oily water separator ows 2.2-11 gpm

OILY WATER SEPARATOR OWS 2.2-11 GPM

USER GUIDE & REFERENCE MANUAL

Village Marine Tec. Fresh Water from the Sea

Corporate Sales Office/Manufacturer

2000 W. 135th Street, Gardena, CA 90249 (800) 421-4503 / (310) 516-9911

Fax: (310) 538-4038 E-Mail: [email protected] http: www.villagemarine.com

FACTORY SHOWROOM AND SERVICE FACILITIES

SAN DIEGO, CALIFORNIA FT. LAUDERDALE, FLORIDA WEST PALM BEACH, FLORIDA 2820 Shelter Island Drive 802 S.E. 17TH Street Causeway 155 Blue Heron Blvd. San Diego, CA 92106 Ft. Lauderdale, FL 33316 Riviera Beach, FL 33404 (800) 774-9292 / (619) 226-4195 (800) 625-8802 / (954) 523-4900 (866) 881-4168 / (561) 844-3320 Fax: (619) 226-4199 Fax: (954) 523-2920 Fax: (561) 844-2276 E-Mail: [email protected] E-Mail: [email protected] E-Mail: [email protected] SEATTLE, WASHINGTON PORTSMOUTH, VIRGINIA HONOLULU, HAWAII 1540 N.W. 46TH Street 100 Seventh Street, Suite 102 296 Mokauea Street, Suite 101 Seattle, WA 98107 Portsmouth, VA 23704 Honolulu, HI 96819 (888) 847-7472 / (206) 788-9595 (888) 512-3167 / (757) 399-1350 (808) 842-9995 / (877) 842-9995 Fax: (206) 788-9590 Fax: (757) 399-1449 Fax: (808) 842-9996 E-Mail: [email protected] E-Mail: [email protected] E-mail: [email protected]

TABLE OF CONTENTS

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1.0 INTRODUCTION 1

1.1 UNPACKING AND HANDLING 2 1.2 PERFORMANCE SPECIFICATIONS 2 1.3 PHYSICAL CHARACTERISTICS 2 1.4 UTILITY REQUIREMENTS 2 1.5 ENVIROMENTAL REQUIREMENTS 3

2.0 INSTALLATION 5

2.1 LOCATION FOR OWS 5 2.2 TO INSTALL THE OWS 5 2.3 TO CONNECT THE ELECTRICAL 6

3.0 GENERAL THEORY OF OPERATION 7

3.1 THEORY OF OPERATION 7 3.2 OPERATIONAL DESCRIPTION – SEPARATOR SECTION 7 3.3 OIL DISCHARGE MODE 8 3.4 CONTROL PANEL 8 3.5 CONTROLS AND INSTRUMENTATION 8

4.0 OPERATION 11

4.1 TO START THE OWS 11 4.2 TO SHUT DOWN UNIT 11 4.3 MAINTENANCE SHUTDOWN 12

5.0 MAINTENANCE 13

5.1 PUMP MOTOR LUBRICATION 13 5.2 CLEANING THE SEPARATOR 15 5.3 SYSTEM PROLONGED SHUTDOWN 15

6.0 DISASSEMBLY AND REPAIR 17

TABLE OF CONTENTS

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6.1 SCOPE 17 6.2 TOP HAT REMOVAL AND DRAIN 17 6.3 TOP HAT INSTALLATION 17 6.4 SEPARATION MEDIA REPLACEMENT 17 6.5 LIQUID LEVEL PROBE REMOVAL 17 6.6 LIQUID LEVEL PROBE INSTALLATION 18

7.0 TROUBLESHOOTING 19

8.0 DRAWINGS AND DIAGRAMS 21

9.0 PARTS REFERENCE 27

10.0 MANUFACTURER’S LITERATURE 33

USCG CERTIFICATE OF APPROVAL

PUMP INFORMATION

BILGE OIL ALARM - INSTRUCTION MANUAL

INTRODUCTION

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1.0 INTRODUCTION SYSTEM DESCRIPTION Village Marine Tec’s (VMT) Oily Water Separators (OWS) are well-engineered systems, designed and built to purify oily water to an overall content of less than 15 parts per million (ppm). The Oily Water Separators are designed in accordance with the requirements of IMO Resolution MEPC.60(33) (Guidelines and Specifications for Pollution Prevention Equipment for Machinery Space Bilges of Ships) as incorporated into 46 CFR 162.050. HOW TO USE YOUR MANUAL This User Guide & Reference Manual contains important information about the safe operation and maintenance of your Oily Water Separator unit. We advise you to please read through the entire User Guide & Reference Manual carefully to ensure you familiarize yourself with the operation of your OWS system and follow the recommendations within the manual, to help make your water purification experience trouble-free and enjoyable. SAFETY WARNINGS Throughout this User Guide & Reference Manual you will see many important statements or labels indicated on the product with the following words:

Indicates a strong possibility of severe personal injury or death if warning instructions are ignored.

Indicates hazards or unsafe practices of product may cause minor personal injury or may cause property damage.

NOTE: Text specifies useful information.

INTRODUCTION


1.1 UNPACKING AND HANDLING The Oily Water Separator is shipped pre-assembled. There are no special instructions towards unpacking and handling of the watermaker system. Inspect the RO unit to verify it was not damaged in transit. Be sure to mark and record all hose locations for reference, if disconnection of hoses become necessary. DO NOT EXPOSE THE OILY WATER SEPARATOR UNIT TO FREEZING TEMPERATURES WITHOUT PROPER STEPS TO TREAT THE UNIT FOR SUB-FREEZING TEMPERATURES.

1.2 PERFORMANCE SPECIFICATIONS

Parameter Specification Model Number: OWS-2.2, 4.4, 8.8, and 11

Raw water temperature range: 34°-113° F (1-45°C)

Maximum bilge/oily water inlet pressure: 0 psi(1)

Minimum product water production(2): 2.2-11 GPM (Respectively)

Maximum inlet oil concentration (for continuous operation): 100%

Backflush cycle duration: Variable

Table 1.1 - Performance Characteristics

(1) For inlet pressure greater than recommended limits, contact VMT for technical service. (2) Water production will be directly affected by the amount of back pressure on the system pump.

