Flowserve GESTRA OR 52-7 Installation Instructions Manual

Brand: Flowserve

Model: GESTRA OR 52-7

Category: Toys & accessories

Type: Installation Instructions Manual

Flowserve GESTRA OR 52-7 is an oil & turbidity detector designed to continuously monitor and detect oil contamination in water, making it ideal for use with oily water separators and as a 15 ppm bilge alarm on marine vessels. It meets the requirements of the International Maritime Organization (IMO) for bilge alarm monitors (MEPC. 107 (49)).

Installation Instructions 818788-00

Oil & Turbidity Detector

OR 52-7



GESTRA Steam Systems

OR 52-7

Contents

Important Notes

Usage for the intended purpose .............................................................................................................4

Safety note .............................................................................................................................................4

Danger ...................................................................................................................................................4

Explanatory Notes

Scope of supply ......................................................................................................................................5

Description .............................................................................................................................................5

Function ................................................................................................................................................. 5

Page

Functional Elements

Measuring sensor ORG 12 .................................................................................................................... 14

Measuring transducer ORT 7.................................................................................................................15

Key .......................................................................................................................................................16

Commissioning Procedure

Factory setting ......................................................................................................................................17

Warning ................................................................................................................................................17

Checking electrical connection .............................................................................................................17

Checking installation .............................................................................................................................17

First commissioning .............................................................................................................................18

Programming mode ..............................................................................................................................19

Other parameter settings ...................................................................................................................... 20

Technical Data

Measuring transducer ORG 12 ................................................................................................................6

Measuring transducer ORT 7...................................................................................................................7

Name plate / marking ............................................................................................................................. 8

Dimensions OR 52-7 ...............................................................................................................................9

Installation

OR 52-7 ................................................................................................................................................10

Example of installation ..........................................................................................................................11

Electrical Connection

Measuring transducer ORT 7 ................................................................................................................12

Note .....................................................................................................................................................12

Attention ...............................................................................................................................................12

Tools .....................................................................................................................................................12

Wiring diagram OR 52-7 ....................................................................................................................... 13

Notice ..................................................................................................................................................13

Contents – continued –

Malfunctions

OR 52-7 ................................................................................................................................................25

Table listing error codes ........................................................................................................................25

Page

Annex

Type approval certiﬁcate ...............................................................................................................30 – 33

EG-Baumusterprüfbescheinigung (Modul B) .................................................................................... 34, 35

EC Type Examination Certiﬁcate (Module B) .................................................................................... 36, 37

Declaration of Conformity .....................................................................................................................38

Data Storage

Memory Card ........................................................................................................................................23

Note .....................................................................................................................................................23

Data indication .....................................................................................................................................23

Operating steps – see Fig. 8 .................................................................................................................23

Note .....................................................................................................................................................24

Operating ﬂowchart ..............................................................................................................................24

Start, Operation, Alarm and Function Test

Start and operation ...............................................................................................................................21

Alarm 1 and 2 ......................................................................................................................................22

Functional test .....................................................................................................................................22

Calibration

OR 52-7 ................................................................................................................................................26

Maintenance

Cleaning the glass cylinder ..................................................................................................................27

Replacing the drying cartridge ..............................................................................................................27

Replacing the light emitter/receiver ......................................................................................................27

Attention ...............................................................................................................................................27

Replacing the equipment fuse ...............................................................................................................27

Warning ................................................................................................................................................28

Spare parts ...........................................................................................................................................28

Note .....................................................................................................................................................28

Decommissioning

Warning ................................................................................................................................................29

Removal ...............................................................................................................................................29

Disposal................................................................................................................................................29

Important Notes

Usage for the intended purpose

The GESTRA Turbiscope OR 52-7 is designed for the continuous monitoring and detection of oil

contamination of water and used in conjunction with oily water separators as 15 ppm bilge alarm.

The equipment meets the requirements of the International Maritime Organization (IMO) for bilge alarm

monitors, MEPC. 107 (49).

Danger

The solenoid of the solenoid valve Clw can reach up to 80 °C during operation.

The terminal strips of the measuring transducer ORT 7 can be live during operation.

This presents the risk of electric shock.

Cut off power supply before mounting, removing or connecting the terminal strips.

Safety note

The equipment must only be installed and commissioned by qualiﬁed and competent staff.

Retroﬁtting and maintenance work must only be performed by qualiﬁed staff who – through adequate

training – have achieved a recognised level of competence.

