Graviner Mk7 Oil Mist System the Remote Display Unit Crashed and show application oil mist display winCE .EXE encountered a serious error and must shutdown ，we restart system have the same condition

Summary of Contents for Carrier GRAVINER Mk 7

Page 1 PROPRIETY RIGHTS NOTICE The information contained in this manual is the property of Carrier Fire & Security UK Ltd and may not be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor stored in any retrieval system or any nature without the express written authority of Carrier Fire &...
Page 2: Table Of Contents
TABLE OF CONTENTS Chapter Page DESCRIPTION ..........................1 1.1 INTRODUCTION 1.2 DESCRIPTION 1.3 TECHNICAL SPECIFICATION 1.4 SYSTEM OVERVIEW INSTALLATION AND COMMISSIONING..................10 2.1 CONTROL UNIT MOUNTING 2.2 CONTROL UNIT CABLING 2.3 DETECTOR MOUNTING 2.4 DETECTOR CABLES 2.5 REMOTE DISPLAY UNIT 2.6 REMOTE DISPLAY UNIT CABLING 2.7 CONNECTING THE SYSTEM 2.8 SYSTEM CHECKS PRIOR TO SWITCHING ON...
Page 3 4.1 ENGINE ISOLATIONS 4.2 DETECTOR ISOLATIONS 4.3 SYSTEM MONITORING 4.4 ROUTINE MAINTENANCE SCHEDULE 4.5 READING DETECTOR PARAMETERS 4.6 DETECTOR CLEANING 4.7 DECOMMISSIONING FAULT FINDING ........................... 95 5.1 FAULT INDICATIONS 5.2 FAULT DIAGNOSTICS AND REMEDIES 5.3 SYSTEM TEST LOG. SPARE PARTS ........................... 118 6.1 CONTROL UNIT 6.2 REMOTE DISPLAY UNIT 6.3 DETECTOR...
Page 4 LI ST OF I LLUSTRATI ONS Figure Title Page Figure 1 Areas of Failure 2 Stroke Engine Figure 2 Areas of Failure 4 Stroke Engine Figure 3 Graviner Mk7 OMD Components Figure 4 Typical System Configuration With Membrane Figure 5 Typical System Configuration Without Membrane Figure 6...
Page 5 Figure 35 System Configuration Menu Figure 36 Engine Names Screen Figure 37 Engine Names Saved Figure 38 Set Time / Date Screen Figure 39 Save Time / Date Figure 40 Engineers New Pin Screen Figure 41 Engineers New Pin Confirmation Screen Figure 42 Save New Engineers Pin Figure 43...
Page 6 Figure 72 Slowdown Relay Test Figure 73 Pre-Alarm Relay Test Figure 74 Fault Relay Test Figure 75 Test Menu Engineers Level Figure 76 Test Menu Backup Alarm OK screen Figure 77 Smoke Tester Figure 78 Smoke Test Figure 79 Remote Display Unit Splash Screen Figure 80 Detecting Engines Figure 81...
Page 7 Figure 109 Engine Overview Screen Pre-Alarm Figure 110 Engine Screen Pre-Alarm, Accept Figure 111 Engine Screen Pre-Alarm, Accept Figure 112 Engine Overview Screen Alarm Figure 113 Engine Screen Pre-Alarm, Accept Figure 114 Engine Screen Pre-Alarm, Accept Figure 115 Relay Function Modes Figure 116 Engine Isolation Menu Figure 117...
Page 8 Figure 146 Pulling Tool Figure 147 Sample Chamber Cleaning Figure 148 Engine Overview Screen Fault Figure 149 Remote Display Unit Communication Fault Figure 150 Engine Screen Detector Fault Figure 151 Detector Status Screen Communications Fault Figure 152 Engine Screen Detector Fault Figure 153 Detector Status Screen LED Fault...
Page 9 Figure 183 Control Unit Earth Wire Figure 184 Ribbon Connector Ferrites Figure 185 Ribbon Cable Removal Figure 186 Control Unit Terminal Blocks Figure 187 Control Unit With Membrane Figure 188 Ribbon Cable Removal Figure 189 Display Unit Spares Figure 190 Detector Spares Figure 191 Base Fixing Screw Removal...
Page 10 OI L MI ST DETECTOR WARRANTI ES 1. Carrier Fire & Security UK Ltd (Carrier) warrants, for a period of 3 years from the handover of the new vessel which is installed with Graviner Mk7 Oil Mist Detector (OMD) system to the system...
Page 11 6. The Warranties are conditional upon: a. the buyer or OMD system owner giving written notice to Carrier of the alleged defect, such notice to be given immediately when the buyer or OMD system owner discovers or ought to have discovered the defect;...
Page 12: Description
INTRODUCTION High temperatures, in excess of 200 C that occur on bearing surfaces under initial failure conditions, can lead to a rapid generation of oil vapour When the hot vapour contacts the relatively cooler atmosphere of the crankcase it condenses into a fine mist, with typical particle sizes of around 0.5 to 5 microns in diameter.
Page 13: Description
The Graviner Mk 7 OMD provides the following benefits: • Auto addressed system monitoring up to 10 detector heads per Control Unit • Up to 10 Control Units per single system.
Page 14 Each detector communicates electronically over a serial data link via the engine mounted Control Unit with the Remote Display Unit designed to be mounted within the Engine Control Room. This eliminates the need to enter the machinery space in alarm conditions. March 2021 Page 3 of 143 59812-K007 Rev 17...
Page 15: Figure 4 Typical System Configuration
Figure 4 Typical System Configuration With Membrane March 2021 Page 4 of 143 59812-K007 Rev 17 Business Confidential...
Page 16: Figure 5 Typical System Configuration
Figure 5 Typical System Configuration Without Membrane March 2021 Page 5 of 143 59812-K007 Rev 17 Business Confidential...
Page 17: Technical Specification
TECHNICAL SPECIFICATION Detector Mounting ¾ inch BSP Enclosure Rating IP65 Material Sample Tube Carbon Loaded PTFE Detector Black Du Pont Nylon 70G33L Indicators Green Detector On Alarm Amber Detector Fault Power Consumption 1.5W Operating Temperature Rating 0 to 70 Storage Temperature Rating C to 60 Height 153mm...
