ATT_I.A_4404_593_B.pdf

TP: 4404

(HM&E MANUAL)

TECHNICAL MANUALS

OIL CONTENT METER, MODEL ER-35A –

INSTRUCTION MANUAL

SHIMADZU CORPORATION

DISTRIBUTION STATEMENT D. - Distribution authorized to Department of Homeland Security, DoD and their contractors to protect publications required for official use or for administrative or operational purposes only, determined on 29 January 2009. Other requests for this document shall be referred to Commander, USCG Surface Forces Logistics Center, ESD - Tech Info Mgmt Br, 2401 Hawkins Point Road (M/S 25), Baltimore, MD 21226

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties.

DESTRUCTION NOTICE. - For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

PUBLISHED UNDER AUTHORITY OF THE U.S. COAST GUARD

SWBS 593

SECTION: B

Department of Homeland Security

UNITED STATES

COAST GUARD

Individual Manual Application Sheet

Technical Publications Number

Section Applicability

SWBS Number 593 SWBS Element Title

ENVIRONMENTAL POLLUTION CONTROL

SYSTEMS

Section Identifier B

Equipment Functional Description

OIL CONTENT METER, MODEL ER-

35A - INSTRUCTION MANUAL

CI Functional Description ESWBS Code Remarks

Planset Hulls

618-WMEC 615, 616, 617, 618, 619

627-WMEC 620, 621, 623, 624, 625, 626, 627, 629, 630

INSTRUCTION MANUAL

FOR

OIL CONTENT METER

MODEL ET-35A

(P/N 321-30670-02)

SHIMADZU CORPORATION

1 . GENERAL

2. STANDARD SETUP

3. SPECIFICATIONS

4. PRINCIPLE OF OPERATION

5. CONSTRUCTION

5.1 Sampling and Detection Section

5.2 Control Section

6. INSTALLATION 10

6.1 Installing the Main Unit 10

6.2 Piping Diagram 11

6.3 Winng 12

. PRECAUTIONS 16

8. TEST RUN

9. OPERATION 18.

10. TROUBLESHOOTING AND REMEDIES 18

11 . LIST OF REPAIR PARTS

I t

1 . GENERAL

In order to keep the seas free of oil pollution, the discharge of oily water from ships is regulated by the International Maritime Organization (IMO) . Bilge water and fuel tank ballast is processed through (15ppm) oily water separators to reduce the oil concentration to less than 15ppm before discharging it overboard . The oil content meter ET-35A measures the oil concentration of oily water separator effluent, and activates alarm signals oil content is measured in excess of 15 ppm .

These alarm signals can be used to automatically control electric valves to recirculate discharge water through the oily water separator .

Ol 4 - 10 mm dia . fitting holes

Screws for opening door

® Sample inlet

Sample outlet

Indicator

® POWER pushbutton switch

TEST pushbutton switch

Name plate

15C cable fitting for input power

Q 1© 15C cable fitting for alarm signal

Fig. 1 Oil Content Meter Model ET-35A

2. STANDARD SETUP

3. SPECIFICATIONS

Measuring method : Measurement of turbidity before and after emulsification by ultrasonic vibration .

Measuring range :

0 to 30 ppm, lppm resolution .

Accuracy :

Less than ±5 ppm (at 15 ppm)

Measurement cycle time :

15 seconds

Alarm signal :

15 ppm alarm; Two circuit contact output .

Out of order alarm; One circuit output .

Power fail ; One circuit output.

(Contact capacity ; 220V AC, 1A)

Water pressure:

0.3 to 2 kg/cm2 (4.5 to 30 prig)

Sample flow rate :

0.9 to 2.5 Q/min. (0.25 to 0.65 gal/min)

Data output :

Oil content value in ppm by liquid crystal digital display.

Red LED warring light when value exceeds 15 ppm .

Green LED indicates value less than 15 ppm.

Red LED indicates instrument malfunction.

Environmental requirements :

Temperature :

55°C (127°F) max .

Humidity; 90% RH max.

Vibration ; ±0.70 (13.2-80Hz)

±lmm (2-13.2Hz)

Rolling ; 22.5°max .

Power requirements :

100/110/115/220V AC ±10%

50160Hz, 150 VA

External Dimensions :

245(W) X 141(D) X 310(H) mm

(9.6"X5.6"X12.2")

Weight :

Approx. 8 kg (17.2lbs)

-~ 2;_

Item P/N Quantity

0-ring, 1A, P12.5 036-10214 4

0-ring, 1A, P16 036-10217 4

Fuse, 2A 072-01014-84 2

Fuse, 3A 072-01015-84 2

Measuring cell 321-28423

4 PRINCIPLE OF OPERATION

The Model ET-3 5A oil content meter samples water as it leaves the oily water separator, and .

measures the oil content by detecting the increase in turbidity after ultrasonic emulsification .

The sample is introduced into the measuring cell when solenoid valve mV opens . Bubbles generated during the sample change are removed with low energy ultrasonic vibration, (cycle ar) .

During timing cycle t1, the baseline turbidity of the sample (T1) is measured. The detector consists of one light source and two CdS photo detectors . Detector io measures light transmitted through the sample, and detector' i0 measures scattered light at angle 0 .

Turbidity is defined as :

T = K • iO / io where, K = Constant multiplier iO = Strength of scattered light at angle 0, io = Strength of transmitted light .

The turbidity signal T is sent to the counting circuit which consists of a counter and an indicator by means of an A-D converter. The value of the turbidity signal T1 is stored as the number of pulses measured during timing cycle t1 .

Typically, oil in water is suspended in large drops . When the sample is exposed to high energy ultrasound, these large drops are broken into very small droplets, or emulsified . The emulsified oil increases sample turbidity .

During timing cycle ue, high energy ultrasound emulsifies the oil in the sample . This high energy pulse is followed by a low energy pulse in timing cycle ar which removes air bubbles from the sample .

The ar pulse is 1/10th as strong as the ue pulse.

The number of counts measured during timing cycle t2 is equivalent to turbidity T2 and is sent .to the counter by means of the A-D converter.

The turbidity difference between T2 and T1 represents the oil content of the sample, and the result of these internal calculations is displayed as oil content in ppm . Suspended solids, air bubbles, material on the sample cell windows and dissolved materials which discolor the sample are excluded from the measurement. Thus, only oil content . is measured .

An alarm signals oil content in excess of 15 ppm, and two contacts are activated which are typic-ally used to recirculate bilge water through the oily water separator, and to activate the separator clean up cycle .

The ET-35A performs self-checking routines, and if a malfunction is found a separate circuit is activated which signals detector malfunction.

Samping and detection section

Control section

Detection section

Solenoid valve

Vibrator

T--K ie/io io fl4G

L Outlet

Inlet

Pressure switch

50KHz Generator

A/D Converter

III _ Timer

Indicator L ppm

DA

(Option)

15 sec.

1 mV Ar t 1 ue ar t l u fl

I

Fig. 2 ET-35A Block Diagram

Iii --I

DC Power supply j r i

I

I I I I I i I

External devices

Printer

~/ Date

PPM

Alarm phone

I DIQ Discharge valve

Recorder

CONSTRUCTION

The ET-35A oil content meter consists of a sampling and detection section and a control section .

These sections are inclosed in a',splash proof metal case .

O1

Sampling and detection section

Power supply printed circuit board

50kHz generator printed circuit board

Main amplifier printed circuit board

Terminal assembly for external connections

Matching coil for vibrator

Variable resistor VR3 for zero adjustment

Variable resistor VR1 for sensitivity adjustment

Fig. 3 ET-35A Oil Content Meter, Inside Views

5.1 Sampling and Detection Section

This section consists of two solenoid valves, a detecor and measuring cell, and an ultrasonic vibrator. A pressure switch is located on the measuring cell inlet . side, and when the water pressure exceeds 0.3 kg/cm2 the ET-35A automatically begins the sampling cycle .

Solenoid valve mV opens to introduce sample into the measuring cell, and valve mV (measuring cell bypass control valve) closes. These two valves operate in opposition to each other permitting alternate sampling and sample by-pass.-

The detector measures ample'turbidity, and the ultrasonic vibrator removes air bubbles from the sample, emulsifies oil in the sample, and cleans the measuring cell . windows .

Fig. 4 Sampling and Detection Section (1P/N 321-30671-01)

(1) Ultrasonic vibrator (P/N 321-36740)

© 4-M4 set screw for vibrator (P/N 020-46549)

3Q 4-M5 set screw for sampling and detection section

(P/N 020-46568)

® Detection section (P/N 321-38507)

© Solenoid valve (mV) (P/N 321-48295)

© Solenoid valve (mV) (P/N 321-48295)

® Pressure switch (PIN 321-48293)

® Screw for pressure adjustment cell

5.2 Control Section

The control section consists of a power supply printed circuit board (PCB), a 50 kHz generator for the ultrasonic vibrator, and a main PCB .

5.2.1 Power supply PCB

This circuit board converts AC power to stabilized DC power . A 2 amp fuse, a 21 pin terminal assembly for connecting external devices, and an alarm relay are also mounted on this board .

