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OilExpress 4

Oil Condition Monitoring System

User’s Guide

MOLECULAR SPECTROSCOPY

Summary of Contents for OilExpress 4

Page 1: ...OilExpress 4 Oil Condition Monitoring System User s Guide MOLECULAR SPECTROSCOPY ...

Page 2: ...r errors contained herein for incidental consequential damages in connection with furnishing performance or use of this material Copyright Information This document contains proprietary information that is protected by copyright All rights are reserved No part of this publication may be reproduced in any form whatsoever or translated into any language without the prior written permission of Perkin...

Page 3: ... Material Safety Data Sheets 26 Overview of the OilExpress 4 System 27 System Specifications 28 Liquid Autosampler 29 Connection Panel 30 Varispan Pipetting Arm and VersaTips 30 System Liquid Container s 31 Labware Configurations 33 Sample Racks 34 Tip Boxes 38 Injection Station 40 Autosampler Safety Shield and Stop Button 42 Spectrometer Module 43 Spectrometer Sample Compartment 43 Sample Shuttle...

Page 4: ...lExpress 4 Software 96 Removing and Installing the Flow Cell 97 Disassembling the Flow Cell for Deep Cleaning 103 Empty Cell Spectrum 105 Calibrating the Pathlength of the Flow cell 109 Installing the Flow Cell Injection Station Fluid Lines 114 Autosampler Maintenance 118 Daily Preventative Maintenance 118 Weekly Preventative Maintenance 119 Spectrometer Maintenance 121 Changing to a Single spectr...

Page 5: ...Introduction ...

Page 6: ...ment unless stated otherwise For all other procedures you should contact your PerkinElmer Service Representative Using this Guide This guide describes how to use your OilExpress 4 System and perform any customer maintenance tasks We recommend that you use it as follows 1 Read the Warnings and Safety Information starting on page 17 before using your OilExpress 4 System 2 Read Overview of the OilExp...

Page 7: ...PC keyboard is used to show that you have to press two keys at the same time for example ALT F Part Numbers All eight digit numbers are PerkinElmer part numbers unless stated otherwise Notes Warnings and Cautions Three terms in the following standard formats are also used to highlight special circumstances and warnings NOTE A note indicates additional significant information that is provided with ...

Page 8: ...po de circunstancias Caution Attention Nous utilisons le terme CAUTION ATTENTION pour signaler les situations susceptibles de provoquer de graves détériorations de l instrument ou d autre matériel Les détails sur ces circonstances figurent dans un encadré semblable à celui ci Caution Attenzione Con il termine CAUTION ATTENZIONE vengono segnalate situazioni che potrebbero arrecare gravi danni allo ...

Page 9: ...ircunstancias Warning Danger Nous utilisons la formule WARNING DANGER pour avertir des situations pouvant occasionner des dommages corporels à l utilisateur ou à d autres personnes Les détails sur ces circonstances sont données dans un encadré semblable à celui ci Warning Pericolo Con il termine WARNING PERICOLO vengono segnalate situazioni che potrebbero provocare incidenti alle persone Troverete...

Page 10: ...e injection station sample racks and tip boxes A Spectrum Two FT IR spectrometer fitted with a sample shuttle and a water resistant flow cell A fluid control module FCM For additional throughput a second spectrometer and associated FCM can be incorporated in OilExpress 4 DUO systems NOTE A single spectrometer system can be upgraded to a DUO system Refer to Spares and Consumables on page 141 or con...

Page 11: ...the molecular structure Chemical bonds within a molecule are said to exhibit characteristic infrared absorptions A record of the frequencies at which absorption takes place for an organic compound is called its infrared spectrum An infrared spectrum of a compound will reveal information about its molecular structure as the existence of specific groups of atoms may be confirmed from the presence of...

Page 12: ...e oxides react with water also produced by the combustion process to form sulfuric acid The sulfuric acid is neutralized by the oil s basic additives forming inorganic sulfates A rapid increase in the sulfate value may indicate the use of a high sulfur content fuel poor combustion over cooling or the rapid depletion of anti wear additive Ester breakdown Synthetic lubrication oils usually contain a...

Page 13: ... water alone does not necessarily indicate a coolant problem but may result from condensation due to a low operating temperature Water contamination can also occur in hydraulic systems through leakage or condensation in reservoirs Unburned fuel The presence of fuel in the oil indicates poor combustion due to an incorrect fuel air ratio a clogged air filter or an ignition problem It may also indica...

Page 14: ... compared to alarm limits derived from statistical analysis of data for the appropriate machine and lubricant type Standard practices and test methods ASTM International publishes several documents discussing lubricants analysis by FT IR including both direct trending and spectral subtraction methods1 4 For the Analysis methods supported by OilExpress 4 refer to Analysis Methods on page 16 A colle...

Page 15: ...ng Fourier Transform Infrared FT IR Spectrometry ASTM International 2010 http www astm org Standards E2412 htm 2 ASTM D7412 09 Standard Test Method for Condition Monitoring of Phosphate Antiwear Additives in In Service Petroleum and Hydrocarbon Based Lubricants by Trend Analysis Using Fourier Transform Infrared FT IR Spectrometry ASTM International 2009 http www astm org Standards D7412 htm 3 ASTM...

Page 16: ...Petroleum Based EP Fluid Petroleum Lubricant Polyol Ester Fluid Direct trending See ASTM E2412 101 This method is also compatible with the analyses specified by Standard Test Methods D7412 D7414 and D7415 Turbine Oils Turbine Fluids Synthetic Turbine Direct trending Contains additional calculations for turbine fluids including phenolic antioxidant oxidation and unsaturated esters Measures analytes...

Page 17: ...Warnings and Safety Information ...

Page 18: ...ard Safety and Health Policy The information provided does not cover every safety procedure that should be practiced Ultimately maintenance of a safe laboratory environment is the responsibility of the user and the user s organization Please consult all manuals supplied with your OilExpress 4 System before you start working with the system Carefully read the safety information in this chapter and ...

Page 19: ... liquid container away from the OilExpress 4 System and any heat sources or other electrical systems Always keep the lid on the system liquid and waste liquid containers The system waste liquid container must be vented externally or connected to an extraction system A connector for 6 mm internal diameter tubing is fitted to the lid supplied with the waste container for the OilExpress 4 System DO N...

