PerkinElmer OilExpress System User manual

OilExpress System
User’s Guide
MOLECULAR SPECTROSCOPY

Release History
Part Number Release Publication Date
L1050039 J December 2010
Any comments about the documentation for this product should be addressed to:
User Assistance
PerkinElmer Ltd
Chalfont Road
Seer Green
Beaconsfield
Bucks HP9 2FX
United Kingdom
Or emailed to: [e-mail]
Notices
The information contained in this document is subject to change without notice.
Except as specifically set forth in its terms and conditions of sale, PerkinElmer makes no
warranty of any kind with regard to this document, including, but not limited to, the
implied warranties of merchantability and fitness for a particular purpose.
PerkinElmer shall not be liable for errors contained herein for incidental consequential damages in
connection with furnishing, performance or use of this material.
Copyright Information
This document contains proprietary information that is protected by copyright.
All rights are reserved. No part of this publication may be reproduced in any form whatsoever or
translated into any language without the prior, written permission of PerkinElmer, Inc.
Copyright © 2010 PerkinElmer, Inc.
Produced in the UK.
Trademarks
Registered names, trademarks, etc. used in this document, even when not specifically marked as such,
are protected by law.
PerkinElmer is a registered trademark of PerkinElmer, Inc.
Frontier and Spectrum are trademarks of PerkinElmer, Inc.

Contents
Introduction...............................................................................................5
About this Manual ............................................................................................. 6
Using this Guide ......................................................................................... 6
Conventions...................................................................................................... 7
Conventions Used in this Manual ................................................................. 7
Part Numbers............................................................................................. 7
Notes, Warnings and Cautions..................................................................... 7
The OilExpress System .....................................................................................10
A Guided Tour of the OilExpress System............................................................11
Power Switch and Communications Ports....................................................12
The Liquid Autosampler....................................................................................13
X – Y – Z Arm............................................................................................14
Pumps ......................................................................................................14
Sample Injection/Wash Port.......................................................................15
Sampling Probe/Needle..............................................................................15
Sample Rack .............................................................................................16
Solvent Bottle............................................................................................16
Overview of the Sampling Procedure ..........................................................17
Analyzer Measurement .....................................................................................20
Analyzer Sample Compartment...................................................................20
2-Port Flowcell ..........................................................................................21
FT-IR Liquid Autosampler for Oils: Specifications................................................22
Warnings and Safety Information ...........................................................23
OilExpress System Safety Summary...................................................................24
General Safety.................................................................................................25
Location and Ventilation.............................................................................26
Mechanical Hazards...................................................................................26
Electrical Safety.........................................................................................26
Samples and Waste ...................................................................................27
Laser Safety Regulations...................................................................................28
Warning Labels................................................................................................29
Autosampler Labels ...................................................................................29
Warning Signs on the Instrument ...............................................................30
EMC Compliance ..............................................................................................31
EC Directive ..............................................................................................31
FCC Rules and Regulations.........................................................................31
Use of Flammable Solvents and Samples ...........................................................32
Heptane....................................................................................................33
Material Safety Data Sheets..............................................................................35
Unpacking and Installation......................................................................37
Overview.........................................................................................................38
Instrument Requirements.................................................................................39
Unpacking .......................................................................................................40
Unpacking the Autosampler........................................................................40
Unpacking and Installing the Sample Shuttle...............................................41
Positioning the OilExpress System.....................................................................42
Installing the Liquid Autosampler ......................................................................43
Electrical Connections................................................................................43
Installing the Fluid Line Support Arm ..........................................................44
Installing Racks (if ordered) .......................................................................45
Autosampler Tubing Connections ......................................................................46
Fluid Tubing System ..................................................................................46
Installing the Flowcell in the Sample Shuttle................................................49
Waste Container........................................................................................49
Installing the Syringe.................................................................................50