Explanatory Notes

Description

Scope of supply

Measuring transducer ORT 7

Measuring sensor ORG 12 with

1 Solenoid valve

1 Drying cartridge (ﬁtted)

1 Light emitter (supplied but not ﬁtted)

1 Spare gasket kit

The oil & turbidity detector OR 52-7 can be used:

■ On board of marine vessels for monitoring the oily water separating equipment for bilge water

according to IMO Resolution MEPC. 107 (49) as 15 ppm oil content alarm.

Function

The measuring sensor is a photometric measuring device consisting of a light source (light emitter)

and a light receiver ﬁtted with two photosensitive elements.

The constant light beam generated in the measuring sensor passes through the transparent liquid. Any

foreign matter which is not dissolved scatters the beam, with emulsiﬁed oils scattering the light mainly

in the forward direction. The intensity of the scattered light is converted into an electric current and then

used as measure of the degree of contamination.

The measuring transducer has the following functions:

■ Control of the measuring sensor and signal evaluation

■ Control of the purging valve

■ Limit ALARM 1 and ALARM 2

■ Analog actual value output 0/4 – 20 mA

■ ALARM 2 indicates a malfunction in the turbidity sensor

■ Indication of actual value / limits

■ Storage and indication of alarm, malfunction and status messages

■ Control of the bilge bypass via output ALARM 2

Technical Data

Measuring transducer ORG 12

Nominal size

DN 10, connection 3/8" to DIN ISO 228

Nominal pressure

PN 10

Fluid

Water

pH value

Up to 10.5 (a pH value of 11 and above will lead to wear of the glass, depending on the temperature!)

Fluid temperature range

0 – 60 °C with drying cartridge

Ambient temperature

Max. 60 °C

Materials

Measuring sensor: ORG 12

Housing cover: 0.6025 galvanised

Wetted parts: 0.6025 galvanised

Throttle: 1.4571

Screwed union: St

Glass cylinder: Duran 50

Internal seal: Silicone

Oil-seal rings: Perbunan

Housing: 0.6025 galvanised

Cleaning ring: EPDM sponge rubber

Light emitter

Glow lamp 12 V / 10 W BA 15s

Electric connection via 4 m connecting cable ﬁtted with four pole connector,

protection IP 65

Light receiver

Two silicon photoelectric cells

Electric connection via 4 m connecting cable ﬁtted with four pole connector,

protection IP 65

Purging valve

2/2 way solenoid valve

Directly controlled, normally closed

Connection: 3/8" ISO 228

Valve body: Brass

Internals: Ms 2.0401 / S. S. 1.4104

Internal seal: FKM

Solenoid: Voltage 24 V / 50 Hz, 43 / 24 VA

Electric connection via 4 m connecting cable ﬁtted with four pole connector,

protection IP 65

Weight

ORG 12: approx. 6.8 kg

Technical Data – continued –

Measuring transducer ORT 7

Inputs / outputs

2 Photocells for inputs: directly transmitted light / scattered light,

1 Voltage output for light emitter, 1 – 12 V, pulse-amplitude modulated,

1 Signal input for separator ON/OFF,

1 GPS input RS 485, 4800 Baud, NMEA 183 protocol, data record GPRMC,

3 Volt-free change-over contacts for alarm 1, 2 and purging valve (Clw),

contact material AgNi 0.15,

max. contact rating for switching voltages 24 V AC/DC, 115 V AC and 230 V AC: resistive / inductive 4 A,

1 Current output 0/4 – 20 mA as actual value output, max. load 500 ohm.

Indicators and adjustors

1 LCD display for indicating the actual value, limits, status and malfunctions,

8 Membrane keys,

4 LEDs for indicating alarm, status and malfunction

3 Green LEDs on basic circuit board for monitoring the operating voltages

Data storage

DataFlashcard 8 MB

Measuring range

0 to 25 ppm (ppm = parts per million)

Actual value output

0 or 4 mA = 0 ppm, 20 mA ≥ 25 ppm

Limits for alarm 1 and 2, adjustment range

Adjustable between 0 and 15 ppm

Delay of response for alarm 1 and 2, adjustment range

Adjustable between 0 and 15 sec.

