TANDELTA OQSExISG2 User manual

UG/OQSxG2/23/0025
OIL QUALITY SENSOR
& ASSOCIATED
ACCESSORIES
USER GUIDE

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CONTACT DETAILS
Tan Delta Systems plc
1 Carrera Court
Church Road
Dinnington
Sheffield
UK
S25 2RG
Tel: [phone]
[e-mail]
Copyright notice
This manual and its content are copyright of Tan Delta Systems plc - © 2023 All rights reserved.
This document may not be distributed, transmitted electronically or stored on any other website or other
form of electronic retrieval system without express written permission of Tan Delta Systems, with the
exception of printing or downloading (to local storage) for personal and non-commercial use only.
The content also may not be exploited for commercial purposes without express written permission of Tan
Delta Systems.
Disclaimer
Read these instructions carefully and look at the equipment to become familiar with the device before
trying to install, operate, service, or maintain. Always ensure the correct configuration, installation, and
connection of the sensor in accordance with these instructions prior to any use.
The information contained within this manual affects your legal rights, responsibilities, and safety. Failure
to read and follow any instructions and warnings contained within this document may result in a serious
injury to yourself or others, damage to your Tan Delta Systems product(s), or damage to other objects.
By installing and using your Tan Delta Systems product(s), you are agreeing that you acknowledge and
understand this disclaimer and warning.
Tan Delta Systems accepts no liability for damage, injury or any legal responsibilities incurred directly or
indirectly from the use of this product. The user shall at all times observe safe and lawful practices
including, but not limited to, those set out in this document and any associated reference documents.

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AMENDMENT SHEET
Version No.
Amendment
Amended By
Date
2.0
Document re-write
R Vahter
24/10/2022
2.1
Gateway Hub Update
R Vahter
05/12/2022
2.2
Format changes
R Vahter
06/02/2023
2.3
Update to page numbering
R Vahter
10/03/2023
2.4
Update to Display Express
R Vahter
05/06/2023
2.5
General Updates to Display Express &
Communications Protocols. Update to
Software License.
R Vahter
09/11/2023

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(Page Intentionally Blank)

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1Contents
1Contents .............................................................................................. 4
1.1 Figures .......................................................................................... 8
2System Architecture ............................................................................. 10
3Accessories......................................................................................... 11
4Introduction........................................................................................ 12
4.1 Important Safety Notes......................................................................12
5Measuring Oil Quality ............................................................................ 13
5.1 Introduction...................................................................................13
5.2 Tan Delta Number............................................................................13
5.3 Oil Degradation ...............................................................................13
5.4 TDN Value vs Loss Factor Percentage .....................................................13
5.5 Traffic Lights..................................................................................14
5.6 Numbering/Levels............................................................................14
5.7 Clean Point (Start Point) ....................................................................14
5.8 Loss Factor ....................................................................................15
6OQSxG2 (Standard Sensor) ...................................................................... 16
6.1 Sensor Configuration.........................................................................16
6.1.1 Set Up..................................................................................16
6.2 Installation ....................................................................................20
6.2.1 Precautions ...........................................................................20
6.2.2 Choosing the Sensor Mounting Location...........................................21
6.2.3 Fitting Method ........................................................................21
6.2.4 Electrical Connection................................................................22
6.3 Cleaning & Maintenance ....................................................................23
6.4 Physical Dimensions..........................................................................24
6.5 Product Specification........................................................................24
6.5.1 Environmental Specifications.......................................................24
6.5.2 Physical Characteristics .............................................................24
6.5.3 Available Threads ....................................................................24
6.5.4 Connections ...........................................................................25
6.5.5 Electrical ..............................................................................25
6.5.6 Data Output/Input ...................................................................25
6.5.7 Oil Quality Detection Parameters..................................................25
6.5.8 Range and Accuracy .................................................................25
6.5.9 Standards and Certification.........................................................25
7EX GEN II ATEX, IECEX, US/C, UKEX Oil Quality Sensor .................................... 26
7.1 Important Safety Notes......................................................................26
7.2 Additional EX notes: .........................................................................27
7.3 External Marking on product or in accompanying documentation. ...................28
7.4 What’s in the box? ...........................................................................30
7.5 Configuration .................................................................................30
7.5.1 Set Up..................................................................................31
7.6 Installation ....................................................................................31

