Graviner Manual
Graviner Manual
Graviner Manual
INSTALLATION,
OPERATION AND
MAINTENANCE
MANUAL
1-59812-K001
The information contained in this manual is the property of UTC Limited 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 UTC Limited.
Chapter 3 MAINTENANCE 62
3.1 ROUTINE MAINTENANCE 62
3.2 DETECTOR HEAD REPLACEMENT 63
3.3 DETECTOR HEAD REFURBISHMENT 64
3.4 FAN REPLACEMENT 66
3.5 CABLE REPLACEMENT 67
3.6 CONTROL UNIT PCBs 68
3.7 REPLACEMENT OF 8 ENGINE STATUS DISPLAY MEMBRANE 70
3.8 REPLACEMENT OF LCD DISPLAY 70
3.9 REPLACEMENT OF FUNCTION KEY / LCD DISPLAY MEMBRANE 71
3.10 REPLACEMENT OF JUNCTION BOX PCB 71
3.11 DECOMMISSIONING 71
2. UTC warrants for a period of 12 months from delivery that individual OMD’s supplied as spares
shall be free from defects in workmanship or materials during normal usage.
f. Any modifications to or installations performed on the OMD’s and/or OMD system outside
the scope of normal routine maintenance or running repairs without the express prior
written approval of UTC;
g. Deterioration, staining or corrosion of parts which will occur due to normal exposure and
usage;
h. Alleged defects not materially affecting the quality or proper functioning of the OMD
system.
7. The Warranties can be transferred to any new owner of the OMD system provided UTC is
informed in writing within 30 days of the transfer. The OMD System Warranty cannot be
transferred to another UTC OMD system.
8. Save to the extent amended by the provisions set out above, KPL’s standard terms and conditions
of sale shall apply.
1.1 INTRODUCTION
o
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. When the density of these particles reaches
between 30 to 50 mg/I (Milligrams per litre), depending upon the type of oil, an explosive
condition exists.
Main Bearing
Bottom End
Bearing
1.2 DESCRIPTION
The system comprises three main components (refer to Figure 3):
Detectors 1-E3561-301 (with base)
1-D5622-001 (replacement head only)
Engine Junction Boxes 1-D4720-001-XX with 20mm Power & Comms Connections
or
1-53836-K224-XX with 25mm Power & Comms Connections
Control Panel 1-53836-K170 (Bulkhead Mounting)
1-53836-K206 (Flush mount)
Control Panel
Junction Box
Main Engine 7 Cylinder
Junction Box
Auxillary Engine 5 Cylinder
Control Unit
Enclosure Rating IP32
Scanning lime 1.2 seconds for 64 Detectors
Max No. of Detectors 64
Max No. of engines monitored 8
Power Supply 2 x 24Vdc (+30% -25%)
Protection 2 x 2.5A self re-settable fuses inside Control Unit
Insulation Flash tested to 2000V for 1 minute
Power Consumption 5.2W
o
Temp Rating 0 – 55 C
Humidity level 95%
Dimensions
Bulkhead Mounted: Height 313mm (270mm mounting centres)
Width 500mm (445mm mounting centres)
Depth 118mm
Panel Mounted: Height 309mm
Width 559mm
Depth 118.5mm
Weight 8.7kg
System Outputs: Volt-free change over contacts rated at 30Vdc 1A
Main Alarm 1 set (energised during normal operation)
Fault Alarm 1 set (energised during normal operation)
Engine Slowdown / Shutdown 8 sets, 1 set per engine (de-energised during normal
operation)
Alarm Ranges Average 0.3mg/l to 1.3mg/l (adjustable)
Deviation 0.05mg/l to 0.5mg/l (adjustable)
Backup 1.6mg/l (fixed)
The User level is essentially for read only interrogation and does not allow any adjustments to
be made to alarm settings or system configuration.
The Engineer level is password protected and allows access to most functions and the full
range of settings.
1.5.1 Controls
The Control Unit offers the following controls :-
THE ACCEPT KEY resets the main alarm relay, silences the internal sounder. The
display will then enter the individual display for the engine(s) in alarm. If there is more
than one engine in alarm the display will scroll between engines.
