Turn the fCA switch to TEST. Once connected, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor.

11. When the fCA test is complete, the backflush knob on the dCA stops moving. Backflush the system while the Enpac Oil displays the data. See “Flushing the fCA” on page 51.

12. To ensure accurate test results, always perform a minimum of two tests and compare the results. Choose Run Test to perform more tests, repeating step 10.



When the data analysis is complete, the Enpac Oil displays the Route Result Menu. Choose Save Result.

13. Choose Save Average. After you save your result, the cursor appears in the Comments field. Press the letter or number keys to type comments and press <Enter>. You can enter up to 17 characters. These comments are stored as inspection codes in the host software. See “Entering Inspection Codes” on page 134 for more information.

14. Continue with the route, repeating these steps until the Enpac Oil screen states, “User route has been completed!” Press <Enter> key to continue and backflush the sensor. To unload your data to the host software, see Chapter 8 “Loading and Unloading.”



Using the dVA to Collect List Data for ViscosityTo collect list data, load the Enpac Oil with a list and attach the correct sensor. You probe on to the test port when the TEST CYCLE screen appears.


2. Choose [3] dVA from the Enpac Oil Main Menu. The dVA Main Menu appears.

3. Choose [3] Route Sample from the dVA Main Menu. The Route Menu appears.

4. If you are testing a low viscosity fluid, choose Low Visc Test. If you are testing a high viscosity fluid, choose High Visc Test, then choose OK. Low viscosity range is from 1 cSt to 460 cSt. High viscosity range is from 460 cSt to 9999 cP. For more information, see “Configuring the dVA” on page 60.

5. Next, choose if you want to compare the test results to new oil specs as defined in the host software. For information on setting up those specifications, see “Setting Up Measurement Definitions with the dVA for Viscosity” on page 103. Choose Yes to compare to loaded oil specs from the host software or No to not compare at all.



6. If you have selected cSt as the measurement unit, you must enter the specific gravity of the test fluid. Press <Enter> after typing in the correct measurement.

7. Next, enter the temperature of the test sample. Press <Enter> after typing in the correct temperature.

8. Next, enter the pressure of the test sample. Press <Enter> after typing in the correct pressure.

9. The Communications screen appears, and you have 10 seconds to connect the sensor to the test port valve.

10. Probe on to the test port valve with the dVA sensor. Once connected, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor.

11. When the dVA test is complete, the backflush knob stops moving. Backflush the sensor when the Enpac Oil displays the data. See “Backflushing the dVA Sensor” on page 68.



When the data analysis is complete, the Enpac Oil displays the Route Result.

Test results appear in cSt or cP, depending on your Enpac Oil settings. For more details on changing these settings, see “Configuring the dVA” on page 60.

Choose the Project option <F3> if you want to project the results to a certain temperature.

12. To ensure accurate test results, always perform a minimum of two tests and compare the results. Choose Run Test to perform more tests, repeating steps 6–11.

13. Once you have completed tests with satisfactory results, choose Save Results. The Save Result screen appears.

14. Choose Save Ave if you want to save the average of both results.

15. After you save your result, the cursor appears in the Comment field. Press the letter or number keys to type comments and press <Enter>. You can enter up to 17 characters. These comments are stored as inspection codes in the host software. See “Entering Inspection Codes” on page 134 for more information.

16. Continue with the route until the Enpac Oil screen states, “User route complete!” Press any key to continue and follow instructions for backflushing the sensor. To unload your data to the host software, see Chapter 8 “Loading and Unloading.”.

Entering Inspection CodesYou enter inspection codes in the comment section after saving data on the Enpac Oil. The information is then unloaded to the host software with your list data for use in reports. Inspection codes let you record operating conditions while collecting data. You can include inspection codes in your reports. Inspection codes can also appear as text on your trend plots in the host software. Follow these instructions to enter inspection codes in the comment field after collecting data.

Once you have selected a Save Result option from the Save Result menu, the cursor enters the Comments: field located at the bottom of the screen. You can enter comments a few different ways.

z To enter letters, press the number keys multiple times until the letter appears.

z To enter numbers, press the number key once.



Choose OK when you have finished typing. To leave the Comment field blank, simply choose OK without typing anything. The Enpac Oil continues to the next point on the list.

For example, if you detect an abnormal noise from a machine while taking an oil sample, you may want to record that in the Comments section as an inspection code. The default inspection code assigned to Abnormal Noise is 7 in the host software. In this example, you would see the number 7 if you typed it in to the Enpac Oil. You would see ABNORMAL NOISE if you typed it in to the Enpac Oil. The host software displays exactly what was typed in the Enpac Oil.

You can also assign inspection codes directly to an item in the Hierarchy Tree or location in the host software. See the printed or online User’s Guide for more information.

Moving through a ListThe Enpac Oil moves through a list in the same order as stored in the host software. Once you collect data, save the result, and enter any comments for a particular point, the Enpac Oil displays the Route Menu for the next point on the screen. Each point follows another until you complete the list.

You can also choose which list point for which you want to collect data. This option allows you to move around within a list. To select a specific list point, follow these steps.

1. From the Main Menu for either dCA or dCA-fCA, choose [2] Route Sample. From the dVA Main Menu, choose [3] Route Sample. The Route Menu appears.

2. On the dCA Route Menu or the dCA-fCA Route Menu, choose Examine Route. On the dVA Route Menu, choose Examine Route. The dVA Route Menu screen appears.

3. Press the arrow keys to scroll up and down until the record you wish to display is on screen, then press the number for that record and press <Enter>. The Route Menu appears with the information from that list point. You can then follow the directions for collecting data for that particular list point.

If you wish to skip a point when collecting list data, choose Skip Point from the Route Menu. See “Skipping Points” on page 136.



Skipping PointsFrom the Route Menu you have the option of skipping a list point. You may want to do this if the machine is down or a sample is not available for that particular list point. To skip a point, follow these steps.

1. When you are at the correct location and point, double check the Equipment Code and Equipment Name fields in the Route Menu to make sure they match the point you wish to skip.

2. From the Route Menu, choose Skip Point. The Skip Point screen appears.

3. In the Reason field, use the letter keys to type in a reason for skipping the point. You can enter up to 17 characters in this field.

Note: For skipped points, the text entered in the Reason field is not unloaded and does not appear as an inspection code in the host software.

4. Press <Enter> when you are finished, and the Enpac Oil continues on the route.

Collecting Unscheduled DataUnscheduled data is additional data you collect that is not part of a list. While collecting samples, you may notice some conditions that you want to analyze further. You may also want to collect data for undefined points (points that are not currently in your database), or existing points that are not in your current list.

Unscheduled measurements are processed into individual measurement points when you unload the data collector, and units are assigned according to the INI file. See “Unscheduled measurements for the dCA” on page 190 in the Appendix for detailed information.


Collecting Unscheduled Data


Using the dCA to Collect Unscheduled Particle Count DataThe Enpac Oil data collector allows you to collect unscheduled data and save the results to unload to the host software. Follow these steps to collect unscheduled data using the dCA sensor.



3. Choose [1] Run dCA from the dCA Main Menu. The Communications screen appears, and you have 10 seconds to connect the sensor to the test port valve.

4. Probe on to the test port valve with the dCA sensor. For information about probing on, see “Probing On with the dCA” on page 34. Once connected, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor.


When the data analysis is complete, the Enpac Oil displays the Result Menu.

Test results appear in ISO code, NAS code, or number of particles greater than 5, 10, or 15 microns, depending on your Enpac Oil settings. For more details on changing these settings, see “Configuring the dCA” on page 31.




Note: If the first two results vary by more than 10%, perform a third test. If the third result varies by more than 10% in relation to both previous results, you may need to clean the sensor screen. If the third result does not vary more than 5% from one of the previous results, consider the two closest to each other as the correct results and ignore the other result. The result which is farthest from the other two may have occurred due to incorrect operation of the dCA sensor, such as such as inconsistencies in holding the sensor at the test port valve, or residual contamination in the machine fluid lines.

7. Once you have completed tests with satisfactory results, choose Save. The Save Result screen appears.

8. Choose [3] Save Average if you want to save the average of both results.

9. Type comments in the Comments: field and press <Enter>. You can enter up to 17 characters. These comments are stored as inspection codes in the host software. See “Entering Inspection Codes” on page 134. Once you press <Enter>, the Save Result screen appears.

10. Using the letter keys, enter the Equipment Code, which becomes the Location ID in the host software, and Equipment Name, which becomes the Location Description in the host software.

11. Press <Enter> when each field is complete. After you have entered all the information, the dCA Sample menu appears and you can exit or take another measurement.



Using the fCA to Collect Unscheduled Ferrous Count DataThe Enpac Oil data collector allows you to collect unscheduled data and save the results to unload to the host software. Follow these steps to collect unscheduled data using the fCA sensor.


2. Choose [2] dCA - fCA from the Enpac Oil Main Menu. The fCA-dCA Main Menu appears.

3. Choose [1] Run dCA First from the dCA - fCA Main Menu. The dCA Sample Menu appears.

4. Choose [1] Run Test from the Sample Menu. The Communications screen appears, and you have 10 seconds to connect the sensor to the test port valve.





7. Take two averages, repeating steps 3–6. After you finish the tests, the fCA option screen appears. Choose Yes.

8. Next, the Save Result screen appears. Choose <F4> Save Avg.

9. Next, the run fCA test screen appears. Choose Yes to run an fCA test.

10. Probe onto the test port with the fCA. Attach the dCA sensor to the fCA. See “Connecting the fCA” on page 49. Turn the fCA switch to TEST. Once connected, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor.

11. When the fCA test is complete, the backflush knob on the dCA stops moving. Backflush the system while the Enpac Oil displays the data. See “Flushing the fCA” on page 51.

12. To ensure accurate test results, always perform a minimum of two tests and compare the results. Choose Run Test to perform more tests, repeating steps 10 and 11.

When the data analysis is complete, the Enpac Oil displays the Route Result screen. Choose Save Result.



13. Choose Save Avg <F4>. After you save your result, the cursor appears in the Comments field. Press the letter or number keys to type comments and press <Enter>. You can enter up to 17 characters. These comments are stored as inspection codes in the host software. See “Entering Inspection Codes” on page 134 for more information.

Using the dVA to Collect Unscheduled Viscosity DataThe Enpac Oil data collector allows you to collect unscheduled data and save the results to unload to the host software. Follow these steps to collect unscheduled data using the dVA sensor.


2. Choose [3] dVA from the Enpac Oil Main Menu. The dVA Main Menu appears.

3. If you are testing a low viscosity fluid, choose [1] Low Visc Test. If you are testing a high viscosity fluid, choose [2] High Visc Test from the Route Menu. Low viscosity range is from 1 cSt to 460 cSt. High viscosity range is from 460 cSt to 9999 cP. For more information, see “Configuring the dVA” on page 60.



4. Next, you must choose if you want to compare the test results to new oil specs as defined in your configuration. For information on setting up those specifications, see “Entering New Oil Specifications” on page 65. Choose Yes or No.

5. If you have selected cSt as the measurement unit, you must enter the specific gravity of the test fluid. Press <Enter> or <F4> after typing in the correct measurement.

6. Next, enter the temperature of the test sample. Press <Enter> or <F4> after typing in the correct temperature.

7. Next, enter the pressure of the test sample. Press <Enter> after typing in the correct pressure.

8. The Communications screen appears, and you have 10 seconds to connect the sensor to the test port valve.



9. Probe on to the test port valve with the dVA sensor. Once connected, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor.

10. When the dVA test is complete, the backflush knob stops moving. Backflush the sensor when the Enpac Oil displays the data. See “Backflushing the dVA Sensor” on page 68.

When the data analysis is complete, the Enpac Oil displays the RESULT MENU.

Test results appear in cSt or cP, depending on your Enpac Oil settings. For more details on changing these settings, see “Configuring the dVA” on page 60.


12. Once you have completed tests with satisfactory results, choose [2] Save Result s. The Save Result screen appears.

13. Choose <F3> Save Ave if you want to save the average of both results.

14. After you save your result, the cursor appears in the Comments field. Press the letter or number keys to type comments and press <Enter>. You can enter up to 17 characters. These comments are stored as inspection codes in the host software. See “Entering Inspection Codes” on page 134 for more information.

Storing Unscheduled Data in the Host SoftwareWhen you unload unscheduled data from the Enpac Oil, the host software stores it in the database. The host software always stores unscheduled data in the unscheduled destination in the hierarchy of the database. You set the unscheduled destination with the Set Unscheduled Dest. command from the Tools menu. See the printed or online User’s Guide for more information.



Reviewing Collected DataWith the Enpac Oil, you can retrieve test results from your list and display them in different units. You can also view the distribution of the particle size over a range of sizes. The list is displayed in the order the samples were taken. If you take unscheduled data it is appended to the end of the list if the list is complete, or the data is inserted in the order it was collected if the data was taken in the middle of a list. To view collected data, follow these steps.

1. After collecting data, return to the dCA Main Menu. At this menu, choose [3] View Data. If you are currently going through a list and are at the Route Menu, choose [4] View Data. The View Data screen appears.

2. The Enpac Oil displays one test result at a time. Press <F2> Next until the number of the record you wish to display is on screen.

3. Choose OK when you are finished reviewing the collected data, and the Enpac Oil returns to the previous menu.


Chapter 10

10. Using Lube Link

This chapter describes the Lube Link software to collect data and covers the basic operations of the Oil Sensor Interface. It includes the following sections:

Overview of Lube Link ...................................................................... 146

Setting Up Lube Link Data Collection .............................................. 146

Configuring the dCA ......................................................................... 151

Configuring the dVA.......................................................................... 154

Connecting to the Oil Sensor Interface ............................................. 160

Collecting dCA Data ......................................................................... 162

Collecting dCA/fCA Data.................................................................. 164

Collecting dVA Data.......................................................................... 166

Viewing Particle Count and Ferrous Count Data ............................. 170

Viewing Viscosity Data ...................................................................... 174

Reports............................................................................................... 175

Exporting and Importing Data .......................................................... 183


Chapter 10 - Using Lube Link

Overview of Lube LinkLube Link is a Windows-based software application that provides an interface with the Entek oil sensors to make it easy to collect particle counts or viscosity data using the dCA, fCA, or dVA using your computer. The graphical user interface helps you arrange the data according to machines and samples. Lube Link is used with the Oil Sensor Interface to connect your computer to the dCA, fCA, or dVA and collect data. With Lube Link, you can use the Entek oil analysis instruments from a desktop or notebook computer directly, without the use of a Portable Condition Monitor (PCM) data collector.

Using Lube Link, you can choose which units to collect, store, and display. Unit selections for the dCA include ISO codes, particle counts, SAE, gravimetric, and NAS codes. For the fCA, you can view ferrous particles greater than 10 (FP>10). For the dVA, you can view centipoise (cP) or centistokes (cSt) at 25, 40, or 100 degrees Celsius.

With the dVA, you can compare your data values to new oil specifications. You can store these specifications in a lubricant library stored in Lube Link.

This chapter discusses how to use Lube Link to collect and store information from your dCA, fCA, or dVA instruments. This chapter shows how to connect to an Oil Sensor Interface, how to set up an instrument using Lube Link, how to collect data, and how to view plots and data.

This chapter is intended for people using Lube Link and the Oil Sensor Interface to collect data and perform analysis. This chapter contains step-by-step instructions for using the dCA, fCA, or dVA with Lube Link.

Setting Up Lube Link Data CollectionLube Link uses a hierarchy structure to store and organize the data collected with the dCA, fCA, or dVA. Each bottle icon represents a data file. You can double-click the icons to view the data. Each row represents a set of data collected at a certain date and time.

dVA data

fCA data

represents a data file

dCA data

Setting Up Lube Link Data Collection


Each data file, or machine, can be used to represent one location in your host software database. You can export to that exact location if you are using Enlube PM, EMONITOR Odyssey, or Enshare. This section also shows you how to set up the export of those files. See “Choosing the Export Location” on page 147.

Choosing the Default File DirectoryWhen you first start Lube Link, the default directory is the root directory. You must change this default directory to your Lube Link program directory. To do so, follow these steps.

1. From the Setup menu, choose Lube Link File Directory.

2. Choose the Browse button. Select the directory that contains LFW files.

3. Choose OK .

After choosing the correct directory, the Lube Link database view shows all the data contained in the .lfw files in the directory.

