Model 15Ppm Xoc-01 Bilge Alarm: Operation Manual [PDF]

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MODEL 15ppm XOC-01

BILGE ALARM

OPERATION MANUAL

1 Summary ···················································14 2 Performance parameters ·······································14 3 Structure ···················································15 4 Using method ···············································16 4.1 Installation ················································16 4.1.1 Chamber mounting 4.1.2 Pipe connection 4.1.3 Wiring 4.2 Operation··················································18 4.3 Data print

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4.4 To change form ·············································20 4.5 To change ink ribbon ·········································21 4.6 To change memory card ······································22 5 Maintenance ·················································22 6 Trouble shooting ··············································23 7 Transportation and storage ······································23 8 Complete sets and spare parts ····································24 9 Attentions ····················································24

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1. Summary Model XCO-01 15ppm bilge water alarm instrument is not only used for the continuous detection of oil and sewage in the bilge of ship, but also used for the monitoring of oily waste water in the fields of chemical industry, petroleum and environmental protection etc. Model XCO-01 15ppm bilge water alarm instrument has acquired the approval of CCS，and its technical performance conforms to the third part “ Authorization of Technical Conditions of Environmental test of Anti-pollution Equipments”, the second section “ Authorized Test and Performance Technical Conditions of 15ppm Warning Device for Bilge Water”, MEPC.107 (49) Resolution - “Revised Guide and Technical Conditions of Anti-pollution Equipments for Bilge Water in Ship Craft” which was passed on the 18th, July of 2003. This instrument has the advantages of compacting and firm design structure, IP45 guard rank, so it can completely adapts to the working environment in cabin. Model XCO-01 15ppm bilge water alarm instrument has a lot of functions, such as, to display measurement result, set 15ppm warning value, output analog signal of sewage standard discharge control total amount to measurement value, and also provide these services including data print, storing and inquiry of historical data etc. Besides, model XCO-01 15ppm bilge water alarm instrument can record date, time, alarming state and running state. 2. Performance parameters Measurement range: 0-30ppm(When the measured sample water concentration is over 40ppm, digital pipe begins to show 80ppm). Measurement precision: ±5ppm Alarm indication: two emitting LED Concentration value display: 3-bit LED Alarm point: 15ppm Weight: about 13.5Kg Power supply: AC220±10% 50Hz±5% Power consumption: 20W Safeguard grade: IP45 Operational environment: 0 ～ 55 ℃ , relative humidity 95 ～ 100%, normal

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3 Structure Inside detailed structure of this instrument, see Figure 1.

Main component of this instrument is electrical-optical converter. on the panel of instrument is set data display panel with operating key board. Inside of the instrument chamber,have a set data-processing circuit board and a set micro printer. on the bottom are power supply, output unit and data-printing output signal, including power switch, fuse box, mains transformer, mains filter, alarm 3

control relay, output terminals etc. 4、Using method 4.1 Installation 4.1.1 Chamber mounting Installation dimension of model XOC-01 15ppm bilge water alarm instrument, see Figure2.

This instrument is fixed on installation site perpendicularly with four M8 bolts, near sampling point of oil-water separator as possible, in order to avoid of alarm delay caused by collecting water sample. Around the instrument, there should be enough space for convenient maintenance. 4.1.2 Pipe connection The instrument connected with outside, see Figure 3.

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It is commanded that pipe connection adopts φ8×1mm red copper pipe. Pipe joint in left middle of chamber is sample water intake joint, and outlet joint is on the outlet part of measurement box top. Pipe connections all adopt standard cutting sleeve joints. There is a valve for oil-free water and sample water conversion on the instrument. It had better to choose water sample collecting point on the perpendicular unit of discharge pipe of oil water separator, in order to reduce entrapped air in sample liquid. Make the sample glass tube of this instrument to be full of sample liquid that flows upwards. Avoid of collecting water sample from the top or bottom of horizontal segment of discharge pipe of oil water separator.

4.1.3 Wiring Open the chamber door, and you can see 12 wiring terminals, power, alarm instrument and control electromagnetic valve cable that is connected with wiring terminals through four φ20mm stuffing box at the bottom of the instrument. Typical terminal wirings, see figure 4.