Page 18 Remote Display Unit Enclosure Rating IP32 Material ABS (PA-765+) Max No. of detectors Max No. of engines monitored Power Supply 24Vdc (+30% -25%) Power Consumption 6.0W Operating Temp Rating Storage Temperature Rating C to 60 Humidity level Dimensions Height 225mm (202mm mounting centres) Width 240mm...
Page 19: System Overview
Alarm, then the Back Up Alarm will operate, but it will not operate the slowdown/shutdown relay. This is an additional functional precaution added by Carrier Fire & Security UK Ltd which can be connected in any way the customer requires. This is usually connected to a warning beacon or siren;...
Page 20 This process can be followed in section 2.9 of this manual. The Service level is also password protected (different from the Engineer Menu) and allows access to all functions. This is only available to authorised Carrier personnel and authorised Service Providers. March 2021...
Page 21: Installation And Commissioning
CONTROL UNIT MOUNTING The Control Unit 1-53836-K270 (1-53836-K270-01 Caterpillar only) or 1-53836-K276 is designed for on- engine mounting and it is recommended that the Control Unit is installed as near to the centre of the engine as possible to minimise detector cable lengths. Mounting is via the four M6 locating holes in the box.
Page 22: Control Unit Cabling
Figure 7 Control Unit 1-53836-K276 (Without Membrane) CONTROL UNIT CABLING 24v DC I nput supply The Mk7 Control Unit should be powered from a floating 24v DC supply (+30% -25%) rated at 1.0Amp continuous rated, with 2.5Amp surge for 1.5ms. PLEASE NOTE: - The Control unit(s) may not operate correctly if the external 24v power supply is referenced to the vessel earth and there is also a risk the input protection circuitry in the units could be damaged.
Page 23 Suggested cables Lapp Kabel CY cable 3 core 2.5mm Prysmian LSM-HF 3 core 2.5mm Helkama LKAM-HF 3 core 2.5mm Refer Figure 8 for connector location. Refer Figure 29 for wiring drawing. Modbus Cable type Individually screened 2 pair data cable, 24AWG, low capacitance, low smoke halogen free. Outer diameter 7mm (max) Cables should be segregated from high voltage cables and follow good installation practice Approved cables:...
Page 24 End of Line Jumper Modbus Connector End of Line Jumper Connection Relay Output Connectors 24v DC input Connector Figure 8 Control Unit PCB March 2021 Page 13 of 143 59812-K007 Rev 17 Business Confidential...
Page 25: Detector Mounting
DETECTOR MOUNTING Each detector is mounted to an individual crankcase via a ¾ inch BSP threaded hole. Ensure all detectors fitted to the engine are locked tightly in place by means of the lock nut supplied. It is recommended that the detector be located at the upper part of the crankcase wall where it is not in the direct line of the oil throw.
Page 26: Figure 10 Detector Head Installation
Figure 10 Detector Head Installation March 2021 Page 15 of 143 59812-K007 Rev 17 Business Confidential...
Page 27: Figure 11 Detector Head Installation (Short Sample Pipe)
Figure 11 Detector Head Installation (Short Sample Pipe) March 2021 Page 16 of 143 59812-K007 Rev 17 Business Confidential...
Page 28: Detector Cables
DETECTOR CABLES Each detector must be connected to the Control Unit by way of a supplied detector cable. Refer Figure 12. Ensure that the cables are run in a suitable cable tray and clipped at regular intervals to ensure they cannot be subjected to mechanical damage caused by vibration.
Page 29: Figure 13 Detector Cable Assembly (Straight Connector)
Figure 13 Detector Cable Assembly (Straight Connector) March 2021 Page 18 of 143 59812-K007 Rev 17 Business Confidential...
Page 30: Figure 14 Detector Cable Assembly (Right Angle Connector)
Figure 14 Detector Cable Assembly (Right Angle Connector) March 2021 Page 19 of 143 59812-K007 Rev 17 Business Confidential...
Page 31: Remote Display Unit
REMOTE DISPLAY UNIT The Remote Display Unit part number 1-53836-K271 must be mounted in the Engine Control Room (ECR) or similar safe environment, do not mount in an Engine Room as it is not designed to be mounted in this type of environment.
Page 32: Figure 16 Flush Mounting For Remote Display Unit
Figure 16 Flush Mounting for Remote Display Unit March 2021 Page 21 of 143 59812-K007 Rev 17 Business Confidential...
Page 33: Figure 17 Bulkhead Mounting For Remote Display Unit
Figure 17 Bulkhead Mounting for Remote Display Unit March 2021 Page 22 of 143 59812-K007 Rev 17 Business Confidential...
Page 34: Remote Display Unit Cabling
REMOTE DISPLAY UNIT CABLING 24v DC I nput supply The Mk7 Remote Display Unit should be powered from a floating 24v DC supply (+30% -25%) rated at 1.5 Amp continuous rated, with 2.5Amp surge for 1.5ms. The external supply should be connected via a Hirschmann GM216 NJ power connector. PLEASE NOTE: - The Remote Display Unit may not operate correctly if the external 24v power supply is referenced to the vessel earth.
Page 35 Modbus Cable type Individually screened 2 pair data cable, 24AWG, low capacitance, low smoke halogen free. Outer diameter 7mm (max) To prevent signal crosstalk OMD cables should be segregated from high voltage cables and follow good installation practice Please Note: The Remote Display Unit Modbus data cable should NOT be connected when the power is applied to the unit.
Page 36: Figure 20 Remote Display Unit 1-53836-K271
24v DC Modbus Connector Connector Figure 20 Remote Display Unit 1-53836-K271 The use of RS485 based signalling allows the RDU and Control Unit to be located a large distance apart. The following drawings show the wiring pin out for 3 methods of connecting the extended Modbus cable. March 2021 Page 25 of 143 59812-K007 Rev 17...
Page 37 Remote Display Unit 5m Cable A (Red) Screen GND (Black) B (Black) Cable To Control Unit Figure 21 Terminal Block Connection March 2021 Page 26 of 143 59812-K007 Rev 17 Business Confidential...
