User handbook

Author: GM

Handbook
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Index
1 Change control .........................................................................................................................................3
2 Introduction ..............................................................................................................................................4
3 Measuring principle ..................................................................................................................................5
4 OILWEAR 2.0 INTERFACES ........................................................................................................................6
5 GENERAL SPECIFICATIONS ........................................................................................................................8
6 Connecting the sensor ........................................................................................................................... 10
7 Modbus communication ....................................................................................................................... 11
7.1 Introduction ................................................................................................................................. 11
7.2 Modbus address definition .......................................................................................................... 12
7.3 Results data registers................................................................................................................... 12
7.4 Modbus integration ..................................................................................................................... 12
7.5 Quick integration test .................................................................................................................. 14
8 Hydraulic subset .................................................................................................................................... 15
9 Maintenance.......................................................................................................................................... 16
10 Annex 1: TCP/IP connection setup ........................................................................................................ 17
10.1 Required hardware and software ................................................................................................ 17
10.1.1 Hardware ................................................................................................................................. 17
10.1.2 Software .................................................................................................................................. 17
10.2 Procedure .................................................................................................................................... 17
10.2.1 TCP/IP configuration................................................................................................................ 17
10.2.2 Ping check ................................................................................................................................ 19
11 Annex 2: Modbus RTU connection ........................................................................................................ 21
11.1 Required hardware and software ................................................................................................ 21
11.1.1 Hardware ................................................................................................................................. 21
11.1.2 Software .................................................................................................................................. 21
11.2 Procedure .................................................................................................................................... 21
11.2.1 RS-485 configuration ............................................................................................................... 21
11.2.2 Modbus master configuration................................................................................................. 22

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1 Change control
Version FW version Comments
1 - Initial draft
3.4 - Last released version
3.5 - Annex addition & rebrand

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2 Introduction
This handbook describes the key features of the OilWear 2.0 system, whose primary function is to monitor
existing particles in the lubricating oil for industrial equipment. The core of the system is the measuring
module, which is based on the patented technology of digital image and video processing. It quantifies
particles greater than 4 microns present in fluids and classifies them related to the ISO, NAS, or SAE
standards.
The OilWear 2.0 (OW2.0) system is prepared to be installed as a bypass to the lubrication circuit. Thus, a
small hydraulic subsystem is required to prepare the oil flow so that the measurement can be taken.
This sensor is offered in two different setups. The measurement module can be installed as a stand-alone
device, or it can be fitted in a housing, as shown in Figure 1.

Figure 1. OilWear Sensor 2.0.

The OilWear 2.0 device is in the process of being protected through the following patents:
• European Patent n. 16382179.6
• US Patent n. 15/496,430

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3 Measuring principle
Atten2 OW2.0 sensors measure fluid contamination and condition using optical acquisition systems and
digital image processing algorithms.

Figure 2. The measurement principle of Atten2 OilWear2.0.

Periodical images are obtained, and processed in the sensor and the information collected is delivered via
Modbus to the customer acquisition system.

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4 OILWEAR 2.0 INTERFACES

The OW system is designed to be fitted as a bypass onto the industrial machine’s lubrication circuit. Via one
of its digital outlets, the OW is designed to deliver a value of the cleanliness codes of the measurement
(related to the selected standard – ISO, NAS, or SAE) of the oil sample that it receives through the bypass,
without interfering with the regular operation of the machine. Also, this equipment is capable of offering
information about wear particle root cause and particle pictures.
So, the system has two distinct interfaces: a hydraulic one plus an electrical/electronic one.

Figure 3. Interfaces of the OilWear 2.0. System. Stand-alone sensor (left) and housing (right).

Currently, the system provides all communications based on the Modbus protocol indicated in the table
below. The end-user is capable of modifying sensor parameters to choose between each type, with the
configuration app.

REFERENCE COMMUNICATIONS
OilWear 2.0 A Modbus RTU RS485-
2W
OilWear 2.0 B Modbus TCP/IP Ethernet
Table 1: OW2.0 System Communication Protocols.