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7.6.1 Precautions ...........................................................................31
7.6.2 Choosing the Sensor Mounting Location...........................................32
7.6.3 Fitting Method ........................................................................32
7.6.4 Electrical Connection................................................................33
7.7 Cleaning & Maintenance ....................................................................37
7.8 Physical Dimensions..........................................................................37
7.9 Product Specification........................................................................38
7.9.1 Environmental Specifications.......................................................38
7.9.2 Physical Characteristics .............................................................38
7.9.3 Connectivity ..........................................................................38
7.9.4 Electrical ..............................................................................38
7.9.5 Data Output/Input ...................................................................38
7.9.6 Range and Accuracy .................................................................39
7.9.7 Standards and Approvals ............................................................39
8Display Express.................................................................................... 40
8.1 Introduction...................................................................................41
8.1.1 Interfaces .............................................................................42
8.1.2 Analog outputs........................................................................42
8.2 Configuration .................................................................................42
8.2.1 Connecting OQDe to Insight. .......................................................42
Figure 25 - Connecting to the OQDe via Wi-Fi Hotspot ..................................43
8.2.2 Navigating Insight ....................................................................43
8.2.3 Connecting OQDe to Wireless Local Area Network (WLAN) ....................47
8.2.4 Finding IP Address of OQDe on Wireless Local Area Network (WLAN) ........47
8.2.5 Upgrading Firmware .................................................................48
8.2.6 Configuring a display using CADS ..................................................50
8.3 Installation ....................................................................................53
8.3.1 Mounting...............................................................................53
8.3.2 Connection ............................................................................53
8.4 Operation......................................................................................55
8.4.1 Switching On ..........................................................................55
8.5 Product Specification........................................................................55
8.5.1 Environmental Specifications.......................................................55
8.5.2 Connectivity ..........................................................................55
8.5.3 Functionality..........................................................................56
8.5.4 Standards and Approvals ............................................................56
8.5.5 Display .................................................................................56
8.5.6 Data Logging ..........................................................................57
8.5.7 Physical Characteristics .............................................................57
8.5.8 Power ..................................................................................57
8.5.9 Compatibility .........................................................................57
8.5.10 Event Codes ..........................................................................58
9Oil Quality Gateway .............................................................................. 59
9.1 Introduction...................................................................................59
9.1.1 IMPORTANT SAFETY NOTES .........................................................59
9.2 Gateway Configuration ......................................................................60

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9.2.1 Set up Configuration USB ...........................................................60
9.3 Gateway Installation.........................................................................64
9.3.1 System Architecture .................................................................64
9.3.2 Mounting OQTg .......................................................................64
9.3.3 Wiring Gateway Hub .................................................................64
9.4 Sensor Configuration.........................................................................66
9.5 Product Specification........................................................................66
9.5.1 Environmental Specifications.......................................................66
9.5.2 Physical Characteristics .............................................................66
9.5.3 Connectivity ..........................................................................66
9.5.4 Electrical ..............................................................................66
9.5.5 System Specifications................................................................66
9.5.6 Gateway Hub .........................................................................67
9.5.7 Standards and Approvals ............................................................67
10 Configuration And Data Management Software (CADS) .................................... 68
10.1 Introduction ................................................................................68
10.2 Set Up .......................................................................................68
10.3 Operation ...................................................................................69
10.3.1 Oil Database .........................................................................69
10.4 Live Readings...............................................................................70
10.4.1 Take Readings .......................................................................70
10.4.2 Cleaning ..............................................................................71
10.5 Data Download.............................................................................71
10.5.1 Download from OQDe (Legacy V1 Display ONLY) ...............................71
10.5.2 Data Graphing .......................................................................72
11 Interface Options ................................................................................. 73
11.1 Tan Delta Communication Protocol.....................................................73
11.1.1 Checksum.............................................................................74
11.1.2 Command Overview.................................................................74
11.1.3 Read Current Readings Command “Rr” ..........................................75
11.1.4 Read Memory Command “Rm” ....................................................75
11.1.5 Read Config Data Command “Rc”.................................................76
11.1.6 Read Version and Serial Number Command “Rv”...............................76
11.1.7 Parameter Addresses ...............................................................77
11.2 CANopen ....................................................................................77
11.2.1 CAN Interface ........................................................................78
11.2.2 OQS-CAN Specification .............................................................78
11.2.3 Connection Details ..................................................................78
11.2.4 CANOpen Communication ..........................................................78
11.2.5 CAN Communication without CANOpen Functionality .........................82
11.3 Modbus ......................................................................................88
11.3.1 Hardware .............................................................................88
11.3.2 Configurable Parameters...........................................................88
11.3.3 Communication Mode...............................................................88
11.3.4 Message Framing ....................................................................88
11.3.5 Function Codes ......................................................................89

