Online Particle Counter - QualiOPC™ OL1

Online Particle Counter – QualiOPC™ OL1

Continuous contamination monitoring is critical where fluid cleanliness directly impacts system reliability. The QualiOPC™ OL1 is an online particle counter designed for real-time measurement of particulate contamination in hydraulic oils, lubricating oils, and a wide range of industrial fluids. It uses semiconductor laser optics with the light-blocking detection principle to deliver consistent particle count data while systems remain in operation.

Built for uninterrupted online monitoring, this model integrates smoothly into industrial condition monitoring setups. It provides real-time cleanliness grading along with stable, repeatable measurements, making it suitable for applications where ongoing insight is required rather than periodic sampling.

The QualiOPC™ OL1 supports automated continuous detection with configurable test intervals and live flow monitoring. Communication flexibility is supported through RS485 and RS232 interfaces, with optional 4–20 mA output for process integration. Data storage via USB allows convenient result logging, while an optional water activity sensor enables detection of micro-level moisture content in oil systems.

Designed as a compact solution for on-site continuous monitoring, the Online Particle Counter – QualiOPC™ OL1 tracks particle concentration and cleanliness trends in real time. This helps maintenance teams identify developing contamination issues earlier and respond quickly, improving operational stability without disrupting system performance.

The instrument integrates a semiconductor laser, high-precision sensing components, and a light-blocking measurement system within a durable aluminum housing. Its construction is optimized for demanding industrial environments, offering strong resistance to electrical interference, elevated temperatures, and pressure variations, making it suitable for harsh operating conditions where reliability is essential.

Online Particle Counter – QualiOPC™ OL1 Applications

Hydraulic Systems:
QualiOPC™ OL1 is well-suited for continuous contamination monitoring in hydraulic circuits. It provides real-time particle data that supports maintenance planning, helps track contamination trends, and reduces the risk of wear-related damage to critical components.

Lubrication Monitoring:
The system is designed for use in lubrication networks such as turbine oils, compressor systems, gear oils, and bearing lubrication lines. It supports continuous oil cleanliness tracking, making it valuable for reliability-focused maintenance programs and equipment protection strategies.

Industrial Manufacturing:
In production and process environments, QualiOPC™ OL1 delivers continuous online cleanliness information that supports quality control and maintenance decision-making. With multiple communication interfaces, it can be integrated into plant-wide monitoring and automation systems for streamlined data flow.

Power, Heavy Equipment, and Marine Applications:
The instrument is suitable for demanding operational environments across power generation, heavy machinery, transportation, and marine systems. It provides reliable contamination monitoring in conditions where equipment performance, system stability, and operational continuity are critical.

Standards

QualiOPC™ OL1 aligns with internationally recognized fluid cleanliness and particle contamination standards used in industrial, power, and aerospace applications.

• ISO 4406 – Defines fluid cleanliness coding based on particle count levels in hydraulic and lubrication systems.

• NAS 1638 – Provides a classification system for contamination levels in aerospace and high-precision fluid systems.

• SAE AS4059 – Establishes cleanliness classification for aerospace and industrial fluid applications based on particle distribution.

• ISO 4402 – Historical calibration reference standard for liquid automatic particle counters.

• ISO 11171 – Current calibration and verification standard for automatic particle counting instruments, ensuring measurement accuracy and traceability.

• ROCT 17216 – Russian standard for particle contamination classification in working fluids used across industrial systems.

Online Particle Counter – QualiOPC™ OL1 Key Features

QualiOPC™ OL1 is designed for continuous, real-time monitoring of particle contamination in hydraulic and lubrication systems, providing consistent insight into fluid cleanliness without interrupting operation.

• Real-time online monitoring enables continuous tracking of particle contamination in hydraulic and lubrication circuits.

• Semiconductor laser light source combined with a light-blocking detection method ensures fast response and stable particle measurement.

• High-precision particle sensor delivers strong resolution and reliable particle counting performance.

• Automatic continuous detection with configurable sampling intervals for flexible monitoring cycles.

• Real-time flow monitoring provides visibility of fluid conditions as they pass through the sensing zone.

• Multi-standard cleanliness compatibility with configuration options to match application needs. Key reference standards include ISO 4406, NAS 1638, SAE AS4059, ISO 4402, ISO 11171, and ROCT 17216 for North American and international use cases.

• Calibration support aligned with ISO 4402 and ISO 11171 for measurement consistency and traceability.

• Communication interfaces including RS485, RS232, and optional 4–20 mA output for integration with PLCs, industrial systems, and monitoring platforms.

• USB-based data export and onboard storage for easy reporting and record keeping.

• Optional water activity sensor enables detection of micro-level moisture in oil systems.

• Rugged aluminum housing provides strong resistance to electrical interference, temperature variations, and pressure fluctuations.

• Compact design allows installation in space-constrained online monitoring points across industrial systems.

Theory and Method

QualiOPC™ OL1 operates using the light-blocking principle, also known as the shading method. In this approach, particles suspended in the fluid pass through a focused laser sensing zone and temporarily interrupt the light beam. These interruptions are converted into electrical signals, which are then processed to determine particle size distribution and total particle count.

This measurement principle is widely used in fluid cleanliness analysis due to its fast response time, strong immunity to external interference, consistent repeatability, and high level of measurement accuracy.

QualiOPC™ OL1 is engineered for continuous online monitoring rather than batch sampling. It continuously analyzes flowing fluids, delivering real-time particle contamination data and cleanliness grading without interrupting system operation. Users can configure detection intervals according to application requirements, allowing flexible monitoring strategies.

In addition, the system includes real-time flow monitoring through the sensing channel, ensuring stable measurement conditions and improving data reliability during long-term operation in hydraulic and lubrication systems.

Online Particle Counter - QualiOPC™ OL1 Technical Specification

Parameter	QualiOPC™ OL1
Product Name	Online Particle Counter
Model	QualiOPC™ OL1
Light Source	Semiconductor laser
Detection Principle	Light-blocking / shading method
Particle Size Range	1 μm–600 μm, depending on selected sensor
Sensitivity	1 μm (ISO 4402) or 4 μm(c)
Counting Volume	10 mL
Counting Accuracy	±1 pollution level
Test Sample Temperature	0°C to 80°C
Operating Temperature	-20°C to 60°C
Storage Temperature	-30°C to 80°C
Voltage	DC 9 V or DC 12–36 V
Detection Channels	8
Fixed Particle Sizes	1, 2, 5, 10, 15, 25, 50, 100 μm or 4, 4.6, 6, 10, 14, 21, 38, 70 μm(c)
Flow Rate Range	10–50 mL/min or 50–300 mL/min
Online Test Pressure	0.2–10 MPa; optional pressure-reducing device up to 40 MPa
Result Storage	USB interface to USB disk
Dimensions	100 × 75 × 70 mm
Weight	About 1 kg
Communications	RS485 or RS232; optional 4–20 mA
Optional Feature	Water activity sensor for micro-water content in oil