Page 20: ...fied herein the protection provided by the equipment may be impaired Electrical Safety The OilExpress 4 System excluding the Spectrum Two spectrometer must be disconnected from all voltage sources before any adjustment replacement and maintenance or cleaning up of any major liquid spills The Spectrum Two spectrometer must be disconnected from all voltage sources before it is opened for any adjustm...

Page 21: ...1010 1 IEC 60950 or equivalent standards Ensure that you have sufficient power outlets for your OilExpress 4 system Table 3 Table 3 Power outlets required for OilExpress 4 systems Product Power Outlets OilExpress 4 OilExpress 4 XL 6 OilExpress 4 DUO OilExpress 4 XL DUO 8 Includes powered USB hub PC and monitor You may need to provide an appropriate multi socket power strip to provide power outlets...

Page 22: ... where it will be exposed to strong magnetic fields Ensure that there are no overhanging shelves and no water pipes or faucets that could leak onto the OilExpress 4 System The OilExpress 4 system must be installed on a flat and level bench such as part number 5085685 free from vibrations or mechanical shocks The bench must be strong enough to support the weights specified in Table 4 Table 4 Dimens...

Page 23: ...nal waste container must be placed either beneath the instrument or nearby on the floor The waste container must be lower than the fluid control module s Observe local and national regulations when disposing of waste from the OilExpress 4 System ...

Page 24: ...and waste liquid containers DO clean up leakages and spillages immediately and thoroughly DO move the system liquid container away from the OilExpress 4 System before you fill it DO dispose of flammable materials according to accepted approved practices and never pour flammable materials down a drain or sink DO use only approved containers or tanks to store flammable materials DO transfer flammabl...

Page 25: ...then remove the deck plates to access the drip trays However removing the deck plates may invalidate the deck calibration which could lead to an autosampler collision We recommend that you contact your PerkinElmer Service Representative to check if recalibration is required ...

Page 26: ...ems required in specific national supra national and state jurisdictions To obtain a safety data sheet for a particular compound follow the steps described below NOTE To read MSDS pdf files you will need Adobe Reader 5 0 or later An installation of this software is available on the Software Utilities CD 1 Launch your web browser and navigate to the PerkinElmer web site www perkinelmer com If you a...

Page 27: ...Overview of the OilExpress 4 System ...

Page 28: ...pectrometer system 70 per hour Dual spectrometer system DUO 100 per hour Sample Volume 800 µL Typical Solvent Volume per sample 3 0 mL for 15W40 oil Typical Waste Volume per sample 3 8 mL for 15W40 oil equivalent Sampling Tips 1 mL wide bore disposable tips Sample to sample Carry over 0 1 Solvent to sample Carry over 1 typical Maximum Sample Container Height mm all rack types 100 Maximum Sample Co...

Page 29: ...osampler features A robotic arm with four sampling VersaTips that can move independently in the z direction VersaTips are used directly to dispense system liquid but can pick up disposable tips to transfer samples eliminating cross contamination Independent liquid lines for each VersaTip enabling the use of dual solvents for FT IR analysis and oil dilution Flexible sample presentation the deck can...

Page 30: ... please contact your PerkinElmer Customer Care Representative Varispan Pipetting Arm and VersaTips The OilExpress 4 autosampling system consists of a robotic arm with four sampling tips that can move independently in the z direction The flexible spacing between the sampling tips enables the autosampler to sample from multiple containers simultaneously and enables more than one sample container typ...

Page 31: ...nd oil dilution mode VersaTips 1 2 3 and 4 are used with disposable tips for oil sampling VersaTips 1 and 3 are used without tips to dispense solvent for dilution VersaTips 2 and 4 will be used to dispense system liquid to clean the flow cell System Liquid Container s WARNING In the event of a solvent spillage isolate the power to the OilExpress 4 System components immediately and then clean up th...

Page 32: ...hen fitting the container lid If necessary turn the container rather than the lid Refer to Use of Flammable Solvents and Samples on page 24 for recommendations to follow when using and dispensing flammable materials OilExpress 4 System Liquid Additive Adding the OilExpress 4 System Liquid Additive part number N9308354 to the system liquid at 0 5 v v has been found to reduce soot build up when anal...

Page 33: ... to your autosampler Ensure that you refer to the appropriate Deck Layout information in the OilExpress 4 on screen Help before starting an analysis The Deck Layouts are arranged to minimize the risk of contaminating samples or clean tips in the unlikely event of a drip from a tip All sample analyses run from the top right to the bottom left of the deck and within each sample rack from the top rig...

Page 34: ...where in some cases an adaptor plate is required to achieve the correct layout It also provides the sampling order and for dual FT IR and oil dilution configurations which labware will be used by OilExpress 4 software for FT IR analysis and which will be used by WinPREP software for oil dilution If the Deck Layout displayed does not correspond to the configuration on the autosampler deck or the ty...

Page 35: ...e autosampler deck OilExpress can also be configured to support other sample racks in some cases This requires support from PerkinElmer engineering to create adaptor plates and labware files as well as service support to configure a custom layout for the autosampler For more information on setting up a custom layout consult your PerkinElmer Product Specialist or Service Representative 96 position ...

Page 36: ...way only as the rack feet are keyed to the sample rack locators on the adaptor plate The adaptor plate consists of two parts that are connected together by two fastening screws that also function as locating pins on the autosampler deck The correct configuration depends on the type of OilExpress 4 System and the location on the deck Refer to Figure 11 and Table 5 Figure 11 96 position rack adaptor...

Page 37: ...es in four columns of eight samples One 32 position rack can be installed on the OilExpress 4 System while up to three can be installed on the OilExpress 4 XL System The rack consists of two parts a tray and a top plate If the two layers are correctly positioned then the two locating holes will match Figure 12 When the 32 position rack is located correctly on the deck the extended handle is at the...

Page 38: ...red for use with the OilExpress 4 System Figure 14 One contains the clean disposable tips that are used to aspirate samples The other should be empty and is used by the autosampler for depositing used tips Figure 14 Used tip box with drip tray and clean tip box with disposable tips The clean and waste tip boxes are positioned on the autosampler deck to minimize the chance of contaminating clean ti...

Page 39: ...s 4 on screen Help Source Tip Box Adaptor Plate OilExpress 4 with 96 position rack only If you have an OilExpress 4 standard system and are using the 96 position sample rack then an adaptor plate is required to position the clean tips correctly on the autosampler deck Figure 16 Racks of clean tips clip into the source boxes in the usual way No adaptor plate is required for the OilExpress 4 XL syst...