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11.3.6 Troubleshooting .....................................................................92
11.4 J1939 on CANbus ..........................................................................94
11.4.1 CAN Interface ........................................................................94
11.4.2 OQS-CAN Specification .............................................................94
11.4.3 Connection Details ..................................................................94
11.4.4 J1939 Communication ..............................................................96
12 Data Analysis Guide .............................................................................. 98
12.1 Tan Delta Full Spectrum Holistic (FSH) Data ..........................................98
12.1.1 Display Express (OQDe).............................................................98
12.1.2 CADS application .................................................................. 100
12.1.3 Insight............................................................................... 100
12.1.4 TD Online........................................................................... 101
12.1.5 Digital Data ........................................................................ 103
12.1.6 Example Good Sensor Output Readings ........................................ 104
12.2 Dynamic Maintenance Optimisation (DMO) .......................................... 104
12.2.1 Display Express (OQDe)........................................................... 104
12.2.2 TD Online........................................................................... 105
12.2.3 Partially / Fully Integrated Sensors ............................................ 109
12.3 Advanced Fault Detection (AFD) ...................................................... 110
12.3.1 Oil Degradation.................................................................... 111
12.3.2 Contamination (Water / Coolant)............................................... 111
12.3.3 Wear Metal Contamination ...................................................... 112
12.3.4 Fuel Dilution ....................................................................... 113
12.3.5 Soot Contamination ............................................................... 113
12.3.6 TBN Decrease ...................................................................... 114
12.4 Event Identification & Validation (EIV)............................................... 114
12.5 Rate of Change (ROC)................................................................... 116
12.6 Remaining Useful Life (RUL) ........................................................... 117
13 Cleaning Guide ...................................................................................118
13.1 Cleaning the Tan Delta Sensor......................................................... 118
13.1.1 Health & Safety.................................................................... 118
13.1.2 Introduction........................................................................ 119
13.1.3 Selecting a solvent cleaner ...................................................... 119
13.1.4 Cleaning Procedure –Loctite 7063 or Similar Solvent ....................... 120
13.1.5 Cleaning Procedure –Odourless Kerosene ..................................... 121
13.1.6 Cleaning Procedure - Deep Cleaning ........................................... 122
13.1.7 Cleaning Procedure –Alternative Solvent Test ............................... 123
14 Appendix ..........................................................................................124
14.1 Oil Condition Conversion Chart........................................................ 124
14.2 Oil Temperature Analog Output ....................................................... 125
14.3 Software License Agreements ......................................................... 126

