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© 2010-2011, Consilium AB
G2000 Ambient Oil Mist Detector
Content
1 PREFACE 5
1.1 ABOUT THIS MANUAL 5
1.2 INQUIRIES AND FEEDBACK 6
1.3 ABOUT THE SYSTEM 7
1.4 SPECIFICATIONS 8
1.5 CHOOSING THE RIGHT ALARM LEVELS – OPACITY OF OIL MIST 11
2 INSTALLATION 13
2.1 GENERAL 13
2.2 WHERE TO INSTALL THE SYSTEM 14
2.3 SAFETY ASPECTS 14
2.4 CONTROL AT DELIVERY 15
2.5 STANDARD INSTALLATION 16
2.5.1 Fiber optic mini heads 16
2.5.2 Fiber optic cables 18
2.5.3 Monitoring Unit 18
2.5.4 Remote Digital Display and Alarm Annunciator (optional) 19
2.6 ELECTRICAL CONNECTIONS 19
3 COMMISSIONING 21
3.1 CALIBRATION 21
3.2 SETTING OF ALARM LEVELS 22
4 MAINTENANCE 23
5 TROUBLE SHOOTING 24
6 PART LIST 26
7 DIGITAL DISPLAY 29
7.1 SPECIFICATIONS OF THE DIGITAL DISPLAY 29
7.2 BLOCK DIAGRAM 30
7.3 ROUTING DIAGRAM 30
7.4 SCROLLING HELP TEXTS 32
7.5 CONFIGURING — OPERATING THE FUNCTION KEYS 33
3
Preface
Table of Figures
FIGURE 1: SCAN OF THE LLOYD'S REGISTER TYPE APPROVAL CERTIFICATE (PAGE 1) 9
FIGURE 2: DECLARATION OF CONFORMITY (FOR CE MARKING) 10
FIGURE 3: OPACITY VERSUS PATH LENGTH FOR DIFFERENT CONCENTRATION 12
FIGURE 4: G2000 INSTALLATION LAYOUT – TOP VIEW 14
FIGURE 5: STANDARD INSTALLATION OF THE G2000 AMBIENT OIL MIST DETECTOR 16
FIGURE 6: MOUNTING POSITION OF THE OPTICAL MINI HEADS 17
FIGURE 7: FIBER OPTIC MINI HEAD 17
FIGURE 8: FIBER OPTIC CABLE CONNECTION TO LENS 18
FIGURE 9: MONITORING UNIT 19
FIGURE 10: TERMINAL CONNECTIONS DIAGRAM INSIDE THE MONITORING UNIT 20
FIGURE 11: FAST SET-POINT ADJUSTMENT PROCEDURE 22
FIGURE 12: DEFAULT CONNECTION DIAGRAM – G2000 AOMD TO ALARM MONITOR M4200 37
4
G2000 Ambient Oil Mist Detector
1 Preface
The instructions are given in general terms and do not take into consideration a
specific installation. As such, the instruction manual is designed for the equipment
delivered by Consilium Marine & Safety AB.
The manual does not describe all possible situations, but only the most common
and known situations. It cannot replace the necessary education and training of the
personnel.
Should situations not described in this manual occur that cannot be solved in ac-
cordance with normal known practice and good workmanship, the operator should
contact Consilium Marine & Safety AB for instructions.
This manual does not claim to cover all details or variations in equipment or to
provide for every possible contingency that may arise during installation, opera-
tion, or maintenance.
Consilium Marine & Safety AB reserves the right to minor alterations and im-
provements owing to developments without being obliged to enter the correspond-
ing changes in this manual.
Consilium Marine & Safety AB reserves the copyright of the manual. Without
prior written permission of Consilium Marine & Safety AB, the manual may not
be copied and given to unauthorized people.
5
Preface
In all correspondence or when ordering spare parts, please carefully state the
equipment type and fabrication number which you can find on the label inside the
monitor cabinet.