Page 40: ...e deck position of each tip box For more detailed information about your deck layout you can also refer to the OilExpress 4 on screen Help If you are not sure of the position on the deck of a tip box select it in the table and then click GoTo with Varispan The arm will then move to the position of tip 1 in that box Injection Station The injection station is used to dispense samples and cleaning so...

Page 41: ...fill cup Sample is then dispensed via the fill cup into tubing connected to the flow cell Samples are dispensed via disposable tips on VersaTips 1 and 3 For DUO systems two samples are dispensed simultaneously into both fill cups VersaTip 1 always dispenses an aspirated oil sample into Fill Cup 1 For single spectrometer systems sample is dispensed into Fill Cup 1 only using VersaTips 1 and 3 alter...

Page 42: ...g you to remove any tips that are fitted to the VersaTips and then confirm this action by selecting the Disposable tips have been removed from the 4 tip arm check box Figure 19 Autosampler suspended dialog CAUTION Failure to remove disposable tips from the VersaTips may lead to a collision that could cause damage to your autosampler When you click OK the autosampler will not move until you perform...

Page 43: ...d beam enters the compartment through an aperture on the left After passing through the sample it enters the detector area through an aperture on the right side of the sample compartment The spectrometer supplied has either KBr or ZnSe sample compartment windows CAUTION Potassium Bromide KBr is a hydroscopic material and KBR windows although coated can be damaged by high levels of humidity Refer t...

Page 44: ...e 21 Sample Shuttle The liquid presence sensor used to detect the front of the sample fluid flowing into the flow cell is located on the sample shuttle The sensor is connected to and powered by the fluid control module FCM Refer to Liquid Presence Sensor on page 45 The sample shuttle is powered via the Spectrum Two instrument Refer to Connections on the Spectrometer on page 46 Flow Cell The two po...

Page 45: ...ative during the installation However you will need to recalibrate after any flow cell maintenance or refurbishment Refer to Calibrating the Pathlength of the Flow cell starting on page 109 for more information Liquid Presence Sensor The liquid presence sensor located on the sample shuttle is used to detect the front of the sample fluid flowing into the flow cell as the sample is dispensed from th...

Page 46: ...ctions on the Spectrometer The Spectrum Two power supply adaptor can operate on electricity supplies of 50 or 60 Hz and in the 100 to 230 V range without any adjustment The mains power cord supplied will depend on the requirements of your region The Spectrum Two spectrometer uses an 18 V power adaptor The power adaptor connector and communications ports are on the rear of the spectrometer Figure 2...

Page 47: ...n procedure the diagnostic LED on the rear of the instrument is yellow indicating that the instrument is running a series of self checks At the end of the initialization period the diagnostic LED will flash orange The sample shuttle will also initialize and the shuttle will move When the spectrometer is on the Power ON LED on the front of the instrument will be lit green The spectrometer is connec...

Page 48: ... the sample to the flow cell for FT IR analysis Post analysis the FCM facilitates the emptying of the flow cell and movement of the sample liquid to a waste transfer container inside the FCM and ultimately out to the external waste container The FCM then carries out similar vacuum assisted sequences with system liquid dispensed into the fill cup to wash the fluid lines and the flow cell leaving th...

Page 49: ...ata PerkinElmer OilExpress FCMPerformance Your PerkinElmer Service Representative may request this file Connections on the FCM The connections on the rear of the FCM are shown in Figure 29 The electrical connections are at the top of the panel The fluid and exhaust connections are mounted on a block at the bottom of the panel Figure 29 Connections on the rear of the FCM CAUTION The FCM should be k...

Page 50: ... to the mains power adaptor and switched on the ON LED will be lit green Figure 30 Electrical Connections on the FCM The cable from the liquid presence sensor on the sample shuttle connects into the SENSOR port on the FCM The fluid control module is connected by USB cable to the powered USB hub which is in turn connected to the PC running OilExpress 4 software NOTE DO NOT connect the USB cable or ...

Page 51: ...ell to the waste transfer container WTC in the FCM and the WTC to the external waste liquid container The EXHAUST outlet vents solvent vapor from the pump to the waste container Ensure that the waste liquid container is lower than the FCM so that any vapor condensing in the line will drain to the container The waste liquid container should be vented to a suitable outlet Figure 31 Fluid connections...

Page 52: ...ure 32 Figure 32 Connector for venting the waste liquid container DO NOT remove the connector from the waste liquid container while it is in use as the container may become pressurized We recommend that you do not put the waste container in a location where you cannot see the liquid level The waste container does not contain a level sensor and so you must ensure that it is emptied regularly If the...

Page 53: ...tray which is resistant to sample and solvent drips but any larger spillages should be cleaned up immediately For DUO systems the two FCM and spectrometer modules are stacked to reduce bench space Figure 33 Figure 33 Stacking of a DUO system The mounting system can be easily moved away from the side of the autosampler for flow cell or spectrometer maintenance Two pins on the mounting system connec...

Page 54: ...ore information During the system installation by your PerkinElmer Service Representative the separation of the sensors will be matched to the separation of the sample containers positioned in the sample rack on the deck This means that you cannot simply change your sample rack type in the OilExpress 4 software to use the Ultrasonic Liquid Level Sensor Bar with another rack type you will need to c...

Page 55: ... example in Figure 36 two sample racks are required for the analysis of 192 samples on an OilExpress 4 XL System The software first prompts you to load Sample Rack 1 and Sample Rack 2 containing samples 97 to 192 at the rear of the deck and then click Continue The heights of samples will then be scanned Figure 36 Position Sample Rack For Ultrasonic Height Scan dialog The next step is to move Sampl...

Page 56: ...e Figure 38 NOTE The dialog will not list any sample positions that were defined as Do Not Analyze in the Samples table or those for which a custom height was entered For each sample listed you can enter a fixed Sampling Height and then Continue the analysis The minimum or maximum if applicable sampling height for the current Rack Type is entered by default For more information refer to the Ultras...

