Parker Kittiwake LinerSCAN User manual

LinerSCAN
Instruction Manual
aerospace
climate control
electromechanical
filtration
fluid & gas handling
hydraulics
pneumatics
process control
sealing & shielding

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5th Generation
On-Line Wear Metal Debris Sensors
Installation and operation
User Manual: MA-K17510-KW

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Key to Symbols
!
= Caution
= Note – Helpful Hints and Tips
About This Manual
This manual is divided as follows
1 Contents
2 Introduction and Intended Use
3 Installation
4 Commissioning
5 Operation
6 Interpreting Results
7 Troubleshooting and Fault Finding
8 Maintenance and Servicing
Do not discard this manual!
This instruction manual comprises a functional part of the Kittiwake LinerSCAN product. The
instruction manual must be kept safe for future reference. It also provides a record of system
maintenance.
For General Enquiries, please contact:
Kittiwake Developments Limited
3-6 Thorgate Road
Littlehampton
West Sussex
BN17 7LU
United Kingdom
Tel: [phone]
Fax: [phone]
Email: [email protected]m
Web: www.linerscan.com
Products featured in this manual are protected by US Patent No. US 6051970.

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1 Contents
1 Contents.................................................................................................................................................... 3
2 Introduction and Intended Use ................................................................................................................... 4
2.1 LinerSCAN Software ............................................................................................................................. 4
2.2 Units - ppm............................................................................................................................................ 4
2.3 Alarm .................................................................................................................................................... 4
2.4 Principle of Operation ............................................................................................................................ 5
2.5 Important: Safety Summary ................................................................................................................... 6
2.6 Maintenance ......................................................................................................................................... 7
2.7 Calibration and Service ......................................................................................................................... 7
2.8 Pressure leak testing............................................................................................................................. 7
3 Installation ................................................................................................................................................. 8
3.1 LinerSCAN - What is Supplied............................................................................................................... 9
3.2 LinerSCAN - What is not included........................................................................................................ 11
3.3 Technical Data .................................................................................................................................... 11
3.4 General information............................................................................................................................. 13
3.5 LinerSCAN System Schematic - Functional ......................................................................................... 15
3.6 LinerSCAN System Schematic - Electrical ........................................................................................... 16
3.7 Installation of LinerSCAN..................................................................................................................... 18
4 Commissioning........................................................................................................................................ 33
4.1 Start the sensors ................................................................................................................................. 34
4.2 Start the LinerSCAN Software ............................................................................................................. 34
4.3 Setting Measurement Period ............................................................................................................... 37
4.4 Fault Finding ....................................................................................................................................... 38
5 Operation ................................................................................................................................................ 39
5.1 Important............................................................................................................................................. 40
5.2 LinerSCAN Software ........................................................................................................................... 40
6 Interpreting Results ................................................................................................................................. 56
6.1 Introduction ......................................................................................................................................... 57
6.2 Normal Wear over lifetime ................................................................................................................... 58
6.3 Part Replacement................................................................................................................................ 59
6.4 New Liner Feed-rates .......................................................................................................................... 60
6.5 Fuel Quality and catalyst fines ............................................................................................................. 61
6.6 Effect of Maintenance.......................................................................................................................... 64
6.7 Normal running.................................................................................................................................... 66
6.8 Feedrate optimisation .......................................................................................................................... 66
6.9 Scuffing............................................................................................................................................... 67
6.10 Conclusions .................................................................................................................................... 67
6.11 References ..................................................................................................................................... 67
7 Troubleshooting and Fault Finding........................................................................................................... 68
7.1 Software Problems .............................................................................................................................. 69
7.2 Electrical Problems.............................................................................................................................. 72
7.3 Sensor Filling and measurement problems .......................................................................................... 73
7.4 Oil Flow Testing .................................................................................................................................. 76
7.5 Blockage Check .................................................................................................................................. 79
7.6 Frequently Asked Questions................................................................................................................ 80
8 Maintenance and Servicing...................................................................................................................... 83
8.1 Introduction ......................................................................................................................................... 84
8.2 Connecting to RS232 .......................................................................................................................... 86
8.3 Servicing Solenoid Valves ................................................................................................................... 87
8.4 Cleaning of the sensor......................................................................................................................... 89
8.5 Changing the fuse ............................................................................................................................... 93