Excessive or convoluted, piping configurations may reduce unit production below minimum requirements. If you have any questions about your installation, contact VMT for technical service.

1.3 PHYSICAL CHARACTERISTICS Refer to PAGE 28 for weight and dimensions of the OWS.

1.4 UTILITY REQUIREMENTS Refer to the Piping and Instrumentation Diagram (P&ID) in Section 9.0: DRAWINGS AND DIAGRAMS for interconnection properties. Refer to the nameplate attached on control box top for power requirements.

Utility Design Pressure Minimum

Design Pressure Maximum

Oily Water Inlet -20 FT 0

Effluent Discharge 0 30

Unit Drain N/A N/A

Fresh/Flush Water Supply(1) 20 (PSI) 50 (PSI)

Oil Discharge(1) 0 35

Table 1.2 - Utility Requirement

(1) For discharging oil during backflush mode, the fresh water supply pressure must exceed the oil discharge piping system pressure by at least 15 psi.

INTRODUCTION


1.5 ENVIROMENTAL REQUIREMENTS

Parameter Specifications Ambient Temperature Range 34°-113°F (1°-45°C)

Pitch: ±108 (6 sec cycle)

Roll: ±308 (12 sec cycle)

Table 1.3 - Nominal Operating Conditions

INTRODUCTION


INSTALLATION


2.0 INSTALLATION 2.1 LOCATION FOR OWS

Village Marine Tec. recommends installing the OWS unit in the ship, as low as possible. To minimize the amount of external piping, the OWS should be installed as close to the ship’s Oily Waste Holding Tank and overboard discharge connection.

Figure 1: Recommended Installation Location

The unit must be mounted no higher than 20 ft above the bilge water intake. If there are any questions about the installation, please contact VMT for technical assistance.

2.2 TO INSTALL THE OWS

Every installation is unique, the mounting instructions are provided for guidance only. It is recommended that you use your own discretion as to the exact method of mounting and placement of any mounting bolt holes.

Step 1: Place the OWS unit in an appropriate location and drill a minimum of four (4) holes, one through each of the four stanchion bottom support plate. When drilling holes always check to make sure that the drill bit will not pass through to any component of the separator or cause any other kind of damage to the mounting area. Mount the OWS unit securely making sure that the four base stanchions are continuously supported.

Step 2: Refer to the system drawings in Section 9.0: DRAWINGS AND DIAGRAMS for the connection

requirements. Make the following plumbing connections to the pipping interfaces: A FOOT VALVE AND STRAINER MUST BE INSTALLED BY THE CONSUMER TO PREVENT FOREIGN MATERIAL OBSTRUCTING AND CLOGGING THE OWS. FAILURE TO INSTALL A FOOT VALVE WITH A SUITABLE STRAINER MAY VOID THE OWS SYSTEM WARRANTY. Connect the oily water inlet line to the check valve located on the left side of the unit when facing control panel (see Table 1.4 for raw water utility requirements). The inlet piping should at least equal in size to the inlet connection size. A foot valve and strainer must be installed at the end of the inlet piping where it takes suction from the bilge. INLET AND DISCHARGE INTERCONNECTING LINES SHOULD CONSTRUCTED OF SUITABLE MATERIAL. PLASTIC MATERIALS SUCH AS PVC MAY NOT BE SUITABLE DUE TO THEIR INCOMPATIBILITY WITH CERTAIN FUELS AND OILS.

NOTE: Verify all piping connections are airtight. Excessive air in solution with the clean water effluent results in erroneous high oil content readings.

WATERLINEWATERLINE

INSTALLATION


A) Connect the clean water discharge to an unobstructed suitably sized line that is also connected to an appropriate drain. The clean water discharge connection is ¾” FNPT and is located at the pump discharge connection on the left side of the OWS (when facing the control panel). If the clean water is discharged overboard, ensure the discharge port is above the waterline. If the clean water must be discharged below the water line please contact VMT technical department for installation advice.

B) Connect the oil discharge to an unobstructed ¾” line that is connected to the top of the oily waste

storage tank. The oil discharge connection is ¾" FNPT and is located on the back side of the unit (when facing the control panel) near the top.

C) Connect a flush/fresh water source to the ¾" flush water supply line. This connection is ¾" FNPT is

connected at the Fresh Water Solenoid Valve. DO NOT CONNECT THE SYSTEM DRAIN LINE TO THE CLEAN WATER EFFLUENT PIPING AS WATER DRAINED FROM THE SEPARATOR MAY HAVE RESIDUAL OIL LEVELS GREATER THAN 15 PPM.

2.3 TO CONNECT THE ELECTRICAL

TURN OFF ALL ELECTRICAL POWER FOR USE WITH THE RO UNIT PRIOR TO CONNECTING TO THE RO POWER SOURCE. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONS HANDLING THE UNIT.

NOTE: Adhere to all electrical codes and regulations governing the installation and wiring of electrical

equipment. Typical codes specify the type and size of conduit, wire diameter, and class or wire insulation depending upon the amperage and environment.

NOTE: The power supply should always be of greater service rating than the requirements of the RO

unit. This will assure proper voltage even if power supply voltage is slightly less than required. Never connect the RO unit to a line that services another electrical device. THE RO UNIT SHOULD HAVE ITS OWN INDEPENDENT POWER SUPPLY.

Step 1: Connect the correct voltage/power supply to the power cord provided. Step 2: Connect a suitable ground to the OWS unit skid (as determined by the specifics of your installation).

GENERAL THEORY


3.0 GENERAL THEORY OF OPERATION

3.1 THEORY OF OPERATION Oil and water does not mix easily. Given enough time to elapse, a static mixture of oil and water will almost separate on its own. There are special polymers that have strong affinities for oil. The design and construction of your VMT OWS takes maximum advantage of both of these principles in order to reduce effluent oil concentrations to less than 15 part per million (ppm). To minimize oily water agitation, the system pump is placed on the discharge side of the unit. Minimizing agitation on the inlet stream reduces emulsified oil (i.e. suspended in solution) amounts, increasing the overall efficiency of the separation process. Upon entering the separator, the oily water enters a large diameter first-pass chamber, reducing its stream velocity. Decelerating the oily water stream is critical, it maximizes amount of time for gravity separation to take place. The slower the stream velocity, the longer the oily water will be in contact with the polymer filtration media. The first-pass chamber is filled with specially designed polymer rings that have a high surface area to weight ratio. As the oily water flows along the surface of the polymer rings, small droplets will adhere to its surface. When enough has collected, the oil droplet's natural buoyancy will cause it to release and float to the separator top. When enough oil collects at the top, the unit automatically backflushes the accumulated oil out of the unit and into a waste holding tank. Prior to exiting the separator, the reduced concentration oily water mixture passes through a second-pass polishing chamber. This chamber is completely filled with tightly packed polymer beads that are designed to remove any remaining oil from the effluent stream. This design ensures the effluent discharge is at or less than 15 ppm oil by weight.

3.2 OPERATIONAL DESCRIPTION – SEPARATOR SECTION The oily water sucked out of the bilge through a Purchaser supplied foot valve. This valve strains out large particles and objects accumulated in the bilge. The oily water stream then flows through a check valve (see Section 3.3: OIL DISCHARGE MODE) and into the separator. Upon reducing the oily water stream velocity, it enters the first-pass chamber taking up approximately ½ of the total volume of the separator. The chamber is capped with a removable metal retaining screen that is designed to contain the polymer separation media. It is in this chamber that the bulk of the oil separation takes place. After flowing vertically down through the first pass chamber, the oily water stream passes through a second retaining screen into the second-pass chamber. This chamber contains tiny polymer beads designed to remove any oil residual oil from the water stream.

Figure 2: System Diagram

GENERAL THEORY


3.3 OIL DISCHARGE MODE When enough oil collects at the top of the separator, a liquid level monitoring assembly automatically reconfigures the system and begins discharging oil to the ship supplied Oily Waste Holding Tank. The actual process is as follows: The oil discharge process is initiated when enough oil has accumulated to cover the entire length of the longest of the three level probes. A signal is sent to secure the system pump, shut the clean water discharge valve and open the fresh water valve. Fresh water then flows into the unit through the bottom and forces the oil out through the oil discharge piping. When sufficient oil has been discharged to enable the water to contact the shortest liquid probes, the automatic flush mode secures and the system returns to its normal configuration

3.4 CONTROL PANEL The OWS is equipped with a centralized control panel for monitoring of all important unit functions and operating parameters. The specific control switches and status (indicating) lights utilized are as follows: CONTROL SWITCHES (1) ON/OFF CONTROL SWITCH

Controls the operation (ON/OFF) of the entire system. Placing the switch in the "OFF" position prevents all operation of the system regardless of the position of the Flush switch.

(2) MODE CONTROL SWITCH Three position switch that controls activation of the Oil Discharge mode

(3) MANUAL

immediately reconfigures system and activates a system flush regardless of oil level. Unit will continue to flush until Flush switch is placed in either "Off" or "Auto" positions.

(4) OFF Deactivates oil discharge capability

(5) AUTO Reconfigures system and activates a system flush whenever the liquid level indicator detects a high oil level. After a fixed amount of oil is discharged, automatically reconfigures the system for normal operations.

STATUS (INDICATING LIGHTS) (6) CLEAN WATER DISCHARGE LIGHT

GREEN light illuminates whenever the unit is operating in its normal mode and is discharging clean effluent.

(7) OIL DISCHARGE LIGHT

AMBER light illuminates whenever the unit is operating in the Oil Discharge mode and is discharging either oil or fresh water.

(8) POWER ON LIGHT

RED light illuminates whenever the unit is receiving the power necessary for operation. This light will illuminate regardless of whether the unit is actually operating.

3.5 CONTROLS AND INSTRUMENTATION The following table illustrates how the quality and quantity of permeate produced by a RO system is affected by changes in temperature, salinity and pressure:

GENERAL THEORY


CALL OUT DESCRIPTION FUNCTION

FR Flow Restrictor Ensures constant flow through system not to exceed rated capacity

(not on all models).

P1 System Pump Provides suction pressure necessary to provide adequate effluent

flow.

PG1 Pump Discharge Pressure

Gauge

Monitors pump discharge pressure

PG2 Vacuum and Pressure

Gauge

Monitors separator section pressure (vacuum pressure during

normal operations and positive pressure during flushing).

PRV1 Pump Discharge Pressure

Relief Valve

Relieves excess pressure during normal operations

V1 Clean Water Discharge Valve

Normally closed solenoid operated valve that sends treated water

overboard

V2(2) Dirty Water Discharge Valve Normally closed solenoid operated valve that returns water to bilge

when oil content is greater than 15 ppm

V3 Oil Discharge Check Valve Prevents back flow into the unit from the oily waste system during

normal operations

V4 Oily Water Inlet Check Valve Prevents back flow from the unit into the bilge during fresh water

flushing (i.e. during oil discharge mode)

V5 Drain Valve Manual ball valve that is used to drain the unit for maintenance

V6 Flush Water Supply Valve Solenoid operated valve that is open during flushing operations and

shut during normal operations

V7(2) OCM Flush Valve Flushes OCM cell with fresh water

OCM1(2) Oil Content Monitor Measure discharge oil concentrations and directs effluent to bilge

when oil concentration is greater than 15 ppm

SW1 System Start/Stop Switch Provides operational control of the system

SW2 Mode Control Switch Provides operational mode control of the system

F1(1) Filter Coalescer Utilizes a oil absorbent coalescing filter to remove residual oil to

ultra-high purity levels (1) For units equipped with (optional) Filter Coalescer (2) For units equipped with (optional) Oil Content Monitor

Table 3.1 - Factors Affecting Permeate Quality

GENERAL THEORY

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OPERATION

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4.0 OPERATION 4.1 TO START THE OWS NOTE: For the initial start-up, verify to first complete the system installation in accordance with Section

2.0: INSTALLATION for preparation for use, installation, and start-up. Step 1: Check tightness of all lines and fittings. Step 2: Verify the POWER ON light illuminates. Step 3: Verify the Drain Valve (V5) is shut. Step 4: Place the MODE CONTROL switch in the AUTO position. Step 5: Place the ON/OFF switch in the ON position. Verify the OIL DISCHARGE light illuminates. Step 6: Inspect all plumbing connections in the unit for leakage. Secure the unit and repair any leaks prior to

proceeding. Once the leaks are repaired, repeat the start-up procedure from the beginning. 4.2 TO SHUT DOWN UNIT Step 1: Place MODE CONTROL switch in OFF position. Step 2: Place ON/OFF switch in OFF position. Step 3: Verify CLEAN WATER DISCHARGE and OIL DISCHARGE lights have gone out.

OPERATION

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4.3 MAINTENANCE SHUTDOWN

This procedure should be used if any system connections must be broken or the separator itself must be opened for maintenance.

NOTE: This procedure incorporates a gravity drain of the separator that will remove most, but not all of

the water from the separator. Step 1: Place MODE CONTROL switch in MANUAL position. Step 2: After approximately 30 seconds elapsed, place MODE CONTROL switch in OFF position. Step 3: Place ON/OFF switch in OFF position Step 4: Verify CLEAN WATER DISCHARGE and OIL DISCHARGE lights have gone out. Step 5: Open the Drain Valve (V5). Step 6: When no more water flows from the drain connection, shut the Drain Valve.

MAINTENANCE

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5.0 MAINTENANCE

The table below details the specific recommended system maintenance requirements for the Village Marine Tec Oily Water Separators.

Table 5.1 - Maintenance Task Chart.

(1) For units equipped with (optional) Filter Coalescer

5.1 PUMP MOTOR LUBRICATION

NOTE: Motors should be re-lubricated at least once a year.

Step 1: Locate the grease fittings near the motor shaft. Wipe the fitting clean. Step 2: Remove filler and drain plugs. Free drain hole of any hard grease if present (use a wire if necessary). Step 3: Add 2-3 strokes of grease using a low pressure grease gun (see Table 5.2 for grease type). Injecting

grease too quickly can cause untimely bearing malfunction. Inject grease slowly for approximately 1 minute.

Location Type

Pump Motor Chevron SRI Grease - NGLI 2 ExxonMobil PolyrexEM Grease Shell Oil Dolium R - NGLI 2 Texaco Premium RB O-rings and Gaskets Glycerin or Silicone Lubricant

Table 5.2 - Motor and HP Pump Lubrication Requirements.

DO NOT mix grease types. Keep consistent the grade and type of grease used for motor. Also, keep the grease CLEAN.

Step 4: If the motor is equipped with a motor drain plug, replace the drain plug (if removed) and start OWS unit.

Let RO to run motor for approximately 20 minutes. Step 5: Secure the OWS unit, wipe off any of the drained grease and replace the fill and drain plugs, as

required. The motor is now ready to resume operation.

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Clean/inspect external foot valve or strainer • 0.5

Clean and inspect coalescer filter(1) • 2.0

Replace coalescer filter(1) • 1.0

Lubricate pump motor • 0.5

MAINTENANCE

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COMMENT/DISCREPANCY REPORT

Village Marine Tec Oily Water Separator Model OWS ______

Plant No: Date: Log Task No: Time: System Affected: Technician : Comment/Discrepancy: Corrective Action: Action Taken: Date Completed:

Printed Name:

Signature:

Figure 5.1 - Sample Discrepancy Report

MAINTENANCE

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5.2 CLEANING THE SEPARATOR

NOTE: If the discharge of water into the waste oil tank is unacceptable, a line must be installed to manually diver the oil discharge link back to the bilge when cleaning.

Step 1: Stop the system pump by placing the Operation Switch (21) in the OFF position. Step 2: Place the Operation Switch in the MANUAL position; This will start the backwash. If hot water 100°F –

150°F (37°C-65°C) is available, it should be utilized for backwash and oil discharge. Step 3: Allow the system to remain in backwash for approximately 30 minutes. 5.3 SYSTEM PROLONGED SHUTDOWN

The waste oil is an excellent breeding ground for bacteria. During shutdowns of more than three days, the OWS should be flushed to prevent bacteria from forming. For extended durations of shutdowns or storage periods (greater than 2 months), the OWS should be cleaned and drained.

NOTE: If the discharge of water into the waste oil tank is unacceptable, a line must be installed to manually diver the oil discharge link back to the bilge when cleaning.

Step 1: Flush the separator by placing the Operation Switch on the Control Box in the manual position to backwash for approximately 5 minutes.

Step 2: Place the Operation Switch to the OFF position. Step 3: Place the Power Switch on the Control Box to the OFF position.

MAINTENANCE

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DISASSEMBLY AND REPAIR

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6.0 DISASSEMBLY AND REPAIR

6.1 SCOPE This section provides instructions for removal, disassembly and repair of the Village Marine Tec Models OWS Oily Water Separator and its components.

6.2 TOP HAT REMOVAL AND DRAIN Step 1: Place separator ON/OFF switch in the "OFF" position.

WATER DRAINED FROM THE SEPARATOR MAY HAVE RESIDUAL OIL LEVEL OF GREATER THAN 15 PPM. DO NOT DISCHARGE OVERBOARD IF WATER IS GREATER THAN 15 PPM.

Step 2: Connect OWS drain to a dedicated holding tank or bilge (if not connected during initial installation). NOTE: If holding tank is at level or above the OWS, use a boost pump to complete the system drain.

Step 3: Open the Drain Valve (V5). Drain separator until no flow is witnessed as pipe/hose termination point.

Step 4: Remove bolts securing top hat. Carefully remove and set aside, o-rings and bolts, for re-assembly.

Step 5: Place a tape mark on the separator and top hat to ensure proper alignment during re-assembly.

Step 6: Remove and set aside the top. Be careful not to place the oil probe cord under tension. Remove oil

probe cords at control box if necessary (see Section 6.6 – LIQUID LEVEL PROBE REMOVAL). 6.3 TOP HAT INSTALLATION Step 1: Install probes (if required) in accordance with Section 6.5: LIQUID LEVEL PROBE INSTALLATION. Step 2: Using handles, align tape marks on separator main vessel and top hat and replace gasket and top hat. Step 3: Re-install bolts and tighten nuts. Step 4: Fill and start separator in accordance with Section 4.1: THE START THE OWS. If leakage occurs

around the gasket, secure filling and tighten retaining nuts. Refill and repeat until no leaks are observed. 6.4 SEPARATION MEDIA REPLACEMENT

In normal and proper operation, the media will not require replacement. Periodic thorough cleaning can be done by flushing with hot water (up to 150°F). If media replacement is required due to special circumstances, then remove top hat as per Section 6.2: TOP HAT AND REMOVAL and remove separation screen to remove media.

6.5 LIQUID LEVEL PROBE REMOVAL

Step 1: Remove plug, or tape, from bushing. Step 2: Replace level probes, with compression fittings, in separator top hat. Step 3: Tighten compression fittings. NOTE: For proper level relay function, isolate the probes from another and keep the brass bushings in

proper orientation.

DISASSEMBLY AND REPAIR

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6.6 LIQUID LEVEL PROBE INSTALLATION

Step 1: Place separator ON/OFF switch in the “OFF” position. Step 2: Loosen compression fittings holding all three level probes in place. Step 3: Remove all three level probes, along with compression fittings, as a unit from separator top hat. Step 4: Plug or tape over bushing to prevent debris from entering the separator.

TROUBLESHOOTING

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7.0 TROUBLESHOOTING This section is designed to guide the operator of the Village Marine Tec Oily Water Separator units in locating the probable cause of the most frequently encountered problems. This section can only be a guide to solving potential problems with the RO unit and cannot contain all possible malfunctions, nor can it contain all possible ways to determine the cause of a malfunction. The best troubleshooting tool is the knowledge of the plant gained through experience. Any condition not covered in this section may be resolved by contacting any Village Marine Tec Service Department. Preliminary procedures: 1. Always check for loose connections or broken wires when checking electrical parts. Checking for continuity and

solid contact can prevent hours of wasted effort. 2. Always inspect and test equipment or apparatus for probable cause of malfunction before performing

replacement. When using the troubleshooting guide on the following pages read all the probable causes before taking any action. Use good common sense and then use the probable cause that most likely fits the given situation.

TROUBLESHOOTING

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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Clogged foot valve and/or strainer

Inspect foot valve /strainer and remove any foreign matter.

Closed outlet valve

Open outlet valve.

Pump Repeatedly Trips or Relief Valve Opens

Pump short circuit

Replace damaged wiring.

Foreign material on level probe(s)

Remove level probe(s) and wipe clean

Liquid Level Control relay short circuit

Check probe insulation and/or replace relay

System Won't Enter Flush Mode

Oil leaking past Oil Discharge check valve, V3

Troubleshoot valve. Replace if necessary

Foreign material on level probe(s)

Remove level probe(s) and wipe clean.

Liquid level control relay short circuit

Check probe insulation and/or replace relay.

System in Continuous Flush Mode

Clean Water Valve stuck open

Troubleshoot valve. Replace if necessary.

Clogged foot valve

Inspect foot valve and remove any foreign matter

Pump clogged

Open pump casing and remove foreign matter.

Reduced System Flow

Pump damaged

Troubleshoot pump. Replace if necessary

Table 7.1: Maintenance Task Chart.

DRAWINGS AND DIAGRAMS

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8.0 DRAWINGS AND DIAGRAMS

DRAWINGS AND DIAGRAMS

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PARTS REFERENCE

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9.0 PARTS REFERENCE

PARTS REFERENCE

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MANUFACTURER’S LITERATURE

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10.0 MANUFACTURER’S LITERATURE

MANUFACTURER’S LITERATURE

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RIVERTRACEENGINEERING LTD

INSTRUCTION MANUALBILGE OIL ALARM

UNIT P KINGSFIELD BUSINESS CENTRE,PHILANTHROPIC ROAD

REDHILL, SURREY, RH1 4DPTELEPHONE; +44(0)0870 7702721 FAX: +44(0)08707 702722http://www.rivertrace.com Email: [email protected]

INSTRUCTION MANUAL Doc. 107080 Rev CBILGE OIL ALARM - TYPE OCD CM

RIVERTRACE ENGINEERING LIMITED PAGE 2 OF 25

IMPORTANT NOTICE

Re: Replacement components for Bilge Oil Alarms.

General

All monitors in our range are inspected and tested to I.M.O. requirements at ourfactory prior to delivery.

In normal use the units should operate correctly and without fault over a longperiod of time requiring only small amounts of maintenance to be carried out asoutlined in the instruction manual.

Rivertrace Engineering Limited only recommend the use of fast breaking bilgecleaning detergents.

Component Replacement/Repair

When replacing or repairing electronic components (except fuses) please notethat due to varying component characteristics it may be necessary to re-adjustor calibrate the monitor.

Failure to carry out the correct procedure could result in the monitor over orunder reading which in turn could lead to oil pollution and the consequencesthat follow.

Repair carried out by individuals or companies other than Rivertrace approvedService Centres is not advised. Unless under supervision/ instruction fromRivertrace personnel.



CONTENTS

SECTION TITLE PAGE NO.

1. Introduction 3

2. Important Notes 4

3. Principle of Operation 5

4. Specification 6

5. Constructional Details 7

6. Autoclean System 8

7. Installation 10

8. Wiring 11

9. Commissioning 14

10. Operating Instructions 18

11. Trouble Shooting Guide 19

12. Operator Maintenance 21

13. Spares 22



1. INTRODUCTION

The OCD CM Bilge Alarm Unit has been designed specifically for use inconjunction with 15ppm oily-water separator units. It has a specification andperformance which meets the requirements of the International MaritimeOrganisation specifications for Bilge Alarm Units contained in Resolution MEPC60 (33).



2. IMPORTANT NOTES

a) This equipment must be installed and operated in strict accordance withthe instructions contained in this manual. Failure to do so will impair theprotection provided.

b) Installation and servicing must be undertaken by a competent andsuitably skilled person.

c) The equipment must be provided with a sound electrical earthconnection.

d) The unit must be isolated from the electrical supply before anymaintenance of the equipment is attempted.

e) All National or local codes of practice or regulations must be observedand, where applicable, are deemed to take precedence over anydirective or information contained in this manual.

f) Hazardous voltages are present within the monitor enclosure.

g) We recommend that after use the monitor should be flushed with cleanwater to prevent scale or other deposits forming in the cell tube



3. PRINCIPLE OF OPERATION

Multiple optical sensors measures a combination of light scattered andabsorbed by oil droplets in the sample stream. The sensor signals are then readby a microprocessor, which uses advanced solids discrimination algorithms todetermine the oil content of the sample. This improved algorithm results in aperformance greater than twice the required solids rejection set down in MEPC60 (33). The microprocessor also drives a 0-5v, 1-5V, 0 – 20mA or 4 – 20mA dclinearised output, two seven segment displays, six light emitting diodes, two oilalarm relays (at adjustable 1 – 15ppm set points) and one fault relay (used todrive autoclean when fitted).

The microprocessor continuously monitors the condition of the sensorcomponents and associated electronics to ensure that calibration accuracy ismaintained over time and extremes of environmental conditions.

In the event of a failure the oil alarm relays and fault relay are set to the alarmstate (de-energised) and both alarm status indicators and fault indicator are setto RED. An error code is displayed on the two seven segment displays relatingto the fault identity.



4. SPECIFICATION

Range : 0 – 30 ppm (Trend to 40 ppm)

Accuracy : Better than IMO MEPC 60 (33)

(+/- 5 ppm)

Concentration Indication : 2 x 7 segment LED

Alarm Operating Points : 1 - 15ppm (adjustable)

Alarm 1 Operating Delay : 0-20 sec (adjustable)

Alarm 2 Operating Delay : 10-240 sec (adjustable)

Alarm Contact Rating : 8A @ 240V

Alarm Relay Mode : De-energised in Alarm State

Fault Indication : Alphanumeric code

Output Signal : 0–20mA, 4–20mA (820 Ω max load) ,

0–5V & 1–5V DC (50 KΩ min load)

Projected Life (Electronics) : > 50,000 Hours

Ambient Temperature : +1°C to +55°C

Humidity : 90% RH Max @ 55°C

Sample Temperature : +1°c TO +60°c

Sample Flow : 0.5 to 2 Litre/Minute

Sample Pressure : 0.1 to 10 Bar

Clean Water Requirement : As for Sample

Weight : 2.25kg (stand alone monitor)

7.5kg (autoclean option)

Size : 215 x 242 x 73mm(stand alone monitor)

290 x 468 x 76mm(autoclean option)

Supply Voltage : 2 models available 230V/115V ac and

24V ac

Supply Variation : ± 10% of Nom. Voltage

Supply Frequency : 50/60 Hz

Consumption : 10VA Max Alarm (stand alone monitor)

: 50VA (during autoclean cycle)

Degree of Protection : IP 55

Electrical installation (overvoltage)classification : EN61010-1EC664 category 11



5. CONSTRUCTION DETAILS (Refer to Fig 5.1)

The OCD CM, in common with other versions of the OCD series, is a veryrobust instrument ideally suited to the aggressive environments of marine enginerooms.

The measuring cell is a sealed unit set to the right hand side of the enclosure.The inlet pipe is situated on the bottom of the cell (8) and the outlet pipe issituated on the top right hand side of the cell (3). A desiccator (7) to eliminatemoisture around the outside of the glass tube and a throttle (6) to regulate flowand maintain pressure are also fitted to the cell.

The main electronics are all contained within the enclosure on two printed circuitboards. Additionally a small PCB containing transmitters and sensors iscontained within the measuring cell. The display board (2) is mounted to thefront cover and provides the PPM display (4) and the six light emitting diodes.The mother board (1) is mounted to the back of the enclosure and contains thepower supply, alarm relays, digital to analogue and amplification circuitry.

The front of the monitor is fitted with a membrane user interface containing threepush buttons (9), and windows for the LED displays.

Fig 5.1 CM Construction Configuration

75

ITEM No. DESCRIPTION ITEM No. DESCRIPTION1 MAIN P.C.B. ASSEMBLY 6 THROTTLE2 DISPLAY P.C.B. ASSEMBLY 7 DESICCATOR3 SAMPLE OUTLET ¼ “ BSPP 8 SAMPLE INLET ¼ “ BSPP4 PPM DISPLAY 9 PUSHBUTTONS5 CELL CAP

INSTRUCTION MANUAL Doc. 107180 Rev. CBILGE OIL ALARM - TYPE OCD CM


6. Autoclean System (where fitted) (refer to Fig 6.1)

The Autoclean System adds another level of reliability to the OCD CM throughthe automation of the cell cleaning process. The assembly is designed toclean the cell tube every 5 – 60 minutes (user selectable see section 9 subsection 7) to reduce the build up of scale and other deposits on the inside of theglass.

The OCD CM is mounted onto a stainless steel back plate (4). Two conduitsprovide passage for wiring between the monitor and the customer terminalenclosure (3). Wiring is also provided to connect the solenoid valve (2) to theterminal enclosure which in turn is connected to the autoclean control relay(fault relay on stand alone monitor). The solenoid valve controls the air flow tothe autoclean cylinder (1) which drives a wiper up and down to clean the celltube. The air inlet fitting is ¼ BSPT and flow should be regulated between 4 and6 bar.

It is important to note that all the existing wiring on the panel isessential to the operation of the autoclean system and that removal

of any such connections will impair the operation of the monitor.

Fig 6.1 CM Autoclean Construction Configuration

ITEM No. DESCRIPTION1 AUTOCLEAN CYLINDER2 SOLENOID VALVE3 CUSTOMERS TERMINAL ENCLOSURE4 MOUNTING PLATE



Below is shown an expanded view of the customer terminal enclosure. Terminalidentities match with those shown in section 8 (Fig 8.1) except for the fault relaywhich is not available with the autoclean option.

Fig 6.2 CM Autoclean Terminal Enclosure

All remaining connections to the OCD CM can be made as shown in thefollowing sections.

+ -SIGOUT L N AL1 AL2



7. INSTALLATION (Refer to Fig 7.1)

See section 2 for important notes.

Location

The OCD CM monitor should be located on or in close proximity to the oily-waterseparator to minimise response delays. Under no circumstances should thedistance between the monitor and the separator exceed 8 metres since thiswould result in a response time of more than 20 seconds and breach IMOregulations.

Mounting

Mount the OCD CM by means of 4 x M4 screws on to a rigid vertical surface andpreferably with the display panel of the monitor at eye level.

Fig 7.1 Installation Guidelines

SAMPLE

CLEANWATER

DRAIN

2 M MIN

200 mm

ENSURE LEVELIS CLEAR OFBILGE WATER

10 mmPIPING



8. WIRING (Refer to Fig 8.1)

See Section 2 for important notes concerning wiring.

This unit must be connected to the mains supply via a suitably rated andapproved fused isolator unless such fusing/isolation is provided by associatedequipment. When fitted the isolator should be close by, readily accessible andmarked as to function.

Cable entries can accept cables from 6 to 12 mm diameter. The terminalblock will accept cable cores of up to 4 mm and cables carrying hazardousvoltages must be at least 0.75 mm csa . When terminating mains cabling atmonitor and electrical source, the earth conductor must be made longer thanthe live and neutral conductors.

To select between 230V and 115V supply a link (or two in the case of 115 V), isattached on JP1 and JP2 in the relative formations shown in fig 8.1. The link mustbe electrically insulated and at least 0.25 mm csa.

Note to make connections to J11, J12, JP1 and JP2 terminals may be pulled outof PCB connections via tags or links provided.

Connections to the cables should be made as shown in Fig 8.1

22

2



Fig 8.1 Terminal Connections OCD CM

Connector todisplay board

ALARM 1 ALARM 2 FAULT

+ I OUT & - I OUT(0 - 20 or 4 - 20)

V OUT & - V OUT(0 - 5 or 1 - 5)

USER SELECTABLESEE SECTION 9 - 6

Connectorto cell

JP1 JP2

JP1 JP2

230 V SUP

115 V SUP

MAINS IN

+ V OUT- V OUT+ I OUT- I OUT

* NOTE IF A 24V CM MONITOR IS TO BE USEDKEEP JP1 AND JP2 AS FOR 230V



Precise wiring details will vary dependent upon the control system to beemployed but the most frequently used systems employ Alarm relay 1 for controlpurposes and Alarm relay 2 for alarm annunciation only.

Typical Control System

The two most frequently employed systems are:-

a) Pump Stop on AlarmWith a pump stop system Alarm relay 1 controls the energisation of thebilge pump Direct On Line starter coil.

b) Recirculate on AlarmA recirculate system employs Alarm relay 1 to control a solenoid valvewhich energises or de-energises a pneumatically operated 3 way valve.

The disadvantage of a pump stop system is that in the event of an alarm action,the process of discharging bilge water is halted and it may be impossible torestart the process without first flushing with clean water. This problem is avoidedwhen a 3 way diversion valve is provided since on alarm the contaminated bilgewater will be switched from the overboard discharge back to the bilge pumpsuction or bilge space. The separation process will continue until such time asthe pollution level falls below alarm 1 set point PPM at which time the dischargewill be directed overboard.



9. COMMISSIONING


Fig 9.1 User Interface guideline

On completion of the installation, wiring and piping carry out the following checks:-

1) Electrical• Check that the power supply voltage on cables 1 and 2 are within

limits.• Check to confirm that a good connection to earth has been made.



2) Piping• Check all piping connections for leaks and rectify as appropriate.

Functional Tests (refer to Fig 9.1)• Turn the supply voltage to the Monitor on, the display (1) should read

FC (Factory Calibration) for 3 Seconds. (*note this will only change toCC if a full scale calibration is performed outside factory conditions).

• The monitor will then run through a self diagnostic and initialisationroutine. During this time the display will count down from 40 to 0 andback up to 40 again. Alarm LED’s will extinguish + illuminate at alarmset points.

• Run oil free water through the instrument for a short period to purge thesystem of air and dirt.

• Adjust the Throttle screw (Fig 5.1 – 6) in the cell cap so that the flowrate through the cell is between 0.5 and 2 litres/min. NB. The flow rateshould be checked on both the clean water supply and the separatorsample supply. If the clean water supply is obtained from a highpressure source, it may be necessary to restrict this at a point up-streamof the clean water/sample 3 way selector valve.

• Switch the clean water supply to the instrument and after 2 minutes setzero in accordance with the Operating Instructions (see sect 9.5).

• Set-up the monitor to give a 0 – 5V analogue output and connect avolt meter across + V out and – V out (see sect 9.6). The reading shouldnot vary by more than 0.25v above zero (equivalent to + 1.5ppm). Ifthe reading varies by a greater amount, air entrapment is almostcertainly present and changes to the sample piping or sampling take-off point may be necessary.

3) Setting Alarm points (refer to Fig 9.1)• Alarm 1 and alarm 2 are both factory set to 15 PPM. To adjust these

points the following procedure should be followed .

• To adjust alarm 1 set pointPress & release the DOWN or UP KEY (10 or 9) repeatedly until the PPMLED (3) and the ALARM 1 ADJUST LED (6) are both on, the alarm 1 PPMset point is now displayed. Press & release the SET/ZERO KEY (8).Adjust the PPM value by pressing the UP or DOWN KEY (10 or 9) until thedesired value is displayed. Acknowledge the desired value by pressingand releasing the SET/ZERO KEY (8)

• To adjust alarm 2 set pointPress & release the DOWN or UP KEY (10 or 9) repeatedly until the PPMLED (3) and the ALARM 2 ADJUST LED (7) are both on, the alarm 2 PPMset point is now displayed. Press & release the SET/ZERO KEY (8).Adjust the PPM value by pressing the UP or DOWN KEY (10 or 9) until thedesired value is displayed. Acknowledge the desired value by pressingand releasing the SET/ZERO KEY (8)



4) Setting Alarm delays (refer to Fig 9.1.)

• Alarm 1 and alarm 2 delays are factory set to 0 and 10 secondsrespectively. To adjust these delays the following procedure should befollowed .

• To adjust alarm 1 delayPress & release the DOWN or UP KEY (10 or 9) repeatedly until theSECONDS LED (2) and the ALARM 1 ADJUST LED (6) are both on, thealarm 1 delay is now shown on the display (1). Press & release theSET/ZERO KEY (8). Adjust the SECONDS value by pressing the UP orDOWN KEY (10 or 9) until the desired value is displayed.Acknowledge the desired value by pressing and releasing theSET/ZERO KEY (8)

• To adjust alarm 2 delayPress & release the DOWN or UP KEY (10 or 9) repeatedly until theSECONDS LED (2) and the ALARM 2 ADJUST LED (7) are both on, thealarm 2 delay is now shown on the display (1). Press & release theSET/ZERO KEY (8). Adjust the SECONDS value by pressing the UP orDOWN KEY (10 or 9) until the desired value is displayed.Acknowledge the desired value by pressing and releasing theSET/ZERO KEY (8)

5) Calibrating for clean water (refer to Fig 9.1)

• Insure that there is no flow through the cell. Remove cell cap andclean the inside of the cell tube with bottle brush provided. Replacethe cell cap.

• To calibrate the monitor to local clean water ensure that clean wateris passing through the measuring cell then Press & hold the SET/ZEROKEY (8) for 3 seconds in PPM monitor mode (i.e. LEDS 2,4,5,6 and 7 areall off).

• The display (1) will flash alternately CL and blank for 8 seconds afterwhich the display will read 0 PPM

• If calibration was not successful bC will appear on the display. To clearthis error simply press the SET/ZERO KEY, and the original calibration willbe retained.

Note ALARM 2 DELAY is shown in multiples of ten(e.g. display reads 9 but the delay is 90 seconds)

Note Clean water calibration can only re-zero the display ifthe clean water sample is within 2 PPM of factory set value.



6) Output range Selection (refer to Fig 9.1)

• To select the output range, the correct cable connections should bemade first.

• If an output range of 0 – 20 mA or 4 – 20 mA is required terminals + IOUT and – I OUT should be connected on J11(see section 8 fig 8.1).

• If an output range of 0 – 5 V or 1 – 5 V is required terminals + V OUT and– V OUT should be connected on J12 (see section 8 fig 8.1).

• Using the user interface Press & release the DOWN or UP KEY (10 or 9)repeatedly until the display (1) shows OP for Output range selection

• To adjust the output press & release the SET/ZERO KEY (8)• The present range is now shown (r0 or r4). Refer to table below below

to see which output range is selected with different combinations ofconnections.

Table 9.1 Output Range Selection Reference

Cable Connections Range Selected Output Range+ I OUT and – I OUT r0 0 – 20 mA

+ V OUT and – V OUT r0 0 – 5 V dc+ I OUT and – I OUT r4 4 – 20 mA

+ V OUT and – V OUT r4 1 – 5 V dc

7) Auto clean cycle frequency (where fitted)

• Using the user interface Press & release the DOWN or UP KEY (10 or 9)repeatedly until the display shows AC.

• To view the current frequency Press & release the SET/ZERO KEY (8). Theauto clean frequency is now shown in minutes on the display.

• Adjust the frequency by pressing the UP or DOWN KEY (10 or 9) untilthe desired value is displayed.

• Acknowledge the desired value by pressing and releasing theSET/ZERO KEY (8).



10. OPERATING INSTRUCTIONS (Refer to Fig. 9.1)

a) Switch on the power supply.b) Allow 2 minutes for the instrument to warm up.c) Flow oil free water through the system for a few minutes. If the display is

greater than zero clean water calibration will need to be performed (seesection 9 sub section 5).

d) Switch the instrument sample supply valve from the clean water supply to the separator sampling point connection.

The instrument is now ready for use.

e) When the sample is flowing through the monitor the display will adjust toshow the current oil content of the sample

f) If the oil concentration exceeds any of the alarm set points (PPM), theAlarm 1 or 2 indicator (4 & 5) will be illuminated and the correspondingalarm relay will operate as soon as the set delay time for each alarm hasexpired.

g) If an error code is displayed on the screen. The fault relay and bothalarm relays will be activated. The error codes translate as follows

Table 10.1 Error code translation table

Error Code MeaningOr PPM value out of rangeSH Excessive solids contentbC Bad clean water calibration see page 15 sect.5E1 Scatter signal too lowE2 Transmission signal too lowE3 Scatter signal too highE4 Transmission signal too high

For trouble shooting on these errors see section 11.



11. TROUBLE SHOOTING GUIDE

Symptoms



The monitor has alarmdelays to prevent excessivevalve switching.

Change delay times. Seepage 15. Setting alarm delays.Alarm 1 delay cannot be setbeyond IMO specifications.

Monitor is in alarmcondition but overboardvalve is open.

Foreign material lodged invalve.

Poor or non existentconnection to alarm relay.

Component fault on mainPCB.

Clean or replace valve.

Check relay connections. Seepage12, figure 8.1

Replace main PCB. See page22, Spares



12. OPERATOR MAINTENANCE (Refer to Fig. 5.1)


AT WEEKLY intervals:-

a) Check the zero with oil free water flowing through the instrument andreset if necessary (see section 9 sub section 5).

b) Flush the cell with oil free water.c) Isolate the instrument from both sample and oil free water supply.d) Unscrew and remove the cell cap (5).e) Insert a bottle brush into the cell using an upwards and downwards motion through the entire length of the cell several times.f) Remove the bottle brush and replace the cap (5).g) Re-connect the oil free water supply and allow this to flow through the

instrument for a few minutes.h) Re-check the zero calibration againi) Re-connect the instrument to the separator sampling point

AT MONTHLY intervals:-

a) Check the colour of the DESICCATOR window (7) to ensure it is blue,indicating correct moisture content of cell. Replace Desiccator if colouris either PINK or WHITE.

b) Install new Desiccator by unscrewing the old Desiccator unit (7) andinserting a new one. DO NOT OVERTIGHTEN DESICATOR – Finger tight issufficient. Ensure the O ring seats properly against the cell houseing.

AT YEARLY intervals (units with autoclean / manual clean only):-

At yearly intervals (or where necessary) the wiper ring on the autoclean /manual clean assembly (where fitted) should be replaced. This can beordered from RTE directly as part no. 103136



13. SPARES

When ordering spares, it is important to supply details of the type of monitor,serial number of monitor, part number of each spare required, its description andany other relevant information.

RECOMMENDED ON-BOARD SPARES

Item Qty Part NumberDesicator 1 107413Bottle brush 1 100244Fuse (115/230 V Version) 1 106989Fuse (24 V Version) 1 101877

OTHER SPARES

Item Qty Part NumberCell assembly + matched chip 1 106970 + 107195Main PCB 115/230 VAC 1 107053Main PCB 24 VAC 1 107258Display PCB 1 107037Cable Gland 1 106883Membrane Overlay 1 106847Manual Clean Unit 1 107229Manual/Auto Clean Wiper Ring 1 103136Calibration Verification fluid 1 107651

oily water separator ows 2.2-11 gpm

Documents