THE RESET KEY resets all alarms, faults and returns the system to normal.
The MAIN DISPLAY key always returns the display to this page from anywhere in the
software.
The ENGINE DISPLAY control calls up the individual engine cylinder readings and
the average. It also displays the deviation and average alarm settings. The cursor
keys allow each engine in the system to be displayed in turn.
THE HOLD KEY holds the display for 15 seconds.
The MAIN MENU key allows access to all the USER, ENGINEER and SERVICE
menus. At the bottom of each displayed page the active navigation keys for that page
are shown.
The MAIN DISPLAY and MAIN MENU keys allow fast return to the normal display or
the main menu from anywhere in the software. If this function is carried out from a
password protected area i.e. ENGINEER or SERVICE menu, then a RESET must
also be carried out.
THE TEST KEY enters the test menu at User level functions only.
Quit
Enter
N/C N/O C ~ N/C N/O C N/C N/O C N/C N/O C N/C N/O C
Power is On
Interface Board Junction Box
and is normal
Monitoring
Mode
N/C N/O C ~ N/C N/O C N/C N/O C N/C N/O C N/C N/O C
N/C N/O C ~ N/C N/O C N/C N/O C N/C N/O C N/C N/O C
Fault
Power is On
and Engine 1 Alarm Interface Board Junction Box
Oil Mist Alarm
was detected
N/C N/O C ~ N/C N/O C N/C N/O C N/C N/O C N/C N/O C
ENG1 Alarm
N/C N/O C ~ N/C N/O C N/C N/O C N/C N/O C N/C N/O C
Alarm Alarm
2.1 INSTALLATION
2.1.1 Control Unit Mounting
The Control Unit is designed for either bulkhead or flush mounting, and must be installed in a
control room or similar environment, not in the engine room.
For bulkhead mounting fix to a rigid structure using the four M6 mounting flanges at the rear of
the unit.
For flush mounting a bezel, part number 1-35100-K187 can be supplied (refer to Figure 9).
The position of the Control Unit must be sited for optimum visibility of the display. Sufficient
space must be left around the Control Unit to allow the fitting and routing of the cables, and to
facilitate easy access to all aspects of the Control Unit. A minimum of 500mm must be allowed
at the front of the Control Unit to allow the door to be opened.
Figure 10 MK6 Control Unit Flush Mounting Installation Drawing Cut Out Details
Notes:
o
1. Cable Spec 8-core screened (90 C) Halogen free & oil resistant.
2. Cable lengths are ‘straight lengths’.
3. Clips to be secured every 0.5m (clips are not supplied by Kidde Fire
Protection).
4. Do not exceed the minimum bend radius as shown.
The pin to pin connections for the Detector cables are shown in the table below:
Connector Pin Last Detector
Colour of wire Function
No. Function
1 Pink Comms Out - TB10 EOL-
1 White Comms In - C- in
2 Yellow Comms In+ C+ in
2 Brown Comms Out + TB10 EOL+
3 Grey Backup Alarm Back-up Alarm
5 Blue 0v supply 0V
6 Red 24v supply +24V
Centre Screen Cable screen Cable screen
POWER
AUX ENGINE CABLE
(AS ABOVE) JUNCTION BOX 5 MK6 CONTROL PANEL
COMMS
CABLE
POWER
AUX ENGINE CABLE
(AS ABOVE) JUNCTION BOX 6
COMMS CABLE
2 X EXTERNAL
24V DC SUPPLY
INPUTS
MAX 14 OFF DETECTOR HEAD CABLES
Exposed screen
Feed the cable into the Control Unit via a metal EMC gland, e.g. Lapp Kabel Skintop MS-SC-
M-XL range, ensuring that the metal prongs make contact with the exposed cable screen as
shown below. The gland should be fixed in place using a toothed nut to cut through the Control
Unit paint.
Cable gland
Earthing Prongs
Connect the 24v and 0v in to TB5 on the Terminal Board, 1-44782-K183, see Figure 24.
