TruckCheck Manual

TruckCheck Manual
User Manual
OSA4™ VERSION 7.2 – Windows 7
Original Instructions
Guide to the OSA4™ Analyzer
certified
ASTM D7417-10
PREFACE
This user manual is the first part of the complete guide to the OSA4™
Analyzer. This manual is intended to guide operators of the Analyzer through the
normal procedures associated with processing oil samples.
This manual is intended for mechanics, technicians, or anyone else who wants to
learn the proper way to analyze oil samples using the OSA4™ Analyzer. The
introductory sections of this manual orient the user with the equipment and
supplies that are used. The Standardization section covers the procedures that
give the user confidence that the Analyzer is performing to specifications. The
largest section of this manual is the How To... section. The reader is taken
through a step-by-step process of how to analyze an oil sample. The Printing
and Flushing sections complete the start-to-finish organization of this manual.
This manual includes features that are designed to aid the reader in quickly
referencing helpful information. The outlining is extensive so that the reader can
easily find the topic of interest. Useful tips are emphasized in boxes entitled
“Key to Successful Oil Analysis.” The electronic version of this document
includes hyperlinks and bookmarks to further speed the reader’s access to
information.
 Copyright 2013
On-Site Analysis, Inc.
7108 Fairway Drive
Suite 130
Palm Beach Gardens, FL 33418
561-775-5756
On-Site Analysis, Inc. declares that their OSA4™ Oil Analyzer with the following models:
MotorCheck™, TruckCheck™, MilitaryCheck 3M™, MetalLab™, and MicroLab™ are classified
within the following directives:
EU Low Voltage Directive 2006/95/EC
EU Electromagnetic CompatibilityDirective 2004/108/EC
EN 60950-1:2006 - EN55022 (2006) +A1:2007 - EN 55024 (1998) + A2:2003
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User Manual Outline
I-Introduction
Overview .................................................................................................................................. 4
Safety Information .................................................................................................................... 5
Analyzer Features .................................................................................................................... 6
II-Getting Started
Routine Tasks ........................................................................................................................... 8
Cleaning the Electrodes and Electrode Maintenance ............................................................... 9
Necessary Supplies .................................................................................................................. 13
The Main Menu ...................................................................................................................... 14
III-Standardization
Explanation ............................................................................................................................ 15
Baseline Test .......................................................................................................................... 16
Verify Metals .......................................................................................................................... 17
Standardize ............................................................................................................................. 18
IV-How to Analyze an Oil Sample
Collecting the Oil Sample and Data ...................................................................................... 20
Sample Introduction .............................................................................................................. 20
Test Selection ......................................................................................................................... 20
Vehicle and Customer Data Entry ......................................................................................... 22
New Customer – New Vehicle ............................................................................................... 28
The Analysis Cycle ................................................................................................................ 30
On Screen Reporting ............................................................................................................. 31
V-Printing Reports
Optional Report Formats ...................................................................................................... 32
Printing History Reports ...................................................................................................... 33
VI-Flushing
AutoFlush ............................................................................................................................... 35
Manual Flush......................................................................................................................... 35
IR Night Flush ...................................................................................................................... 38
VII-Extended Metal Standardization
Explanation............................................................................................................................ 39
Standardization...................................................................................................................... 39
VIII-Dual Temperature Viscometer
Viscometer Only.………………………………………………………………………………………42
Operation………….……………………………………………………………………………………42
Standardization…………….…………………………………………………………………………..42
VIV-Addendums
Addendum A (Particle Counter Operations & Requirements)…………………………………..48
Addendum B (Over Pressure – Sample Intake Assist)………………………………….…..……..49
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I.
Guide to the OSA4™ Analyzer – User Manual
INTRODUCTION
OVERVIEW
This is the User Manual for the OSA4 Analyzer. The OSA4™ oil Analyzer is a tool for evaluating the
condition of engines, transmissions, gearboxes and hydraulics. The Analyzer tests for wear debris and
other contaminates in the oil. The Analyzer also tests the physical properties of the oil itself. By
comparing test results to normal conditions, the OSA4™ Analyzer can recommend if any maintenance
or repair actions are necessary.
The OSA4™ Analyzer is a tandem spectrometer that integrates an Optical Emissions Spectrometer
(OES) and an Infrared Module. The OES excites a portion of the used oil sample and measures the
concentration of sub-microscopic metals in solution. These metals are present due to component wear,
normal and abnormal, inside the component. The Infrared Module scans a portion of the used oil
sample to measure the physical properties of the oil and look for contaminants.
An onboard computer controls both spectrometers and tabulates the results gathered from each.
Information about the oil and the vehicle provided by the operator, along with the test results, are
evaluated by the Analyzer’s proprietary software. The software generates a report that includes the
test results and a diagnostic statement. The diagnostic statement is a summary of the test results and
an evaluation of the condition of the engine or transmission being tested. The diagnostic statement
may also recommend maintenance for specific engine or transmission components.
