CONDITION MONITORING
Know what is wearing before the machine tells you
Oil carries evidence. As lubricated machinery wears, ferrous particles enter the oil. Their size, quantity and progression can provide an indication of what is happening inside the machine long before a failure becomes obvious.
Gill WearDetect monitors that debris continuously, in real time, helping maintenance teams understand changing machine condition and make decisions based on what the oil is telling them.
Simulated machine. Move your pointer right to speed up the wear.
- Real-time ferrous debrisMonitored continuously in the lubricating oil
- Fine and coarse particlesDistinguished separately, so the trend shows what is wearing
- Water and oil temperatureMonitored alongside the debris
- Integrates with plant control0-10 V, 4-20 mA, CANbus or Modbus RTU
The technology
The oil knows more than the maintenance schedule does
Routine maintenance works to a timetable. Condition monitoring looks at what is actually happening inside the equipment.
WearDetect detects ferrous debris carried in lubricating oil and distinguishes between fine and coarse particles. It also monitors water presence and oil temperature, providing additional information about the condition of the lubrication system.
The result is a continuous stream of condition data rather than a periodic snapshot.
Fine ferrous debris
Small wear particles that can indicate developing mechanical deterioration.
Coarse ferrous debris
Larger particles that can provide evidence of more significant wear.
Water presence
An indication of water contamination within the lubricating oil.
Oil temperature
Context for the condition of the lubrication 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.
The product
One sensor. A window into machine condition.
WearDetect detects and reports fine and coarse ferrous debris in real time, alongside water presence and oil temperature. That makes it possible to monitor changes in the oil continuously rather than relying solely on scheduled inspection or taking samples after a problem has already developed.
WearDetect
WearDetect is an oil debris sensor designed for continuous monitoring of ferrous wear particles in lubricated machinery. It feeds an existing control or condition-monitoring system.
WearDetect with Display
The same sensing technology with an integrated display, for applications where the debris measurement needs to be read directly at the machine.
No single Condition monitoring 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.
Choosing between them
The question is where you need to see it
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 |
| Datasheet | Datasheet | Datasheet |
Why monitor wear?
Failure is an event. Wear is a process.
Mechanical failure rarely begins at the moment the machine stops. Wear develops over time. Particles enter the lubricant, accumulate and change as components deteriorate.
Monitoring the oil gives maintenance teams a way to observe that process while the machine is still operating. That can support a shift from purely scheduled maintenance towards decisions informed by the actual condition of the equipment.
From data to decision
A warning is useful. A trend is better.
A single measurement tells you what is happening now. Continuous monitoring lets you see change. WearDetect provides ongoing information about ferrous debris, water presence and oil temperature, allowing the monitoring system to identify changes over time and helping maintenance teams investigate before deterioration becomes failure.
The value is not simply detecting particles. It is being able to see what is changing inside the machine.
Put the sensor where the evidence passes
Equipment type, lubrication system, oil characteristics, available space and the receiving system all influence how WearDetect should be deployed.
See installation options →The measurement has to reach the team
WearDetect is designed as part of the wider monitoring or control system rather than as an isolated measurement.
See integration →Understand the wear first
Gill's technical resources explore oil-condition measurement, wear debris and the practical side of monitoring lubricated machinery.
Explore knowledge →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
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.
Applications
If it is lubricated, it can be telling you something
WearDetect is intended for oil-lubricated machinery where developing mechanical wear needs to be detected and monitored. The specific application and lubrication system determine the appropriate installation.
EnginesMonitor ferrous debris within lubricating systems to identify changes in machine condition.Construction vehicle engine monitoring →
GearboxesObserve wear particles circulating through the lubricant.Drivetrain and machinery condition →
Rotating machineryMonitor developing wear where unexpected failure carries significant operational consequences.Bearing wear monitoring →
Industrial equipmentAdd continuous condition information to maintenance and asset-management strategies.Mining, quarrying and cement →Specification
The detail that turns a sensor into a specification
| 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 |
| 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 |
| Datasheet | WearDetect Iss 11 | WearDetect with Display Iss 9 |
The WearDetect datasheet provides the detailed information needed for installation and integration, including measurement capability, physical requirements and interface information. Debris measurement range, accuracy, supply voltage, operating temperature and IP rating are held there. For application-specific questions, speak to our team.
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 WearDetect
Questions
Frequently asked questions
What is oil condition monitoring?
Oil condition monitoring uses measurements from lubricating oil to provide information about the condition of the oil and the machinery it is protecting. Gill WearDetect monitors ferrous wear debris, water presence and oil temperature continuously.
What is an oil debris sensor?
An oil debris sensor detects particles carried in lubricating oil. WearDetect specifically detects ferrous particles and reports fine and coarse debris in real time.
What does WearDetect measure?
WearDetect detects fine and coarse ferrous wear particles and monitors water presence and oil temperature.
Why monitor ferrous wear particles?
Ferrous particles are produced as ferrous components wear. Monitoring them continuously can provide information about developing mechanical wear and changes in machine condition.
Can condition monitoring replace scheduled maintenance?
Not necessarily. Condition monitoring provides additional information about machine condition and can support maintenance decisions. How it is used alongside existing maintenance practices depends on the equipment and maintenance strategy.
Where can WearDetect be used?
WearDetect is designed for oil-lubricated machinery such as gearboxes, engines and hydraulic systems, in industrial processes, power generation, transport and mining. It suits oils, fuels and coolants. The machine and lubrication system decide the best fitting point.
Does WearDetect measure oil temperature?
Yes. Oil temperature is monitored alongside ferrous debris and water presence, providing additional context for the condition of the lubrication system.
Can WearDetect be integrated into an existing monitoring system?
The appropriate integration depends on the equipment, installation and receiving system. Gill can discuss the interface and configuration requirements for the application.
How is WearDetect installed?
WearDetect fits in one of two ways. As a smart sump-plug replacement, a thread adaptor goes into the existing drain port and the sensor probe is inserted into the adaptor and secured with a grub screw. In an oil bypass circuit, it is fitted inline using an adaptor kit. The electronics sit in a separate enclosure, so they can be mounted where there is room.
Which thread types does WearDetect fit?
Thread adaptors cover the common drain port types, with 17 thread mounting options across metric, UNF and BSPP profiles, plus NPT. Water detection is not available when the sensor is fitted with an NPT thread adaptor. Tell us the drain port size and thread and we will confirm the right adaptor.
Can I inspect the sensor without draining the oil?
Yes, on an inline installation. The bypass adaptor kit includes isolation valves, so the sensor can be removed for inspection without a full drain-down. An adaptor fitting without valves is also available where isolation is not needed.
Which outputs does WearDetect provide?
WearDetect is available with 0 to 10 V or 4 to 20 mA analogue outputs, or CANbus or Modbus RTU digital outputs, so it can feed a PLC, SCADA or condition monitoring system directly.
Is there a version with a built-in display?
Yes. WearDetect with Display uses the same sensing technology with an integrated local display, for machines where someone needs to read the result at the equipment.
How do I specify WearDetect?
Start with the machine and lubrication system. Useful information includes the equipment type, lubricant, installation point, operating conditions and what the monitoring system needs to receive.
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.
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