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2 Introduction and Intended Use
This manual covers the Kittiwake LinerSCAN system for monitoring the ferrous wear debris in waste
cylinder lubricant on slow speed diesel engines.
Optimisation of cylinder lubricant feed rates has significant financial benefits. Control of cylinder feed
rates is enabled through the sensor’s feedback of an allowable amount of wear debris in the waste
cylinder lubricant.
Wear debris is generated from the rubbing of piston rings against the liner in a slow speed diesel
engine.
The waste oil is diverted through the sensor in a U pipe set up which ensures the sensor is filled with
oil, which then flows to the drain. Compressed air blasts are used in the measure process (to empty a
full sensor and to stop the sensor clogging.)
2.1 LinerSCAN Software
The LinerSCAN software reads the output and controls the sensors when monitoring a slow speed
diesel engine. The software has the following features:
•LinerSCAN data with respect to Engine hours
•Sensor configuration settings (air blast duration and measure interval)
•Engine major component change (liners and pistons) – this allows for sudden changes in
readings to be reviewed – and understood.
•Input to log parameters such as; fuel Sulphur level, scavenge space pressure and TBN
•Multiple cylinder control
•Graphing function
•Sensors communicating over the network will not measure when another sensor is using the
air supply. This is to stop sensors operating the air blast purge concurrently, with obvious
implications on blast effectiveness.
•Blocked sensor warning
2.2 Units - ppm
LinerSCAN sensors report the amount of ferrous [Ferro-magnetic] debris contained in the fluid sample
which fills the measurement chamber. Ferrous debris is expressed in parts per million (ppm) by
weight.
2.3 Alarm
LinerSCAN is equipped with Alarm outputs, enabling connection to a ship’s alarm system.

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2.4 Principle of Operation
The sensor is based on the principals of Magnetometry to enclose the sample fluid in a magnetic field.
The sensor has two symmetrical measurement chambers: measure and reference halves. The
reference half is kept empty, whilst the measure half is filled with fluid sample. The sensor measures
the difference between the halves; the result is due to ferrous debris. This configuration results in
extremely temperature stable and repeatable measurements: both coils experience the same
environments and external influences.
Oil which may contain ferrous particles is supplied to the measure half; this is then emptied by an air
blast ‘flush’ to complete the reading. The sensor takes two readings per measurement: empty
chamber and full chamber. The reference half of the sensor has factory fitted blanking plugs – do not
remove. Contamination of this empty and sealed chamber may affect readings.
Reference Half
Measure Half

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2.5 Important: Safety Summary
This equipment is designed to comply with EN61010-1.
Warning: This equipment has not been approved for use in an explosive atmosphere.
Please ensure you thoroughly read and understand this user document before attempting to install or
operate the LinerSCAN range of wear debris sensors covered in this manual, derivatives or related
equipment.
If the equipment is used in a manner, or for a specific purpose other than that described in this
manual, then any safety protection may be impaired.
The sensors are designed to be connected to pressurised systems – including pneumatic
(Compressed Air) lines and hydraulic systems. A responsible body, the end user or system integrator
is responsible for ensuring the safety of associated systems, hoses or pipe-work containing fluids. This
includes isolation for maintenance to the sensor(s).
This equipment must be installed and operated by qualified persons only.
!
Caution:
The sensors are connected together in this application by waste cylinder lubricant drain pipes, the
scavenge space and common compressed air and electrical power supplies.
Therefore when maintenance is undertaken all common supplies [power, air, oil and drain] need
turning off [disconnecting at source] or the valves to the sensor closed to isolate the sensor from the
system [recommended]. Open the main drain valve to allow the engine to function.
!
Caution:
•Never use the sensor near combustible gases or liquids.
•Never disassemble, repair, or tamper with the sensor.
•Ensure that the supply voltage is within the specifications and means of isolation fitted.
•Ensure the load currents do not exceed the rated values.
•Ensure all associated equipment and pipe-work specification is the same or greater than the
operating specifications for the sensor.
•Check all associated equipment and pipe-work for correct connection before powering the unit.
•Check all wiring for correct connection before powering the unit.
•Never weld to a pipe which contains or has contained oil
•The sensor case must be earthed

