Manual Analex

PQ® Technology Ferrous Debris Monitor
Installation and Operation Manual

PQ® Technology Ferrous Debris Monitor
Installation and Operation Manual
MA-K18063-KW Issue 9
March 2015
Ferrous Debris Monitor ANALEXpqL
TABLE OF CONTENTS
1 Introduction ................................................................................... 4
1.1 Quick Guide..................................................................................... 6
1.2 Certificates ...................................................................................... 8
1.3 Cleaning .......................................................................................... 9
1.3.1 Cleaning The Main Enclosure.......................................................... 9
1.3.2 Cleaning The Touchscreen.............................................................. 9
1.3.3 Cleaning The Carousel .................................................................... 9
1.4 Calibration, Maintenance & Service ................................................10
1.5 Practical Hints ................................................................................10
1.6 „PQ Index‟ Versus „PPM Of Iron‟ .....................................................11
1.7 How Useful Is Measurement For Iron Only? ...................................11
2 Safety Summary ...........................................................................12
3 Technical Information ..................................................................13
3.1 Specification ...................................................................................13
3.2 Features .........................................................................................14
3.3 Rear Panel .....................................................................................15
3.4 Adaptors .........................................................................................15
3.5 Part Numbers .................................................................................16
3.5.1 FG-K17000-KW ............................................................................. 16
3.6 Spares ............................................................................................16
3.7 Accessories ....................................................................................17
4 Starting To Use The ANALEXpqL................................................18
4.1 Location ..........................................................................................18
4.2 How To Ensure Accuracy And Optimum Performance ...................19
4.3 Connecting The Power Supply .......................................................20
4.4 Sampling And Sample Preparation .................................................20
4.4.1 Grease Samples ............................................................................ 20
4.4.2 Oil Samples ................................................................................... 21
4.4.3 Using Sample Bottles And Sample Pots ........................................ 22
4.4.4 Shaken / Settled Samples ............................................................. 24
5 Operation ......................................................................................26
5.1 Powering Up The ANALEXpqL .......................................................26
5.2 Colour Touchscreen Display...........................................................26
5.3 Main Menu......................................................................................27
5.4 Set Up ............................................................................................28
2
ANALEXpqL Ferrous Debris Monitor
5.4.1 Calibrate .........................................................................................29

5.4.2 Set Time & Date .............................................................................30
5.4.3 Align Carousel ................................................................................30
5.4.4 Options ...........................................................................................30
5.4.4.1 Default Format................................................................................30
5.4.4.2 Custom Format...............................................................................31
5.4.4.3 Auto Transmit PQ Index After Every Measurement ........................31
5.4.4.4 Sample ID Mode.............................................................................31
5.5 Measure ......................................................................................... 32
5.5.1 Manual Measure.............................................................................33
5.5.1.1 Abort ..............................................................................................33
5.5.1.2 Results ...........................................................................................33
5.5.2 Magazine Measure .........................................................................34
5.5.3 Remote Measure ............................................................................34
5.6 Data Manager................................................................................. 35
5.7 Transmit ......................................................................................... 36
5.7.1 Transmitting via Serial RS-232 .......................................................36
5.7.2 Storing On The USB Flash Drive ....................................................37
5.8 Printing ........................................................................................... 37
5.9 Shut Down ...................................................................................... 37
6 Troubleshooting ........................................................................... 38
Appendices ................................................................................................. 41
A. Remote Measure Commands ......................................................... 41
B. Remote Support Using UltraVNC ..... Error! Bookmark not defined.
3
1 Introduction
Key to Symbols
! = Caution
= Note – Important information and helpful hints and tips
For General Enquiries, please contact:

Kittiwake Developments Ltd
3-6 Thorgate Road
Littlehampton Tel: +44 1903 731470
West Sussex Fax: +44 1903 731480
BN17 7LU Email: [email protected]
United Kingdom Web: www.kittiwake.com
Do Not Discard This Manual

The Installation and Operation Manual is a functional part of the
ANALEXpqL product and must be kept for future reference.
Please retain all original packaging for shipping purposes. Kittiwake will not be
liable for damage to returned goods resulting from inadequate packaging.
4
This manual covers the Kittiwake ANALEXpqL Ferrous Debris Monitor. The
instrument provides the most accurate means of detecting and measuring
ferrous wear debris in lubricating oils, hydraulic oils and greases. The rugged,
compact and stable monitor delivers retrievable data quickly and simply,
ensuring fast, accurate and consistent management of lubricating oil samples.
Unrestricted by particle size or distribution, combined with speed and ease of

use, the ANALEXpqL is an extremely effective laboratory based screening tool
for multiple samples prior to further analysis by ICP or XRF.
Condition monitoring of machinery lubricants is an established method of

predicting and avoiding impending machinery breakdown. Worn components
can be identified early and replaced before any serious damage occurs.
Production can be maintained, machinery life extended and the return on capital
investment increased.
The ANALEXpqL is not designed to make absolute measurements on debris

