Flowserve GESTRA OR 52-7 User manual

1
Installation Instructions 818788-00
Oil & Turbidity Detector
OR 52-7

GESTRA Steam Systems
OR 52-7

2
Contents
Important Notes
Usage for the intended purpose .............................................................................................................4
Safety note ............................................................................................................................................. 4
Danger ...................................................................................................................................................4
Explanatory Notes
Scope of supply ...................................................................................................................................... 5
Description .............................................................................................................................................5
Function .................................................................................................................................................5
Page
Functional Elements
Measuring sensor ORG 12 ....................................................................................................................14
Measuring transducer ORT 7.................................................................................................................15
Key.......................................................................................................................................................16
Commissioning Procedure
Factory setting......................................................................................................................................17
Warning................................................................................................................................................ 17
Checking electrical connection .............................................................................................................17
Checking installation.............................................................................................................................17
First commissioning ............................................................................................................................. 18
Programming mode .............................................................................................................................. 19
Other parameter settings ......................................................................................................................20
Technical Data
Measuring transducer ORG 12 ................................................................................................................ 6
Measuring transducer ORT 7...................................................................................................................7
Name plate / marking .............................................................................................................................8
Dimensions OR 52-7............................................................................................................................... 9
Installation
OR 52-7................................................................................................................................................10
Example of installation.......................................................................................................................... 11
Electrical Connection
Measuring transducer ORT 7 ................................................................................................................12
Note .....................................................................................................................................................12
Attention............................................................................................................................................... 12
Tools.....................................................................................................................................................12
Wiring diagram OR 52-7 .......................................................................................................................13
Notice ..................................................................................................................................................13

3
Contents – continued –
Malfunctions
OR 52-7................................................................................................................................................25
Table listing error codes........................................................................................................................25
Page
Annex
Type approval certificate...............................................................................................................30 – 33
EG-Baumusterprüfbescheinigung (Modul B).................................................................................... 34, 35
EC Type Examination Certificate (Module B) .................................................................................... 36, 37
Declaration of Conformity .....................................................................................................................38
Data Storage
Memory Card........................................................................................................................................23
Note .....................................................................................................................................................23
Data indication .....................................................................................................................................23
Operating steps – see Fig. 8 .................................................................................................................23
Note .....................................................................................................................................................24
Operating flowchart ..............................................................................................................................24
Start, Operation, Alarm and Function Test
Start and operation ...............................................................................................................................21
Alarm 1 and 2 ......................................................................................................................................22
Functional test .....................................................................................................................................22
Calibration
OR 52-7................................................................................................................................................26
Maintenance
Cleaning the glass cylinder ..................................................................................................................27
Replacing the drying cartridge ..............................................................................................................27
Replacing the light emitter/receiver ......................................................................................................27
Attention............................................................................................................................................... 27
Replacing the equipment fuse............................................................................................................... 27
Warning................................................................................................................................................ 28
Spare parts...........................................................................................................................................28
Note .....................................................................................................................................................28
Decommissioning
Warning................................................................................................................................................ 29
Removal ...............................................................................................................................................29
Disposal................................................................................................................................................29

4
Important Notes
Usage for the intended purpose
The GESTRA Turbiscope OR 52-7 is designed for the continuous monitoring and detection of oil
contamination of water and used in conjunction with oily water separators as 15 ppm bilge alarm.
The equipment meets the requirements of the International Maritime Organization (IMO) for bilge alarm
monitors, MEPC. 107 (49).
Danger
The solenoid of the solenoid valve Clw can reach up to 80 °C during operation.
The terminal strips of the measuring transducer ORT 7 can be live during operation.
This presents the risk of electric shock.
Cut off power supply before mounting, removing or connecting the terminal strips.
Safety note
The equipment must only be installed and commissioned by qualified and competent staff.
Retrofitting and maintenance work must only be performed by qualified staff who – through adequate
training – have achieved a recognised level of competence.