This manual is about operating the OSA4 Analyzer. The introduction will acquaint you with the features
of the Analyzer and bring your attention to safety concerns. The Getting Started section will instruct
you on the simple tasks associated with operating the Analyzer and how to use the other items supplied
with it. Standardizing the Analyzer is an important first step in getting comfortable with its operation. In
the following sections you will be given details on how to properly analyze a sample of oil and produce
useful reports.
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SAFETY INFORMATION
To reduce the risk of injury, do not open the instrument enclosure or remove access panels. There are
no user serviceable parts inside. Refer servicing to qualified service personnel.
WARNING LABELS
Special labels are placed where hazards exist.
SPECIFIC WARNINGS
Do Not Defeat the Spark Door Interlocks
Defeating Spark Door Interlocks may expose the user to UV Radiation that can cause permanent
eye damage.
Defeating the Spark Door Interlocks may expose the user to voltages that are lethal.
Operate in a Well Ventilated Area
The Analyzer produces ozone when high voltage is arcing across the electrodes.
Do Not Introduce Flammable Fluids into the Analyzer
Never attempt to introduce fuels such as gasoline, kerosene, and diesel fuel into the
Analyzer. Fuels may ignite and explode causing injury.
Only introduce used oil samples from diesel engines, gasoline engines, gearboxes, hydraulics and
transmissions.
Key to Successful Oil Analysis:
Never attempt to introduce anti-freeze, water, brake fluid,
or fuel into the Analyzer. These fluids will cause
irreparable damage.
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ANALYZER FEATURES
The basic features of the OSA4™ Analyzer are listed here. Becoming familiar with these features is
necessary as you will need to interact with them routinely during the normal operation of the Analyzer.
The photo at the end of this section illustrates the location of each of the following features of the
OSA4™ Oil Analyzer.
Spark Stand
This door should be closed at all times unless performing routine maintenance.
Sipper Straw
The Oil Straw draws sample oil into the Analyzer where it is pumped through the flow system for
analysis. This is a consumable item and has to be replaced for every sample.
Waste Bottle
Oil that has been analyzed and flushing solution that has been purged through the flow system
drains into this container.
Flush Bottle
The Flush Bottle contains a flushing solution (CheckFlush) used to clean out the flow system and is
used during the low standardization process. This bottle needs to be checked on a daily basis.
ON / OFF Switch – Reset Switch
The power switch is an illuminated rocker switch located on a recessed bulkhead along the right
side of the Analyzer.
Flush / Flush Bracket
This bracket is included with units that have an optional Dual Temperature Viscometer. It allows for
a larger flush bottle to be attached to the side of the OSA4.
Waste Port
This port can be set up by an OSA engineer to allow for larger waste containers. A special tube is
inserted in the interior of waste door and this port becomes active. The port is equipped with a
female 3/8-18 NPT.
Keyboard
Keyboard is used for entering information and operating the Analyzer.
Touch Screen Display
The flat panel LCD touchscreen displays operator keyed information and Analyzer status.
Printer (not shown)
Analysis reports are printed from a printer located near the Analyzer. Typically, the printer sits on
the shelf of a cart supporting the Analyzer.
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Modem/Network (not shown)
A computer modem connection to the Analyzer facilitates problem diagnosis and maintenance from
remote customer service centers. A dedicated telephone line or a network IP address connected to
the Analyzer via the modem/network connection on the back panel is a requirement at Analyzer
placement sites.
Touch Screen Display
Spark Door
Sipper Stand
Flush Bottle
Flush Bracket
Keyboard
On/Off
Reset Switch
Waste Port
Waste Door
*****Please note that your Analyzer may be a different color based on the model ordered*****
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II.
Guide to the OSA4™ Analyzer – User Manual
GETTING STARTED
ROUTINE TASKS
Emptying the Waste Bottle
The waste bottle collects the used sample oil and flushing solution that has been circulated through
the flow system. There is a sensor to alert you to empty the waste bottle. The waste bottle is
accessed behind the Flush / Waste Door. Check the waste bottle occasionally to be sure that the
sensor is working properly.
Replacing the Flush Bottle
The Flush Bottle contains the fluid that cleans the instrument between samples and is used during
low standardization. There is a sensor to alert you to a low level of flushing solution. The flush bottle
is accessed behind the Flush / Waste Door. Check the flush bottle regularly and replace it when it
gets low. If your unit is equipped with an optional DTV - the flush is located on the right side in the
DTV Flush Bracket.
Key to Successful Oil Analysis:
Keep an adequate level of flushing solution in the flush
bottle. An inadequate level of flush will cause crosscontamination between oil samples.
SAMPLE INTRODUCTION:
Shake sample gently, then attach straw to analyzer sample intake, and insert into sample bottle, as
shown below.