Feed the cable into the Control Unit via a metal EMC gland, e.g. Lapp Kabel Skintop MS-SC-
M-XL range, ensuring that the metal prongs make contact with the exposed cable screen as
shown. The gland should be fixed in place using a toothed nut to cut through the Control Unit
paint.
Communications Cable:
2 Twisted low capacitance pairs, 27(7) AWG tinned copper conductors, foam polyolefin
insulation, each pair foil screened with a tinned copper drain wire, low smoke halogen free
o o
sheath – grey, outside diameter 8.1mm, operating temperature 0 C to 70 C.
Approved cables
Beldon 9729
Helkama RFE-HF(i) 2x2x0.75
FS Cables 2402PIFFH
Jinro 60V RCOP(IS)
Earthing prongs
4. Connect the power cable in place at the Interface Board within the Control Unit.
Connect the wires in to the Junction Box Communications and Power Input terminals.
2. Feed the cable through a metal EMC gland, e.g. Lapp Kabel Skintop MS-SC-M-XL range,
ensuring that the metal prongs make contact with the exposed cable screen as shown
below
4. Connect the wires in to the Junction Box terminals as detailed in the table below and
tighten the gland.
1. Remove the adhesive label covering the access port to the address switches.
2. Use an instrument screwdriver to set the switches.
The left-hand switch sets the TENS, the right hand switch sets the UNITS.
3. Detectors are supplied with the switches set to 00 as factory default.
4. The Detector addresses must be sequential and should run in sequence from engine
to engine, i.e. if the last Detector head on the first engine is address 08, then the first
Detector head on the second engine must be 09. It is essential that if Detector heads
are removed for overhaul they are returned to their original position or they must be
re-addressed.
5. Clean the Detector head in the area around the address switches and indicator lights
with wet and dry wipes to ensure any oil or grease is removed. Attach the switch
window label so that both the indicator lights are visible through the clear window and
the switches are covered by the opaque area. Ensure the label is fully adhered to
maintain the IP65 rating of the Detector and the product guarantee.
6. The engine/cylinder number and address should be written on the invalidate
guarantee label in the position shown.
2.3.2 Check that the Detector addressed 01 is connected to the Detector 1 position in the Junction
Box, and the Detector addressed 02 is connected to the Detector 2 position in the Junction
Box etc. Ensure that the pink and brown wires from the last Detector are connected in to
the EOL terminals in the Junction Box.
2.3.3 Ensure that the Communication and Junction Box power supply cables are connected
correctly at the Junction Box (refer to section 2.2.3).
2.3.4 Check the cable run of the Communication and Junction Box power supply cables back from
the Junction Box to the Control Unit to ensure that they are not damaged.
2.3.5 Ensure that the Communication and Junction Box power supply cables are connected
correctly at the Control Unit.
2.3.6 Ensure that the Engine Slowdown/Shutdown, Main Alarm and Fault Alarm relays are
connected correctly at the Control Unit.
b. Push the nylon pipe of the smoke tester into the connector on the side of the Detector
base body (refer to Figure 45).
c. Dip the wick into the bottle of smoke oil and reseal the bottle firmly
Note: Only a small quantity of oil is required.
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.
f. Observe the wick is still smouldering, insert nylon pipe into the pipe connector of the
Detector and squeeze the pipette bulb.
g. After tests are completed the MAXIMUM ACTUAL AVERAGE, DETECTOR PEAK
LEVEL and current AVERAGE readings should be erased. This can be done via the
Configuration option in the Engineer Main Menu then using CLR. Maximum Average and
CLR Peak & Average.
h. To release the pipe from the connector, press in the blue plastic collar on the end of the
connector at the same time as pulling the pipe out
i. Remove the nylon pipe from the pipe connector for stowage purposes.
j. The wick is reusable and can be left in the wick holder. Fully extinguish the wick after use
at all times.
k. Refer to the Material Safety Data Sheet in the event of health or safety issues.
The User access level allows for READ only. No adjustments are possible but all data and
settings can be read.
The Engineer access level is password protected and allows the system to be configured and
read. It also allows the alarm settings to be adjusted. The system is supplied with a default
password, but it can be altered to suit individual operators. The default password will always
remain active for emergency.
