Eaton WSPS 05 User manual

WSPS 05
Online –sensor for water in oil diagnostics
Instruction manual
Version 1.6
Serial-no.: ..................
Version valid from: 25.11.2015

2
Index
page
1. SAFETY INFORMATION 3
1.1. Dangers of maloperation...................................................................................3
1.2. Conventional use ...............................................................................................3
2. OPERATION AND INSTALLATION 4
2.1. General informations.........................................................................................4
2.2. Measuring principle ...........................................................................................4
2.1. Sensor installation.............................................................................................5
2.2. Evaluating measurements.................................................................................5
3. MAINTENANCE 6
3.1. Sensor cleaning .................................................................................................6
4. CALIBRATION 6
4.1. Water saturation.................................................................................................6
4.2. Integrated temperature sensor..........................................................................6
5. APPENDIX 7
5.1. Technical Data....................................................................................................7
5.2. Dimensions.........................................................................................................7
5.3. Pin assignment...................................................................................................8
5.4. Sensor characteristic.........................................................................................8
5.5. Application areas - compatibility ......................................................................9
5.6. Trouble shooting................................................................................................9
5.7. Shipment.............................................................................................................9

3
1. Safety information
1.1. Dangers of maloperation
The WSPS 05 underwent a safety and acceptance test based on IEC 1010-1/EN 61010 –1
part 1. Integrated electronic and hydraulic elements serve protection purposes and ensure
safe handling if used the conventional way. False operation or abuse, as well as
insensitivity for the device’s limits and safety instructions will result in immediate danger for
the following:
the operator’s health and life,
the WSPS 05 and all systems it is connected to,
the accuracy of the WSPS 05,
the environment.
This manual includes information and safety instructions, which guarantee safe handling
and support your devices unobjectionable condition.
Therefore it is a necessity for all people who operate, install or maintain this device to mind
this manual.
1.2. Conventional use
With this WSPS 05 you have purchased an effective diagnostic system for the saturation
level of water in oil. It operates very reliable and meets the requirements of daily use.
The set is recommended and tested for the use with:
Standard hydraulic oils: HL, HLP
Triglyceride: HETG
Aircraft hydraulics: Mil H 5606
Synthetic ester: HEES
Lubrication oils: CLP
Limits:
Maximum acceptable pressure at the sensor 25 bar (362,5 psi)
Maximum oil temperature 90° C (194° F)
Maximum acceptable flow rate at the sensor 2 m/s (6,5 ft/s)
The WSPS 05 should always be operated with 12...30 V DC!

4
2. Operation and installation
2.1. General informations
Water in hydraulic- and lubricating oil is a fluid contamination, which has to be limited
urgently due to its negative effects on the characteristics of fluids. Among other effects, it
does accelerate oil aging, it causes the failure of polarizing additives, it increases the acid
number and it worsens filterability. Effects for a hydraulic or lubricating system are very
manifold and cause significantly increased wear, drastically increased risk of failure of
components as well as malfunctions.
Important for these effects of water is whether water present in the fluid is free or
emulsified, not the total amount of water. Only free water does have the dangerous
chemical or biological reactivity. Therefore the detection of the presence of free or
emulsified water in a hydraulic or lubricating system is of great importance.
2.2. Measuring principle
The WSPS 05 does utilize a capacitive sensor for measurements.
It uses polymeric foil as dielectric for interelectrode capacitance.
This foil is capable of absorbing water molecules due to its microporous structure.
This absorption causes a change in capacity of this element, which is converted into the
output signal between 4 and 20 mA.
Measurements are the water saturation of the fluid in percent, which is direct proportional
to the output signal of the sensor. (see also the characteristic of the sensor in chapter 5.4)
In addition to that a temperature sensor is integrated to determine the exact temperature of
the fluid while measuring.
There is a difference to the measurement of the absolute water content with the Karl-
Fischer-method. The Karl- Fischer-method determines the total amount of free and
emulsified water in mg –water / kg –oil.
The WSPS 05 gives the saturation level of the fluid with water in percent.
The indication 100 % means that the fluid is totally saturated.
Saturation values depend on the temperature!
A relation to the measured saturation values and the stated ppm (mg / kg) value according
to Karl Fisher’s method is ascertained by the 100 % saturation curve (100% of saturation =
f(T)) for the measured fluid and the fluid temperature measured at the same time with the
saturation.