Also, upon request, the hydraulic hoses and electric cords are provided so that the device can be correctly
fitted onto the machine. Only the necessary hoses and patch cords should be selected, and only of the
length that is needed. Listed below are the hoses/patch cords for all the electrical and hydraulic interfaces.
A Patch cord for connecting the OW2.0 to the electrical panel that provides 24VDC power and RS485-2W
communication. There are different length options. For other options, please contact Atten2. The
OW2_Wire_A is designed to keep the system sealed (IP65).
• OW2_Wire _A-5: 5 meters long
• OW2_Wire _A-10: 10 meters long
• OW2_Wire _A-15: 15 meters long

An OW Ethernet connection patch cord to an Ethernet port that provides TCP/IP communication. There are
different length options. For other options, please contact Atten2. The OW2-ETH is designed to keep the
system sealed (IP65).
• OW2-ETH-5: 5 meters long
• OW2-ETH-10: 10 meters long
• OW2-ETH-15: 15 meters long

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ELECTRICAL patch cords

OW2_Wire_A-5 Main Connector Patch Cord 5M
OW2_Wire_A-10 Main Connector Patch Cord 10 M
OW2_Wire_A-15 Main Connector Patch Cord 15 M
OW2-ETH-5 Ethernet Connector Patch Cord 5M
OW2-ETH-10 Ethernet Connector Patch Cord 10 M
OW2-ETH-15 Ethernet Connector Patch Cord 15 M
Table 2: Additional Interface Components.

Hydraulic hose (INLET and OUTLET) for the bypass connection with the machine’s lubrication system. There
are different lengths available. If a different length is needed, please contact Atten2.

HYDRAULIC HOSES
OW-OIL-A (OIL INLET) Hydraulic Hose 2M
OW-OIL-A (OIL INLET) Hydraulic Hose 3M
OW-OIL-A (OIL INLET) Hydraulic Hose 5M
OW-OIL-B (OIL OUTLET) Hydraulic Hose 2M
OW-OIL-B (OIL OUTLET) Hydraulic Hose 3M
OW-OIL-B (OIL OUTLET) Hydraulic Hose 5M
Table 3: Additional Hydraulic Components.

Upon request, a set of hose adapters (BSP type) are also provided to ensure correct fitting onto the threads,
with male/male reducers for the following thread sizes: ½”, 3/8”, and ¼”. Screws are also provided to assist
in the mechanical installation of the OW 2.0 onto the machine, and a mechanical clamping solution is also
provided.

MECHANICAL INSTALLATION
OW-MEC-B Screws for fixing brackets in (x4)
place
Table 4: Additional fixing accessories.

Extended information can be found in the “Installation and Commissioning Handbook”.

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5 GENERAL SPECIFICATIONS
UNIT.
ELECTRICAL
Nominal Minimum Maximum
Power supply* 24 VDC 20 28 V
Consumption 50 mA 40 600 mA
*Reverse Voltage Protection
Electrical Inlets/Outlets
Modbus RTU over (RS485-2W)* Reading/Configuration
Modbus TCP over Ethernet* Reading/Configuration
* Independent use. Selection depends on the user.
Dimensions
Height 80 mm
Width 45 mm
Depth 45 mm
Weight
When circuit empty 0.5 Kg

Operating temperature -30 70 ºC

Humidity RH 0 95 %
Storage Temperature -40 90 ºC
Operating pressure 0.1 50 bar
Maximum pressure 150 bar
Operating oil flow 0.2 0.1 0.4 l/min
Housing IP 65
MATERIALS
BK7, Aluminum, VITON
Wettable Material
Other materials upon request
External Material Aluminum, Nylon
Connections 1/8" BSP female
Certifications CE, UL (od.)
Branding Serial Number, Logo, Patent info, certifications.
Maintenance period 3 years (80% of sensitivity)
Calibration Following ISO 11171 standard
Viscosity 460 (max) cSt
Table 5: OW2.0 General Specifications

Results (depending on the sensor selected)

Resolution >4um
Results ISO4406, NAS 1638, AS 4059
ISO Code Range 8-27
±1 ISO Level at normal conditions
Precision ±2 ISO Level, not favorable conditions (i) presence of water,(ii) presence
of air,(iii) low opacity,(iv) High flow range

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>4, >6,>10, >14, >21, >38, >70um particle counts per ml.
Wear-related Shaped particles (>20um) per ml.
Output Number of Bubbles per ml
Oil degradation index (%)
Image (1 per test)
Error Log Last 200 errors
Data Log Last 10000 measurements
Test time Adjustable 60-3600 seconds

Table 6: OW2.0 Results specifications.

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6 Connecting the sensor

The OW 2.0 system has various electrical/electronic interfaces to control its operation.