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1.1 Figures
Figure 1 - System Architecture ........................................................................... 10
Figure 2 - Typical Oil Degradation Curve................................................................ 13
Figure 3- Example of Oil Quality Warnings & Alarms .................................................. 14
Figure 4 - Setting up a sensor for configuration (Standard sensor shown) ......................... 17
Figure 5 - CADS Search Screen............................................................................ 17
Figure 6 - Communication Options ....................................................................... 18
Figure 7 - Advanced Settings.............................................................................. 19
Figure 8 - Oil Selection .................................................................................... 19
Figure 9 - Cable Fitting .................................................................................... 20
Figure 10 - Installing the Sensor .......................................................................... 21
Figure 11 - Pin Outs for Power Supply & Data Output................................................. 22
Figure 12 - Generic Warnings / Alarms (Inc 4-20mA ) ................................................. 22
Figure 13 - Physical Dimensions .......................................................................... 24
Figure 14 - OQSExISG2 Contents.......................................................................... 30
Figure 15 - Setting Up the OQSExISG2 for Configuration.............................................. 31
Figure 16 - Installing the Sensor .......................................................................... 32
Figure 17 - Wiring Diagram for Power Supply & Data Output (Inc 4-20mA) ........................ 33
Figure 18 - Current Loop Output Resistance Limitations Graph ..................................... 34
Figure 19 - Connection to other Tan Delta and 3rd Party Products / Interfaces .................. 35
Figure 20 - ExOQSxG2 Ex-Sensor Installation Drawing (Rev 2) STAMPED............................ 36
Figure 21 - EX Sensor Physical Dimensions .............................................................. 37
Figure 22 - Temperature Graph .......................................................................... 38
Figure 23 - OQDe Top View................................................................................ 41
Figure 24 - Product Label with QR-Code ................................................................ 42
Figure 25 - Connecting to the OQDe via Wi-Fi Hotspot................................................ 43
Figure 26 -Status Screen................................................................................... 43
Figure 27 - Data Log Screen ............................................................................... 45
Figure 28 - Settings Screen ................................................................................ 45
Figure 29 –Default Parameters and Configuration Options........................................... 46
Figure 30 - Oil Condition Values per Application...................................................... 46
Figure 31 - Displaying IP Address of OQDe in CADS .................................................... 47
Figure 32 - Upgrading Firmware (1)...................................................................... 48
Figure 33 - Upgrading Firmware (2)...................................................................... 48
Figure 34 - Upgrading Firmware (3)...................................................................... 49
Figure 35 - Upgrade Reboot ............................................................................... 49
Figure 36 - CADS Identification Screen .................................................................. 50
Figure 37 - CADS Default Configurations ................................................................ 51
Figure 38 - CADS Custom Application Configuration................................................... 52
Figure 39 - OQDe Mounting Dimensions.................................................................. 53
Figure 40 - OQDe Connection ............................................................................. 54
Figure 41 - Wiring diagram for OQDe Power Supply and Data output (4-20mA)................... 55
Figure 42 - List of Event Codes ........................................................................... 58
Figure 43 –OQTg System Architecture................................................................... 60
Figure 44 - OQTg Configurator............................................................................ 60

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Figure 45 - OQTg Configurator Home Screen ........................................................... 61
Figure 46 - LAN Settings ................................................................................... 61
Figure 47 - WLAN Settings ................................................................................. 62
Figure 48 - Default Network............................................................................... 62
Figure 49 - Create New Network ......................................................................... 63
Figure 50 - Save Settings to USB.......................................................................... 63
Figure 51 - System Architecture .......................................................................... 64
Figure 52 –Gateway Hub Wiring.......................................................................... 65
Figure 53 - Driver Update.................................................................................. 69
Figure 54 –Live Readings Screen ......................................................................... 70
Figure 55 - CADS Data Download ......................................................................... 71
Figure 56 - CADS Graph .................................................................................... 72
Figure 57 - Oil Status Indicator ........................................................................... 99
Figure 58 - Tan Delta OQDe Display Express ............................................................ 99
Figure 59 - CADS data (Note: data shown for a sensor tested out of oil).......................... 100
Figure 60 - TD Online Live Readings Display ........................................................... 101
Figure 61 - TD Online Alerts & Alarms Dashboard..................................................... 102
Figure 62 - TD Online Data Explorer Menu ............................................................. 102
Figure 63 - Example Raw CAN Data ..................................................................... 103
Figure 64 - Example Raw CAN Data (2) ................................................................. 103
Figure 65 - Example Sensor Output Readings.......................................................... 104
Figure 66 - OQDe DMO Alert Examples ................................................................. 105
Figure 67 - TD Online Alerts.............................................................................. 105
Figure 68 - TD Online Setting an Alert.................................................................. 106
Figure 69 - Adding a Smart Rule ......................................................................... 106
Figure 70 - Entering Smart Rule Values................................................................. 107
Figure 71 - Setting an Email Alert ....................................................................... 107
Figure 72 - Completing Email Alert Details ............................................................ 108
Figure 73 - Alerts Set Up.................................................................................. 108
Figure 74 - Generic Warning / Alarms (inc 4-20mA) .................................................. 109
Figure 75 - Data Logic Table ............................................................................. 110
Figure 76 - Normal Behaviour ............................................................................ 111
Figure 77 - Water Ingress ................................................................................. 112
Figure 78 - Wear Metal Contamination ................................................................. 112
Figure 79 - Fuel Dilution .................................................................................. 113
Figure 80 - Soot Contamination.......................................................................... 113
Figure 81 - TBN Decrease................................................................................. 114
Figure 82 - Oil Change Carried Out Correctly.......................................................... 115
Figure 83 - Oil Change Not Carried Out Correctly .................................................... 115
Figure 84 - Oil Top-Up Intervention..................................................................... 116
Figure 85 - Cleaning the Sensor (1) ..................................................................... 120
Figure 86 - Cleaning the Sensor (2) ..................................................................... 120
Figure 87 - Cleaning the Sensor (3) ..................................................................... 121

