Deckma Hamburg OMD-2008 User manual

I N S T R U C T I O N M A N U A L
15ppm Bilge Alarm
OMD-2008
Standard Version
and Versions with
Electric Valve (EV)
Flow Control (FC)
Manual Cleaning Unit (MCU)
DECKMA HAMBURG GmbH
Kieler Straße 316, D-22525 Hamburg - Germany
Tel.: [phone], Fax: [phone]
Internet: www.deckma.com eMail: [email protected]

DECKMA HAMBURG GmbH
Issue: 25.09.2015 preliminaryInstruction Manual OMD-2008 (All Versions) Page 1 of 28
IMPORTANT NOTICE
Replacement components for 15ppm Bilge Alarms.
General
All monitors in our range are inspected and tested to the related I.M.O.
requirements at our factories prior to delivery. In normal use the units should
operate correctly and without fault over a long period of time requiring only small
amounts of maintenance to be carried out as outlined in the instruction manuals.
It is very important to correctly identify the Type and Version of the instrument for
technical support, or for ordering spare parts. Please include instrument type,
Version, and serial number, and if possible instrument date of commissioning into
any communication.
Service Exchange Units
In the event of a monitor malfunction due to electrical or electronic component
failure it is our recommendation that a service exchange unit be ordered.
The defective instrument should be returned to our works within 30 days of
supplying the service exchange unit, then only the repair charge is payable.
Otherwise the whole cost of a service exchange unit becomes payable.
This procedure is by far the easiest and most cost effective way of ensuring the
monitor on board conforms to I.M.O. resolution MEPC.107(49).
Remark:
According the MEPC.107(49) § 4.2.11 the unit has to be checked at IOPP
Certificate renewal survey by the manufacturer or persons authorized by the
manufacturer. Alternatively the unit may be replaced by a calibrated 15 ppm Bilge
Alarm.
The OMD-2008 EVFC is designed in that way, that only the measuring cell needs
to be changed, as this unit carries the Calibration Certificate. The Calibration
Certificate with the date of the last calibration check should be retained onboard
for inspection purposes.
If for some reasons the computer unit needs to be changed, it has to be made
sure, that the Memory Card will remain on board for at least 18 month. The new
computer unit will carry its own memory card. The old card can be insert into the
new unit only for reading. Writing is only possible with the card delivered with the
new computer unit. For details see section 13.1.

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Warranty
Our warranty terms are12 months after installation but maximum 18 months after
delivery ex works. The maker undertakes to remedy any defect resulting from
faulty materials of workmanship except wearing parts.
The maker's obligation is limited to the repairs or replacement of such defective
parts by his own plant or one of his authorized service stations.
The purchaser shall bear the cost and risk of transport of defective parts and
repaired parts supplied in replacement of such defective parts.
ANY DISMANTLING OR BREAKING OF A SEAL WILL VOID THE
WARRANTY

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Contents
1 Introduction ............................................................................................................. 4
1.1 General ..................................................................................................................... 4
1.2 Instrument Versions and Options .............................................................................. 4
2 Important Notes ...................................................................................................... 6
3 Principle of operation ............................................................................................. 7
3.1 Measuring Principle ................................................................................................... 7
3.2 Adjustment ................................................................................................................ 7
3.3 Displays and Alarms ................................................................................................. 7
3.4 Electronic record ....................................................................................................... 8
4 Specifications ......................................................................................................... 9
5 Construction ......................................................................................................... 11
5.1 Overview ................................................................................................................. 11
5.2 Computer Unit ......................................................................................................... 11
5.3 Measuring Cell ........................................................................................................ 11
5.4 Other devices .......................................................................................................... 12
6 Installation ............................................................................................................. 14
7 Piping ..................................................................................................................... 16
8 Wiring ..................................................................................................................... 18
8.1 Typical Control System ........................................................................................... 20
8.2 Remote EV Electric Valve control ............................................................................ 20
9 Power Supply ........................................................................................................ 20
10 Commissioning .................................................................................................. 21
10.1 Electrical and Piping ................................................................................................ 21
10.2 Flow rate adjustment ............................................................................................... 21
10.3 Functional Tests ...................................................................................................... 22
10.4 Programming Mode ................................................................................................. 24
11 Operating instructions ...................................................................................... 29
11.1 Operator Notes........................................................................................................ 29
12 Operator Maintenance ....................................................................................... 30
12.1 Manual Cell Clean Unit (MCU) ................................................................................ 31
13 Fault finding ....................................................................................................... 34
13.1 Memory Card .......................................................................................................... 37
14 Calibration .......................................................................................................... 37
14.1 Calibration and repeatability check .......................................................................... 37
14.2 Function Test at Classification Survey and Port State Control ................................. 38
15 Spare Parts......................................................................................................... 39
15.1 Recommended On Board Spares ........................................................................... 39
16 REMARKS .......................................................................................................... 40