Figure 4. Interface Details of the OilWear 2.0 System.

OW2.0 Wire is based on an M12 5-pin male connector. This connector groups together the Power Supply
and Modbus RTU Interface lines. The pins are distributed as follows.

PIN FUNCTION OH-WIRE_A COLOUR CODE

2 VDC IN White
3 GND IN Blue
5 D– (RS485) Gray
4 D+ (RS485) Black
Figure 5. OW2.0 Pin-out Connector

Please refer to the Modbus section of the Users Handbook for the description of the analogue Modbus
(RS485 D+/D-) access and output. An OW2-Wire_A-NN patch cord is provided for connection to the electrical
panel. OW2-ETH-NN is the input connector to the internal TCP/IP server of the OilWear 2.0 system. For the
description of the Modbus TCP/IP access, please refer to the Modbus Section.
The OW is designed to start working automatically with the default setting. Sensor led provides information
about sensor power conditions and TCP/IP communication.

Color Status Information

Red Stable Powered up
Orange Stable TCP/IP communication
Orange Blinking TCP/IP data transmission

Figure 6. OW2.0 LED information.

The system’s measuring principle does not require OW to be calibrated for the oil type being used in the
target system, except for the OilHealth degradation measurement.
On all its interfaces the OW displays the latest measurement of the Oil Cleanliness (related to the selected
cleanliness standard), particle counting (compared to the standard), shape detection, as well as fault origin
detection.
The result of the measurement is shown through the various channels fitted onto the OW sensor.

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7 Modbus communication

Modbus is a communications protocol located at levels 1, 2 and 7 of the OSI Model, based on the
master/slave (RTU) or client/server (TCP/IP) architecture, designed in 1979 by Modicon for its range of
programmable logic controllers (PLCs). Having become a de facto industry standard communications
protocol, it is the most widely available for the connection of industrial electronic devices.
Modbus allows the control of a network of devices and communicates the results to a computer. Modbus is
also used for the connection of a supervisory computer with a remote unit (RTU) in supervisory systems data
acquisition (SCADA). There are versions of the Modbus protocol for serial port and Ethernet (Modbus/TCP).
Information from this section has been obtained from the Modbus organization reference documentation.
Each device in the Modbus network has a unique address. Any device can send Modbus commands,
although usually only one master device is allowed. Each Modbus command contains the address of the
device to which the command is sent. All devices receive the frame, but only the recipient executes it. Each
of the messages includes redundant information that ensures its integrity at reception. The basic Modbus
commands allow an RTU device to be controlled to modify the value of one of its registers or to request the
contents of those registers.
Modbus is based on an approach of coils, registers and functions. The Modbus data model distinguishes
between digital inputs (discrete input), digital outputs (coils), input registers, and holding registers. The
digital inputs and outputs occupy one bit, while the registers, both input and holding, occupy two bytes.
MODBUS uses a ‘big-Endian’ representation for addresses and data items. This means that when a numerical
quantity larger than a single byte is transmitted, the most significant byte is sent first.

Figure 7. Types of data registers in the Modbus protocol.

Each device defines its coils and registers in its physical memory where information is stored, and the master
sends or extracts this information. To extract the information, the master is required to send information
regarding the function and the value.

Figure 8. Modbus communication schema.

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Depending on the communication protocol selected, Modbus address information is different.

Type Modbus TCP/IP Modbus RTU
Interface Ethernet RS485-2W
Address IP address* COM Port
Port 502 -
Baud rate* - 57600
Slave ID* 10 10
Data bits: 8
Modbus
Stop bits: 1
configuration*
Parity: Even
*configurable upon request