PC Software and Hardware Requirements.........................................................51
Software Requirements .............................................................................51
Hardware Requirements............................................................................51
Upgrading from a Previous Version of OilExpress...............................................52
Upgrading from OilExpress v3.x.................................................................52
Upgrading from earlier versions .................................................................52
Installing the OilExpress Software.....................................................................54
Default Users for OilExpress.............................................................................58
Starting up OilExpress and Configuring your Instrument ....................................59
Calibration.......................................................................................................60
Calibrating the Autosampler.......................................................................60
Calibrating the Pathlength of the Flowcell...................................................66
Installing the Arm Shield ...........................................................................67
Background to Used Oil Analysis .............................................................69
Background to Used Oil Analysis.......................................................................70
Infrared Absorption...................................................................................70
Why Analyze Used Oils? ............................................................................70
Methods of Analysis ..................................................................................71
Degradation Products................................................................................72
Common Contaminants .............................................................................73
Analysis Methods ......................................................................................73
Sample Preparation .........................................................................................74
Filtering the Oil.........................................................................................74
Sample Presentation Requirements............................................................74
Routine Maintenance and Troubleshooting.............................................75
Maintenance Schedule .....................................................................................76
Autosampler Maintenance Procedures...............................................................77
Flushing the Syringe Pump ........................................................................77
Cleaning the Syringe Seal..........................................................................77
Cleaning the Sampling Probe .....................................................................77
Cleaning the Sample Rack .........................................................................77
Cleaning the Injection and Wash Port.........................................................77
Cleaning the Z-Rack..................................................................................77
Cleaning the Splash Guard/Safety Shields...................................................78
Cleaning the Lead Screw and Lead Screw Encoder......................................78
Cleaning X-Y-Z Mechanism ........................................................................78
Inspecting the Insulation Block/ALIDUM Cable Assembly.............................79
Checking the Fluid Path (Tubing) ...............................................................79
Replacing the Sample Probe/Needle...........................................................79
Replacing the Syringe Seal ........................................................................80
Replacing a Syringe...................................................................................80
Replacing the Reagent Syringe Seal ...........................................................80
Replacing the 3-port Valve.........................................................................82
Replacing the Insulation Block/ALIDUM Cable Assembly..............................82
Lubrication ...............................................................................................84
Changing the Autosampler Fuses ...............................................................84
Replacing the Tubing ................................................................................85
Replacing Reagent and Needle or Cell Tubing.............................................85
Replacing Waste Tubing............................................................................86
Maintenance of the Flowcell .............................................................................87
Routine Cleaning of the Flowcell, Using Software Utilities ............................87
Deep Cleaning the Flowcell, Involving Disassembly .....................................88
Warranty Exclusions and Limitations.................................................................91
Spares and Consumables .................................................................................92
Troubleshooting ..............................................................................................93
Appendices...............................................................................................97
Appendix 1: Decontamination...........................................................................98
Appendix 2: WEEE Instructions for PerkinElmer Products...................................99
Index............................................................................................................ 100

Introduction

6 . OilExpress System User's Guide
About this Manual
This manual contains the following sections:
•Introduction
•Warnings and Safety Information
•Unpacking and Installation
•Background to Used Oil Analysis
•Routine Maintenance and Troubleshooting
•Index
Using this Guide
This guide tells you how to install and maintain the OilExpress System; we recommend that
you use it as follows:
1. Read
Warnings and Safety Information on page 23 and this section before using your
OilExpress System.
2. Read
The OilExpress System on page 10, to learn about the analyzer.
3. Follow the procedures in
Unpacking and Installation on page 37.
4. Read the
Maintenance Schedule on page 76 to learn what maintenance the OilExpress
System requires.
5. Read
Background to Used Oil Analysis on page 69 to learn about sample preparation
and the information that can be obtained by analyzing used oils.
You should use this guide in conjunction with the documentation supplied with your
spectrometer.

Introduction . 7
Conventions
Conventions Used in this Manual
Normal text is used to provide information and instructions.
Boldtext refers to text that is displayed on the screen.
UPPERCASE text refers to keys on the PC keyboard. ‘+’ is used to show that you have to
press two keys at the same time, for example, ALT+F.
Part Numbers
All eight-digit numbers are PerkinElmer part numbers unless stated otherwise.
Notes, Warnings and Cautions
Three terms, in the following standard formats, are also used to highlight special
circumstances and warnings.
NOTE:A note indicates additional, significant information that is provided with some
procedures.

8 . OilExpress System User's Guide
CAUTION
We use the term CAUTION to inform you about situations that could
result in serious damage to the instrument or other equipment. Details
about these circumstances are in a box like this one.
Caution (Achtung)
Bedeutet, daß die genannte Anleitung genau befolgt werden muß, um
einen Geräteschaden zu vermeiden.
Caution (Bemærk)
Dette betyder, at den nævnte vejledning skal overholdes nøje for at
undgå en beskadigelse af apparatet.
Caution (Advertencia)
Utilizamos el término CAUTION (ADVERTENCIA) para advertir sobre
situaciones que pueden provocar averías graves en este equipo o en
otros. En los recuadros como éste se proporciona información sobre
este tipo de circunstancias.
Caution (Attention)
Nous utilisons le terme CAUTION (ATTENTION) pour signaler les
situations susceptibles de provoquer de graves détériorations de
l'instrument ou d'autre matériel. Les détails sur ces circonstances
figurent dans un encadré semblable à celui-ci.
Caution (Attenzione)
Con il termine CAUTION (ATTENZIONE) vengono segnalate situazioni
che potrebbero arrecare gravi danni allo strumento o ad altra
apparecchiatura. Troverete informazioni su tali circostanze in un
riquadro come questo.
Caution (Opgelet)
Betekent dat de genoemde handleiding nauwkeurig moet worden
opgevolgd, om beschadiging van het instrument te voorkomen.
Caution (Atenção)
Significa que a instrução referida tem de ser respeitada para evitar a
danificação do aparelho.