5
2.1. Sensor installation
The WSPS 05 is intended for inline measurements.
oTherefore the sensor should be integrated at a circulating, respectively turbulent
point of the hydraulic system in order to generate reliable measurements.
oPlease make sure that maximum limits for flow rate and pressure are not exceeded.
oThe time to reach balance on the sensor can vary and depends on a number of
factors, such as the oil’s viscosity.
Connect the provided cable to your monitoring and evaluation system. (see also pin
assignment in chapter 5.3)
Connect the sensor cable to the WSPS 05 by using the plug.
The sensor is now ready for operation.
2.2. Evaluating measurements
Green range (0...70% saturation)
The presence of free water is unlikely. The water solved in the oil is not a threat!
Yellow range (70...90% saturation)
The presence of free water in small amounts is probable. Additional measurements and
actions to reduce the water content are suggested.
Red range (90...100% saturation)
Water is present in its free form. It is a threat and a potential danger of the hydraulic or
lubricating system.
Actions to reduce the water content in the fluid are urgently necessary!
The calculation to mg/kg (ppm)–water content is only possible with the specifically
saturation characteristic.
Saturation characteristics for specific oils are available upon request.

6
3. Maintenance
3.1. Sensor cleaning
Cleaning the WSPS 05 is necessary from
time to time, especially if the sensor is being
used for different fluids.
As cleaning fluid, clean petroleum benzin
or even clean Isopropanol can be used.
When cleaning the sensor, please remove
the protective cap and proceed with
extreme caution.
4. Calibration
4.1. Water saturation
Upon delivery of the WSPS 05 is calibrated based on defined salt solutions.
It is recommended to carry out an annual examination of the calibration by comparison
with a hygrometer in air. In case of variations > 5%, the sensor is to be sent to the
manufacturer for a new calibration.
4.2. Integrated temperature sensor
Upon delivery of the WSPS 05 the integrated temperature sensor is calibrated.
An annual examination of the calibration at ambient temperature is recommended using a
commercially available thermometer. If a new calibration is necessary (variation of the rated
value> 10%) the sensor must be sent to the manufacturer.

7
5. Appendix
5.1. Technical Data
Measuring range: Saturation level: 0 –100 %
Temperature: - 25...+ 100 °C / - 13 °F...212 °F
Accuracy: Saturation level: 2 %
Temperature: 0,4 %
Operating pressure: 0...25 bar / 0...362,5 psi
Flow velocity: 2 m/s / 6,6 ft/s
Ambient temperature: - 25...+ 85 °C /- 13 °F...185 °F
Temperature range of fluid: - 40...+ 90 °C /- 40 °F...194 °F
temporary + 100 °C / 212 °F
Survival temperature: 90 °C / 194 °F
Storage temperature: -40…+100 °C / -40 °F…212 °F
Power supply: 12...30 VDC
Analogue outputs: 2 x 4...20 mA
Protection class: IP 65
Screw thread: G ¾
Ohmic resistance:
5.2. Dimensions

8
4
5.3. Pin assignment
WSPS 05 - Sensor
Pin 1
+ 12...30 V DC
Pin 2
Output 4...20 mA
(Saturation)
Pin 3
+ 12...30 V DC
Pin 4
Output 4...20 mA
(Temperature)
Cable color (Connection cable):
1: brown (+ 12...30 V DC )
2: white (4...20 mA ) Saturation
3: blue (+ 12...30 V DC )
4: black (4...20 mA ) Temperature
5.4. Sensor characteristic
1
4
3
2
1
2
3
4
mA
+ 12...30 V DC
0 V DC
1 (3)
WSPS 05
2 (4)

9
5.5. Application areas - compatibility
Applicable for:
Hydraulic oils H, HL, HLP, and HV
Gear oils C, CL, CLP
Motor oils, Gas oils
MIL-H-5606 E
Vegetable oils (HTG, Triglyceride)
Synthetic ester (HEES)
5.6. Trouble shooting
No settings of the WSPS 05 are done by the operator.
Malfunctions, which could be eliminated by one, are limited to cleaning the sensor and
checking cables for brakes.
Any other case requires sending in the WSPS 05 sensor to Eaton Technology GmbH,
Altlussheim branch in order to recover the functions.A brief description of the problem would
expedite the trouble shooting and the repair process. To check your warranty or to answer
questions by phone we need the serial number and the date of purchase of the instrument.
5.7. Shipment
Article no.:
(1) Water sensor WSPS 05 337181
(2) Sensor cable, L = 5 m 323961
(3) Seal 308536
(4) Instruction manual 337461

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©2012 Eaton Corporation. All Rights Reserved.
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owners. Litho USA.
All information and recommendations appearing in this brochure concerning the
use of products described herein are based on tests believed to be reliable.
However, it is the user’s responsibility to determine the suitability for his own use
of such products. Since the actual use by others is beyond our control, no
guarantee, expressed or implied, is made by Eaton as to the effects of such use or
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