Page 38: Connecting The System
A (Red) B (Black) Cable To Remote Display Control Unit Unit 5m Cable GND (Black) Screen Figure 22 Junction Box Connection GND (Black) Screen Cable To Remote Display Control Unit Unit 5m Cable A (Red) B (Black) Figure 23 Inline Connector CONNECTING THE SYSTEM 2.7.1 Input power...
Page 39: Figure 24 Power Cable
Exposed screen Figure 24 Power cable Feed the cable into the Control Unit via a metal IP65 EMC gland supplied, ensuring that the metal prongs make a good contact with the exposed cable screen as shown below. Cable gland Earthing Prongs Figure 25 Power cable through EMC gland Alternatively, both the earth and screen of the cable may be terminated in the screen terminal, SCN,...
Page 40: Figure 26 Control Unit Relay Cable Assembly
Figure 26 Control unit relay cable assembly Feed the cable into the control unit via a metal IP65 EMC gland supplied, ensuring that the metal prongs make a good contact with the exposed cable screen as shown. 2.7.3 Control Unit to Detector Connections At the Detector, screw the connector to the top of the Detector.
Page 41 Note: Numbering indicates correct Detector installation position. Figure 28 Control unit - Detector cable assembly 2.7.4 Modbus Cables The Modbus connection between the Remote Display Unit and the first Control Unit should be made using a suitable cable, refer to section 2.6. For each of the Modbus connections strip the cable to the required length to connect to the terminals in the Control Unit, including the drain wires for the cable screens.
Page 42: Figure 29 Wiring Drawing
Figure 29 Wiring Drawing March 2021 Page 31 of 143 59812-K007 Rev 17 Business Confidential...
Page 43: System Checks Prior To Switching On
SYSTEM CHECKS PRIOR TO SWITCHING ON 2.8.1 Ensure that the 24v DC input power supply cable is connected correctly at each Control Unit (if more than one installed). 2.8.2 Check the cable run of all Modbus Communication cables between all installed Control Units to each other and to the Remote Display Unit (if installed) or AMS to ensure that it is not damaged.
Page 44: System Setup / Configuration With A Remote Display Unit
SYSTEM SETUP / CONFIGURATION WITH A REMOTE DISPLAY UNIT With all connections completed and checked, power up the Control Unit(s) and Remote Display Unit, the following power up screen will show for a few seconds on the Remote Display Unit. If there is more than one Control Unit connected to the display the Modbus address needs to be set up via the USB connection on the Control Unit before it can talk to the Remote Display Unit.
Page 45 Figure 32 Engine Overview Screen User Level Enter password 012345. Figure 33 Engineers Login Screen Figure 34 Engine Overview Screen Engineer Level March 2021 Page 34 of 143 59812-K007 Rev 17 Business Confidential...
Page 46 Figure 35 System Configuration Menu Press the up and down arrows to cycle through possible Engine Names, this figure shows one engine connected but may show up to ten. Figure 36 Engine Names Screen Please see below for the full list of Engine Names. is selected for each Engine.
Page 47 Engine Name Selection List (supported by Control Unit Software versions to P66200-107 and lower) Displayed on Displayed on Text label Text label Icon as Icon as Auxiliary Engine 1 Main Engine 1 ME 1 Auxiliary Engine 2 Main Engine 2 ME 2 Auxiliary Engine 3 Fuel Supply Unit...
Page 48 Engine Name Selection List (supported by Control Unit Software versions P66200-108 and above) Displayed Displayed on Text label Text label on Icon as Icon as Main Engine 1 Generator 1 Main Engine 2 Generator 2 Main Engine 3 Generator 3 Main Engine 4 Generator 4 Main Engine 5...
Page 49 Figure 37 Engine Names Saved The Display will return to the System Configuration Menu screen, Figure 35 on the System Configuration Menu, Figure 35 Note Time and Date must be entered even if the correct Time and Date is displayed . Figure 38 Set Time / Date Screen Figure 39...
Page 50 The Display will return to the System Configuration Menu screen, Figure 35 Use numeric keys to enter a new 6-digit pin and then store in a safe place where only authorised users can access it Figure 40 Engineers New Pin Screen Use numeric keys to re-enter the new 6-digit pin.
Page 51 The Display will return to the System Configuration Menu screen, Figure 35 Note Once the Logs are saved, only Carrier approved Service Providers can download them. , Figure 34 To setup the Detectors on each Engine, press the button under the mg/l display for the Engine being setup.
Page 52 Figure 46 Engine Screen Engineers Level Menu. Figure 47 Engine Menu Press the up and down arrows to scroll through possible Detector Names, this figure shows one detector connected but may show up to ten Detectors. Please see below for the full list of Detector Names. Figure 48 Detector Names Screen is selected for each Detector.
Page 53 Detector Name Selection List (supported by Control Unit Software versions P66200-107 and below) Text label Displayed on Text label Displayed on Icon Icon as Detector 1 Cylinder 14 Detector 2 Cylinder 15 Detector 3 Cylinder 16 Detector 4 Cylinder 17 Detector 5 Cylinder 18 Detector 6...
Page 54 Text label Displayed on Text label Displayed on Icon Icon as Detector 1 Cylinder 14 Detector 2 Cylinder 15 Detector 3 Cylinder 16 Detector 4 Cylinder 17 Detector 5 Cylinder 18 Detector 6 Cylinder 19 Detector 7 Cylinder 20 Detector 8 Fuel Supply Unit 1 Detector 9 Fuel Supply Unit 2...
Page 55 Figure 49 Detector Names Saved To return to the Engine Screen, Figure 46 To set the individual Detector parameters, press the button under the mg/l display for the required detector. Figure 50 Detector Selection Figure 51 Detector Status Screen Press the up and down arrows to select the desired Alarm and Pre-Alarm Levels. Slow/Shutdown Alarm Limits 2.4mg/l, default 1.8mg/l Pre-Alarm Limits...
Page 56: Control Unit Modbus Addressing
Figure 52 Detector Menu The display will return to the Detector Status Screen, Figure 51. the detector Selection Screen, Figure 50. Repeat setting Detector settings for the number of Detectors connected. Figure 53 Alarm Levels Saved to return to Engine Overview screen. Repeat setting Engine Names &...