Choosing the Export LocationIf you are using Enlube PM, EMONITOR Odyssey, or Enshare, you can choose the exact location you want to export the data to. Once this location is set up, the data is exported to that location. The export process either happens manually or automatically.

You can set up an automatic export after data is collected. From the Setup menu, choose Export , then make sure there is a check mark next to Auto Export After Test . Otherwise, you can manually export the data by right-clicking the machine in the database window and choosing Export . For more information on exporting data, See “Exporting and Importing Data” on page 183.



Follow these steps to set the export location.

1. Select the data file in the database view.

2. Right-click on the selected data file and choose Change Export Location.

3. Choose Browse.

4. Select the location in the database by expanding the hierarchy. You must select the lowest level, which is the location level.

5. When you have selected a location, choose OK . It should appear similar to the following illustration.

6. Choose OK to return to the Lube Link database view.

Inserting New MachinesYou can create new data storage files to represent new samples from a machine. This creates a new machine in the database view.

Setting Up Lube Link Data Collection


1. In the Lube Link database view, select the upper level database icon, as shown below.

2. From the Edit menu, choose Insert. Or, right-click on the database icon and choose Insert. Or, press the Insert key. The following dialog box appears.

highest level database icon



3. Enter a name for the file. This name appears on the Lube Link database view.

4. Next, choose the Hierarchy Name tab. The following dialog box appears.

5. Choose the Browse Database button. The following dialog box appears.

6. Select a location in your current host software database. If you do not use Enlube PM, EMONITOR Odyssey, or Enshare, this browser is not available to you. Choose OK to

Configuring the dCA


close the Location Browser. The hierarchy you choose appears in the dialog box.

7. Once you have filled in all the fields, choose OK to close the dialog box. The new addition appears in the Lube Link database view.

Setting Up a Lab Stand for Lube LinkA convenient use for Lube Link would be with a portable or desktop computer next to a lab stand, or bench-top apparatus. For information on setting up and using the lab stand, see “Using the Bench-Top Apparatus” on page 88.

Configuring the dCABefore you begin testing with the dCA, you must configure it. You can configure the dCA in Lube Link by choosing dCA/fCA Sensor from the Setup menu. There are several options available to you. This section explains each configuration option.



Setting Screen Size and Fluid Type1. In the database view, select a bottle icon. Then, from the Setup menu, choose Fluid

Type. The following dialog box appears.

2. Select the number representing the correct sensor screen size according to the color of the sensor screen, which is in the table below. For example, if your sensor screen is black, choose 15µ for Screen Size.

3. Next to Viscous fluid, select the type of fluid, either Hydraulic or Lubricant .

4. Choose OK .

Color Screen size




Configuring the dCA


Setting Screen Calibration1. From the Setup menu, choose dCA/fCA Sensor. Choose the Calibration tab. The

following dialog box appears.

2. Enter the calibration number engraved on the flat side of the screen. See “Assembling the dCA Sensor with Sensor Screen” on page 35 to see how to get the screen out of the dCA. Make sure you enter the value next to the correct sensor screen size.

3. Choose OK .

Setting Particle Count DistributionYou can display particle size distribution while you are viewing data using Lube Link. If you would like to view the data in different particle sizes, you can set the particle size distribution by following these steps.

1. From the Setup menu, choose dCA/fCA Sensor. Choose the Distribution tab. The following dialog box appears.

2. Next to each Field value, enter the particle count you want to display.

3. Choose OK .



Configuring the dVABefore you begin testing with the dVA, you must configure it. This section goes through the configuration process, including entering the probe serial number, and the settings for low and high viscosity fluids.

Entering the Probe Serial NumberThe probe serial number is used to match the sensor with calibration information. This number must be input for accurate results. To enter the probe serial number, follow these steps.

1. From the Setup menu, point to dVA Sensor, then Setup dVA Sensor. Choose the Serial Number tab. The following dialog box appears.

2. Unscrew the probe tip from the dVA tube. The serial number is located on the base of the probe tip, inscribed in the metal.

3. Enter the serial number (up to four characters) of the probe you are going to use for testing. The serial number is used to match the sensor with calibration information. Do not include any letters at the beginning of the number when entering it.

4. Choose OK .

Calibrating the Probe for Low or High Viscosity FluidsTo calibrate the dVA probe for your testing, you create a test fluid and enter specific values, including specific gravity and viscosity at 40°C for the dVA probe. Low viscosity range is from 1 cSt to 460 cSt. High viscosity range is from 460 cSt to 9999 cP.

Note: The reason for having the upper limit in centipoise instead of centistokes is the cSt upper limit is determined by dividing the cP viscosity value by the specific gravity you enter. To determine your upper limit in cSt, divide 9999 by the specific gravity of the test fluid and the result is the upper cSt limit.

If the test viscosity limit of 9999 cP is exceeded, Lube Link displays an error message and the test viscosity value is not displayed or stored.

If this is the first time you have calibrated your probe, you must first create an entry in the lubricant library for the test fluid. You should receive a bottle from Entek containing the calibration fluid for the dVA. All parameters you need for the test are on the bottle label.

Configuring the dVA


Entering the test fluid parameters1. From the Setup menu, choose Lubricant Library . The following dialog box appears.

2. Choose New. The following dialog box appears.

3. Select the previously-created Entek calibration fluid.

4. Choose OK . The new entry is included in the list of oil specifications.



Run the Calibration Wizard1. From the Setup menu, point to dVA Sensor, then dVA Sensor Calibration. The

following dialog box appears. Choose High Viscosity or Low Viscosity, and enter the probe number next to Serial Number. Choose Next to continue.

2. If you chose High Viscosity, skip this step. If you chose Low Viscosity previously, you must choose the viscosity range, Lower, Middle , or Higher. Choose Next to continue.

Configuring the dVA


3. Select the Entek calibration fluid from the list of oil specifications. Choose Next.

4. Enter the Oil Pressure and Oil Temperature for the calibration fluid. You can change the units if needed. Choose Finish.

5. Attach the dVA to the Oil Sensor Interface and to the computer. Probe on to the test port, then press Finish to test the sample.



Setting the Default Viscosity Units You can choose cP(centipoise), or cSt (centistokes), for the default display units. Follow these steps to set the default viscosity units.

1. From the Setup menu, point to dVA Sensor, then Setup dVA Sensor. Choose the Unit tab. The following dialog box appears.

2. Choose the unit you want the data displayed in, selecting from cP or cSt.

3. Choose OK . The data collected will be stored in the selected unit.

Entering New Oil Specifications in the Lubricant LibraryYou can enter and save new oil specifications to use for comparing your viscosity results to a known value. For example, you may want to observe how your oil viscosity values change over a month’s use. You can enter the new oil specifications and compare the month-old oil to those specifications. For more information about the comparison, see “Comparing Test Results to New Oil Specifications” on page 168.

Configuring the dVA


To enter new oil specifications, gather the information from your oil supplier and enter it by following these steps.

1. From the Setup menu, choose Lubricant Library . The following dialog box appears.

2. Choose New. The following dialog box appears.

3. Enter the manufacturer name, a description of the fluid, the viscosity value at 40C and 100C, and the specific gravity.

4. Choose OK . The new entry is included in the list of oil specifications.



Connecting to the Oil Sensor InterfaceThe Oil Sensor Interface is a small box with different connectors on each side. You can use this interface to connect your dCA, fCA, or dVA directly to your computer instead of using the Portable Condition Monitor (PCM).

Connector InformationYou must supply power to the Oil Sensor Interface using the included power connector. Also, you must use the serial cable supplied in the kit. It is a standard RS-232 extension cable. This section provides information about each connector.

Power supplyz 8–12 VDC

z 100 mA minimum

Plug details:

z Center pin positive

z Plug - 5.5 mm outer diameter, 2.1 mm inner diameter

Connection to the dCA cablez DB-25 plug

Connection to the dVA cablez DB-25 plug

Connection to the computer cablez DB-9 receptacle

Connecting to the Oil Sensor Interface


Serial cable to computerz RS-232 extension cable, with straight through wiring (pins 2 and 3 are not swapped)

Setting the Computer Communications PortYou can select the communications port you are using to connect to the Oil Sensor Interface by following these steps.

1. Select the machine you want to collect data for in the Lube Link database window.

Or click 2. From the File menu, choose Oil Test. The following dialog box appears.

3. To change the COM port that you connected the serial cable to, choose the button with the computer on it. The following dialog box appears.

4. Select the COM port from the Communications device list and choose OK .



Collecting dCA DataAfter you have set up the file in the Lube Link database, you can take data from that machine.



3. To select the dCA for testing, choose the left-hand button. The following dialog box appears.

4. Choose Use dCA sensor and choose OK .

Click 5. To start testing the sample, choose the Test button. The following screen appears if you are running a test for the first time.

Collecting dCA Data


6. Choose Yes to allow Lube Link to read the calibration information. This step takes less than five seconds.

7. Next, probe on to the sample port with the dCA. When it begins collecting data, the following screen appears.

8. When data collection is complete, the results are displayed as shown below.

9. Choose OK to close the Oil Test dialog box. The results are stored in the database files and can be accessed by double-clicking the sample’s date/time stamp in the database view.

test results



Collecting dCA/fCA DataAfter you have set up the file in the Lube Link database, you can take data from that machine.



3. To select the fCA for testing, choose the left-hand button.

4. Choose Use dCA sensor and select Also use fCA sensor and choose OK .

Click 5. To start testing the sample, choose the Test button. The following screen appears.

Collecting dCA/fCA Data


6. Choose Yes to allow Lube Link to read the calibration information. This step takes less than five seconds.

7. Probe onto the test port with the fCA. Attach the dCA sensor to the fCA. See “Connecting the fCA” on page 49. Turn the fCA switch to TEST. Once connected, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor. When it begins collecting data, the following screen appears.



test results



Collecting dVA DataAfter you have set up the file in the Lube Link database, you can take data from that machine.



3. To select the dVA for testing, choose the left-hand button.

4. Choose Use dVA sensor and enter the Serial number. The calibration, or serial number is inscribed on the large end of the dVA probe.

Choose either High viscosity test or Low viscosity test. Low viscosity range is from 1 cSt to 460 cSt. High viscosity range is from 460 cSt to 9999 cP.

Choose OK .

Click 5. To start testing the sample, choose the Test button. If you get an error message, see “Troubleshooting Error Messages” on page 169.

Collecting dVA Data


6. The dVA Test Wizard begins. Select one of the sample lubricants from the oil database and choose Next.

7. Enter the Pressure and Temperature of the fluid sample. Note that you can select different units.

8. Probe onto the test port with the dVA. Once connected, the backflush knob begins to move and the constant pressure of the system pushes the fluid up into the sensor. When it begins collecting data, the following screen appears.





Comparing Test Results to New Oil SpecificationsThe dVA test using Lube Link allows you to compare your viscosity test results to an oil specification. The program compares the tested viscosity to what the viscosity should be for your oil at the test temperature.

1. After you press the Test button to begin a viscosity test, Lube Link shows the following dialog box. Select a fluid from the list.

2. Choose the fluid by clicking on the row, then choose Next.

test results

Collecting dVA Data


3. Next, enter the temperature and pressure of the sample and press <ENTER>. If you have chosen the dVA test results to be in centistokes (cSt), you must enter specific gravity as well. Choose OK .

4. The test cycle begins. Probe onto the test port with the dVA and take the measurement.

Troubleshooting Error MessagesThis section contains some of the common error messages in Lube Link and offers suggestions for making it work correctly.

No connection between computer and Oil Sensor Interface. Please check cable connections.

This message appears if the connections are not secure between the Oil Sensor Interface and the computer. Also, be sure you are using the correct RS-232 serial cable with the Oil Sensor Interface.

If you believe the connections are secure, and you are using the correct serial cable, try unplugging the Oil Sensor Interface from the power source and plugging it back in. This action can reset the Oil Sensor Interface and help it begin communications again.



Unable to open COM1.

This message appears if the selected COM port is not available to the Oil Sensor Interface, or cannot be detected. If you have a mouse or other device connected to your COM1 port, you need to use the COM2 port for the Oil Sensor Interface.

Check the selected device by opening the Oil Test dialog box and choosing the Computer button. In the Interface Port Setup dialog box, select the correct Communications device. Make sure it is connected to the port on the computer by tracing back the cable to the port.

Unable to find dVA calibration file...

This message appears if the calibration number entered in the does not match the numbered calibration file in the Lube Link directory. This can happen for several reasons.

z The Lube Link program directory has been changed, and the calibration file does not exist or does not match the entered number.

z The calibration file has been deleted or renamed.

z The entered number is incorrect, and does not match the calibration file number.

z The calibration value has changed and was entered incorrectly.

Lube Link will create a new calibration file if you choose Yes. However, that calibration value may not be accurate. The original calibration number is inscribed in the metal on the dVA probe. Use that number if you have not re-calibrated the probe. When you re-calibrate the probe, Lube Link creates the calibration file in the Lube Link directory. You should use the latest calibration value if it is available.

Viewing Particle Count and Ferrous Count DataLube Link makes it simple to quickly display the data by double-clicking the data value in the database view. In addition, Lube Link displays one unit in the database view, based on your settings. You can view graphs of the collected data from a dCA and an fCA, and change the color settings for those graphs. In addition to particle counts, this display shows you ISO and NAS codes, as well as gravimetric units.

This section discusses the options for viewing data and methods for viewing data.

Viewing Particle Count and Ferrous Count Data


Setting Default Display Units for Particle CountYou can view one result unit in the main Lube Link window, as pointed out in the illustration below. The settings are global for all the data in Lube Link. In other words, you cannot change the results for one machine and not another.

To set the default display units, follow these steps.

1. From the Setup menu, choose Results/Units. The following dialog box appears. Press F1 for a description of the fields.

2. Choose OK . The Lube Link screen redraws, and closes all open samples. When you re-open the samples, you see the new units.

result unit for dVA: cSt40

result unit for dCA: ISO-2



Setting Plot ColorsYou can set the dCA and fCA plot colors, including background, and bar color. These settings are applied globally to all plots displayed on screen. This setting does not change the colors of plots in reports. To change report plots, see “Setting Up Reports” on page 177.

1. From the Setup menu, choose Colors. The following dialog box appears.

2. From the Plot Element list, select which item you want to change. Your choices are Background, dCA Graph Bar, or fCA Graph Bar. Each is pointed out in the illustration below.

3. Select a color under Basic Colors, or select a new color from the color bar and choose Add to Custom Colors.

4. Choose OK when you are finished selecting colors. The color changes are applied globally to all plots that are displayed on screen.

Background

dCA Graph Bar

fCA Graph Bar

Viewing Particle Count and Ferrous Count Data


Viewing Plots of Particle DataTo view the data in a bar graph plot, simply select the point you want to view, and double-click the point in the database view.

The plot has a log scale in the x-axis, and the particle count for each size is displayed in the plot. Below the plot the ISO Code and other units are displayed.

You can print the plot by choosing Print . It will be sent to the default printer.

Choose Close to close the data display.

Printing Plots of Particle DataTo print the data in the plot, double-click the point in the database pane. Choose the Print button. The plot is printed to the default printer selected in Lube Link.

To change the default printer for Lube LinkTo change the printer, follow these steps.

1. From the File menu, choose Printer Setup. The following dialog appears.

2. Select a printer from the drop down list. Choose Properties to change the settings for the printer. Choose OK when all settings are as you want them.



Viewing Viscosity DataLube Link allows you to view viscosity results by double-clicking the icon in the database view. Lube Link also displays one data point in the database view, based on your settings, so you can quickly assess the current state of the machine.

This section shows you how to change the default display settings and quickly display viscosity data.

To view the viscosity data, select the data point you want to view, then double-click to see a spreadsheet of the data for that point.

Setting Default Display Units for ViscosityYou can view one result unit in the main Lube Link database window, as pointed out below. The settings are global for all the data in Lube Link. In other words, you cannot change the results for one machine and not another.

result unit for dVA: cSt40

result unit for dCA: ISO-2

result unit for fCA: %Ferrous and FP>10

Reports


To set the default display units, follow these steps.

1. From the Setup menu, choose Results/Units. The following dialog box appears. Press F1 for a description of the fields.

2. Choose OK . The Lube Link screen redraws, and closes all open samples. When you re-open the samples, you see the new units displayed.

ReportsUsing Lube Link, you can generate reports for on screen display and for printing. This section discusses how to set up reports and generate reports on collected data.