Page 57: ...rosene to the dilution tubes NOTE VersaTips 2 and 4 are primed with heptane for use as a cleaning solvent for FT IR analysis For details on using the OilExpress 4 system for oil dilution refer to the OilPrep Oil Dilution System Operation Manual Document Number 8860042 You can import the sample names used in the oil dilution protocol in WinPREP into the Samples table in OilExpress 4 software Refer ...

Page 58: ...far left of the deck away from the sample racks and tip boxes The autosampler status is Scanning The spectrometer status is Idle Refer to Ultrasonic Liquid Level Sensor Bar Optional on page 54 for more information 6 The autosampler syringes are initialized The syringes are initialized with the Varispan arms located over the injection station waste trough During syringe initialization the syringes ...

Page 59: ...ler status is Loading The spectrometer status is Idle 10 The autosampler moves to the first two sample positions in a sample rack and aspirates the first two samples into the disposable tips Samples in position 1 and 2 are aspirated Each disposable tip is lowered into the sample to the appropriate sampling height and the sample is aspirated The volume aspirated is 800 µl 11 The autosampler then mo...

Page 60: ... cleaning settings Only 700 µl of sample is dispensed to the cell 14 When the sample is detected if required the FCM draws the sample into the flow cell 15 The sample spectrum is collected The autosampler status is Idle The spectrometer status is Scanning 16 The autosampler positions VersaTip 2 over Fill Cup 1 NOTE For some low viscosity samples VersaTip 1 may remain in Fill Cup 1 until after the ...

Page 61: ...ialog Figure 45 20 The autosampler then moves the disposable tip on VersaTip 3 into position over Fill Cup 1 of the injection station and dispenses the second sample as before The autosampler status is Loading The spectrometer status is Idle 21 The sample spectrum is collected The spectrometer status is Scanning 22 During the sample measurement the autosampler moves the disposable tips over the wa...

Page 62: ...flow cell are cleaned and dried Dual spectrometer DUO System If you have a DUO dual spectrometer system the sampling procedure is as follows 1 Start Analysis is selected on the Samples screen 2 OilExpress 4 connects to the autosampler 3 Start is selected on the Batch Initialization dialog Refer to Figure 8 4 The fluid control modules FCMs are initialized The FCM initialization includes a fit for p...

Page 63: ... then Idle 8 Each spectrometer collects a background spectrum The autosampler status is Idle The spectrometer status is Background 9 The autosampler moves to the first available clean tip in the first available clean tip box and loads a disposable tip on VersaTips 1 and 3 When starting from a full tip box tips in position 1 and 3 and not in position 1 and 2 are collected The autosampler status is ...

Page 64: ...y the OilExpress 4 software to calculate parameters such as the time required for the FCM to pump the sample into the flow cell and the adaptive cleaning settings Only 700 µl of sample is dispensed to the cell 14 When the sample is detected if required the FCM draws the sample into the flow cell 15 The sample spectra are collected The autosampler status is Preparing The spectrometer status is Scan...

Page 65: ...lable clean tip and loads a disposable tip on VersaTips 1 and 3 from the next two available positions These are collected from positions 2 and 4 19 The autosampler returns to the injection station and positions VersaTips 2 and 4 over Fill Cups 1 and 2 20 When the spectrum has been collected the FCM draws the sample to its internal waste container The spectrometer status is Idle The liquid presence...

Page 66: ...ound spectrum The autosampler status is Idle The spectrometer status is Background 23 The FCM pumps air through the system to dry the flow cell and the fluid lines The air dry time is defined by the user on the Autosampler Setup dialog Figure 45 The autosampler status is Loading The spectrometer status is Idle 24 As the system is dried the autosampler moves VersaTip 1 to the first available sample...

Page 67: ...Getting Started with OilExpress 4 ...

Page 68: ...self with the OilExpress 4 software environment Prepare your samples for analysis Prime your system before an analysis Set the sampling heights Extract your data from OilExpress 4 software Set up and run an analysis Use AVI calibration to improve consistency in results between spectrometers and across OilExpress 4 systems Change the scan settings Determine if your system is working as expected ...

Page 69: ...ble click the OilExpress 4 shortcut icon on the desktop A dialog is displayed that may require your login details 3 If required enter your User name and Password and then click OK The default user name and password are Administrator and administrator respectively We recommend that you create a new user and password the first time you log on to OilExpress 4 On start up OilExpress 4 software will co...

Page 70: ... previously saved batches and the Setup menu which contains links to administration and instrument setup options including creating new users calibrating the flow cell pathlength and selecting your autosampler labware Toolbar The application toolbar B provides quick access to some operations such as creating a new batch or copying and pasting information in the Samples table The tools available de...

Page 71: ...ia the View menu Figure 41 OilExpress 4 Process Controls panel Main Screen The Main Screen D is where you enter information about your batch for example batch or sample information or view the analysis progress or spectra The contents of the Main Screen reflect the Process Controls shortcut selected in the Navigation Bar Status Bar The Status Bar E located at the bottom of the workspace displays i...

Page 72: ...using OilExpress 4 software to set up and run your oil analyses To open the Help file select Contents from the Help menu This menu also includes links to the PerkinElmer website PerkinElmer on the Web and information about the software About To open a Help topic listing user replaceable parts for your system select Spares and Consumables ...

Page 73: ...amples depends on your sample container Refer to the OilExpress 4 on screen Help for more information If you do not have the optional Ultrasonic Liquid Level Sensor Bar installed then you must define the height of your batch samples on the Autosampler Setup dialog Refer to Defining the Sampling Heights on page 75 A ruler is supplied with the system part number L9004568 to help you determine the he...

Page 74: ... tubing to the VersaTips for any air bubbles and if required select the option to prime the system NOTE This option will be selected by default the first time an analysis is run after starting the OilExpress 4 software application Figure 43 Batch Initialization dialog showing Prime option During the prime each syringe is twice filled with system liquid which is dispensed via the fill cup through t...

Page 75: ...ubing then you may need to prime the system more than once before starting an analysis For this you can use the Prime option on the Autosampler Control screen in OilExpress 4 Figure 44 Figure 44 Prime option on the Autosampler Control dialog Refer to the topic Autosampler Control in the OilExpress 4 on screen Help for more information ...

Page 76: ...ixed Heights If you do not have the optional Ultrasonic Liquid Level Sensor Bar then Use Fixed Heights will be selected by default and you must define the height of your samples to ensure that they are aspirated correctly The fixed height is defined as the height of the sample measured from the bottom of the sample holder not the deck The minimum fixed height you can enter depends on your sample c...

