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Maintenance

Page

of 82

Maintenance

8.1 Planned maintenance

NOTICE

The following maintenance program is for general use and must be

adjusted in accordance with your specific system requirements and

conditions.
The maintenance program is based on optimum conditions and

compliance with the system specifications. Failure to comply with the

system specifications can affect how often maintenance must be carried

out on the system and its components.

Planned Maintenance Program

Description

As ne

ary

eek

Mon

thly

Quar

terly

ery 6 mon

ths

Yearly

ery 2 y

ear

ery 3 y

ear

ery 4 y

ear

ery 5 y

ear

Main

tenanc

Instruction Numb

G6111 PAH sensor

Visual check

• PAH sensor

• PAH measuring chamber

Cleaning of PAH sensor and

measuring chamber

Validation of PAH sensor

Calibration of PAH sensor

PAH sensor replacement

G6120 Turbidity sensor

Validation of Turbidity

sensor

Calibration of Turbidity

sensor

Visual check

• Measuring chamber

Cleaning of Turbidity

measuring chamber

Turbidity wiper blade

replacement

MI6200-

0001

Summary of Contents for Maritime G6200

Page 1: ...G6200 Water Monitoring System User Manual Document ID number 103864 Maritime...

Page 2: ...Instruments A S reserves the right to make adjustments and improvements to its products and systems This means that documentation is subject to change without notice Green Instruments A S has taken al...

Page 3: ...Menu structure 17 4 1 Security and login 20 4 2 Settings 21 4 3 System settings 22 4 4 Alarm action 24 5 Installation 25 5 1 Mechanical 25 5 1 1 System installation 25 5 1 2 Sampling point 26 5 1 3 L...

Page 4: ...9 7 Validation Calibration 42 7 1 Introduction 42 7 2 pH Validation calibration 44 7 3 Turbidity validation calibration 48 7 4 PAH validation calibration 52 7 4 1 PAH validation methods 53 7 4 2 PAH s...

Page 5: ...troubleshooting 66 10 2 PH Temperature 69 11 System hibernation 72 12 Maintenance instructions 73 MI6200 0001 73 MI6200 0002 74 MI6200 0003 75 MI6200 0004 76 MI6200 0005 77 MI6200 0007 78 MI6200 0008...

Page 6: ...pdate 39 Figure 7 1 Main page 43 Figure 7 2 Login screen 43 Figure 7 3 pH Validation calibration procedure 44 Figure 7 4 Valves 45 Figure 7 5 G6130 pH pop up menu 46 Figure 7 6 G6130 pH validation men...

Page 7: ...n this user manual When a term is first used it will be written out in full and include its abbreviation for the sake of clarity Description Abbreviation Exhaust Gas Cleaning System EGCS Marine Enviro...

Page 8: ...ed to the system Having a WMS on board is an extremely effective way of ensuring compliance with international regulations The G6200 WMS is fully compliant with MEPC 259 68 MEPC 340 77 The system desi...

Page 9: ...ater Special precaution is taken to avoid interference from dissolved gasses and bubbles and an integrated wiper keeps optical fouling at a minimum Certified calibration solutions are used to perform...

Page 10: ...50 C Sample purity Particle size of max 2 mm Sample condition The system is designed for maritime SO2 scrubber wash water containing seawater polluted seawater freshwater with NaOH residue particles...

Page 11: ...erials PVC fused silica glass AISI 316 PVDF and NBR Signal RS 232 and Analog 0 4 20 mA Active Accuracy Max 5 of sensor range or Max 5 of the nominal standard test concentration which value is no less...

Page 12: ...e 12 of 82 Ver 1 1 Revision March 2022 Power supply Refer to Electrical Drawings Wetted materials AISI 316 or PPS glass PVDF PVC Signals 2 Analog 4 20 mA Passive Accuracy Max 0 2 pH unit Specification...

Page 13: ...te of delivery Store calibration kits at 5 25 C Calibration solutions can become damaged at temperatures below 0 C and temperatures above 25 C may reduce their accuracy and lifetimes However storage t...

Page 14: ...e pressure as low as possible in order to maximize pump lifetime Do not block a safety valve s drain or outlet connection as this will damage components Check the safety valve to ensure it functions c...

Page 15: ...isolating electrical power by a clearly marked external switch or circuit breaker The external switch or circuit breaker must be in close proximity to the system and within easy reach of the operator...