Consilium Marine & Safety AB appreciates all feedback and suggestions for im-
provement. If you have any questions or find any errors in the manual, you are
welcome to contact us at the following address:
6
G2000 Ambient Oil Mist Detector
The G2000 Ambient Oil Mist Detector is designed to detect oil mist in open spaces.
The G2000 is usually installed in engine rooms, pump rooms, or other rooms with
hydraulic installations, especially above hydraulic power packs and hydraulic ag-
gregate pumps.
As a standard configuration, the G2000 Ambient Oil Mist Detector consists of the
following main elements:
The G2000 uses a high-power infrared light beam. It is a single-pass system where
the light beam is transmitted from the optical fiber of the transmitter across the
monitored area to the optical fiber of the receiver. The optical transmitter and re-
ceiver are placed in the monitoring unit.
The beam is absorbed and scattered by oil mist and smoke causing a reduction in
the amount of light received by the transceiver. The monitoring unit displays the
opacity. It indicates 0% if there is no opacity and 100% if the light beam is totally
blocked. The alarms will activate if the opacity exceeds the preset limits.
Please note that the G2000 Ambient Oil Mist Detector will also react to smoke, dust
or other obstructions intercepting the light beam. Consequently the reading of the
sensor will change and possibly trigger an alarm. This might be perceived as a
"false alarm", but at the same time it gives you an indication of other malfunc-
tions. The following section only relates to the opacity levels of oil mist in ambi-
ent air.
7
Preface
1.4 Specifications
Monitoring Unit
Power Supply 210–250 VAC or 105–130 VAC – 50/60 Hz – 12 VA max.
20–30 VDC – 12 VA max.
Ambient temperature 0°C – 55°C
Output signal 4…20 mA (4 mA ≈ 100% — 20 mA ≈ 0% Opacity) max. 800 Ω
(linearized) 0…10 V DC (0 V ≈ 100% — 10 V ≈ 0% Opacity) max. 10 mA
Display 0–100% opacity level (programmable)
Accuracy Better than 2% of full scale
Alarm delay default 5 s (programmable 0–99 s)
Relay voltage max. 250 V AC, max. 2A, NC/NO
Relay function 2 relays, volt free, freely configurable — default NC
Default alarm levels Relay 1 at 5% opacity and Relay 2 at 10%
Dimensions/Weight H×W×D: 300 × 200 × 150 mm / 5.5 kg
Enclosure IP 65 Steel box
Recommended min- Power supply: 3 × 1.5 mm² w/screen
imum cable size Signal cable: 2 × 0.75 mm² w/screen
Alarm cable: 2 × 2 × 0.75 mm² w/screen
Optional Equipment
Visualization & data logging
Alarm annunciator for panel mounting
Data-system integration
8
G2000 Ambient Oil Mist Detector
9
Preface
Declaration of Conformity
Type: G2000
Name: Ambient Oil Mist Detector
Managing Director
Appointed by Green Instruments A/S as the responsible person for CE marking and con-
formity with the relevant EU directives
10
G2000 Ambient Oil Mist Detector
The lower alarm level at 5% opacity is used as a lens-cleaning warning. While the
higher alarm level of 10% is used as the oil mist alarm.
Fouling of lenses will result in reduced translucency between the two lenses. The
system cannot directly differentiate between the opacity effect of contaminated
lenses and the opacity effect of oil mist. Therefore the lenses need to be cleaned
regularly. A failure to clean the lenses will de facto lower the alarm level of the ac-
tual oil mist alarm. If 4% of the opacity between the lenses is due to lens contami-
nation then the actual oil-mist alarm will already be triggered at 6% opacity due to
oil mist. A failure to clean the lenses will thus not result in a failure of the system.
The 10% alarm level is chosen to trigger an alarm for oil mist with a concentration
of more than 0.2 mg/l.
In principle, the opacity of oil mist will depend on the concentration of oil mist,
the size of oil droplets, and the path length of the actual oil-mist cloud which in-
tersects the light beam.
Regarding the size of oil droplets, as a rule, smaller oil droplets have lower igni-
tion temperature due to the larger surface to volume ratio. Larger oil droplets are
less dangerous due to higher ignition temperatures. However, smaller droplets
have a higher opacity effect and are thus easier to detect than larger droplets.