Page 77: ...ple you can enter a custom value to override the sensed height In the example in Figure 46 the first sample will use the Control Sample height defined on the Autosampler Setup dialog at 40 mm the second will use the Batch Sample height defined at 60 mm and the third will use the custom value of 32 mm entered on the Samples screen The Sampling Height cell for the fourth sample is blank and so will ...

Page 78: ... Figure 47 This facilitates further analysis of spectra using another software package such as Spectrum software The option No output spectra is selected by default Ø Select Reporting Options from the File menu On the dialog you can enter a name and location for the folder and select the file type from the drop down list You can also choose between Absorbance A and Transmittance T ordinate units F...

Page 79: ...CSV Export Wizard Ø Select Setup CSV Export from the File menu and then select Enable export to CSV file on the General CSV Export Properties dialog Figure 48 On the dialog you can enter a File name and location for a new file or Browse to an existing file Figure 48 CSV Export Properties dialog You can select the Field Separator Character that will be used to separate values within the file The de...

Page 80: ...l sample analysis or at the end of a batch Figure 49 Figure 49 Analysis Reports and Checks Reports on the Reporting Options Dialog Reports are displayed automatically as part of System Checks and the Pathlength Calibration However you can choose to print the report by selecting the appropriate option in the Checks Reports section ...

Page 81: ... new racks at the appropriate time during the analysis You are also prompted to replace clean and used tip boxes as required 2 Click in the Batch Identification field and type a unique batch identifier 3 If required click in the Batch Description field and type in a brief description of the batch 4 Click Samples NOTE If the Batch Identification you have entered has already been used a warning mess...

Page 82: ... may find it useful to include the rack number or position for example Sample 1_1 8 Click in the next cell in the Analysis column to display a drop down arrow 9 Click on the arrow and select the appropriate analysis method from the list 10 Select the relevant Oil Type from the drop down list if required for your analysis method The oil types available will depend on the analysis method selected ...

Page 83: ...subtraction to ensure accurate results for direct trending methods This is no longer necessary as you can select an empty cell spectrum to be subtracted for each flow cell on the Spectrometer Setup dialog Refer to Empty Cell Spectrum on page 105 for more information NOTE For more information about reference spectra including how to collect a new reference and details of the analysis methods provid...

Page 84: ...ution type a value for the Dilution Factor NOTE The Dilution Factor column is not displayed by default Refer to the topic Modifying the Samples Table in the OilExpress 4 on screen Help for information about hiding or displaying columns 15 If you are using the Mineral or Synthetic oil methods click in the Fuel Calibration column then click the Browse button The Mineral Oil and Synthetic Oil methods...

Page 85: ...you have completed the Samples table click Start Analysis The Batch Initialization Dialog is displayed This dialog contains important information about preparing the autosampler for your sample analysis CAUTION Failure to follow the instructions on the Batch Initialization dialog may result in damage to the autosampler The dialog lists how many sample racks are required at the start of the analysi...

Page 86: ...y as appropriate The tip count will be reset for each box 23 Click Close to exit the Reset Tip Boxes dialog and return to the Batch Initialization dialog 24 Ensure that there is sufficient system liquid to perform your batch and that there is sufficient capacity remaining in the waste container 25 Check the fluid lines and syringes for air bubbles and if you want to Prime the autosampler before st...

Page 87: ...at you can reset the tip count When the analysis has completed the system displays the Batch Analysis Report dialog which lists any issues identified during the sample analysis that might make a sample result unreliable A report will be printed if the appropriate Reporting Option was selected NOTE At any point during an analysis when a dialog is displayed requiring user intervention a sound alert ...

Page 88: ...then type your new value or select a value from the drop down list Figure 50 Instrument Settings dialog showing the Basic tab The Basic tab is where you set the Start and End points of the scan range in wavenumbers You can also define the duration of the scan The Advanced tab enables you to select advanced options such as the scan Resolution 4 cm 1 by default and AVI correction NOTE For more infor...

Page 89: ...divergence and uniformity Differences can occur between instruments when using different sampling accessories and when components are changed AVI correction enables calibration and lineshape to be maintained The Absolute Virtual Instrument is an instrument with theoretical performance such that the result of measuring a known sample on such an instrument can be predicted So if we measure with a re...

Page 90: ...ion uses the methane gas cell in the internal filter wheel of the spectrometer You should perform the AVI calibration with the sample shuttle installed in the sample compartment which provides a 4 cm 1 J stop NOTE If you have a DUO system the AVI calibration must be performed for both spectrometers for the AVI correction to be applied To set up an AVI Calibration in OilExpress 4 software 1 Select ...

Page 91: ...ttle moves to the background position and the background spectrum is collected When the scan is complete the methane cell in the automated filter wheel is rotated into the beam path The spectrum of the methane cell is collected When the calibration is complete the sample shuttle returns to the sample position 4 Click OK to exit the dialog ...

Page 92: ...ysis process as a whole spectrometer autosampler flow cell and data analysis is performing as expected You should choose a control sample that contains known quantities of the components of interest and is similar in composition to your samples Add a row for the control sample in the Samples table and select the appropriate analysis method Select Control Sample as the Sampling Height NOTE This opt...

Page 93: ...e definition of that is for your individual application NOTE If you have a DUO system the checks are run on the spectrometers independently To run the tests Ø Select System Checks from the View menu select the appropriate spectrometer and the checks you want to run and then click Start If you want to modify any of the thresholds used during the system checks or the Quant method used by the Cell Co...

Page 94: ...s a background spectrum and then collects the spectrum of a polystyrene reference sample a polystyrene reference is installed in the internal filter wheel of the spectrometer It then measures the wavenumber at the specified peaks If the wavenumber value is within the tolerances defined during setup the check passes At the end of the tests a report containing the results will be displayed It will b...

Page 95: ...Maintenance and Troubleshooting ...

Page 96: ...s tissues and heptane Refer to Disassembling the Flow Cell for Deep Cleaning on page 103 Cleaning Using OilExpress 4 Software If you frequently run samples with high soot values you can use the options on the Autosampler Control screen to Flush the fluid lines and flow cell s with additional solvent Figure 52 Alternatively you can Load a cleaning solution into the flow cell s and leave it in conta...