quantity - it monitors trends. To be significant, the PQ Index must change by at
least 10% relative to the previous measurement. Empty bottles/pots and clean
oil often give a slightly positive PQ Index This is normal and will not affect trends
as long as they give consistent readings.
Quick Start
90 → 264 Vac
5
1.1 Quick Guide
MEASURE
Manual ► Toggle number of ► Append to File. ► Choose an existing file ► And Again. Swap
measures for this Add new results to or type name of new sample and repeat test.
sample existing results file file. Print. Use Kittiwake
Press Go to printer.
New File. commence measure Transmit. Transmit via
Create a new file for sequence. RS-232 or to a USB
these results memory stick.
Save & Exit
Exit (no save)
Magazine (Non standard option. Special order only)
Remote ► Allows remote control from an external PC
DATA MANAGER
Highlight a file in ► View ► View the file ► Print
the list Rename
Delete
Transmit
Rename ► Type new filename
Delete ► Single File.
Delete highlighted file.
All Files.
Delete all files.
Transmit ► Transmits file via
RS-232 (9-way D type
connector) and to a
removable drive (USB
memory stick) if inserted.
TRANSMIT
Highlight a file in ► Selected File. ► Transmits file(s) via
the list Delete highlighted file. RS-232 (9-way D type
All Files. connector) and to a
Delete all files. removable drive (USB
memory stick) if inserted.
SET UP
Calibrate ► Calibrate instrument ► Place the correct ► Save results
using 0PQ and standard puck on the
750PQ standards carousel when Cancel
supplied by Kittiwake instructed. Press Go.
Set Time & Date ► Use toggles to adjust
time and date (ISO
standard format)
Align ► Run the Carousel
Align Sequence. Note
that this sequence is
automatically carried
out whenever the
instrument is switched
on.
Options ► See Section 5.4
SHUT DOWN
Hold button ► Are you sure? ► Do not remove power
down for 3 until instructed to do so.
seconds
1.2 Certificates
8
1.3 Cleaning
If aggressive fluids (e.g. phosphate esters) are being tested, particular care
should be taken to avoid contact between the fluid and the ANALEXpqL. It is
very important to keep the instrument clean, particularly the platen surface
underneath the carousel. Otherwise, a new sample may become contaminated
by a previous spilt sample.
To clean, use a damp cloth moistened with a warm detergent solution. Do not
use aggressive solvent cleaners as they may damage the surface.
1.3.1 Cleaning The Main Enclosure

Lightly wipe the body of the instrument. Do not scrub as this may damage the
paint finish.
1.3.2 Cleaning The Touchscreen

Any fluids should be removed immediately to avoid staining. Shut down the
instrument and lightly wipe the screen with the cloth. Do not scrub hard and
wipe only in a horizontal or vertical motion. Never wipe in a circle.
1.3.3 Cleaning The Carousel

The carousel may require cleaning during normal use to ensure it is clear of
any metal debris or spilt samples. Shut down the instrument, remove the
power and only then remove the carousel by firmly pulling it upwards.
Carefully clean the platen base and both sides of the carousel before
realigning the location pins and pressing down firmly on the carousel to fully
reattach. When correctly positioned, the carousel should not rock at all.
Upon switching on the power, the unit will self-align. Re-calibrate before further
use since the carousel has been removed. This is critical to ensure accuracy of
subsequent measurements.
It is strongly advised to shut down and power off before cleaning. If the carousel
is ever removed and replaced without shutting down, ensure that the unit is Re-
Aligned (see Section 5.4.3) and Re-Calibrated (see Section 5.4.1) before re-
use.
9
1.4 Calibration, Maintenance & Service

The ANALEXpqL uses proven, patented magnetometry combined with internal
microprocessing to indicate metallic particle contamination. The supplied
standards should be used for calibration of the instrument at regular intervals
and these standards should be returned to Kittiwake for re-calibration as
specified on the accompanying certificates.
There are no user serviceable parts in the ANALEXpqL. If required the fuse can
be replaced by removing the fuse cover on the rear. Spare fuses are available
from Kittiwake Developments Ltd (see Section 3.6).
For continued performance, Kittiwake recommends that the ANALEXpqL is

serviced, checked and calibrated regularly by the factory. The recommended re-
calibration period is 18 months.
1.5 Practical Hints

For best stability, the ANALEXpqL should be left permanently switched on so
that the temperature inside the instrument stabilises. Temperature variations are
a significant source of error and warm samples should not be left on the sensor.
Do not apply pressure to the top surface of the instrument - this may lead to
spurious results and cause damage.
When an oil sample (either in a plastic pot or in a bottle) is in the measurement

position, it must be in intimate contact with the sensor coil. The rotating carousel
guides the sample across the top surface of the platen to the sensor position. It
is important that the sample (or the 750 PQ standard) is a loose fit in the
carousel aperture (or adapter). Due to the effects of temperature or spilled
material, the sample (or the 750 PQ standard) may cease to be an "easy fit" in
the carousel aperture. If it is held tightly in the carousel so that it is no longer in
intimate contact with the sensor during a measurement, errors may result.
It is important that sample pots sit correctly on the measurement sensor

otherwise major errors may result. The pots supplied by Kittiwake are suitable
for PQ measurements. It is essential that all plastic sample pots are individually
examined before use and that any pips or projections are removed using a
sharp knife. See section 4.4.34.4.2. Sample pots and plastic bottles must only
be used once - NEVER try to clean and re-use these.
10
1.6 ‘PQ Index’ Versus ‘PPM Of Iron’

Users of Spectroscopic Oil Analysis (SOA) methods report their data in parts
per million. However, SOA methods are often inaccurate in absolute terms
because of the insensitivity of these techniques to large particles and the
problem of sample inhomogeneity. SOA is typically most efficient with sample
particles <5 microns in size.
Many commercial laboratories are now using both SOA and PQ side by side
and the analytical results from the two techniques are often interpreted in the
following manner. If the "PQ Index" is less than the "ppm Fe" analysis by SOA,
it is likely that all debris is <5 microns in size (this is typical for corrosive wear
particles). If the "PQ Index" and the "Fe ppm" by SOA are similar or especially if
the PQ Index is higher then it is likely that there will be large particles in the
sample. The sample is then examined by microscope to check for the presence
of large particles.
1.7 How Useful Is Measurement For Iron Only?