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2.6 Maintenance
The sensor(s), power supplies and accessories contain no user serviceable parts. Do not attempt to
dismantle.
Please retain all original packaging for shipping purposes. All fluids must be removed from the
equipment before return and the sensors in and be cleaned appropriately. Kittiwake will not be liable
for damage to returned goods resulting from inadequate packaging.
2.7 Calibration and Service
LinerSCAN uses proven, patented Magnetometry; combined with internal micro-processing to indicate
metallic particle contamination. The factory calibrated sensors guarantee high reliability with long term
stability.
For continued performance, Kittiwake recommends that the LinerSCAN system is serviced,
checked and calibrated regularly by authorised Kittiwake installation and service personnel.
!
The minimum recommended inspection and service period is twelve months.
!
The minimum recommended re-calibration period is two years.
2.8 Pressure leak testing
All sensors are factory pressure tested; as a result there may be a small amount of test fluid present in
the sensor.

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3 Installation
Installation

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3.1 LinerSCAN - What is Supplied
LinerSCAN is supplied under the following part numbers:
Product Code Description Item Quantity
FG-K17400-KW LinerSCAN Sensor complete (one per cylinder)
3 metre cable (sensor to sensor)
Sensor
½” BSP Isolation Valves
Weld Boss
Hydraulic to BSP fitting
45°Hose fitting
Straight Hose Fitting
Hydraulic oil hose (1 metre)
Quick Coupling air connection
1
2
3
4
5
6
7
8
9
1
1
2
2
2
3
4
2
1
1
3
8
2
9
5
4
6
7
7
3
4
7
7
6
8
5

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Product Code Description Item Quantity
FG-K17401-KW LinerSCAN Software and Network (one per engine)
Terminal Box #1
Terminal Box #2
5 metre cable (sensor to sensor)
PC to Network dongle
Software installation disc
System computer Connector
LinerSCAN terminating connector
Airline Pressure Switch
Calibration check standard
Manuals x 2 (pre Installation and Main manual)
1
2
3
4
5
6
7
8
9
10
1
1
1
1
1
1
1
1
1
1
2
3
4
9
7
6
8
5
1
10

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3.2 LinerSCAN - What is not included
LinerSCAN is supplied as a core group of components. Since each ship installation is unique, the level
of additional equipment will vary. Below is a general list of required equipment:
•Air Line Fittings, Valves and Hose
•Computer
•Cable
•24V Power supply
•Sensor mountings, Brackets and fasteners
3.3 Technical Data
3.3.1 Sensor performance
Detection 0-2000 parts per million [ppm]
Un-combined ferrous debris by weight
Accuracy +/-30ppm
3.3.2 Sensor General
Zeroing method : Air Blast
Zeroing synchronisation method : Sensor controlled solenoid valve
Sensor bore diameter 10mm
Permitted Fluid temperature : 10 to 65°C
Ambient operating temperature: 0-65°C
IP rating:
Enclosure
Internal components
IP24
IP65
Weight: 17kg
Size: 300 x 300 x 150mm (H x W x D)
3.3.3 Terminal Box
Ambient operating temperature: 0-65°C
IP rating: IP65
Weight: 5kg
Size: 200 x 400 x 125mm (H x W x D)
3.3.4 LinerSCAN software: PC requirements
Operating System Microsoft Windows XP, Service Pack 2 or later’
Microsoft Windows 7
Minimum screen resolution 1200 x 800
Connections 2 free USB ports