Page 97: ...l materials WARNING Take care not to touch the zinc selenide ZnSe windows when handling the flow cell or wear protective gloves Zinc selenide is toxic by ingestion Avoid contact with skin or eyes 1 Ensure that the flow cell is empty If required use the Flush option on the Autosampler Control screen to flush and dry the flow cell 2 Exit OilExpress 4 software 3 Disconnect the autosampler spectromete...

Page 98: ... on the Luer lok connector approximately one half turn counter clockwise until loose and then pull to remove from the port on the injection station Figure 53 Disconnect Luer lok connection at the injection station 7 Unfasten the thumbscrew on the shuttle hinged arm securing clip Figure 54 Figure 54 Flow cell installed in sample shuttle Securing clip ...

Page 99: ...ing clip open 9 Rotate the hinged arm slightly clockwise while carefully releasing the lower port tubing from the groove to move the liquid presence sensor clear of the slide holder Ensure that the tubing is not trapped in the groves Figure 56 Figure 56 Shuttle hinged arm open and tubing clear 10 Remove the flow cell from the shuttle taking care not to catch the tubing on the shuttle ...

Page 100: ... blue nut connector and ferrule 13 Perform any maintenance on the cell or locate a new cell To replace the flow cell in the system 1 Ensure that the blue nut connector and the ferrule are correctly fitted to the end of the tubing The narrow end of the ferrule should point inwards as shown in Figure 58 NOTE If the threads on the connector are damaged replace it with a new connector and ferrule to p...

Page 101: ...heir respective grooves in the liquid presence sensor as you do so 7 Ensure that the tubing to the injection station is sited correctly in the lower groove and that the tubing to the FCM is sited correctly in the upper grove Refer to Figure 54 8 Close the catch ensure that the tubing is not stretched or crimped and then secure the screw CAUTION Ensure that no tubing or cabling is loose on or aroun...

Page 102: ...isting flow cell has been disassembled collect a new empty flow cell spectrum using Spectrum software Refer to Empty Cell Spectrum on page 105 17 Prime the system using the Prime option on the Autosampler Control screen to clear the system of air bubbles and check for leaks NOTE After any maintenance on the fluid lines inspect them for leaks before running an analysis or leaving the system unatten...

Page 103: ...indows as these can damage the windows Reaction with acids will release a toxic and irritating gas H2Se Keep away from oxidizing materials NOTE The torque driver part number L9003631 and 3 mm hexagonal bit part number L9003632 supplied must be used to reassemble the flow cell Using other tools could cause the flow cell windows to crack or break 1 Follow the procedure in Removing and Installing the...

Page 104: ...ter the pathlength 4 Reassemble the flow cell in the following order The former The rubber gasket The back window smooth on both faces and has no holes in it The PTFE spacer wedged with thicker end at bottom of cell The front window engraved on one face and has two holes in it The PTFE gasket refer to Step 5 The front of the cell refer to Step 6 5 Align the two holes in the PTFE gasket with the tw...

Page 105: ...ure for reinstalling the flow cell in the sample shuttle described in Removing and Installing the Flow Cell starting on page 97 Before using the system collect the spectrum of the empty flow cell and then recalibrate the flow cell pathlength The empty cell spectrum should be collected before any system liquid or sample is loaded into the flow cell Refer to Empty Cell Spectrum on page 105 It is ess...

Page 106: ...form a pathlength calibration The empty cell spectrum is collected using a Macro in Spectrum software NOTE The macro was installed to the C pel_data macros folder during your OilExpress 4 System installation and has the file name OilExpress Empty Cell prc To collect a new empty cell spectrum 1 Ensure that the sample shuttle and flow cell are installed in the spectrometer 2 Exit OilExpress 4 softwa...

Page 107: ...and the Instrument Connection dialog is not displayed If you are not connected to the correct spectrometer chose Select Instrument from the Instrument sub menu of the Setup menu within Spectrum to display the Instrument Connection dialog 5 Select the Instrument from the drop down list and then click Connect If you have a DUO system you need to ensure that you select the appropriate spectrometer Sp...

Page 108: ...also updated to include the Macro Data Collection controls You can use these to stop the macro running 8 In the Sample Table enter the flow cell serial number The flow cell serial number is printed on the front of the cell 9 Click Background on the Measurement bar to collect a background spectrum The shuttle will automatically move to the background position 10 Click Scan to collect the spectrum o...

Page 109: ...ence Spectra with your spectral subtraction method then you can also use the empty cell correction although it is not critical it may improve the accuracy of your results However your reference spectra must also be empty cell corrected To do this you can use the Reference Spectrum analysis method with empty cell correction enabled in OilExpress 4 software to collect your reference spectra Calibrat...

Page 110: ...rum Quant software applications The method must return the pathlength value in millimeters mm and contain a single property component for determination To determine the pathlength of the cell 1 Dispense a sample appropriate for your Quant method into a sample container The sampling height used for the pathlength calibration is the System Checks sampling height as defined on the Autosampler Setup d...

Page 111: ...ect the Clean fluid lines after calibration check box Clean fluid lines after calibration is selected by default The flow cell and fluid lines are always dried after the calibration check is completed This option only controls if you want to flush the lines with your system liquid usually technical grade heptane before the fluid path is dried 8 If you want to change the Quant method from the defau...

Page 112: ...em will use the next available clean tip If the tip count indicates that the tip boxes need to be refilled or the used tip boxes emptied before the pathlength calibration started then the Reset Tip Boxes dialog will be displayed automatically 13 When you have completed the actions click Start to continue The system will perform a background scan aspirate the calibration sample fill the flow cell a...

Page 113: ...he correct calibration sample was used and the sample is not contaminated The correct resolution was used for the Quant method 4 cm 1 resolution for the Pathlength squalane method or 8 cm 1 resolution for the CELLPATH method Using a 4 cm 1 resolution for the CELLPATH method will give high residual ratio values The thresholds defined for the pathlength calibration on the Pathlength Calibration Prop...

Page 114: ...ll or wear protective gloves Zinc selenide is toxic by ingestion Avoid contact with skin or eyes 1 If installed remove the flow cell from the shuttle and remove all connections as described in Removing and Installing the Flow Cell starting on page 97 Ensure that the FCM is disconnected from the mains power and that the liquid presence sensor is disconnected from the FCM 2 Fit a blue nut connector ...

Page 115: ...tubing is secured Figure 63 The connector should be initially hand screwed onto the flow cell until finger tight Then apply an additional tightening of 1 8 of a turn using the 5 5 mm wrench supplied part number 09923411 Figure 63 Flow cell with tubing connected to both ports 7 Place the flow cell into the shuttle The shuttle hinged arm should be open pushed back and the securing clip should be ope...

Page 116: ...replacing the tubing to the lower flow cell follow the instructions in Installing the Sample Shuttle on page 124 to install the sample shuttle in the lower spectrometer taking care not to trap the loose tubing from the flow cell 12 Direct the longer tubing from the upper port of the flow cell across the front of the spectrometer towards the FCM ensuring that there are no loops or crimps in the tub...

Page 117: ...system the tubing is connected to Fill Cup 1 shown in Figure 67 which is to the rear of the autosampler deck For a DUO dual spectrometer system lower flow cell is connected to Fill Cup 1 and the upper flow cell is connected to Fill Cup 2 Push the Luer lok connector into the connection on the injection station then turn the lock hub on the Luer lok connector approximately one half turn clockwise Fi...

Page 118: ...mber L1610028 Wipe the deck clean immediately after a spillage to prevent liquid draining through the locating holes Any liquid that passes through the holes will be collected in drip trays underneath the deck plates These can be removed by undoing the screws at each corner of the deck plate CAUTION If a serious spillage occurs then remove the deck plates to access the drip trays However removing ...

Page 119: ...r is 5 L part number L9004517 Cleaning the VersaTips Check the VersaTips daily for dirt or damage The VersaTips are cleaned when the instrument is primed Refer to Priming the System on page 74 NOTE If a tip is damaged contact your PerkinElmer Service Representative Weekly Preventative Maintenance Priming the System If the system has been unused for any extended period you should Prime the system u...

Page 120: ...ide of the tubing air gaps and any blockages or stationary pockets of liquid Tighten the connections between the flow cell and the injection station and between the injection station and the FCM If you need to replace the tubing refer to Installing the Flow Cell Injection Station Fluid Lines on page 114 To replace all other tubing or components contact your PerkinElmer Service Representative Check...

Page 121: ...eters Ø Select the Toolbox option for the appropriate instrument on the Spectrometer Setup dialog to display the Adjustments Toolbox NOTE After replacing the source using the Source Replacement Wizard we recommend that you run the Source Matching Wizard for optimal lifetime of your source For a full description of user maintenance procedures for the Spectrum Two spectrometer refer to the Spectrum ...

Page 122: ...onnect the spectrometer and corresponding FCM from the mains power supply Removing the Sample Shuttle Ensure that you wear appropriate protective gloves when handling fluid lines that may contain harmful materials To remove the sample shuttle from the sample compartment of the spectrometer 1 Ensure that the flow cell is empty If required use the Flush options on the Autosampler Control screen to f...

Page 123: ...crew anticlockwise the blue nut connector from the mounting block on the rear of the FCM Refer to Figure 31 which shows a blue nut connector already installed in the mounting block 8 If you are removing the sample shuttle from the lower spectrometer in a DUO system then push the spectrometer and FCM mounting system away from the autosampler until you have sufficient access to reach inside the samp...

Page 124: ... Position the sample shuttle accessory on the ledge in the sample compartment and slide it into position Push it firmly home to ensure that the multi way connector on the rear of the sample shuttle accessory mates properly with the spectrometer connector The shuttle should click into place 2 If required push the spectrometer and FCM mounting system back against the autosampler so that the pins on ...

Page 125: ...OTE After any maintenance on the fluid lines inspect them for leaks before running an analysis or leaving the system unattended WARNING When the sample shuttle initializes take care that your fingers tie etc are not trapped by the movement ...

Page 126: ...M using a soft cloth dampened with detergent or degreasant Always perform a patch test on an inconspicuous area Check the connections on the rear of the FCM for leaks and tighten the connectors if required Ensure that all tubing is free of crimps Avoid spilling liquid onto the FCM Clean all external spills immediately ...

Page 127: ... Troubleshooting 127 Moving the System If you move your OilExpress 4 System we recommend that you contact your PerkinElmer Service Representative to check the autosampler deck calibration before using the system again ...

Page 128: ...e PC for the optional Ultrasonic Liquid Level Sensor Bar Spectrometer is not selected on the Spectrometer Setup dialog Confirm that the correct spectrometer is selected on the Spectrometer Setup dialog especially if you have recently changed from dual to single spectrometer mode Connecting to spectrometer service warnings indicating spectrometer error Service message The applicable spectrometer is...

Page 129: ...The hub should not be connected to the USB expansion card fitted to the PC for the optional Ultrasonic Liquid Level Sensor Bar Refer to Electrical Connections on the FCM on page 50 Initialization and Analysis Start from Initialization dialog Autosampler error Autosampler is not powered on Ensure that the autosampler is connected to mains power and that the ON OFF switch is ON Refer to Connection P...

Page 130: ...Service Representative Ultrasonic Liquid Level Sensor Bar fails to detect heights Sample level too low Check that all sample levels are above the minimum height for the sample container Sample not present Ensure that all containers contain samples and are loaded into the sample racks in the correct sampling order Sensor bar is not connected to the PC via additional card Ensure that the sensor bar ...

Page 131: ...efer to Inspecting the Fluid Path Tubing and Syringes on page 120 If you are unable to resolve the issue contact your PerkinElmer Service Representative System liquid tubing is not immersed in system liquid Check the system liquid tubing is in the liquid Refill system liquid if required Use the Prime button on the Autosampler Control dialog to Prime system 2 3 times more until there is no air in t...

Page 132: ...ialog as required If this fails to resolve the problem contact your PerkinElmer Service Representative Tips in tip boxes do not match software count VersaTips are in position over the tip box but there are no tips If the next position contains tips click Retry If not remove any tips that are fitted to the VersaTips confirm this action by selecting the Disposable tips have been removed from the 4 t...

Page 133: ...uired Check connections and tighten if required FCM hardware failure Contact your PerkinElmer Service Representative Provide the log file for the FCM that failed if required Refer to Fluid Control Module on page 48 FCM Timed out transferring from the waste container to the external waste bottle Tubing from the FCM to the external waste container has a leak or blockage Check all the connections at ...