The PQ technique responds significantly to ferromagnetic materials such as iron
and nickel. There are applications concerning wear in aluminium engines and in
white metal bearings where the PQ might not be applicable. However, even for
used oil analysis programmes concerning wear in diesel engines (a good
example of a "multi-element" application), the PQ technique easily identifies the
release of larger particles due to "filter breakthrough".
11
2 Safety Summary
Please ensure you thoroughly read and understand this user manual before
attempting to operate the ANALEXpqL.
If the equipment is used in a manner, or for a specific purpose other than that
described in this user manual, then any safety protection may be impaired.
 Never use the ANALEXpqL near combustible gases or liquids.
 Never disassemble, repair, or tamper with the ANALEXpqL.
 Ensure that the supply voltage is within the specifications with means of
isolation fitted.
 Check all wiring for correct connection before powering the unit.
 The ANALEXpqL, power supply & accessories contain no user
serviceable parts. Do not disassemble.
 When handling oil samples, protective gloves and safety goggles should
be worn.
 The ANALEXpqL has a rotating carousel. Care should be taken to avoid
damage to the equipment or injury to the user.
Warning! This equipment has not been approved for use in an explosive
! atmosphere.
! Caution! This equipment must be operated by qualified persons only.
12
3 Technical Information
The ANALEXpqL is designed for the measurement of oil or grease samples

direct from sample bottles or pots.
! All values are displayed in PQ units unless otherwise stated.
3.1 Specification
Resolution 1PQ
Measurement Range 0 – 5000PQ
Accuracy † ±4PQ or 1% [whichever is greater]

†
Repeatability ±4PQ or 1% [whichever is greater]
‡
Reproducibility ±4PQ or 1% [whichever is greater]
Minimum PQ Detection 1PQ
Cycle Duration 4.2 seconds

Stable temperature between +10°C and
Ambient Temperature Limits
+30°C
Environment Required for
Laboratory environment between +20°C and
Optimal Accuracy and
+24°C
Repeatability
Size & Weight 370mm x 230mm x 140mm (3.6kg)
Ingress Protection Rating IP20
Product Life In excess of 4 million operations
Fuse Rating 1.6A, 250V, 5x20mm Antisurge Fuse
Supply Voltage Range 24V dc ±10%
† Accuracy complied at 750PQ. The PQ index of a sample may vary with temperature. The published accuracy, repeatability and
reproducibility figures were compiled using the following conditions. Ambient room temperature between +20°C and +24°C. Stable
samples held at room temperature and isolated from cold surfaces.
‡ Reproducibility figures are based on averaging a series of 10 consecutive measurements per test sample on each instrument. The
instrument was calibrated after every 100 measurements.
13
3.2 Features
 Measures ferrous debris directly from the oil in the sample bottle or from a
grease sample placed in the grease sample adapter.
 Large backlit graphical display for clear user prompts and easy viewing of
results.
 Colour touchscreen allows easy entry of data via a full alphanumeric
keypad.
 Auto zero between each sample.
 Universal power supply allows use with a wide range of supply voltages.
Colour
Touchscreen
Display
Rotating
Carousel
Durable
Enclosure
14
3.3 Rear Panel
Fuse Holder 2 x USB Ports

DC Input 2 x USB Ports
RS-232 Serial Port PS/2 Port

External Display Port
3.4 Adaptors
Pot Adaptor Bottle Adaptor

(with 5ml sample pot) (with 100ml sample bottle)
15
3.5 Part Numbers

The ANALEXpqL is supplied as shown in Section 3.5.1. Spares and
accessories are available as shown in Sections 3.6 and 3.7 respectively.
3.5.1 FG-K17000-KW
Description Notes
ANALEXpqL Standalone Instrument

User Manual
0PQ & 750PQ Standards Pack User Calibration Kit
0PQ 5ml Pot Standard & ANALEXpqL Test
Pack
2m Null Modem Cable For RS-232 Comms to a PC
5ml Oil/Grease Sample Pots & Lids
Power Supply and Mains Cable
100ml Bottle Adaptor (41mm)
5ml Pot Adaptor
USB Flash Drive For Data Storage
Shipping Carton Retain all original packaging
3.6 Spares
In addition to any items listed above, ANALEXpqL spares can be ordered using
the following part numbers:
Kittiwake Part No. Description Notes
FG-K3-207-KW 100ml Sample Bottles & Lids Pack of 288

FG-K15004-KW 5ml Sample Pots & Lids Pack of 100
FG-K15005-KW 5ml Sample Pots & Lids Pack of 3000
AS-K18525-KW ANALEXpqL Fuse Pack 3 fuses
For use with Kittiwake
FG-K15710-KW 100ml Bottle Adaptor (41mm)
sample bottles
16
FG-K16062-KW 5ml Pot Adaptor

FG-K18532-KW USB Flash Drive ANALEXpqL compatible
ANALEXpqL Shipping Carton
FG-K18535-KW
Assembly
FG-K18305-KW Thermal Paper 20 rolls
FG-K18137-KW 0PQ & 750PQ Standards Pack
0PQ 5ml Pot Standard &
FG-K18351-KW
ANALEXpqL Test Pack
0PQ & 750PQ Standards Pack - Customer to return
FG-K18538-KW
Exchange existing pack
0PQ 5ml Pot Standard & Customer to return
FG-K18539-KW
ANALEXpqL Test Pack - Exchange existing pack
3.7 Accessories
ANALEXpqL accessories can enhance the functionality of the instrument. They
can be ordered using the following part numbers:
FG-K18300-KW Thermal Printer Kit

FG-K18305-KW Thermal Paper 20 rolls
Use barcode labels to
identify samples and
FG-K18311-KW Intelligent Barcode Scanner kit enter their codes
automatically into the
ANALEXpqL
For PC‟s without a serial
BI-K17132 USB to RS-232 Adapter
comms port
Low Range Second Standard
FG-K18695-KW
(40-60PQ)
FG-K16065-KW Slide Adaptor
Available on request Robotic handling system
17
4 Starting To Use The ANALEXpqL
4.1 Location
 The ANALEXpqL is designed to operate on a flat, level surface such as a
workbench or desk.
 The instrument contains a sensitive measuring head that is designed to
detect ferrous debris in oil or grease samples. Ensure that the unit has
plenty of free space around it (300mm to the sides and 500mm above), and
is distant from metal objects, large power cables and electrical machinery
etc. Also ensure that there are no other ANALEXpqL instruments, heavy
machinery or high power transformers within 2m.
 The ANALEXpqL is very sensitive to changes in temperature. Therefore,
locate the unit in a thermally stable environment, avoiding direct heat
sources or drafts.
 Site the instrument away from strong magnetic fields, such as near
loudspeakers or microwave ovens (these can even affect the instrument
through walls).
 Make sure any computers, monitors or other instruments are at least 1m

away. Do not operate a mobile phone within 2m of the instrument.
 Metal benches can cause balance problems for the sensing coils. This
includes the bench top and/or frame. The same is true for moving metal
components such as automatic loaders or door handles.
 Ensure jewellery is at least 20cm away from the instrument whilst

measurements are being taken.
 If using the instrument in conjunction with a mechanical sample presenter,
consideration should be given to the possibility of the sensor being
disturbed by electromagnetic noise or movement of metal components in
the mechanism. Such devices have been used successfully in the past but
some trials may be necessary to understand how the readings may be
affected.
! Failure to follow these guidelines will affect the accuracy of the instrument.
18
4.2 How To Ensure Accuracy And Optimum Performance

 Ensure the location meets the requirements in Section 4.1.
 The ANALEXpqL takes approximately 2 hours to reach a stable
temperature. For optimum accuracy following power up, wait 2 hours
before taking measurements.
 Do not touch sample bottles whilst the unit is measuring - this will affect
the result and could knock the carousel out of alignment.
 Keep the carousel and platen base clean at all times. See Section 1.2
(Cleaning).
 Grit, dirt and especially metal particle debris between the bottle and the
sensor will affect the reading and cause errors.
 Many printer toners and inks (especially for laser and ink-jet printers)
contain elements which could drastically affect the measurement. Use
thermal printers if possible. Labels placed on bottle lids or pot bases should
be avoided.
19
4.3 Connecting The Power Supply

a) Connect the cable from the supplied power supply to the rear of the unit.
b) Plug the mains lead into the power supply and then into a suitable earthed
power socket.
c) Turn on the switch at the power socket.
Never remove the power from the ANALEXpqL before safely shutting down.
! See Section 5.9.
4.4 Sampling And Sample Preparation

The ANALEXpqL can measure metal wear particles in either grease samples or
oil samples. Whichever the type, always ensure that a representative sample is
taken, using a consistent sampling procedure. This will ensure the most
accurate test results and trending data for your machinery.
Bottles, pots, slides or millipore filters can be used to present samples to the
instrument. However, measurement of samples within a bottle is the most
convenient method. It can provide additional information when compared with
samples in pots (see Section 4.4.4), does not require transfer of sample and the
same container may be used for PQ measurement and particle counting.
4.4.1 Grease Samples

 Grease samples must be presented in the small 5ml pots provided
with the instrument (AS-K15308).
 The grease samples must be ﬂush with the top of the sample pot.
 Place the pot adaptor into the carousel to ensure the sample is centrally
located over the measuring head.
Care should be taken to ensure a representative sample is taken. The wear

debris from both grease samples and oil samples is very dependant on the
sampling point.
For maximum accuracy below 100 PQ with 5ml grease samples, the
ANALEXpqL should be re-calibrated prior to measuring. Use the 0 PQ 5ml Pot
Standard supplied in kit FG-K18351-KW during calibration.
20
4.4.2 Oil Samples

 Oil samples may be presented in a standard Kittiwake 100ml sample
bottle (FG-K3-207-KW) or small 5ml pot (FG-K15004-KW).
 If using a sample bottle, fill to a depth of at least 40mm.
 Shake the sample before measuring to ensure wear debris is evenly
distributed.
 Always use the correct bottle or pot adaptor.
 If using a sample bottle place the sample bottle into the aperture
with the lid facing downwards.
Always use the correct adapter, a well homogenized sample and consistent
presentation to the instrument in a pot or a bottle with the lid downwards and a
geometrically flat lid.
21
5ml Oil/Grease Sample Pot 100ml Oil Sample Bottle
4.4.3 Using Sample Bottles And Sample Pots

Always use the correct sample adapter in the sample aperture of the
measurement carousel for your particular measurement container. This will
ensure that the sample is correctly positioned centrally over the measurement
sensor. If the sample is not in an exactly central position, erroneous results
may occur. Adapters are available for bottles, pots and slides.
Bottles may be measured upright (base down) or in an inverted position (lid

down) provided their lids are leak proof. Bottle lids are usually flatter than
bottle bases. Metal lids, plastic lids with foil inserts and lids that affect the
magnetic field, for example Bakelite lids, should be avoided.
There is an inverse relationship between the measured PQ Index and the

distance between the sensor and the sample. Ideally, the sample container
should be in intimate contact with the sensor and bottles/pots should therefore
have flat bases. Bottles with convex bases or lids should be avoided.
Over-tightening bottle lids may force them to become convex and therefore
unsuitable for use.
Likewise, bottles/pots with pips (left over from the moulding process) on the
base or lid should be avoided, since this will also affect the PQ Index result.
Sample containers should be examined before use and any pips or
projections removed using a sharp knife.
22
Flat base or lid
X Concave lid or base
X Convex lid or base
X Pip on lid
40mm Minimum
23
4.4.4 Shaken / Settled Samples

It has been shown1,2 that a PQ Index measurement on a well-shaken sample
is independent of the volume of sample in the bottle provided this exceeds a
critical depth. The critical depth will vary with the size of bottle and is typically
about 10mm (roughly equivalent to 7.5ml of sample) for a standard 35ml or
30mm diameter bottle. A PQ Index obtained using 35ml bottles is about three
times greater when compared with the same oil measured using the pot
method with just 2ml of sample.
The PQ technique is often employed as a screening device to help decide

which samples justify further examination by other analysis methods. Allowing
the debris to settle in the bottle before measurement may further increase the
magnitude of the PQ readings, but readings on a sample that has been
allowed to settle are only semi-quantitative unless the sample volume is
controlled.
Some PQ users make a preliminary measurement on a settled bottle followed

by a quantitative measurement after shaking the bottle for 30 seconds. If a
well-shaken sample bottle is left undisturbed in the PQ carousel, repeat PQ
Index readings will be seen to increase with time as debris settles to the
bottom of the bottle. A rapid rate of increase is an indication of the presence of
large particles in the sample.
1 A. R. Ma s s o u d i , M. H. J ones and B. J . Ro y l a n c e -
Un i v e r s i t y Co l l e g e of S wa n s e a . " A Ra p i d Por t ab l e
Fer r ous De b r i s Mo n i t o r " . S. T. L . E. Ann ua l Me e t i n g ,
Ca l g a r y , Ma y 1 9 9 3 .
24
2 M. H. J on es an d A. R. Ma s s o u d i - Un i v e r s i t y Co l l e g e o f
S wa n s e a . " T h e T D P Q: a sol ut i on t o t he anal ys i s of l ar ge
we a r p a r t i c l e s " . I NS I GHT V o l 3 7 No 8 Au g u s t 1995.
25
5 Operation
5.1 Powering Up The ANALEXpqL
Having switched on the power (see Section 4.3) the ANALEXpqL will initiate its
start-up and self-test sequence. This takes about one minute. Once completed,
the MAIN MENU will be displayed.
5.2 Colour Touchscreen Display

The touchscreen display provides the user interface. A USB or PS/2 keyboard
may be attached if desired to ease data entry. The User Interface is constructed
of a simple hierarchy of menu pages. Each page has its name in the top right-
hand corner to ease navigation. In the top left-hand corner, there is often a
„back arrow‟ button to navigate back to the previous page. If the interface is not
used for about 2 minutes, it returns to the main menu.
The screen displays results in real time. See Section 5.5.1.2.
26
5.3 Main Menu
There are 5 options available on the Main Menu:

a) Set Up. Set up the instrument (calibrate, align, set date & time, comms
options etc). See Section 5.4.
b) Measure. Taking sample measurements. See Section 5.5.
c) Data Manager. Manage stored data (print, rename, delete etc). See
Section 5.6.
d) Transmit. Transmit some or all stored data to an external PC or USB stick.
See Section 5.7.
e) Shut Down. Safely shut down the instrument by holding this button for 3
seconds and following the instructions. See Section 5.9.
27
5.4 Set Up
There are 4 options available on the Set Up Menu:

a) Calibrate. Recalibrate the instrument to avoid inaccuracies caused by
issues such as temperature drift.
b) Set Time & Date. The time and date will be recorded in every results file so
ensure it is correctly set.
c) Align Carousel. The ANALEXpqL has the ability to self align the rotating
carousel.
d) Options. There are many user options that can be set up to manage the
way results are stored and transmitted. These options can all be set on this
page.
28
5.4.1 Calibrate
The Check Standards Pack FG-K18351-KW contains two other small grease
standards which may be measured to check whether the ANALEXpqL is in
need of re-calibration.
To calibrate, the user should use the supplied 0PQ and 750PQ Standards.
There are two 0PQ standards supplied:-
a) AS-K18138. This is found in pack FG-K18137-KW and should be used
for calibration prior to measuring using sample bottles.
b) AS-K18352-KW. This is found in pack FG-K18351-KW and should be
used for calibration prior to measuring using 5ml sample pots.
The calibration sequence measures the 0PQ and 750PQ Standards and
carries out calculations and checks. If the check accuracy is not high enough,
the user will be instructed to repeat the calibration. If the check accuracy
meets the requirements the user has the option to save or disregard the
calibration.
When the ANALEXpqL is first switched on, it should be left to stabilise for at
least 2 hours before initially calibrating.
If the ANALEXpqL is relocated, it should be recalibrated.
For the highest level of accuracy it is recommended that the unit be recalibrated
after every 500 measurements or 8 hours, whichever comes first.
If the carousel is ever removed for cleaning, upon replacement the instrument
should be re-aligned and then recalibrated.
The 0PQ and 750PQ Standards must be at stable laboratory temperature before
calibrating. Do not place them on a cold surface prior to calibration.
For the highest level of accuracy at low PQ levels, a 0PQ standard may be
made by the user. Take a clean, unused sample of the specific oil being
measured and pour a volume identical to the volume being measured, into an
unused sample bottle/pot.
Samples must never be removed or placed whilst the carousel is engaged in a

! calibration sequence. This will cause misalignment and may damage the
motor.
29
5.4.2 Set Time & Date

Select each field individually and set up using the up / down toggle arrows.
Alternatives, key in the values using a USB or PS/2 keyboard. Press Save
when complete, or use the back arrow to exit without saving.
The date is presented in the dd/mm/yyyy format.
5.4.3 Align Carousel

With the carousel in position, select the Align Carousel button to automatically
re-align the carousel. It is recommended that re-alignment be carried out
every 24 hours.
If the carousel is removed for cleaning, it must be re-aligned upon

replacement and the instrument must be recalibrated. It is recommended that
the unit be shut down before the carousel is removed, in which case the
realignment will occur automatically upon switching on.
5.4.4 Options
Results data may be transmitted in a number of formats. The PQ index is
always transmitted as a signed 5-digit integer, e.g. +00750. Once all desired
options have been selected on this page, press Save. To exit without saving,
press Cancel.
5.4.4.1 Default Format

