Dr. E. Horn Water in Oil (WiO) system FRG00032

Water in Oil Sensor (WiO)

The Water in Oil system from Dr. E. Horn consists of a sensor FRG00032, a connection box GHG02088-5, a connection cable KSG03244-1, and three relay outputs. Additionally, to the basic standalone version, is the option to get an analogue output for water content and oil temperature, as well as an indicator box with analog indicator(s), operating devices, and an acoustic alarm.

The WiO Sensor benefits you with:

Water in oil saturation monitoring
System protection
Service on request
Precision engineered
Harsh environment capability.

We deliver directly and globally to end-users, agents, and resellers.
Contact us at marine@insatech.com.

How does the WiO system work?

Oil can hold a certain amount of dissolved water, where the maximum amount of water that oil can hold is characterized by the "saturation point". Above this point free water precipitates, which can lead to corrosion inside your engine.

Traditionally, you would measure the free water in your oil or emulsion, but the WiO system senses the absolute content of absorbed water in oil. Thus, the Water in Oil Sensor FRG00032 physically detects the water activity based on the capacitive measuring principle.

Because the WiO system is installed in a vigorous stainless-steel housing the sensor resists the most demanding environmental conditions.

Moreover, you get a highly flexible system that offers a simple integration with the sensor and the connection and processing unit (GHG02088-5 or MPU010) with several options for output signal and functions for event memory.

Additionally, the AC version together with the processing unit GHG02088-5 gives you the possibility of not only reading the analog signals of temperature and AW, but also the alarm signals supported by relay technology.

OBS: A great feature of the sensor FRG00032 is the fact, that it does not need any cleaning.

The WiO system consists of:

The Water in Oil System from HORN consist of:

Sensor FRG00032
Connection and processing box GHG02088-5 or MPU010
Connection cable KSG03244-1

Additionally, to the basic standalone version, is the option to get an analogue output for water content and oil temperature, as well as an indicator box with analog indicator(s), operating devices, and an acoustic alarm.

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Typical Applications:

The WiO system is applicable in various fields including:

Marine engines
Power generation
Oil transformers
Hydraulic aggregates
Large gear units
Heavy duty applications.

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Two Different Sensor Shafts

The WiO sensor is available with two different lengths of the shaft; A sensor shaft with the length of 68 mm or 138 mm.

Sensor Shaft Length 68 mm

Sensor Shaft Length 138 mm.

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3 Available Main Processing Units

See the technical data for the main processing unit: MPU010-I-K, MPU010-I-G, and GHG02088-5 below.

MPU010-I-K
Power supply	8 ... 32 VDC, max. permissible ripple ≤ 5 % (protected by automatic fuse) 2 power supply inputs (redundancy)
Power consumption	approx. 10 W
Polarity protection	Yes
Operating/ Storage temperature	-25 ... +85 °C
Relative humidity	< 90 %, non-condensing
Weight	Approx. 1000 g.
Protection degree	IP 67
EMC-standard	DIN EN 55016 and DIN EN 55022, safety rules acc. EN 61000-4, -6 rules for type approval test accord. GL
Connection to PE	Copper mesh band
Cable glands	M12 for sensor M 12 for power supply M12 for relays M12 for analog out M12 for CAN bus Cable size M12: ø5 ... 6.5mm
Sensor interface	I²C
Relays	PAV (pre-alarm-value), MAV (main-alarm-value), STATUS Photo-MOS output: < 60 VDC, 500 mA (Short Circuit Protected SCP)
Analog output	current output or voltage output (details configurable: 4-20 mA or 0-10 VDC, others on request), galvanic isolated, user selectable
Current output load	max.1200 Ω
Ethernet	Transmission rate max. 100 Mbit/s, galvanic isolated, IP-Address adjustable
CAN	Transmission rate 20 kBaud ... 1 Mbaud, galvanic isolated, Node ID adjustable 1...127
Configuration/ display	CAN open-protocol / Web page over ethernet