Mains voltage

24 V +10 / –15 %, 50/60 Hz

230 V +10 / –15 %, 50/60 Hz (optional)

115 V +10 / –15 %, 50 / 60 Hz (optional)

Power consumption

50 VA

Fuse

24 V: Thermal fuse M 1.6 A 5 x 20,

230 V: Thermal fuse M 0.2 A 5 x 20

115 V: Thermal fuse M 0.4 A 5 x 20

Housing

Field case for wall mounting,

Case material: die-cast aluminium

Cable gland / Electrical connection

8 cable glands with integrated cable clamps, M 16 x 1.5

3 Three-pole screw-type terminal strips, conductor size 0.75 mm2

8 Multi-pole screw-type terminal strips, detachable, conductor size 1.5 mm2

Protection

IP 65 to EN 60529

Admissible ambient temperature

0 – 55 °C

Weight

3.6 kg

Technical Data – continued –

Name plate / marking

Fig. 1

Year of manufacture

Ser.Nr.: 3923581xxxxx

ORG12

OR 52-7

ORT7

Öl- / Trübungsmelder

Oil- / Turbitity Detector

Détecteur d’huile et de turbidité

ORT 7

250 V ~ T 2,5 A

Range 0 - 25 ppm

Tamb = 55°C (131°F)

Manufacturer

GESTRA AG, Münchener Str.77

D-28215 Bremen

Telefon +49(0)421 3503-0

Telefax +49(0)421 3503-393

E-Mail [email protected]

0736 - ....

Oil-content meter OR 52-7 (15ppm Alarm)

approved by SEE-BG

according IMO-Resolution MEPC.107(49)

Approval No. IMO/EC 320030

24 V 50/60 Hz 50VA IP 65

Before removing cover isolate from

power supplies

See installation instructions

Avant d'ouvrir le couvercle dèconnecter

complètement l'appareil

Voir instructions de montage

Vor Öffnen des Deckels Gerät

freischalten!

Betriebsanleitung beachten

Technical Data – continued –

Dimensions OR 52-7

Measuring sensor ORG 12

Measuring transducer ORT 7

Fig. 2

approx. 200 approx.170

approx. 225

ON ALARM 1 ALARM 2 SYSTEM

GESTRA

ORT 7

OKP

240

260

110

160

Depth 91 mm

Installation

OR 52-7

Use the support and install the measuring sensor ORG 12 as close as possible to the separator in

order to keep the supply delay to a minimum. According to MEPC. 107 (49) in the event of an alarm

(oil content =/> 15 ppm) the contaminated water must be diverted from the separator to the bilge as

quickly as possible, i. e. within no more than 20 seconds.

Use a 10x1 mm copper or stainless steel pipe to connect the measuring sensor ORG 12/22 with the

sampling point of the separator and the clear water supply. The sampling point should be provided in a

vertical section of the separator outlet pipe so as to avoid any impairment caused by air bubbles.

In order to ensure that the arrangement for the extraction of samples gives a truly representative

sample make sure that the ﬂuid ﬂow always passes through the sensor under all operating conditions

and that any by-passing of the oil separator is prevented.

If it is not possible to provide the sampling point in a vertical pipe, a lateral arrangement in a horizontal

pipe is also possible.

For overboard pipes having an outside diameter of up to 75 mm a tee piece for the extraction of

samples can be used. If the size of the pipe exceeds 80 mm, make sure that the sampling arrange-

ment extends approx. 25 % into the overboard line.

Install the vacuum breaker above the highest point of the oil separator.

Attach the measuring transducer ORT 7 to a stable vertical surface. If possible mount the indicator at

eye level for easy viewing and provide sufﬁcient space for service and maintenance work.

The measuring transducer is designed for wall mounting. The distances between the ﬁxing holes are

indicated on the back of the equipment.

To access the ﬁxing holes undo the cover screws and open the cover.

Installation – continued –

Example of installation

ON ALARM 1 ALARM 2 SYSTEM

GESTRA

ORT 7

OKP

Three-way control valve Overboard line

To bilge To bilge

Pressure-

maintaining

valve

(if required)

Mount

vacuum

breaker

above

the oil

separator

10 x 1 mm

copper or stainless steel pipe

Inlet Outlet

bilge

Separator

outlet

Clear water

inlet (water

pressure

≥ 2.5 bar)

Fig. 3

Electrical Connection

Measuring transducer ORT 7

1. Undo cover screws and open cover.

2. Detach all three-pole terminal strips from the base board and pull connecting lines through cable

glands.

3. Mark connecting lines: “Mains”, “Alarm 1”, “Alarm 2”, “Light emitter” and “Light receiver”.

4. Connect all terminal strips in accordance with the wiring diagram. Connect screens only to ORT 7.

5. Connect PE with the earthing screw in the housing.

6. Re-attach terminal strips.

7. Tighten the cable glands in order to seal the cable entry. Use the supplied sealings plugs to seal off

any unused cable glands.

