Oil Quality Sensor – OilAlert

IPU’s OilAlert oil quality sensors provide real-time oil condition monitoring in vehicles, ships, gensets, turbines and many other types of mechanical devices.

Unlike off-site lubricant testing, OilAlert sensors constantly monitor the condition of your engine oil, transmission oils and hydraulic fluids. If a machine is running, its oil is being checked. With some OilAlert packages the results can even be broadcast back to your service depot in real-time and alarms raised automatically if problems are detected.

OilAlert uses a permittivity sensor that accurately and constantly monitors the condition of any lubricant in engine blocks, gearboxes or axles.

OilAlert oil quality sensors can send oil condition readings to an optional display on a control panel or in a vehicle cab

OilAlert oil quality sensors can send oil condition readings to an optional display on a control panel or in a vehicle cab

Adding this solution to mechanical devices:

  • Increases the reliability of critical equipment by alerting managers to problems with lubricants or mechanical parts.
  • Extends the life of your critical equipment by ensuring they are always properly lubricated.
  • Reduces oil costs by limiting oil changes to when they’re needed rather than when they’re scheduled.
  • Reduces downtime and loss of productivity by extending service intervals.
  • Reduces disruption to work by eliminating machine failures caused by lubrication degradation (75% of system failures are related to engine lubrication)
  • Improves efficiency by being able to plan maintenance cycles.

 

Understanding the results couldn’t be simpler

A sudden change in values indicates a pending technical problem. By shutting down the equipment quickly the operator can prevent a bad situation turning into a financial disaster.

The sensor can be wired into the equipment’s management system so an automatic shutdown can be triggered if a human operator is not on-hand.

Combining the sensor with IPU’s datalogger produces the ultimate tool for protecting your investment in critical equipment. It transmits data from the OilAlert sensor back to a service depot so an entire fleet of vehicles or equipment can be monitored in realtime. With central management, mechanical problems can be identified early. Preventative action can be taken to avoid major failures and costly downtime.

OilAlert transmits realtime oil condition data back to a service depot anywhere in the world

OilAlert transmits realtime oil condition data back to a service depot anywhere in the world

Traditional methods of testing lubricant condition can be slow and prone to human error. In open cast mines, for example, a 100t dump truck can be far from its base before the results of a lab-based oil test reveal a critical problem; an operator can miss the alerts being broadcast by his OilAlert display.

Whatever the cause, the result can be disastrous to the profitability and efficiency of your operation.

Data from OilAlert sensors, third-party sensors and the engine management system is instantly sent to a central location by OilAlert.

Data from OilAlert sensors, third-party sensors and the engine management system is instantly sent to a central location by OilAlert.

OilAlert solves the problem by using a cellular (GPRS) link to broadcast real-time lubricant condition reports. These are received by E/LOG, a sophisticated software package that captures and trends a wide range of engine parameters. Problems are detected and identified immediately. If the problem is not urgent it can be added to the vehicle’s next service schedule. If a major failure is predicted the operator can be told to stop before the problem materialises.

 

Monitor and improve oil quality

Our all-in-one packaged solution reduces lubricant costs and increases operational efficiency. It combines the remote diagnostic capabilities of OilAlert with the extended service intervals possible with OilLife bypass oil filters.

OilAlert and an OilLife bypass oil filter system can extend oil life as well as monitoring it.

OilAlert and an OilLife bypass oil filter system can extend oil life as well as monitoring it.

By incorporating IPU’s OilLife extended oil system (formerly known as EOLS), OilAlert can increase the life of lubricating oil by a factor of four. The combination of OilAlert and OilLife reduces operating costs, increases productivity and gives you absolute assurance that all your equipment, vehicles or vessels are being kept in perfect working order.

OilLife bypass oil filters use a unique combination of chemical filtration, physical filtration and and thin-film evaporation to remove water, gaseous and solid contaminants from oil. The chemical filtration action removes the acids that would otherwise break down the oil’s structure. The physical filtration action removes wear particles as small as 1µm. The thin-film evaporation chamber prevents the formation of harmful acids by removing water, light hydrocarbons and sulphur dioxide.

The end result is an unprecedented extension in the life of lubricating oils and a corresponding reduction in lubricant costs. OilLife systems can reduce oil and filter costs by 75%.

In practice, this means that vehicles that previously had to stop work for oil-change services every 500 hours can continue to run, only needing to stop every 2,000 hours when a major service is scheduled. The productivity gains are huge.

 

OilAlert Lite suits any industry

OilAlert sensors are tough enough to function in any environment. They are built to withstand the dirt-clogged atmosphere in mines and landfill sites, the incessant workload on board ships, the constant vibration in construction and transport vehicles and the huge range in temperatures experienced by diesel generator sets.

 

OilAlert Lite is an accredited solution

OilAlert’s analysis is so accurate and comprehensive it will transform the profitability and reliability of your operation. But don’t just take our word for it. Bob Cutler, the General Manager of ALcontrol Oil Analysis Laboratories, says

“After several months of testing, we were able to establish that the OilAlert* sensor is an excellent indicator of oil condition”

 

OilAlert Lite is simple to install

The OilAlert Lite oil quality sensor is integrated into the oil flow that feeds existing pressure sensors and filters. There is no effect on oil flow or pressure in the current system. No modifications are needed to the engine block itself.

OilAlert oil quality sensors do not require any modifications to the engine block

OilAlert oil quality sensors do not require any modifications to the engine block

 

The importance of lubricant testing

Poor engine lubrication is commonly cited as contributing to 75% of system failures. Few businesses can afford expensive engine rebuilds, the loss of productivity they cause and the damage to their reputation that follows. OilAlert sensors are a simple and cost-effective way to protect your profitability, productivity and reputation.

IPU's OilAlert oil quality sensor can prevent costly breakdowns on essential equipment

IPU’s OilAlert sensors can prevent costly breakdowns on essential equipment

 

An OilAlert oil quality sensor reduces costs

OilAlert is more than an early-warning system; it reduces costs too. Most organisations operate a dual service schedule with engine oil being changed both during and between major services.

Many of these oil changes are unnecessary. They are timed according to the theoretical life of the oil, not its actual condition. Oil is often discarded and machines taken out of service while the oil is still delivering adequate engine lubrication. OilAlert sensors give you the data and the confidence to change oil when it needs changing, reducing oil and filter costs and extending service intervals.

 

OilAlert helps your business

OilAlert sensors are perfect partners for all hard-working machinery. The worse the conditions, the heavier the workload, the more critical the application, the more essential OilAlert becomes:

  • Open cast and underground mining vehicles.
  • Construction and earth-moving vehicles.
  • Commercial and military shipping.
  • Passenger transport.
  • Haulage.
  • Landfill power generation.
  • Renewable power generation.
  • Standby power generation.
OilAlert sensors monitor oil condition for mining and quarrying vehicles

OilAlert sensors monitor oil condition for mining and quarrying vehicles

OilAlert sensors reduce the maintenance burden by providing oil condition monitoring for wind turbines

OilAlert sensors reduce the maintenance burden by providing oil condition monitoring for wind turbines

OilAlert oil quality sensors keep construction equipment working by providing real-time oil condition monitoring

OilAlert oil quality sensors keep construction equipment working by providing real-time oil condition monitoring

OilAlert sensors monitor ships' maintenance needs by providing remote oil condition monitoring

OilAlert sensors monitor ships’ maintenance needs by providing remote oil condition monitoring

 

OilAlert helps OEM manufacturers differentiate themselves

Everybody’s looking for an edge, the benefit that makes their trucks, lorries or ships stand out from the competition. OilAlert delivers that benefit.

By incorporating OilAlert into your equipment you can deliver benefits far beyond the capabilities of your competitors, benefits that attract new customers and retain old ones:

  • Reduced downtime.
  • Better management.
  • Reduced costs.
  • Increased reliability.
  • Longer service intervals.

 

Sensor specifications

Physical Characteristics
Material Stainless Steel AISI304
Dimensions 90mm x 37mm (L x W)
Weight 160g
Power
Power supply 9-30 V DC
Average power consumption 0.4W
Power consumption 30mA continuous
Analog output 4-20mA
Digital Output
RS232 9600 baud bi-directional
RS485 9600 baud half duplex
Modbus on RS232 & RS485
CANbus CANopen protocol
Environmental
Protection IP67 when connected
Operating Temperature -20°C to +120°C
External Pressure 0 bar to 20 bar
Fluid Pressure up to 20 bar
Detection
Detection for Oxidisation
Water Contamination
Glycol Contamination
Fuel Contamination
Dirt Contamination
TAN
TBN
Viscosity Breakdown
Wear Particles
Soot
Oil Temperature
Electrical Connection
Type 6 Pin Lumberg
Mechanical Connection
Type M32 Hex Head
3/8” or 1/2” BSP Thread
DIN 3869 Ring Seal or Dowty Seal
Oil Measurement
OQUs 10 to 100
Accuracy Repeatability +-3%
Standards
Conformity BS EN 60068-2-30 (Test Db – Cyclic Humidity)
BS EN 60068-2-6 (Test Fc – Sine Vibration)
BS EN 60068-2-27 (Test Ea – Mechanical Shock)
EN 61000-6-4:2007 (Generic Emissions Standard for Industrial Environments)
EN 61000-6-2:2005 (Generic Immunity Standard for Industrial Environments)

 

Video

Combining IPU’s OilAlert and OilLife systems adds an unbeatable edge to any mechanical equipment, vehicle or vessel. OilLife reduces operating costs by safely extending service intervals and OilAlert sensors give you the confidence to extract maximum productivity. Watch our videos to see some typical scenarios:

 


* We’ve changed the name of the sensor in this quotation to reflect a product rebrand – it’s still the same product though.

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