Lube Link allows you to specify the date range for the report, and specify the type of data the report displays. The Report Builder allows you to change fonts, colors, and margins for printing and displaying the reports. The default reports should work well for most uses.



Header

Page Title

Body:InformationNote: This

information onlyappears on the

first page of thereport.

Footer

Body:Result

Body:dCA Graph

Reports


Setting Up ReportsYou can modify your reports by using the Report Builder. You can set up the margins, fonts, colors, headers, footers, and body of the report. To do so, follow these steps.

1. From the Setup menu, choose Report Builder. The following dialog box appears.

2. On this dialog box, you can choose the page layout units (inches or millimeters) and margins for the pages of the report.

3. To change other elements of the report, choose the buttons on the right-hand side of the dialog box. The following sections tell you what each button is used for.

4. Choose OK to close the Define Report dialog box. Your modifications will be seen in the next report you generate. If you already have a report on screen, you will have to re-generate it for the changes to take place.



To change the report header1. From the Setup menu, choose Report Builder.

2. Choose the Header button. The following dialog box appears.

3. You can change the Font of the text, the Color of the text, and insert special codes. You must activate the cursor in order to enable the Insert Code button. When you choose Insert Code, the following dialog box appears.

4. Choose Use to insert the selected code into the report header.

5. You can add more rows to the report header by double-clicking in the spreadsheet row. The following shows an example of this.

6. Choose OK when the report header is complete.

Reports


To change the page title1. From the Setup menu, choose Report Builder.

2. Choose the Page Title button. The following dialog box appears.

3. You can change the Font of the text, the Color of the text, and insert special codes. You must activate the cursor in order to enable the Insert Code button. When you choose Insert Code, the following dialog box appears.

4. Choose Use to insert the selected code into the page title.

5. You can add more rows to the page title by double-clicking in the spreadsheet row. The following shows an example of this.

6. Choose OK when the page title is complete.



To change the report body1. From the Setup menu, choose Report Builder.

2. Choose the Body button. The following dialog box appears.

3. Select a choice under Font/Color, then choose the Font button or Color button to change the attributes of that section. Each section is described below.

Information - The Information section of the report body is listed at the top of each piece of data. This section contains the file name and directory it is located in. It also contains the Export Location information for EMONITOR Odyssey or Enshare or Enlube PM, as well as the date and time that the data was collected.

Result - The Result section contains the actual data that is collected. For the dVA, the result section is the table containing the selected viscosity readings. For the dCA and fCA, the result section is the x-axis and y-axis of the plot, as well as a listing of results.

dCA Graph - Choose this to change the color of the bars for the dCA data.

fCA Graph - Choose this to change the color of the bars for the fCA data.

4. Under dVA Options, select the viscosity values you would like displayed in the report body.

5. Choose OK when you are finished with the report body settings.

To change report plot colors1. From the Setup menu, choose Report Builder.

2. Choose the Body button. The following dialog box appears.

3. Select either dCA Graph or fCA Graph under Font/Color, then choose the Color button.

4. Choose OK when you are finished with the report body settings.

Reports


To insert page numbers or date codesYou can insert page numbers, the current date, or the current time into any of these areas in the report:

z Header

z Page Title

z Footer

1. Open choose Header, Page Title, or Footer, you can insert codes. You must activate the cursor in order to enable the Insert Code button. When you choose Insert Code, the following dialog box appears.

2. Choose Use to insert the selected code into the line. Your choices are:

z Current Date

z Current Time

z Page Number



Generating Reports on SamplesOr click 1. From the File menu, choose Generate Report to open the following dialog box. The

file name corresponds to the machine you selected when you choose Generate Report.

4. Select the data records you want to include in the report. You can limit this in a number of ways.

z Select records one at a time by clicking on a record under Record List.

z Choose Select All to select all records in the list.

z Choose Clear All to clear any selections.

z Under Record Type, select the check box to only display dCA or dVA.

z Under Date/Time, you can limit the selection based on when the data was collected.

5. After selecting the records, choose Preview to view the report on screen. Or, choose Print to send the report to the printer.

Printing ReportsAfter generating the report as described in “Generating Reports on Samples” on page 182, you can either choose the Print button, or choose Preview to see it on screen and then choose Print from the File menu.

Exporting and Importing Data


To change the default printer for Lube LinkTo change the printer, follow these steps.

1. From the File menu, choose Printer Setup. The following dialog appears.

2. Select a printer from the drop down list. Choose Properties to change the settings for the printer. Choose OK when all settings are as you want them.

Exporting and Importing Data You can export your Lube Link data to Enlube PM, Enshare, or EMONITOR Odyssey. You can select the units that you want to export, and set up the export to occur automatically.

The export command creates a .lab file in the Lube Link program directory. If you have automatic export selected, this .lab file is created immediately after data collection.

Once you have the .lab file, you can import it into the host software using the Data Import or Oil Lab Import command from the Tools menu. This section discusses how to export and import data to the host software.



Selecting Units for Export1. From the Setup menu, choose Export , and then choose Export Options. The

following dialog box appears.

2. Select the checkboxes for each unit you want to export to your host software database. These settings are applied globally, to each file. These settings will be used the next time you export data to the database.

Exporting Data to the Host SoftwareYou can either export one measurement at a time or choose to export all the data in one data file. The data file is represented as a machine in the Lube Link database view. If you double-click the data file, all the measurements underneath it are displayed. Those measurements can be exported individually if you wish.



Or click 1. Select a machine or measurement from the database view. Right-click on the item and choose Export . You can choose either the individual measurement or the entire machine. If you choose the entire machine, the following dialog box appears.

2. Select the measurements you want to export. You can limit the selections by type of measurements or by the date of data collection. Press F1 for more information about this dialog box.

3. Choose Export when the selection is as you want it. Lube Link creates a .lab file in the program directory named using the date/time stamp for the current computer settings. Note that the export file name does not reflect the collection date/time stamp, but instead reflects the file creation date/time stamp.



Importing Data into Host SoftwareAfter exporting the data to a .lab file, you must import the data into your host software. You can import the data into Enlube PM, EMONITOR Odyssey, or Enshare. Follow these steps to do so.

1. In Enlube PM, choose Oil Lab Import from the Tools menu.

In EMONITOR Odyssey or Enshare, choose Data Import from the Tools menu.

The following dialog box appears.

2. Click the Set up import button.

3. Browse to the Lube Link Export Directory that you set up in Lube Link. Next to Files of type, select Lube Link and enter *.lab next to File name. Choose Open.

4. Choose the blue arrow button to import the data into your database. If needed, the data import creates the hierarchy items that are needed to match the location selected in Lube Link.

The newly imported data is tagged and appended to the current list if any other measurements are tagged. Tagging the measurements makes it easy to quickly check the data.



Setting Up Automatic ImportYou can schedule the import task to happen automatically.

1. In Enlube PM, choose Oil Lab Import from the Tools menu.

In EMONITOR Odyssey or Enshare, choose Data Import from the Tools menu.

The following dialog box appears.

2. Make sure the correct file type is set for import. For Lube Link files, the file type is .lab.

3. Choose the Schedule button.

4. Select the settings for the frequency that you want to import data automatically. Press F1 for more information about this dialog box.

5. Choose OK . The import will occur at the next scheduled time.

Exporting Data to ExcelYou can also export the data to Excel 97. Currently, Excel 97 is the only version of Excel that you can export data to. Follow these steps to do so.

1. Select the measurement or machine that you want to export to Excel. Right-click and choose Export to Excel 97.

2. Lube Link launches Excel 97 and places the data into a spreadsheet, then graphs it in a plot. You can export individual measurements or the entire machine.

Note that you can also view the exported data in table format by choosing the dCA tab.


Appendix

Appendix

The Appendix contains two sections. The first explains the data collector INI file, which contains various default values for use with the Enpac Oil. The second section addresses common questions that may arise when using the Enpac Oil with the host software.

Data Collector INI File Options ....................................................... 190

Frequently Asked Questions and Answers ........................................ 192


Appendix

Data Collector INI File OptionsThe INI file options control the default settings for the Enpac Oil when communicating with host software. There are two separate INI files for the dCA and the dVA. The file name for the dCA is DCA.INI, and the file name for the dVA is DVA.INI.

Caution: Modifying the INI file affects how the Enpac Oil communicates with host software. Do not change the settings in the INI file unless you are sure you know the effect of your changes. Always back up the INI file before making any changes.

Changes from the INI files that worked with the PCMIf you previously used a PCM 9000 to load and unload dCA and dVA routes, the INI file is slightly modified in order to work with the Enpac Oil. There are four entries in the INI file that are necessary for the Enpac Oil to work. These additions go under the [Communications] section:

DsrTimeout=4000

ReadIntervalTimeout=32000

DTRControl=Enable

RTSControl=Enable

The Entek installation program will modify the INI files for you when you install the Enpac Oil driver files.

Communication timingThe following options are in the [Flags] section of the INI file and define the default values EMONITOR Odyssey, Enshare, and Enlube PM use for communication timing. Time values are in milliseconds.

Unscheduled measurements for the dCAUnscheduled measurements taken with the Enpac Oil are processed into individual measurement points when you unload the data collector. The host software can create and store up to 18 points for each unscheduled measurement you collect with the dCA, and up to 20 points with the dCA - fCA combination. The default line in the DCA.INI file (as shipped) includes all measurement units. These default values can be changed in the DCA.INI file. The following options are in the [Flags] section of the INI file and define the default values the host software uses when unloading unscheduled measurements.


Option Function

Attempts Number of times to retry communication after error.

WriteWait Length of time to wait before writing each packet.

ReadTimeout Length of time for reading packets and receiving acknowledgment from data collector for writing packets.

Data Collector INI File Options


Each character corresponds to a specific measurement type, as shown in the following chart.

For example, if you want PC>=10 as your only measurement type for unscheduled measurements, you would change other particle count settings to N but leave a Y in the third position. You can leave the last two for the ferrous particle count, which is only unloaded when there is unscheduled ferrous data. You would modify the Unscheduled line in the DCA.INI file to look like:

Unscheduled=NNYNNNNNNNNNNNNNNNYY

Unscheduled measurements for the dVAFor unscheduled data, the host software creates measurements with units of either centistokes (cSt@40C) or centipoise (cP@25C) per single test from the dVA. You have the option to create either one measurement in a particular unit or two measurements of each unit. By default, the INI file is configured to create both measurements with each unit. To change the default, modify the line in the DVA.INI file.

Character Measurement Default

1 PC>=2 Y

2 PC>=5 Y

3 PC>=10 Y

4 PC>=15 Y

5 PC>=20 Y

6 PC>=25 Y

7 PC>=30 Y

8 PC>=40 Y

9 PC>=50 Y

10 PC>=100 Y

11 ISO - 2 Y

12 ISO - 5 Y

13 ISO - 15 Y

14 NAS 5-15 Y

15 NAS 15-25 Y

16 NAS 25-50 Y

17 NAS 50-100 Y

18 NAS > 100 Y

19 FP > 10um Y

20 %Ferrous Y

Character Measurement Default

1 cSt@40C Y

2 cP@25C Y


Appendix

For example, if you want cST@40C as your only measurement type for unscheduled measurements, you would change the second position to an N but leave a Y in the first position. You would modify the Unscheduled line in the DVA.INI file to look like:

Unscheduled=YN

Frequently Asked Questions and AnswersThis section contains the most frequently asked questions about using the Enpac Oil with the host software.

Setting Up Measurement Definitions in the Host Software

Q: Why don’t the oil analysis units or Collection Specifications appear?If you do not have an updated database which includes the oil analysis units and collection specifications, these units will not appear in the measurement definition pane in the host software. In order to use these units, your database must be updated. Contact Customer Support if your database does not contain the oil analysis units.

Q: Why do unsupported measurement definitions appear in the host software?Each data collector supports only certain selections in the drop down lists in the measurement definition pane. The host software automatically displays the correct selections when you select one or more active collectors. You select the active data collector with the Set Active Collectors command in the Tools menu in the host software. If you do not set the dCA or dVA as the active collector, you may not be able to select Process as your measurement definition type. The selections are affected in either of these two ways:

z If you do not select any collectors, the host software displays all possible selections, not just those for the dCA or dVA.

z If you select two or more different collectors, the host software displays only the selections that are available for both collectors.

Q: Why can’t I edit the measurement definition units?The host software does not allow you to change some of the information for a measurement definition after you collect data for that measurement definition. This prevents you from comparing data with different measurement definition selections or collecting data that will not be easily comparable. You cannot edit the following columns in the Measurement Definition pane after you collect data for the following:

z Data Type

z Units

You can, however, change the Collection and Storage columns for a measurement definition after collecting data. You must create a new measurement definition if you wish to store data with different units. Because the Enpac Oil collects only process measurements, the Filter options do not affect your data.

Frequently Asked Questions and Answers


Loading Lists to the Enpac Oil

Q: Why won’t the host software load a list to the data collector?First, check the communication cable between the host software and the data collector. If the communication link between them is correct, there may be other reasons why the host software will not load a list into the Enpac Oil.

z The baud rate settings do not match in both the host software and the Enpac Oil. See “Selecting the Correct Communication Settings in the Enpac Oil” on page 111 and “To select the correct communication settings in the host software” on page 110 to correct this. Note that after you reset the data collector, the baud rate defaults to 19200. The host software defaults to 38400.

z The data collector still has a list loaded in it. The Enpac Oil requires that you unload or delete the list before loading another list. See “Deleting or Resetting Lists in the Data Collector” on page 113 for more details.

z The Microsoft ActiveSync settings are preventing the host software from connecting. See “Connecting to the Enpac Oil using ActiveSync” on page 119.

Q: Why does the host software rebuild the Quickload files?the host software rebuilds a Quickload file before loading it to the data collector when any one of the following change for the list:

z Measurement definitions in that list

z Locations in that list

z Hierarchy level of items in the Hierarchy Tree that affect measurement definitions in the list

z Collection specification of a measurement definition in that list

Q: How can I load more than one list at a time?You can only load one list at a time. But, the host software can combine lists for you into one larger list. Select more than one list in the host software in the Load/Unload dialog box. When you choose the Load button, the host software asks you to save the combined lists under a new list name, then it proceeds with the loading process. The lists are combined in the order you select them. Note that you cannot combine dCA and dVA measurements into the same list.

Note: Only one dCA or one dVA list can be loaded at one time. However, a dCA list and a dVA list can both be stored on the Enpac Oil at one time.


Appendix

Q: How do I tell when loading and unloading is complete?

The Enpac Oil returns to the previous menu when loading and unloading is complete. If you need additional troubleshooting information, there are several considerations for establishing communications. Check for these items.

z Communication settings (baud rate and protocol) between the host software and the Enpac Oil are the same. Note that after you reset the data collector, the baud rate defaults to 19200. The host software defaults to 38400.

z The Enpac Oil is displaying the Communicate with PC screen.

z You select the Load/Unload command from the Tools menu in the host software and choose the list.

This communication link remains until you do one of the following to break communication:

z Close the Load/Unload dialog box.

z Disconnect the cable between computer and Enpac Oil.

z Abort the communication process by pressing <F2> to abort communications and exit the Communicate with PC screen on the Enpac Oil.

Q: What do I do when the Enpac Oil locks up?On rare occasions, the data collector may lock up and become inoperable. If this happens, try turning it off and on again. If this does not work, you must reset the data collector by removing the battery plate and using a paperclip to press the reset button. See “Resetting the Data Collector” on page 19.

Caution: Resetting the data collector is like rebooting your computer. Use this function when the data collector is “locked up” and not responding to key presses. You will delete any unloaded lists using this method.

Note: If the data collector locks up repeatedly, please note the conditions that cause it to lock up and contact Customer Support. See “Customer Support” on page 5.

Collecting Data with the Enpac Oil

Q: Why are the alarms not showing up as target values?Alarms in the host software are represented as target values in the Enpac Oil. First, check the Trigger column in your Alarm pane in the host software. You select the alarms you want to load with a measurement definition in the host software by setting the Trigger column to Yes for the alarm. If you select an alarm that the data collector can handle, that alarm is loaded into the data collector when you load the list. The Enpac Oil can handle only a single Above alarm for each measurement definition. There are two cases when the host software does not load the same alarms you selected:

z The data collector cannot support the alarm you selected.

z You selected two or more alarms for the measurement definition.