5
Explanatory Notes
Description
Scope of supply
Measuring transducer ORT 7
Measuring sensor ORG 12 with
1 Solenoid valve
1 Drying cartridge (fitted)
1 Light emitter (supplied but not fitted)
1 Spare gasket kit
The oil & turbidity detector OR 52-7 can be used:
■On board of marine vessels for monitoring the oily water separating equipment for bilge water
according to IMO Resolution MEPC. 107 (49) as 15 ppm oil content alarm.
Function
The measuring sensor is a photometric measuring device consisting of a light source (light emitter)
and a light receiver fitted with two photosensitive elements.
The constant light beam generated in the measuring sensor passes through the transparent liquid. Any
foreign matter which is not dissolved scatters the beam, with emulsified oils scattering the light mainly
in the forward direction. The intensity of the scattered light is converted into an electric current and then
used as measure of the degree of contamination.
The measuring transducer has the following functions:
■Control of the measuring sensor and signal evaluation
■Control of the purging valve
■Limit ALARM 1 and ALARM 2
■Analog actual value output 0/4 – 20 mA
■ALARM 2 indicates a malfunction in the turbidity sensor
■Indication of actual value / limits
■Storage and indication of alarm, malfunction and status messages
■Control of the bilge bypass via output ALARM 2

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Technical Data
Measuring transducer ORG 12
Nominal size
DN 10, connection 3/8" to DIN ISO 228
Nominal pressure
PN 10
Fluid
Water
pH value
Up to 10.5 (a pH value of 11 and above will lead to wear of the glass, depending on the temperature!)
Fluid temperature range
0 – 60 °C with drying cartridge
Ambient temperature
Max. 60 °C
Materials
Measuring sensor: ORG 12
Housing cover: 0.6025 galvanised
Wetted parts: 0.6025 galvanised
Throttle: 1.4571
Screwed union: St
Glass cylinder: Duran 50
Internal seal: Silicone
Oil-seal rings: Perbunan
Housing: 0.6025 galvanised
Cleaning ring: EPDM sponge rubber
Light emitter
Glow lamp 12 V / 10 W BA 15s
Electric connection via 4 m connecting cable fitted with four pole connector,
protection IP 65
Light receiver
Two silicon photoelectric cells
Electric connection via 4 m connecting cable fitted with four pole connector,
protection IP 65
Purging valve
2/2 way solenoid valve
Directly controlled, normally closed
Connection: 3/8" ISO 228
Valve body: Brass
Internals: Ms 2.0401 / S. S. 1.4104
Internal seal: FKM
Solenoid: Voltage 24 V / 50 Hz, 43 / 24 VA
Electric connection via 4 m connecting cable fitted with four pole connector,
protection IP 65
Weight
ORG 12: approx. 6.8 kg

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Technical Data – continued –
Measuring transducer ORT 7
Inputs / outputs
2 Photocells for inputs: directly transmitted light / scattered light,
1 Voltage output for light emitter, 1 – 12 V, pulse-amplitude modulated,
1 Signal input for separator ON/OFF,
1 GPS input RS 485, 4800 Baud, NMEA 183 protocol, data record GPRMC,
3 Volt-free change-over contacts for alarm 1, 2 and purging valve (Clw),
contact material AgNi 0.15,
max. contact rating for switching voltages 24 V AC/DC, 115 V AC and 230 V AC: resistive / inductive 4 A,
1 Current output 0/4 – 20 mA as actual value output, max. load 500 ohm.
Indicators and adjustors
1 LCD display for indicating the actual value, limits, status and malfunctions,
8 Membrane keys,
4 LEDs for indicating alarm, status and malfunction
3 Green LEDs on basic circuit board for monitoring the operating voltages
Data storage
DataFlashcard 8 MB
Measuring range
0 to 25 ppm (ppm = parts per million)
Actual value output
0 or 4 mA = 0 ppm, 20 mA ≥ 25 ppm
Limits for alarm 1 and 2, adjustment range
Adjustable between 0 and 15 ppm
Delay of response for alarm 1 and 2, adjustment range
Adjustable between 0 and 15 sec.
Mains voltage
24 V +10 / –15 %, 50/60 Hz
230 V +10 / –15 %, 50/60 Hz (optional)
115 V +10 / –15 %, 50 / 60 Hz (optional)
Power consumption
50 VA
Fuse
24 V: Thermal fuse M 1.6 A 5 x 20,
230 V: Thermal fuse M 0.2 A 5 x 20
115 V: Thermal fuse M 0.4 A 5 x 20
Housing
Field case for wall mounting,
Case material: die-cast aluminium
Cable gland / Electrical connection
8 cable glands with integrated cable clamps, M 16 x 1.5
3 Three-pole screw-type terminal strips, conductor size 0.75 mm2
8 Multi-pole screw-type terminal strips, detachable, conductor size 1.5 mm2
Protection
IP 65 to EN 60529
Admissible ambient temperature
0 – 55 °C
Weight
3.6 kg