Page 57 NOTE: The Reset button must be pressed within 5sec of pressing the Accept button Press Figure 54 Control Unit Membrane a. The current Modbus address of the Control Unit will now be flashing (1sec on, 1sec off) (Refer Figure 55) b.
Page 58 Current Modbus address flashing Press required numerical button for 1sec Figure 55 Control Unit Membrane c. The Green LED above the button pressed will now be flashing. The Control Unit will automatically store this new Modbus address. d. When the address has been changed, the Control Unit returns to normal operation and indicates the number of detectors connected.
Page 59 Type B USB Type B USB Connection Connection Control Unit With Membrane Control Unit Without Membrane Figure 56 Control Unit USB Connector Connect the other end of the USB Lead to a USB socket on your computer (refer Figure 57) Figure 57 Computer Connection Type A USB Connector...
Page 60 Figure 58 Engine Screen Figure 59 Engineers Login Select the required Control Unit Address (this is the Modbus address) Figure 60 Select Modbus Address Repeat the above for the number of Control Units installed per system. After the addresses have been changed, please ensure that the EOL jumpers are fitted to the last Control Unit only, all other Control Units need to have both the EOL jumpers removed.
Page 61 2.10.3 Configuring the number of engines on the Remote Display Unit Once all Control Units have the correct Modbus addresses, the Remote Display Unit will need to be programmed to detect the required number of engines on the system. log in as an Engineer. Figure 61 Engine Overview Screen User Level...
Page 62: Commissioning The System
Figure 64 System Configuration Menu After a few seconds the following will be seen on the Remote Display Unit, this shows one engine connected but may show up to ten. Figure 65 Detecting Engines 2.11 COMMISSIONING THE SYSTEM Following the installation of the system the functionality should be checked to ensure that the system is operating correctly, and the required responses are produced by the AMS.
Page 63 Figure 66 Engine Overview Screen User Level Enter password 012345. Figure 67 Engineers Login Screen Figure 68 Engine Overview Screen Engineer Level March 2021 Page 52 of 143 59812-K007 Rev 17 Business Confidential...
Page 64 Press the button under the mg/l display for the Engine to be tested Figure 69 Engine Selection Press the test button to bring up the Test Menu Figure 70 Engine Screen Engineers Level To test the Slowdown/Shutdown Figure 71 Test Menu Engineers Level Ensure that the correct engine slowdown/shutdown response is indicated by the AMS.
Page 65 Figure 72 Slowdown Relay Test . You will be returned to Figure 71 To de- To test the Pre- Figure 73 Pre-Alarm Relay Test . You will be returned to Figure 71 Ensure that the correct engine response is indicated by the AMS. To de-activate the Pre-Alarm Rela , the fault relay is normally energised Figure 74...
Page 66 2.11.3 Backup Alarm Test The Backup Alarm is a hard-wired link from each Detector installed on a Control Unit. This facility will allow any D operate the Backup Alarm Relay. The integrity of the Backup Alarm signal between the Control Unit and the Detector a Backup Alarm Test should be performed.
Page 67 Pipette Bulb Wick Holder Wick Pipe Connector Nylon Pipe Figure 77 Smoke Tester b. Push the nylon pipe of the smoke tester into the connector on the side of the detector base body (refer to Figure 78). Figure 78 Smoke Test Dip the wick into the bottle of smoke oil and reseal the bottle firmly Note: Only a small quantity of oil is required.
Page 68 d. Ignite the wick of the smoke tester and blow out the flame. Squeeze the pipette bulb to keep the wick smoking. Note: Care to be taken with this activity at all times. e. While the wick is still smouldering, insert it into the pipe connector and squeeze the pipette bulb. Observe the wick is still smouldering, insert nylon pipe into the pipe connector of the detector and squeeze the pipette bulb.
Page 69: Operation
Under normal operation the detector continuously monitors the oil mist level in the engine. The Control Unit communicates with each connected detector to obtain the measured oil mist level and the detector status. The Control Unit determines if the measured oil mist level is above the alarm levels or if there is a fault condition and activates the appropriate relays.
Page 70 Figure 80 Detecting Engines The display should indicate the correct number of engines have been found and a bar graph displayed for each. The number shown in the bottom right of the display indicates the Remote Display Unit software number and version.
Page 71: Access Levels
ACCESS LEVELS There are three access levels available, each allowing access to various options within the system. 3.2.1 User Level At power up the system defaults to User level access, allowing access to view system information. No changes can be made to the system configuration at User level. 3.2.2 Engineer Level A 6-digit pin is required to access the Engineer Level.
Page 72: Engine Screen User
3.2.3 Service Level A 6-digit pin is required to access the Service Level. Service level access is reserved for Carrier approved Service Engineers. ENGINE SCREEN USER Information on a single engine can be accessed by pressing the required engine button under the bar graph.
Page 73: Engine Status Information
Figure 85 Engine Screen User The name of the detector is shown above the bar graph and in the button below the bar graph. The level displayed on the bar graph and numerically below the bar graph indicates the oil mist level being measured by the detectors at that moment in time.
Page 74: Test Menu
Slow Down Isolated Indicates Yes if the Slowdown/Shutdown Relay is isolated. Watchdog Fault Indicates Yes if a Control Unit software failure has caused the Control Unit to be automatically reset. Detector Fault Indicates Yes if a fault has occurred on any detector on the engine. Memory Fault Indicates Yes if a fault has been detected in the Control Unit memory TEST MENU...
Page 75 Use the Up and Down arrows to scroll through the events in this screen. Figure 88 Event Log All Events The events log may be filtered to show events occurring on a particular date. Figure 89 Event Log Date Selection Use the Up and Down arrows to scroll through the events in this screen.
Page 76 Figure 91 Event Type Selection Use the Up and Down arrows to scroll through the events in this screen. Figure 92 Event Log by Event Use the Up and Down arrows to select the Detector to search. event log by selected Detector. Figure 93 Detector Selection March 2021...
Page 77: Detector Screen User
Use the Up and Down arrows to scroll through the events in this screen. Figure 94 Event Log by Detector screen, Figure 85. DETECTOR SCREEN USER In addition to information relating to the engine information can also be displayed for the individual detectors.
Page 78: Alarm Test
ALARM TEST The Alarm Test allows an alarm condition to be simulated on the detector. The indications on the detector, Control Unit and Remote Display Unit will be as per a slowdown/shutdown alarm however the slowdown/shutdown alarm will not be activated, allowing the test to be performed without shutting down the engine.
Page 79 Figure 99 Detector Alarm User Press the Accept button Figure 100 Accept Ok March 2021 Page 68 of 143 59812-K007 Rev 17 Business Confidential...
Page 80: Engineers Access
OK Accept Figure 101 Detector Alarm Reset Press the Reset button Figure 102 Detector Reset ENGINEERS ACCESS While interrogation and testing of the system is available at the User access level changes to the system configuration requires logging in to the Engineers access level, see section 3.2.2. Figure 103 Engine Overview Screen Engineer Level...
Page 81: Engine Screen Engineers
Figure 104 System Configuration Menu Number of Engines The number of engines connected to the Remote Display Unit is automatically detected on power up however this can be altered manually if necessary. Use the up and down arrows to set the required value. Detect Engines Manually requests the Remote Display Unit to check the number of engines connected.
Page 82: Engine Menu
3.12 ENGINE MENU Figure 106 Engine Menu Isolate Allows isolation Detectors, Pre-Alarm Relay Slowdown/Shutdown Relay, see section 4.1 Clear Peak Clears all detector peak readings Detector Names Assigns names to identify each detector on the engine, see Figure 48 Exit Returns to the Engine Screen 3.13 DETECTOR MENU...
Page 83: Pre-Alarm Operation
Figure 108 Detector Menu Isolate Allows isolation of the detector, see section 4.2 Read Params Displays the internal parameters of the detector, see section 4.5 Alarm Level Sets the Slowdown/Shutdown Alarm level for the detector, see Figure 51 Pre-Alarm Sets the Pre-Alarm level for the detector, see Figure 51 Save Save the Alarm and Pre-Alarm levels to the Control Unit Back...
Page 84: Slowdown/Shutdown Alarm Operation
Figure 110 Engine Screen Pre-Alarm, Accept Press Accept Figure 111 Engine Screen Pre-Alarm, Accept Prior to resetting the Engine, it is recommended that any additional events which may have occurred are examined. A list of events can be shown by pressing the View Events button. The alarm may be reset once the oil mist level falls below the pre-alarm level.
Page 85: Backup Alarm
Figure 112 Engine Overview Screen Alarm Press the button under the bar graph to display the Engine Screen. The detector in alarm is displayed in red. Figure 113 Engine Screen Pre-Alarm, Accept Press Accept Figure 114 Engine Screen Pre-Alarm, Accept Prior to resetting the Engine, it is recommended that any additional events which may have occurred are examined.
Page 86: Relay Operation
Whilst any Detectors are in a Backup Alarm condition the Accept key is inoperative until the oil mist level drops below 3.0mg/l. It is possible for a healthy Detector to produce a Backup alarm if the level of oil rises very rapidly. NOTE - The Backup Alarm will not operate the Slowdown/Shutdown Relay 3.17 RELAY OPERATION...
Page 87 Slowdown/ Relay Backup Unit off Unit on Pre-Alarm Fault Description Alarm Shutdown Pre-Alarm Engine Slow/Shutdown Alarm Backup-alarm Fault Figure 115 Relay Function Modes March 2021 Page 76 of 143 59812-K007 Rev 17 Business Confidential...
Page 88: Engine Isolations
Warning: Do not work on the system unless the power is switched off or isolated. Caution: Ensure that anti-static handling procedures are observed applied when working on the system, i.e. Anti- Static Wrist Straps Warning: The Guarantee label around the Detector Head is fitted to ensure that the Detector head is not tampered with.
Page 89 4.1.1 Isolating all detectors Press the All Detectors: Isolate button isolate All Detectors. Figure 117 Isolate All Detectors Figure 118 Isolate All Detectors - OK To de-isolate all detectors Figure 119 De-isolate All Detectors March 2021 Page 78 of 143 59812-K007 Rev 17 Business Confidential...
Page 90 Figure 120 De-isolate All Detectors - Yes 4.1.2 Isolate the Pre-Alarm Relay Press the Pre-Alarm relay: Isolate button isolate the Pre-Alarm Relay. Figure 121 Isolate Pre-Alarm Relay Figure 122 Isolate Pre-Alarm Relay - Ok To De-Isolate the Pre-Alarm March 2021 Page 79 of 143 59812-K007 Rev 17 Business Confidential...
Page 91 Figure 123 De-isolate Pre-Alarm Relay Figure 124 De-isolate Pre-Alarm Relay - Yes Figure 125 De-isolate Pre-Alarm Relay - Ok 4.1.3 Isolate the Slowdown/Shutdown Alarm Relay Press the Slow down relay: Isolate button isolate the Slowdown/Shutdown Alarm Relay. March 2021 Page 80 of 143 59812-K007 Rev 17 Business Confidential...
Page 92 Figure 126 Isolate Slowdown/Shutdown Alarm Relay Figure 127 Isolate Slowdown/Shutdown Alarm Relay - Ok To De-Isolate the Slowdown/Shutdown Figure 128 De-isolate Slowdown/Shutdown Alarm Relay March 2021 Page 81 of 143 59812-K007 Rev 17 Business Confidential...
Page 93: Detector Isolations
Figure 129 De-isolate Slowdown/Shutdown Alarm Relay - Yes Figure 130 De-isolate Pre-Alarm Relay - Ok DETECTOR ISOLATIONS 4.2.1 Detector Isolations via the remote display unit In addition to isolating all detectors on an engine, individual detectors maybe isolated. To perform isolations on individual detectors it is necessary log in to Engineering access level.
Page 94 Figure 132 Isolate Detector - Ok To De- Figure 133 De-isolate Detector Press Figure 134 De-isolate Detector - Yes March 2021 Page 83 of 143 59812-K007 Rev 17 Business Confidential...
Page 95 Figure 135 De-isolate Detector - Ok 4.2.2 Detector Isolations via the Control Unit For a Control Unit with membrane individual detectors can also be isolated at the Control Unit. To isolate a Detector at the Control Unit fitted with a Membrane, press the Detector number button for 2 seconds until the relevant Detector Fault / Isolate indicator is steady.
Page 96: System Monitoring
SYSTEM MONITORING The OMD Mk7 provides access to a range of system parameters that can be used to monitor system operation and can also give an early indication of changes in the engine. Engine Status, see section 3.4. Provides an indication of engine faults and isolations as well as the peak oil mist levels measured on the engine.
Page 97 3. Internally inspect all Mk7 Control Unit(s) in the OMD system. 4. All Detectors installed on the engine(s) plus any Detector Heads which are considered as usable spares by the vessel (external view), document the status of the LEDs on each Detector. 5.
Page 98 Ensure: The Alarm and Pre-Alarm level settings are correct, The Detector is NOT Isolated, There are NO active Faults shown. If any Faults are indicated, please take appropriate actions to clear the indication(s). 10. Carry out Parameter readings of each Mk7 Detector prior to any cleaning taking place. See section 4.5.
Page 99 Figure 140 Emulsified oil in the detector base Fuel in the lube oil (a green colour in the lube oil) may indicate a problem with the fuel oil heaters or leaking valves. Figure 141 Fuel in the lube oil Metal particles may indicate wear due to high vibration levels.
Page 100: Reading Detector Parameters
a. Record the Remote Display Unit serial number (found on the rear of the unit) b. For each Control Unit record the type, membrane or non-membrane, and serial number (found on the inside of the lid) Record the Remote Display Unit software version (found on the engine over-view screen) d.
Page 101: Detector Cleaning
Figure 143 Detector Parameters Peak Level The highest oil mist level indicated by the detector since the peak level was reset. Current Level The current oil mist level indicated by the detector. Offset Digipot Value set during the production of the detector. The value is specific to the detector.
Page 102 Detector Head Detector Base Detector Sample Pipe Figure 144 Detector Assembly The oil mist detection chamber in each Detector Head must be inspected at regular intervals and cleaned to remove any build-up of oil splash or carbon deposits created by the operation of the engine. The OMD system will automatically warn the Users when the detection optics become partially obscured and must be cleaned.
Page 103 To clean a detector: - 1. With the detector isolated disconnect the cable connector fitted to the top of the Detector Head. 2. Using a 4mm hexagonal key, loosen the two fixing screws in the Detector Base. The screws are self-retaining.
Page 104 10. Using the following images on this page as a guide, apply the Graviner recommended glass cleaning fluid to a foam bud and wipe carefully around the inside of the oil mist detection opening in the Detector Head. (Note: Do not use any electronic contact cleaners, isopropyl alcohols, flux removers, any harsh chemical cleaners, etc., as these will affect the Detector performance.) Figure 147 Sample Chamber Cleaning...
Page 105: Decommissioning
DECOMMISSIONING All the components of the Graviner Mk7 OMD system must be disposed of as electrical/electronic equipment waste. i.e. using waste disposal methods in accordance with current local waste disposal regulations. March 2021 Page 94 of 143 59812-K007 Rev 17 Business Confidential...
Page 106: Fault Finding
Warning: Do not work on the system unless the power is switched off or isolated. Caution: Ensure that anti-static handling procedures are observed applied when working on the system, i.e. Anti- Static Wrist Straps Prior to conducting fault diagnostics on the OMD system it is recommended to isolate the Pre-Alarm and Slowdown/Shutdown Relays and the detectors being examined see sections 4.1 and 4.2.
Page 107 5.1.2 Control Unit Faults In the case of a fault with a Control Unit the indications are: Detector No fault indication. Control Unit Activation of the Fault Relay Control Unit with membrane Fault indicator on flashing Remote Display Unit Displays the Engine Overview Screen with the engine name button, under the bar graph, of the engine in fault displayed in blue.
Page 108 5.1.4 Fault List A list of the fault messages that may be viewed in the Event Log are detailed below. Event Log Message Description Backup Alarm Test Following a Backup Alarm Test the Control Unit failed to detect the activation of the backup alarm signal from a detector. The event message will identify which detector has failed.
Page 109: Fault Diagnostics And Remedies
A list of the fault that are not listed in the Event Log are detailed below. Fault Description Remote Display time and When setting the date and time via the Remote Display Unit the date incorrect displayed date and time are incorrect. The Remote Display Unit uses a Lithium battery to maintain the internal real time clock, when the battery reaches its end of life the time and date are no longer maintained.
Page 110 If the fault indication moves to the new position of the cable, the cable has failed and should be replaced. 7. Open the Control Unit lid 8. Swap the detector harness connecting to the PCB with an adjacent harness. There is a push bar at the side of the connector to release it, taking care not to damage the connection wires or the connector pins/connections.
Page 111 Alternatively, an inspection of the engine event log, see section 3.6, will list the event: Communications Fault Detector X 5.2.2.1 Single Detector in fault Having established which detector is in fault it is necessary to establish the cause of the fault using the following steps.
Page 112 5.2.3 Contamination Low Fault As part of the oil mist measurement process light is passed across the sample chamber to illuminate the oil mist particles in the sampled air. Over time condensing oil can build up on the sample chamber walls causing the light in the sample chamber to be reduced.
Page 113 4. Compare the Current Contamination Value with the Original Contamination Value after the Detector has been cleaned. If the Detector is NOT within 20% of the Original Contamination Value after cleaning it should be replaced as it is at the end of its Service Life. 5.2.4 Control Unit Error The Control Unit continually checks the data held in memory to ensure that it has not been corrupted.
Page 114 Figure 155 Engine Status Screen Watchdog Fault Identify the fault being indicated, in this case a Control Unit Watchdog fault. Alternatively, an inspection of the engine event log, see section 3.6, will list the event: Controller Watchdog Engine X Having established which Control Unit is in fault the following steps should be followed. 1.
Page 115 5.2.6 Fan Fault The fan fitted to the detector head is required to draw the air from the engine into the detector sample chamber. The detector continuously monitors the operation of the fan and communicates a fault to the Control Unit if the fan stops rotating. To identify which detector is at fault, from the Engine Overview Screen, Figure 148, select the required engine.
Page 116 Figure 158 Detector Head Removal 2. Remove and invert the top part of the Detector head. Examine the base moulding seal and replace if damaged or perished, see Figure 159. Screw Removal Figure 159 Base Moulding Seal Caution: Do not press the fan, only handle the outer housing. 3.
Page 117 Figure 160 Pulling Tool One Fixing Screw Retaining Plug Figure 161 Fan Removal 4. Examine the 4 off compression springs and the fan retainer plug; replace any bent or damaged items from the spares. 5. Remove the fixing screw holding the fan socket to the mounting plate and unplug the fan from the detector head.
Page 118 Figure 162 Engine Screen Detector Fault Select the faulty detector to access the Detector Status Screen. Figure 163 Detector Status Screen Memory Fault Identify the fault being indicated, in this case a Memory fault. Alternatively an inspection of the engine event log, see section 3.6, will list the event: Gain Digipot Read Fault Detector X Having established which detector is in fault the following steps should be followed.
Page 119 Figure 164 Engine Screen Detector Fault Select the faulty detector to access the Detector Status Screen. Figure 165 Detector Status Screen Memory Fault Identify the fault being indicated, in this case a Memory fault. Alternatively, an inspection of the engine event log, see section 3.6, will list the event: Offset Digipot Read Fault Detector X Having established which detector is in fault the following steps should be followed.
Page 120 To identify which detector is at fault, from the Engine Overview Screen, Figure 148, select the required engine. Figure 166 Engine Screen Detector Fault Select the faulty detector to access the Detector Status Screen. Figure 167 Detector Status Screen Photodiode Fault Identify the fault being indicated, in this case a Photodiode fault.
Page 121 Due to the memory capacity with normal operation of the system it is expected that memory will last over 20 years before the memory limit is met. Note the system configuration data is not stored in this memory and is not affected by potential loss of data when the memory limit is reached.
Page 122 Figure 170 Detector Status Screen Watchdog Fault Identify the fault being indicated, in this case a Watchdog fault. Alternatively an inspection of the engine event log, see section 3.6, will list the event: Watchdog Fault Detector X Having established which detector is in fault the following steps should be followed. 1.
Page 123 Note: To maintain the warranty for the Control Unit changing of the battery should be performed by an approved Service Engineer. The OMD Mk7 system can function independently of the RDU allowing the RDU to be disconnected whilst the rest of the OMD system remains in operation. In this case the Modbus connector should be removed BEFORE removing the 24V input to the RDU.
Page 124 Figure 174 RTC Battery Orientation 7. Using a suitable tool remove and replace the battery, ensuring that the new cell is latched firmly in position. 8. Re-attach the casing(s), taking care not to over tighten the fixing screws and reconnect the 24V power connections FOLLOWED by the Modbus connector.
Page 125 Figure 176 Control Unit Middle Fixing Screws 3. Tilt the metal can taking care not to detach the ribbon cables from the PCB. 4. Note the orientation the existing battery, see Figure 177 (the positive terminal is facing outwards) Figure 177 Control Unit Battery Orientation 5.
Page 126 7. Replace the PCB in the Control Unit enclosure. 5.2.14 Remote Display Unit not communicating with the Control Units In the event of a communications failure between the Remote Display Unit and the Control Unit(s) the bar graph for the engine will be displayed with a cross through it. Figure 178 Remote Display Unit Communication Fault In the event of a communications failure the following steps should be followed:...
Page 127 If the Modbus addresses are incorrect set them to the correct values, see section 2.10.1 7. Observe the number of Control Units failing to communicate with the Remote Display Unit. If the system has multiple Control Units fitted with some units communicating correctly replace the Control Unit PCB in the non-communicating Control Units, see section 6.1.1.
Page 128: System Test Log
Figure 180 Remote Display Exception Error In this case: 1. Open the Plastic flap at the front of the Remote Display Unit 2. To the right of the USB socket is the RDU reset button. 3. Using a small probe or opened paper clip push the reset button If the Remote Display Unit operates correctly no further action is required.
Page 129: Spare Parts
CONTROL UNIT Figure 182 Control Unit Spares March 2021 Page 118 of 143 59812-K007 Rev 17 Business Confidential...
Page 130 Control Unit Spares I tem Description Part No. Control Unit with Membrane 1-53836-K270 Control Unit with Membrane (Caterpillar) 1-53836-K270-01 Control Unit without Membrane 1-53836-K276 Printed Circuit Board c/w Ribbon Cables 1-43782-K172-00 Printed Circuit Board w/out Ribbon Cables 1-43782-K172-01 Printed Circuit Board c/w Ribbon Cables 1-43782-K172-02 (Caterpillar) 25mm Blanking Plug...
Page 131 6.1.1 Control Unit PCB Replacement Note: The Modbus data cable to the Remote Display Unit should NOT be connected to or disconnected from the Control Unit with the power applied to the Control Unit or the Remote Display Unit. 1. Prior to powering down the Mk7 OMD system use the Remote Display Unit to read and make note of the parameters below.
Page 132 Figure 184 Ribbon Connector Ferrites 5. Disconnect the ribbon cables from the Control Unit lid taking care not to damage the pins and contacts. The ribbon cables are removed from the lid connectors not the PCB. There is no requirement to remove the metal can from the PCB. Figure 185 Ribbon Cable Removal 6.
Page 133 Figure 186 Control Unit Terminal Blocks 7. Disconnect the detector connectors (1 through to 10) There is a push bar at the side of the connector to release it, taking care not to damage the connection wires or the connector pins/connections.
Page 134 Figure 187 Control Unit With Membrane 15. The Pre-Alarm and Slowdown Alarm values for each detector are reset to their original values see Figure 52. 6.1.2 CONTROL UNIT MEMBRANE A new Control Unit Lid will be supplied fitted with the Membrane. 1.
Page 135 6.1.3 Control Unit (Pre-Alarm, Slowdown/Shutdown and Backup Alarm or Fault Relay Cable Replacement (Supplied by Others) 1. Switch off the system. 2. Remove the Control Unit Lid by removing the 4 screws 3. Disconnect the damaged relay cable from the Control Unit. 4.
Page 136: Remote Display Unit
REMOTE DISPLAY UNIT Figure 189 Display Unit Spares March 2021 Page 125 of 143 59812-K007 Rev 17 Business Confidential...
Page 137 Remote Display Unit Spares Item Description Part No. Remote Display Unit 1-53836-K271 24VDC Power Socket (no Cable) 1-27400-K304 Modbus Connector (no Cable) 1-27400-K305 Modbus Connector c/w 5m Cable 1-43682-K297 24VDC Power Socket c/w 5m Cable 1-43682-K296 6.2.1 Remote Display Unit Replacement The OMD Mk7 system can function independently of the Remote Display Unit allowing the Remote Display Unit to be disconnected whilst the rest of the OMD system remains in operation.
Page 138: Detector
DETECTOR Figure 190 Detector Spares Detector Spares I tem Description Part No. Detector Complete 1-53836-K269 Detector Complete (Short Sample Pipe) 1-53836-K269-01 Detector Head Replacement Assembly 1-53836-K272 Fan Assembly (1 Screw) 1-D5622-005-02 Fan Assembly (2 Screw) 1-53569-K005 Base Unit sub-Assembly 1-D5622-101 Base Unit sub Assembly (Short Sample 1-D5822-102 Pipe)
Page 139 6.3.1 Detector Head replacement WARNI NG - Do NOT remove the Detector from the base whilst the engine is in operation. This action should be carried out whilst the engine is stopped to avoid the possibility of hot oil coming out of the Detector Base. 1.
Page 140 6.3.3 Detector Cable Replacement 1. Isolate the Detector with the damaged cable. 2. Remove the cable connector on top of the Detector. 3. Identify the cable to be removed at the Control Unit 4. Unscrew the cable connector at the Detector and discard the damaged cable. 5.
Page 141: Spares Kits
SPARES KITS 6.4.1 Commissioning Kit Commissioning Kit D9221-026 consists of: Description Part No. Category Cleaning Wipes 1-A7311-001 Consumables Smoke Test Oil -30 ml 1-D9221-028 Consumables Bottle Wick - 150 mm 1-17100-H06 Consumables Smoke Tester 1-D9221-029 Tools Materials Safety Data Sheet Information 6.4.2 Service Kit...
Page 142: Recommended Operational Spares
RECOMMENDED OPERATIONAL SPARES Recommended Operational Spares Description Part No. Commissioning Kit 1-D9221-026 Service Kit 1-D9221-027 OMD Mk7 Detector Head 1-53836-K272 For systems with more than 10 detectors, it is recommended that additional detector head assemblies (1-53836-K272) are supplied. COMPLETE SPARE PARTS LIST Description Part No.
Page 143 Cable Assemblies 90º Connector Description Part No. Length 1.0m Cable with 90° Connector 1-43682-K285-1.0 Metres 1.5m Cable with 90° Connector 1-43682-K285-1.5 Metres 2.0m Cable with 90° Connector 1-43682-K285-2.0 Metres 2.5m Cable with 90° Connector 1-43682-K285-2.5 Metres 3.0m Cable with 90° Connector 1-43682-K285-3.0 Metres 3.5m Cable with 90°...
Page 144 Cable Assemblies Straight Connector Description Part No. Length 1.0m Cable with Straight Connector 1-43682-K286-1.0 Metres 1.5m Cable with Straight Connector 1-43682-K286-1.5 Metres 2.0m Cable with Straight Connector 1-43682-K286-2.0 Metres 2.5m Cable with Straight Connector 1-43682-K286-2.5 Metres 3.0m Cable with Straight Connector 1-43682-K286-3.0 Metres 3.5m Cable with Straight Connector (Discontinued)
Page 145 Description Part No. Spare Parts Cotton Wick (1 hank = 10 meters) 1-17100-H06 No longer sold separately Connector Push in 1-21888-K073 Replaces 1-B5465-307 25mm Metal Gland 1-22540-K028 25mm Blanking Plug 1-22540-K029 24VDC Power Socket (no Cable) 1-27400-K304 Modbus Connector (no Cable) 1-27400-K305 Mk5 - Mk7 Retrofit Plate 1-35100-K274...
Page 146: Caterpillar Detectors
Figure 192 Caterpillar Detector with Short Sample Pipe, 1- 53836-K269-03 March 2021 Page 135 of 143 59812-K007 Rev 17 Business Confidential...
Page 147 Figure 193 Caterpillar Detector with Standard Sample Pipe, 1- 53836-K269-02 March 2021 Page 136 of 143 59812-K007 Rev 17 Business Confidential...
Page 148 Cable Assemblies 90º Connector Description Part No. Length 0.50m Cable with 90° Connector 1-43682-K298-0.50 0.50 Metres 0.59m Cable with 90° Connector 1-43682-K298-0.59 0.59 Metres 0.65m Cable with 90° Connector 1-43682-K298-0.65 0.65 Metres 0.70m Cable with 90° Connector 1-43682-K298-0.70 0.70 Metres 0.78m Cable with 90°...
Page 149 March 2021 Page 138 of 143 59812-K007 Rev 17 Business Confidential...
Page 150 GRAVINER Mk7 OIL MIST DETECTOR SYSTEM WEEKLY CONTAMINATION READINGS Engine Detector Name Original Contamination Value Contamination Low Limit Current Current Current Current Current Current Current Current Current Current Date Contamination Contamination Contamination Contamination Contamination Contamination Contamination Contamination Contamination Contamination Value Value Value Value...
Page 151 EXAMPLE SHEET Generator 1 Engine Detector Name Det. 1 Det. 2 Det. 3 Det. 4 Original Contamination 3948 3004 3564 2754 Value Contamination 1974 1502 1782 1377 Low Limit Current Current Current Current Current Current Current Current Current Current Date Contamination Contamination Contamination...
Page 152 March 2021 Page 141 of 143 59812-K007 Rev 17 Business Confidential...
Page 153 Twice Yearly Maintenance See Section 4.3 for further details ☐ External Inspection Performed ☐ Internal Inspection Performed ☐ Detector ☐ Correct number of engines and detectors displayed on the Remote Display Unit ☐ System component software versions documented ☐ Event Logs inspected and recorded ☐...
Page 154 Annual Maintenance See Section 4.3 for further details ☐ System component serial numbers and software versions recorded ☐ System functions verified ☐ Event Logs and System Test Logs inspected and recorded ☐ Detectors cleaned, status and parameter readings checked ☐ Detector bases inspected and cleaned ☐...

Carrier GRAVINER Mk 7 Installation, Operation And Maintenance Manual

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