Frequently Asked Questions and Answers


In both these cases, the host software combines and simplifies the alarms you selected. It creates an alarm that the data collector can handle. The simplified alarm is often more conservative, which means that a measurement may appear to be in alarm in the data collector. After unloading the data, the host software checks the measurement against the actual alarms you created for the measurement definition. For more information on alarms, see “Alarms and the Data Collector” on page 104.

Q: What if my dCA results are inconsistent?Inconsistent results are defined as differing by more than 10% low or high. There are several procedures to try to correct inconsistent results.

z Clean your sensor screens. See “Cleaning dCA Sensor Screens” on page 36.

z Check all the settings in the Enpac Oil to make sure that they are consistent with the data you wish to collect. See “Configuring the dCA” on page 31.

z Visually inspect the sensor screen with a microscope or magnifying glass to look for holes, tears, or stretched areas on the screen.

z Inspect internal o-rings for tears, cracks, or splits, and to make sure an o-ring is not missing.

z Check your test pressure. Pressure should be constant. The recommended pressure is 60 psi.

Q: What if I continually get an Invalid Test message?There are several procedures to try if your Enpac Oil displays “Invalid Test” after every test.

z Reset the Enpac Oil by removing the battery back and pressing the reset button with a paperclip.

z Check the dCA sensor connector for missing or bent pins, and to ensure that you have a firm connection.

z Inspect the cables from the dCA to Enpac Oil and the Oil Sensor Interface for cuts or crimps.

z Grasp the cable just above the rubber connector from the dCA, and gently pull outward. Significant movement could signify a problem. Contact Customer Support for assistance.

z Slowly pull the black backflush knob out to its full extension. Make sure the piston moves tightly and smoothly. Jumps, knocks, or pulling could signify misalignment.

z Hold the box-like section of the dCA sensor to your ear and shake gently. Rattling or clinking could signify loose parts or broken glass. Contact Customer Support for assistance. Do not open the dCA transducer.

z Inspect internal o-rings for tears, cracks, or splits, and to make sure an o-ring is not missing.

Q: How can I see more sizes in the particle count distributions?The Enpac Oil can display up to seven particle sizes of the distribution at a time. If you need to see higher particle sizes such as PC>100, you can modify the particle size display. See “Configuring the dCA” on page 31 for instructions.


Appendix

Unloading Data from the Enpac Oil

Q: How do I delete a list from the Enpac Oil after unloading it?The data collector can automatically delete the list. When the unload is complete, the Enpac Oil displays Status: COMPLETE and the progress bar closes in the host software. The Enpac Oil asks that you confirm that the data unload was successful so that it can delete the data file. Press <Y> if you can confirm that the data was successfully unloaded, and the Enpac Oil will delete the list.

If a list already exists in the Enpac Oil you will have to manually delete it before loading another. See “Deleting or Resetting Lists in the Data Collector” on page 113.

Q: How do I print reports after unloading data? the host software allows you to print reports to a printer immediately after unloading the data from the Enpac Oil to your database. This allows you to view the results of the data just unloaded. To do so, select Auto Reports on Unload in the Unload Options dialog box and highlight the desired reports.For more information see “Automatically Printing Reports after Unloading” on page 117.


Glossary

Glossary

The Glossary contains definitions of many of the terms used with oil analysis systems. Boldface type indicates terms that are defined elsewhere in the glossary.

abrasion – A general wearing away of a surface by constant scratching, usually due to the presence of foreign matter such as dirt, grit, or metallic particles in the lubricant. It may also cause a break down of the material (such as the tooth surfaces of gears). Lack of proper lubrication may result in abrasion.

abrasive wear – (or cutting wear) comes about when hard surface asperities or hard particles that have embedded themselves into a soft surface and plough grooves into the opposing harder surface, e.g., a journal.

absolute filtration rating – The diameter of the largest hard spherical particle that will pass through a filter under specified test conditions. This is an indication of the largest opening in the filter elements.

absolute viscosity – A term used interchangeably with viscosity to distinguish it from either kinematic viscosity or commercial viscosity. Absolute viscosity is the ratio of shear stress to shear rate. It is a fluid's internal resistance to flow. The common unit of absolute vis-cosity is the poise or centipoise (1/100th of a poise). It is occasionally referred to as dy-namic viscosity. Absolute viscosity and kinematic viscosity are expressed in fundamental units. Commercial viscosity such as Saybolt viscosity is expressed in arbitrary units of time, usually seconds. Absolute viscosity divided by fluid density equals kinematic vis-cosity.

active data collector – The active data collector(s) determine the valid options for setting up measurement definitions. For example, if you have two active data collectors:

DC1 can measure velocity in both in/sec and mm/sec

DC2 can measure velocity only in in/sec

The only available velocity units are in/sec, because that is common to both data collec-tors. Note that this is different from the current data collector.

absorbent filter – A filter medium that holds contaminant by mechanical means.

absorption – The assimilation of one material into another; in petroleum refining, the use of an absorptive liquid to selectively remove components from a process stream.

AC Fine Test Dust (ACFTD) – A test contaminant used to assess both filters and the con-taminant sensitivity of all types of tribological mechanisms.

accumulator – A container in which fluid is stored under pressure as a source of fluid power.

acid – In a restricted sense, an acid is any substance containing hydrogen in combination with a nonmetal or nonmetallic radical and capable of producing hydrogen ions in solution.

acidity – In lubricants, acidity denotes the presence of acid-type constituents whose concen-tration is usually defined in terms of total acid number. The constituents vary in nature and may or may not markedly influence the behavior of the lubricant.

additive – A compound that enhances some property of, or imparts some new property to,


the base fluid. In some hydraulic fluid formulations, the additive volume may constitute as much as 20 percent of the final composition. The more important types of additives include anti-oxidants, anti-wear additives, corrosion inhibitors, viscosity index improv-ers, and foam suppressants.

additive stability – The ability of additives in the fluid to resist changes in their performance during storage or use.

adhesion – The property of a lubricant that causes it to cling or adhere to a solid surface.

adhesive wear – This is often referred to as galling, scuffing, scoring, or seizing. It happens when sliding surfaces contact one another, causing fragments to be pulled from one sur-face and to adhere to the other.

adsorbent filter – A filter medium primarily intended to hold soluble and insoluble contam-inants on its surface by molecular adhesion.

adsorption – Adhesion of the molecules of gases, liquids, or dissolved substances to a solid surface, resulting in relatively high concentration of the molecules at the place of contact; e.g. the plating out of an anti-wear additive on metal surfaces.

adsorptive filtration – The attraction to, and retention of particles in, a filter medium by electrostatic forces, or by molecular attraction between the particles and the medium.

aeration – The state of air being suspended in a liquid such as a lubricant or hydraulic fluid.

A.G.M.A. – Abbreviation for “American Gear Manufacturers Associations,” an organization serving the gear industry.

agglomeration – The potential of the system for particle attraction and adhesion.

air, compressed – Air at any pressure greater than atmospheric pressure.

air breather – A device permitting air movement between atmosphere and the component in/on which it is installed.

alarms – You set alarms in the host software to alert you to a change in the measurement. Alarms are called target values in the Enpac Oil.

alkali – Any substance having basic (as opposed to acidic) properties. In a restricted sense it is applied to the hydroxides of ammonium, lithium, potassium and sodium. Alkaline ma-terials in lubricating oils neutralize acids to prevent acidic and corrosive wear in internal combustion engines.

analytical ferrography – The magnetic precipitation and subsequent analysis of wear debris from a fluid sample This approach involves passing a volume of fluid over a chemically treated microscope slide which is supported over a magnetic field. Permanent magnets are arranged in such a way as to create a varying field strength over the length of the sub-strate. This varying strength causes wear debris to precipitate in a distribution with re-spect to size and mass over the Ferrogram. Once rinsed and fixed to the substrate, this debris deposit serves as an excellent media for optical analysis of the composite wear par-ticulates.

anhydrous – Devoid of water.

anti-foam agent – One of two types of additives used to reduce foaming in petroleum prod-ucts: silicone oil to break up large surface bubbles, and various kinds of polymers that de-crease the amount of small bubbles entrained in the oils.


anti-friction bearing – A rolling contact type bearing in which the rotating or moving mem-ber is supported or guided by means of ball or roller elements. Does not mean without friction.

anti-oxidants – Prolong the induction period of a base oil in the presence of oxidizing con-ditions and catalyst metals at elevated temperatures. The additive is consumed and deg-radation products increase not only with increasing and sustained temperature, but also with increases in mechanical agitation or turbulence and contamination – air, water, me-tallic particles, and dust.

antistatic additive – An additive that increases the conductivity of a hydrocarbon fuel to has-ten the dissipation of electrostatic charges during high-speed dispensing, thereby reduc-ing the fire/explosion hazard.

antiwear additives – Improve the service life of tribological elements operating in the boundary lubrication regime. Antiwear compounds (for example, ZDDP and TCP) start decomposing at 90° to 100°C and even at a lower temperature if water (25 to 50 ppm) is present.

API engine service categories – Gasoline and diesel engine oil quality levels established jointly by API, SAE, and ASTM, and sometimes called SAE or API/SAE categories; for-merly called API Engine Service Classifications.

API gravity – A gravity scale established by the American Petroleum Institute and in general use in the petroleum industry, the unit being called “the A.P.I. degree.” This unit is de-fined in terms of specific gravity as follows:

Degrees API ={ 141.5 }- 131.5

{Specific gravity 60° F/60° F }

archive data – The measurement data that you store in host software is called archive data. It includes all the process measurements that you have collected and unloaded or en-tered into the program.

ash – A measure of the amount of inorganic material in lubricating oil. Determined by burn-ing the oil and weighing the residue. Results expressed as percent by weight.

asperities – Microscopic projections on metal surfaces resulting from normal surface-finish-ing processes. Interference between opposing asperities in sliding or rolling applications is a source of friction, and can lead to metal welding and scoring. Ideally, the lubricating film between two moving surfaces should be thicker than the combined height of the op-posing asperities.

A.S.T.M. = American Society for Testing Materials – A society for developing standards for materials and test methods.

atomic absorption spectroscopy – Measures the radiation absorbed by chemically unbound atoms by analyzing the transmitted energy relative to the incident energy at each frequen-cy. The procedure consists of diluting the fluid sample with methyl isobutyl ketone (MIBK) and directly aspirating the solution. The actual process of atomization involves reducing the solution to a fine spray, dissolving it, and finally vaporizing it with a flame. The vaporization of the metal particles depends upon their time in the flame, the flame temperature, and the composition of the flame gas. The spectrum occurs because atoms in the vapor state can absorb radiation at certain well-defined characteristic wavelengths. The wavelength bands absorbed are very narrow and differ for each element. In addition, the absorption of radiant energy by electronic transitions from ground to excited state is


essentially and absolute measure of the number of atoms in the flame and is, therefore, the concentration of the element in a sample.

Automatic Transmission Fluid (ATF) – Fluid for automatic, hydraulic transmissions in motor vehicles.

axial-load bearing – A bearing in which the load acts in the direction of the axis of rotation.

backflush – The method of expelling fluid from the dCA sensor when you finish collecting data. Backflushing the sensor clears the dCA sensor screen of built-up hard particle con-tamination. You can backflush either manually or using the laboratory apparatus.

backwash – The method of expelling remaining fluid by loosening the screen housing from the dCA sensor once you have backflushed it. Merely backwashing the fluid will not completely clear the screen.

babbitt – A soft, white, non-ferrous alloy bearing material composed principally of copper, antimony, tin and lead.

bactericide – Additive included in the formulations of water-mixed cutting fluids to inhibit the growth of bacteria promoted by the presence of water, thus preventing odors that can result from bacterial action.

ball bearing – An antifriction rolling type bearing containing rolling elements in the form of balls.

barrel – A unit of liquid volume of petroleum oils equal to 42 U.S. gallons or approximately 35 Imperial gallons.

base – A material which neutralizes acids. An oil additive containing colloidally dispersed metal carbonate, used to reduce corrosive wear.

base stock – The base fluid, usually a refined petroleum fraction or a selected synthetic material, into which additives are blended to produce finished lubricants.

baseline measurement – A reference measurement you identify from the archive data for a measurement definition. It indicates the proper or ideal operating condition for a piece of equipment. You can use it as a comparison to other measurements and in alarms.

bearing – A support or guide by means of which a moving part such as a shaft or axle is po-sitioned with respect to the other parts of a mechanism.

bench-top apparatus – This device is used for testing bottle samples with the dCA sensor. The apparatus includes two pressure chambers and a backflush tower and it uses an air supply to provide pressure.

beta rating – The method of comparing filter performance based on efficiency. This is done using the Multi-Pass Test which counts the number of particles of a given size before and after fluid passes through a filter.

beta-ratio (ß-Ratio) – The ratio of the number of particles greater than a given size in the influent fluid to the number of particles greater than the same size in the effluent fluid, under specified test conditions (see “Multi-Pass Test”).

bitumen – Also called asphalt or tar, bitumen is the brown or black viscous residue from the vacuum distillation of crude petroleum. It also occurs in nature as asphalt “lakes” and “tar sands.” It consists of high molecular weight hydrocarbons and minor amounts of sulfur and nitrogen compounds.

black oils – Lubricants containing asphaltic materials, which impart extra adhesiveness, that


are used for open gears and steel cables.

blow-by – Passage of unburned fuel and combustion gases past the piston rings of internal combustion engines, resulting in fuel dilution and contamination of the crankcase oil.

boundary lubrication – Form of lubrication between two rubbing surfaces without devel-opment of a full-fluid lubricating film. Boundary lubrication can be made more effective by including additives in the lubricating oil that provide a stronger oil film, thus prevent-ing excessive friction and possible scoring. There are varying degrees of boundary lubri-cation, depending on the severity of service. For mild conditions, oiliness agents may be used; by plating out on metal surfaces in a thin but durable film, oiliness agents prevent scoring under some conditions that are too severe for a straight mineral oil. Compounded oils, which are formulated with polar fatty oils, are sometimes used for this purpose. Anti-wear additives are commonly used in more severe boundary lubrication applications. The more severe cases of boundary lubrication are defined as extreme pressure conditions; they are met with lubricants containing EP additives that prevent sliding surfaces from fusing together at high local temperatures and pressures.

breakdown maintenance – Any maintenance performed after a machine has failed to return it to an operating state.

bridging – A condition of filter element loading in which contaminant spans the space be-tween adjacent sections of a filter element, thus blocking a portion of the useful filtration.

bright stock – A heavy residual lubricant stock with low pour point, used in finished blends to provide good bearing film strength, prevent scuffing, and reduce oil consumption. Usu-ally identified by its viscosity, SUS at 210°F or cSt at 100°C.

brinelling – Permanent deformation of the bearing surfaces where the rollers (or balls) con-tact the races. Brinelling results from excessive load or impact on stationary bearings. It is a form of mechanical damage in which metal is displaced or upset without attrition.

Brookfield viscosity – Apparent viscosity in cP determined by Brookfield viscometer, which measures the torque required to rotate a spindle at constant speed in oil of a given tem-perature. Basis for ASTM Method D 2983; used for measuring low temperature viscosity of lubricants.