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No1/2 wiring terminals are external power supply of the instrument; No3/4 wiring terminals are assistant power supply that supply work power to the controlled alarm instrument and electromagnetic valve; No 5/6/7 wiring terminals are corresponding to assistant contact point of alarm relay 1, and No 6 wiring terminal is common point; No 8/9/10 wiring terminals are corresponding to assistant contact point of alarm relay 2, and No 9 wiring terminal is common point. No 1 relay is used to alarm, and No 2 relay is used to control external electromagnetic valve. In the conditions of electrical outage or alarming, contact between No5 and No 6 terminal breaks, contact between No 6 and No 7 terminal is connected, contact between No 8 and No 9 terminal breaks, contact between No 9 and No 10 terminal is connected. In the condition that power is connected and the instrument runs normally, contact between No5 and No 6 terminal is connected, contact between No 6 and No 7 terminal breaks, contact between No 8 and No 9 terminal is connected, contact between No 9 and No 10 terminal breaks. No 11 and No12 wiring terminals are used to monitor the running of oil water separator, Users must use this function to meet the regulatory requirements. No 11 and No12 wiring terminals were cut short ex factory, please make the two terminals broke, and then connect it with a contactor that controls the running of motor of oil water separator. 4.2 Operation Before operation, please check the following parts: 4.2.1 Electric part： Earth terminal is reliable or not. Power voltage is corresponding to the rated voltage of the instrument. 4.2.2 Pipeline： Check all the pipelines, leaky or not. If the above checks are ok, it proves that the instrument is good, and the instrument can be operated. When oil concentration of water sample is equal to or more than 15ppm, No 1 alarm indicator will light within 2 seconds, and while No 1 relay stop working. If oil concentration of water sample does not fall below 15ppm within 5 seconds, No 2 alarm indicator will light, and while No 2 relay stop working. Before the instrument stop running, fill clean water to the 6

instrument for 2 minutes, and then cut off the power. Start up the instrument again after closing it every time for 10 seconds, in order to ensure normal operation of the instrument. 4.3 Data print To print the data to be inquired, please input the date of inquired data, and the detailed method is as the following: (1) Press “1” key, the two-digit number displayed on panel stands for year, and the first digit flashes continuously. If modifying year, please input directly a two-digit number that stands for year, for example, to input the two-digit number “05” that stands for the year of 2005, please press the number key “0”, and then the first digit stop flashing, but the second digit begins to flash continuously, after that, to press the number key “5”, and the second digit stop flashing, but the first digit begins to flash. If the year displayed on panel is right, please press “Enter” key. If the year does not need to be modified, also please press “Enter”. (2) To press “2” key, at this time the two-digit number that stands for month displays on panel, and the first digit flashes continuously. If modifying month, please input directly a two-digit number that stands for month, for example, to input the two-digit number “08” that stands for August, please press the number key “0”, and then the first digit stop flashing, but the second digit begins to flash continuously, after that, to press the number key “8”, and the second digit stop flashing, but the first digit begins to flash. If the month displayed on panel is right, please press “Enter” key. If the month does not need to be modified, also please press “Enter”. (3) To press “3” key, at this time the two-digit number that stands for the date displays on panel, and the first digit flashes continuously. If modifying date, please input directly a two-digit number that stands for the date, for example, to input the two-digit number “26” that stands for the date, please press the number key “2”, and then the first digit stop flashing, but the second digit begins to flash continuously, after that, to press the number key “6”, and the second digit stop flashing, but the first digit begins to flash. If the date displayed on panel is right, please press “Enter” key. If the date does not need to be modified, also please press “Enter”. (4) Press “▼” key, and press “Print”. Thus, printer will print out the alarming data on some day of some month of some year. For example, to print the following data: 2005-8-26 15：05 15：10 15：15 15：20 15：25 15：30