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Maintaining the Electrodes
The software will prompt you when required adjustments are needed. If it is necessary to adjust the
electrode gap then you must also standardize the Analyzer. Refer to the Standardization section of
this manual for details.
The electrodes are on a stand inside the Spark Door.
positioned vertically – one above the other.
The upper and lower electrodes are
The gap is the distance between the upper and lower electrodes. The gap should be no more than
5/32 of an inch. The flat end of the gap tool (supplied with instrument) can be used as a “Go/No-Go”
gauge for measuring the electrode gap. A 5/32 allen wrench is used to loosen the screw that holds
the upper electrode and is included with the Analyzer’s supplies.
The electrodes are located on a stand inside the Spark Door.
CLEANING THE ELECTRODES - Refer to figure below
Use a cotton swab to clean the upper electrodes. First, clean the inside of the upper electrode by
inserting the swab down through the center of the electrode and turning clockwise. Then, insert the
swap between the electrodes and wipe the flat surfaces of both electrodes.
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CHECKING AND ADJUSTING THE ELECTRODE GAP (“GAPPING”)
Electrode gap
The electrode gap is the distance between the upper and lower electrodes. One side of the
white electrode gap tool (shown below) is used as a “Go/No-Go” gauge for measuring the electrode
gap (5/32”).
As samples are run, the gap between electrodes will increase.
Upper electrode holder
Upper electrode holder
screw (5/32” Allen)
Upper electrode set screw (5/32” Allen)
Upper electrode
Lower electrode
Lower electrode set
screw (0.05” Allen)
Electrode Gap
Tool
Figure E-1
If the electrodes are not properly gapped (Go/No-Go gauge is loose, or gap is too tight to insert
gauge), then follow the procedure below to reset the electrode gap.
Resetting Electrode Gap (“Gapping”)
Insert the flat end of the gap tool between the electrodes as shown in Figure E-1.
Loosen the upper electrode holder screw (5/32” Allen). Let the upper electrode holder slide
down till it is flush with the top of the white electrode gap tool. Retighten the upper electrode holder
screw.
NOTE: Anytime the gap is changed, the unit must be Standardized.
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CHECKING THE HEIGHT OF THE LOWER ELECTRODE
Note: The lower electrode will slowly decrease in size with use. It is recommended to regularly
check the height of the lower electrode.
Place the grooved (U-shaped) end of the white electrode gap tool (shown in Figure E-2 below)
around the bottom electrode. If the electrode falls below the height of the ‘U’ shaped tool, then it is
time to change the electrode. .
Figure E-2
CHANGING ELECTRODES
To change electrodes –. Remove the Upper Electrode screw shown in the picture below right.
Loosen the upper electrode holder screw, and slide the upper electrode straight up out of its holder.
After raising the upper electrode out of its holder, remove the lower electrode. The lower electrode
has a .05 Allen screw holding it in place. Loosen the Allen screw, and remove the lower electrode
by turning counter-clockwise. Anytime you change the bottom electrode, change the upper
electrode as well. The upper electrode can be removed from its holder by loosening the screw in
the upper holder. The upper electrode is reversible, so pull it out and if it is in good shape place it
back in reversed and tighten screw - Otherwise, replace with a new Upper electrode.
Lower electrode Allen screw
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Replace bottom electrode by turning in new one clockwise. Insert upper electrode holder down
through slot, and adjust the upper electrode so that about 3/8" of the electrode (or the approx.
thickness of the gap tool's U-shaped section protrudes from the bottom of the holder (refer to
picture, top of this page) then replace the upper electrode screw and tighten it to secure the upper
electrode. Re-gap between the electrodes, making sure to tighten the upper electrode holder screw
(refer to page 9).
Anytime an upper or lower electrode are replaced- the unit must be Standardized.
CAUTION
DO NOT OVER TIGHTEN SOCKET HEAD CAP SCREWS LOCATED ON ELECTRODE HOLDER
socket head cap screw should be finger tight plus ¼ turn with wrench only
over tightening of screw may cause stress/cracking to holder
CLEANING THE COLLIMATOR
The collimator acts as the “eyes” of the spectrometer (OES) used to detect and measure wear metals in
oil samples. As such, the collimator lens needs to be cleaned periodically to maintain the OSA’s ability
to measure these wear metals.
The collimator lens looks like the lens of a camera and is located to the left of the electrodes.
Daily - wipe the collimator lens gently with a clean, lint-free cloth (the Kim-Wipes supplied with the
analyzer are to be used for this purpose).
CAUTION
Be careful not to apply excess pressure to the lens, as moving the lens will affect the
alignment of the collimator, possibly resulting in inaccurate results.
Servicing the Printer
Re-supplying paper is usually all you need to do for the printer. Check the paper tray and add
paper as necessary, following the instructions included with the printer. When the printer needs
service, it will indicate with the Light Emitting Diode (LED).