5.2.2 50 kHz generator PCB

The 50 kHz ultrasonic wave generated by this board energizes the ultrasonic vibrator .

The generator frequency may be adjusted by turning the core .

5 .2.3 Main PCB

On this printed circuit board is a counter circuit, timer, ppm indicator and alarm circuit .

(1) Counter circuit

The counter circuit counts the detector signal pulses from turbidity measurements T i and

T2 . The difference between these two values is calculated and the resulting value in ppm is displayed in the LCD .

(2) Timer

The timer circuit generates timed pulses which determine sequencing and timing of each measurement function .

Table 11

Operation 1 2 3 4 5 7 8 10 11 12 13 14

1.

Solenoid valve :

I I

I I I I i mV opening and m V I fI I I I i I I i I I

II .I

closing i I I I I I I I I I I I I i ~ I i { I I

I I 7 i I i I I , I I I ar: Removal of air bubbles i ; ; ; I- I I j I j i I I I--- I I I I I I I I I I i I I I t, : Measurement of raw water I I

I i

I i

I I I -1-

I i i

I I I

I I

I I j I

I i Iturbidity j j t I I I ue: Sample emulsification j j I i I i I I i I

II

I I I I I I I I I I I I I i ar : Removal of air bubbles i t i I I I I I I I I I

~ I I I I I I I I I I I I I I is : Measurement of i I I I I I I I I I I emulsification turbidity I I I i I I I I

I I I I I I f I I I I i I I I I I I I I i

I I I f I I I I I I I t I 1 l I 1 I I 1 i I

(3) ppm indicator and alarm

Oil content values from 0 to 30 ppm are displayed on a 7-segment liquid crystal display (LCD) . When, the oil content exceeds 30 ppm HHH appears in the display . When the oil content is below 15ppm a green light is turned on, and when 15ppm or greater, the green light is extinguished, a red light begins to flash and contacts are closed which can be used to activate valves which recirculate the discharge water . A separate LED alarm indicates the presence of high suspended solids, excessive air bubbles or coloration, and instrument error .

(a)

(b)

19 11

8-

Fig . 5

Indicator Panel

LED (green) POWER

This fight is on when the power switch is on. .

LED (red) WARNING

Indicates either :

cycled through the ET-35A for 15 minutes) .

Blown 2A fuse

Abnormal heat generation in ultrasonic generator

Fault in main PCB

Stained or damaged measuring cell

OIL CONTENT

Abnormal incoming water

In either of the following cases :

High suspended solids concentration

Excessive air bubbles

Excessive water pigmentation

Dirty measuring cell

Instrument problem (if the WARNING LED remains on after clean water has been

HIGH LED (red) Flashes when oil content exceeds 15ppm.

4 LOW LED (green) on when oil content is below 15ppm .

Liquid Crystal Display (LCD) displays oil content in parts per million (ppm) .

zero point and sensitivity adjustment (Fig. 3)

(4) Zero point adjustment

Variable resistor VR3 is used to adjust the display to zero . Decrease displayed value by turning clockwise. Clean water must be cycled through the .ET-35A for 5 to 10 minutes to clean the measuring cell before making this adjustment .

(5) Sensitivity adjustment

Variable resistor VR1 is used to calibrate the display to 15ppm when water containing

15ppm oil is being measured. Turning VR1 clockwise increases the display value .

6 . INSTALLATION

6.1 Installing the main unit

The ET-35A is held in place with 4 bolts. As noted in the drawing below, the exit fitting "T" must be removed to install bolt 'H' . Replace fitting `T' using Teflon tape or equivalent to assure a good seal .

When mounting the oil content meter, type ET-35A on the rack :

After tightening fixing screws of

(in four places), screw the part of t to be fixed.

FRESH SAMPLE

WATER

OUTLET

Fig. 6 Installing the main unit

-10-i

( POWER switch with connector (P/N 321-44538)

Q TEST switch with connector (P/N 321-44539)

Q3 Joint for piping A ID 06 (P/N 320-00312)

1 Joint for piping (P/N 320-00321)

© Joint for piping (P/N 320-00321)

© 1SC cable fitting (P/N 072-60507)

© Joint for piping C ID 4p4.2 (P/N 320-00327)

6.2 Piping Diagram

The two fittings on the lower left side of the ET-35A should be connected in a manner similar to that which is diagramed below.

ET-35A

Drain

Notes :

Change only :

1 .

2 .

Oily water separator I

~--J L J

Outlet B 1

Inlet for fresh r T' water/sea water

(For checking and washing) ..

V, V1

0.3^'2kg/cm2 t

Fig . 7 Suggested Piping Diagram r- 4

Open drain at the end

C ffInlet Pressure P

Line (outlet) must be less than 2 meters long.

Pipes A, B and C should' be 10mm OD X 8mmID copper tubing .

3 . Inlet pressure (P at pressure gauge) is controlled by adjusting valves V 1 and V2 .

should be kept in the range of 0 .3 to 2 kg/cm' . Design pressure is 0.8 kg/cm' .

6.3 Wiring

Three cable fittings are: provided at the bottom of the ET-35A oil content meter . The left-most fitting is used for the AC power supply, and the two fittings to the right are used for connecting alarm devices .

cS b Ol

15 C cable fitting for input power

15 C, cable fitting for alarm signal

O3

15 C, cable fitting for alarm signal

Damper cable

Fuse F, 3A

Fuse :F, 2A

Fig. 8 Wire Connections

-12-

Vibrator i I I I L I

Power fail' I alarm relay I

Fuse F2 2A t switch i

II

II

Power transformer

10 4 Contacts for power fail

TS2

21 22 23 24 25 26 27 28 29

AC 100 110/115 220 PC PB PA S2 S1

i

/0-

Measuring cell

TS1

Photo sensor

C

Ultrasonic generator

Amplifier

1 . 2

AC ACC ACC WC WB WA A2C A2B A2A A1C A1B AlA

T1

AC Power

Contacts for supply

WARNING

detection circuit

A/D converter relay

Timer

10 11

Fig. 9 Connection Diagram

Contacts for alarm i i

6 .3 .1 Power supply requirements

Connect the AC power supply to terminals 1, AC and 2, ACC on terminal strip TS1 . The ground side of the power supply should be connected to terminal 2, ACC if it is known prior to installation . Connect the jumper cable on terminal strip TS2 as described in the following table to meet the incoming voltage requirements .

6 .3 .2 Alarm contact

When the oil content exceeds 15ppm, contacts for the alarm are switched as follows :

Contacts 10, A1C and 11, A1B are opened.

Contacts 10, A1C and 12, AlA are closed .

Contacts 7, A2C and 8, A2B are opened .

Contacts 7, A2C and 9, A2A are closed .

Connect the small pump and miniature solenoid valve to the output of ( or (Z. (The capacity must be less than 2A .)

6 .3 .3 WARNING contact

When the WARNING LED is lit, contacts for WARNING are changed as follows .

Contacts 4, WC and 5, WB are opened .

Contacts 4, WC and 6, WA are closed.

6 .3 .4 Power fail contact

When both the AC power supply switch and the pressure are changed as follows .

Contacts 25, PC . and, 26, PB are opened.

Contacts 25, PC and 27, PA are closed .

switch are on, contacts for power fail

Input voltage (V) Jumper cable connection terminal

100 22,10021, AC

110or115 23,110/11521, AC

220 24,22021, AC

6 .3 .5 In case the contact with voltage is necessary:

(D 0

Jumper cable

AC input power supply

When the oil content exceeds 15ppm, the same voltage as AC input power supply is output between 3-9 and 3-12, respectively.

When the WARNING LED is lit, the same voltage as AC input power supply is output between 3-6 .

When both the AC power supply switch and the pressure switch are on, the same voltage as AC input power supply is output between 3-27 .

Fig. 10 Connection of Contact with Voltage

22 23 24 25

26 27

11 1 2

PRECAUTIONS

Inlet water pressure

The inlet water pressure must be kept in the range of 0.3 to 2.0 kg/cm2 by adjustin manual inlet valves . Design pressure is 0.8 kg/cm' .

Sampler water

The operating principle of the, ET-35A oil content meter is based on the difference in turbidity before and after emulsification by ultrasonic vibration . If an emulsifying agent is present in the sample water, the oil content measurement will be inaccurate.

the

IMO resolution A. 393 (X) states that emulsifier in the bilge of a vessel will cause significant error in measurement by this type of device, and that for this reason emulsifiers should not be used.

Washing (Before and after use)

The sample inlet passage may be dirty, and for this reason fresh water or sea water should flow through the ET-35A for about 5 minutes before and after measurement .

The display value should be at or near zero ppm at the and of the cleaning cycle .

8. TEST RUN

A test run of the ET-35A should be carried out in the following manner .

(1) Verity proper connection of electrical and tubing connections prior to testing .

(2) Close inlet valves for cleaning water and for sample water coming from the oily water separator.

(3) Depress the ET-35A power switch . The green power lamp should light to indicate proper connection to the power supply .

(4) Open the cleaning water supply line to the half open position .

(5) While observing the -pressure gauge, adjust the inlet pressure of the cleaning water to between

0.3 and 1.0 kg/cm2 . When the inlet pressure is properly adjusted, the pressure switch will activate the ET-35A. For the first one or two minutes of operation, 888 will appear in the display, then the value will gradually approach zero (0) . Make sure that water continuously drains from the drain pipe during the test run.

(6) After approximately two minutes of operation, depress and hold down the TEST switch on the control panel. After several seconds, the green LED (LOW) will turn of and the red LED

(HIGH) will flash. The oil content LCD will display HHH, and alarm signal will be activated .

This series of events indicates normal operation .

(7) Turn off the TEST switch. (The TEST switch is automatic resetting type and turns off auto-matically by releasing the hand from it .)

(8) Close the inlet valve for washing water .

(9) Open the inlet valve for the sample water line at the outlet of the oily water separator . Adjust the supply pressure to 0.3 to 1 kg/cm 2 . (Sample measurement starts .)

(10) After the operation is completed, change the inlet valve of the sample water line at the outlet of the oily water separator from open position to close position . (Sample measurement is completed .)

(11) Change the valve at the inlet of the washing water line from close position to a half open posi-tion, and adjust the pressure to about 0.8 kg/cm2 while observing the inlet pressure gauge .

(12) After approx. five minutes, change the valve at the inlet of the washing water line from half open position to close position . In this case, ET-35A stops its operation when the inlet pressure is 0 kg/cm' even if the power, switch is set to ON position .

(13) Turn off the power switch .

9. OPERATION

For the maintenance of the oil content meter model ET-35A, flow the fresh water (or sea water) for approx. five minutes, measure the sample at the outlet of the oily water separator and flow the fresh water (or sea water) again for about five minutes .

Refer to "8 . Test Run

(2) -+ (3) -> (4) -+ (5) -+ (8) - (9) --> (10) -+ (11) -> (12) -> (13)" .

The operation will not start unless the sample pressure at the inlet of ET-35A is from 0.3 to 2.0 kglcm2 .

10. TROUBLESHOOTING AND REMEDIES

1) When the LED ofPOWER for indication of the input power supply does not light even when the power switch is set to ON position .

Check for blown fuse F 1 (3A) and be sure that the specified input power is supplied .

2) The red LED is lighted when measuring the sample of high density of oil content .

Stop measuring the sample and flow the fresh water or sea water for a while from the sample inlet until the lighting of LED stops and the indication nears 0 ppm .

3) WARNING LED is lighted .

In this case, the following three causes are considered . Remove the set screws for the door of

ET-35A, open the door and you will see either of the three LEDs on the printed circuit board is lighting.

LED (D31) of the main ampg4er-ptinted circuitdboard is_lightii}g. (refer to Fig. 3 4O ) High SS concentration, coloring of the sample, mixed air bubbles and such are considered .

Flow the clean water for more than 15 minutes.

LED of the generator printed circuit board is lighting . (refer to Fig . 3 O3 )

Resonance frequency of the vibrator and the oscillation frequency of the generator do not agree. Turn the core of the matching coil and adjust the matching to maximize the sound volume while listening to the cavitation sound .

LED of the power supply printed circuit board is lighting . (refer to Fig . 3 OZ )

Cut fuse F2 (2A) is the cause . Replace the fuse. If the above remedies cannot correct the cause, refer to the service manual since defective , part is suspected .

4) ppm is not indicated even by keeping the TEST switch depressed.

Either the sample is not in the measuring cell or the sample is of high SS concentration . If the sample is not flowing, cause the sample to flow into the measuring cell .

NO. Parts Name P/N

Solenoid valve with connector pin 321-48295

2 Pressure switch with wire and connector pin 321-48293

3 Detector (Detection section) 321-38507

Measuring cell 321-28423

5 Power supply printed circuit board 321-44529-01

6 50kHz generator printed circuit board 321-44527

7 Main amplifire printed circuit board 321-44525

8 Ultrasonic vibrator 321-36740

9 Fuse, 2A 072-01014-84

10 Fuse, 3A 072-01015-84-

11 POWER switch with connector 321-44538-

12 TEST switch with connector 321-44539

13 Solenoid repair kit 321-46797

14 0-ring, 1A, P12.5 036-10214

15 0-ring, 1 A, P16 036-10217

16 Measurement section (Smpling and detection section) 321-30671-01

17 0-ring, 1A, P14 036-10215._

18 Green top for switch 064-50013-03

19 Red top for switch 064-50013-04

20 Joint for piping A 320-00312

21 Joint for piping C 320-00327

22 Joint for piping 320-00321