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Technical Data – continued –
Name plate / marking
Fig. 1
Year of manufacture
Ser.Nr.: 3923581xxxxx
ORG12
OR 52-7
ORT7
Öl- / Trübungsmelder
Oil- / Turbitity Detector
Détecteur d’huile et de turbidité
ORT 7
250 V ~ T 2,5 A
Range 0 - 25 ppm
Tamb = 55°C (131°F)
Manufacturer
GESTRA AG, Münchener Str.77
D-28215 Bremen
Telefon [phone]
Telefax [phone]
E-Mail [email protected]
0736 - ....
Oil-content meter OR 52-7 (15ppm Alarm)
approved by SEE-BG
according IMO-Resolution MEPC.107(49)
Approval No. IMO/EC 320030
24 V 50/60 Hz 50VA IP 65
Before removing cover isolate from
power supplies
See installation instructions
Avant d'ouvrir le couvercle dèconnecter
complètement l'appareil
Voir instructions de montage
Vor Öffnen des Deckels Gerät
freischalten!
Betriebsanleitung beachten

9
Technical Data – continued –
Dimensions OR 52-7
Measuring sensor ORG 12
Measuring transducer ORT 7
Fig. 2
approx. 200 approx.170
approx. 225
ON ALARM 1 ALARM 2 SYSTEM
GESTRA
ORT 7
OKP
240
260
110
160
Depth 91 mm

10
Installation
OR 52-7
Use the support and install the measuring sensor ORG 12 as close as possible to the separator in
order to keep the supply delay to a minimum. According to MEPC. 107 (49) in the event of an alarm
(oil content =/> 15 ppm) the contaminated water must be diverted from the separator to the bilge as
quickly as possible, i. e. within no more than 20 seconds.
Use a 10x1 mm copper or stainless steel pipe to connect the measuring sensor ORG 12/22 with the
sampling point of the separator and the clear water supply. The sampling point should be provided in a
vertical section of the separator outlet pipe so as to avoid any impairment caused by air bubbles.
In order to ensure that the arrangement for the extraction of samples gives a truly representative
sample make sure that the fluid flow always passes through the sensor under all operating conditions
and that any by-passing of the oil separator is prevented.
If it is not possible to provide the sampling point in a vertical pipe, a lateral arrangement in a horizontal
pipe is also possible.
For overboard pipes having an outside diameter of up to 75 mm a tee piece for the extraction of
samples can be used. If the size of the pipe exceeds 80 mm, make sure that the sampling arrange-
ment extends approx. 25 % into the overboard line.
Install the vacuum breaker above the highest point of the oil separator.
Attach the measuring transducer ORT 7 to a stable vertical surface. If possible mount the indicator at
eye level for easy viewing and provide sufficient space for service and maintenance work.
The measuring transducer is designed for wall mounting. The distances between the fixing holes are
indicated on the back of the equipment.
To access the fixing holes undo the cover screws and open the cover.

11
Installation – continued –
Example of installation
ON ALARM 1 ALARM 2 SYSTEM
GESTRA
ORT 7
OKP
Three-way control valve Overboard line
To bilge To bilge
Pressure-
maintaining
valve
(if required)
Mount
vacuum
breaker
above
the oil
separator
10 x 1 mm
copper or stainless steel pipe
Inlet Outlet
To
bilge
Separator
Separator
outlet
Clear water
inlet (water
pressure
≥ 2.5 bar)
Fig. 3

12
Electrical Connection
Measuring transducer ORT 7
1. Undo cover screws and open cover.
2. Detach all three-pole terminal strips from the base board and pull connecting lines through cable
glands.
3. Mark connecting lines: “Mains”, “Alarm 1”, “Alarm 2”, “Light emitter” and “Light receiver”.
4. Connect all terminal strips in accordance with the wiring diagram. Connect screens only to ORT 7.
5. Connect PE with the earthing screw in the housing.
6. Re-attach terminal strips.
7. Tighten the cable glands in order to seal the cable entry. Use the supplied sealings plugs to seal off
any unused cable glands.
8. Close housing lid and tighten cover screws.
Attention
■The oil & turbidity detector has a power consumption of max. 50 VA. Please make sure
that the power supply is rated for 100 VA.
■To protect the output relay contacts fuse electric circuits with 2.5 A (slow-blow).
■Provide connected contactors and actuators with RC combinations (in accordance with
manufacturers’ specifications) in order to suppress interferences.
■Make sure that the disconnecting switch (Fig. 4) is easily accessible and in the close
proximity of the equipment (EN 61010-1).
■Mark respective switch as disconnecting device for the measuring transducer.
This switch can be dispensed with if the control cabinets are upstream of the equipment
and fitted with a disconnector for the measuring transducer.
Note
■ The light emitter/receiver and the purging valve are fitted with a 4 m long connecting
cable and only have to be connected to the measuring transducer.
■ The terminal strips on the CPU board of the ORT 7 cannot be detached.
■ Strip off approx. 25 mm of the cable insulation coating and screen of the connecting
cables for the signal input of the separator ON/OFF and for the GPS input.
Tools
■Screwdriver for cross-recess screws, size 1 and 2.
■Screwdriver for slotted screws, size 2.5, completely insulated to VDE 0680
■Conductor end sleeve pliers
■Insulation stripper

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Electrical Connection – continued –
Wiring diagram OR 52-7
Fig. 4 Shown position of contacts: Alarm 1 and 2, separator OFF and power failure
Notice
Fig. 4 shows an example where the water will be run back to the ship‘s bilge in the event of an alarm
(oil content > 15 ppm) or auxiliary power failure.
With different limit settings alarm contact 1 can, for instance, be used for the first alarm and alarm
contact 2 for the main alarm.
For bilge water monitoring a pneumatic three-way valve can be controlled by the alarm contact 2 via a
solenoid valve. If the turbidity of the effluent is too high (alarm caused by ingress of oil or dirt particles
introduced into the system during start-up) the three-way valve will divert the contaminated water to
the bilge tank. The separation continues until the oil content falls below 15 ppm and the cleaned water
can be discharged overboard.
DS
1 2 23
3
3
3
3 3 3 3
L N
0/4-20mA
R 500
2
2
2
2 2 2 2 2
1
1
1
1 1 1 1 1
S
D
L
Alarm2 Alarm1
ORT 7
Basis
ORG
ORT 7 CPU
A B S
Separator GPS
1
12
233
key “+” :
Clw - On
key “-” :
Clw - Off
Clw
24VAC
Clw
1
2
2
1
3
4
1
- wire no.
12
External wiring Measuring sensor
Disconnecting switch
External
wiring
Purging valve
To first alarm
Attached in housing
cover
Solenoid valve
Three-way valve
Earthing screw
in housing
PE L N
N
L

14
Functional Elements
Measuring sensor ORG 12
Fig. 5
7
ON ALARM 1 ALARM 2 SYSTEM
GESTRA
ORT 7
OKP
1
5
4
3
2
6
8

15
Functional Elements – continued –
Measuring transducer ORT 7
Fig. 6
ON ALARM 1 ALARM 2 SYSTEM
GESTRA
ORT 7
OKP
4
§
"
!
0
9
Fig. 7
VDR4
VDR5
VDR3
L3
P2P1 P3
C24
C25
C26
R34
/%&
$

16
Functional Elements – continued –
Key
1Light emitter
2Measuring cell
3Solenoid valve Clew
4Cleaning device
5Drying cartridge
6Throttling device
7Measuring transducer ORT 7
8Cable glands
9LCD display
0System LED
!Keypad
"LED Mains voltage ON
§LED Alarm 1 and 2
$Terminating resistor GPS interface
%Memory card
&Locking piece for Memory Card
/Circuit board for ORT 7 CPU

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Commissioning Procedure
Factory setting
The measuring transducer features the following factory set default values:
■ Limit alarm 1: 15 ppm
■ Limit alarm 2: 15 ppm
■ Delay of response alarm 1: 1 second
■ Delay of response alarm 2: 1 seconds
Warning
The terminal strips of the measuring transducer ORT 7 may be live during operation!
This presents the risk of severe injuries due to electric shock!
Cut off power supply before opening the housing lid!
Checking electrical connection
Before commissioning the equipment:
■ Check the connection of the supply voltage
■ The supply voltage is indicated on the name plate
■ Make sure that the connections of the signal inputs and alarm contacts are in accordance with the
wiring diagram.
Checking installation
■ Check all pipe connections for leaks and eliminate any leaks you encounter.
■ Unscrew the drying cartridge and remove the seal. Then screw the cartridge in again.

18
Commissioning Procedure – continued –
First commissioning
1. Apply supply voltage to the measuring transducer.
The green LED ON will be illuminated and alarm 2 is
signaled.
2. When the equipment is switched on, the system window
appears for approx. 3 seconds, indicating the following:
Name of the equipment,
Certificate,
Serial number,
Number of the software version.
3. After approx 3 seconds the measurement window
appears, indicating the following:
Oil content (in large characters),
State: Warm up
Current time / date in UTC
4. After approx. 30 seconds the actual value in ppm is
indicated in the measurement window. If this value is
below 15 ppm the message Alarm 2 is cancelled and the
equipment state “Ready” is indicated. If, however, the
value continues to exceed 15 ppm, the message Alarm 2
remains active and the equipment state “ppm>Limit” is
indicated.
5. Press now key +. The purging valve opens and Alarm 2 is
indicated. The equipment state “Clear Water ON” appears.
Rinse the measuring transducer ORG 12 for at least
15 minutes with oil-free water and operate the cleaning
device 42 – 3 times, Fig. 5. During the rinsing process
with oil-free water the measuring window should show
0 ppm. If this is not the case switch to programming
mode, Parameter Value Offset, and reduce the zero point
by a max. of 5 ppm.
6. To close the purging valve press key –. The equipment
state “Ready” or “ppm>Limit” or any other alarm message
is indicated.
Note that in the measurement window the keys and and “OK” do not have a function. If you
want to enter the programming mode press key P.
Device
Certif.
Ser.Nr.
Vers.
: ORT7
: IMO
: MEPC.107(49)
: 392358
: 311137.10
Flowserve Gestra
OIL CONTENT :
ppm
State: WarmUp
8
UTC 10:46 2006-12-06
OIL CONTENT :
ppm
State: ready
8
UTC 10:46 2006-12-06
OIL CONTENT :
ppm
State: ClearWater ON
0
UTC 10:46 2006-12-06

19
The following parameters can be selected and, if required, changed:
Value Offset (reduction of zero point 0-5 ppm),
Output (Output of actual value 0 / 4-20 mA),
Alarm 1 Limit Value (Limit Alarm 1, 0-15 ppm),
Alarm 2 Limit Value (Limit Alarm 2, 0-15 ppm),
Alarm 1 Time Delay (Delay of response for alarm 1, 0-15 sec),
Alarm 2 Time Delay (Delay of response for alarm 2, 0-15 sec),
Datalog Export (transferring the storage data to a PC by means of PC software).
1. Press key Pto enter the programming mode. The amber
system LED will be illuminated and the window showing
the parameter that was changed last appears.
2. Press  or  to scroll forwards / backwards until the
desired parameter is shown.
3. Press key P(P = change) to activate the parameter chan-
ge. To quit the programming mode without any changes
press key OK (OK = back). The window that was active
before you switched the mode will reappear.
4. After having activated the parameter change by pressing
key Puse the keys +/–to adjust the value within the
permissible limits.
5. To cancel the new setting press key P(P = abort). The old
value will then remain valid.
6. To confirm and activate the new value press key OK
(OK = confirm). The parameter window appears again.
7. Press key OK (OK = back) to quit the programming mode.
The window that was active before you switched the mode
will reappear.
Programming mode
Commissioning Procedure – continued –
Parameter
act Value Offset
Value : 0 ppm
= prev = next
= backOKP = change
Parameter
act Value Offset
Value : 2 ppm
= inc Para = dec Para
= confirmOKP
+
= abort
Parameter
act Value Offset
Value : 2 ppm
= prev = next
= backOKP = change

20
Commissioning Procedure – continued –
Other parameter settings
Note
The export of data (Parameter Datalog Export) is described in a separate operating
manual.
Parameter
Output 0/4 . . 20 mA
Value : 4 mA
= prev = next
= backOKP = change
Parameter
Datalog Export
Start
= prev = next
= backOKP = change
Parameter
Alarm2 Limit Value
Value : 15 ppm
= prev = next
= backOK
P= change
Parameter
Alarm2 Time Delay
Value : 5 sec
= prev = next
= backOKP = change