BTU – British thermal unit. The amount of heat required to raise the temperature of 1 pound of water 1 degree Fahrenheit.

bubble point – The differential gas pressure at which the first steady stream of gas bubbles is emitted from a wetted filter element under specified test conditions.

built-in-dirt – Material passed into the effluent stream composed of foreign materials incor-porated into the filter medium.

bulk modulus (of elasticity) – A ratio of normal stress to a change in volume. A term used in determining the compressibility of a fluid. Data for petroleum products can be found in the International Critical Tables.

burst pressure rating – The maximum specified inside-out differential pressure that can be applied to a filter element without outward structural or filter-medium failure.

bushing – A short, externally threaded connector with a smaller size internal thread.

bypass filtration – A system of filtration in which only a portion of the total flow of a circu-lating fluid system passes through a filter at any instant or in which a filter having its own circulating pump operates in parallel to the main flow.


bypass valve (relief valve) – A valve mechanism that assures system fluid flow when a pre-selected differential pressure across the filter element is exceeded; the valve allows all or part of the flow to bypass the filter element.

calibration number – The number located on the sensor screen or dVA sensor tube, which can be changed using the calibration validation program.

calibration validation program – The dCA screen validation program to ensure accurate results with the sensor screen. CVP fluid is used for this procedure.

cams – Eccentric shafts used in most internal combustion engines to open and close valves.

capacity – The amount of contaminants a filter will hold before an excessive pressure drop is caused. Most filters have bypass valves which open when a filter reaches its rated ca-pacity.

capillarity – A property of a solid-liquid system manifested by the tendency of the liquid in contact with the solid to rise above or fall below the level of the surrounding liquid; this phenomenon is seen in a smallbore (capillary) tube.

carbon – A non-metallic element, number 6 in the periodic table. Diamonds and graphite are pure forms of carbon. Carbon is a constituent of all organic compounds. It also occurs in combined form in many inorganic substances; i.e., carbon dioxide, limestone, etc.

carbon residue – Coked material remaining after an oil has been exposed to high tempera-tures under controlled conditions.

carbonyl iron powder – A contaminant which consists of up to 99.5% pure iron spheres.

case drain filter – A filter located in a line conducting fluid from a pump or motor housing to reservoir.

catalyst – A substance which speeds a chemical action without undergoing a chemical change itself during the process. Now used in catalytic converters to control amount of unburned hydrocarbons and CO in automobile exhaust.

catalytic converter – An integral part of vehicle emission control systems since 1975. Oxi-dizing converters remove hydrocarbons and carbon monoxide (CO) from exhaust gases, while reducing converters control nitrogen oxide (NOx) emissions. Both use noble metal (platinum, palladium or rhodium) catalysts that can be "poisoned" by lead compounds in the fuel or lubricant.

catastrophic failure – Sudden, unexpected failure of a machine resulting in considerable cost and downtime.

category – A grouping of similar equipment used for setting alarms. For example, you can group all water pumps into a category called Water Pumps. For each combination of units (g’s, ips, mm, …) and measurement filter defined in the category, you can also define:

z Category variables such as warning and danger alarms.

z Band variables such as alarms or percentage change for each band in the band set for the category.

category variable – A value that you can apply in alarms across all equipment in a category. Category variables allow you to change alarm levels for all equipment in a category with-out having to change each alarm individually. Note that the host software does not create an alarm if you do not define the value of a category variable for the combination of units and measurement filter in the measurement definition.


cavitation – Formation of an air or vapor pocket (or bubble) due to lowering of pressure in a liquid, often as a result of a solid body, such as a propeller or piston, moving through the liquid; also, the pitting or wearing away of a solid surface as a result of the collapse of a vapor bubble. Cavitation can occur in a hydraulic system as a result of low fluid lev-els that draw air into the system, producing tiny bubbles that expand explosively at the pump outlet, causing metal erosion and eventual pump destruction.

cavitation erosion – Material-damaging process which occurs as a result of vaporous cavi-tation. "Cavitation" refers to the occurrence or formation of gas- or vapor- filled pockets in flowing liquids due to the hydrodynamic generation of low pressure (below atmospher-ic pressure). This damage results from the hammering action when cavitation bubbles im-plode in the flow stream. Ultra-high pressures caused by the collapse of the vapor bubbles produce deformation, material failure and, finally, erosion of the surfaces.

cellulose media – A filter material made from plant fibers. Because cellulose is a natural ma-terial, its fibers are rough in texture and vary in size and shape. Compared to synthetic media, these characteristics create a higher restriction to the flow of fluids

centipoise – (cP) The standard unit of absolute viscosity in the centimeter-gram-second sys-tem. It is the ration of the shearing stress to the shear rate of a fluid and is expressed in dyne seconds per square centimeter. One centipoise equals 0.01 poise.

centistokes – (cSt) The standard unit of kinematic viscosity in the centimeter-gram-second system. It is expressed in square centimeters per second. One centistoke equals 0.01 stoke.

centralized lubrication – A system of lubrication in which a metered amount of lubricant or lubricants for the bearing surfaces of a machine or group of machines are supplied from a central location.

centrifugal separator – A separator that removes immiscible fluid and solid contaminants that have a different specific gravity than the fluid being purified by accelerating the fluid mechanically in a circular path and using the radial acceleration component to isolate these contaminants.

chemical stability – The tendency of a substance or mixture to resist chemical change.

chip control (grit control, last-chance) filter – A filter intended to prevent only large par-ticles from entering a component immediately downstream.

circulating lubrication – A system of lubrication in which the lubricant, after having passed through a bearing or group of bearings, is recirculated by means of a pump.

clean – A cleanliness definition for fluids defined as having fewer than 100 particles greater than 10 microns per milliliter. A clean fluid is used to complete the calibration validation program.

clean room – A facility or enclosure in which air content and other conditions (such as tem-perature, humidity, and pressure) are controlled and maintained at a specific level by spe-cial facilities and operating processes and by trained personnel.

Cleanliness Level (CL) – A measure of relative freedom from contaminants.

clearance bearing – A journal bearing in which the radius of the bearing surface is greater than the radius of the journal surface.

cloud point – The temperature at which waxy crystals in an oil or fuel form a cloudy appear-ance.


coalescor – A separator that divides a mixture or emulsion of two immiscible liquids using the interfacial tension between the two liquids and the difference in wetting of the two liquids on a particular porous medium.

coefficient of friction – The number obtained by dividing the friction force resisting motion between two bodies by the normal force pressing the bodies together.

cohesion – That property of a substance that causes it to resist being pulled apart by mechan-ical means.

cold cranking simulator (CCS) – An intermediate shear rate viscometer that predicts the ability of an oil to permit a satisfactory cranking speed to be developed in a cold engine.

collapse – An inward structural failure of a filter element which can occur due to abnormally high pressure drop (differential pressure) or resistance to flow.

collapse pressure – The minimum differential pressure that an element is designed to with-stand without permanent deformation.

compound – (1) Chemically speaking, a distinct substance formed by the combination of two or more elements in definite proportions by weight and possessing physical and chemical properties different from those of the combining elements. (2) in petroleum pro-cessing, generally connotes fatty oils and similar materials foreign to petroleum added to lubricants to impart special properties.

compounded oil – A petroleum oil to which has been added other chemical substances.

compressibility – The change in volume of a unit volume of a fluid when subjected to a unit change of pressure.

compression ratio – In an internal combustion engine, the ratio of the volume of combustion space at bottom dead center to that at top dead center.

compressor – A device which converts mechanical force and motion into pneumatic fluid power.

consistency – The degree to which a semisolid material such as grease resists deformation. (See ASTM designation D 217.) Sometimes used qualitatively to denote viscosity of liq-uids.

contaminant – Any foreign or unwanted substance that can have a negative effect on system operation, life or reliability.

contaminant (Dirt, ACFTD) capacity – The weight of a specified artificial contaminant that must be added to the influent to produce a given differential pressure across a filter at specified conditions. Used as an indication of relative service life.

contaminant failure – Any loss of performance due to the presence of contamination. Two basic types of contamination failure are: Perceptible – gradual loss of efficiency or per-formance, and Catastrophic – dramatic, unexpected failure.

contaminant lock – A particle or fiber-induced jam caused by solid contaminants.

contamination control – A broad subject which applies to all types of material systems (in-cluding both biological and engineering). It is concerned with planning, organizing, man-aging, and implementing all activities required to determine, achieve and maintain a specified contamination level.

coolant – A fluid used to remove heat. See Cutting fluid.


copper strip corrosion – A qualitative measure of the tendency of a petroleum product to corrode pure copper.

core – The internal duct and filter media support.

% correl – The percentage of peaks in the used oil infrared spectrum which match those in the reference oil. A sudden decrease in this value usually means that the oil was mixed with a different type.

corrosion – The decay and loss of a metal due to a chemical reaction between the metal and its environment. It is a transformation process in which the metal passes from its elemen-tal form to a combined (or compound) form.

corrosion inhibitor – Additive for protecting lubricated metal surfaces against chemical at-tack by water or other contaminants. There are several types of corrosion inhibitors. Polar compounds wet the metal surface preferentially, protecting it with a film of oil. Other compounds may absorb water by incorporating it in a water-in-oil emulsion so that only the oil touches the metal surface. Another type of corrosion inhibitor combines chemical-ly with the metal to present a non-reactive surface.

coupling, quick disconnect – A coupling which can quickly join or separate lines.

coupling – A straight connector for fluid lines.

cracking – The process whereby large molecules are broken down by the application of heat and pressure to form smaller molecules.

crown – The top of the piston in an internal combustion engine above the fire ring, exposed to direct flame impingement.

cryogenics – The branch of physics relating to the production and effects of very low tem-peratures.

cutting fluid – Any fluid applied to a cutting tool to assist in the cutting operation by cooling, lubricating or other means.

current data collector – The data collector selected in host software for communication dur-ing load and unload operations. Note that this is different from the active data collector.

current list – The most recently recalled or created list of measurement definitions held in the computer’s memory or saved on the computer’s hard disk. You can also view plots or create a report from the data associated with the current list.

cycle – A single complete operation consisting of progressive phases starting and ending at the neutral position.

cylinder – A device which converts fluid power into linear mechanical force and motion. It usually consists of a moveable element such as a piston and piston rod, plunger rod, plunger or ram, operating with in a cylindrical bore.

data collector – A data collector is a device that measures and stores vibration and other data. Oil analysis data may include process measurements in particle counts. In other data col-lectors, vibration data may include magnitude, spectrum, time waveform, and phase data.

database – One or more related files that contain information on a common topic. The host software database contains both the hierarchical setup for the machinery as well as the data collected from the machinery.

Database window – The Database window contains one or more displays of information


from the database. The Database window can be split into two or more parts, called panes. The different panes in the Database window are: Hierarchy, Location, Measure-ment Definition, Alarms, and Archive data.

dCA sensor – The digital CONTAM-ALERT sensor assembly used with the Portable Con-dition Monitor (PCM) to measure particle counts. Contains the sensor screen.

deaerator – A separator that removes air from the system fluid through the application of bubble dynamics.

degas – Removing air from a liquid, usually by ultrasonic and/or vacuum methods.

degradation – The progressive failure of a machine or lubricant.

dehydrator – A separator that removes water from the system fluid.

delamination wear – A complex wear process where a machine surface is peeled away or otherwise removed by forces of another surface acting on it in a sliding motion.

demulsibility – The ability of a fluid that is insoluble in water to separate from water with which it may be mixed in the form of an emulsion.

density – The mass of a unit volume of a substance. Its numerical value varies with the units used.

deposits – Oil-insoluble materials that result from oxidation and decomposition of lube oil and contamination from external sources and engine blow-by. These can settle out on ma-chine or engine parts. Examples are sludge, varnish, lacquer and carbon.

depth filter – A filter medium that retains contaminants primarily within tortuous passages.

desorption – Opposite of absorption or adsorption. In filtration, it relates to the downstream release of particles previously retained by the filter.

detergent – In lubrication, either an additive or a compounded lubricant having the property of keeping insoluble matter in suspension thus preventing its deposition where it would be harmful. A detergent may also redisperse deposits already formed.

dialog box – A dialog box contains the options and settings for a command. Dialog boxes allow you to enter information, as well as to review and change existing settings, before you execute the command.

dielectric strength – A measure of the ability of an insulating material to withstand electric stress (voltage) without failure. Fluids with high dielectric strength (usually expressed in volts or kilovolts) are good electrical insulators. (ASTM Designation D 877.)

differential pressure indicator – An indicator which signals the difference in pressure be-tween any two points of a system or a component.

digital CONTAM-ALERT – The brand name for the portable particle count sensor, referred to as the dCA or dCA sensor in this manual.

digital VISC-ALERT – The brand name for the portable viscosity sensor, referred to as the dVA or dVA sensor in this manual.

dirt capacity (dust capacity) (contaminant capacity) – The weight of a specified artificial contaminant which must be added to the influent to produce a given differential pressure across a filter at specified conditions. Used as an indication of relative service life.

dispersant – In lubrication, a term usually used interchangeably with detergent. An additive,


usually nonmetallic ("ashless"), which keeps fine particles of insoluble materials in a ho-mogeneous solution. Hence, particles are not permitted to settle out and accumulate.

disposable – A filter element intended to be discarded and replaced after one service cycle.

dissolved gases – Those gases that enter into solution with a fluid and are neither free nor entrained gases.

distillation method (ASTM D-95) – A method involving distilling the fluid sample in the presence of a solvent that is miscible in the sample but immiscible in water. The water distilled from the fluid is condensed and segregated in a specially-designed receiving tube or tray graduated to directly indicate the volume of water distilled.

drum – A container with a capacity of 55 U.S. gallons.

duplex filter – An assembly of two filters with valving for selection of either or both filters.

dVA sensor – The digital VISC-ALERT sensor that allows you to obtain viscosity informa-tion in either centipoise or centistokes.

effluent – The fluid leaving a component.

elastohydrodynamic lubrication – In rolling element bearings, the elastic deformation of the bearing (flattening) as it rolls, under load, in the bearing race. This momentary flat-tening improves the hydrodynamic lubrication properties by converting point or line con-tact to surface-to-surface contact.

electrostatic separator – A separator that removes contaminant from dielectric fluids by ap-plying an electrical charge to the contaminant that is then attracted to a collection device of different electrical charge.

element (Cartridge) – The porous device that performs the actual process of filtration.

emission spectrometer – Works on the basis that atoms of metallic and other particular ele-ments emit light at characteristic wavelengths when they are excited in a flame, arc, or spark. Excited light is directed through an entrance slit in the spectrometer. This light pen-etrates the slit, falls on a grate, and is dispersed and reflected. The spectrometer is cali-brated by a series of standard samples containing known amounts of the elements of interest. By exciting these standard samples, an analytical curve can be established which gives the relationship between the light intensity and its concentration in the fluid.

emulsibility – The ability of a non-water-soluble fluid to form an emulsion with water.

emulsifier – Additive that promotes the formation of a stable mixture, or emulsion, of oil and water. Common emulsifiers are: metallic soaps, certain animal and vegetable oils, and various polar compounds.

emulsion – Intimate mixture of oil and water, generally of a milky or cloudy appearance. Emulsions may be of two types: oil-in water (where water is the continuous phase) and water-in-oil (where water is the discontinuous phase).

end cap – A ported or closed cover for the end of a filter element.

engine deposits – Hard or persistent accumulation of sludge, varnish and carbonaceous res-idues due to blow-by of unburned and partially burned fuel, or the partial breakdown of the crankcase lubricant. Water from the condensation of combustion products, carbon, residues from fuel or lubricating oil additives, dust and metal particles also contribute.

environmental contaminant – All material and energy present in and around an operating


system, such as dust, air moisture, chemicals, and thermal energy.