Introduction . 9
WARNING
We use the term WARNING to inform you about situations that could
result in personal injury to yourself or other persons. Details about
these circumstances are in a box like this one.
Warning (Warnung)
Bedeutet, daß es bei Nichtbeachten der genannten Anweisung zu einer
Verletzung des Benutzers kommen kann.
Warning (Advarsel)
Betyder, at brugeren kan blive kvæstet, hvis anvisningen ikke
overholdes.
Warning (Peligro)
Utilizamos el término WARNING (PELIGRO) para informarle sobre
situaciones que pueden provocar daños personales a usted o a otras
personas. En los recuadros como éste se proporciona información sobre
este tipo de circunstancias.
Warning (Danger)
Nous utilisons la formule WARNING (DANGER) pour avertir des
situations pouvant occasionner des dommages corporels à l'utilisateur
ou à d'autres personnes. Les détails sur ces circonstances sont données
dans un encadré semblable à celui-ci.
Warning (Pericolo)
Con il termine WARNING (PERICOLO) vengono segnalate situazioni
che potrebbero provocare incidenti alle persone. Troverete
informazioni su tali circostanze in un riquadro come questo.
Warning (Waarschuwing)
Betekent dat, wanneer de genoemde aanwijzing niet in acht wordt
genomen, dit kan leiden tot verwondingen van de gebruiker.
Warning (Aviso)
Significa que a não observância da instrução referida poderá causar um
ferimento ao usuário.

10 . OilExpress System User's Guide
The OilExpress System
The OilExpress System is optimized for the determination of lubricant degradation products.
Based on infrared spectroscopy, the system is capable of measuring the following parameters
in lubricants:
•Soot loading
•Anti-wear additive depletion
•Glycol
•Water
•Nitration
•Oxidation
•Sulfonation
•Fuel contamination

Introduction . 11
A Guided Tour of the OilExpress System
Figure 1 The OilExpress System
The PerkinElmer OilExpress System (Figure 1) is a bench-top instrument that provides all the
following in one self-contained unit:
•A spectrometer, fitted with a sample shuttle.
NOTE: The spectrometer may be a Frontier IR System, Spectrum 100 or 400 Series, or
Spectrum One instrument. For full details on how to install and use your
spectrometer, refer to the documentation supplied with your instrument.
•A Liquid Autosampler designed to analyze up to 60 samples an hour.
•A water-resistant flowcell.
The system is controlled by dedicated oil analysis OilExpress software resident on a PC.
NOTE: See the help system available from the Help menu in the OilExpress software, which
includes a tutorial and full information on using the software.

12 . OilExpress System User's Guide
Power Switch and Communications Ports
The power switch, AC power cable connector, and communications ports are on the rear of
the spectrometer. The power switch is marked I/O (on/off).
The power switch, AC power cable connector, and communications ports are located on the
left-hand side of the Autosampler (see Figure 2).
Figure 2 Location of the Autosampler power switch
The spectrometer is connected to a PC, either point-to-point or over a network.
The Liquid Autosampler module is connected to the same PC via an RS232 link.
Power switch

Introduction . 13
The Liquid Autosampler
The OilExpress System uses a Liquid Autosampler to enable the rapid sampling of up to 60
oil samples per hour. Figure 3 shows a general view of the Liquid Autosampler.
The Liquid Autosampler provides:
•Minimal sample carry-over by flushing the needle and flowcell with solvent.
•A 2-port flowcell that is designed for the analysis of viscous liquids.
•Flexible sample presentation: a rack that holds 30 sample bottles, or test tube racks
with a capacity of 240.
•Solvent bottle.
•Two high-resolution syringe pumps to provide robust, reliable liquid handling.
Figure 3 The liquid autosampler

14 . OilExpress System User's Guide
X – Y – Z Arm
X-frame
Arm
Insulation Block
Z- rack
Coax Cable
CCU-9000
ADRI-9 Board
ADRI-9 Board Cover
X-slide
Figure 4 X – Y – Z arm mechanism
The X – Y – Z arm movements are controlled by stepper motors linked by drive belts.
Pumps
The Autosampler uses two syringe pumps. These pumps are located on the back panel of the
auto stepper motor driven syringe pump (Figure 5). The pump consists of a syringe drive, a
valve drive, and control electronics. The head of the syringe is attached to the valve
assembly that controls the input and output of the fluid path. The plunger of the syringe is
attached to the syringe drive that moves the plunger up and down.
Figure 5 The sample pump

