ATT_I.B._4404_593_C.pdf

TP: 4404

(HM&E MANUAL)

TECHNICAL MANUALS

OIL CONTENT METER, MODEL ER-35A –

SERVICE 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: C

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 C

Equipment Functional Description

OIL CONTENT METER, MODEL ER-

35A - SERVICE 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

SERVICE MANUAL

OIL CONTENT IVIETER

Model ET-35A

SHIMADZU CORPORATION

Kyoto, JAPAN

1.

2.

5.

CONTENTS

GENERAL 1

HOW TO FIND A MALFUNCTIONING UNIT

2.1 Alarm signal is given even when oil content meter

2.2

2.3 2.4 2.5 2.6 shows zero Alarm signal is given when the meter shows more than 15 ppm Alarm is not given with high concentration oily water Alarm is given by fresh water flow PPM indication is widely fluctuated Alarm lamp in control room is lighted

. HOW TO FIND A MALFUNCTIONING PART IN THE

DEVICE

3.1 POWER LED is not lighted 9

3.2 WARNING LED is lighted. (LED ON power printed

circuit board in the main body is lighted.) 9

3.3 WARNING LED is lighted. (LED ON main printed

circuit board in the main body is lighted.) 10

3.4 WARNING LED is lighted. (LED ON 50 kHz

3.7 Alarm signal is given when ppm indication

shows zero 15

4. DESCRIPTION OF PRINTED CIRCUIT BOARDS AND

FLOW PATH DETECTOR 16

LIST OF REPAIR PARTS 22

4.1 Main printed circuit board 16

4.2 50 KHz oscillator printed circuit board (Ultrasonic

4.3

1 .

GENERAL

The oil content meter Model ET-35A is designed to be used together ..with the oily water separator (filtering device) to give a bilge alarm . Bilge water should be overboard discharged after its oily concentration is reduced to less than 15 ppm .

The oil content meter Model ET-35A measures the oily concentration in the water at oil water separator outlet side and when it exceeds 15 ppm or the meter is failured, an alarm signal is given .

Operations of entire; system should be studied carefully in order to find out a malfunctioning part correctly.

Fig. 1 shows a typical system of bilge water treatment .

Oil discharge

Oily water separator adjusting valve

(]Filtering device)

Oil discharge

ET-35A

N

Oil level detector l

Fig. 1 Bilge water treatment system

To slop tank

Alarm in control room

2. HOW TO FIND A MALFUNCTIONING UNIT

2.1 Alarm signal is given even when oil content meter shows zero .

Possible cause: Inlet pressure is low.

Start bilge pump and check its outlet pressure to oily water separator .

Open valves in the line from separator outlet to ET-35A.

Check inlet pressure of

ET-35A .

Check if bilge pump is pumping sample water surely .

Set inlet pressure of sample water to 0.5

- 1 .0 kg/cm2.

See [3.6] .

Replace pump.

Z

Introduce fresh water for a while (30 min .). Flush the pip-ing up to ET-35A by fresh wa-ter to clean it thoroughly .

Take a glassful of drain coming from ET-35A to vi-sually check the presence of oily concentration .

2.2 Alarm signal is given when the meter shows more than 15 ppm .

Possible causes : * High oil concentration

* Contamination of piping

Visually check outlet discharged water .

ET-35A OK

Yes

Refer to [2.41 .

2.3 Alarm is not given with high concentration oily water.

Possible cause: Improper adjustment of ultrasonic wave matching

Introduce fresh water for 30 min .

Turn on TEST switch of ET-35A .

(Keep depressing for approximately 30 sec-onds.)

Check output signal from main printed circuit board .

See [4.11 Adjustment of main printed circuit board .

If detector is defective, replace it. (Part number is 321-38507 .)

If main printed circuit board is defective, re-place it (Part number is 321-44525 .)

In the event measuring cell is broken, re-place it. (Part number is 321-28423 .)

Improper adjustment of ul-trasonic wave matching.

See (4.21 for adjustment of matching .