The default format lists all results in standard .csv format as follows:
BATCH_ID,hh:mm,dd/mm/yyyy,value1,value2,value3…..valueN
The “values” detail the PQ Index but may also be prefixed with the Sample
ID. This depends on the Sample ID Mode that has been selected (see
Section 5.4.4.4). For example:
BATCH_ID,hh:mm,dd/mm/yyyy,sample1value1,sample2value2,sample3value3
…..sampleNvalueN
30
5.4.4.2 Custom Format

Alternative formats may be adopted. The custom format lists all results as
follows:
value1,value2,value3….valueN,
[Note the addition of a final comma delimiter which is not present in Default Mode]
The date and headers (Batch ID and the term “PQ”) may also be added
when Custom Format is selected, as follows:
dd/mm/yyyy,BATCH_ID,PQ,value1,value2,value3….valueN,
The field Delimiter may also be changed using the up and down toggle
arrows when in Custom Format as follows:
dd/mm/yyyy#BATCH_ID#PQ#value1#value2#value3….valueN#
Again, the “values” detail the PQ Index but may also be prefixed with the
Sample ID. This depends on the Sample ID Mode that has been selected
(see Section 5.4.4.4). For example:
dd/mm/yyyy#BATCH_ID#PQ#sample1value1#sample2value2#sample3value3
….sampleNvalueN#
5.4.4.3 Auto Transmit PQ Index After Every Measurement

When selected, this feature will transmit every result via RS-232 as soon as
the measurement is taken. The PQ index is transmitted as a signed 5-digit
integer, e.g. +00750<CR>
5.4.4.4 Sample ID Mode
There are 3 options - Off, Auto and Manual.

a) When „Off‟ is selected, no sample ID is appended to each result.
b) When „Auto‟ is selected, a 3 digit Sample ID is appended to every
result. The number starts at 001 for every new file and automatically
increments whenever a new sample is measured (using And Again or
Append to File).
c) When „Man‟ (Manual) is selected, the user must add a Sample ID for
every sample placed on the carousel. The ID‟s may be added using the
touchscreen keyboard, a USB or PS/2 keyboard, or the optional USB
intelligent barcode scanner kit (FG-K18311-KW).
31
5.5 Measure
There are 2 options available on the Measure Menu (a third is unavailable on

the standard instrument):
a) Manual. Manually place samples on the instrument and take
measurements. Each sample may be repeatedly measured up to 99 times.
b) Magazine (unavailable).
c) Remote. Operate the ANALEXpqL remotely via a PC with Serial
Communication (RS-232). Additional PC applications are not provided for
remote control, but the available commands are described in Appendix A.
There is a back arrow at the top left corner which can be pressed to return to
the previous screen. This selection is present on many screens.

! measure sequence. This will cause misalignment and may damage the motor.
32
5.5.1 Manual Measure
There are 3 options available:

a) Append to File. Select an existing data file and append new results to it.
The “Current Results” can also be chosen – these are the most recent
results that have been saved.
b) New File. Create a new BATCH ID file to store results. Note that the
BATCH ID file name may not include the following characters:
\ / : * ?.” < > |
c) Measurement(s) per sample. Choose how many times to measure each
sample by using the up and down toggle arrows.
As soon as the “Go” button is selected, the measuring sequence commences.
5.5.1.1 Abort
A measuring sequence can be aborted by pressing the Abort button. All
current results up until the abort are still available when the “Current
Results” selection is made from the “Append to File” list.
5.5.1.2 Results
As a measurement sequence takes place, the results are displayed on the
touchscreen. The left hand column lists the sample ID if that option has
been selected (see Section 5.4.4.4) and the right hand column lists the PQ
Index. If the list extends beyond a page, use the page up and page down
arrows to view the results.
Following the completion of a sequence of measurements, the user has 5

options:-
a) And Again. Upon selecting this option, the same number of
measurements will be taken of the next sample placed on the carousel.
Ensure the sample is correctly positioned before pressing the button.
b) Print. Print the displayed results to the optional USB printer. See
Section 5.8 for more details of printing to the optional USB printer.
c) Transmit. Transmit some or all stored data to an external PC or USB
stick. See Section 5.7.
d) Save & Exit. Save the results and exit to the Measure Menu.
e) Exit (No Save). Select to exit without saving the results. If Appending to
File, this selection simply discards the latest set of results.
33
5.5.2 Magazine Measure

This is a non-standard option and available only as a special order.
5.5.3 Remote Measure

This feature allows the ANALEXpqL to be operated via a remote PC using
RS-232 serial comms. Connect the supplied D-type cable (EL-K18056) to the
rear of the ANALEXpqL and to a PC. If the PC does not have a 9-way RS-232
D-Type connector, an optional USB to RS-232 adaptor may be used (BI-
K17132).
Run a suitable terminal emulator on the PC (such as „Tera Term‟ or „Hyper

Terminal‟) and set it up as follows:
Bits per second 9600 Stop bits 1

Data bits 8 Flow control None
Parity None
The available commands for remote control are detailed in Appendix A. Note
that these must be entered in CAPITAL letters. To exit the Remote Measure
mode, press the back arrow.

! measure sequence. This will cause misalignment and may damage the motor.
34
5.6 Data Manager
The Data Manager allows the user to manage any stored results file. Press and
highlight the desired Batch ID and then select one of 4 options:
a) View. Display the results and allows the user to Print, Rename, Delete or
Transmit them. See Section 5.8 for more details of printing to the optional
USB printer.
b) Rename. Rename the selected Batch ID. Note that the Batch ID name may
not include the following characters:
\ / : * ?.” < > |
c) Delete. Delete the selected file or delete ALL files.
d) Transmit. Transmit selected results file via RS-232 and/or USB (whichever
is attached). See Section 5.7.
Press the back arrow at any time to return to the Main Menu.
35
5.7 Transmit
The Transmit button allows the user to transmit all stores results files in one go.
The option to highlight a single Batch ID and transmit that is also available.
Once the transmission has completed, press the “OK” button.
Press the back arrow at any time to return to the Main Menu.
5.7.1 Transmitting via Serial RS-232