Most printing problems are easily remedied. Make sure the printer has paper and is powered
on. Turning the printer off and back on can clear up other problems.
Occasionally the toner cartridge and/or printer drum will need to be replaced. Patches of light
printing on the report page are indications that the toner cartridge needs to be replaced. If the LED
indicator light for a Paper Jam is blinking and you can’t find a paper jam, that’s an indication that the
drum needs to be replaced. Please contact your customer service center for replacement toner
cartridges or printer drums.
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NECESSARY SUPPLIES
Test Standard (29087-00)
The High Standard solution is a blue colored base-oil that contains precisely controlled amounts of
each of the metals needed for Standardization.
CheckFlush Solution
(29088-01)
The flush solution is a non-toxic, environmentally friendly oil cleaning fluid. The flush solution is used to
purge the flow system, and run low standard.
Sample Bottles
(29002-01 – 2 oz.) (29002-05 – 5 oz.)
Sample bottles are typically 2 to 5 ounces in capacity. The Basic Analyzer usually uses less than two
ounces of oil for a complete analysis. The sample bottles are pre-cleaned and should not be re-used
to avoid contamination. Units equipped with a DTV (Viscometer) will use five ounces of sample.
Report Paper (29011-00)
Report paper is pre-printed having a logo on the front and an explanation of oil analysis results on the
back. The explanations are helpful when interpreting oil analysis results.
Input Sheets (29021-00)
Input sheets are half-sheet sized pre-printed forms that are helpful to fill-out when taking oil samples
from vehicles. When several samples are being processed it is important that the input sheets can be
identified to differentiate sample bottles.
Cleaning Supplies
 Cleaning Swabs
(29033-00)
Only certain sized cotton swabs will fit properly through the upper electrode. Care should be taken
so that the swab does not get stuck in the upper electrode.
 Clean Shop Rags or New Paper Towels
Clean Shop rags or new paper towels are used to wipe off the top electrodes and clean up any oil
spills.
Sipper Straws (29822-00) Box of 350
Sipper Straws are a single use sample intake straw that are swapped out with each individual sample.
The straw is removed from the box by holding the bend area and placed directly over the metal intake.
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THE MAIN MENU
The main menu of the User Interface is the first screen that is displayed when the Analyzer is poweredup. From the main menu, all of the Analyzers functions can be accessed. The main menu is shown
below. Page numbers for description of the main menu features are provided. Some of the items
described here are elsewhere in the User Manual [U.M.]
WHEN THE ANALYZER IS BOOTED FROM THE DESKTOP – THE USER ID AND
PASSWORD ARE “1” AND “1”.
THIS LOG-IN MESSAGE BOX WILL APPEAR BRIEFLY AS THE UNIT WARMS UP
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III. STANDARDIZATION
EXPLANATION
Occasionally, it is necessary to standardize the OSA4™ Analyzer in order to compensate for minor
changes affecting the Analyzer’s calibration.
You do not have to standardize the Analyzer unless 1) you have adjusted the Electrode Gap, 2) the
Test Standard routine prompts you to, or 3) the message box tells you to at the beginning of a sample
run.
You should run the Verify Metals routine when prompted by the software, or whenever you question the
Analyzer’s performance.
Prior to running the Verify Metals routine, a Check Baseline Test should be performed.
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CHECK BASELINE TEST
The Baseline Test is used to determine if there is contamination in the flow system or on the electrodes
of the Analyzer. It should be performed at the beginning of each day, or any time you wish to confirm
that the Auto Flush cycle has sufficiently cleaned the internal lines and electrodes after running a highly
contaminated sample. To run this test, simply select the OSA Maintenance button from the Main Menu
located at the top right of the screen. Select the ‘Standardization’ option, and the ‘Standardize Options’
Screen will appear as shown below. Select ‘Check Base Line’ from the list of options.
When the Baseline Test begins, you will be given instructions to clean the electrodes. Refer to
Cleaning the Electrodes in the How to Analyze an Oil Sample section of this manual for a description of
the proper technique. Follow the directions on the screen to perform the Baseline Test.
After cleaning the electrodes, press the OK key and the Analyzer will run the test. Press CANCEL if you
want to return to the main menu.
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At the end of the test, a message box will display informing you if there is contamination, or that the
System is clean, OK to proceed. If there is contamination, then the Analyzer will give you instructions
to flush, clean the electrodes, and try the test again.
Key to Successful Oil Analysis:
Clean the electrodes thoroughly prior to starting the
Baseline test. A dirty electrode will cause the test
to fail.
VERIFY METALS
The Verify Metals function allows you to check the Analyzer’s standardization. To run this test, choose
Verify Metals from the Standardize Options screen and press ENTER. When the test begins, you will
be given instructions like those shown on the screen below. Refer to Cleaning the Electrodes in the
How to Analyze an Oil Sample section of this manual for a description of the proper technique.
Press the OK key and the Analyzer will run the test, or press CANCEL to return to the main menu.
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At the end of the test a message box will display informing you if the test of the Analyzer is within
specifications. If the Test Standard is not within specifications, then a message box will provide you
with instructions to try the test again or to proceed to Standardization.
Key to Successful Oil Analysis:
Please clean the electrodes prior to starting Test
Standard. A dirty electrode will cause the test to fail.
STANDARDIZE
To standardize the Analyzer, select ‘Standardize Metals’ from the Standardize Options screen.
When the standardization process begins, you will be given instructions like those shown on the screen
below. Press OK to continue or CANCEL to return to the main menu.
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Standardization is comprised of two parts, Low Standardization and High Standardization. All the
operator has to do is insert a clean sipper straw into the Test Standard fluid (Blue 50 ppm standard),
connect to the silver sipper nozzle and follow the instructions. Carefully follow all on-screen instructions
completely. The total process will take about 15 minutes to complete. Upon completion, the Analyzer
will display a message stating whether or not the standardization was successful. If unsuccessful, the
software will prompt you on what to do next.
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IV. HOW TO ANALYZE AN OIL SAMPLE
COLLECTING THE OIL SAMPLE & SAMPLE DATA
To analyze oil from any component, you must first obtain a sample. There are two methods for
sampling the oil. You can either catch a sample during a drain or you can pull a sample through the
dipstick. Provisions for sampling have either been provided with the OSA4™ Analyzer. Refer to the
Training Manual or other supporting documents for detailed instructions.
SAMPLE INTRODUCTION
When you have a sample to analyze, remove the lid from the bottle, and shake the sample thoroughly.
Select a sipper straw from the box attached to the right side of OSA by grabbing it at the bend of the
straw where the ridges are located. Place the straw into the bottle - long side down - and slide the straw
onto the silver sipper nozzle as shown below.
TEST SELECTION
The analysis of your oil depends on the type of sample you are running. You must specify if the sample
comes from a transmission, gasoline, diesel engine, etc. and also the application you will be using to
run the sample.
The Main Menu page (shown below) is where the initial application is first selected. The available
modes are –
ON-ROAD TRUCK (which includes Bus, RV, and Trucks)
AUTO
OFF-ROAD
MARINE
INDUSTRIAL
RAILROAD
COMMERCIAL GENSET
Ensure you are in the proper application - The applications differ based on 1) Databases used for
equipment selection, 2) Rules and Evaluation statements used on the reports, and 3) Tests that will be
run on the particular sample.
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The example used for demonstration will be ON-ROAD Trucking Mode.
Check Base Line, Verify Metals and the Standardization are all logged at the bottom of the Main Menu
for reference as to when the next scheduled maintenance item is due. These messages keep track of
time since they were run last. If you exceed the time limit- a message will appear stating that you need
to run the test(s). It will allow you to run 5 more samples before stopping Analysis.
BEGIN BY SELECTING THE ‘START’ BUTTON
Press the blue START button from the main menu, or you can enter a Vehicle ID number in the box
above START if the sample has been preloaded or previously run.
After pressing START a Customer Information grid will be shown
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VEHICLE AND CUSTOMER DATA ENTRY
Select the Customer you wish to use and press the ‘Select’ button. You can sort the customer list by
selecting one of the 4 categories in the top right of the screen – Last Name (Customer Name), First
Name, Vehicle ID, or City.
If your Customer is not in the list, press the ‘New Customer’ button in the top left corner and follow the
instructions on page 28.
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The example below was sorted by the Vehicle ID. This allows you to see all the Vehicles in the system
and the applicable Customer Name.
Select the Vehicle ID you wish to run and press the ‘Select’ button. The example above used Vehicle ID
AB123456 corresponding to Customer – ABC TRUCKING.
You can use this Vehicle, or select a new Vehicle ID by choosing the ‘New Vehicle’ button. If you
choose the New Vehicle button – proceed to page 29.
Highlight the Vehicle you want to use and press the ‘Select’ button. The following screen will appear
asking you to choose a component testing option.
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Choose the testing option from the choices above, and the next screen will appear. This example uses
a Diesel Engine option.
Select the component you wish to use from the list and press the ‘Select’ button.
Note that you can change any of the settings (Customer, Vehicle Info) by choosing the ‘Change’ button
to the right of the selection.
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You can now edit the fields shown above. When finished, select the ‘Oil Info’ button to move to the next
screen.
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Fill out the required information on the Oil Info page. The oil brand and oil type are selected using the
drop down lists. If your oil is not listed in the drop down box, select custom as an oil brand and enter
your oil brand and oil type in the extra fields provided. You will be asked to save these custom oils
when you finish the entry process. You can add sample notes and the operators name if desired. Press
the ‘Analyze’ button when finished and the screen below will be shown
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The ability to Change any of the selections is available along with the ability to select which tests you
want to perform on the sample. Physical Properties, Metals (Basic and Extended), Measured Viscosity
(if unit is equipped with a Viscometer). Calculated will be selected if there is no Viscometer present.
Any combination of the tests can be run.
You can also choose which type of report you need, whether or not to print an ‘Understanding your
report’ and also whether the report prints automatically at the end of the sample run.
Selecting the ‘Set my selection as default’ check box saves your set-up settings for future samples.
Press the GO button when ready to Analyze the sample.
A message box will also prompt you to place a clean straw on the sipper intake, and then place the
bottle under the straw.
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NEW CUSTOMER
If the Customer you are running the sample for is not listed—press the ‘New Customer’ button and the
screen below is shown. Fill out as much information as possible to ensure that the proper customer is
aligned with the correct unit information.
.
Press the ‘Save’ button when data entry is completed and follow instructions on entering unit
information.
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NEW VEHICLE
If a vehicle has not been analyzed before or is not preloaded into the system, it is necessary to use the
New Vehicle data entry section. When the ‘New Vehicle’ button is pressed the following screen is
shown.
Fill out the data entry as completely as possible for the Vehicle by selecting the drop down arrow
and selecting the proper make and model. If the make and model you require is not listed, select
‘Custom’ from the drop down choices and fill in your data in the field that appears. You will then be
asked to save this custom make and model at the end of the data selection.There are extra fields to
add Jobsite and Description if needed.
Once the data is complete, press the ‘Save’ button and follow the instructions to complete the
sample.
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THE ANALYSIS CYCLE
The analysis takes about 10 - 12 minutes to complete (based on the components in your Analyzer)
after the data entry and manual tasks have been performed. The status bar indicates progress as the
sample is processed. If you want to stop the analysis, press the STOP button. The stop process takes
15-30 seconds to complete.
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ON-SCREEN REPORTING
When the analysis is complete, an analysis report may be briefly displayed on the screen. An example
of the on-screen report is shown below. The report will include the results of the analytical tests along
with a diagnostic statement. Severity codes will also be printed with the test results. Green indicates
normal conditions.
After the results are displayed, the Analyzer will begin the Auto Flush process and ask you to perform
the task of removing the sample. Remove the sample and press OK so that the Analyzer can reset
and be ready for the next analysis.
The On-screen reporting gives you the ability to print and view the report at the end of the analysis
cycle.
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Guide to the OSA4™ Analyzer – User Manual
PRINTING REPORTS
OPTIONAL REPORT FORMATS
Depending on how the Analyzer has been configured, the Analyzer may automatically print a hardcopy
of the analysis in the following formats.
NUMERIC OR NUMERIC HISTORY REPORT
The Numeric Report is a standard laboratory style report with wear metal concentrations reported in
parts-per-million and physical properties that are quantified in their appropriate units. The results range
from normal to severe. A diagnostics statement is included which suggests problem sources and
recommended service actions. Numeric History can contain up to 3 different sample results per page.
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PRINTING HISTORY REPORTS
To print the report for a sample that has just been analyzed, select the DATA button on the Main Menu,
then select ‘Reports – View / Print / Export’ from the Data Settings.
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The Search by button on the right top can be used to change the sorting options from Sample
ID, Vehicle ID and Last Name (Customer Name). Once the sample is found, select it and the
report will be displayed and printed.
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VI. FLUSHING
AUTO FLUSH AFTER SAMPLE RUN
The computer controls the Auto Flush. The software evaluates the last sample’s level of contamination
and determines what type of flush to perform on the system. The user has no control over the duration
of the Auto Flush.
The other Flush options are contained within the OSA Maintenance button located on the main menu –
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MANUAL FLUSH
Selecting Flush gives you the following options-
VISCOMETER FLUSH
The Viscometer and Particle Counter Flush (if equipped on your unit) allows the user to perform
additional cleanings directly to the Viscometer and the Particle Counter. This function gives the user
additional tools to fight sample carry over and contamination contained within these two components.
SHORT FLUSH
The short flush applies an extra flush to the system when light contamination is encountered.
MEDIUM FLUSH
The medium flush applies an extra flush to the system when mid-range contamination is encountered.
LONG FLUSH
The long flush applies an extra flush to the system when heavy contamination is encountered.
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When doing a SHORT, MEDIUM or LONG Flush, the screen below will prompt you to put a 3 ounce
bottle under a clean straw.
IR NIGHT FLUSH
The IR Night Flush should be selected each night when the unit will no longer be used. This flush is
used to ‘soak’ the IR module cell windows and ensure they stay clean from soot buildup. Selecting this
button starts a procedure that checks the amount of sooty samples run during the day. If there were
any run, the instructions on the screen will prompt you through an automated process.
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VII. STANDARDIZING EXTENDED METALS
EXPLANATION
Occasionally, it is necessary to standardize the extended metals of the OSA4™ Analyzer in order to
compensate for minor changes affecting the Analyzer’s calibration.
You do not have to standardize the Analyzer unless 1) you have adjusted the Electrode Gap, or 2) the
Test Extended Metals Standard routine prompts you to, or 3) the message box tells you to at the
beginning of a sample.
You should run the Test Extended Metals Standard routine 3 days / 72 hours after a Full
Standardization, or whenever you question the Analyzer’s performance.
Prior to running the Test Extended Metals Standard routine, a Baseline Test should be performed.
The 10 Basic Metals include – Iron (Fe), Chromium (Cr), Lead (Pb), Copper (Cu), Tin (Sn), Aluminum
(Al), Molybdenum (Mo), Silicon (Si), Sodium (Na), and Potassium (K).
The Extended Metals package includes the 10 Basic Metals plus – Titanium (Ti), Manganese (Mn),
Vanadium (V), Boron (B), Magnesium (Mg), Calcium (Ca), Barium (Ba), Phosphorous, Nickel, (Ni) and
Zinc (Zn).
STANDARDIZATION
Select OSA Maintenance from the Main Menu, and the select Standardization. From the Standardize
options screen, select ‘Standardize Metals’.
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Clean the electrodes, and place a clean straw into the (blue) Test Standard Fluid and connect to the
silver sipper nozzle.
A message will appear asking the following, “Standardization of basic metals is not required at this
time. Do you still wish to standardize basic metals ” Select the YES button to proceed.
Press OK , as shown on screen pictured below after cleaning electrodes and inserting Test Standard
Fluid (blue).
After 30% has elapsed on the status bar, a message will appear on screen asking to again clean the
electrodes. Do so and press the OK button when finished.
This method will last 10-15 minutes
A message will then appear stating “Basic Metal Standardization Completed”. If you see otherwise,
Select CANCEL and repeat previous extended metals standardization steps.
This now indicates that Basic Metal Standardization is completed. Press OK button to continue on to
Extended Metal Standardization.
A message may appear asking the following, “Standardization of extended metals is not required at this
time. Do you still wish to standardize extended metals ?” press YES button to continue.
Clean the electrodes thoroughly, and place a clean straw into the (yellow) Low Concentration Standard
- and connect to the silver sipper nozzle.
Press the OK button when ready to continue
A message will appear on screen asking to clean the electrodes when the status bar is at 40%. Do so
and select the OK button when finished.
This method will last 10 minutes.
A message will appear stating “Extended Metals LCS Standardization Stand Completed”.
If error message appears, press CANCEL and return to beginning steps for LCS Standardization.
Extended metals Low Concentration Standard is now complete. Select the OK button to continue on to
Extended metals High Concentration Standard. Clean the electrodes thoroughly, and place a clean
straw into the (brown) High Concentration Standard - and connect to the silver sipper nozzle.
Select OK when ready (as shown below).
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This method will last approximately 10 minutes.
A message will appear stating “Extended Metals HCS Standardization Completed” (as shown below)
If you see otherwise, CANCEL, and repeat previous steps for the HCS standardization.
Extended metals High Concentration Standard is now finished. Select the OK button.
A message stating “Standard is Finished” will appear. Select the OK button to begin automatic flushing
procedure.
Follow screen instructions and select OK on all flushing messages that appear.
** Extended Metal Standardization is now complete **
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VIII. DUAL TEMPERATURE VISCOMETER (DTV)
EXPLANATION
The Dual-Temperature Viscometer (DTV) is a fully integrated component for the OSA that generates a
100 Centigrade Viscosity, a 40 Centigrade Viscosity, and a Viscosity Index. This patented device
works seamlessly in the background generating these measurements during the course of a normal
OSA sample run.
If your OSA is equipped with a DTV, you will be prompted at the end of the data entry cycle to choose
what type of Viscosity you would like to run.
The Calculated Button does not use the DTV and calculates the viscosity of the oil based on the
weight first entered during data entry and applying the measurements and physical property tests
against this starting point.
The Measured Button runs both V40 and V100 simultaneously
The 40C Only runs only a Viscosity at 40 C
The 100C Only runs only a Viscosity at 100C.
OPERATING THE DTV
Operation of an OSA with the DTV is the same method used in How to Analyze a Sample. The time
frame is longer because of the additional DTV component. Five (5) ounce sample bottles are needed
when running a sample using the DTV. Never reuse the 5 ounce sample bottles after the test is
completed.
STANDARDIZING THE DTV
Once every 6 months the DTV will need to be standardized. Included with your OSA will be two
viscosity standard bottles: Low Viscosity Standard (Pink Fluid) and High Viscosity Standard (Green
Fluid). Pour these into separate 3 ounce sample bottles and label them accordingly. From the Main
Menu Select the OSA Maintenance Button, then Visc Standardization Button.
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A log in will appear that is password protected so that only instructed personnel can standardize the
Viscometer. Enter your user name and password given during setup and training.
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On the labels of your bottles of Viscosity Standard (Low and High) you will have measurements for
Viscosity at 40° C and 100° C. As you move through the Viscosity standardization process you will
need these measurement numbers to enter in the appropriate fields for standardization.
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The first message as shown below will appear. Make sure that the number from your Low Viscosity
Standard at 40°C (on the pink fluid bottle label) is entered into this field, then Press OK.
The message as shown below will appear. Make sure that the number from your High Viscosity
Standard at 40°C (on the pink fluid bottle label) is entered into this field, then Press OK.
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The message as shown below will appear. Make sure that the number from your Low Viscosity
Standard at 100°C (on the green fluid bottle label) is entered into this field, then Press OK.
The message as shown below will appear. Make sure that the number from your High Viscosity
Standard at 100°C (on the green fluid bottle label) is entered into this field, then Press OK.
Press OK and a message box as follows will appear.
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Place a clean straw into the Low Viscosity Standard (Pink Fluid) - and connect to the silver sipper
nozzle and press OK.
Once this process has finished another message will come up asking you to insert the High Viscosity
Standard (Green Fluid).
Pull the Low Viscosity Standard out from the sipper nozzle. Place a clean straw into the High Viscosity
Standard (Green Fluid) - and connect to the silver sipper nozzle after this message appears.
The Viscosity Standardization process will be concluded after the High Viscosity Standard has finished.
Once completed, you can remove the standard bottle from the sipper nozzle and continue running
samples.
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VIV. ADDENDUMS
A D D E N D U M
A
Instruments equipped with a particle counter module
Sample Preparation Procedure for Particle Measurement
If the sample to be measured has been standing for any period of time, particle settlement and
agglomeration will occur. It is essential that the agglomerates be broken up and the
contaminant particles become dispersed evenly throughout the contents of the sample bottle in
an ultrasonic bath. Energize the bath for 30 seconds or until no surfacing air bubbles are
observed. Remove the sample bottle from the ultrasonic bath and gently turn the sample
bottle over five times, taking care not to introduce air bubbles into the liquid prior to analyzing
with the OSA Oil Analyzer, particle counter function. Reference sample preparation procedure
outlined below.
1) Fill ultrasonic bath with 3 inches of water, turn on heater and energize for a minimum of
two minutes (to degas the system).
WARNING
DO NOT ENERGIZE AN EMPTY ULTRASONIC BATH.
Energizing an empty ultrasonic bath may cause damage to the instrument
2) Vigorously shake the sample bottle by hand for 15 seconds.
NOTE
A minimum of 4 ounces of sample is required when using the particle
counting function of the OSA Oil Analyzer
3) Place the sample bottle in an ultrasonic bath and energize the bath for 30 seconds or
until no surfacing bubbles are observed.
4) Remove the sample bottle from the ultrasonic bath then gently turn the bottle over five
times, taking care not to introduce air bubbles into the oil fluid.
5) Place the sample bottle under the sipper of the OSA and immediately start analysis.
Reference section IV-How to Analyze an Oil Sample (page 20) of this manual.
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A D D E N D U M
B
Instruments equipped with sample bottle cap overpressure module
Over Pressure Sample Bottle Cap Module
When high viscosity oil samples are to be measured (> ISO320), the analyzer will prompt the
user to utilize the sample bottle over pressure cap module, as shown below:
Follow the instructions below when prompted on the screen.
1) Ensure that the inside of sample bottle cap is clean by wiping with a clean cloth.
2) Install sample bottle cap onto sample bottle
a. Align the sample bottle and cap, then rotate bottle until cap is tight.
NOTE
Sample bottle cap MUST be on tight
A loose fit will result in an air leak preventing instrument from achieving
proper air pressure within the sample bottle
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3) Remove the sample tray located directly beneath the sample intake nozzle, as shown
below - This will allow sample bottle to be placed in the well underneath, providing
clearance for the over-pressure sample cap.
4) Loosen straw fitting ( no need to fully remove fitting ) located in the center of the sample
bottle pressure cap, then insert straw through center fitting and finger tighten the fitting.
NOTE
Do NOT over tighten fitting around straw.
Over tightening the straw input fitting may result in collapsing/damaging the straw
causing an air leak preventing instrument from achieving proper air pressure
within the sample bottle
5) As shown below, set sample bottle into sample "well" below intake nozzle, and attach
the straw sipper to the sample intake nozzle:
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6) Start analysis.
Reference section IV-How to Analyze an Oil Sample (page 20) of this manual.
7) Follow all prompts in the order that they appear.
Ensure that the straw has been inserted over the analyzer’s intake nozzle prior to
activating the overpressure function.
When overpressure function is activated, contents of the sample container will be forced
out through the straw.
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