2.4 Alarm is given by fresh water flow.

Possible cause : Contamination of piping

Turn on TEST switch of ET-35A .

(Keep depressing for approximately 20 sec-onds.)

Check output signal from main printed circuit board .

See [4.1] Adjustment of main printed circuit board .

If detector is defective, replace it. (Part number is 321-38507 .)

If main printed circuit board is defective, re-place it. (Part number is 321-44525.)

In the event measuring cell is broken, replace it .

(Part number is 321- 28423 .)

2.5 PPM indication is widely fluctuated .

Possible causes : * Defect of ET-35A

* Effect of suspended solids or air bubbles

* Contamination of piping

Introduce fresh water for 30 min .

Turn on TEST switch of ET-35A .

(Keep depressing for approximately 20 sec-onds .)

Check output signal from main printed circuit board .

See . [4 .1 ] Adjustment of main printed circuit board .

If detector is defective, replace it. (Part number is 321-38507.)

If main printed circuit board is defective, re-place it. (Part number is 321-44525 .)

In the event measuring cell is broken, re-place it. (Part number is 321-28423 .)

2.6 Alarm lamp in control room is lighted .

Possible causes : * Contamination of piping

* Incorrect wiring at terminal for alarm signal

LED unit in control room must be adjusted again .

(It may be other problem than ET-35A .)

Normal

Recheck alarm terminals A1A, Al B, A1 C/A2A, A2B, A2C in low= er terminal board TS1 on power printed circuit board . See Fig. 18 in instruction manual.

Check wiring .

3. HOW TO FIND A MALFUNCTIONING PART IN THE DEVICE

3.1

POWER LED is not lighted.

Possible causes: * Sample inlet pressure is low .

Pressure switch is defective.

Check ET-35A inlet pressure .

Turn on POWER switch of ET-35A.

Inlet pressure 0 .5 - 1 .0 kg/cm2

ET-35A OK

Check continuity of pressure switch contact .

See [4.6] How to check pressure switch .

Pressure switch Parts No .

320-01433

3.2 WARNING LED is lighted.

(LED ON power printed circuit board in the main body is lighted .)

(See Fig. 4)

Possible cause: Blow-out of fuse 2A

Check if fuse 2A is blown .

If blown, mount a new fuse 2A.

Parts No .072-01014

Stop to supply fresh water/sample water and turn on ET-35A power switch .

Check fuse 2A again.

Operate the meter with fresh water/sample water .

ET-35A OK

Power unit circuit board is de-fective .

Replace it with a correct one.

(Part number is 321-44529 .)

Oscillator printed circuit board is defective. Replace it .

(Part number is 321-44527.)

After replacement, adjust it in accordance with [4.2] Ultrasonic wave matching ad-justment during operation .

3.3 WARNING LED is lighted. (LED ON main printed circuit board in the main body is lighted .) (See Fig. 2 )

Possible causes : When LED D31 is lighted, ultrasonic wave matching is not adjusted correctly. When LED D32 is lighted, too high oil concentration sample is introduced or detection unit is defective .

Function of ultrasonic wave oscilla-tor is reduced . See (4 .2] Ultrason-ic wave matching adjustment dur-ing operation .

Adjust matching .

Check if LED D31 goes off.

ET-35A OK

- 10

Adjust ET-35A inlet pres-sure in the range of 0 .5 - 1 .0 kg/cm2.

Check output signal from main printed circuit board. See [4.11 Adjustment of main printed cir-cuit board .

If detector is defective, replace it .

(Part number is 321-38507.)

If main printed circuit board is defective, re-place it.

(Part number is 321-44525 .)

Check if LED D32 is lighted .

In the event measuring cell is broken, replace

it. Part number is 321-28423 .)

I Check if LED D32 goes off.

ET-35A OK is

Supplementary explanation LED D31 : This lamp lights when reduction in oscillation intensity of ultrasonic wave oscillation occurred consecutively 8 times in every measurement .

LED D32: This lamp lights when sample water with much suspended solids or dark color sample is introduced into measurement section consecutively four times .

3.4 WARNING LED is lighted. (LED ON 50 kHz oscillator P .C.B. in the main body is lighted.) (See Fig. 3)

Possible cause: Ultrasonic wave function is defective .

Check water flow from outlet .

Check ultrasonic wave sound .

Yes

Check if measuring cell is damaged, referring to [4 .11 Main printed circuit board .

When it does not work well, make adjustment of matching coil .

See [4.2] Ultrasonic wave matching adjustment during operation .

When 50 KHz generator printed circuit board is defec-tive, replace it with a correct one. (Parts No. 321-44527)

It is afraid that detector is defective .

Check the output signal of main printed cir-cuit board. See [4.1] .

It if is defective, replace detector. (Parts No. 321-38507)

Replace the measuring cell .

(Parts No . 321-28423)

- 12 -

3.5 PPM indication is widely fluctuated.

Possible cause: * Contamination of piping

* Effect of suspended solids or air bubbles

Take sample water at outlet of ET-35A .

Check if sample water contains suspended solid or airbubbles .

Check if PPM indication shows around zero .

Securely fasten ET-35A inlet joint so that airmay not enter into the meter .

And, introduce fresh water for 20 min . a t 0.4 - 0.5 kg/cm2 .

Sample water has causes of abnormality .

Suspended solids or air bubbles are contain-ed .

3.6

Sample water is not visible at outlet .

Possible causes: Inlet pressure is low.

Check inlet pressure .

Inlet pressure 0 .5 - 1 .0 kg/cm2

Yes

Adjust pressure setting position by turning ad-justment screw of pressure switch in counter-clockwise direction .

See (P) in [4.61 How to check pressure switch .

3.7 Alarm signal is given when ppm indication shows zero.

Possible causes : Measuring cell is damaged.

Check if water is discharged from ET-35A outlet.

Introduce fresh water for 30 min .

Turn on test switch of ET-35A .

(Keep depressing for approximately 20 seconds.)

OK

Inlet pressure 0.5 - 1.0 kglcm2

Measuring cell is damaged .

Replace it. (Parts No . 321- 28423)

Check output signal from main. printed circuit board.

See (4.11 Adjustment of main printed circuit board .

If detector is defective, replace it. (Part number is 321-38507.)

If main printed circuit board is defective, re-place it. (Part number is 321-44525.)

In the event measuring cell is broken, re-place it. (Part number is 321-28423 .)

4:

DESCRIPTION OF PRINTED CIRCUIT BOARDS AND

FLOW PATH DETECTOR

4.1

Main printed circuit board

CND

ne

J 0^ nnnnnnnnnnnnnnnnnhna

UUUUUUUUPUUUUOUUUUUU

nnnnnnnnnnni,nnnnnnnnn

1JUrJUUU1!UUUUUU000UUUU

Z v53 sm yo

M4

M11

D31 This lights when ultrasonic wave oscillator became defective .

At. the same time, a warning lamp provided on the indicator lights .

D32 This lights when high suspended solids - .re detected.

At the same time, a warning lamp provided on the indicator lights .

O r U bMv "Oy

) M 22 z

1g deb bib no mK~" z

M20 s 0 p

C

G y ] C o ~ yC C a .r I

C I a l:

M

UUUUU UUUUUUs C-3 nnnnnnrtnnnnn

ON

0 U

Zero adjustment of display (Display is reduced to zero by clockwise turn ing).

Refer to the instruction manual for adjustment .

Sensitivity adjustment (Sensitivity is increased by clockwise turning.)

z Main Circuit Board

[Checking main printed circuit board]

Check following (1) and (2) using a tester.

(1) Across A and GND

Use fresh water and actuate I ultrasonic wave oscillation :

i

The voltage should be in. the: range of DC 1.7 V - 3.0 V.

Use fresh water and stop ultrasonic wave oscillation :

The voltage should be in the' range of DC 1 .0 V - 1.3 V .

(2) Across B and GND

Use fresh water and actuate ultrasonic wave oscillation :

The voltage should be in the range of DC 6.0 V - 11 .0 V.

Use fresh water and stop ultrasonic wave oscillation :

The voltage should be in the range of DC 3 .8 V - 5.0 V.

In the event (1) is normal and (2) is abnormal, main printed circuit board is defective.

In the event (1) is abnorma~, detector is defective or the measuring cell is defective (damaged) .

4.2

50 kHz oscillator printed circuit board .

(Ultrasonic wave matching adjustment during operation)

(1) Instruments used:

Oscilloscope

X-axis 5 ps/Div., Y-axis 50 V/Div .

(2) Connection of terminals of oscillator printed circuit

See illustration shown right .

(3) Voltage:

Adjust the voltage in the range of 50 V and 70 V AC . A clear waveform as shown below should appear on the oscilloscope .

board :

(4) Sound:

An intermitte -1t chirp sound should be heard at air bubbles venting timing (ar-1 and ar-2) . Another jarring sound should be heard at ultrasonic wave timing (ue) .

Note:

In the event a clear waveform , appears with voltage in the range of 50V - 70V AC, and no sound is heard, the vibrator is defective . Replace it. (Parts No . 321-36740) See [4.5] for re-placement .

In the case no oscilloscope is available, make adjustment by hearing the sound generated at ultrasonic wave oscillation .

Namely, turn matching adjustment core at ultrasonic wave oscil-lation and stop it when jarring sound becomes maximum .

GND

0(9

Connect oscilloscope probe here . ;

Matching adjustment core

Tt

Ur

R

M{ R1~

0-- Q- 15 .' ~ 0

T --o -e o- *.& Rd Rf

-flRa C of o--oR' ~, bfU b' ~°

U uo

`b= R( gig. 3", l{Hz Oscillator P"ructe Circuit: Boar

[Checking of 50 kHz oscillator printed circuit board] Check fQ lowing points using a tester.

Across F'and GND Use fresh water or sample water and actuate ultrasonic oscillation:

The voltage should be in the range of 80 - 85 V .

D,G only during oscillation .

U e fresh water or sample water .

Tile voltage should be in the range of 10 - 20 V

PC only when it is a timing for the air bubble .

r a O O

LED 1lghts when ultrasonic oscillator is defective .

4.3

Power printed circuit board

In, mn

I e!

[Checking power print circuit board]

Check following (1)~ (2) and (3) using a tester .

(1) Across J and GND

Use fresh water and actuate ultrasonic wave oscillation:

The voltage should be 24 V DC.

Use fresh water and stop ultrasonic wave oscillation

The voltage should be 24 V DC.

(2) Across K and . GND Use fresh water and actuate ultrasonic wave oscillation:

The voltage should be 15 V DC .

Use fresh water and stop ultrasonic wave oscillation :

The voltage should be 15 V DC.

(3) Across L and GND

Use fresh water and actuate ultrasonic wave oscillation:

The voltage should be 5 V DC .

Use fresh water and stop ultrasonic wave oscillation :

The voltage should be 5 V DC.

In the event any ok (1), X(2) or (3) is abnormal, the power printed circuit board is defective .

I

4.4 Replacement of cell at flow path and detection unit

Dismounting procedures:

(1) Loosen four screws.

(2) Remove the flow path and . detector from the case .

(3) Remove Ol and O' screws.

screws and manually move ® and(4) Loosen

O' outside .

(5) Take out

II and III

(6) Loosen four screws, and slide Juracon as illustrated . - After that, slide upward. Take care so that fixing block from 6 fixing block

1 "0" ring provided at the bottom of fixing block may not disengage .

(7) Remove detector from Juracon block .

(8) Replace cell provided iri-' detector.

(Take care so that (9 and o9 ' "0" rings provided at upper and lower portion of 8 cell may not be lost .

(9) After the cell is replaced, restore them in the order of (8), (7), (6), (5), (4), (3), (2), and (1) .

Make sure a total of four "0" rings present .

CAUTION:

(a) When mounting vibrator to fixing block, take care

Fixing screw Screw for vibrator holding plate Vibrator holding plate Vibrator Screw for fixed block Fixing block Juracon block Detector Cell 0-ring P16 0-ring P12 .5 s

Fig. 5 Replacement of Cell at Flow Path and Detection Unit sc.) that vibrator is fixed at the center of a hole of `o) fixing block . QO

01(b) When interior of the detector is wet, be sure to wipe it off thoroughly using a dry cloth . ®

5®

(7 Q9 1®

4.5 Replacement of vibrator at flow path and detector .

Dismounting procedures:

(1) Loosen four @ screws.

(2) Remove the flow path and detector from the case .

(3) Remove () and T' screws.

(4) Loosen Q)" and(A" screws and manually move @ and U2 ' outside .

(5) Take out

(6) Remove vibrator.

rubber plate in vibrator ferrite portion . (It does not matter that (12 magnet is still on 13 rubber plate .)

(7) Remove (9 coil. (Take care not to mount the vibrator upside-down or right and left in reverse direction .)

(8) Replace (3) vibrator.

(9) Insert Q)l coil into U vibrator. (Be sure to set the coil in same direction before replacement.)

(10) Insert (@ magnet and fix it with (@ rubber plate .

(Use an adhesive to stick the ferrite on the both side of n13 rub-ber plate .)

(11) Place the assembled (3) vibrator in the care of fixing block.

(12) Hold O vibrator with (~) and O', and fix it with T, Q', T" and T"' screws .

CAUTION:

(a) When mounting (~) vibrator to (~) fixing block, take care so that

I t I rL!

6 Replacement of vibrator at flow path and detector

Take care not to flaw this part of the ferrite, as it is very fragile .

(~) vibrator is fixed at the center of a hole of (~) fixing block .

@) Fixing screw

Screw for vibrator holding plate Vibrator holding plate

@ Vibrator (~) Fixing block

Coil Magnet

9 qn) Rubber plate

4.6 Checking of pressure switch

(1) Turn on POWER switch of ET-35A .

(Check if the POWER green LED is lit .)

(2)

Introduce fresh water or sample water.

(When the concentration is not displayed on the concentration indicator even with more than 1 kg/cm' of flow-in pressure, check the contact point of the pressure switch .)

Fig. 7

After turning off the input power, loosen 2 Q screws and replace the pressure switch.

Pressure switch •adjustment screw By turning this screw in counterclock-wise direction, the pressure setting position is lowered and the switch can be activated in lower water pressure.

Check conductance between these.

(As the lead wire is covered by black insulation tube, apply the tester to the exposed metal part.)

If there is no conductance when .

fresh water is not introduced*d in the inlet of ET-35A, the pressure switch is working normally .

If there is conductance when fresh water is introduced in the inlet of ET-35A, the pressure switch is working normally.

Replace the pressure if it is abnormal .

5.

LIST OF REPAIR PARTS

N . Parts Name Part No .

(1) Joint for piping 320-00293-20

(2) Solenoid' valve 320-00440

(3) Pressure: switch 320-01433

(4) Detection section 321-38507

(5) Measuring cell 321-28423

(6) Power supply printed circuit board 321-44529

(7) 50 KHz generator printed circuit board 321-44527

(8) Main amplifier printed circuit board (with timer and D/A circuit board)

321-44525

(9) Vibrator 321-36740

(10) Fuse 2A' 072-01014

(11) Fuse 3A, 072-01015

(12) POWER' switch 320-01437-02

(13) TEST switch 320-01437-01

(14) Valve seat, solenoid valve 320-00425

(15) Pressure gauge 320-00417

(16) Joint for' piping B 320-00313

(17) Tee 035-32002

(18) Nipple for piping 035-45502

(19) Joint for piping 1/4 320-00294-20

(20) Water draining switch 320-01437-01

(21) Flow path detection unit 321-30671

22 0-ring P12.5 036-10214

(23) 0-ring P16 036-10217

(24) Tube FEP TF 185 8 x 6 320-00121-01

LIST OF REPAIR PARTS