Connect the supplied D-type cable (EL-K18056) to the rear of the
ANALEXpqL and to a PC with a 9-way RS-232 D-Type connector. If the PC
does not have this connector, a USB to RS-232 adaptor can be fitted at the
PC end. An adaptor, part number BI-K17132, is available from Kittiwake
Developments Ltd.
Run a suitable terminal emulator on the PC (such as „Tera Term‟ or „Hyper

Terminal‟) and set it up as follows:
Bits per second 9600 Stop bits 1

Data bits 8 Flow control None
Parity None
If in doubt consult your IT technician. If the D-type cable is connected and the
terminal emulator correctly set up, data will be transmitted whenever the
36
Transmit button is pressed. The transmitted data will be in .csv format by

default but this may be modified by the user. See Section 5.4.4.2.
5.7.2 Storing On The USB Flash Drive

The ANALEXpqL can store results data onto the supplied USB Flash Drive, or
any other USB flash drive formatted as a Removable Drive. The data is all
stored in a single text file named as follows:
testresults.dat
If the USB Flash Drive is connected (leave it for at least 5 seconds once fitted
to ensure it is active), data is appended to this file whenever the Transmit
button is pressed. The appended data will be in .csv format by default but this
may be modified by the user. See Section 5.4.4.2.
5.8 Printing
The optional thermal printer (FG-K18300-KW) can be connected to the
ANALEXpqL via a USB port. When connected, pressing Print will produce a
hard copy of the results. The printer kit contains 1 roll of paper. Additional paper
is available. See Section 3.7
5.9 Shut Down

From the Main Menu, press and hold the Shut Down button for 3 seconds. If
you are sure you want to shut down, when asked Press the “Yes” button. Do not
remove the power until instructed to do so.
The ANALEXpqL is not fitted with a switch to help protect the instrument from
accidental power down which may cause loss of data or instrument damage.
37
6 Troubleshooting
Symptom Possible cause Solution
Make sure the ANALEXpqL is located away

Interference from from sources of magnetic fields such as
adjacent objects heavy machinery, motors, transformers and
heavy power cables.
Ensure that there is no external

contamination of the sample bottle or grease
Unclean instrument pot with oil or metal particles. If necessary
wipe the bottle or pot with a clean tissue
before measuring.
Results are
erratic Make sure the sample temperature is stable
Changing temperatures before measuring. The sensor head is very
sensitive to temperature changes.
Irregular sample Ensure the carousel is firmly pressed into

positioning position.
Printed labels may Remove labels from close to sensor. Use a

contain magnetic iron thermal printer instead of a laser or ink-jet
oxide and carbon black printer.
In order to get consistent results always

ensure the same sampling routine is followed
Results are This is a result of and that the same time period is used
particles settling in the between taking the sample and measuring
changing with
sample due to gravity on the meter. Utilise the rate of change as an
time and is normal. indicator of debris particle size in the sample.
The faster the change, the larger the
particles.
Ensure the sample is homogenous and that

any ferrous debris is evenly distributed
throughout. For highest accuracy, before
Poorly mixed sample
taking measurements place all samples on a
Results are different mechanical mixer for more than 30 seconds
every time the to ensure a homogeneous mix is attained.
sample is tested
Make sure the ANALEXpqL is located away
Interference from from sources of magnetic fields such as
adjacent objects heavy machinery, motors, transformers and
heavy power cables.
38
Remove the carousel and ensure its

Carousel is not underside is clean. Also clean the platen,
Unclean instrument
aligning especially the small alignment sensor near
the perimeter.
Shut down and remove the carousel and

ensure its underside is clean. Also clean the
Unclean instrument
platen. When replacing the carousel, push
firmly.
Carousel is not
turning correctly Before switching on, check the carousel is
able to rotate by manually turning it without
Carousel pushed down
excessive force. If it is difficult to rotate by
to hard
hand, remove the carousel again and use
less force when replacing it.
The ANALEXpqL takes a few moments to

New hardware has register which hardware has been
recently been connected connected. Wait for 5 seconds and retry
input.
Touchscreen is The ANALEXpqL takes a few moments to set

The date and time has
up the new time and date. Wait for 30
not registering been changed
seconds and retry input.
inputs
The only method of shutting down is by
removing the power. Ensure the instrument
Instrument has
has been in an inoperable state for more
malfunctioned
than 2 minutes, then remove the power for at
least 10 seconds. Restart the instrument.
Ensure the instrument has been left to

stabilise for at least 2 hours after being
switched on.
Calibration keeps
Changing temperatures
failing
Ensure both standards are at a stable room
temperature and have not been resting on a
cold surface.
Low Memory Warning Batch ID name contains Press the BACK button repeatedly until the
appears when the following characters message disappears and then press
pressing Save & Exit which are not permitted: Exit (No Save).
from Measure Screen Repeat measurements with a suitable Batch
\ / : * ?.” < > |
yet there are not ID name that does not contain these
many files to delete characters
39
The cable supplied is a Null Modem Cable

which is wired differently to a standard serial
Incorrect cable used
communications cable. Ensure that the
supplied cable is used.
Incorrect set up See section 5.7.1

RS-232 serial
communication is not
working
Commands are not typed All remote messages must be typed using
using capital letters capital letters.
Commands are not being Press carriage return. NB sometimes the

followed by a carriage command will not appear on the terminal
return screen until carriage return is pressed.
The following 2 files

cannot be renamed:
-
Z CALIBRATION DATA
Z CURVE
Unable to Rename
File in Data Manager Newly entered Batch ID
name contains the
following characters that Choose a name that does not include these
are not permitted: characters
\ / : * ?.” < > |
40
Appendices
A. Remote Measure Commands

The following commands are available when in Remote Measure Mode. Each
must be entered into the terminal emulator on the remote PC using CAPITAL
LETTERS followed by a carriage return. The command typed may not be seen
on the screen until carriage return is pressed.
Command Description
Return the Serial Number of the ANALEXpqL in the format WHOPQL123456,
WHO
where the serial number is 123456.
Carry out a single measurement and return the result in the format
MEAS MEAS+VALUE, for example MEAS+00750 where the PQ index is 750PQ.
Any text string following this command (before pressing carriage return) is
displayed on the touchscreen display. For example, command
DSPL DSPLANALEXpqL will display "ANALEXpqL" on the touchscreen display. A
maximum of 4 lines of 20 characters may be displayed.
From the Main Menu, enter the Remote Measurement Mode. Use this command
SETRC rather than pressing the touchscreen “REMOTE” button when running remote
software to control the instrument.
EXITRC Exit the Remote Measurement Mode.
RES Reset the carousel to its home position. Once complete, RES,OK is returned.
Query Status. Returns any active alarm messages: QS,01 to QS,09.

QS
Else QS,OK is returned.
ALIGN Realign the carousel. Once complete, ALIGN,OK is returned.
CAL Place the instrument into the calibration mode ready for further commands.
Once in calibration mode, this command commences measurement of the 0PQ
CAL0PQ Standard. Once complete, CAL0PQ,OK is returned.
Once the response CAL0PQ,OK has been received, commence
measurement of the 750PQ Standard using this command. CAL750PQ,OK
is returned after initial measures are made. The instrument automatically
continues to make further accuracy checks using the 750PQ Standard. If the
checks are successful CAL,OK is returned and the results are saved. The
CAL750PQ instrument then exits the CAL mode. If accuracy is unacceptable,
CAL,ALInvalid PQ Index is returned. The Calibration is aborted and
the instrument exits the CAL mode. With this response, remove the error
message from the touchscreen by using the commands EXITRC and then
SETRC.
41
Kittiwake Developments Ltd Kittiwake Asia Pacific
3 - 6 Thorgate Road Littlehampton E-8-6 Block E Megan Avenue 1
West Sussex BN17 7LU United Kingdom 189 Jalan Tun Razak Kuala Lumpur 50400 Malaysia
Tel: + 44 (0)1903 731470 Tel: +60 (3) 2333 8906
Email: [email protected] Email: [email protected]
Web: www.kittiwake.com Web: www.kittiwake.com
Kittiwake GmbH Kittiwake Americas

Marie-Curie-Str. 5 5177 Richmond Avenue Suite 1145
25337 Elmshorn Germany Houston TX 77056
Tel: +49 (4121) 700 890 Tel: +1 713 255 7255
Email: [email protected] Email: [email protected]
Web: www.kittiwake.de Web: www.kittiwake-americas.com
Kittiwake Proactive Technologies Pvt Ltd

405 Ansals Majestic Tower 17, Block G1
Vikas Puri Community Centre
New Delhi 11008 India
Tel: (+91) 11 65356292
Email: [email protected]
MA-K18063-KW Issue 9 Web: www.kittiwake.com

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PQ® Technology Ferrous Debris Monitor

Installation and Operation Manual

5.4.1 Calibrate .........................................................................................29

= Note – Important information and helpful hints and tips

For General Enquiries, please contact:

Do Not Discard This Manual

Unrestricted by particle size or distribution, combined with speed and ease of

Condition monitoring of machinery lubricants is an established method of

The ANALEXpqL is not designed to make absolute measurements on debris

Magazine (Non standard option. Special order only)

Remote ► Allows remote control from an external PC

1.3.1 Cleaning The Main Enclosure

1.3.2 Cleaning The Touchscreen

1.3.3 Cleaning The Carousel

1.4 Calibration, Maintenance & Service

For continued performance, Kittiwake recommends that the ANALEXpqL is

1.5 Practical Hints

When an oil sample (either in a plastic pot or in a bottle) is in the measurement

It is important that sample pots sit correctly on the measurement sensor

1.6 ‘PQ Index’ Versus ‘PPM Of Iron’

1.7 How Useful Is Measurement For Iron Only?

! Caution! This equipment must be operated by qualified persons only.

The ANALEXpqL is designed for the measurement of oil or grease samples

! All values are displayed in PQ units unless otherwise stated.

Measurement Range 0 – 5000PQ

Accuracy † ±4PQ or 1% [whichever is greater]

Minimum PQ Detection 1PQ

Cycle Duration 4.2 seconds

Ingress Protection Rating IP20

Product Life In excess of 4 million operations

Fuse Rating 1.6A, 250V, 5x20mm Antisurge Fuse

Supply Voltage Range 24V dc ±10%

3.3 Rear Panel

Fuse Holder 2 x USB Ports

RS-232 Serial Port PS/2 Port

Pot Adaptor Bottle Adaptor

3.5 Part Numbers

ANALEXpqL Standalone Instrument

Kittiwake Part No. Description Notes

FG-K3-207-KW 100ml Sample Bottles & Lids Pack of 288

Kittiwake Part No. Description Notes

FG-K16062-KW 5ml Pot Adaptor

Kittiwake Part No. Description Notes

FG-K18300-KW Thermal Printer Kit

4 Starting To Use The ANALEXpqL

 Make sure any computers, monitors or other instruments are at least 1m

 Ensure jewellery is at least 20cm away from the instrument whilst

4.2 How To Ensure Accuracy And Optimum Performance

4.3 Connecting The Power Supply

4.4 Sampling And Sample Preparation

4.4.1 Grease Samples

Care should be taken to ensure a representative sample is taken. The wear

4.4.2 Oil Samples

5ml Oil/Grease Sample Pot 100ml Oil Sample Bottle

4.4.3 Using Sample Bottles And Sample Pots

Bottles may be measured upright (base down) or in an inverted position (lid

There is an inverse relationship between the measured PQ Index and the

Flat base or lid

X Concave lid or base

X Convex lid or base