Maritime G6100 Operation Manual Download Page 1

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G6100

Water Monitoring

System

Operation Manual

ocumen

t ID n

umb

.: 02480

Maritime

Summary of Contents for G6100

Page 1: ...G6100 Water Monitoring System Operation Manual Document ID number 02480 Maritime...

Page 2: ...Program Menu Structure Page 2 of 110 Figure 1 1 Program Menu Structure of the Water Monitoring System...

Page 3: ...CTION 29 4 3 1 Trend Graph 29 4 4 RUN 29 5 COMMISSIONING 30 5 1 WM 30 5 2 WMR 31 5 3 WMRTU 32 5 4 WMP 33 5 5 WMPH 34 6 VALIDATION CALIBRATION 36 6 1 VALIDATION CALIBRATION OF THE PH MODULE 37 6 2 VALI...

Page 4: ...3 WMP 55 8 1 4 WMPH 55 9 EXPECTED LIFETIME 56 9 1 PAH 56 9 1 1 G6110 PAH 56 9 1 2 G6111 PAH 56 9 2 TURBIDITY 57 9 3 PH TEMPERATURE 57 9 4 IMPELLER PUMP 58 9 5 HOSE PUMP 59 10 STORAGE HANDLING 60 10 1...

Page 5: ...ng the Logged Data 26 Figure 4 17 System Info Page 26 Figure 4 18 Trend Page 29 Figure 4 19 Trend PAH Page 29 Figure 6 1 pH Validation Calibration Procedure 37 Figure 6 2 PAH Validation Calibration Pr...

Page 6: ...1 Validation Calibration Liquid Selection 42 Table 6 2 Validation Tolerance Table 42 Table 6 3 Validation Calibration Liquid Selection 45 Table 12 1 Analog Diagnostic Table G6111 PAH Sensor 67 Table 1...

Page 7: ...nstructions for the operation of the water monitoring system including sensor modules and sampling systems will be described in this manual Note that each system is configured at the factory according...

Page 8: ...ments Green Instruments A S Erhvervsparken 29 DK 9700 Br nderslev Denmark Phone 45 9645 4500 Fax 45 9645 4501 Email spares greeninstruments com Web www greeninstruments com 1 3 About the System The wa...

Page 9: ...The Turbidity Module can detect sooth particles and suspended soil in the water Special precaution is taken to avoid interference from dissolved gasses and bubbles and an integrated wiper keeps optica...

Page 10: ...Integrated flow sensor detects sample flow Sample Pressure Max 3 bar g Sample Temperature 0 50o C Sample Purity Particle size of max 2 mm Sample Condition Avoid air and particles in the sampling syst...

Page 11: ...ified upon order Power Supply Refer to Electrical Drawings Wetted Materials G6110 AISI 316 acetal Titanium gr 2 sapphire glass PVDF and NBR G6111 PVC fused silica glass AISI 316 PVDF and NBR Signal G6...

Page 12: ...unit Sampling Systems Optional Pressure Reduction Cabinet WMR Equipment 20 mesh strainer Pressure Reducing Valve Relief Valve ON OFF Valve Flow Regulating Valve De bubbler Manometer Connections Refer...

Page 13: ...Material AISI 304 Painted or Polycarbonate Hose Pump Cabinet WMPH Equipment 20 mesh strainer Flow Regulating Valve External Hose pump Debubbler and Manometer Connections Refer to the PI diagram the I...

Page 14: ...tions Refer to the Electrical Drawings Sample Temperature 0 50 C Sample Purity Particle size of max 2 mm Sample Condition Avoid air and particles in the sampling system Dimensions Weight Refer to the...

Page 15: ...de is kept moist The electrode will be damaged if it dries out The cap must be removed prior to start up of the system The pH temperature sensor is also fitted with a plug to prevent moisture from ent...

Page 16: ...n Instruments A S cannot be held liable for any resulting damage or injury HAZARDOUS VOLTAGE Disconnect the power before installing or servicing the equipment Ignoring this warning can result in sever...

Page 17: ...in operation Damage of components can occur Before removing any wetted components please depressurize the system HARMFUL COMPONENTS The water can contain poisonous components that are potential harmfu...

Page 18: ...e manual are only for general illustration purposes The monitor unit uses an HMI module as a combined work and operating station Figure 4 1 Menu Structure 4 1 Home The 5 blue buttons of the home page...

Page 19: ...trolling the system will be inhibited Figure 4 2 Home Page 4 1 1 PAH Note The PAH value shown in the Figure 4 2 Home Page is compensated for effects of turbidity The same value can be found in the sys...

Page 20: ...Range G6110 PAH DUAL RANGE On dual range systems It is important to calibrate both low and high range It is possible to switch between the ranges on the PAH calibration page Please refer to Figure 4 5...

Page 21: ...ibration G6111 PAH DUAL RANGE Figure 4 8 G6111 PAH Dual Range 4 1 2 Turbidity pH Temperature or Flow After pressing the blue Turbidity pH Temperature or Flow buttons a notice referring to this manual...

Page 22: ...r Alarms and System Info can be entered without any password The Setup page and the Logging page however require a password User service Password 1234 Figure 4 10 Settings Page 4 2 1 Setup Note It is...

Page 23: ...Alarm is triggered This timer provides dry run protection of the pump hence changing the timer setting should be considered carefully Flow Establish Time When the On Off valve or the pump is activated...

Page 24: ...ed when performing the zero calibration High Raw The RAW signal captured when performing the span calibration Refresh Stores edited values Please note the system is calibrated at the factory The facto...

Page 25: ...rors low flow communication errors and memory status The alarms are displayed in a log showing active alarms and the alarm history Use the active alarm button or alarm history button for detailed diag...

Page 26: ...rmat is csv thus allowing editing in Excel or similar program Figure 4 16 Logging Page for Exporting the Logged Data 4 2 5 IP Address Configuration 1 Touch an empty area of the touch screen for few se...

Page 27: ...n Sheet correspond with the values stored in the system settings If this is not the case then carefully write down the calibration values used for PAH and the Timer settings These values can be found...

Page 28: ...User User admin Password green 14 Go to Home screen Press PAH 15 Select the desired range setting by pressing the required range box field 16 Press the desired range button The button should turn gre...

Page 29: ...allows the user to scroll in time and zoom in out The system will require some time to update and visualize the logged data 4 4 Run The system control switch in the bottom right corner controls the p...

Page 30: ...on manual has been filled out Inlet and outlet hoses are connected as specified with reference to the installation layout The flow paths to and from the system are not blocked The power supply connect...

Page 31: ...with reference to the installation layout The flow paths to and from the system are not blocked The power supply connections are as specified in the Electrical Drawings Protective earth is connected C...

Page 32: ...stem by switching on the automatic fuse Observe the start up of the water monitoring unit and the sensor modules Set the IP address following section 4 2 5 Verify that all functions described in the c...

Page 33: ...an ON OFF switch please pay attention to the position of this to avoid START issues A local ON OFF switch is standard for motors used for pump Type B The motor for pump Type B also includes an inbuil...

Page 34: ...flow Please check if the flow path is blocked by any closed valves or by the protection cap on the pH sensor If no blockage is found the alarm could be caused by air in the system In this case the ala...

Page 35: ...must be at the top connection and outlet must be at the bottom connection Please refer to Diagram inside the junction box of the motor to change the direction of rotation Note The pump pressure shoul...

Page 36: ...tion is a normal part of the maintenance of the sensor modules A calibration will only be required if the displayed values during validation deviate more than the accuracy stated for the sensor module...

Page 37: ...tion fluid drain off to collect the discharge 2 VALVE 2 is in STOP position Then set VALVE 1 to DRAIN position 3 Loosen the union nut by hand and park the sensor in the clamp 4 Clean the electrode and...

Page 38: ...the electrode moist 15 Put the sensor back to the measuring chamber and fasten the union 6 2 Validation Calibration of the Turbidity Module Steps 1 8 and 25 describe the procedure to perform a valida...

Page 39: ...Loosen the union nut on the top remove the wiper park it 15 Turn VALVE 2 from STOP to DRAIN and back to STOP again when draining is done 16 Pour Standard 40 NTU into the chamber DO NOT FILL COMPLETEL...

Page 40: ...is functioning correctly Calibration is used to correct PAH reading offsets Figure 6 2 is a flow chart entailing the procedures that must be done to ensure a correct functioning PAH module Figure 6 2...

Page 41: ...performance of the PAH module Calibration of the PAH module is required when The displayed validation value deviates more than 5 of sensor range or The displayed validation value deviates more than 5...

Page 42: ...ELECTION Module Type Calibration Liquid g l Validation Liquid g l Low Range Calibration High Range Calibration Low Range High Range Low Calibration High Calibration Low Calibration Middle Calibration...

Page 43: ...PAH chamber bushing tool Figure 6 4 Clean the bushing thoroughly Figure 6 4 PAH Chamber Bushing Placement 2 Press the PAH area on the home screen Press Calibration Mode Login press Calibration Mode a...

Page 44: ...the validation is not successful please refer to Figure 6 2 7 Remove and clean the PAH chamber bushing 8 Empty out the validation liquid from the calibration chamber and wipe it dry with a new cleani...

Page 45: ...re 6 2 5 Empty out the validation liquid from the calibration chamber and wipe it dry with a new cleaning pad Clean the PAH sensor 6 4 Calibration of the PAH Module ATTENTION Do not leave the sensor i...

Page 46: ...from the PAH measuring chamber using the PAH chamber bushing tool Figure 6 7 Clean the bushing thoroughly Figure 6 7 PAH Chamber Bushing Placement 2 Press the PAH area on the home screen Press Calibr...

Page 47: ...n chamber in an upright position Press the corresponding Calibrate button when the highest stable raw count appears A calibration point has now been stored 7 Remove and clean the PAH chamber bushing 8...

Page 48: ...A calibration point has now been stored 5 Empty out the calibration liquid from the calibration chamber and wipe it dry with a new cleaning pad Clean the PAH sensor 6 Repeat steps 3 to 5 until all re...

Page 49: ...mation in section 1 2 ATTENTION Failure to react upon the service interval requirement can affect the accuracy performance and functionality of the sensor which will compromise the requirement s of th...

Page 50: ...vice engineers can perform a full factory calibration in our factory or onboard the vessel A new calibration certificate will be issued For further inquiry please refer to contact information in secti...

Page 51: ...l guidelines and must be adjusted based on specific system experiences The intervals are based on optimum conditions and failure to comply with system specifications can impact intervals Planned Maint...

Page 52: ...ation x PAH Sensor Replacement x G6120 Turbidity sensor Validation of Turbidity sensor x Calibration of Turbidity sensor x Visual check to see if cleaning is needed Measuring chamber x Cleaning of Tur...

Page 53: ...ace Pump Impeller and End Cover x MI6100 0011 Replace Pump Shaft Seal x MI6100 0012 WMP pump Type B Inspect Pump Impeller End Cover and Housing x Replace Pump Impeller x MI6100 0015 Replace Pump Mecha...

Page 54: ...il and salt deposits In order to clean and flush away solids manually please attach the syringe to the CAL INPUT of VALVE 4 and use the syringe to suck out any remaining water inside the measuring cha...

Page 55: ...nd cover wear plates and shaft seal in stock as spare parts 8 1 4 WMPH Check that the pump pressure is not unnecessarily high High pressures will result in reduced lifetime of the pump hose Pressure r...

Page 56: ...compromise the requirement s of the regulatory agencies 9 1 2 G6111 PAH The lifetime of the PAH Sensor is mainly limited by the internal light source Before each sensor leaves the factory the remaini...

Page 57: ...ter quality It must be replaced when necessary Figure 9 1 Wire connections for Emitter Receiver and Wiper Unit 9 3 pH Temperature The lifetime of the pH temperature sensor is mainly limited by the lif...

Page 58: ...ick to the pump housing after stand still It is important to ensure that the impeller is not stuck prior to attempting startup The entire pump unit can be replaced or the necessary spare parts can be...

Page 59: ...ure Recommended pressure 0 8 2 0 bar Pump cavitation Insufficient lubrication of hose and rollers The rollers of the hose pump must be properly adjusted to maximize the hose lifetime Adjustment is don...

Page 60: ...rts are kept in stock for when the system is used again after a long period of inactivity Impeller End cover Shaft seal pH electrode If the system is inactive for at least 30 days carry out the follow...

Page 61: ...and also to evacuate air 10 4 pH Electrode The electrode must be calibrated after storage if the recommended calibration interval is overdue The electrode has a shelf life of approximately 12 months 1...

Page 62: ...priate type for return of equipment All returned equipment must be free from any hazardous substances such as acids alkalis solvents etc Therefore it is important to carefully clean the equipment prio...

Page 63: ...iner open blocked valves check hoses are intact Check and adjust the flow regulating valve Air in system evacuate air by disconnecting the relevant hoses Low flow Check system for blockages especially...

Page 64: ...horoughly G6111 Check clean the sensor and chamber thoroughly Check expiration date of PAH sensor certificate Validate the PAH Sensor Check remove bubbles in calibration liquid Check calibration liqui...

Page 65: ...tly e g wall brackets Pump speed too high reduce pump speed Insufficient nominal width of the pipes increase nominal width Pump base plate loose Fasten base plate Hose pump Reduced operational lifetim...

Page 66: ...eposits Clean or replace the pump hose Flange insufficiently tightened Retighten flange Insufficient grease Top lubricant The pump does not start up Insufficient motor performance Check motor and repl...

Page 67: ...ns of diagnostics via the 4 20 mA signal A G6111 supports the following means of diagnostics via the 4 20 mA signal Figure 12 1 Figure 12 1 mA Measurement using Multimeter G6111 PAH Sensor Fault Descr...

Page 68: ...efer to cleaning guide below After cleaning the PAH chamber can be remounted Cleaning guide for G6110 PAH measuring chamber 1 Remove the PAH sensor 2 Dismount the PAH chamber by following maintenance...

Page 69: ...meter Calibration data is stored within the pH sensor while the pH electrode acts as the sensing element During field calibration the factory calibration data within the sensor is updated overwritten...

Page 70: ...h 3 times Calibration Success Figure 12 2 pH Negative offset Reading Too Low Example 2 pH Positive Offset Reading Too High Step Description Buffer solution Observed pH Calibration Data Conclusion Step...

Page 71: ...rift please immerge 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 Dr...

Page 72: ...art Description The specific appearance of the spare parts is subject change without notice the function however will not change WMR WMP WMPH TYPE A 02589 Pump Type A 103125 Start Capacitor Pump Type...

Page 73: ...r for pump Type A 02661 O ring for end cover Type A 03408 Shaft V ring Type A WMR WMP WMPH TYPE B 03613 Pump TYPE B Version 2 103007 Start Capacitor Pump Type B 103008 Run Capacitor Pump Type B 03629...

Page 74: ...51 Motor Shaft Seal Type B 03616 Impeller for pump NBR 55 mm Type B 03614 Mechanical seal Type B 03617 Wear plate without hole Type B 03618 Wear Plate With Punched Hole St S Type B 03615 O Ring for Im...

Page 75: ...function however will not change 02435 Flow Regulating Valve 02686 Ball Valve W Actuator 02703 Pressure Reduction Valve 02687 Pressure Holding Valve Relief Valve 02438 Compression Ferrule OD 10 Mm 02...

Page 76: ...ut Fitting 02968 Flow Sensor Upgrade Kit Incl part no 02966 02967 01462 02966 Signal A D Converter 02967 Flow Sensor 01462 Connection Cable 1 5m Female 03558 Modbus TCP to RTU RS 485 Converter 00358 S...

Page 77: ...function however will not change 02507 Stiffener Sleeve 12 10mm 02237 Power Supply 24V 00505 Fuse Automatic Fuse C 6KA 4A 2P 02197 Fuse Automatic 6A 03630 Automatic Fuse 3A 24V DC 03552 Bus Coupler Mo...

Page 78: ...wever will not change 03647 2 CH Analog Input Module 02404 2 CH Digital Output Module 01992 End Module 01887 HMI Display Configuration Needed 03554 Communication Cable SUB D Male Male 60cm 02410 Isola...

Page 79: ...0 g l Reconditioned Only available if returning used PAH Sensor 03444 PAH Sensor 0 800 g l Reconditioned Only available if returning used PAH Sensor 03551 PAH Dual Range Sensor 0 100 800 g l Reconditi...

Page 80: ...ction however will not change G6111 PAH Module 102060 G6111 PAH sensor 0 100 g l Low range 102070 G6111 PAH sensor 0 800 g l High range 102100 G6111 PAH sensor 0 100 800 g l Dual range 103420 G6111 PA...

Page 81: ...of the spare parts is subject change without notice the function however will not change 02342 Turbidity Analyzer 02385 Turbidity Light Source 02394 Turbidity Emitter 02395 Turbidity Receiver 02805 T...

Page 82: ...re parts is subject change without notice the function however will not change 02387 Turbidity O ring set 03264 Wiper Collar Kit PH Module 02344 pH Sensor without Electrode 02329 pH Chamber 02389 Elec...

Page 83: ...libration Kit Refill Inlet pH Turbidity 4 x pH4 7 10 Buffer 1 x Turbidity 0 10 40 NTU 1 x Cleaning Pad 1 x Validation Calibration Guide G6100 Calibration Kit 02315 Calibration kit complete PAH 0 100 g...

Page 84: ...U 8 x PAH 0 400 800 g l 4 x Syringe Cleaning Pad 1 x PAH Calibration Chamber PAH Chamber bushing Tool Needle Validation Calibration Guide 03561 Calibration Kit Complete Refill PAH 0 100 800 g l Incl r...

Page 85: ...G6111 Calibration Kit 102949 G6111 Calibration Kit Complete Refill PAH 0 100 g l Incl relevant certificates 4 x pH4 7 10 Buffer 1 x Turbidity 0 10 40 NTU 8 x PAH 0 50 100 g l 4 x Syringe Cleaning Pad...

Page 86: ...ration Kit Complete Refill PAH dual range 0 100 800 g l Incl relevant certificates 4 x pH4 7 10 Buffer 1 x Turbidity 0 10 40 NTU 4 x PAH 0 100 400 800 g l 8 x PAH 50 200 g l 4 x Syringe Cleaning Pad 1...

Page 87: ...appearance of the spare parts is subject change without notice the function however will not change 02258 Turbidity Standard 40 NTU 02253 PAH Solution 0 g l 02255 PAH Solution 50 g l 02316 PAH Solutio...

Page 88: ...02559 for 1 year operation 2 x Pump Impeller 1 x Shaft Seal 2 x End Cover 1 x O ring for End Cover 1 x Shaft V ring 1 x Wiper Blade 1 x Electrode for pH Sensor 1 x Gasket for pH Sensor 2 x O ring PAH...

Page 89: ...trode for pH Sensor 1 x Gasket for pH Sensor 2 x O ring PAH Chamber 1 x Turbidity O ring 02959 Recommended Spare Parts Kit for WM30 Type A for 1 year operation 1 x Pump Impeller 1 x Shaft Seal 1 x End...

Page 90: ...Appendix Page 90 of 110 14 Appendix...

Page 91: ...ition for WM units Turn INTERNAL VALVE to DRAIN position and CLOSE the BALL VALVE for WMRTU units 4 Loosen the black union nut A on the top and remove the wiper unit B park it 5 Pull wiper blade C out...

Page 92: ...ter 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 replacemen...

Page 93: ...This instruction identifies the locations of the Turbidity Sensors O rings O ring seal replacement must be carried out by a trained technician Difficulty 1 5 Overhaul Interval Estimated Time Consumpti...

Page 94: ...rval Estimated Time Consumption When necessary 15 min Spare Parts Tools Part no Description Qty Item 02805 Turbidity Wiper Unit Small size flat headed screwdriver Medium size flat headed screwdriver 2...

Page 95: ...Spare Parts Tools Part no Description Qty Item 02342 Turbidity Analyzer 1 Small size flat headed screwdriver 1 x allen key 2 x 19mm spanners Instructions Steps Note Make sure the power supply is swit...

Page 96: ...ling to do so may damage the pH electrode and or sensor 2 Unscrew the grey nut on the pH sensor and pull up the sensor from the measuring chamber A 3 Unscrew the old pH electrode by turning it counter...

Page 97: ...me Consumption When necessary 10 min Spare Parts Tools Part no Description Qty Item 02703 Pressure Reduction Valve 1 1 x 5mm Allen Key 02687 Pressure Holding Relief Valve 1 Instructions Steps 1 Warnin...

Page 98: ...stimated Time Consumption Every 6 month 2 min Spare Parts Tools Part no Description Qty Item 02703 Pressure Reduction Valve 1 x 13mm Spanner Instructions Steps 1 Remove protective black plastic cap A...

Page 99: ...test of the pressure holding relief valve is done by adjusting the pressure in the system by means of the pressure reduction valve 3 Remove protective black plastic cap on the pressure reduction valv...

Page 100: ...rained technician Difficulty 1 5 Overhaul Interval Estimated Time Consumption Every 6 month 15 min Spare Parts Tools Part no Description Qty Item 03409 Pump Spare Parts Kit 1 Flat headed screwdriver I...

Page 101: ...e electrical motor which exposes the part of the seal that sits on the shaft itself D E 4 Gently remove the part of the seal that sits on the shaft without damaging the shaft Also remove O ring from s...

Page 102: ...er 17 19 mm Spanner Instructions Steps 1 Take photos or notes on how the existing pH sensor is installed This will make it easy to install the replacement sensor 2 Uninstall the old pH sensor using a...

Page 103: ...the motor so that the remaining roller is not pressing against the pump hose 7 Dismount the front cover A 8 Remove the press flange D from the pump housing Be careful not to drop any shim plates 9 Re...

Page 104: ...the end cover A 2 Remove old impeller and O rings without damaging the pump housing Note when the end cover is removed the pump is not attached to the motor and is only fixed by the impeller and motor...

Page 105: ...consists of two parts a stationary and a rotating part G 7 Remove the rear plate H And push the stationary seal out i e using a screwdriver I 8 Gently fit the new stationary seal in the rear plate Ap...

Page 106: ...hose connecting Valve 3 to the PAH chamber Keep the nuts and compression rings B3 B5 Remove the PAH chamber 5 Unscrew and remove old gasket from the thread of the 2 upper fittings from the used PAH ch...

Page 107: ...ions in this guide during pump replacement Make sure the power supply is Off prior to replacing the pump Tools to be used Hose cutter or knife Small screwdriver Allen key Spanner 13 19 24 mm A Disasse...

Page 108: ...tion 7 10 Mount the below Fitting Union Attention It is important to hold the tube and fitting straight no twisting while fasten fitting illustration 8 Mount the Fitting Union T piece Illustration 9 1...

Page 109: ...on 1 2 It is recommended to flush this area with clean tap water when a coating of salt is present illustration 3 Signs of unacceptable leakage seal failure illustration 4 If there is a coating of sal...

Page 110: ......

Page 111: ...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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Maritime G6100, Operation Manual

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