MPU010-I-G
Power supply	8 ... 32 VDC, max. permissible ripple ≤ 5 % (protected by automatic fuse) 2 power supply inputs (redundancy)
Power consumption	approx. 10 W
Polarity protection	Yes
Operating/ Storage temperature	-25 ... +85 °C
Relative humidity	< 90 %, non-condensing
Weight	Approx. 1000 g.
Protection degree	IP 67
EMC-standard	DIN EN 55016 and DIN EN 55022, safety rules acc. EN 61000-4, -6 rules for type approval test accord. GL
Connection to PE	Copper mesh band
Cable glands	M12 for sensor M25 for power supply M25 for relays, analog out, CAN Cable size M12: ø5 ... 6.5mm Cable size M25: ø12.5 ... 20.5mm
Sensor interface	I²C
Relays	PAV (pre-alarm-value), MAV (main-alarm-value), STATUS Photo-MOS output: < 60 VDC, 500 mA (Short Circuit Protected SCP)
Analog output	current output or voltage output (details configurable: 4-20 mA or 0-10 VDC, others on request), galvanic isolated, user selectable
Current output load	max.1200 Ω
Ethernet	Transmission rate max. 100 Mbit/s, galvanic isolated, IP-Address adjustable
CAN	Transmission rate 20 kBaud ... 1 Mbaud, galvanic isolated, Node ID adjustable 1...127
Configuration/ display	CAN open-protocol / Web page over ethernet

GHG02088-5
Power supply	8 ... 32 VDC, max. permissible ripple ≤ 5 % (protected by automatic fuse) 2 power supply inputs (redundancy)
Power consumption	approx. 2 W
Polarity protection	Yes
Operating/ Storage temperature	-25 ... +85 °C
Relative humidity	< 90 %, non-condensing
Weight	Approx. 700 g.
Protection degree	IP 67
EMC-standard	DIN EN 55016 and DIN EN 55022, safety rules acc. EN 61000-4, -6 rules for type approval test accord. GL
Connection to PE	Copper mesh band
Cable glands	M16 for sensor M25 for power supply M25 for relays, analog out Cable size M16: ø6 ... 10.5mm Cable size M25: ø11...20mm
Sensor interface	AC
Relays	PAV (pre-alarm-value), MAV (main-alarm-value), STATUS Photo-MOS output: < 60 VDC, 500 mA (Short Circuit Protected SCP)
Analog output	current output (4-20 mA), galvanic isolated
Current output load	max. 500 Ω

Smart Sensor Technology
– Decentralized Intelligence for Engine Safety

Horn sensors continuously measure critical parameters to ensure engine safety. They can be sold individually or integrated into our monitoring systems, providing customized solutions tailored to customer needs.

Ensuring Safety for Large Engines and Drives

Horn specialize in safety solutions for large 4-stroke and 2-stroke engines, whether used in marine vessels, power generation, or industrial applications on land.

Looking for something else? See our selection of sensors from HORN:

Sensors

FAQ

What is the HORN Water in Oil Sensor used for?

The HORN Water in Oil Sensor (WiO) is designed to continuously monitor water content in lubricating and hydraulic oils. It helps prevent equipment damage by detecting water contamination early, ensuring optimal oil quality and system reliability.

How does the sensor measure water content in oil?

The sensor uses capacitive measurement technology to determine the water activity (aw-value) in oil. This provides an accurate and real-time indication of free and dissolved water content.

What are the main advantages of the HORN WiO Sensor?

Continuous real-time monitoring of water content
Helps prevent equipment failures caused by water contamination
Easy integration with existing systems
Robust design for harsh environments

What is the measurement range of the sensor?

The sensor measures water activity (aw-value) from 0 to 1, where 0 represents completely dry oil and 1 indicates the oil is fully saturated with water. It also provides temperature compensation for precise readings.

Can the HORN WiO Sensor differentiate between free and dissolved water?

Yes, the sensor detects both dissolved and free water by measuring the water activity (aw). A value close to 1 indicates that the oil is fully saturated and free water may be present.