EP (Extreme Pressure) lubricants – Lubricants that impart to rubbing surfaces the ability to carry appreciably greater loads than would be possible with ordinary lubricants without excessive wear or damage.

erosion – The progressive removal of a machine surface by cavitation or by particle impinge-ment at high velocities.

extreme pressure (EP) additive – Lubricant additive that prevents sliding metal surfaces from seizing under conditions of extreme pressure. At the high local temperatures asso-ciated with metal-to-metal contact, an EP additive combines chemically with the metal to form a surface film that prevents the welding of opposing asperities, and the consequent scoring that is destructive to sliding surfaces under high loads. Reactive compounds of sulfur, chlorine, or phosphorus are used to form these inorganic films.

fabrication integrity point – The differential gas pressure at which the first stream of gas bubbles are emitted from a wetted filter element under standard test conditions.

false brinelling – False brinelling of needle roller bearings is actually a fretting corrosion of the surface since the rollers are the I.D. of the bearing. Although its appearance is similar to that of brinelling, false brinelling is characterized by attrition of the steel, and the load on the bearing is less than that required to produce the resulting impression. It is the result of a combination of mechanical and chemical action that is not completely understood, and occurs when a small relative motion or vibration is accompanied by some loading, in the presence of oxygen.

fatigue chunks – Thick three-dimensional particles exceeding 50 microns indicating severe wear of gear teeth.

fatigue platelets – Normal particles between 20 and 40 microns found in gear box and rolling element bearing oil samples observed by analytical ferrography. A sudden increase in the size and quantity of these particles indicates excessive wear.

fatigued – A structural failure of the filter medium due to flexing caused by cyclic differen-tial pressure.

fCA sensor – The attachment to the dCA that allows you to obtain a ferrous particle count.

ferrous CONTAM-ALERT – The brand name for the portable ferrous particle count sensor, referred to as the fCA or fCA sensor in this manual.

ferrogram – A filter that has ferrous particles trapped on it which can be viewed under a mi-croscope for wear debris analysis.

ferrography – An analytical method of assessing machine health by quantifying and exam-ining ferrous wear particles suspended in the lubricant or hydraulic fluid.

film strength – Property of a lubricant that acts to prevent scuffing or scoring of metal parts.

filter – Any device or porous substance used as a strainer for cleaning fluids by removing suspended matter.

filter efficiency – Method of expressing a filter's ability to trap and retain contaminants of a given size.

filter element – The porous device which performs the actual process of filtration.

filter head – An end closure for the filter case or bowl that contains one or more ports.


filter housing – A ported enclosure that directs the flow of fluid through the filter element.

filter life test – A type of filter capacity test in which a clogging contaminant is added to the influent of a filter, under specified test conditions, to produce a given rise in pressure drop across the filter or until a specified reduction of flow is reached. Filter life may be ex-pressed as test time required to reach terminal conditions at a specified contaminant ad-dition rate.

filter media, depth – Porous materials which primarily retain contaminants within a tortuous path, performing the actual process of filtration.

filter media, surface – Porous materials which primarily retain contaminants on the influent face, performing the actual process of filtration.

filtration (Beta) ratio – The ratio of the number of particles greater than a given size in the influent fluid to the number of particles greater than the same size in the effluent fluid.

filtration – The physical or mechanical process of separating insoluble particulate matter from a fluid, such as air or liquid, by passing the fluid through a filter medium that will not allow the particulates to pass through it.

fire point (Clevelend Open Cup) – The temperature to which a combustible liquid must be heated so that the released vapor will burn continuously when ignited under specified conditions.

fire-resistant fluid – Lubricant used especially in high-temperature or hazardous hydraulic applications. Three common types of fire-resistant fluids are: (1) water-petroleum oil emulsions, in which the water prevents burning of the petroleum constituent; (2) water-glycol fluids; and (3) non-aqueous fluids of low volatility, such as phosphate esters, sili-cones, and halogenated hydrocarbon-type fluids.

flash point (Cleveland Open Cup) – The temperature to which a combustible liquid must be heated to give off sufficient vapor to form momentarily a flammable mixture with air when a small flame is applied under specified conditions. (ASTM Designation D 92.)

flow, laminar – A flow situation in which fluid moves in parallel lamina or layers.

flow, turbulent – A flow situation in which the fluid particles move in a random manner.

flow fatigue rating – The ability of a filter element to resist a structural failure of the filter medium due to flexing caused by cyclic differential pressure.

flow rate – The volume, mass, or weight of a fluid passing through any conductor per unit of time.

flowmeter – A device which indicates either flow rate, total flow, or a combination of both.

fluid – A general classification including liquids and gases.

fluid analysis – See oil analysis.

fluid, fire resistant – A fluid difficult to ignite which shows little tendency to propagate flame.

fluid compatibility – The suitability of filtration medium and seal materials for service with the fluid involved.

fluid friction – Friction due to the viscosity of fluids.

fluid opacity – Related to the ability of a fluid to pass light.


fluid power – Energy transmitted and controlled through use of a pressurized fluid.

flushing – The act of preparing a test port for testing by expelling a small amount of the test fluid through the test port, clearing it of residue and contaminants.

force feed lubrication – A system of lubrication in which the lubricant is supplied to the bearing surface under pressure.

fretting – Wear phenomena taking place between two surfaces having oscillatory relative motion of small amplitude.

fretting corrosion – Can take place when two metals are held in contact and subjected to re-peated small sliding, relative motions. Other names for this type of corrosion include wear oxidation, friction oxidation, chafing, and brinelling.

friction – The resisting force encountered at the common boundary between two bodies when, under the action of an external force, one body, moves or tends to move relative to the surface of the other.

FTIR = Fourier Transform Infrared Spectroscopy – A test where infrared light absorp-tion is used for assessing levels of soot, sulfates, oxidation, nitro-oxidation, glycol, fuel, and water contaminants.

full flow filter – A filter that, under specified conditions, filters all influent flow.

full-flow filtration – A system of filtration in which the total flow of a circulating fluid sys-tem passes through a filter.

full-fluid-film lubrication – Presence of a continuous lubricating film sufficient to com-pletely separate two surfaces, as distinct from boundary lubrication. Full-fluid-film lubri-cation is normally hydrodynamic lubrication, whereby the oil adheres to the moving part and is drawn into the area between the sliding surfaces, where it forms a pressure – or hy-drodynamic – wedge.

gage – An instrument or device for measuring, indicating or comparing a physical character-istic.

galling – A form of wear in which seizing or tearing of the gear or bearing surface occurs.

gasohol – A blend of 10% anhydrous ethanol (ethyl alcohol) and 90% gasoline, by volume. Used as a motor fuel.

generated contaminant – Caused by a deterioration of critical wetted surfaces and materials or by a breakdown of the fluid itself.

graphite – A crystalline form of carbon having a laminar structure, which is used as a lubri-cant. It may be of natural or synthetic origin.

gravimetric analysis – A method of analysis whereby the dry weight of contaminant per unit volume of fluid can be measured showing the degree of contamination in terms of milli-grams of contaminant per litre of fluid.

gravity – See Specific Gravity; API Gravity.

grease – A lubricant composed of an oil or oils thickened with a soap, soaps or other thick-ener to a semisolid or solid consistency.

hardness – The resistance of a substance to surface abrasion.

head – An end closure for the filter case or bowl which contains one or more ports.


heat exchanger – A device which transfers heat through a conducting wall from one fluid to another.

High Pressure Sampler II – (HPS II) The device used with the dCA sensor for testing par-ticle counts on-line where system pressure is between 150 and 3500 psi.

housing – A ported enclosure which directs the flow of fluid through the filter element.

hydraulic fluid – Fluid serving as the power transmission medium in a hydraulic system. The most commonly used fluids are petroleum oils, synthetic lubricants, oil-water emul-sions, and water-glycol mixtures. The principal requirements of a premium hydraulic flu-id are proper viscosity, high viscosity index, anti-wear protection (if needed), good oxidation stability, adequate pour point, good demulsibility, rust inhibition, resistance to foaming, and compatibility with seal materials. Anti-wear oils are frequently used in compact, high-pressure, and capacity pumps that require extra lubrication protection.

hydraulic oil – An oil specially suited for use as either the specific gravity or the API gravity of a liquid.

hydraulics – Engineering science pertaining to liquid pressure and flow.

hydrocarbons – Compounds containing only carbon and hydrogen. Petroleum consists chiefly of hydrocarbons.

hydrodynamic lubrication – A system of lubrication in which the shape and relative motion of the sliding surfaces causes the formation of a fluid film having sufficient pressure to separate the surfaces.

hydrofinishing – A process for treating raw extracted base stocks with hydrogen to saturate them for improved stability.

hydrolysis – Breakdown process that occurs in anhydrous hydraulic fluids as a result of heat, water, and metal catalysts (iron, steel, copper, etc.)

hydrolytic stability – Ability of additives and certain synthetic lubricants to resist chemical decomposition (hydrolysis) in the presence of water.

hydrometer – An instrument for determining either the specific gravity of a liquid or the API gravity.

hydrostatic lubrication – A system of lubrication in which the lubricant is supplied under sufficient external pressure to separate the opposing surfaces by a fluid film.

hypertext link – A connection between two topics in the Online Help System. There are two types of hypertext links. The first is a hypertext jump, indicated by green text with a solid underline. The second is a hypertext pop up, indicated by green text with a dashed under-line. Clicking on a hypertext jump displays the underlined help topic. Clicking on a hy-pertext pop up displays a window containing a definition of the underlined term.

hypoid gear lubricant – A gear lubricant having extreme pressure characteristics for use with a hypoid type of gear as in the differential of an automobile.

image analyzer – A sophisticated microscopic system involving a microscope, a television camera, a dedicated computer, and a viewing monitor similar to a television screen.

immiscible – Incapable of being mixed without separation of phases. Water and petroleum oil are immiscible under most conditions, although they can be made miscible with the addition of an emulsifier.


in-line filter – A filter assembly in which the inlet, outlet and filter element axes are in a straight line.

indicator – A device which provides external evidence of sensed phenomena.

indicator, pressure – An indicator that signals pressure conditions.

indicator, differential pressure – An indicator which signals the difference in pressure be-tween two points, typically between the upstream and downstream sides of a filter ele-ment.

influent – The fluid entering a component.

infrared spectroscopy – An analytical method using infrared absorption for assessing the properties of used oil and certain contaminants suspended therein. See FTIR.

infrared spectra – A graph of infrared energy absorbed at various frequencies in the additive region of the infrared spectrum. The current sample, the reference oil and the previous samples are usually compared.

ingested contaminants – Environmental contaminant that ingresses due to the action of the system or machine.

ingression level – Particles added per unit of circulating fluid volume.

inhibitor – Any substance that slows or prevents such chemical reactions as corrosion or ox-idation.

insolubles – Particles of carbon or agglomerates of carbon and other material. Indicates dep-osition or dispersant drop-out in an engine. Not serious in a compressor or gearbox unless there has been a rapid increase in these particles.

intensifier – A device which converts low pressure fluid power into higher pressure fluid power.

interfacial tension (IFT) – The energy per unit area present at the boundary of two immis-cible liquids. It is usually expressed in dynes/cm (ASTM Designation D 971.)

inspection codes – Some data collectors allow you to store an inspection code with a mea-surement. Inspection codes are entered as comments in the Enpac Oil, and can be used to indicate the operating condition of a piece of equipment, or the condition of an oil sam-ple. They can also be assigned directly to an item in the Hierarchy Tree or a location, or by importing data.

ISO Solid Contaminant Code (ISO 4406) – The International Standards Organization’s system of indexing particle count information to represent certain contaminant levels. A code assigned on the basis of the number of particles per unit volume greater than 5 and 15 micrometers in size. Range numbers identify each increment in the particle population throughout the spectrum of levels.

ISO Standard 4021 – The accepted procedure for extracting samples from dynamic fluid lines.

ISO viscosity grade – A number indicating the nominal viscosity of an industrial fluid lubri-cant at 40°C (104°F) as defined by ASTM Standard Viscosity System for Industrial Fluid Lubricants D 2422. Essentially identical to ISO Standard 3448.

journal – That part of a shaft or axle that rotates or angularly oscillates in or against a bearing or about which a bearing rotates or angularly oscillates.


journal bearing – A sliding type of bearing having either rotating or oscillatory motion and in conjunction with which a journal operates. In a full or sleeve type journal bearing, the bearing surface is 360° in extent. In a partial bearing, the bearing surface is less than 360° in extent, i.e., 150°, 120°, etc.

Karl Fischer Reagent Method (ASTM D-1744-64) – The standard laboratory test to mea-sure the water content of mineral base fluids. In this method, water reacts quantitatively with the Karl Fischer reagent. This reagent is a mixture of iodine, sulfur dioxide, pyridine, and methanol. When excess iodine exists, electric current can pass between two platinum electrodes or plates. The water in the sample reacts with the iodine. When the water is no longer free to react with iodine, an excess of iodine depolarizes the electrodes, signaling the end of the test.

kinematic viscosity – The absolute viscosity in centipoise divided by the specific gravity of a fluid, when both are at the same temperature. The unit of kinematic viscosity is the stoke or centistoke (1/100 of a stoke).

lacquer – A deposit resulting from the oxidation and polymerization of fuels and lubricants when exposed to high temperatures. Similar to, but harder, than varnish.

laminar particles – Particles generated in rolling element bearings which have been flat-tened out by a rolling contact.

lands – The circumferential areas between the grooves of a piston.

lead naphthenate – A lead soap of naphthenic acids, the latter occurring naturally in petro-leum.

light obscuration – The degree of light blockage as reflected in the transmitted light imping-ing on the photodiode.

liquid – Any substance that flows readily or changes in response to the smallest influence. More generally, any substance in which the force required to produce a deformation de-pends on the rate of deformation rather than on the magnitude of the deformation.

list – A set of measurement definitions. You can create a list from individual measurement definitions or from other lists. A list can be saved in, and recalled from, the database. The most recently recalled or created list is called the current list . You can load one or more lists into a data collector, and you can plot or report on the data from the items in a list.

List window – A window that contains a display of locations in the current list. A list is a set of measurement definitions. You can open only one List window, and the List win-dow cannot be split into panes.

load-carrying capacity – Property of a lubricant to form a film on the lubricated surface, which resists rupture under given load conditions. Expressed as maximum load the lubri-cated system can support without failure or excessive wear.

location – A location can be a physical point in a plant, in an area, on an equipment train, or on a machine. For vibration measurements, a location is a combination of a physical point and a direction for the measurement. For oil analysis data, a location is a position on your machinery where you collect oil samples. Each location is attached to an item in the Hierarchy Tree.

Lube Link software – Lube Link is a Windows-based software application that provides an interface with the oil sensors to make it easy to collect particle counts or viscosity data using the dCA, fCA, or dVA using your computer.


lubricant – Any substance interposed between two surfaces in relative motion for the pur-pose of reducing the friction and/or the wear between them.

lubricity – Ability of an oil or grease to lubricate; also called film strength.

magnetic – A separator that uses a magnetic field to attract and hold ferromagnetic particles.

magnetic filter – A filter element that, in addition to its filter medium, has a magnet or mag-nets incorporated into its structure to attract and hold ferromagnetic particles.

magnetic plug – Strategically located in the flow stream to collect a representative sample of wear debris circulating in the system: for example, engine swarf, bearing flakes, and fatigue chunks. The rate of buildup of wear debris reflects degradation of critical surfaces.

manifold – A filter assembly containing multiple ports and integral relating components which services more than one fluid circuit.

manifold filter – A filter in which the inlet and outlet port axes are at right angles, and the filter element axis is parallel to either port axis.

measurement – A measurement is a single reading collected from a location and controlled by a measurement definition. Measurements are usually collected with a data collector, and stored in the database.

measurement definition – A measurement definition is a set of parameters that controls the collection of a measurement. It defines the type of measurement (magnitude, process, spectrum, time, …). It also includes the collection, measurement filter, and storage spec-ifications. Each measurement definition is attached to a location.

media migration – Material passed into the effluent stream composed of the materials mak-ing up the filter medium.

medium – The porous material that performs the actual process of filtration. The plural of this word is "media".

metal oxides – Oxidized ferrous particles which are very old or have been recently produced by conditions of inadequate lubrication. Trend is important.

micrometre (µm) – See micron.

micron – The unit of measure representing one millionth of a meter, approximately 0.000394 of an inch. Relatively speaking, a grain of salt is about 60 microns and the eye can see particles to about 40 microns.

microscope method – A method of particle counting which measures or sizes particles using an optical microscope.

mineral oil – Oil derived from a mineral source, such as petroleum, as opposed to oils de-rived from plants and animals.

miscible – Capable of being mixed in any concentration without separation of phases; e.g., water and ethyl alcohol are miscible.

moly – Molybdenum disulfide, a solid lubricant and friction reducer, colloidally dispersed in some oils and greases.

motor – A device which converts fluid power into mechanical force and motion. It usually provides rotary mechanical motion.

multigrade oil – An oil meeting the requirements of more than one SAE viscosity grade clas-


sification, and may therefore be suitable for use over a wider temperature range than a single-grade oil.

multipass or recirculation test – Filter performance tests in which the contaminated fluid is allowed to recirculate through the filter for the duration of the test. Contaminant is usually added to the test fluid during the test. The test is used to determine the Beta-Ratio (q.v.) of an element.

naphthenic – A type of petroleum fluid derived from naphthenic crude oil, containing a high proportion of closed-ring methylene groups.

