WEARDETECT
The oil knew first
Real-time ferrous wear debris monitoring, from the sump plug.
Oil-lubricated machinery does not usually fail without leaving evidence behind. Gears, bearings and other components shed wear particles into the oil as they deteriorate. The difficulty is seeing that evidence early enough.
From industrial gearboxes and power-generation equipment to mining machinery, transport and renewable-energy assets, WearDetect puts condition information inside the machine rather than waiting for the next sample to come back.
Magnetic debris capture
Measures fine and coarse debris
Water presence and oil temp
Continuous or alert output
Analogue or digital output
4-20mA, 0-10V, CANbus, Modbus
- Sump plug or bypassReplaces the existing sump plug, or fits an oil bypass line
- Oils, fuels and coolantsThe fluids named in the current product information
- Local display optionRead debris levels at the machine with WearDetect with Display
- No moving partsNothing mechanical in the sensor itself
The measurement challenge
Between samples, the machine keeps changing
Oil analysis is valuable. It is not continuous. A sample taken today tells you what the machine looked like today. Wear that begins tomorrow can continue developing for weeks before the next sample is taken, sent away, analysed and returned.
That gap matters most when the equipment is expensive, remote or difficult to access. A gearbox on a production line can stop an entire process. A mining machine can be operating far from a workshop. A power-generation asset can contain critical rotating equipment in a location where access itself carries a cost.
WearDetect closes the gap between periodic inspection and what the machine is doing now. It continuously captures ferrous debris from the oil, allowing changes in wear to become part of the condition-monitoring picture while the equipment remains in operation.
Measured in the oil
Ferrous debris captured directly from the oil circuit, continuously.
Fine and coarse
Distinguishes fine from coarse ferrous debris, rather than a single count.
Water and temperature
Reports water presence and oil temperature from the same point.
Analogue or digital
0-10V, 4-20mA, CANbus or Modbus RTU into your existing system.
INSTALLATION
Built around the machine, not around a laboratory sample
WearDetect can be installed in two principal ways:
Sump plug installation
The sensor replaces the existing sump plug, placing the measurement directly in the oil circuit.
Oil bypass installation
Where a suitable sump-plug position is unavailable, WearDetect can be installed in an oil bypass circuit.
The electronics are housed separately on the standard version, providing greater flexibility where space around the sensing point is restricted.
Tell us the machine, fluid and installation arrangement and we can help determine the appropriate configuration.
Choose your WearDetect
One sensing technology. Different ways to use the information.
Both versions use the same magnet, the same fine and coarse debris measurement and the same output options. What changes is where you read the result.
WearDetect
For installations where the measurement feeds an existing control or condition-monitoring system. Oil debris sensor with a separate electronics enclosure.
WearDetect with Display
For applications where the debris measurement needs to be read directly at the machine. The same sensing technology with an integrated display.
No single WearDetect does all of that. Our team can suggest a pairing.
WearDetect does not require a separate monitoring ecosystem. Outputs include 0-10V, 4-20mA, CANbus and Modbus RTU, so the sensor can feed existing PLCs, SCADA systems, condition-monitoring platforms or other control architectures. The standard product uses a separate electronics enclosure, giving installation flexibility where the sensing point itself has limited space.
WearDetect connected into a remote condition-monitoring platform, allowing wear trends to be viewed away from the machine. It is an integration route, not a separate sensor. Make an enquiry about connecting it.
Choosing between them
The question is where you need to see it
Everything else is common to both. The magnet, the fine and coarse debris measurement, water and temperature, and the output options are the same on each. WearDetect supersedes the earlier 1599 oil debris sensor, which is supported for its installed base.
| Specification | Feeds a monitoring systemWearDetect | Read at the machineWearDetect with Display |
|---|---|---|
| Choose it when | The data goes straight to a monitoring system and no local display is needed | Somebody needs to read debris levels standing at the machine |
| Measures | Captured fine and coarse ferrous debris | Captured fine and coarse ferrous debris |
| Also reports | Water presence, oil temperature | Water presence, oil temperature |
| Electronics | Separate enclosure | Integrated display |
| Analogue output | 0-10V or 4-20mA | 0-10V or 4-20mA |
| Digital output | CANbus or Modbus RTU | CANbus or Modbus RTU |
| Installation | Smart sump plug replacement, or oil bypass line | Smart sump plug replacement, or oil bypass line |
| Fluids | Oils, fuels and coolants | Oils, fuels and coolants |
| Datasheet | Datasheet | Datasheet |
The technology
A magnet at the heart of the measurement
WearDetect uses a powerful magnet to capture ferrous particles suspended in the oil. The sensor monitors the debris captured and distinguishes fine and coarse ferrous particles, providing a more informative picture than a simple particle count.
Fine debris and coarse debris tell different stories. The sensor can also report water presence and oil temperature, giving additional information from the same measurement point.
What it detects
One measurement point. More information about what is happening inside the machine.
The result is not a diagnosis by itself. It is another source of evidence that can be combined with oil analysis, vibration, temperature, operating history and other condition-monitoring data.
A change in the amount or character of captured debris can provide a reason to investigate, correlate the measurement with other condition data and decide whether maintenance action is required.
Outputs your system reads
0-10V, 4-20mA, CANbus or Modbus RTU, chosen to match the PLC, SCADA or condition-monitoring platform it feeds.
See integration →Calibration software
Software support for WearDetect installations, alongside the datasheet, manual and engineering support.
View software →Part of a wider programme
WearDetect sits alongside laboratory oil analysis and vibration monitoring rather than replacing them.
What it is not →See it work
WearDetect, catching failure while it is still small
Two short films on oil debris monitoring, and what it tells you before a gearbox tells you itself.
Failure starts small
Built in Britain. Trusted worldwide.
Prefer to watch them together? Watch them all on the Gill Group channel
What it measures
WearDetect technical specifications
| Specification | WearDetect | WearDetect with Display |
|---|---|---|
| Measures | Captured fine and coarse ferrous debris | Captured fine and coarse ferrous debris |
| Also reports | Water presence, oil temperature | Water presence, oil temperature |
| Non-ferrous debris | Not the target measurement | Not the target measurement |
| Water detection | Minimum 10 per cent free water | Minimum 10 per cent free water |
| Analogue output | 0-10V or 4-20mA | 0-10V or 4-20mA |
| Digital output | CANbus or Modbus RTU | CANbus or Modbus RTU |
| Electronics | Separate enclosure | Integrated display |
| Installation | Smart sump plug replacement, or oil bypass line | Smart sump plug replacement, or oil bypass line |
| Fluids | Oils, fuels and coolants | Oils, fuels and coolants |
| Moving parts | None | None |
| Datasheet | WearDetect Iss 11 | WearDetect with Display Iss 9 |
Debris measurement range and resolution, accuracy, supply voltage, operating temperature range and IP rating are held on the released datasheet, WearDetect Iss 11 and WearDetect with Display Iss 9, and are not reproduced here. Ask for the current issue before specifying.
WearDetect complements your condition-monitoring programme. It is not intended to replace laboratory oil analysis or vibration monitoring, and it measures ferrous debris, so non-ferrous wear requires other techniques. Its value is different: continuous visibility between samples. Water detection is designed to identify significant free water rather than trace moisture, with detection from around 10 per cent free water. Water detection is not available when the sensor is fitted with an NPT thread adaptor.
Applications
Where an unplanned stop costs more than the sensor
WearDetect is designed for oil-lubricated machinery where developing wear matters and access, downtime or recovery carries a significant cost.
Renewable energyWind turbines place machinery in locations where maintenance access can be difficult and expensive. WearDetect provides continuous ferrous debris monitoring for oil-lubricated drivetrain and generation equipment.Drivetrain and machinery condition →
Industrial process plantA failed gearbox can stop more than the gearbox. Continuous debris information lets developing mechanical wear become part of the maintenance decision rather than being discovered after an unexpected stoppage.Industrial process →
MiningMining machinery can operate in remote environments where recovery and repair are expensive. Continuous debris monitoring provides condition information at the machine rather than relying solely on periodic sampling.Mining, quarrying and cement →
TransportEngines and gearboxes accumulate wear according to how they are operated. WearDetect provides continuous ferrous debris information between scheduled services.Rail and rolling stock →READING THE TREND
See the difference between wear and worsening wear
WearDetect distinguishes between fine and coarse ferrous debris, rather than treating every captured particle as equivalent.
That gives engineers another dimension of information when watching a machine over time.
A single reading is useful. A trend is more useful.
A change in the amount or character of captured debris can provide a reason to investigate, correlate the measurement with other condition data and decide whether maintenance action is required.
The principle of detecting deterioration through debris is particularly interesting in renewable energy. In one wind farm application, a standard WearDetect fitted in a generator’s cooling air picked up ferromagnetic debris from loosening stator wedges, with both the accumulated debris and an accelerating accumulation rate used as warning signs. Read application note AN0064.
Failure leaves evidence before failure becomes the event.
RENEWABLE ENERGY
The gearbox can start telling you before the turbine does
A wind turbine can continue generating while mechanical deterioration develops inside its drivetrain.
The challenge is not simply detecting failure. It is getting useful information early enough to investigate what is changing and plan the response.
WearDetect monitors ferrous debris in lubricating oil, providing continuous information about developing wear in gearboxes and other oil-lubricated machinery.
See the wear before it becomes a maintenance event.
Accessories
WearDetect accessories
Sensor head fittings, inflow adaptors and set-up kit for WearDetect. Pick a model to see only the parts that fit it.
Order a fitting. Every WearDetect installation needs a sensor head fitting to suit the port it screws into. It is ordered separately.
Showing all 17 parts
Sensor head fittings
Required- Sensor head fitting, M20 x 1.5
- Sensor head fitting, M22 x 1.5
- Sensor head fitting, M24 x 2.0
- Sensor head fitting, 1/2 inch BSPP
- Sensor head fitting, 3/4 inch x 16 UNF
- Sensor head fitting, 1/2 inch NPT
- Sensor head fitting, 3/4 inch NPT
- Sensor head fitting, 1 inch NPT
- Sensor head fitting, 1 1/4 inch NPT
- Sensor head fitting, 1 1/2 inch NPT
- Sensor head fitting adaptor kit
Installation
- Inflow adaptor kit, 1 inch
- Inflow adaptor kit, 1.5 inch
- Inflow adaptor for the M20 x 1.5 sensor
- Sensor conduit kit, sensor to electronicsFits WearDetect with display
Set-up and configuration
- USB to micro USB cable, 1.8 m
Spares
- Debris demonstration strip
Order accessories with your sensor or on their own. Quote the part number when you get in touch.
Technical resources
Everything you need to specify, install and configure WearDetect
Questions
Frequently asked questions
Where can WearDetect be installed?
WearDetect can be installed as a sump-plug replacement or within an oil bypass circuit. The appropriate arrangement depends on the machine and oil system.
Does WearDetect detect non-ferrous wear?
No. The WearDetect sensing principle uses a magnet to capture ferrous particles, so non-ferrous debris is not the target measurement. Where non-ferrous wear is important, WearDetect should be used alongside other monitoring techniques.
Does WearDetect replace laboratory oil analysis?
No. WearDetect complements laboratory analysis by providing continuous information between samples. Laboratory analysis can provide information that WearDetect does not, including characteristics outside its ferrous-particle measurement.
What outputs are available?
WearDetect supports 0-10V and 4-20mA analogue outputs, together with CANbus and Modbus RTU digital outputs. The exact configuration should be confirmed against the current product specification.
What is the difference between WearDetect and WearDetect with Display?
Both use the same core sensing technology. WearDetect has a separate electronics enclosure and is intended to feed an external monitoring system. WearDetect with Display adds an integrated local display for applications where the measurement needs to be viewed at the machine.
Can WearDetect be used on a wind turbine?
WearDetect can be considered for oil-lubricated drivetrain and generation equipment where continuous ferrous debris monitoring is relevant. The machine, oil system, installation arrangement and monitoring architecture should be reviewed before specification. For a generator example, see application note AN0064.
How does WearDetect help with predictive maintenance?
WearDetect provides continuous information about captured ferrous debris, allowing changes in the measurement to be monitored between scheduled inspections and oil samples. It does not predict every failure by itself. It provides additional evidence that can support maintenance decisions.
How much water can WearDetect detect?
The current product information specifies a minimum of around 10 per cent free water. WearDetect is intended to identify significant free water rather than trace moisture. Water detection is not available when the sensor is fitted with an NPT thread adaptor.
What information do you need to specify WearDetect?
The useful starting point is the equipment, fluid, installation arrangement and monitoring system. From there, Gill can advise on the sensing configuration, fitting and output requirements.
Have an application to discuss?
Speak to our team
Tell us what you need to measure, where and under what conditions. We’ll help you work out the appropriate approach.
Enquiring about WearDetect
- Our team replies. Not an account manager, and not a queue.
- We aim to respond in one working day. Monday to Friday.
- No obligation. Just honest advice on whether Gill is the right fit.