What output signals does the sensor provide?

The sensor features an analog 4-20 mA output and a Modbus RTU (RS485) digital interface, allowing easy integration with monitoring and control systems.

Is the sensor suitable for marine and industrial applications?

Yes, the sensor is ideal for use in marine engines, hydraulic systems, turbines, and industrial lubrication systems, where continuous oil monitoring is essential.

What types of oils can the sensor be used with?

The sensor is compatible with lubricating oils, hydraulic oils, and turbine oils, making it suitable for a wide range of applications.

Does the sensor require calibration?

The sensor is factory-calibrated and does not require regular calibration. However, verification against reference samples can be performed if needed.

What maintenance is required for the sensor?

The sensor is designed for long-term operation with minimal maintenance. Regular checks of system functionality and occasional cleaning of the sensor tip (if exposed to oil contamination) may be required.

For technical questions

Martin Søvind Jensen

Tel: +45 2761 4502

Email: Martin.Sovind@insatech.com

Write to Martin

For commercial inquiries

Astrid Mihut

Tel.: +45 5537 2095

Email: Marine@insatech.com

We Deliver Directly to End Customers, Resellers, and Agents – Globally

At Insatech, we are proud to offer our high-quality products to all customers worldwide. Whether you’re an end customer, a reseller, or an agent, you can purchase directly from us.

By choosing us, you gain direct access to all our products, eliminating the need for intermediaries. Our global distribution possibilities ensure fast and reliable delivery to your doorstep, wherever you are.

We strive to make it easy for you as an end consumer to find the products you are looking for while supporting agents and resellers looking to grow their business. Whether you’re buying for your use or resale, we’re here to meet your needs.

Discover how simple it is to work directly with a trusted global distributor – shop with confidence at Insatech today!

Brochure - Water in Oil (WiO) system - HORN
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Manual - Water in Oil (WiO) system - HORN
English | pdf

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Article - Water in Oil (WiO) system - Drawing - HORN
English | pdf

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Manual - Quick Instructions Water in Oil (WiO) Sensor - HORN
English | pdf

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Technical Specifications FRG00035
Output interface	I: I²C R / N (Note 1): RS232 C: Relay (2x) A: Analog (2x) AC (Note 2): Analog (2x) / Relay (3x)
Output information	I: Humidity, Temp., PAV, MAV R / N (Note 1): Humidity, Temp., PAV, MAV C: PAV, MAV A: Humidity, Temp. AC (Note 2): Humidity, Temp., PAV, MAV, STATUS
Output characteristics	I: Serial R / N (Note 1): Serial C: Analog 4 ... 20mA / load max. 500 Ω. Relay max. 500mA A: Analog 4 ... 20mA / load max. 500 Ω. Relay max. 500mA AC (Note 2): Analog 4 ... 20mA / load max. 500 Ω. Relay max. 500mA
Accuracy of humidity measurement	±3%
Pressure resistance against medium	10 bar
Protection degree	IP67
Power supply	I: 5 VDC ± 5% R / N (Note 1): 18 ... 32 VDC, max. perm. ripple ≤ 5% C: 18 ... 32 VDC, max. perm. ripple ≤ 5% A: 18 ... 32 VDC, max. perm. ripple ≤ 5% AC (Note 2): 18 ... 32 VDC, max. perm. ripple ≤ 5%
Current consumption	< 50mA
Polarity protection	yes
Cable length	I: max. 50m R / N (Note 1): max. 25m C: max. 50m A: max. 50m AC (Note 2): max. 50m
Certificates	Class approval DNV
Dimensions	Standard shaft length: 68 mm/ 138 mm (others on request), see drawing Connecting thread: outer thread G ¾ (inner thread G ¾ on demand)
Notes	1) R = Short circuit protected (SCP)/ N = Non-SCP; Only for HORN-Bearing Distance Monitoring System (BDMS) 2) Only in combination with GHG02088-5