8. Close housing lid and tighten cover screws.

Attention

■ The oil & turbidity detector has a power consumption of max. 50 VA. Please make sure

that the power supply is rated for 100 VA.

■ To protect the output relay contacts fuse electric circuits with 2.5 A (slow-blow).

■ Provide connected contactors and actuators with RC combinations (in accordance with

manufacturers’ speciﬁcations) in order to suppress interferences.

■ Make sure that the disconnecting switch (Fig. 4) is easily accessible and in the close

proximity of the equipment (EN 61010-1).

■ Mark respective switch as disconnecting device for the measuring transducer.

This switch can be dispensed with if the control cabinets are upstream of the equipment

and ﬁtted with a disconnector for the measuring transducer.

Note

■ The light emitter/receiver and the purging valve are fitted with a 4 m long connecting

cable and only have to be connected to the measuring transducer.

■ The terminal strips on the CPU board of the ORT 7 cannot be detached.

■ Strip off approx. 25 mm of the cable insulation coating and screen of the connecting

cables for the signal input of the separator ON/OFF and for the GPS input.

Tools

■ Screwdriver for cross-recess screws, size 1 and 2.

■ Screwdriver for slotted screws, size 2.5, completely insulated to VDE 0680

■ Conductor end sleeve pliers

■ Insulation stripper

Electrical Connection – continued –

Wiring diagram OR 52-7

Fig. 4 Shown position of contacts: Alarm 1 and 2, separator OFF and power failure

Notice

Fig. 4 shows an example where the water will be run back to the ship‘s bilge in the event of an alarm

(oil content > 15 ppm) or auxiliary power failure.

With different limit settings alarm contact 1 can, for instance, be used for the ﬁrst alarm and alarm

contact 2 for the main alarm.

For bilge water monitoring a pneumatic three-way valve can be controlled by the alarm contact 2 via a

solenoid valve. If the turbidity of the efﬂuent is too high (alarm caused by ingress of oil or dirt particles

introduced into the system during start-up) the three-way valve will divert the contaminated water to

the bilge tank. The separation continues until the oil content falls below 15 ppm and the cleaned water

can be discharged overboard.

1 2 23

3 3 3 3

L N

0/4-20mA

R 500

2 2 2 2 2

1 1 1 1 1

Alarm2 Alarm1

ORT 7

Basis

ORG

ORT 7 CPU

Separator

GPS

233

key “+” :

Clw - On

key “-” :

Clw - Off

Clw

24VAC

Clw

- wire no.

External wiring Measuring sensor

Disconnecting switch

External

wiring

Purging valve

To ﬁrst alarm

Attached in housing

cover

Solenoid valve

Three-way valve

Earthing screw

in housing

PE L N

Functional Elements

Measuring sensor ORG 12

Fig. 5

ON ALARM 1 ALARM 2 SYSTEM

GESTRA

ORT 7

OKP

Functional Elements – continued –

Measuring transducer ORT 7

Fig. 6

ON ALARM 1 ALARM 2 SYSTEM

GESTRA

ORT 7

OKP

Fig. 7

VDR4

VDR5

VDR3

P2P1 P3

C24

C25

C26

R34

/%&

Functional Elements – continued –

Key

1 Light emitter

2 Measuring cell

3 Solenoid valve Clew

4 Cleaning device

5 Drying cartridge

6 Throttling device

7 Measuring transducer ORT 7

8 Cable glands

9 LCD display

0 System LED

! Keypad

" LED Mains voltage ON

§ LED Alarm 1 and 2

$ Terminating resistor GPS interface

% Memory card

& Locking piece for Memory Card

/ Circuit board for ORT 7 CPU

Commissioning Procedure

Factory setting

The measuring transducer features the following factory set default values:

■ Limit alarm 1: 15 ppm

■ Limit alarm 2: 15 ppm

■ Delay of response alarm 1: 1 second

■ Delay of response alarm 2: 1 seconds

Warning

The terminal strips of the measuring transducer ORT 7 may be live during operation!

This presents the risk of severe injuries due to electric shock!

Cut off power supply before opening the housing lid!

Checking electrical connection

Before commissioning the equipment:

■ Check the connection of the supply voltage

■ The supply voltage is indicated on the name plate

■ Make sure that the connections of the signal inputs and alarm contacts are in accordance with the

wiring diagram.

Checking installation

■ Check all pipe connections for leaks and eliminate any leaks you encounter.

■ Unscrew the drying cartridge and remove the seal. Then screw the cartridge in again.