Page 16: ...tem before removing any wetted components WARNING Harmful components poisoning and chemical burns hazard The water can contain poisonous components that are potential harmful to humans and animals Som...

Page 17: ...wn in Figure 4 1 Figure 4 2 shows the trend screen and Figure 4 3 shows the alarm screen The illustrations use yellow lines and yellow boxes to show the relationships between screens and different use...

Page 18: ...Water Monitoring System User Manual Page 18 of 82 Ver 1 1 Revision March 2022 Figure 4 1 HMI home screen layout menu structure and settings options...

Page 19: ...Menu structure Page 19 of 82 Figure 4 2 Trend screen Figure 4 3 Alarm screen...

Page 20: ...tart stop and local remote functions Level 2 Service Only for trained personnel The user can access system settings calibration validation and moving average functions Level 3 Admin ATTENTION The foll...

Page 21: ...er to Figure 4 6 The settings screen also contains greyed out buttons To enable these contact Green Instruments Figure 4 6 Settings screen Pressing the pH Turbidity or PAH button will generate a pop u...

Page 22: ...nsures that air does not enter the system during the start up phase The On Off valve or the pump will turn on after the Remote Start Delay period has expired This function is only active in remote ope...

Page 23: ...minute Alarm default setting 1 5 l minute Range 1 5 10 l minute Flow alarm delay The flow alarm delay allows for small flow fluctuations without trigging the flow alarm When the WMS is sampling flow...

Page 24: ...t setting 0 seconds Range 0 4 seconds ATTENTION Changing the high pressure warning alarm delay set points can cause system failure and will void the system warranty 4 4 Alarm action Some of the system...

Page 25: ...equipment safe from welding grinding sparks heat electric current and electromagnetic effects Consult all relevant technical documentation to ensure correct installation ATTENTION The following requi...

Page 26: ...able that measures are taken to prevent air from entering the sampling system otherwise this will increase the risk of air locks and system failure Take the presence or accumulation of particles at th...

Page 27: ...tion from Green Instruments The power supply for the WMS must be in accordance with the power supply specified in the electrical documentation 5 2 2 Power The characteristics of the WMS power supply m...

Page 28: ...Modbus IP address To configure this IP address the user must change to Level 2 and navigate to System Settings Here it is possible to change the PLC Ethernet 2 address which is used for Modbus communi...

Page 29: ...Boolean 0 1 0 400002 8 0 All OK 1 Alarm pH Signal Alarm Boolean 0 1 0 400002 9 0 All OK 1 Alarm Temperature Signal Alarm Boolean 0 1 0 400002 10 0 All OK 1 Alarm Flow Signal Alarm Boolean 0 1 0 40000...

Page 30: ...he location of the port After connecting the network the IP address of the HMI must be configured To do this the user must access the HMI menu This is done by pressing screen corner 1 and then pressin...

Page 31: ...to the device is achieved by means of a private point to point connection Access to this connection is strictly controlled and all data sent and received on the connection are encrypted Figure 5 3 Rem...

Page 32: ...After carrying out the adjustment switch the handle on the motor protection unit from the OFF position to the ON position Ensure that the protective earth is connected Ensure that the communication co...

Page 33: ...e sequence of the power supply is correct and that the rotation direction of the motor corresponds to the inlet outlet connection on the pump Carefully read and follow the instructions in the pump man...

Page 34: ...off the pump or motor valve Follow the MODBUS map in section 5 3 2 to identify relevant functions 6 1 2 Local operating mode When the WMS is in local mode it is possible to operate the system manually...

Page 35: ...tion MI6200 0009 to adjust the reduction valve Figure 6 1 Inlet valve arrangement 6 2 2 Safety valve All WMSs are equipped with a safety valve to reduce the risk of pressure damage The safety valve is...

Page 36: ...and length For systems equipped with a pressure reduction valve the setpoint pressure of the pressure reduction valve will also affect the flow of water through the WMS In general water flow through...

Page 37: ...sensor signals to remove sudden peaks The filter function calculates the mean value of the signal over a given time Maximum mean time is 20 seconds To deactivate this function enter a 0 in the moving...

Page 38: ...relevant system data is logged and saved It can be exported in an editable format to the SD card located in the PLC The SD card can then be inserted into a PC and the files copied to a folder on the P...

Page 39: ...e System Settings screen Refer to Figure 5 2 Press the system settings button in the System Settings screen Figure 6 4 Software update Note Both PLC and HMI updates must be executed in the correct ord...

Page 40: ...s 2 Remove the existing SD card from the SD slot in the PLC and store it while carrying out the software updates 3 Press the three dots on the green PLC FW button 4 Follow the instructions on the HMI...

Page 41: ...l update remove the USB memory stick again 7 Remember to reinsert the existing USB memory stick in the USB slot on the back of the HMI After these updates have been carried out perform a power off on...

Page 42: ...accuracy stated for the given module in section 2 2 The system will notify the user of the result of the validation with either a Validation Passed or Validation Failed message If the validation is p...

Page 43: ...of 82 Figure 7 1 Main page To perform a validation press the settings button and login as a service user with level 2 access Refer to section 4 1 or Figure 7 2 below to see how to log in as a service...

Page 44: ...calibration NO NO No further action required Contact supplier YES YES Calibration accepted pH Validation Calibration Cleaning Perform validation Perform calibration Validation accepted Have you cali...

Page 45: ...lve 3 Find a clean cloth and pH buffer 7 4 Loosen the pH sensor union nut by hand and remove the sensor from its measuring chamber 5 Clean the electrode and check if the measuring chamber needs cleani...

Page 46: ...Make sure the rotary switch on the sensor is set to position M and that the pH buffer and sensor has the same temperature Open a bag of pH buffer 7 Place the sensor into the pH buffer Stir the sensor...

Page 47: ...er 4 7 10 or follow steps 13 21 below Figure 7 7 G6130 pH calibration 14 Calibration procedure set the rotary switch ring from position M to the position that corresponds with the pH buffer number bei...

Page 48: ...deviates more than 2 NTU Steps 1 12 and 30 32 describe the validation procedure for the turbidity module Steps 13 32 describe the procedure for local calibration of the Turbidity module 1 Select Local...

Page 49: ...7 9 using standard 10 NTU or follow steps 10 12 below Figure 7 9 Turbidity validation 10 Enter the turbidity concentration used and press the Start Validation button 11 Wait for the display to update...

Page 50: ...Press to select Formazine STD 18 Press to begin Zero Calibration observe Calibrating Zero Note Pressing the again will skip the zero calibration 19 After approximately 1 minute the text Fill Span Sol...

Page 51: ...ur Standard 10 NTU into the chamber until the lenses are covered DO NOT FILL COMPLETELY 29 Refit the wiper unit and tighten the union nut and observe a 10 NTU value on the display 30 If the displayed...

Page 52: ...ed to correct PAH reading offsets Figure 7 9 is a flow chart showing the procedures that must be done to ensure the PAH module is functioning correctly NO No further action required Contact supplier Y...

Page 53: ...ned maintenance schedule found in section 8 in this manual to ensure the correct performance of the PAH sensor Calibration of the PAH sensor is only required when The displayed validation value deviat...

Page 54: ...s vital so please use a cloth free from oil when cleaning the optical windows NOTICE It is vital to wipe the sensor dry prior to and between any validation calibration attempt Take care to wipe dry al...

Page 55: ...ration as quickly as possible after opening the ampoule to ensure the best performance and validity of the calibration liquid Do not leave the sensor in the PAH calibration liquid more than 15 seconds...

Page 56: ...ion Figure 7 12 G6111 PAH pop up menu Figure 7 13 PAH validation Enter PAH liquid concentration value based on the sensor range please select the validation liquid in accordance with Table 7 1 3 Take...

Page 57: ...esult If the validation is successful a calibration is not required If the validation fails refer to Figure 7 9 7 Drain the validation liquid from the calibration chamber and wipe the calibration cham...

Page 58: ...ibration chamber Ensure that no air is mixed with the calibration solution Look into the chamber to check and remove any air bubbles using the tip of the needle 4 Insert the cleaned PAH sensor in the...

Page 59: ...he system and its components Planned Maintenance Program Description As necessary Weekly Monthly Quarterly Every 6 months Yearly Every 2 years Every 3 years Every 4 years Every 5 years Maintenance Ins...

Page 60: ...unit replacement x MI6200 0004 Turbidity analyser replacement x MI6200 0005 G6130 pH Temp sensor Visual check pH sensor pH measuring chamber x Cleaning of pH sensor pH measuring chamber x pH electrod...

Page 61: ...program that has been adapted to suit your system requirements and conditions 8 2 1 PAH NOTICE Exercise caution when cleaning to avoid damaging optical windows The PAH sensor is generally kept clean...

Page 62: ...to mounting the sensor to ensure that the tip of the electrode is kept moist 8 3 Lifetime of components 8 3 1 PAH The lifetime of the PAH sensor is mainly determined by the internal light source Befo...

Page 63: ...electrode The electrode has a shelf life of 1 year at 25 C and has an operating lifetime of approximately 1 year at 25 C Storage or operation at higher temperatures or pressures will shorten the lifet...

Page 64: ...f the PAH sensor s 3 year replacement due date to schedule its replacement Prior to delivery a full calibration will be carried out by the manufacturer to comply with the requirement s of the regulato...

Page 65: ...ration certificate will be issued Contact Green Instruments A S for further information 9 5 Return of equipment Return of equipment must be coordinated with manufacturer You will receive a Return form...

Page 66: ...afety regulations 10 1 General troubleshooting Trouble Possible Cause Action Electrical Display is dead Circuit breaker Power supply Check the circuit breaker Check power supply the power supply needs...

Page 67: ...disconnect it from the junction box There is no turbidity measurement on the display Replace the Turbidity analyser or the sensor PAH module Incorrect indication of PAH value Dirty sensor window or ch...

Page 68: ...k flow alarm set point Air in system Evacuate air by disconnecting the relevant pipework Wrong readings Fluctuations of readings Air bubbles Check the sampling line Visual check that the de bubbler is...

Page 69: ...ectrode If a defective pH electrode has been replaced by a new pH electrode then the calibration data must be overwritten However the field calibration data stored in the sensor will not match the new...

Page 70: ...epted Red LED will flash 3 times Calibration success Figure 10 1 pH negative offset reading too low Example 2 pH positive offset reading too high Step Description Buffer solution Observed pH Calibrati...

Page 71: ...t immerse the sensor in e g clean tap water note the initial displayed pH value leave the sensor in the water for 15 minutes then note the displayed value after 15 minutes Calculate drift Drift Initia...

Page 72: ...spare parts If the system is inactive for at least 30 days carry out the following procedure Isolate the system by shutting off the inlet and outlet valves Set power to OFF by turning the main switch...

Page 73: ...manual open close the valve 3 Open the DRAIN VALVE 4 Loosen the wiper unit and observe the water draining out of the cabinet 5 Pull the wiper blade C out of slot D in the wiper arm E and dispose of th...

Page 74: ...t the emitter light source connector B from receptacle J2 on the print 4 Gently squeeze the retaining tabs C together and pull to withdraw the light source D from its housing E 5 Carefully remove the...

Page 75: ...cedure 1 Turn OFF the WMS by switching the MAIN SWITCH on the right side of cabinet to O position 2 Close the INLET VALVE and OUTLET VALVE Note In case of motor valve turn the handle on the bottom of...

Page 76: ...g the MAIN SWITCH on the right side of cabinet to O position 2 Close the INLET VALVE and OUTLET VALVE Note In case of motor valve turn the handle on the bottom of the motor valve to enable manual open...

Page 77: ...o O position 2 Remove front cover on Turbidity analyser 3 Remove the plate under the front cover 4 Disconnect all wires and take the cables out Note Take photos or notes on exactly how the existing an...

Page 78: ...from the measuring chamber A 6 6A For systems in operation Unscrew the old pH electrode by turning it counter clockwise B 6B For systems in commissioning Unscrew the shipping plug by turning it count...

Page 79: ...valve Procedure 1 Turn OFF the WMS by turning the MAIN SWITCH on the right side of cabinet to O position 2 Close the INLET VALVE and OUTLET VALVE Note In case of motor valve turn the handle on the bot...

Page 80: ...pare Parts Tools Part no Description Item 02703 Pressure reduction valve 1 x 13mm Spanner Procedure 1 Start sampling and ensure water is running through the system 2 Remove protective black plastic ca...

Page 81: ...the system by means of the pressure reduction valve 2 Remove protective black plastic cap on the pressure reduction valve 3 Unscrew locking nut 4 Turn the pressure adjusting screw counter clockwise to...

Page 82: ...f the cabinet 5 Uninstall the old pH sensor using a small flat headed screwdriver to disconnect the pH sensor wiring inside the monitoring unit Use the 17 19 mm spanner to loosen the cable gland then...

Page 83: ...en Instruments USA Inc 6750 N Andrews Avenue Suit 200 Fort Lauderdale FL 33309 USA Tel 1 954 613 0400 usa greeninstruments com ASIA Green Instruments S Pte Ltd 4008 Ang Mo Kio Avenue 10 01 09 10 Techp...

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