Particle Counter Sensor

Particle Counter Sensor – QualiOPC™ 60

The performance of a particle counter sensor directly influences the precision of oil cleanliness and fluid contamination analysis systems. QualiOPC™ 60 is a compact optical sensing module designed for accurate particle sizing and counting in inline, portable, and laboratory-based monitoring solutions.

QualiOPC™ 60 functions as a high-precision analytical sensor that detects solid particles suspended in liquids using the optical light-blocking principle. As particles pass through the sensing zone, variations in the light signal are converted into reliable particle size and count data, enabling consistent contamination measurement across industrial applications.

This sensor is engineered for integration within advanced oil and liquid particle monitoring systems used in predictive maintenance programs, fluid condition assessment, and quality assurance workflows. Its compact and durable construction makes it suitable for both mobile equipment and fixed installations, while supporting internationally recognized cleanliness and calibration standards such as ISO 4402 and ISO 11171.

Built for demanding industrial environments, QualiOPC™ 60 serves as the core sensing component in portable particle counters, inline monitoring systems, and laboratory-grade contamination analyzers where accurate and repeatable particle detection is essential.

The device utilizes semiconductor laser technology combined with the light-blocking method to identify and measure suspended particles across a wide size range. Its cylindrical, space-efficient design supports seamless integration into modern contamination monitoring setups, ensuring stable performance and high measurement reliability.

Particle Counter Sensor – QualiOPC™ 60 Applications

Hydraulic Oil Monitoring:
QualiOPC™ 60 is well-suited for hydraulic systems where continuous monitoring of wear particles and contamination levels is essential for predictive maintenance strategies. It supports early detection of fluid degradation and helps maintain stable system performance.

Lubricating Oil Analysis:
The sensor integrates into systems designed to measure particulate contamination in industrial and mechanical lubricants. It enables accurate assessment of oil cleanliness and provides insight into overall lubricant condition and service life.

Transformer Insulating Oil Testing:
This application supports power generation and transmission equipment by monitoring dielectric fluid cleanliness. It helps ensure insulation reliability and reduces the risk of performance issues caused by contamination.

Gear, Engine, and Aviation Fuel Inspection:
These use cases focus on detecting and analyzing particle contamination in gear assemblies, engine systems, and aviation fuels. It supports verification of fluid purity, helping protect critical components from wear and efficiency loss.

Inline Industrial Fluid Monitoring:
Designed for compatibility with portable and online particle counter systems, QualiOPC™ 60 is also suitable for real-time industrial fluid condition monitoring. It enables continuous contamination tracking when integrated into advanced instrumentation platforms used for process control and system diagnostics.

Standards

ISO 4402 – A reference standard for fluid particle counting calibration, historically used in defining calibration procedures for optical particle measurement systems.

ISO 11171 – An internationally recognized standard for calibration and verification of automatic particle counters, ensuring accuracy and consistency in particle size and count measurements.

ISO 4406 – A widely used cleanliness coding standard that defines contamination levels in hydraulic and lubrication systems based on particle concentration.

NAS 1638 – A classification system used in aerospace and industrial applications to evaluate and grade fluid contamination levels.

SAE AS4059 – An aerospace and industrial standard that defines fluid cleanliness classes based on particle size distribution and concentration.

GOST 17216 (ROCT 17216) – A particle contamination classification standard used for assessing cleanliness levels in technical fluids across industrial systems.

Particle Counter Sensor – QualiOPC™ 60 Key Features

• Optical light-blocking technology for precise liquid particle sizing and counting.

• High-sensitivity optical design that delivers stable measurement performance and strong resolution for contamination detection.

• Fine particle size channel resolution with a representative interval down to 0.1 µm, depending on system configuration.

• Wide application compatibility for portable, inline, and laboratory particle counting systems.

• Compact and durable construction designed for long-term operation in field instruments and fixed industrial installations.

• Calibration support aligned with internationally recognized standards such as ISO 4402 and ISO 11171.

• Semiconductor laser light source for consistent and reliable optical performance.

• Broad particle measurement range from 1 µm to 500 µm.

• High repeatability with RSD below 2%, ensuring consistent measurement accuracy.

• Adjustable flow rate range from 5 to 60 mL/min, with a standard operating rate of 25 mL/min for measurement.

Theory and Method

QualiOPC™ 60 operates on the optical light-blocking principle for liquid particle detection and analysis. When suspended particles pass through the sensing zone, they partially obstruct the laser beam, creating measurable signal variations. These signal changes are processed to determine particle size distribution and particle count data.

This measurement approach is widely used in fluid contamination monitoring due to its ability to directly evaluate solid particles suspended in oils and industrial liquids. It enables reliable assessment of fluid cleanliness in real time and supports consistent monitoring across different system types.

Designed as a high-sensitivity optical sensing component, QualiOPC™ 60 delivers stable operation, fine resolution, and repeatable measurement performance when integrated into portable, inline, or laboratory particle counting systems.

Particle Counter Sensor - QualiOPC™ 60 Technical Specification

Parameter	QualiOPC™ 60
Model	QualiOPC™ 60
Product Type	Particle Counter Sensor
Light Source	Semiconductor laser
Detection Principle	Optical light-blocking method
Particle Size Range	1 μm to 500 μm
Sensitivity	1 μm (ISO 4402) or 4 μm(c) / 4 μm based on ISO 11171
Detection Speed	5 to 60 mL/min, default 25 mL/min
Cleaning Speed	5 to 60 mL/min
Coincidence Error Limit	12,000 to 40,000 particles/mL
Repeatability	RSD < 2%
Sample Temperature	0°C to 80°C
Length	214 mm
Maximum Height	115 mm
Head Diameter	52 mm
Tail Diameter	46 mm
Mounting	Movable fixture, M4 screw mounting
Compatibility	Portable and online particle counter systems
Calibration Support	ISO 4402, ISO 11171