Commissioning Procedure – continued –

First commissioning

1. Apply supply voltage to the measuring transducer.

The green LED ON will be illuminated and alarm 2 is

signaled.

2. When the equipment is switched on, the system window

appears for approx. 3 seconds, indicating the following:

Name of the equipment,

Certiﬁcate,

Serial number,

Number of the software version.

3. After approx 3 seconds the measurement window

appears, indicating the following:

Oil content (in large characters),

State: Warm up

Current time / date in UTC

4. After approx. 30 seconds the actual value in ppm is

indicated in the measurement window. If this value is

below 15 ppm the message Alarm 2 is cancelled and the

equipment state “Ready” is indicated. If, however, the

value continues to exceed 15 ppm, the message Alarm 2

remains active and the equipment state “ppm>Limit” is

indicated.

5. Press now key +. The purging valve opens and Alarm 2 is

indicated. The equipment state “Clear Water ON” appears.

Rinse the measuring transducer ORG 12 for at least

15 minutes with oil-free water and operate the cleaning

device 4 2 – 3 times, Fig. 5. During the rinsing process

with oil-free water the measuring window should show

0 ppm. If this is not the case switch to programming

mode, Parameter Value Offset, and reduce the zero point

by a max. of 5 ppm.

6. To close the purging valve press key –. The equipment

state “Ready” or “ppm>Limit” or any other alarm message

is indicated.

Note that in the measurement window the keys  and  and “OK” do not have a function. If you

want to enter the programming mode press key P.

Device

Certif.

Ser.Nr.

Vers.

: ORT7

: IMO

: MEPC.107(49)

: 392358

: 311137.10

Flowserve Gestra

OIL CONTENT :

ppm

State: WarmUp

UTC 10:46 2006-12-06

OIL CONTENT :

ppm

State: ready

UTC 10:46 2006-12-06

OIL CONTENT :

ppm

State: ClearWater ON

UTC 10:46 2006-12-06

The following parameters can be selected and, if required, changed:

Value Offset (reduction of zero point 0-5 ppm),

Output (Output of actual value 0 / 4-20 mA),

Alarm 1 Limit Value (Limit Alarm 1, 0-15 ppm),

Alarm 2 Limit Value (Limit Alarm 2, 0-15 ppm),

Alarm 1 Time Delay (Delay of response for alarm 1, 0-15 sec),

Alarm 2 Time Delay (Delay of response for alarm 2, 0-15 sec),

Datalog Export (transferring the storage data to a PC by means of PC software).

1. Press key P to enter the programming mode. The amber

system LED will be illuminated and the window showing

the parameter that was changed last appears.

2. Press  or  to scroll forwards / backwards until the

desired parameter is shown.

3. Press key P (P = change) to activate the parameter chan-

ge. To quit the programming mode without any changes

press key OK (OK = back). The window that was active

before you switched the mode will reappear.

4. After having activated the parameter change by pressing

key P use the keys +/– to adjust the value within the

permissible limits.

5. To cancel the new setting press key P (P = abort). The old

value will then remain valid.

6. To conﬁrm and activate the new value press key OK

(OK = conﬁrm). The parameter window appears again.

7. Press key OK (OK = back) to quit the programming mode.

The window that was active before you switched the mode

will reappear.

Programming mode

Commissioning Procedure – continued –

Parameter

act Value Offset

Value : 0 ppm

= prev = next

= backOKP = change

Parameter

act Value Offset

Value : 2 ppm

= inc Para = dec Para

= confirmOKP

= abort

Parameter

act Value Offset

Value : 2 ppm

= prev = next

= backOKP = change

Commissioning Procedure – continued –

Other parameter settings

Note

The export of data (Parameter Datalog Export) is described in a separate operating

manual.

Parameter

Output 0/4 . . 20 mA

Value : 4 mA

= prev = next

= backOKP = change

Parameter

Datalog Export

Start

= prev = next

= backOKP = change

Parameter

Alarm2 Limit Value

Value : 15 ppm

= prev = next

= backOK

P= change

Parameter

Alarm2 Time Delay

Value : 5 sec

= prev = next

= backOKP = change

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Flowserve GESTRA OR 52-7 Installation Instructions Manual

Brand: Flowserve

Model: GESTRA OR 52-7

Category: Toys & accessories

Type: Installation Instructions Manual

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Flowserve GESTRA OR 52-7 Installation Instructions Manual

Flowserve GESTRA OR 52-7 Installation Instructions Manual

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