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1 Introduction
1.1 General
The OMD-2008 Bilge Alarm Unit has been designed specifically for use in
conjunction with 15 ppm oil-water separator units and has a specification and
performance which exceeds the requirements of the International Maritime
Organization specifications for 15ppm Bilge Alarms contained in Resolution
MEPC. 107 (49).
The unit is supplied with 2 works-adjusted alarms at 15 ppm. Other set points (10
ppm or 5 ppm) are possible and can be adjusted on site at any time by using the
buttons at the front panel.
Instruments with maximum Alarm set-points of 10 ppm or 5 ppm respectively are
available.
If an alarm set point is exceed, the alarms are visible at the front panel and the
appropriate relays are switched. In case of malfunction the System LED at the
front panel will change from blinking green to permanent red.
For the data logging function the unit requires a status input from the separator.
A 0(4) - 20 mA (equal to 0 - 30 ppm) signal output is available for driving a
recorder or external meter.
1.2 Instrument Versions and Options
The OMD-2008 is available in different versions. It may be equipped with an
electric switchover valve for clean water usage, and a Flow Sensor. A Manual
Cleaning Unit (MCU) is available as an option. Different instrument versions are
covered in this document. Please verify instrument version on site and refer to
the relevant sections of this manual.
1.2.1 FC (Flow Control)
Some OMD-2008 instruments are equipped with a Flow Sensor. The Flow
Sensor is positioned in the Drain line of the Measuring Cell. If the flow rate
through the Measuring Cell is too low, or if the sample is not flowing at all, the
Instrument will go to Alarm condition and issue a “Status: Flow?” message.
OMD-2008 FC instruments have a special interface for the Flow Sensor, so that
the current flow rate can be displayed.
It is possible to have a Flow Switch (similar to the Flow Sensor, but with a simple
ON/OFF output) connected to all versions of OMD-2008.

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1.2.2 EV (Electric clean water Valve)
OMD-2008 EV instruments are equipped with an electric switchover valve for the
clean water stream. The valve can be controlled via the menus, or remotely using
the control input.
1.2.3 MCU (Manual Cleaning Unit)
Optionally the instruments can be fitted with a Manual Cleaning Unit. The Manual
Cleaning Unit allows to clean the sample glass tube without opening the
Measuring Cell Head Screw, and without interrupting the normal sample flow.
Maintenance is made easier with the MCU. Please note that operating the MCU
may set the instrument to alarm condition for a few seconds.

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2 Important Notes
a) This equipment must be installed and operated in strict accordance with
the instructions contained in this manual. Failure to do so will impair the
protection provided.
b) Installation and servicing must be undertaken by a competent and suitable
skilled person.
c) The equipment must be connected to the ground according relevant
requirements.
d) The unit must be isolated from the electrical supply before any
maintenance of the equipment is attempted.
e) All National or local codes of practice or regulations must be observed
and, where applicable, are deemed to take precedence over any directive
or information contained in this manual.
f) In case of freezing conditions the measuring cell should be emptied
completely.

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3 Principle of operation
3.1 Measuring Principle
An optical sensor array measures a combination of light scattered and absorbed
by oil droplets in the sample stream. The sensor signals are processed by a
microprocessor to produce linearized output.
If an alarm (works set point 15 ppm, or 10 ppm or 5 ppm respectively) occurs, the
two oil alarm relays are activated after the adjusted time delay.
The microprocessor continuously monitors the condition of the sensor
components and associated electronics to ensure that calibration accuracy is
maintained over time and extremes of environmental conditions.
3.2 Adjustment
The unit is delivered with a works calibration according the IMO-requirements.
The alarm points are set to 15 ppm (or 10 ppm, or 5 ppm for certain versions).
The "Zero" point is also works calibrated and can be re-adjusted on site by using
the programming mode and clean water. See Section 10.4 “Settings-Offset”.
Calibration of the instrument is not permitted. According to IMO Regulations a
calibration check has to be done by the manufacturer or persons authorized by
the manufacturer. The recommended way to ensure a properly calibrated
Measuring Cell on board is to exchange the Measuring Cell.
3.3 Displays and Alarms
In the unit there are two independent oil alarm circuits available. Both can be set
separately from 1 to 15 ppm. From the manufacturing both alarms are set to
15 ppm (according IMO). The set points can be changed according to the
requirements on site, for example to 10 ppm or 5 ppm. An alarm point setting
above 15 ppm is not possible. Instrument versions with limited alarm setpoint
range (10ppm, or 5ppm) are available. This alarm setpoint limit can not be
changed.
Adjustment of the alarm setpoints can be done in the programming mode as
described in Section 10.4. In this mode also the individual adjustment of the time
delays for the alarms can be done.
Both alarm circuits are also related to an alarm LED on the front panel.

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In case of malfunction the “System” LED will indicate any type of internal fault of
the unit. This LED is flashing green in normal conditions and is red in alarm
conditions.
Additional to the alarm LEDs each alarm circuit is equipped with a relay with
potential free switchover alarm contacts. These contacts can be used for external
processing of the signal or for control of further functions.
If a malfunction or failure of the power supply occurs, all three relays (both alarm
relays and the SYSTEMFAULT relay) will switch to alarm condition.
3.4 Electronic record
The OMD-2008 keeps an electronic record. The recorded data can be viewed at
the instrument at any time. Browsing the data does not interfere with the
measurement or instrument operation. Data is stored in excess of 18 Months.

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4 Specifications
Range: 0 – 30 ppm, Trend indication 50ppm
Accuracy According IMO MEPC. 107(49)
Linearity Up to 30 ppm better than ± 2 %
Display Yellow Graphic Display
Power Supply: 24 V - 240V AC or DC
Automatic Voltage selection
Consumption: < 10 VA
Alarm Points 1 + 2: Adjustable between 1 - 15 ppm
(Works adjustment 15 ppm)
Alarm 1 Operating Delay:
(for annunciation purpose)
Adjustable between 1 – 540 sec.
(Works adjustment 2 sec)
Alarm 2 Operating Delay:
(for control purposes)
Adjustable between 1 – 10 sec.
(Works adjustment 10 sec)
System Fault Alarm: Red LED
Alarm Contact Rating: Potential free 1 pole change over
contacts, 3 A / 240 V
Alarm Indication: Red LEDs
Output Signal: 0 – 20 mA or 4 – 20 selectable
ext. Load < 150 
Sample Water Pressure: 0,1 – 10 bar
Sample Flow: Approx. 0,1 - 3 l/min depending on
pressure
Ambient Temperature: + 1 to + 55° C
Sample Water
Temperature:
+ 1 to + 65° C
Roll: Up to 45°
Degree of Protection: IP 65
Pipe Connections: for 6mm OD Cu or SS pipe

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Specification changes for specific versions
OMD-2008 EV
Sample pressure max. 6 bar
Clean water pressure max. 6 bar
Size (Computer Unit) 200 mm W x 200 mm H x 100 mm D
Size (EV-FC-Arrangement) 150 mm W x 290 mm H x 140 mm D
Weight: 5,9 kg
OMD-2008 EVFC
Sample pressure max. 6 bar
Clean water pressure max. 6 bar
Size (Computer Unit) 200 mm W x 200 mm H x 100 mm D
Size (EV-FC-Arrangement) 150 mm W x 290 mm H x 140 mm D
Weight: 5,9 kg
OMD-2008 EVFCMCU
Sample pressure max. 6 bar
Clean water pressure max. 6 bar
Size (Computer Unit) 200 mm W x 200 mm H x 100 mm D
Size (EV-FC-Arrangement) 150 mm W x 290 mm H x 140 mm D
Weight: 5,9 kg
Technical specifications are subject to change without notification

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5 Construction
5.1 Overview
OMD-2008 instruments consist of two main components:
The Computer Unit contains the display PCB with the data logger and the
terminals for external connections.
The Measuring Cell assembly consists of the Measuring Cell, a valve to select
sample water stream, or clean water stream, and, depending on the version of
the instrument, additional devices like a flow sensor.
5.2 Computer Unit
The Computer Unit contains Display, Power Supply, all external electrical
connection terminals, and Memory Card for electronic record.
The Computer Unit is enclosed in a sheet metal housing, with several openings
for metric cable glands underneath. The Computer Unit should be mounted so
that the display and touch button area is easily accessible.
5.3 Measuring Cell
The measuring cell is built out of an all-aluminium, nickel plated body with inlet
and outlet block from stainless steel. It contains optics and electronics and is
connected with the computer unit via a plugged data cable. The Measuring Cell
Fig. 2a:
Dimensions of Computer Unit

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has to be provided with a sufficient sample water stream. It measures the oil
content, and transmits the measured data to the computer unit.
The Measuring Cell has all parameters and calibration data permanently stored,
and the calibration certificate is tied to the Measuring Cell. The recommended
way to renew a calibration is to exchange the Measuring Cell. Under no
conditions should the Measuring Cell be opened or dismantled, doing so would
void both warranty and calibration.
5.4 FW valve
The OMD-2008 uses a switchover valve to control the usage of clean water for
cleaning, or zeroing purposes. Whenever the FW valve is switched to Clean
water position, and not to sample stream position (normal operating position), the
instrument will be in alarm condition.
The valve can be manually operated (OMD-2008), or electrically operated (OMD-
2008 EV). The electric valve can be switched using the programming mode.
5.5 Other devices
Measuring Cell and the valve to switch over from sample water stream to clean
water usage (FW valve) are mounted onto a stainless steel support. The clean
water valve may be a manual switchover valve, or an electric valve, and controls
sample water and clean water usage. A Flow Sensor, or a Manual Cleaning Unit
(MCU) may also be installed.
The OMD-2008 EV-FC can easily be mounted in wall or bulkhead installation.

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Computer Unit Flow Sensor
Measuring Cell Clean Water
Valve EV
Manual Cleaning
Unit (MCU)
(Option)
Fig. 1

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6 Installation
See Section 2 for important notes concerning installation.
The OMD-2008 should be located as close as possible to the oily water separator
to minimize response delays. According MEPC.107(49) the layout of the
installation should be arranged so that the overall response time (including the
response time of the 15 ppm Bilge Alarm, which is less than 5 seconds) between
an effluent discharge from the 15 ppm Bilge Separator exceeding 15 ppm, and
the operation of the Automatic Stopping Device preventing overboard discharge,
should be as short as possible and in any case not more than 20 seconds.
The instrument has to be provided with a representative sample of the separator
effluent water. A sample stream flow rate of approx. 2 Liters per Minute has to be
provided.
Mount the OMD-2008 Computer Unit by means of M6 or M8 screws on to a rigid
vertical surface and preferably with the display panel of the monitor at eye level.
For service and maintenance sufficient space to all sides should be available.
Computer Unit and Measuring Cell assembly should be mounted close to each
other.

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Fig. 2b Dimensions of Measuring Cell assembly
Pipe connections are prepared for 6mm OD stainless steel or coper pipes.
Adapter fittings for other pipe diameters are available upon request. Working
space for maintenance and operation is recommended in front of and above the
instrument.
Care must be taken at mounting of the pipes connections to avoid any torsion of
the housing and damage of the instrument.

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7 Piping
The instrument has to be supplied with a representative sample of the separator
effluent water stream. The sample stream through the instrument is
recommended to be approx. 2 Liters per Minute.
Connect the OMD-2008 EV-FC Monitor to the sample point of the oily-water
separator outlet and to a source of oil free water. Fittings on the Instrument are
for 6 mm OD copper or stainless steel pipe. Adapter fittings for other pipe
diameters are available upon request.
The sample point should be located on a vertical section of the separator outflow
piping to minimize the effects of any entrained air. The tapping point should be at
a level above the outlet of the monitor to ensure the sample cell is flooded at all
times.
If connection to a vertical section of the separator outlet piping is impractical, the
tapping may be made into the side of the horizontal pipe. Avoid top or bottom
entry.
For separator discharge pipes up to 75 mm OD a standard "T"-type junction of
the welded or screwed type is satisfactory for the tapping point. For the separator
discharge pipes of 80 mm OD and above a sample probe should be employed
which protrudes into the discharge piping by approx. 25 % of the ID of the pipe.

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Fig. 3

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8 Wiring
See Section 2 for important notes concerning wiring.
This unit must be connected to the mains supply via a suitable rated and
approved fused isolator unless such fusing / isolation is provided by associated
equipment. When fitted, the isolator should be close, readily accessible and
marked as to function.
Electrical connections are made through the metric cable gland openings
prepared underneath the instrument. Not all openings may be free.
Fig. 4
Precise wiring details will vary dependent upon the control system to be
employed but the most frequently used systems employ alarm relay 1 for alarm
only and alarm relay 2 for control purposes.
Electrical connections are made to the terminal blocks inside the computer
housing. Wires are connected to the terminals by pushing a suitable screwdriver
into the clamp holes to release the internal spring loaded clamps. After the wire is
inserted to the terminal and the screwdriver is removed, the wire is fixed.
If the instrument is operated at high voltages, additional care has to be taken to
provide reliable ground connections. Ground (PE) can be connected direct to the
terminal or, if this is not sufficient according local rules, to the computer housing
(PE bolt inside, right side).
The instrument provides a pilot voltage output at Terminals 3&4. This is internally
connected to the power supply input (Terminals 1&2 via Fuse T2A). The pilot

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voltage can be used to supply additional external circuitry, e.g. alarm lamps or
electrical valves.
Please note: any device connected to the pilot voltage output must be rated for
the voltage the instrument is supplied with. Do not use the pilot voltage for driving
motors, heaters or other high load devices. The pilot voltage is intended for alarm
purposes only.
Fig. 5: Connection Example
Close front cover completely after electrical installation. Water inside the
instrument may result in corrosion and malfunction. Alarm contacts description is
in alarm (non-energized) condition.
Note: In case the OMD-2008 EV-FC is installed as replacement to a
MEPC.60(33) approved separator and no “Status Separator” signal is available, a
link across terminal 11 + 12 can be installed. Alternatively a “Status Separator”
signal can be generated from the Separator control, and an auxiliary relay be
operated with this signal. The Contacts of this relay then can operate the