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3.3.5 Alarms
Alarm Interface:
Warning:
Alarm/Alert:
Contact rating:
Relay contact (NC/NO, Common)
Relay contact (NC/NO, Common)
Max: AC:250V 6A
3.3.6 System electrical
LinerSCAN System
Power Input:
Power consumption:
24V DC
0.7A + (number of sensors x 0.2)
Fuse Rating:
Sensor Internal:
Terminal box #2:
1A Quick Blow
5A Quick Blow
Connections:
System to computer connector
Main terminals:
Alarms:
Air pressure warning switch:
Engine ON/OFF and Air ON/OFF:
Cable Gland ( x 4):
Follow Manufactures instruction.
Wago DIN rail Terminals, 2.5mm
2
Max.
Screw Terminals, 2.5mm
2
Max.
Captive clamp Screw Terminals, 0.5 to 1.5mm
2
Wago DIN rail Terminals, 2.5mm
2
Max.
13mm diameter max.
Cable Specifications
Approval:
Power:
Data, Alarm and Signals:
Cables must be shielded and approved for
Shipboard use.
Min 2.5mm
2
Twisted pair cable, shielded. Min 0.22 mm².
!
= Caution: LinerSCAN is classified as permanently connected equipment, and requires an
external isolating switch or circuit breaker. This must be clearly identifiable, labelled and positioned in
a readily accessible location.
3.3.7 System Plumbing
Scrapedown pipe weld boss
Internal thread:
Overall Length:
Outside diameter:
½ inch BSPP internal thread
37mm
27.2mm
Sensor Oil Flow connection: ½ inch BSPP Hydraulic fitting Female 60°cone
Sensor Oil Return connection: ½ inch BSPP Hydraulic fitting Female 60°cone
Oil flow and return pipe ½ inch (13mm) nominal internal diameter
Sensor air supply: ½ inch BSPP Female
Supplied with quick release couplings
Series 25/26 QR coupling to ½ inch BSP female
Series 25/26 QR coupling to 13mm hose tail
Max air line pressure for Air Blast 10 bar [145psi]
Minimum flow rate 30 litres per minute
Minimum Pressure Scavenge Pressure + 1 bar [15psi]
Air pressure warning switch 1/4 inch BSPP

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3.4 General information
3.4.1 LinerSCAN System
The Kittiwake LinerSCAN system communicates using CAN (Controller Area Network), a ‘bus’ system
especially suited for networking "intelligent" devices, such as sensors. Originally developed for
automotive uses, it is now being used in many industrial automation and control applications.
Industrial CAN components are used to connect the LinerSCAN system to the computer; A ‘Network
to Dongle connector’ terminates the cable run, and a ‘PC to Network dongle’ connects to a PC.
Network to Dongle
Connector
PC to Network Dongle
ToLinerSCAN
Network
To PC
3.4.2 Engine Status Monitor
LinerSCAN needs to know when the engine is ON or OFF. This is done via connection to a volt free
(0V) contact, which tracks the engine on/off signal; Contacts need to be open when the engine is ON
and closed when the engine is OFF.
3.4.3 Air Status Monitor
LinerSCAN needs to know when the airline is ON or OFF. This is done via connection to a pressure
switch in the air line.

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3.4.4 LinerSCAN Sensor schematic
S E N S O R O IL
'R E T U R N '
S E N S O R O IL
'F L O W '
E L E C T R IC A L
C O N N E C T IO N
(T E R M IN A L B O X O R
N E X T S E N S O R )
E L E C T R IC A L
C O N N E C T IO N
(T E R M IN A T O R O R
N E X T S E N S O R )
A IR IN P U T
1 – Connector to Solenoid 5 – Air Input (Quick Release coupling or ball valve)
2 – Solenoid valve – air blast ON/OFF control 6 – Oil ‘U’-Tube
3 – Fuse 7 – Sensor
4 – Junction box (remove cover for RS232 terminals) 8 – level detection sensor (detects if sensor(7) is full)

