Sensyn · Hydraulic Oil Cleanliness
HYDRA
Inline Particle Counter for Lubricating & Hydraulic Oil
Particles down to 1 µm. Classified into ISO 4406, NAS 1638, and GJB 420B — automatically, continuously, inline. No sampling. No lab. Just a compact sensor with a display that tells you exactly how clean your oil is, right now.
1 µm
Detection Threshold
8
Size Bins
~5 sec
Response Time
3
ISO Standards
The Problem
You can’t see particles.
But your hydraulics feel every one.
Hydraulic and lubrication systems are precision instruments. A handful of invisible particles — measured in microns — can degrade valves, score bearings, and block servo circuits. Contamination is the #1 cause of hydraulic system failure, yet most operators only find out after the damage is done.
Invisible damage
Particles as small as 4 µm cause silting in servo valves. 14 µm particles score bearings and accelerate fatigue wear. You can’t see them — but the equipment can feel them.
Blind filter changes
Without real-time particle data, filters are changed on schedules — not condition. You’re either changing too early (wasting money) or too late (allowing contamination through).
Lab lag
Bottle samples sent to labs take days. By the time the ISO code comes back, contamination levels have already changed — and so has the risk profile of your equipment.
HYDRA replaces guesswork with continuous, ISO-certified particle counting — inline, real-time, from a compact sensor with a built-in display.
How It Works
Light goes in. Particles block it.
HYDRA counts what got through.
ISO-certified light-blockage (light-shading) technology based on ISO 4402/11171. Oil flows through the sensor, particles interrupt the beam, and HYDRA classifies each one by size — automatically, continuously.
Optical Blockage
ISO 4402/11171 certified
Particles block a precision light beam, causing signal drops proportional to particle size.
Pulse Height Analysis
8 size bins · 1–100 µm
Each pulse is binned into size classes (>4 µm, >6 µm, >14 µm, etc.) for granular contamination profiling.
Flow Compensation
Internal flowmeter
Built-in flowmeter ensures accurate counts even under varying flow rates. Stable, repeatable results every time.
Auto Cleanliness Coding
ISO 4406 · NAS 1638 · GJB 420B
Generates cleanliness codes automatically and enables threshold alerts matched to OEM specifications.
Capabilities
More than a counter.
HYDRA doesn’t just count particles — it classifies, trends, and interprets contamination to drive proactive maintenance decisions.
Size Distribution Histogram
Categorizes particles by size to detect the dominant wear mode — abrasive cutting vs. fatigue spalling — so you know what’s failing, not just that contamination exists.
Trend Monitoring
Tracks individual size-bin trends over time to identify early wear escalation — catching gradual filter degradation or sudden contamination events before they reach critical levels.
AI-Based Oil Health Index
Combines particle count, size distribution, rate of change, and flow data into a single cleanliness score — one number that tells you if the system is healthy or heading for trouble.
Filtration Efficiency Estimation
Compare upstream vs. downstream particle counts to assess filter performance. Replace on condition, not on schedule — reducing consumable costs while maintaining cleanliness.
OEM Threshold Alarms
Set cleanliness targets per OEM specs and get alerted the moment ISO codes exceed acceptable limits. Configurable thresholds for each size class.
RS-485 / SCADA Integration
Modbus RTU output feeds directly into PLC/SCADA systems. Optional 4–20 mA analogue output for legacy integration. Data where your control system already lives.
Specifications
Compact. Industrial. Always on.
A small sensor with a built-in display. Mounts inline on the oil circuit, reads particles continuously, and outputs cleanliness codes to your control system.
Particle Size Detection
1–100 µm, multi-channel
Cleanliness Standards
ISO 4406 · NAS 1638 · GJB 420B
Flow Rate
10–300 mL/min (opt. 25 mL/min)
Response Time
~5–60 seconds
Data Output
RS-485 Modbus RTU + 4–20 mA
Ambient Temperature
−20 °C to 60 °C
Fluid Temperature
Up to 80 °C
Pressure Handling
2 MPa (40 MPa with reducer)
Applications
Wherever hydraulic cleanliness is critical.
HYDRA monitors lubricating and hydraulic oil systems across industries — from nacelles 100 metres in the air to hydraulic presses on the factory floor.
Wind Turbine Gearboxes
Continuous gearbox oil monitoring in remote nacelles. Detect bearing wear and filter degradation before a technician needs to climb the tower.
Hydraulic Circuits
Manufacturing hydraulic presses, injection moulding, CNC machines. Protect servo valves and actuators from silting and scoring.
Marine Hydraulics
Deck machinery, steering gear, and cargo handling systems. Keep ISO codes within class requirements and prevent off-hire events.
Aviation-Grade Fluids
Ground support equipment, helicopter gearboxes, and flight-critical hydraulic systems where cleanliness compliance is non-negotiable.
Get Started
Stop guessing your ISO code.
HYDRA mounts inline, reads continuously, and displays your cleanliness code on a compact built-in screen. RS-485 output to PLC/SCADA included. One sensor — total particle visibility.
sales@sensyn.in · Compact inline sensor with built-in display