Page 134: ...eparation on page 73 Liquid presence sensor is not connected to the rear of the FCM NOTE The LED on the liquid presence sensor is not lit Disconnect the FCM from mains power and then connect the liquid presence sensor Refer to Electrical Connections on the FCM on page 50 Then reconnect the FCM to the mains power DO NOT connect the liquid presence sensor while the FCM is connected to mains power Tu...

Page 135: ...our PerkinElmer Service Representative Autosampler collision The positioning of labware was incorrect for the selections made on the Autosampler Setup dialog After serious a collision your autosampler should not be used until a PerkinElmer Service Representative has checked the deck calibration Contact your PerkinElmer Service Representative Sample containers over the allowed height were used Deck...

Page 136: ...ste container if required Fill cup blocked Clean fill cup FCM is not connected to the correct fill cup Check that the tubing from the fill cup on the injection station is connected to the flow cell and that the tubing from the flow cell is connected to the FCM End of Analysis Sample not detected by liquid presence sensor Sample was not aspirated Sample was not in correct position on autosampler de...

Page 137: ...olve the issue contact your PerkinElmer Service Representative Air is leaking into the system Check all the connections to valves and syringes the injection station and the flow cell Prime the system until there is no air in the tubing The results obtained for one or more properties are unexpected unacceptable The wrong Oil Type and Analysis method was entered in the Samples screen Ensure the corr...

Page 138: ... sample compartment Empty cell correction is not configured correctly If using the empty cell correction check that the appropriate empty cell spectrum is selected If required repeat the empty cell spectrum NOTE If using the FT IR In Service Lubricants Control Standard the empty cell correction must be enabled to achieve the specifications on the certificate provided The flow cell pathlength is no...

Page 139: ...he injection station and the lower port of the flow cell Sample is outside viscosity range supported by the system Check the viscosity of the sample Thresholds for the Cell Fill Check are not appropriate for the sample Check the scan range and the threshold defined for the Cell Fill Check on the Batch Options dialog OilExpress 4 software operations are very slow or occasionally come to a halt unex...

Page 140: ...he Flow cell on page 109 for possible causes Refer to Calibrating the Pathlength of the Flow cell on page 109 for possible solutions If after taking any appropriate action the Pathlength Calibration continues to fail then contact your PerkinElmer Service Representative AVI Calibration fails Beam is partially or completely blocked Check the sample compartment and ensure that the beam path is clear ...

Page 141: ...N0777599 Polypropylene Tubes 16 mm 67 mm 15 mL pack of 1000 L1191079 4 oz Bottles pack of 600 N9308900 2 oz Bottles pack of 600 N9308901 96 position Sample Rack 17 mm 100 mm tubes L1610015 96 position Sample Rack 16 mm 67 mm tubes L1610027 32 position Sample Rack 4 oz or 2 oz bottles L1610016 Standards Samples and System Liquid OilExpress 4 Installation Kit contains N9308350 N9308351 N9308352 N930...

Page 142: ...te Injection Station Waste Trough pack of 25 50 6008103 6008104 System Liquid Container 2 L L9004516 Waste Container 5 L L9004517 Spectrum Two Spare Parts Spectrum Two Source Replacement Kit L1600243 Spectrum Two Desiccant Replacement Kit L1600244 Spectrum Two ZnSe Window Replacement Kit L1600242 Spectrum Two KBr Window Replacement Kit L1600241 System Upgrades and Accessories Ultrasonic Liquid Lev...

Page 143: ...30 fixed height accommodates the autosampler spectrometer PC monitor and keyboard 5085685 Contact your PerkinElmer Customer Care Representative for more information Refer to the Spectrum Two User s Guide part number L1050228 for a full list of Spectrum Two replacement parts ...

Page 144: ...144 OilExpress 4 System User s Guide ...

Page 145: ...Appendices ...

Page 146: ...from contamination The customer s responsible body is required to follow the Equipment Decontamination Procedure and complete the Certificate of Decontamination These documents are available on the PerkinElmer public website http las perkinelmer com OneSource decontamination htm Alternatively if you do not have access to the internet contact Customer Care Customer Care USA 1 800 762 4000 inside th...

Page 147: ... environment The requirements for waste collection reuse recycling and recovery programs are set by the regulatory authority in your location Contact your local responsible person such as your laboratory manager or authorized representative for information regarding applicable disposal regulations Contact PerkinElmer at the web site listed below for information specific to PerkinElmer products Web...

Page 148: ...n aspirated A small volume of sample 100 µL is aspirated as waste volume The first sample aspirated may come into contact with tiny droplets of system liquid inside the VersaTip and tubing and so the leading part of the sample may pick up these droplets becoming diluted A small amount of air known as a transport gap is aspirated to prevent the sample from dripping from the tip The sample volume is...

Page 149: ...cohol may be used safely Table 6 Materials in fluid path in contact with samples System Component Material Injection Station Fill Cups Polyether ether ketone Injection Station Male to Female Luer Connector Polypropylene Flow Cell Injection Station Tubing Material Fluorinated ethylene propylene Red Luer lok Connector Ethylene tetrafluoroethylene Blue Nut Connector Polypropylene Ferrule Ethylene tet...

Page 150: ...Water 13 Control Samples 92 Conventions In this manual 7 Notes Warnings and Cautions 7 Part numbers 7 CSV Export 79 D Deck Layouts 33 Decontamination 146 Degradation Products 12 Ester breakdown 12 Nitration 12 Oxidation 12 Sulfate 12 Direct Trending 13 16 E Empty Cell Spectrum 105 Ester Breakdown 12 Exporting Results 79 Spectra 78 F Fill Cup 41 Flow Cell 44 93 96 138 139 Cleaning 96 Disassembling ...

Page 151: ...lammable materials 24 Safety Shield 42 Sample Compartment 43 Sample Preparation 73 Sample Racks 34 32 position rack 37 96 position rack 35 Sample Shuttle 44 Flow cell 44 Liquid presence sensor 45 Sampling Heights 76 Scan Settings 88 Soot 13 Spares and Consumables 141 Specifications 28 Spectral Subtraction 13 16 Spectrometer 43 Connections 46 Flow cell 44 Installing sample shuttle 124 Maintenance 1...

Page 152: ...152 OilExpress 4 System User s Guide V Varispan Arm 30 VersaTips 30 W Waste Container 52 Water 13 WEEE Directive 147 Windows Start Menu 69 ...

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