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3.5 LinerSCAN System Schematic - Functional
Sensor x
[Cylinder x]
Sensor x
[Cylinder x]
Sensor 2
[Cylinder 2]
Sensor 1
[Cylinder 1]
1
COMPUTER
ENGINE
COMPRESSED
AIR SUPPLY
PRESSURE
SWITCH
ITTING
ISOLATING
VALVE DRAIN VALVE
1.75m MAXIMUM
ENGINE ROOM
CONTROL ROOM
POWER
SUPPLY
POWER
ISOLATOR
ENGINE ON/O SIGNAL
DIGITAL OUTPUT ‘DRY’ (0V)
CONTACTS
3
2
4
5
1x2x0.22
1x2x0.22
2x2x0.22
3Gx2.5 +(2x2x0.22)
1x2x0.22
Computer
Connector
Computer
Dongle
SHIP ALARM SYSTEM
2 X DIGITAL INPUT OR ‘DRY’ (0V)
CONTACTS
Terminal Box #2
Terminal Box #1
3.5.1 Air supply
Compressed air pipe (6-10 bar usual working air) ½ inch nominal across the main engine at a slight angle to
allow draining via drain valve at the lowest point. The pipe has to be about 500 – 1000 mm underneath the
sensor inlet with T-piece to each unit so that any condensation does not collect in the sensor.
!
Sensor air supply is designed to use Series 25/26 QR couplings (supplied) – which allow auto-shut off from
the air supply when de-coupled from the sensor. If this is not used, an alternative method of isolation must be
used. To avoid unintentional shutting off of air to sensors, do not use QR couplings and isolation valves.
!
= Caution: LinerSCAN is classified as permanently connected equipment, and requires an isolating valve.
This must be clearly identifiable, labelled and positioned in a readily accessible location.

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3.6 LinerSCAN System Schematic - Electrical
A B L1 L2
1 2 3
4 5 6
+
+
NL3
N
NN
PE
PE
PE
TO TERMINAL BOX #2… CABLE 4
CABLE 5
4
Air Pressure Switch
(No Pressure = Open Contacts)
TO LINERSCAN SENSORS
Plug in LinerSCAN
system
TERMINAL BOX #1 CONNECTIONS
1
CABLE 5
PAIR 2 PAIR 1
24V 0V

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+
A B L1 L2 A B
+
NNNPEPEPE
24V
TO TERMINAL BOX #1… CABLE 4
TO COMPUTER… CABLE 1
TO POWER SUPPLY…
ENGINE ON/OFF SIGNAL… CABLE 2
ALARM SIGNAL X 2… CABLE 3
ALARM
WARNING
NO
COM
NC
ENGINE
ON/OFF
PAIR 2 PAIR 1
PAIR B PAIR A
TERMINAL BOX #2 CONNECTIONS
FUSE 5A
0V

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3.7 Installation of LinerSCAN
This section is arranged in order of installation task.
!
Caution: DO NOT CONNECT POWER TO LinerSCAN NETWORK UNTIL DIRECTED.
!
Caution: Ensure all tasks in the pre-installation manual MA-K17500-KW are complete before
proceeding.
3.7.1 Unpack the sensors and Install kit
Unpack all equipment and check delivery for all parts. Notify Kittiwake immediately of missing or
damaged parts. Ensure that all additional (Non-Kittiwake supplied) equipment and accessories
necessary for installation are present before proceeding.
3.7.2 Install PC at desired location
Ensure the PC is securely mounted and that connections to and from PC are secure and not easy to
pull out.
3.7.3 Fit LinerSCAN sensor to the mounting bracket
This will have been prepared under pre-installation work. Affix vinyl numbers to sensors for ease of
identification.
3.7.4 Make the oil and air connections
Make connections in accordance with the ‘General Information’ section, and drawing RS-096 –
detailed in the pre-installation manual MA-K17500-KW.
3.7.5 Connect Sensor to Sensor
Fit the pre-wired cables between the sensors and terminal box – fit the terminating plug to the last
sensor
3.7.6 Terminate and connect all pre-Installed Cable runs
Connections are made in accordance with the ‘General Information’ section. Ensure all power is ‘OFF’
and check wiring connections.

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3.7.7 Connect ‘Network to Dongle’ connector
Follow Manufactures instructions. Use the following settings:
•CAN+ or CANH (Box #2 Terminal B) into 1C+
•CAN– or CANL (Box #2 Terminal A) into 1C-
•Switch ‘ON’ to connect Terminating Resistor
DO NOT plug into the computer.
3.7.8 Install LinerSCAN software
Anti-Virus software can interfere with the installation. Disable Virus checker during installation. If
the PC is not connected to a network or internet, consider disabling virus checker or removing from
PC – software should run faster.
If the software is on a CD-ROM, insert the CD-ROM into the computer’s CD-ROM drive.
Computers using Microsoft Windows 7
Browse the installation CD for the LinerSCAN55.exe icon shown below: