RS PRO 2795420 Fuel & Oil Cleanliness Analyser User Manual

: May 15, 2024
: RS PRO

**RS PRO 2795420 Fuel & Oil Cleanliness Analyzer User Manual

**

Specifications

Specification	Detail
Dimensions	Small – (w)314mm x (d)257mm x (h)152mm (12.4” x 10.1” x 6.0”)Large

– (w)398 mm x (d)310 mm x (h)172 mm (15.7” x 12.2” x 6.8”)
Weight| Small – 4.46 kg (9.8 lbs.) Large – 7.10kg (15.7 lbs.)
Finish| Black impact resistant case
Nominal Battery Voltage| 22.5 VDC
Charge Voltage| 25.2 VDC
Capacity| 4000 mash
Charge time| 2 hours (80%) 5 hours (100%)
Run time| Up to 10 hours (depending on fluid viscosity)
Modes of operation| Tank samplingBottle sampling (200ml minimum sample bottle recommended)
Cleanliness standards| ISO 4406, NAS 1638, SAE AS4059
Pump type| Gear pump
Duty cycle| Continuous
Viscosity range| Small Unit – 1-320 cost (1-300 cost with High Pressure device) Large Unit – 1-2400 cost (1-300 cost with High Pressure device)
Fluid compatibility| Diesel & oil (hydraulic, lubrication, mineral, synthetic)
Fluid temperature| 0 to 60°C (oils)0 to 50°C (diesel)
Ambient temperature| 0°C to +60°C
Environment| Lid closed – IP67 Lid open – IP54
Connections| 1604 minims test points, with 0.6m long 8mm tubing
Pressure| 2.5 bar max (up to 350 bar with optional High Pressure device)
Maximum humidity| 97% relative humidity, non-condensing
Certification| Factory calibration certificate CE declaration
Verification frequency| 12 months recommended
PC requirements| Windows/Mac (with USB port), spreadsheet software (e.g. MS Excel)

Component Identification

Key:

1.) Touch screen display	5.) Printer connection port (optional)
2.) Pump on/off switch	6.) Return / Outlet (Minims Test Point)
3.) Display/sensors on/off switch	7.) Suction / Inlet (Minims Test Point)
4.) Charging port	8.) USB port (at rear of case)

Suction & Return Hose Connections

The unit comes equipped with Minims Test Points. These seal automatically as the coupling is removed, so the connections won’t leak during transit.
Suction & Return Hose Connections

To connect the hoses, screw them onto the Minims Test Points, hand tight only.

Make sure the hose assembly with the strainer is always used on the suction/inlet port.

To disconnect the hoses, unscrew from the Minims Test Point. The hose assemblies do not contain a self-seal mechanism and may drip; keep an oil absorbent spill mat ready and store hoses in a clean plastic bag when not in use. Placing a finger over the end of the hose can prevent oil dripping out of the test point onto the fascia of the unit.

Suction Strainer

Units are supplied with a strainer fitted to the suction tube assembly. The inline strainer has a 270 micron mesh and is used for keeping accidental debris from damaging the pump gears or clogging other components.

The strainer must always be used, otherwise the units warranty may become void.

The strainer can be disassembled for cleaning as shown below and should be checked periodically to ensure the flow is unrestricted.

When taking apart the strainer, note the orientation of the mesh for correct reassembly.

Operating the Unit

On/Off Switches

Units have two push button switches, one for the pump and one for the touch screen.

Note that because the screen regulates the pump speed, the pump will only work when the screen is switched on

Touch Screen Layout

The main window of the touch screen displays all information provided by the particle counter and any other sensor that may be installed. Time and remaining battery capacity is also displayed. The ISO code can change from white to green or red depending on the alarm limits se

If the unit display temperature, pressing the value will switch between Celsius and Fahrenheit.

In the top right corner of the screen is a settings icon, clicking this will open the settings page.
Touch Screen Layout

At the bottom left of the settings page the software version is displayed.

Pump Settings & Priming

Pressing the buttons “Hydraulic & Gear Oil” or “Light Oil & Diesel” will set the pumps test speed to suit your fluid type.

In some situations, the pump speed may need to be temporarily increased for priming or flushing the unit by press the “Prime Speed” buttons.

ISO Alarm Limits

Alarm limits for low (clean) or high (dirty) can be set. Low refers to oil achieving required cleanliness codes in all size categories. High refers to oil exceeding any one of the codes for particulate contamination. When the oil is clean the ISO code on the main screen will turn green, when dirty it will become red, between the two values the text is white.

Datalogging

The unit contains two internal dataloggers, one for the graph and one for the tests. Whenever the unit is switched off the graph will be reset, but this can also be done from the screen without having to switch off the unit. The main data log tied to the sensors will hold 100,000 lines of data (100,000 polls of the sensors) which equates to 138 days of testing.

To create a new log file the button needs to be held down for a couple of seconds, until a confirmation message is displayed. This creates a new log file but does not delete the previous. Clearing log files from the device must be done through the software, either the Particle Pal CSV Reporting Tool or the Particle Pal Device Utility
Datalogging

Entering a Test Name

The main screen shows a “Test Name” field, which can be clicked to bring up a new window. Here a test name can be entered and when the back button is clicked this will be stored in memory. Even if the unit is switched off this test name will remain in memory until it’s been cleared or changed.

The test name will show as a repeating field in the data log file, for easily finding the relevant test.
Entering a Test Name

QR Code

The main screen shows a QR code symbol in the top left. When clicked this will display a full screen QR code containing a web link with all the data from the last 5 tests. Scanning this with your phone will open a webpage where all the data will be mapped into tables and charts, ready for saving as a PDF.

It is best practice to make sure the unit runs long enough to gather 5 sets of data, otherwise the QR code will contain data from previous tests.

Once new data is displayed on the screen wait a minute for all data log files to update before pressing the QR code button. Pressing the button too early may results in data not being included in the code, showing zero values in the report.

Time Zone Adjustment

The display screen is pre-set with the date and date to GMT +0 (UK time) this can be adjusted according to your time zone if required. Specific time adjustments can be done via the Particle Pal Device Utility software.
Time Zone Adjustment

Printer

Units have the option of being supplied with a thermal printer. The most recent set of results shown on the screen can be printed by going to the settings page and clicking the print button.
Printer

Periodically charge the printer with the supplied charging unit to keep the batteries in optimum condition.

The printer uses a 57mm wide paper roll, with a maximum diameter of 55mm.

Battery Charging

Units are fitted with a 6S lithium battery pack and require use of the supplied 25.5V battery charger.

A charge port on the side of the case allows for charging of the battery, which from a complete discharge takes approximately 5 hours (2 hours to reach 80% charge).

To maintain the overall life of the battery, avoid complete discharges.

If the unit is to be stored for prolonged periods of time the battery is best left at 60% charge to maintain an optimum lifespan.
Battery Charging

Battery Charging Unit

The battery charge unit is designed for indoor use only and should not come into contact with water, dust, oils or grease. To prevent overheating, the product should not be covered whilst in use

The mains socket should be easily accessible. In the event of operational error, the plug should be immediately removed from the socket.

A fuse protects the product against short circuit and overload. If the fuse needs to be replaced, the same type and size of fuse should always be used.

Charging Instructions

The charger has a small LED which when connected to a discharged unit will illuminate red. Once charging is complete the LED will turn green.

Note the LED will not turn green if the unit is switched on and in use.

Fluid Viscosity

The portable analyzers are designed to handle a fluid viscosity of up to 320 cost for the small unit or 2400 cost for the larger units. It’s possible to pass high viscosity oils through the unit if they are preheated as per the below table.

Note that as a pre-heated oil passes though the unit it will cool, therefore increasing its viscosity and strain on the pump.

Temperature	Viscosity (cost)
ISO 32	ISO 46
ISO 220	ISO 320
10.0	161
12.0	141
14.0	124
16.0	109
18.0	97
20.0	86
22.0	77
24.0	69
26.0	62
28.0	56
30.0	51
32.0	46
34.0	42
36.0	38
38.0	35
40.0	32
42.0	29
44.0	27
46.0	25
48.0	23
50.0	21

Internal Gear Pump

The internal gear pump provides a steady flow for accuracy of results. Fluids above the rated viscosity can cause excess motor strain and cause it to overheat or slip. It’s important to pay attention to the grade of oil being analyzed and its temperature.

Water Sensor – % Saturation (RH)

The RH option incorporates a sensor into the fluid circuit which measures water saturation as a percentage

The RH sensor measures water content relative to the saturation point of the liquid and outputs the degree of saturation in the range 0-100%. A reading of 0% would indicate a fluid free of water, while a reading of 100% would indicate a fluid that is saturated with water (see diagram below). The capacitance sensor absorbs water molecules from the fluid which change its capacitance value, that capacitance value is directly proportional to the saturation level of the fluid.

Since the effects of free water are more harmful than those of dissolved water, water levels should be maintained well below the saturation point. However, even dissolved water can cause damage, therefore every reasonable effort should be made to keep the saturation levels as low as possible.

As a guideline we recommend maintaining saturation levels below 45% in all equipment.

Sensor Specifications

Specification	Details
Fluid type	Oil
Measurement range	0-100%
Measurement temperature range	0-100°C
Measurement accuracy	±3%
Operating pressure	-0.5 to 50 bar
Voltage supply	1-32 VDC
Power consumption	30-60 mA
Output	4-20 mA
Protection type	IP67
Recalibration	Intervals depend on use, recommended annually

Sensor Working Range

The graph shows the permitted working range for RH sensor. If the sensor is operated permanently outside the range indicated in blue, lasting damage can occur to the sensor element.

If the fluid sample contains free water, it should not be passed through the portable analyzer.

Water Sensor – Parts Per Million (PPM)

The PPM option incorporates a water moisture sensor into the fluid circuit of the portable analyzer

The sensor offers real time measurement of absolute water content in ppm (parts per million) and outputs a value up to the fluids saturation point.

As per BS EN 590 diesel fuel should contain no more than 200ppm (0.02%) of water.

The sensor is calibrated specifically for use with diesel fuel, use with other fluid types will provide inaccurate readings.

Note : If the fluid sample contains free water or has a water content of above 300ppm (cloudy/hazy appearance) it should not be passed through the portable analyzer. Samples above 300ppm will cause the sensor to lock out. If this occurs, clean dry diesel (<100ppm) will need to be flushed through the unit for 15 minutes to 2 hours (depending on level of exposure), where the readings will gradually fall back within its normal operating range

Specifications

Specification	Details
Fluid type	Diesel
Measurement range – water content	0-300 ppm
Measurement temperature range	0-50°C
Measurement accuracy	Less than 10% of limit of measurement range accessible
Operating pressure	Vacuum to 300 bar
Voltage supply	18-28 VDC
Power consumption	30-70 mA
Output	4-20 mA
Protection type	IP65
Recalibration	Intervals depend on use, recommended annually

Density and Viscosity Sensor

The density and viscosity sensor uses a piezo electric device for continuous determination of fluid density and viscosity

To ensure accurate density and viscosity readings the fluid should be clean and maintained at a steady temperature similar to the unit. Contaminant in the form of water or solids may cause higher than expected readings, while an aerated fluid sample will cause lower than expected readings

Specification	Details
Accuracy	Density – 2%Viscosity – 5%
Measurement Range	Density – 0.6 g/cm³ – 1.3 g/cm³ Viscosity – 25 – 400mPa·s
Resolution	Density – 0.001g/cm³ Viscosity – 0.1mPa·s
Working Voltage	DC 9V‐ 32V
Power Consumption	< 30mA @ 24Vdc
Operating temperature	0°C to 70°C (0°C to 50°C for diesel)
Operating pressure	10 bar
Applicable standards	ASTM1657, EN61326-1, EN61326‐ 2‐ 3, ICES‐ 003 B

Density

The unit displays density as kg/m³, which is the same as g/cm³. To convert this to a unit such as kg/l divide the value by 1000.

Viscosity

The unit displays dynamic viscosity as maps (millipascal-second). This is the same as cP (centipoise) e.g. 100 maps = 100 cup

To convert from dynamic to kinematic viscosity such as centistokes, the dynamic viscosity value must be divided by the fluid density.

Example :

If the unit is showing a viscosity of 150 maps and density of 886 kg/m³ then, 150 / 0.886 = 169.3 cost

Troubleshooting

General Operational Errors

Problem	Possible Cause	Solution
Unit will not switch on.	Fully discharged battery.	Connect to the mains and

fully charge the unit.If the LED switches still fail to illuminate there could be an electrical fault or damage to the battery pack from over discharge.
Unit will not prime/run.| Internal tubing/pump gears are dry.High viscosity fluids. Restriction in the suction/discharge lines.| Go into the settings for priming to increase the pump speed and switch the pump off/on. Raise the height of the fluid sample to gravity assist, or create a vacuum using a hand operated thief pump to pull fluid through. Check the hoses and strainer for blockages.
Screen is behaving erratically.| Dirt on the screen or hands.| Wipe the screen clean to remove traces of dirt or oil. In most cases gloves will not work with the touch screen.

Particle Counting

Problem	Possible Cause	Solution
Contamination codes dropped to near zero	A blockage in the flow path	Check

there is adequate flow going through the unit (approximately 20-100ml/min)Check/clean the suction strainer for any contamination
Erratic count levels| Unstable sample| Check for the presence of air. Bubble counts should be maintained below 200 bubbles/ml in each channel.

RH & Water Content

Problem	Possible Cause	Solution
Water content is above 95%	High moisture levels in the sample.Damaged
moisture sensor.	Flush the unit immediately with dry oil to avoid damage to

the moisture sensor. If levels still don’t fall the sensor could be permanently damaged.
Water content bouncing from near 0 to100%| Damaged moisture sensor.| Permanent damaged due to excessive moisture. Sensor will require replacing.

Water Sensor – % Saturation (RH)

The most common fault with RH sensors is displaying high readings at around 100% where the value will not come down. This is known at sensor lockout and occurs from exposure to a fluid sample where the water content is above the oil’s saturation point.

Sensor lockout is resolved by passing clean, dry oil through the unit until the readings start to come down. This could take 15 minutes, or up to 2 hours depending on the level and duration of exposure to water.

Over time, continued exposure to oil above its saturation point will damage the sensor, causing it to respond slower and shorten its useful life.

Water Sensor – Parts Per Million (PPM)

Exposing the PPM sensor to diesel above 300ppm will cause sensor lockout. This be resolved by passing clean, dry diesel (<100 ppm) through the unit until the readings start to come down. This could take 15 minutes, or up to 2 hours depending on the level and duration of exposure to water.

Over time, continued exposure to diesel above 300ppm will damage the sensor, causing it to respond slower and shorten its useful life.

Density & Viscosity Sensor

Errors & Corrective Actions

Problem	Possible Cause	Solution
Negative measuring error Unstable display	Air locks or gas bubbles inside the
transducer	De-aerate the fluid sample Rotate the unit around its axis to try

and release any trapped air inside
Positive measuring error Long-term drift| Sedimentation in the transducer| Flush the unit with clean fluid to remove any debris Rotate the unit around its axis to try and release any trapped dirt inside the transducer
Negative measuring error Long-term drift| Corrosion Abrasion| Return to supplier for cleaning or repair

Particle Count ISO Codes

ISO Codes (ISO4406)

The table below shows the ISO 4406 codes by number of particles per 1 ml of fluid sampled.

ISO 4406 Code	Counts/mL
Greater than	Up to/including
0	0
1	0.01
2	0.02
3	0.04
4	0.08
5	0.16
6	0.32
7	0.64
8	1.3
9	2.5
10	5
11	10
12	20
13	40
14	80
15	160
16	320
17	640
18	1300
19	2500
20	5000
21	10000
22	20000
23	40000
24	80000
25	160000
26	320000
27	640000
28	1300000
29	2500000

ISO Decimal Codes

The S120 particle counter gives a greater insight into cleanliness by showing ISO decimal codes, with the particle counts as per the below table.

Code| Counts/mL| Code| Counts/mL| Code| Counts/mL| Code| Counts/mL| Code| Counts/mL
---|---|---|---|---|---|---|---|---|---
5| 0.16| 10| 5| 15| 160| 20| 5000| 25| 160000
5.1| 0.176| 10.1| 5.5| 15.1| 176| 20.1| 5500| 25.1| 176000
5.2| 0.192| 10.2| 6| 15.2| 192| 20.2| 6000| 25.2| 192000
5.3| 0.208| 10.3| 6.5| 15.3| 208| 20.3| 6500| 25.3| 208000
5.4| 0.224| 10.4| 7| 15.4| 224| 20.4| 7000| 25.4| 224000
5.5| 0.24| 10.5| 7.5| 15.5| 240| 20.5| 7500| 25.5| 240000
5.6| 0.256| 10.6| 8| 15.6| 256| 20.6| 8000| 25.6| 256000
5.7| 0.272| 10.7| 8.5| 15.7| 272| 20.7| 8500| 25.7| 272000
5.8| 0.288| 10.8| 9| 15.8| 288| 20.8| 9000| 25.8| 288000
5.9| 0.304| 10.9| 9.5| 15.9| 304| 20.9| 9500| 25.9| 304000
6| 0.32| 11| 10| 16| 320| 21| 10000| 26| 320000
6.1| 0.352| 11.1| 11| 16.1| 352| 21.1| 11000| 26.1| 352000
6.2| 0.384| 11.2| 12| 16.2| 384| 21.2| 12000| 26.2| 384000
6.3| 0.416| 11.3| 13| 16.3| 416| 21.3| 13000| 26.3| 416000
6.4| 0.448| 11.4| 14| 16.4| 448| 21.4| 14000| 26.4| 448000
6.5| 0.48| 11.5| 15| 16.5| 480| 21.5| 15000| 26.5| 480000
6.6| 0.512| 11.6| 16| 16.6| 512| 21.6| 16000| 26.6| 512000
6.7| 0.544| 11.7| 17| 16.7| 544| 21.7| 17000| 26.7| 544000
6.8| 0.576| 11.8| 18| 16.8| 576| 21.8| 18000| 26.8| 576000
6.9| 0.608| 11.9| 19| 16.9| 608| 21.9| 19000| 26.9| 608000
7| 0.64| 12| 20| 17| 640| 22| 20000| 27| 640000
7.1| 0.706| 12.1| 22| 17.1| 706| 22.1| 22000| 27.1| 706000
7.2| 0.772| 12.2| 24| 17.2| 772| 22.2| 24000| 27.2| 772000
7.3| 0.838| 12.3| 26| 17.3| 838| 22.3| 26000| 27.3| 838000
7.4| 0.904| 12.4| 28| 17.4| 904| 22.4| 28000| 27.4| 904000
7.5| 0.97| 12.5| 30| 17.5| 970| 22.5| 30000| 27.5| 970000
7.6| 1.036| 12.6| 32| 17.6| 1036| 22.6| 32000| 27.6| 1036000
7.7| 1.102| 12.7| 34| 17.7| 1102| 22.7| 34000| 27.7| 1102000
7.8| 1.168| 12.8| 36| 17.8| 1168| 22.8| 36000| 27.8| 1168000
7.9| 1.234| 12.9| 38| 17.9| 1234| 22.9| 38000| 27.9| 1234000
8| 1.3| 13| 40| 18| 1300| 23| 40000| 28| 1300000
8.1| 1.42| 13.1| 44| 18.1| 1420| 23.1| 44000| 28.1| 1420000
8.2| 1.54| 13.2| 48| 18.2| 1540| 23.2| 48000| 28.2| 1540000
8.3| 1.66| 13.3| 52| 18.3| 1660| 23.3| 52000| 28.3| 1660000
8.4| 1.78| 13.4| 56| 18.4| 1780| 23.4| 56000| 28.4| 1780000
8.5| 1.9| 13.5| 60| 18.5| 1900| 23.5| 60000| 28.5| 1900000
8.6| 2.02| 13.6| 64| 18.6| 2020| 23.6| 64000| 28.6| 2020000
8.7| 2.14| 13.7| 68| 18.7| 2140| 23.7| 68000| 28.7| 2140000
8.8| 2.26| 13.8| 72| 18.8| 2260| 23.8| 72000| 28.8| 2260000
8.9| 2.38| 13.9| 76| 18.9| 2380| 23.9| 76000| 28.9| 2380000
9| 2.5| 14| 80| 19| 2500| 24| 80000| >29| 2500000
9.1| 2.75| 14.1| 88| 19.1| 2750| 24.1| 88000| –| –
9.2| 3| 14.2| 96| 19.2| 3000| 24.2| 96000| –| –
9.3| 3.25| 14.3| 104| 19.3| 3250| 24.3| 104000| –| –
9.4| 3.5| 14.4| 112| 19.4| 3500| 24.4| 112000| –| –
9.5| 3.75| 14.5| 120| 19.5| 3750| 24.5| 120000| –| –
9.6| 4| 14.6| 128| 19.6| 4000| 24.6| 128000| –| –
9.7| 4.25| 14.7| 136| 19.7| 4250| 24.7| 136000| –| –
9.8| 4.5| 14.8| 144| 19.8| 4500| 24.8| 144000| –| –
9.9| 4.75| 14.9| 152| 19.9| 4750| 24.9| 152000| –| –