NAS Code – The National Aerospace Society cleanliness code used for particle count in-formation to represent certain contaminant levels.

needle bearing – A rolling type of bearing containing rolling elements that are relatively long compared to their diameter.

neutralization number – A measure of the total acidity or basicity of an oil; this includes organic or inorganic acids or bases or a combination thereof (ASTM Designation D974-58T)

newtonian fluid – A fluid with a constant viscosity at a given temperature regardless of the rate of shear. Single-grade oils are Newtonian fluids. Multigrade oils are NON-Newto-nian fluids because viscosity varies with shear rate.

nitration – Nitration products are formed during the fuel combustion process in internal combustion engines. Most nitration products are formed when an excess of oxygen is present. These products are highly acidic, form deposits in combustion areas and rapidly accelerate oxidation.

nominal filtration rating – An arbitrary micrometer value indicated by a filter manufactur-er. Due to lack of reproducibility this rating is deprecated.

non-Newtonian fluid – Fluid, such as a grease or a polymer-containing oil (e.g., multi-grade oil), in which shear stress is not proportional to shear rate.

nonwoven medium – A filter medium composed of a mat of fibers.

obliteration – A synergistic phenomenon of both particle silting and polar adhesion. When water and silt particles co-exist in a fluid containing long-chain molecules, the tendency for valves to undergo obliteration increases.

oil – A greasy, unctuous liquid of vegetable, animal, mineral or synthetic origin.

oil analysis – Oil analysis or fluid analysis is the process of determining the condition of lu-bricated equipment by examining the concentration of particles or other contaminants in a sample of the lubricant. Typically, increased particle concentration indicates increased wear on the equipment.

oil sensor interface – The connector box used to interface your computer with a dCA, fCA, or dVA, and collect data using the Lube Link software. It must be plugged in to a power supply and connected to the computer.

oiliness – That property of a lubricant that produces low friction under conditions of bound-ary lubrication. The lower the friction, the greater the oiliness.

oil ring – A loose ring, the inner surface of which rides a shaft or journal and dips into a res-ervoir of lubricant from which it carries the lubricant to the top of a bearing by its rotation with the shaft.


open bubble point (boil point) – The differential gas pressure at which gas bubbles are pro-fusely emitted from the entire surface of a wetted filter element under specified test con-ditions.

oxidation – Occurs when oxygen attacks petroleum fluids. The process is accelerated by heat, light, metal catalysts and the presence of water, acids, or solid contaminants. It leads to increased viscosity and deposit formation.

oxidation inhibitor – Substance added in small quantities to a petroleum product to increase its oxidation resistance, thereby lengthening its service or storage life; also called anti-oxidant. An oxidation inhibitor may work in one of these ways: (1) by combining with and modifying peroxides (initial oxidation products) to render them harmless, (2) by de-composing the peroxides, or (3) by rendering an oxidation catalyst inert.

oxidation stability – Ability of a lubricant to resist natural degradation upon contact with ox-ygen.

paper chromatography – A method which involves placing a drop of fluid on a permeable piece of paper and noting the development and nature of the halos, or rings, surrounding the drop through time. The roots of this test can be traced to the 1940s, when railroads used the "blotter spot" tests.

paraffinic – A type of petroleum fluid derived from paraffinic crude oil and containing a high proportion of straight chain saturated hydrocarbons. Often susceptible to cold flow problems.

particle count – The number of particles present greater than a particular micron size per unit volume of fluid often stated as particles > 10 microns per milliliter.

particle density – An important parameter in establishing an entrained particle's potential to impinge on control surfaces and cause erosion.

particle erosion – Occurs when fluid-entrained particles moving at high velocity pass through orifices or impinge on metering surfaces or sharp angle turns.

particle impingement erosion – A particulate wear process where high velocity, fluid-en-trained particles are directed at target surfaces.

patch test – A method by which a specified volume of fluid is filtered through a membrane filter of known pore structure. All particulate matter in excess of an "average size," deter-mined by the membrane characteristics, is retained on its surface. Thus, the membrane is discolored by an amount proportional to the particulate level of the fluid sample. Visually comparing the test filter with standard patches of known contamination levels determines acceptability for a given fluid.

pane – A pane is a part of a window. There are two types of panes: plot and database. A plot pane contains a graphical display of data, like a trend plot. A database pane contains ei-ther the Hierarchy Tree or a spreadsheet showing the information saved in the database.

particle count – The number of particles present at or greater than a particular micron size, typically stated in particles greater than 10 microns per milliliter.

Enpac Oil – The Portable Condition Monitor is a hand held computer used with the dCA, fCA, or dVA sensor for particle count analysis.

permeability – The relationship of flow per unit area to differential pressure across a filter medium.


pH – Measure of alkalinity or acidity in water and water-containing fluids. pH can be used to determine the corrosion-inhibiting characteristic in water-based fluids. Typically, pH > 8.0 is required to inhibit corrosion of iron and ferrous alloys in water-based fluids.

pinion – The smaller of two mating or meshing gears; can be either the driving or the driven gear.

pitting – A form of extremely localized attack characterized by holes in the metal. Pitting is one of the most destructive and insidious forms of corrosion. Depending on the environ-ment and the material, a pit may take months, or even years, to become visible.

pleated filter – A filter element whose medium consists of a series of uniform folds and has the geometric form of a cylinder, cone, disc, plate, etc. Synonymous with "convoluted" and "corrugated".

plot – A plot is a graphical display of data. Examples include trend and time plots.

Plot window – A Plot window contains one or more graphical displays of data. Plot windows can be split into two or more parts, called panes. Note that minimizing a plot window un-links the window from the Database window.

Portable Condition Monitor – (PCM) The hand held computer used with the dCA, fCA, or dVA sensor for particle count analysis.

pneumatics – Engineering science pertaining to gaseous pressure and flow.

poise (absolute viscosity) – A measure of viscosity numerically equal to the force required to move a plane surface of one square centimeter per second when the surfaces are sepa-rated by a layer of fluid one centimeter in thickness. It is the ratio of the shearing stress to the shear rate of a fluid and is expressed in dyne seconds per square centimeter (DYNE SEC/CM2); 1 centipoise equals .01 poise.

polar compound – A chemical compound whose molecules exhibit electrically positive characteristics at one extremity and negative characteristics at the other. Polar com-pounds are used as additives in many petroleum products. Polarity gives certain mole-cules a strong affinity for solid surfaces; as lubricant additives (oiliness agents), such molecules plate out to form a tenacious, friction-reducing film. Some polar molecules are oil-soluble at one end and water-soluble at the other end; in lubricants, they act as emul-sifiers, helping to form stable oil-water emulsions. Such lubricants are said to have good metal-wetting properties. Polar compounds with a strong attraction for solid contami-nants act as detergents in engine oils by keeping contaminants finely dispersed.

polishing (bore) – Excessive smoothing of the surface finish of the cylinder bore or cylinder liner in an engine to a mirror-like appearance, resulting in depreciation of ring sealing and oil consumption performance.

polymerization – The chemical combination of similar-type molecules to form larger mol-ecules.

pore – A small channel or opening in a filter medium which allows passage of fluid.

pore size distribution – The ratio of the number of effective holes of a given size to the total number of effective holes per unit area expressed as a percent and as a function of hole size.

porosity – The ratio of pore volume to total volume of a filter medium expressed as a percent.

positive crankcase ventilation (PCV) – System for removing blow-by gases from the crank-


case and returning them through the carburetor intake manifold to the combustion cham-ber where the recirculated hydrocarbons are burned. A PC valve controls the flow of gases from the crankcase to reduce hydrocarbon emissions.

pour point – Lowest temperature at which an oil or distillate fuel is observed to flow, when cooled under conditions prescribed by test method ASTM D 97. The pour point is 3°C (5°F) above the temperature at which the oil in a test vessel shows no movement when the container is held horizontally for five seconds.

pour point depressant – An additive which retards the adverse effects of wax crystalliza-tion, and lowers the pour point.

power unit – A combination of pump, pump drive, reservoir, controls and conditioning com-ponents which may be required for its application.

predictive maintenance – Predictive maintenance is the process of predicting when a ma-chine will fail based on examining data over a period of time. Predictive maintenance techniques include vibration monitoring and oil analysis.

pressure – Force per unit area, usually expressed in pounds per square inch.

pressure, absolute – The sum of atmospheric and gage pressures.

pressure, atmospheric – Pressure exerted by the atmosphere at any specific location. (Sea level pressure is approximately 14.7 pounds per square inch absolute.)

pressure, back – The pressure encountered on the return side of a system.

pressure, cracking – The pressure at which a pressure operated valve begins to pass fluid.

pressure, rated – The qualified operating pressure which is recommended for a component or a system by the manufacturer.

pressure, system – The pressure which overcomes the total resistances in a system. It in-cludes all losses as well as useful work.

pressure chamber – The test chamber used for bottle samples of lubricating or hydraulic flu-id, allowing them to be pressurized for sampling.

pressure drop – Resistance to flow created by the element (media) in a filter. Defined as the difference in pressure upstream (inlet side of the filter) and downstream (outlet side of the filter).

pressure gage – Pressure differential above or below atmospheric pressure.

pressure line filter – A filter located in a line conducting working fluid to a working device or devices.

preventive maintenance – Maintenance performed according to a fixed schedule involving the routine repair and replacement of machine parts and components.

proactive maintenance – A type of condition-based maintenance emphasizing the routine detection and correction of root cause conditions that would otherwise lead to failure. Such root causes as high lubricant contaminant, alignment and balance are among the most critical.

priming – The act of wetting the internal surfaces of the sensor with the test fluid prior to testing.

probing on – The method used for attaching the dCA, fCA, or dVA sensor or Samplyzer bot-


tle to a test port valve for testing or fluid sampling.

process measurement – Also called process point. A single value that indicates the general condition of a process or equipment.

PSIA – Pounds per Square Inch Absolute. (PSIG + 14.696)

PSID – Pounds per Square Inch Differential.

PSIG – Pounds per Square Inch Gauge (PSIA - 14.696)

pump – A device which converts mechanical force and motion into hydraulic fluid power.

pumpability – The low temperature, low shear stress-shear rate viscosity characteristics of an oil that permit satisfactory flow to and from the engine oil pump and subsequent lubri-cation of moving components.

pump, fixed displacement – A pump in which the displacement per cycle cannot be varied.

pump, variable displacement – A pump in which the displacement per cycle can be varied.

rate of shear – The difference between the velocities along the parallel faces of a fluid ele-ment divided by the distance between the faces.

reducer – A connector having a smaller line size at one end than the other.

refraction – The change of direction or speed of light as it passes from one medium to an-other.

rerefining – A process of reclaiming used lubricant oils and restoring them to a condition similar to that of virgin stocks by filtration, clay adsorption or more elaborate methods.

reservoir – A container for storage of liquid in a fluid power system.

reservoir (sump) filter – A filter installed in a reservoir in series with a suction or return line.

residual dirt capacity – The dirt capacity remaining in a service loaded filter element after use, but before cleaning, measured under the same conditions as the dirt capacity of a new filter element.

return line – A location in a line conducting fluid from working device to reservoir.

return line filtration – Filters located upstream of the reservoir but after fluid has passed through the system's output components (cylinders, motors, etc.).

ring lubrication – A system of lubrication in which the lubricant is supplied to the bearing by an oil ring.

rings – Circular metallic elements that ride in the grooves of a piston and provide compres-sion sealing during combustion. Also used to spread oil for lubrication.

ring sticking – Freezing of a piston ring in its groove in a piston engine or reciprocating com-pressor due to heavy deposits in the piston ring zone.

roll-off cleanliness – The fluid system contamination level at the time of release from an as-sembly or overhaul line. Fluid system life can be shortened significantly by full-load op-eration under a high fluid contamination condition for just a few hours. Contaminant implanted and generated during the break-in period can devastate critical components un-less removed under controlled operating and high performance filtering conditions.

roller bearing – An antifriction bearing comprising rolling elements in the form of rollers.


rust prevention test (turbine oils) – A test for determining the ability of an oil to aid in pre-venting the rusting of ferrous parts in the presence of water.

sample preparation – Fluid factors that can enhance the accuracy of the particulate analysis. Such factors include particle dispersion, particle settling, and sample dilution.

Samplyzer bottle – The brand name of all bottles stocked for resale by Entek IRD that in-cludes a probe tip for collecting samples on-line.

saturation level – The amount of water that can dissolve in a fluid.

Saybolt Universal Viscosity (SUV) or Saybolt Universal Seconds, (SUS) – The time in seconds required for 60 cubic centimeters of a fluid to flow through the orifice of the Standard Saybolt Universal Viscometer at a given temperature under specified condi-tions. (ASTM Designation D 88.)

scuffing – Abnormal engine wear due to localized welding and fracture. It can be prevented through the use of antiwear, extreme-pressure and friction modifier additives.

scuffing particles – Large twisted and discolored metallic particles resulting from adhesive wear due to complete lubricant film breakdown.

semisolid – Any substance having the attributes of both a solid and a liquid. Similar to semi-liquid but being more closely related to a solid than a liquid. More generally, any sub-stance in which the force required to produce a deformation depends both on the magnitude and on the rate of the deformation.

sensor screen – The calibrated screen used with the dCA sensor that comes in 5, 10, or 15 micron increments.

shear rate – Tate at which adjacent layers of fluid move with respect to each other, usually expressed as reciprocal seconds.

shear stress – Frictional force overcome in sliding one "layer" of fluid along another, as in any fluid flow. The shear stress of a petroleum oil or other Newtonian fluid at a given tem-perature varies directly with shear rate (velocity). The ratio between shear stress and shear rate is constant; this ratio is termed viscosity of a Newtonian fluid, the greater the shear stress as a function of rate of shear. In a non-Newtonian fluid – such as a grease or a poly-mer-containing oil (e.g. multi-grade oil) – shear stress is not proportional to the rate of shear. A non-Newtonian fluid may be said to have an apparent viscosity, a viscosity that holds only for the shear rate (and temperature) at which the viscosity is determined.

silt – Contaminant particles 5 µm and less in size.

silting – A failure generally associated with a valve which movements are restricted due to small particles that have wedged in between critical clearances (e.g., the spool and bore.)

single-pass test – Filter performance tests in which contaminant which passes through a test filter is not allowed to recirculate back to the test filter.

sintered medium – A metallic or nonmetallic filter medium processed to cause diffusion bonds at all contacting points.

sleeve bearing – A journal bearing, usually a full journal bearing.

sludge – Insoluble material formed as a result either of deterioration reactions in an oil or of contamination of an oil, or both.

solid – Any substance having a definite shape which it does not readily relinquish. More gen-


erally, any substance in which the force required to produce a deformation depends upon the magnitude of the deformation rather than upon the rate of deformation.

solvency – Ability of a fluid to dissolve inorganic materials and polymers, which is a function of aromaticity.

specific gravity (liquid) – The ratio of the weight of a given volume of liquid to the weight of an equal volume of water.

specific gravity – The ratio of the weight of a given volume of material to the weight of an equal volume of water. Used to convert absolute viscosity to kinematic viscosity.

spectrographic analysis – Determines the concentration of elements represented in the en-trained fluid contaminant.

Spectrographic Oil Analysis Program (SOAP) – Procedures for extracting fluid samples from operating systems and analyzing them spectrographically for the presence of key el-ements.

spin-on filter – A throw-away type bowl and element assembly that mates with a permanent-ly installed head.

spindle oil – A light-bodied oil used principally for lubricating textile spindles and for light, high-speed machinery.

splash lubrication – A system of lubrication in which parts of a mechanism dip into and splash the lubricant onto themselves and/or other parts of the mechanism.

static friction – The force just sufficient to initiate relative motion between two bodies under load. The value of the static friction at the instant relative motion begins is termed break-away friction.

stoke (St) – Kinematic measurement of a fluid's resistance to flow defined by the ratio of the fluid's dynamic viscosity to its density.

strainer – A coarse filter element (pore size over approximately 40 µm)

suction filter – A pump intake-line filter in which the fluid is below atmospheric pressure.

sulfated ash – The ash content of fresh, compounded lubricating oil as determined by ASTM Method D 874. Indicates level of metallic additives in the oil.

sulfurized oil – Oil to which sulfur or sulfur compounds have been added.

superclean – A cleanliness definition for fluids defined as having fewer than 10 particles greater than 10 microns per milliliter.

surface fatigue wear – The formation of surface or subsurface cracks and fatigue crack prop-agation. It results from cyclic loading of a surface.

surface filtration – Filtration which primarily retains contaminant on the influent surface.

surface tension – The contractile surface force of a liquid by which it tends to assume a spherical form and to present the least possible surface. It is expressed in dynes/cm or ergs/cm2.

surfactant – Surface-active agent that reduces interfacial tension of a liquid. A surfactant used in a petroleum oil may increase the oil's affinity for metals and other materials.

surge – A momentary rise of pressure in a circuit.


swarf – The cuttings, and grinding fines that result from metal working operations.

switch, pressure – An electric switch operated by fluid pressure.

synthetic lubricant – A lubricant produced by chemical synthesis rather than by extraction or refinement of petroleum to produce a compound with planned and predictable proper-ties.

synthetic hydrocarbon – Oil molecule with superior oxidation quality tailored primarily out of paraffinic materials.

test port valve – The sampling valve used for on-line sampling and testing. You can attach the dCA, fCA, or dVA sensor directly to a test port valve.

thermography – The use of infrared thermography whereby temperatures of a wide variety of targets can be measured remotely and without contact. This is accomplished by mea-suring the infrared energy radiating from the surface of the target and converting this measurement to an equivalent surface temperature.

thermal conductivity – Measure of the ability of a solid or liquid to transfer heat.

thermal stability – Ability of a fuel or lubricant to resist oxidation under high temperature operating conditions.

thin film lubrication – A condition of lubrication in which the film thickness of the lubricant is such that the friction between the surfaces is determined by the properties of the sur-faces as well as by the viscosity of the lubricant.

thixotropy – That property of a lubricating grease which is manifested by a softening in con-sistency as a result of shearing followed by a hardening in consistency starting immedi-ately after the shearing is stopped.

three-body abrasion – A particulate wear process by which particles are pressed between two sliding surfaces.

thrust bearing – An axial-load bearing.

Timken OK Load – The heaviest load that a test lubricant will sustain without scoring the test block in the Timken Test procedures, ASTM Methods D 2509 (greases) and D 2782 (oils).

Total Acid Number (TAN) – The quantity of base, expressed in milligrams of potassium hydroxide, that is required to neutralize all acidic constituents present in 1 gram of sam-ple. (ASTM Designation D 974.)

Total Base Number (TBN) – The quantity of acid, expressed in terms of the equivalent num-ber of milligrams of potassium hydroxide that is required to neutralize all basic constitu-ents present in 1 gram of sample. (ASTM Designation D 974.)

tribology – The science and technology of interacting surfaces in relative motion, including the study of lubrication, friction and wear. Tribological wear is wear that occurs as a re-sult of relative motion at the surface.

turbidity – The degree of opacity of a fluid.

turbulent flow sampler – A sampler that contains a flow path in which turbulence is induced in the main stream by abruptly changing the direction of the fluid.

unloading – The release of contaminant that was initially captured by the filter medium.


vacuum separator – A separator that utilizes subatmospheric pressure to remove certain gases and liquids from another liquid because of their difference in vapor pressure.

valve, by-pass – A valve whose primary function is to provide an alternate flow path.

valve, directional control – A valve whose primary function is to direct or prevent flow through selected passages.

valve, directional control, servo – A directional control valve which modulates flow or pressure as a function of its input signal.

valve, flow control – A valve whose primary function is to control flow rate.

valve, pressure control, relief – A pressure control valve whose primary function is to limit system pressure.

valve, relief, differential pressure – A valve whose primary function is to limit differential pressure.

valve – A device which controls fluid flow direction, pressure, or flow rate.

valve lifter – Sometimes called a "cam follower," a component in engine designs that use a linkage system between a cam and the valve it operates. The lifter typically translates the rotational motion of the cam to a reciprocating linear motion in the linkage system.

vapor pressure – Pressure of a confined vapor in equilibrium with its liquid at specified tem-perature thus, a measure of a liquid's volatility.

Vapor Pressure-Reid (RVP) – Measure of the pressure of vapor accumulated above a sam-ple of gasoline or other volatile fuel in a standard bomb at 100°F (37.8°C). Used to predict the vapor locking tendencies of the fuel in a vehicle's fuel system. Controlled by law in some areas to limit air pollution from hydrocarbon evaporation while dispensing.

varnish – When applied to lubrication, a thin, insoluble, nonwipeable film deposit occurring on interior parts, resulting from the oxidation and polymerization of fuels and lubricants. Can cause sticking and malfunction of close-clearance moving parts. Similar to, but soft-er, than lacquer.

viscometer or viscosimeter – An apparatus for determining the viscosity of a fluid.

viscosity – Measurement of a fluid's resistance to flow. The common metric unit of absolute viscosity is the poise, which is defined as the force in dynes required to move a surface one square centimeter in area past a parallel surface at a speed of one centimeter per sec-ond, with the surfaces separated by a fluid film one centimeter thick. In addition to kine-matic viscosity, there are other methods for determining viscosity, including Saybolt Universal Viscosity (SUV), Saybolt Furol viscosity, Engier viscosity, and Redwood vis-cosity. Since viscosity varies in inversely with temperature, its value is meaningless until the temperature at which it is determined is reported.

viscosity, absolute – The ratio of the shearing stress to the shear rate of a fluid. It is usually expressed in centipoise.

viscosity, kinematic – The absolute viscosity divided by the density of the fluid. It is usually expressed in centistokes.

viscosity, SUS – Saybolt Universal Seconds (SUS), which is the time in seconds for 60 mil-liliters of oil to flow through a standard orifice at a given temperature. (ASTM Designa-tion D88-56.)


viscosity grade – Any of a number of systems which characterize lubricants according to vis-cosity for particular applications, such as industrial oils, gear oils, automotive engine oils, automotive gear oils, and aircraft piston engine oils.

Viscosity Index (VI) – A commonly used measure of a fluid's change of viscosity with tem-perature. The higher the viscosity index, the smaller the relative change in viscosity with temperature.

viscosity index improvers – Additives that increase the viscosity of the fluid throughout its useful temperature range. Such additives are polymers that possess thickening power as a result of their high molecular weight and are necessary for formulation of multi-grade engine oils.

viscosity modifier – Lubricant additive, usually a high molecular weight polymer, that re-duces the tendency of an oil's viscosity to change with temperature.

viscous – Possessing viscosity. Frequently used to imply high viscosity.

volatility – This property describes the degree and rate at which a liquid will vaporize under given conditions of temperature and pressure. When liquid stability changes, this proper-ty is often reduced in value.

wear – The attrition or rubbing away of the surface of a material as a result of mechanical action.

wicking – The vertical absorption of a liquid into a porous material by capillary forces.

ZDDP – An antiwear additive found in many types of hydraulic and lubricating fluids. Zinc dialkyldithiophosphate.

Abbreviations, Prefixes, and Letter Symbols amp – ampere

ARP – Aeronautical Recommended Practice

ASLE – American Society of Lubrication Engineers. Changed now to Society of Tribologist and Lubrication Engineers (STLE).

ASME – American Society of Mechanical Engineers

ASTM – American Society for Testing Materials

ANSI – American National Standards Institute

atm – atmosphere

BTU – British thermal unit

C or cent. – centigrade

cc – cubic centimeter

cm – centimeter

cfm – cubic feet per minute

GPM – gallons per minute

hp or HP – horsepower

HVI – High Viscosity Index, typically from 80 to 110 VI units.


Hz – Hertz (cycles per second)

ISO – International Standards Organization, sets viscosity reference scales.

JIC – Joint Industry Conference

kg – kilograms

km – kilometer

kHz – thousand Hertz (cycles per second)

log – logarithm (common)

LVI – Low Viscosity Index, typically below 40 VI units.

MIL – military

M – meter

µm – micron (micro-meter)

NFPA – National Fluid Power Association

NEMA – National Electrical Manufacturers Association

NEC – National Electrical Code

NAS – National Aerospace Standard

NASA – National Aeronautics and Space Administration

psi – pounds per square inch

psia – pounds per square inch absolute

rpm – revolutions per minute

SAE – Society of Automotive Engineers, an organization serving the automotive industry.

SSU – Saybolt Universal Seconds (or SUS), a unit of measure used to indicate viscosity, e.g., SSU @ 100° F

STLE – Society of Tribologist and Lubrication Engineers, formerly ASLE, American Soci-ety of Lubrication Engineers.

P – pressure - psi

PPM – parts per million (1/ppm = 0.000001). Generally by weight. 100 ppm = 0.01%; 10,000 ppm = 1%

Q – flow rate - GPM

t – time in seconds

DP – pressure drop psid

DT – temperature change, Fahrenheit

V – total volume (gals)

PREFIXES -U.S. TERM

kilo – Thousand

mega – Million


centi – Hundredth

milli – Thousandth

micro – Millionth

Cleanliness Definitions A cleanliness level for sample bottles having less than:

Clean– 100 particles >10 micron per milliliter

Superclean–10 particles >10 micron per milliliter

Ultraclean–1 particle >10 micron per milliliter

Index


Index

<.> key 139-way D connector 14

Aagitating 87alarms

category variables 100category variables, setting values 101exceeding target level 128loading in Enlube PM 105multiple in Enlube PM 105overview in Enlube PM 104statistics, regenerating 101trigger in Enlube PM 105

approval specification 10arrow keys overview 13assigning inspection codes

See inspection codes, assigningauto reports on unload 117

Bbackflushing

fCA sensor 51lab apparatus for dCA 36lab apparatus for dVA 68manually for dCA 36manually for dVA 68

backwashing 36, 68See also backflushing

ball valve type 81battery

capacity 16checking 13, 16inserting 17overview 15removing 17replacing the fCA battery 50safety switch 17specifications 9

baud ratesetting in host software 110setting in the Enpac Oil 111

bench-top apparatus 151FLUSH knob 36, 68RETRACT 36, 68using 88

Bootloader Configuration windowloading operating system 21overview 20

bottled sampleagitating 87collecting from a 500–3500 psi line 85collecting from a from a 5–500 psi line 84using with bench-top apparatus 89using with portable pressure chamber 88

Ccable

RS-232-C 112serial 112

calibration file 118calibration number

calculating for dVA 41setting for dCA 32setting for the dVA 60

Calibration Validation Program 32, 39categories 101Category command 101category variables 101CE Services 118certification specification 10changing screen sizes or fluids 38clean fluid 39collecting data

bottled sample 83, 84, 85checking settings 125Enpac Oil use 126, 132ensuring accuracy 127, 134, 138, 143ferrogram 52inspection codes 134list data 126lists 126, 135skipping points 136unscheduled 136viewing 144

collecting samplesbottled sample 83, 84directly from a test port 83fluid 81from a 500–3500 psi line 85from a 5–500 psi line 84overview 83test port valves 81

Collection command 102

Index


collection specification 102COM1 port 109comment field 134comments

entering 134inspection codes 106

communicationcable 112device 109diagram 112overview 109setting up Enpac Oil 111setting up host software 109

communications specification 10connecting

bottle to test port valve 84dCA sensor to Enpac Oil 30, 58dCA sensor to test port valve 33dVA sensor to test port valve 59hardware to data collector 13HPS II to test port valve 87

connector panel specification 9control count 41current data collector, selecting 109Customer Support 5

Ddata collector

choosing current 110driver version number 115operating system version number 19resetting 19Windows CE operating system 21

date, setting 23dCA MAIN MENU 24dCA sensor

assembling 35backflushing 36calibration with Lube Link 153collecting data 126configuring with Lube Link 151how it works 30if dropped 28Lube Link particle size distribution 153operating specifications 29overview 28priming 34, 59probing on 33replacing sensor seals 43safety 28screens 35seal and fluid compatibility 42

decimal key 13default viscosity units in Lube Link 158

deleting lists 113diagram

battery 17bottled samples 83communication 112data collector 12direct sampling 83hardware connection 13hardware reset 19RS-232 pin assignments 14security key 112

diluting high viscosity fluids 44, 54display screens, overview 24<DOWN> arrow key 13dVA sensor

assembling 59backflushing 68calibrating probe 61, 63calibration file transfer 118configuring with Lube Link 154entering probe serial number 60entering serial number with Lube Link 154how it works 57new oil specifications 72new oil specifications in Lube Link 168operating specifications 57probing on 59replacing sensor seals 70safety 56seal and fluid compatibility 69setting default units 65

Eenclosure specification 8environmental specification 10ESAFE Agreement 5exporting data using Lube Link 147

F<F1> through <F4> overview 12fCA sensor

cleaning 50collecting data 129connecting 49ferrogram 52flushing 51how it works 48

ferrogram 52filling a sample bottle 84fluid sampling

dynamic 81static 81

Index


fluid typehydraulic 32lubrication 32

GGood Lab Practices 32

Hhardware connection, diagram 13, 112help

Customer Support 5online help in host software 4safety 28

High Pressure Sampler IIsafety 28, 87using 87using to collect a bottled sample 85

host software, online help system 4HPS II

See High Pressure Sampler II

II/O specification 10INI file options 190inspection codes

assigning 106entering 134overview in Enlube PM 104

IrDAinterface 14

ISO codeEnlube PM units 95result settings 127, 137setting Enpac Oil 32

Kkeys

arrow 13decimal (<.>) 13function keys overview 12on/off 13overview 12

LLA-200

See bench-top apparatuslab stand 151

listscollecting data 126deleting 105, 113entering comments 134loading 113, 114loading in Enlube PM 105moving through 135, 136overview in Enlube 105overview in Enlube PM 104Quickload 114selecting 114selecting multiple 114storage capacity 105unloading 116

loading 21alarms in Enlube PM 105lists in Enlube PM 105more than one list in Enlube PM 105operating system 21overview 108preparing the Enpac Oil 113, 116

locked up 19lube library 158Lube Link

calibrating dCA 153calibrating low/high viscosity limits 154comparing viscosity to new oil specifica-

tions 168configuring dCA 151configuring dVA 154default directory 147default viscosity units 158entering dVA probe serial number 154entering new oil specifications 158export location 147inserting new machines 148lab stand 151overview 146set up 146setting up data 146

Lube linkparticle size distribution 153

Mmeasurement definitions

options 94process 94setting up 101

measurement types, Enlube PM 94measurement unit

Enlube PM particle counts 96Enlube PM table 96unscheduled defaults 190

Index


memory cardformatting 26inserting and removing 26overview 25types used with enpac 26

menusoverview 24

monitoringcomponent 81pump effluent 81return line 81

N“No dCA Route” message 127, 130N81

See ProtocolNAS code

Enlube PM units 95result settings 127, 137setting Enpac Oil for 32

Ooil specifications 158<On/Off> key 13online help system

host software 4hypertext links 5topics 5

operating system 21

Pparticle count

result codes 32setting 32, 127, 137

PCMCIA cardSee memory card 25

performance specification 9power specification 9powering down 17powering up 17predictive maintenance 2preparing samples

agitating bottle 88, 91portable pressure chamber 88preventing contamination 89

pressure chamberbench-top apparatus 90portable 88

priming dCA sensor 34, 59probe calibration for dVA 60probe serial number 154

probe-on valve type 81probing on

dCA sensor 33dVA sensor 59

process measurement, Enlube PM 94product specifications 8

approval/certification 10battery/power 9connector panel 9enclosure 8environmental 10I/O and communications 10performance 9system 10

protocolsetting in host software 110setting in the Enpac Oil 111

Qquestions and answers 192Quickload files 114

R<READ/OK> key 12reinitialize Windows CE 20reports

print automatically after unload 117resetting data collector 19result codes, setting 32reviewing data 144<RIGHT> arrow key 13route

See listsroute sample in Enlube PM 105RS-232 interface

cable 14pin assignments 14

RS-232-C cable 112

Ssafety

dCA sensor 28dVA sensor 56HPS II 28

Samplyzer bottle 84security key, diagram 112

Index


sensor screencalibration number 32, 35, 39Calibration Validation 39changing from larger to smaller pore size 38cleaning 36, 37cleaning solvent 37color code 31, 35, 152inserting 35setting calibration 32setting fluid type 32setting size 31, 66

sensor sealscompatibility 69fluid compatibility 42replacing 43

serial numberdata collector 19

set unscheduled destination 143Set Up Computer button 109setting date and time 23settings

checking sensor on Enpac Oil 125hydraulic 32lubrication 32particle size distribution 33, 153screen size 31viscosity default units 65

skipping points 136specific gravity 133Status message 25storage capacity 105superclean fluid 37system specification 10

Ttarget value 128Technical Support

See Customer Supporttest port valves

locating 81preparing 81

time/datedisplay 23setting 23

transfer settingsEnpac Oil 111host software 110

trigger alarms in Enlube PM 105turning off 17turning on 17

Uunits 32unloading

inspection codes 106lists 116lists using host software 116overview 108unscheduled data 117

unscheduled datacollecting 136default measurement units 190storing in host software 143unloading 117

<UP> arrow key 13

Vversion number

data collector driver 115data collector operating system 19

viewing data 144viscosity

dVA sensor 57low/high limits 61, 166low/high limits in Lube Link 154measurement definitions 103units 103

WWindows CE operating system

bootloader 20reinitialize 20

Index


enpac oil user's guide

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