VAL 10 16(Alarm) 10 10 10 10

SEAL NORMAL NORMAL OPEN (Alarm) CLEAR (Alarm) FLOW (Alarm) CL+OP (Alarm) 7

SEPA RUN RUN RUN RUN RUN RUN

15：35 10 CL+FL (Alarm) RUN 15：40 10 FL+OP (Alarm) RUN 15：45 10 O+C+F (Alarm) RUN 15：50 10 CLEAR(Alarm) STOP 15：55 10 NORMAL STOP When the measured sample water concentration is equivalency or over 15ppm, or clean water is used for cleaning or the chamber door is opened, or the Sample water shut-off, the instrument will alarm and record it. In the above print form, the first line “2005-8-26” stands for alarming date, the first row stands for time of recording alarm; the second row “VAL” stands for the corresponding concentration when the instrument alarming; the third row “SEAL” stands for clean instrument and the corresponding state of the chamber door and Sample water flow, that is to say, when the chamber door is opened, the corresponding state is “OPEN”, when the instrument is cleaned with water, the corresponding state is “CLEAR”, when the Sample water shut-off, the corresponding state is “FLOW”, when the instrument is cleaned with water and the chamber door is opened, the corresponding state is “CL+OP”, when the instrument is cleaned with water and the Sample water shut-off, the corresponding state is “CL+FL”, when the Sample water shut-off and the chamber door is opened, the corresponding state is “FL+OP”, when the chamber door is opened and the instrument is cleaned with water and the Sample water shut-off, the corresponding state is “O+C+F”, when the instrument is normal operation, the corresponding state is “NORMAL”, the fourth row “SEPA” stands for running state of oil water separator when the instrument alarming, when oil water separator is running, the corresponding state is “RUN”, and when oil water separator is not running, the corresponding state is “STOP” . How to monitor the running of oil water separator, please referring to 4.1.4 “Wiring”. If the instrument does not alarm in this period, printer will print out “NORMAL”; and if the instrument does not run in this period, printer will print out “OFF”. Note: If you press the "Test" button, the instrument will simulate an alarm when the concentration is 15ppm state, once again press the "Test" button, analog alarm ends.

4.4 To change form After the forms of printer are used up, we need to change form, and the method is as the following: (1)Remove head cover board. See Figure 4-1

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Figure 4-1

(2) Remove printer from instrument faceplate. Illustrated as Figure4-2, clamp the two active clamps with fingers, and remove printer from instrument faceplate. Notice: To ensure switch off printer power before removing printer.

Figure 4-2 (3) Remove stock form shaft from printer. See Figure 4-3.

Figure 4-3 (4) Fix a new stock form around shaft. See Figure 4-4

Figure 4-4 9

(5) Reference to Figure 4-5, cut the new Stock form.

Figure 4-5 (6) Switch on printer power, press “SEL” key to make SEL indicator to go out, and then press “LF” key to turn printer head, at this time send stock form to form feed position under printer head, with some form left outside. After these, press “LF” key or “SEL” key again. Switch off power, lid head cover board on printer, and send form head out of from form exit of head cover board. (7) Illustrated as Figure 4-6, install printer on mounting support of instrument.

4.5 To change ink ribbon Figure 4-6 After printer ink ribbon has been used for a period, it need to be changed. The method is as the following: (1) Reference Figure 4-1, remove head cover board of printer. (2) Remove the old ink ribbon (see Figure 4-7) Notice: Firstly put up left end of ink ribbon, and then put up right end of ink ribbon, finally remove ink ribbon.

Figure 4-7 (3) To change a new ink ribbon. Firstly put right end of ink ribbon on the gear on right end of printer head, put up left end of ink ribbon a little and hold it. If right end of ink ribbon does not touch bottom, please switch the knob on ink ribbon according the arrow direction until right end of ink ribbon touches bottom, and then put down let end. Please check if ink ribbon is straight or not, and if ink ribbon is not straight, straighten it up. (4) Install head cover board again. 4.6 To change memory card 10