The Engineer access level, when selected, a prompt for a password will appear. Enter
0.1,2,3,4,5, then press
Message Priority
Alarm Highest
Comms. fault 2nd highest
Sensor fault 3rd highest
System fault 4th highest
All events are stored in the alarm/fault queue in order of occurrence. The user can scroll
through the queue by use of the arrow keys.
Once an event is active the event is displayed on the LCD in the appropriate format. To clear
the display press the ACCEPT key. Once the ACCEPT key is pressed, the display shows the
ENGINE AVERAGES display.
When an alarm condition exists, the following warning message is displayed regardless of
other information on the display (i.e. alarm events have the highest priority): DEVIATION
ALARM.
2.5.3 Isolation
If required it is possible to isolate any individual Detector, all Detectors on a complete engine
or the engine slow down relays. This allows maintenance to be carried out without affecting the
remaining system. Isolation inhibits all alarms and faults for the isolated item except the
Backup Alarm, which is a fixed level.
Engine Isolation
To isolate all of the Detectors on one particular engine, access the MAIN MENU and select
ENGINEER. Enter either the default password or own unique password if this option has been
used.
1. When in the engineer menu, press key number 3 to highlight ISOLATE and then press the
key.
2. Once in the isolate menu, select 1 ENGINE, press the key and the display will show the
number of engines configured with the word DE-ISOLATED beside each one.
3. Using the ▲ and ▼ keys, highlight the engine required and press the key.
4. The display will show the engine selected with the words DE-ISOLATION - ISOLATE
beside it.
5. Press the ► key to highlight ISOLATE and press the key.
6. The display reverts to showing the number of engines configured, but the selected engine
will have the word ISOLATED flashing beside it instead of DE-ISOLATED.
7. The three lights marked ISOLATE, DETECTOR ISOLATE and ENGINE ISOLATE all
come on.
8. To de-isolate, repeat the above until you reach the display that shows DE-ISOLATION -
ISOLATE (step (4)) beside the selected engine and as DE-ISOLATED is highlighted
press the key and the Detectors on the engine return to normal operation.
9. To return to the normal menu press the ← key once and then the MAIN DISPLAY key.
and the screen returns to showing all Detectors de-isolated and the lights will go off.
11. To return to the normal screen, press the ← key once and press the MAIN DISPLAY key.
Warning: Carrying out test 8. with the engine operating will cause the engine
shut/slow down system to operate if connected.
4. Approximately 3 seconds after the test is initiated the internal sounder will operate for 1
second.
5. After approximately 25 seconds, on successful completion of the test, the display will
return to the Test Menu.
6. This test is now complete. The operator can now either Press the MAIN DISPLAY key
and return to the normal display or select another test option.
This test is automatically performed every 24 hours at 16:00 with respect to the OMD
Control Unit clock.
1. Press the Main Menu key on the Control Unit and select ENGINEER by using the ▼ down
key or the number 2 key.
2. Press the enter key and enter the password when prompted, when entered press the
enter key again.
3. The display will show 7 menu headings defaulted to No. 1 Configure System. Press the
No.4 key or the ▼ down key 3 times to highlight No.4 TEST
4. Press the enter key and 8 test menus will show on the display defaulted to No.1 Alarm
Relay. Press the No.8 key or the ▼ down key 7 times to highlight SLOWDOWN RELAY
5. Press the enter key and the display shows the following defaulting to Engine 1 which will
be highlighted:
RELAY TEST MENU
ENGINE 1 TEST OFF
Note: The number of engines shown is dependent on how many are configured up to a
maximum of 8. However, ENGINE 1 is highlighted as the default setting.
7. Press the ► right key to highlight Activate and the press enter key, the display will show
the following with the words TEST ON flashing.
RELAY TEST MENU
ENGINE I TEST ON
8. The Slowdown relay changes state and all alarms connected to the relay operate, also the
test light on the Control Unit comes on.
9. To cancel the alarm press the enter key and the display will be as step (6) above with
DE-ACTIVATE highlighted.
10. Press the enter key again and the display will be as step (5) above and the test light on
the Control Unit will go out.
11. Press the ← quit key to return to the test menus or the Main Display and RESET to return
to the normal display.
2.7.2 The event log may also be downloaded onto a computer using the serial link connector on the
main processor PCB.
1. Plug serial lead into Com1 on PC and plug in to the round serial connector on the Control
Unit.
HyperTerminal Setup
TM
2. From the Windows start button choose:
TM
3. This should bring up the following box or something similar depending on Windows
version, Windows XP is shown.
4. Type in a name, e.g. OMD6, and choose one of the icons then click ok.
5. In the ‘Connect using:’ drop down box select Com 1 and click ok (note if com 1 is being
used for another application Com 2 can be selected if the pc has 2 communications
ports).
6. This should bring up the following settings screen.
9. From the top level menu select Transfer-> Capture text and in the file box type where you
want the file to be saved and what name e.g. C:\omd.txt then click on the start button.
10. At the Control Unit, go through the menu structure and choose Download Event Log,
then select enter. You should now see the event log downloading into the white panel of
the above screen.
11. When the event log has finished downloading select Transfer-> capture text -> stop.
12. Then using Word, WordPad or Notepad you can examine the event log by loading up
C:\omd.txt.
If you want to do another event log download in the future, launch HyperTerminal from the
start bar as normal and in the first screen there should be a new icon called omd6.ht (if that is
what you called it). Simply double click on this icon and HyperTerminal will be launched with all
the correct settings and the connection to Comm port 1 already established. After that the only
thing that needs setting up is the transfer capture to save the event log.
1-43682-K108-XXX
1-43682-K109-XXX
3. Using a 4mm hexagon key, unscrew 2 off screws from the underside of the Detector head
(refer to Figure 52). The screws are self-retaining.
Caution: Do not press the fan, only handle the outer housing !!
5. Using the Pulling Tool (refer to Figure 54), remove the Fan Retaining Plug by capturing
the shoulder and pulling. Carefully remove the Fan from its mountings (refer to Figure 55).
Caution: Do not press the fan, only handle the outer housing.
12. Reassemble the Detector head and base body. Replace the Detector and then de-isolate.
13. Repeat the procedure for all Detectors to be cleaned.
Refer to the Materials Safety Data Sheet in the event of health or safety issues.
3.5.5 Control Unit Engine Shutdown / Slowdown Alarm, Common Alarm or Fault Relay Cable
Replacement
1. Switch off the system.
2. Disconnect the damaged relay cable from the Control Unit.
3. Disconnect the damaged relay cable from the monitoring equipment.
4. Connect the replacement relay cable to the Control Unit ensuring it is screwed in place.
5. Connect the replacement relay cable to the monitoring equipment.
6. Switch the system on and allow it to initialise.
1. Switch off the system and replace the Main PCB as follows:
2. Remove all connectors, PLG1, PLG2, PLG4, PLG5, PLG8, PLG9 and PLG1O noting the
orientation.
3. Remove 8 off fixing screws. Remove the PCB. Remember to follow antistatic precautions.
4. Fit the replacement PCB with the 8 off screws, re-fit all connectors.
5. Switch on system and allow it to initialise.
6. Re-program the system to the required configuration.
Note: After changing the Processor PCB, it may be necessary to adjust gain control
R2 to ensure the clarity of the LCD.
3.6.2 8 Engine Status Display PCB Replacement. Part No. 1-44782-K098 (refer to Figure 61)
1. Switch off the system and remove the 8 Engine Status Display PCB as follows:
2. Remove the two connectors located on the top left hand side of the board, noting the
orientation.
3. Remove 6 off fixing screws and remove the PCB.
4. Fit the new PCB with the 6 off screws and replace the two connectors.
5. Switch the system on and allow to initialise.
3.6.3 Interface PCB Replacement. Part No. 1-44782-K183 (refer to Figure 58)
1. Switch off the system and replace the PCB as follows:
2. Remove all connecting wires noting their positions.
3. Remove 8 off retaining screws and remove the board.
4. Fit the replacement board in place with the 8 off screws.
5. Re-fit all connecting wires.
6. Switch the system back on and allow to initialise.
3.6.4 Status Display PCB Part No. 1-44782-K102-02 (Refer to Figure 62)
1. Switch off the system and remove the Status Display PCB as follows:
2. Remove the Main Control Processor PCB. (Refer to para 3.6.1)
3. Remove the connectors from the Status Display PCB, noting the orientation.
4. Remove the 4 off fixing screws and remove the PCB.
5. Fit the replacement PCB with the 4 off screws and re-fit the connectors.
6. Re-fit the Main Control Processor PCB.
7. Switch on the system and allow to initialise.
1. Switch off the system and remove the Junction Box PCB as follows:
2. Remove the lid from the Junction Box.
3. Disconnect all of the wires, noting their positions.
4. Remove the 4 off screws securing the board in the box and remove the board, noting the
position of Detector 1.
5. Fit the new board ensuring that Detector 1 is in the same position on the new board as the
removed board and secure with the 4 off screws.
6. Reconnect all the wires and replace the lid.
7. Switch the system on and allow to initialise.
3.11 DECOMMISSIONING
All the components of the Graviner MK6 OMD system may be disposed of as
electrical/electronic equipment waste. i.e. using waste disposal methods in accordance with
current local waste disposal regulations.
4.1 GENERAL
The table below lists a series of failure modes and the likely faults that would be indicated
should that failure mode appear. Also listed are Actions, numbered 1 to 19, which should be
followed if the associated fault appears. On the following pages, Actions 1 to 19 are shown as
flow charts which will assist with fault finding on the Graviner Mk.6 OMD system
Back-up Alarm Fault Backup Fault The back-up signal was not 9.
received at the Control Unit
False Deviation Alarm Deviation Alarm Incorrect deviation alarm setting 12.
No Detectors Detected
No Detectors connected.
On power up a comms fault is Comms Fault 14.
Failure of panel Interface Card
indicated for all Detectors
N
With a digital voltmeter set to DC volts, measure the voltage across each of the SUPPLY IN 24v and 0v
terminals. Are the SUPPLY IN’s voltage between 18v dc and 31.2v dc?
No Yes
Check supply fuse. Check that Is the voltage at IC5 pins 2 and 4 on the
there is no short across the supply Interface Board (P/N 1-44782-K183),
terminals. Replace blown fuse or between 4.75 and 5.25v dc?
faulty cable
No Yes
No Yes
Has the detector been set the the correct address, e.g.
detector 3 is set to 03.
No Yes
No
Yes
No Yes
Replace Junction
Box to Detector Replace the detector
cable.
No Yes
Remove the local junction box cover. Remove the local junction box cover.
Using a DVM is the voltage from the fuse to 0v Is the last detector connected to the end of line
between 18 and 31.2v d.c? resistor
No Yes No Yes
Remove the
Replace panel to Connect the last communications
Replace junction box
junction box power detector in to the end cable from the panel.
board
supply cable. of line terminals Is the voltage
between pins 4 and 3
of the cable
connector >0.2v?
No Yes
Replace panel to
junction box Replace junction box
communications board
cable
No Yes
No Yes
Replace the fan and fan connector. Replace the fan and fan connector.
Fix the detector to the detector base. Fix the detector to the detector base.
De-isolate the detector and press De-isolate the detector and press
reset. reset.
Replace the detector, if the detector After pressing the reset button
fault is not cleared after the another optics test is automatically
automatic retest. completed.
No Yes
No Yes
No
Check connections in
the Junction Box
Replace detector
No Yes
Check that the alarm limit for this Increase the deviation alarm limit for
detectors has not been set too low. the detector accordingly.
N
Check that LED’s D15 and D33 on the Interface Board, (P/N 1-44782-K183), are on.
Yes No
Is the voltage at IC5 pins 2 and 4 on the Are the ship supply fuses intact?
Interface Board, (P/N 1-44782-K183),
between 4.75 and 5.25v dc?
Yes No Yes No
No Yes
No Yes
Replace
Replace the
thecontrol
control
Follow Action 2 panel
panel interface
interfaceboard
board
P/N44782-K183
1-44782-K183