The default alarm levels for the G2000 is based on the calculation for hazardous oil
mists including fine oil spray from minute leaks in hydraulic systems and oil mist
which has boiled off from a hot surface.
11
Preface
100%
90%
0.2 mg/l 1.0 mg/l 2.0 mg/l
80%
60%
Opacity in %
50%
40%
30%
20%
10%
0%
25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400
Path length in cm
Regarding the concentration of oil mist and the path length, the figure above illus-
trates different oil mist opacity levels corresponding with different oil concentra-
tions and path lengths for the oil droplets ranging from 10-20 µm.
For smaller oil droplet size (3-10 µm), much smaller oil mist clouds will trigger
the alarm.
12
G2000 Ambient Oil Mist Detector
2 Installation
2.1 General
To avoid possible damage to the equipment or errors in the monitoring readings
and alarm function, it is important to observe the following points carefully:
The location of the optic mini heads must be suitable for service & clean-
ing.
The optic mini heads must be welded to a structure – typically the ceiling or
a beam, which should vibrate as little as possible.
If welding on structures thinner than 6 mm it is recommended to fit a dou-
ble plate to the structure in order to support the optic mini heads.
The optic mini heads must be properly aligned and securely welded to a
structure. Lens and lock nuts must be tightened firmly.
The optic mini heads and fibers must be protected against mechanical dam-
age, e.g. the optic fibers should not dangle.
Do not turn the optic fibers in the optic mini heads without loosening the
lock nuts first.
Caution
Installation and operation of the G2000 Ambient Oil Mist Detector and as-
sociated equipment must be carried out by skilled, trained and certified
personnel. Consilium Marine & Safety AB does not take any responsibil-
ity of the operation of the system and associated equipment whatsoever.
The equipment must only be applied as specified by Consilium. If the
equipment is used in a manner not specified by Consilium, the protec-
tion provided by the equipment may be impaired.
The successful and safe operation of this equipment is dependent upon
proper handling, installation, operation, and maintenance.
13
Installation
Therefore, the G2000 Ambient Oil Mist Detector should be installed at least above
or on either side of the hydraulic power packs or engines. The ambient air around
other installations with oil under high pressure and/or temperature can be moni-
tored as well (e.g. purifier installations, steering gear, etc.).
The location of the optical mini heads must take into account the design of the
ship structure. The line-of-sight should be 3–9 m long, optional down to 1 m, and
must be free of obstacles that would intercept the beam of light. If the beam of
light is intercepted by objects carried though its path and if the alarm delay is ex-
ceeded, this will cause false alarms.
14
G2000 Ambient Oil Mist Detector
Warning!
Hazardous Voltage: Disconnect power before servicing the system. Ignoring this
warning can result in severe personal injury or material damage. Observe the in-
structions carefully to ensure the correct connection of all power and signal leads.
Ensure that the correct DC or AC voltage is connected to the monitoring unit (see
the rating marked inside the monitoring unit).
Circuit breaker!
The installation must include a means of isolating electrical power by a clearly
marked switch or circuit breaker external to the monitoring unit. The external
switch or circuit breaker shall be in close proximity to the monitoring unit and
within the easy reach of the operator.
Overload protection!
To comply with safety requirements IEC 61010-1 (2003), the installation must in-
clude a means of overcurrent protection to protect against excessive energy being
drawn from the power supply system in case of a fault in the equipment.
Protective earth!
The monitoring unit must be connected to protective earth.
Symbol identification
Caution, risk of danger
Protective earth
The CE mark proves the compliance of the instrument with the requirements of
the relevant EU directives
15
Installation
Scope of supply:
Two (2) optic mini heads (standard)
Two (2) fiber optic cables (standard)
Monitoring unit with digital display and connections (standard)
Alarm annunciator for panel mounting (optional)
Remote digital display for panel mounting with two (2) alarm relays (op-
tional)
Plane glass lens for shorter scanning distances (optional)
Recorder, data logging, and/or visualization system (optional)
Monitoring Unit 7%
Power Supply
Signal Output
Oil Mist
Lens Lens
Note: The optical heads are to be aligned opposite each other in a way that the
light beam from one lens hits the other lens. Thin structure will require additional
support in order to secure stable alignment.
16
G2000 Ambient Oil Mist Detector
The welding supports are to be welded (3) onto ship structure. Please see Figure
6 for two different positions of the welding support (either under the ceiling or on
the walls). In order to avoid false alarms caused by people walking in the moni-
tored area, it is recommended to mount the optical mini heads at a position higher
than the normal height for people (i.e. > 2200 mm from the floor).
17
Installation
When mounting the mini heads, please observe that vibration of the structure
might cause false alarms – especially in case of asynchronous vibration of the two
heads. When welding the mini heads on structures with a wall thickness of less
than 6 mm, it is recommended to fit a double plate before mounting the support.
Furthermore, a permanently fixed angle bar can be installed from lens support to
lens support. This will make the optical alignment more stable.
When installing the two fiber optic heads with a distance of less than 3 m, the sig-
nal becomes too strong due to the focusing effect of the lenses. To avoid this,
please exchange one of the focusing lenses with a plane glass lens (p/n 01041).
In order to check the focus of the lens and the alignment of the optic mini heads,
you can send visible light (e.g. from a flashlight) in from the other end of the fiber
optic cable. Turning the lens will bring the tip of the fiber optic cable into the fo-
cus point, thus focusing the light sent in from the other end of the cable.
The fiber optic cables are then screwed into the connectors of the optic beam
module at the bottom of the monitoring unit. Please note that dangling cables and
especially cable movement at the bottom of the monitoring unit can change the
opacity effect inside the cables and thus affect the measurement. Please fix the ca-
bles with cable clamps or inside a cable tray.
18
G2000 Ambient Oil Mist Detector
Digital Display
Serial Number
Terminals
Automatic Fuse
The alarm annunciator is usually mounted in the control room and connected to
the alarm relays of the monitoring unit. The alarm levels are configured via the
digital display of the monitoring unit. For more information, please see chapter 8.
External monitoring instruments using analog signals such as alarm monitors, re-
corders, and data loggers are usually connected to voltage output (terminals 1&2)
or current output (terminals 3&4) of the monitoring unit.
19
Installation
Terminals 1 to 8 located at the bottom of main board inside the monitoring unit
are connections for signal and alarms.
Caution
After installation has been completed and the wiring has been carefully
checked, the power can be switched on.
20
G2000 Ambient Oil Mist Detector
3 Commissioning
The following adjustment procedure will take you step by step through the ad-
justment of the optic beam module and digital display.
3.1 Calibration
Note
ZERO and SPAN are adjusted to produce the desired output swing be-
tween the lightest and darkest sensing conditions.
SPAN (i.e. 100% opacity) has to be calibrated first and then ZERO (i.e.
0% opacity).
Both SPAN and ZERO are 15-turn clutched potentiometers with slotted
brass elements. A small, flat-bladed screwdriver is required for adjust-
ment.
During calibration, all possible obstruction to the infrared beam (such as
oil mist, smoke, or dust) must be absent in the section between the optic
mini heads. In other words, the transmission of the light must not be af-
fected in any way.
SPAN has to be adjusted first. To adjust SPAN, remove one of the fiber optic
cables completely from the monitoring unit, so the infrared beam is
now interrupted. Then use a screwdriver to adjust SPAN until the indi-
cator displays 100% opacity. If the span calibration screw is turned too
much, the display will show 101% opacity. In that case, turn the span
screw clockwise until 100% is reached.
ZERO is adjusted by putting back the fiber optic cable. Make sure there are no
obstructions to the infrared beam. Now use a screwdriver to adjust
ZERO until the indicator displays 0% opacity. If the zero calibration
screw is turned too much, the display will show –1% opacity. Alarm
21
Commissioning
If it is not possible to obtain 0% opacity, check the alignment of the fiber optic
mini heads. If the alignments is found to be correct and the signal still cannot be
adjusted correctly, the fiber optic cable has to be turned in the optic mini heads to
change the center focus position of the light beam in relation to the lenses (see
section 2.5.2).
If you wish to change the alarm levels, please follow the following fast set-point
adjustment procedure (see chapter 7 for a more detailed instruction).
22
G2000 Ambient Oil Mist Detector
4 Maintenance
Besides normal cleaning of the optical mini heads and lenses, the system does not
require any maintenance.
Cleaning intervals depend on the usual amount of oil, smoke, and dust in the am-
bient air of the area of installation. The accumulation of dirt on the lenses will re-
sult in higher opacity readings and might therefore give false alarms. The lower
alarm is suggested to be set as a lens-cleaning alarm. When the lower alarm is
triggered, please clean the optical mini heads and lenses. If the lower alarm is
used for another purpose, please make sure to set sufficiently short cleaning inter-
vals.
It is strongly recommended to calibrate the system after cleaning the lenses. How-
ever, oil mist, smoke, or dust must not be present in the section between the optic
mini heads during calibration.
23
Trouble Shooting
5 Trouble Shooting
Trouble shooting should always be carried out by trained and certified personnel.
The G2000 Ambient Oil Mist Detector is connected to hazardous electric voltages,
which can cause personal injury if not handled correctly.
24
G2000 Ambient Oil Mist Detector
25
Part List
6 Parts List
Part No. Part Description The specific appearance of the parts Standard
list is subject change without notice; quantity in
the function however will not change use
26
G2000 Ambient Oil Mist Detector
Part No. Part Description The specific appearance of the parts Standard
list is subject change without notice; quantity in
the function however will not change use
Monitoring unit G2000AOMD
230 VAC
6701137-00A 1
(includes 32023, 00037,
00038)
Monitoring unit G2000AOMD
115 VAC
6701138-00A optional
(includes 32023,
00037,00970)
Monitoring unit G2000AOMD 24
VDC
6701139-00A optional
(includes 32023,
00037,00318)
27
Part List
Part No. Part Description The specific appearance of the parts Standard
list is subject change without notice; quantity in
the function however will not change use
1 in
Digital Display 5714D AOMD
6701431-00A 01137
– for input signal 0…10 V -38/-39
Remote Digital Display 5714D
6732023-00A AOMD optional
– for input signal 4…20 mA
1 in
01137
6700037-00A Optic beam module amplifier
01138
01139
28
G2000 Ambient Oil Mist Detector
7 Digital Display
Alarm monitoring is carried out by the digital display. This display can also be used as a re-
mote digital display.
29
Digital Display
Menus:
1.0 = Default state
1.1 = Only if password protected
1.2 = Only if FastSet is enabled (see chapter 3.2 above)
1.3 = FastSet and relay test (see chapter 3.2 – disabled at password 5000-9999)
1.4 = No relay outputs – Not applicable for G2000 AOMD
1.5 = Not applicable for G2000 AOMD
1.6 = No analogue outputs – Not applicable for G2000 AOMD
1.7 = Not applicable for G2000AOMD
30
G2000 Ambient Oil Mist Detector
This display is password protected in stage 1.1 to avoid uninten-
tional change of settings. If the input setting is changed away from
VOLT, all subsequent parameters are lost and will have to be repro-
grammed.
The parameters required for the application described in this manual are:
Input: VOLT Range: 0––10 Decimal Point: 1111
Display Low: 101 Display High: –1 Relay Units: DISP
The password is 2008 – please use with care.
If used as a remote digital display the parameters required are:
Input: CURR Range: 4––20 Decimal Point: 1111
Display Low: 101 Display High: –1 Relay Units: DISP
31
Digital Display
Caution
Please note that the input signal for the digital display in the monitoring
unit of the G2000 AOMD is voltage – VOLT.
If you enter menus CURR, POTM and TEMP all subsequent settings will
be lost and need to be reprogrammed.
32
G2000 Ambient Oil Mist Detector
TC.TY REL2
TC. B select tc sensor type SET enter relay 2 setup
TC. E select tc sensor type SKIP skip relay 2 setup
TC. J select tc sensor type OFF relay 2 disabled
TC. K select tc sensor type
TC. L select tc sensor type SETP
TC. N select tc sensor type xxxx relay setpoint → 10
TC. R select tc sensor type
TC. S select tc sensor type ACT2
TC. T select tc sensor type INCR activate at increasing signal → INCR
TC. U select tc sensor type
DECR activate at decreasing signal
TC.W3 select tc sensor type
TC.W5 select tc sensor type HYS2
TC.LR select tc sensor type
xxxx relay hysteresis → 2
DEC.P – When temperature selected
1111 decimal point position ERR2
111.1 decimal point position HOLD hold relay at error
ACTI activate relay at error
UNIT DEAC deactivate relay at error → DEAC
°C display and relay setup in celsius NONE undefined status at error
°F display and relay setup in fahrenheit
ON.DE
REL1
xxxx relay on-delay in seconds → 5
SET enter relay 1 setup
SKIP skip relay 1 setup
OFF relay 1 disabled
OF.DE
xxxx relay off-delay in seconds → 5
SETP
xxxx relay setpoint → 5 A.OUT
0-20 output range in mA
ACT1 4-20 output range in mA → 4--20
INCR activate at increasing signal → INCR 20-0 output range in mA
DECR activate at decreasing signall 20-4 output range in mA
HYS1 O.LO
xxxx relay hysteresis → 2 xxxx display value for output low
O.HI
ERR1 xxxx display value for output high
HOLD hold relay at error
ACTI activate relay at error O.ERR
DEAC deactivate relay at error → DEAC 23 mA namur ne43 upscale at error
NONE undefined status at error 3.5 mA namur ne43 downscale at error
0mA downscale at error
ON.DE NONE undefined output at error
xxxx relay on-delay in seconds → 5
RESP
xxx.x analogue output response time in seconds
OF.DE
xxxx relay off-delay in seconds → 5 E.PAS
NO disable password protection
YES enable password protection → YES
N.PAS
xxxx select new password → 2008
Note
Faded help texts are not applicable for G2000 AOMD
Defaults are marked with →
33
Alarm Annunciator
If a function does not exist in the display, all parameters are skipped to make the
configuration as simple as possible.
Once the configuration has been entered, the display will show “----”.
Pressing and holding will return to the previous menu or return to the default
state (1.0) without saving the changed values or parameters.
If no key is activated for 2 minutes, the display will return to the default state (1.0)
without saving the changed values or parameters.
Fast set-point adjustment and relay test: These menus allow you to change the
set point without going through the whole menu. Pressing and simultane-
ously will change the state of the relay. This change is indicated by the diodes on
the display. Pressing will save the set-point change. Holding down for more
than 0.5 seconds will return the unit to the default state without changing the set
point.
Password protection: Using a password will stop access to the menu and pa-
rameters. There are two levels of password protection. Passwords between
0000…4999 allow access to the fast set-point adjustment and relay test. (Using
this password stops access to all other parts of the menu). Passwords between
5000…9999 stop access to all parts of the menu, fast set-point and relay test.
(Current set point is still shown). By using the master password 2008, all configu-
ration menus are available.
34
G2000 Ambient Oil Mist Detector
35
Alarm Annunciator
Function
When alarm input is activated, the LED goes flashing, alarm relay 1 and the siren
relay goes ON. When reset button is activated, the LED goes steady and the siren
goes OFF together with alarm 1. When alarm input is de-activated, LED goes
OFF.
Note
Input 1-8 to the Alarm Monitor M4200 is preset from Consilium Marine &
Safety AB to NC to correspond with the NC contacts in the digital display
and alarm giver of the monitoring unit.
36
G2000 Ambient Oil Mist Detector
37
Global Service and Support
Own companies
Sales- and service representatives
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organisation in order to provide our customers with the most competent
service and support. Today Consilium has established own companies in
16 countries plus sales and service representatives in more than 50 countries.
You will find updated contact information on our web-site www.consilium.se.
www.consilium.se