Memory card that is for saving alarming records has some capacity. In general, memory card does not need to be changed for 18 months. However, the more are alarming times in the course of running, the shorter is memory card life. When you have to change memory card, please keep the changed memory card well, in order to look up the past alarming data if it is necessary. The steps to change memory card is as the following: (1) Cut off power supply of instrument. (2) Open chamber door of instrument. (3) To look for memory card. Near the middle of main board of instrument, there is a “MEMORY” integration module, and that is memory card. (4) Remove memory card with a small “—” shaped screwdriver. (5) Fit a new memory card supplied by our company. Notice: One end of memory card in which there is a half circle, is adown (illustrated as printing board), otherwise memory card is possible to be destroyed. Attention: Because memory card life is related to recorded alarming times, please avoid of using the instrument in the following conditions: (1) Chamber door is not close. (2) Clean instrument with water. (3) If instrument alarms continuously, please start-up the instrument again after trouble removal. 5、Maintenance 5.1 Maintenance of glass tube in measurement lab Check out whether the glass tube in the measurement lab is polluted or not after the instrument being used for 1000 hours. Meanwhile the maintenance work is required and the maintenance method is as follows: (1) Switch off power of instrument, let clean water to flow through the instrument for 3 minutes, cut off water supply that flows into the instrument and keep some water in the glass tube. (2) After loosening the plug screw and removing it, wash the glass tube with a cleaning brush until glass tube becomes clean. (3) Tighten the plug screw and switch on power supply. Let oil-free clean water to flow through the instrument for 3 minutes. 5.2 Water left in glass tube should vent to avoid glass tube broken when environmental temperature is below 0℃. 6、Trouble shooting Troubles Causes No display after Power is not connected. start-up Fuse FU1/FU2 is cut. Not cleaned glass tube

Solutions To change power To change FU1/FU2 To clean measurement glass tube Damage of the optical-electrical To inspect and repair the The indication value is converter optical-electrical converter too high Damage of the circuit To inspect and repair the circuit board board 11

Aging optical-electrical The indication value is converter too low Leaked glass tube No printing output No form No alarming even Not correct external wiring if indication value Fuse FU3 is cut. is over warning Damage of alarming value relay 1 Chamber door is not closed Instrument lasts Not cleaned glass tube alarming Out-control of electromagnetic valve

Not correct external wiring Fuse FU3 is cut. Damage of alarming relay 2

To change optical-electrical converter To change glass tube To set form again Correct wiring according to Figure 4 To change fuse FU3 To change alarming relay 1 To close chamber door To clean glass tube Correct wiring according Figure 4 To change fuse FU3 To change alarming relay 1

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Non-professional personnel who have not trained can not repair the instrument, in order to prevent from accidents and unexpected damage.

7、Transportation and storage 7.1 Before packaging and transportation, make sure to drain the pipeline and the measurement lab. Allow to be transported by common vehicles in the condition that the packages are complete, while keep the product from impact, rain and exposing to the sun. 7.2 The instrument should be stored in the room with 2～55℃ environmental temperature, no more than 95% humidity, no corrosive gas in air and exposing to the sun. 8、Complete sets and spare parts 8.1 Complete sets 8.1.1 The instrument, one set 8.1.2 Φ8 joint, two pieces 8.1.3 Fuse 2A three 8.1.4 Specification one 8.1.5 Certification one 8.1.6 Brush one 9、Attentions 9.1 Please read its specification before operation of the instrument. 9.2 Please check carefully power supply before operation of the instrument. 9.3 Our company has been responsible for the damage caused by improper manufacture within a year since the instrument is bought. However, for the damages caused by false operations, free modification, free repair, improper maintenance and force majeure, our company would repair with charge of costs. 9.4 Our company does not supply spare parts of some consumables such as memory card, form, ink ribbon etc, you have to buy if necessary. 12

9.5 The instrument was inspected and tested seriously when it left factory. Only our technicians or the personnel who have been trained and achieved the authorization can calibrate the instrument. Please contact our company if end-user need to calibrate the instrument. The crew should pay attention to the following: according to MEPC（107）49 Resolution, the item 4.2.11 amendment regulates that the calibration effectiveness should be verified when IOPP Annual/Intermediate replacement is inspected. The 15PPM bilge alarm device produced by our company requires that the calibration be conducted every three years, or replace with the verified 15PPM bilge alarm device. The calibration certificate of 15PPM bilge alarm device which shows the date of last calibration date should be preserved on board in case of inspection.

Exemption Clause 1 、 The customer must read the operating instruction carefully before operating the equipment, and maintain the equipment timely in accordance with requirements stipulated in the operating instrution. And our company won’t bear any responsibilities for the equipment’s damages caused by the customer’s improper maintenance or operation. 2、Please the shipowner to confirm the equipment operating normally before leaving China, if the equipment is required to leave Chinese Mainland and shipped to the unrestricted navigation area. If the equipment gets out of order in the unrestricted navigation area, the customer must inform our company fifteen days in aavance for contacting the shipowner, otherwise, our company won’t bear any responsibilities.

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