In the next table OilWear 2.0´s results, the Modbus map can be found. The Modbus map shown below is
defined equally for both communication modes, Modbus RTU-RS4852W and Modbus TCP/IP. Two definitions
of the map are shown.
OW 2.0 Map - INPUT OW 2.0 Compatible map - INPUT/HOLDING
Parameter Unit
Data type Modbus register address Data type Modbus register address
Timestamp - int /*1356-1357*/ int /* 1042-1043 */
>4 microns - /*1402 - 1403*/ short /* 1030 */
ISO 4406 Code >6 microns - float /*1404 - 1405*/ short /* 1031 */
>14 microns - /*1406 - 1407*/ short /* 1032 */
>21 microns p/ml int /*1366-1367*/ -
Big particle count >38 microns p/ml int /*1362-1363*/ -
>70 microns p/ml int /*1358-1359*/ -
Total particles - p/ml int /*1378-1379*/ short /* 1029 */
Total bubbles - b/ml int /*1380-1381*/ short /* 1028 */
OD - % short /* 1018 */ sshort /* 1018 */
Timestamp - int /*63000-63001*/ int /* 1042-1043 */
Cutting p/ml short /*63003*/ short /* 1035 */
Cutting [%] % unsigned char (2nd byte) /*63014*/ -
Sliding p/ml short /*63006*/ short /* 1036 */
Sliding [%] % unsigned char (1st byte) /*63016*/ -
Fatigue p/ml short /*63004*/ short /* 1037 */
Shape Fatigue [%] % unsigned char (1st byte) /*63015*/ -
Fiber p/ml short /*63005*/ short /* 1038 */
Fiber [%] % unsigned char (2nd byte) /*63015*/ -
Air p/ml short /*63002*/ short /* 1039 */
Air [%] % unsigned char (1st byte) /*63014*/ -
Unknown p/ml short /*63007*/ short /* 1040 */
Unknown [%] % unsigned char (2nd byte) /*63016*/ -
Temperature [ºC] ºC float /*62480-62481*/ short /* 1049 */
NAS 1638 (per 100 ml) - - short /*1414*/ short /* 1034 */
Figure 9. OW2.0 results in Modbus map.

• OW2.0 Map (orange color): Both maps contain the same data. This one has extended
features, such as ISO 4406 decimal values, and shape percentages.
• OW2.0 Map (Grey color): Both maps contain the same data. This map is provided for
implementation easiness, in terms of data reading and interpreting and INPUT/HOLDING
presence.
The Modbus map of OW2.0 contains different features that are not explained in this document.

A successful Modbus integration in an acquisition system requires that several topics need to be considered:

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• Register Addresses and Functions: Modbus data is obtained through a combination of

functions and registers. Some Modbus acquisition systems require the introduction of
both function and register in the same area. For example, reading a Modbus INPUT
register “1001”, requires introducing “41001”, which is the combination of function 4
“READ INPUT REGISTERS” plus the register 1001.

Figure 10. Table of public functions in Modbus.

• Modbus offset: In the Modbus/RTU and Modbus/TCP protocols, the addresses are
encoded using 16 bits with a number between 0 and 65,535. These are 0-based
addresses. Therefore, the Modbus protocol address is equal to the Holding Register
Offset minus one. Some acquisition devices have the offset predefined, but others do not.
So, it is essential to check that the address is pointing to the correct register.
• Confusion about Little-Endian vs Big-Endian Word Order: Although Modbus.org standard
documents provide some guidance for implementing the Modbus protocol, they do not
address the question of word order beyond the register level. Modbus implementers
have to make an arbitrary choice as to which address of the register pair contains the
most significant word of 32-bit values such as IEEE-754 single-precision floats and signed
or unsigned 32-bit integers. Most programs for communicating with Modbus slaves can
be configured for either register word order, but the most common default word order
today is Little-Endian.
• Register sectioning: Some of the data contained in the sensor Modbus map encapsulates
two different data values in the same register, one in each byte. The acquisition system
should be able to section this data and interpret this data separately.
• Data type interpretation: Different programming languages offer different names for the
variable types available. Once collected, registers have to be interpreted correctly. The
following table defines the variables as proposed by the sensor interface, with expected
ranges.
Variable type Bytes Range Definition
INT 4 0-42949697295 Unsigned 32-bits integer

FLOAT 4 ±1,5 x 10-45 -±3,4 x 1038 Floating number

SHORT 2 0-65535 Unsigned 16-bits integer

SSHORT 2 -32767 - +32767 Signed 16-bits integer

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CHAR 1 0-255 Unsigned 8-bits integer

Figure 11. Variables definition and range.

• Modbus code reading without lubricant: Base readings for ISO 4406 code are 8/7/6. To
confirm offset, a quick test with the three ISO codes to ensure Modbus offset.
• Comparison with compatible map: Since data is present in different parts of the Modbus
map, double-acquisition can ensure data correctness.
• Shape simulation function: Atten2 can provide support with shape integration. Please
contact our support team to perform a simulated shape data acquisition.

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8 Hydraulic subset
The OilWear 2.0 is based on the OW module, but some additional subsets can be added to ensure measuring
capabilities. The subsystems comprise all the hydraulic components for fluid conditioning in terms of
pressure, temperature and flow adapted to the sensor's optimum capabilities.
The next view of the OilWear system presents the scheme of the subsystems. To clarify any doubts about
any of them, please contact Atten2.
1 Power supply 24VDC
2 Control module
3 Communications switch
4 Power strip with grip
5 Sensor (OW / OH)
6 Pump
7 Pressure gauge
8 Pressure regulating valve
9 /10 Needle valve
11 /12 Check valve
13 Inlet prefilter
14 Flow indicator
15 24 VDC fan
16 Sampling point
17 Heat exchanger
Figure 12. Components of the hydraulic subsystem of the OilWear 2.0.

The hydraulic subset can include the following items, depending on user equipment oil conditions:
• Pumping and overpressure security system
• The electronic system connected to the equipment lubricant status signal
• Communications switch
• Cooling system
Please contact Atten2 for more information on any required subset.

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9 Maintenance
OilWear sensor has been designed and manufactured to operate autonomously during the equipment
lifetime of the machine. Nevertheless, it is strongly recommended to perform a cleaning procedure once a
year to enhance sensor response and durability. Please follow this procedure carefully.
1. Please ensure that the lubrication feeding system to the sensor is blocked or stopped. If
necessary, the circuit must be depressurized.
2. Remove the sensor power supply.
3. After that, proceed to disconnect the hydraulic hoses connected to the sensor. It should
be noted that this action may spill some of the hoses remaining oil. It is strongly
recommended to have a drain pan or any other means for containment and cleaning
procedures:
4. Plastic plugs hose ends.
5. Use absorbent cloths for containment and area cleaning.
6. Container for oil drain if necessary.
7. Then, a flushing system with petroleum ether is required. If no pump is available, this
procedure could be done with the help of a syringe, discharging in the sensor oil inlet,
and making sure the ether comes out from the outlet port. This operation should be
performed until the outgoing ether appearance is similar to the fresh ether. Please note
that the ether is a volatile product, and check the material safety data sheet before use.
8. After ether cleaning, a similar procedure with flowing air is required through the sensor
circuit. Please ensure that the compressed air supply line is filtered and moisture-free.
9. Finally, please connect the hoses back to the system and power the sensor again. Turn on
the lubrication system, and please make sure there are no leakages in the circuit. At this
point, please check that the sensor is delivering correct readings, according to the
installation procedure.

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10 Annex 1: TCP/IP connection setup

• Laptop directly connected to the sensor via RJ45 Ethernet cable, following the image structure:

Figure 13. Modbus TCP Comms scheme.

Please note that the sensor must be turned on during this operation.

The laptop should be equipped with the following software Command prompt for ping checks (cmd.exe)

The first step is to connect the sensor to the TCP/IP network. The computer should be in the same network
as the sensor. The sensor IP address is printed on the case.
1. Click Start Menu/Main Windows button > Control Panel > Network and Sharing Centre. (For
Windows 8 and higher, search for and open Control Panel and select Network and Internet).
2. Click Change adapter settings.

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3. Right-click on Local Area Connection and click on Properties.

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4. Select Internet Protocol Version 4 (TCP/IPv4) and click on Properties.

5. Select "Use the following IP address" and enter the IP address, Subnet Mask, as follows. Click OK and
close the Local Area Connection properties window.

Go to Control Panel -> Command prompt.

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And please insert:

ping XXX.XXX.XXX.XXX (sensor IP address).

The response should be positive. Whether it's not, please contact Atten2.

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11 Annex 2: Modbus RTU connection

• Laptop directly connected to the sensor via RS-485 cable, following the image structure. An RS-485
to USB adaptor may be required. Please follow the cable pinout to successfully connect the device.

Figure 14. Modbus RTU Comms scheme.

Please note that the sensor must be turned on during this operation.

The laptop should be equipped with a standard Modbus master, such as Modbus Poll.

The first step is to configure the RS-485 port in the computer according to the sensor configuration. In the
case of Modbus Poll, these parameters can be configured in the main software.

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Figure 15. Example of RS-485 configuration in Modbus Poll.

In Modbus Poll, acquisition windows can be set up with defined Modbus parameters.

Figure 16. Modbus Poll window configuration.

After configuring, relevant data and no errors should appear on the screen, according to the Modbus map
provided. Whether it's not, please contact Atten2.

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