Introduction . 15
Sample Injection/Wash Port
The Sample Injection/Wash Port (Figure 6 and Figure 7) consists of a waste transfer and
port. After completion of a liquid handling function, the excess sample is discarded in the
waste port. The probe is then moved to the wash port for cleaning. Washing is accomplished
by pumping wash fluid through the probe. The fluid then flows around the outside of the
probe and overflows into the waste port. The waste fluid then travels by gravity out of the
waste tubing to a waste reservoir located below the instrument.
Figure 6 Sample injection and wash ports (side view)
Figure 7 Sample injection and wash ports (top view)
The transfer port is used to transfer the sample to the flowcell located in the sample
compartment of the spectrometer. The transfer port consists of a nylon fitting into which the
sample probe is lowered.
Sampling Probe/Needle
The sample is drawn through the stainless steel needle and delivered to the flowcell via the
transfer port. The needle is cleaned in the wash port: the solvent flows down inside the
needle, and then is forced up around the outside and to waste.
Waste exit port
Sample injection &
wash ports
Wash station
Waste position
Injection port
Interconnect
tubing port
Bolt
v1
v2
v3

16 . OilExpress System User's Guide
Sample Rack
A 30-bottle sample rack is supplied as shown in Figure 8.
Figure 8 Autosampler sample rack
Solvent Bottle
WARNING
In the event of a solvent spillage, isolate the power to the OilExpress
System immediately and then clean up the solvent spill. The system can
then be powered up but the spectrometer should be allowed to stabilize
for at least two hours before measurements are taken.
The recommended solvent for the OilExpress System is heptane. This should be aspirated
from a supply adhering to laboratory safety standards that advise on its safe storage,
handling, use and disposal.
If using the solvent bottle supplied with the OilExpress System (Figure 9), the following is
recommended:
•The solvent bottle should be re-filled away from the OilExpress System, in a
well-ventilated area, and precautions should be taken against static discharge.
•The bottle lid should be used at all times. The solvent bottle lid should be correctly
fitted to the bottle during operation of the OilExpress System.
•The bottle should be stored to the rear of instrumentation at a location where it will not
be knocked accidentally.

Introduction . 17
Figure 9 Solvent bottle
Overview of the Sampling Procedure
1. At the start of an analysis, the wash volume of solvent is drawn up by each pump.
2. The sample pump valve switches to the needle and the cell pump switches to the cell,
and the solvent is dispensed.
3. The needle is lowered into the sample and the sample is aspirated by the drawing down
of the sample pump.
The default volume aspirated is 3.5 ml.
Solvent bottle lid
Solvent bottle

18 . OilExpress System User's Guide
4. The needle then moves to the transfer port.
5. The sample pump dispenses the sample to the cell.
Only 2.1 ml of sample is dispensed to the cell.
To aid the transfer of the viscous liquid and prevent pressure build up, the cell pump is
simultaneously drawn back by the same volume.
6. The OilExpress software performs a sample detection.
7. When the sample has been successfully detected the needle moves to the waste port to
dispense the remaining sample.
8. The sample pump valve switches position so that the pump is connected to the solvent
reservoir.
9. The pump aspirates the solvent.
10. The sample pump valve then switches back to the needle.
11. The needle moves and lowers into the wash port.

Introduction . 19
12. The sample pump dispenses the solvent to flush out the tubing and the needle.
When the needle has been flushed the next sample can be aspirated.
13. When OilExpress has completed scanning the sample, the cell pump valve switches to
the cell and the pump moves to push the sample back through the cell and back
through the transfer port where it then flows to the adjacent wash port.
14. The cell pump valve switches to the reservoir and aspirates solvent.
15. The cell pump valve then switches back to the cell and the pump moves up to flush the
cell and the tubing.
Waste from this process flows back through the cell and the transfer port to waste.

20 . OilExpress System User's Guide
Analyzer Measurement
Analyzer Sample Compartment
WARNING
DO NOT use the OilExpress System when the sample compartment lid is
fitted. Flammable vapor may seep through instrument seals and gaskets
and accumulate under the lid, where it could cause a fire or explosion
hazard.
CAUTION
The sample compartment windows may be composed of a hygroscopic
material, such as KBr; which, although coated, can be damaged by high
levels of humidity. Refer to the documentation supplied with your
spectrometer for details.
If you spill liquid in the sample compartment, wipe it up quickly.
CAUTION
Relative humidity higher than 80% can damage the windows of the
sample compartment.
The sample compartment (Figure 10) is located at the front of the instrument.
Figure 10 Sample compartment of a Frontier IR System
•The infrared beam enters the compartment through an aperture on the left. After
passing through the sample, it enters the detector area through an aperture on the
right side of the sample compartment.
•A sample shuttle is installed in the sample compartment. The sample shuttle is used to
move the flowcell of the Liquid Autosampler in and out of the beam.