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2System Architecture
When unpacking your equipment, please ensure that all of the items listed in the included
Quick Start Guide (QSG) are present. If any item is missing, please contact your distributor
directly or contact [e-mail] for further assistance.
Figure 1 - System Architecture

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3Accessories
Tan Delta Systems produce and supply a range of accessories and add-ons specifically designed
and engineered to work with the Oil Quality Sensor range.
Accessories include the following:
Oil Condition Display Express
Oil Condition Telemetry Gateway
Oil Condition Telemetry Gateway Hub
Oil Condition Sensor Manifold
A range of cables and fittings
For details of the full range of available accessories, please contact your distributor.

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4Introduction
The Tan Delta range of Oil Quality Sensors allow real-time reporting of oil quality in virtually
any application. The sensor utilises sophisticated electronics to indicate the current condition
of oil, relative to an initial profiled condition of new oil.
Based on the sensor output, the oil drain-down intervals may be extended on large industrial
equipment where the cost of replacing and monitoring the oil is expensive. The sensor can
trigger an investigation into the quality of the oil, preventing the need for expensive routine
maintenance.
The Tan Delta Sensors can reduce the overall operating cost of machinery through the removal
of routine inspections, waste oil disposal and subsequent renewal.
The Tan Delta range of Oil Quality Sensors are designed to be easy to use in a variety of
configurations depending on the monitoring equipment to which you would like to interface.
They use a simple connection to connect to a power supply and output the oil condition and
temperature on individual 4-20mA current sink outputs. The connection is also provided with
additional wires if you would like to use an RS485, CANbus or Modbus interface to connect to
an external device or system.
4.1 Important Safety Notes
Please pay attention to the following safety notes:
Standard Sensor is not IECEx certified.
Never reassemble, repair or tamper with a sensor.
Ensure that the supply voltage is within the specified range.
Ensure the load currents do not exceed the rated value.
Check all the wiring for correct connection before powering the unit.
Ensure the sensor case is earthed.

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5Measuring Oil Quality
5.1 Introduction
There are a number of ways to describe oil wear and oil condition:
Tan Delta Number (TDN)
Loss Factor Percentage
5.2 Tan Delta Number
To make it easier to monitor and trend the overall oil condition, regardless of your current
method, we have introduced the “Tan Delta Number” (TDN). The TDN has been designed to be
easy to understand, to give a very good level of accuracy and to create a common language for
describing overall oil wear and oil condition, which can also be combined with other methods
such as ISO cleanliness levels and laboratory test results.
The full scale goes from 1200 to 0, with the value decreasing as oil quality degrades. For most
applications, the useable range is from 1050 to 300.
5.3 Oil Degradation
It is important to understand that oil degradation is exponential and your use of Tan Delta
products should reflect this. Once the TDN begins to fall at an increasing rate you know the oil
is nearing the end of its life and you need to be vigilant. To help with this, our Display Express
has Check, Alert, and OLR functions to alert you to any potential issues.
Figure 2 - Typical Oil Degradation Curve
5.4 TDN Value vs Loss Factor Percentage
The underlying value which the sensor is recording for the oil condition is the Loss Factor
Percentage which is then converted into a TDN value as shown in Appendix (Section 14).

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5.5 Traffic Lights
First and foremost, the TDN scale offers a ‘traffic light’ view of oil quality. There is a Green
section, an Amber section and a Red section to illustrate OK, Warning and Alarm conditions
respectively. The thresholds for these sections can be user-defined for any application. Factors
such as likelihood/nature of contamination, how critical the machinery is and manufacturers’
guidelines should all be considered when setting the thresholds. Please contact your distributor
or [e-mail] for further guidance on setting your warning/alarm levels.
5.6 Numbering/Levels
The TDN scale extends from 1200 down to 0. For most applications, the ‘green’ section
includes all values from 1050 to 420. ‘Amber’ (warning) will go from 400 to 300: this is the
point at which you need to monitor the quality closely and prepare to filter or change the oil.
The ‘red’ (alarm) section applies to values of 300 and below. At this point, the oil needs to be
changed as it is no longer providing sufficient lubrication.
5.7 Clean Point (Start Point)
The starting point for a new oil is called the Clean Point. For most oils, this will generally be
between 950 and 850 on the TDN scale. The actual value will depend on a number of factors
but most importantly how pure the base stock is and what additive packages have been
included.
Figure 3- Example of Oil Quality Warnings & Alarms
As the oil begins to deteriorate the value will decrease.
NOTE: TDN does not start at 1000 for a new, clean oil, as some oils can be improved by
using sophisticated on-line or off-line filtration. Oil can also improve on the TDN scale, as
well as deteriorate.
TDN Oil Quality
--- Sensor in air / no oil detected Alarm (HIGH)
Warning (HIGH)
--- New
--- Good
--- Worn Warning (LOW)
--- Severely worn Alarm (LOW)
--- End of life
1200
1100
500
250
0

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5.8 Loss Factor
A clean oil has a Loss Factor Percentage of approximately 0% and then as the oil changes and
degrades this Loss Factor Percentage increases. For most applications, oil would be considered
to be degraded at a Loss Factor Percentage of 25% and at the “end of life” at a Loss Factor
Percentage of 30% or above.

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6OQSxG2 (Standard Sensor)
6.1 Sensor Configuration
Before installation, it is necessary to configure the sensor to your specifications using the Tan
Delta Configuration and Data Management Software (CADS). This is a software application,
supplied on the USB memory stick, which must be installed on a windows PC or laptop. (Please
note the software does not operate on Mac devices or on Chromebook devices.)
6.1.1 Set Up
6.1.1.1 Install the CADS application onto a PC / Laptop
To install the software:
Connect the PC or laptop to the sensor using the configuration cable.
Connect the memory stick to a USB port on your PC or laptop. Allow the PC/laptop to
automatically update drivers, if needed.
When prompted, select Open folder to view files.
Launch the setup.exe file and follow the instructions in the setup wizard.
When prompted, click on Install.
When installation is complete, CADS is displayed.
It may take up to a minute for the software to identify the OQSxG2.

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6.1.1.2 Launch the software
Launch CADS and wait for the home screen to load.
6.1.1.3 Connect OQSxG2
Once the home screen has loaded, select ‘Configure Oil Quality Sensor’ from the tiles on the
home screen. Next connect the OQSxG2 to your computer using the configuration cable (cable
J) as shown in Figure 4.
NOTE: If sensors are configured to Modbus/CANbus, you must open the software first, and
then connect the sensor.
6.1.1.4 Select sensor
You will be presented with a list of all connected devices, identified by serial number. Select
the required device.
Click the arrow in the top right hand corner to proceed.
Figure 4 - Setting up a sensor for configuration (Standard sensor shown)
Figure 5 - CADS Search Screen

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6.1.1.5 Communications settings
This next screen lists the options for the device you wish to connect the sensor to:
Oil Quality Display Express –sets the sensor to use our proprietary RS485
communications protocol.
Oil Quality Telemetry Gateway –This sets the sensor to CANbus for use with our legacy
range of gateway devices operating on CANbus. Ensure sensors are uniquely numbered
from 1-10. (NOTE: The newer versions of the Gateway Device are supplied configured
for Modbus and therefore require Custom Communications Settings)
Custom Communications Settings –Allows you to select custom node ID and bit rate for
RS485, CANbus, J1939, Modbus.
Note: CANbus Self Starting allows the sensor to power up straight into Operational
mode and begin sending Process Data Object (PDO) responses without validation
from a CANopen master so the sensor can be used on systems without a full
CANopen master.
Note: If you are using the sensor with the OQTg, Node ID must be set uniquely to each
sensor, numbered 1-16.
Figure 6 - Communication Options