Technical Specifications MPU010-I-K
Power supply	8 ... 32 VDC, max. permissible ripple ≤ 5 % (protected by automatic fuse) 2 power supply inputs (redundancy)
Power consumption	approx. 10 W
Polarity protection	Yes
Operating/ Storage temperature	-25 ... +85 °C
Relative humidity	< 90 %, non-condensing
Weight	Approx. 1000 g.
Protection degree	IP 67
EMC-standard	DIN EN 55016 and DIN EN 55022, safety rules acc. EN 61000-4, -6 rules for type approval test accord. GL
Connection to PE	Copper mesh band
Cable glands	M12 for sensor M 12 for power supply M12 for relays M12 for analog out M12 for CAN bus Cable size M12: ø5 ... 6.5mm
Sensor interface	I²C
Relays	PAV (pre-alarm-value), MAV (main-alarm-value), STATUS Photo-MOS output: < 60 VDC, 500 mA (Short Circuit Protected SCP)
Analog output	current output or voltage output (details configurable: 4-20 mA or 0-10 VDC, others on request), galvanic isolated, user selectable
Current output load	max.1200 Ω
Ethernet	Transmission rate max. 100 Mbit/s, galvanic isolated, IP-Address adjustable
CAN	Transmission rate 20 kBaud ... 1 Mbaud, galvanic isolated, Node ID adjustable 1...127
Configuration/ display	CAN open-protocol / Web page over ethernet

Technical Specifications MPU010-I-G
Power supply	8 ... 32 VDC, max. permissible ripple ≤ 5 % (protected by automatic fuse) 2 power supply inputs (redundancy)
Power consumption	approx. 10 W
Polarity protection	Yes
Operating/ Storage temperature	-25 ... +85 °C
Relative humidity	< 90 %, non-condensing
Weight	Approx. 1000 g.
Protection degree	IP 67
EMC-standard	DIN EN 55016 and DIN EN 55022, safety rules acc. EN 61000-4, -6 rules for type approval test accord. GL
Connection to PE	Copper mesh band
Cable glands	M12 for sensor M25 for power supply M25 for relays, analog out, CAN Cable size M12: ø5 ... 6.5mm Cable size M25: ø12.5 ... 20.5mm
Sensor interface	I²C
Relays	PAV (pre-alarm-value), MAV (main-alarm-value), STATUS Photo-MOS output: < 60 VDC, 500 mA (Short Circuit Protected SCP)
Analog output	current output or voltage output (details configurable: 4-20 mA or 0-10 VDC, others on request), galvanic isolated, user selectable
Current output load	max.1200 Ω
Ethernet	Transmission rate max. 100 Mbit/s, galvanic isolated, IP-Address adjustable
CAN	Transmission rate 20 kBaud ... 1 Mbaud, galvanic isolated, Node ID adjustable 1...127
Configuration/ display	CAN open-protocol / Web page over ethernet

Technical Specifications GHG02088-5
Power supply	8 ... 32 VDC, max. permissible ripple ≤ 5 % (protected by automatic fuse) 2 power supply inputs (redundancy)
Power consumption	approx. 2 W
Polarity protection	Yes
Operating/ Storage temperature	-25 ... +85 °C
Relative humidity	< 90 %, non-condensing
Weight	Approx. 700 g.
Protection degree	IP 67
EMC-standard	DIN EN 55016 and DIN EN 55022, safety rules acc. EN 61000-4, -6 rules for type approval test accord. GL
Connection to PE	Copper mesh band
Cable glands	M16 for sensor M25 for power supply M25 for relays, analog out Cable size M16: ø6 ... 10.5mm Cable size M25: ø11...20mm
Sensor interface	AC
Relays	PAV (pre-alarm-value), MAV (main-alarm-value), STATUS Photo-MOS output: < 60 VDC, 500 mA (Short Circuit Protected SCP)
Analog output	current output (4-20 mA), galvanic isolated
Current output load	max. 500 Ω

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Dr. E. Horn Water in Oil Sensor (WiO System) FRG00032

How does the WiO system work?

The WiO system consists of:

Typical Applications: