Flowserve ORGS 11-2 User Manual

ORGS 11-2

Installation Instructions 810801-00

Oil Detector & Alarm ORGS 11-2

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1

Contents

Page

Important Notes

Usage for the intended purpose ..................................................................................... 7

Safety note......................................................................................................................7

Danger ............................................................................................................................7

Explanatory Notes

Scope of supply ..............................................................................................................8

Description ......................................................................................................................8

Function ..........................................................................................................................8

Design .............................................................................................................................8

Technical data .......................................................................................................... 9, 10

Installation

Installation requirements ..............................................................................................10

ORGS 11-2 ...................................................................................................................10

Example of installation .................................................................................................17

Wiring

Measuring electrode ORGS 11-1 ................................................................................. 12

Wiring diagram ORGS 11-1.......................................................................................... 12

Standard settings

Factory setting ..............................................................................................................13

Switch selection of measuring range ........................................................................... 13

Commissioning

Danger ..........................................................................................................................14

Check wiring ................................................................................................................. 14

Apply mains voltage ..................................................................................................... 14

Operate valves.............................................................................................................. 14

Operation

Normal operation, oil alarm ..........................................................................................14

Annex

Danger ..........................................................................................................................15

Fault finding list............................................................................................................. 15

Declaration of conformity.............................................................................................. 16

2

Dimensions

100

Fig. 1

15

70

45

8.5

60

100

~586

~730

~335

8

30

11

30

~96250

3

Design

A

G

F

B

E

B

C

D

Fig. 2

4

Design

H

I J

2

4

1

3

5

Fig. 3

Fig. 4

K

L

M

N

O

5

Key

1

LED “Oil alarm”

2

LED “Oil alarm”

3

LED (without function)

4

LED (without function)

5

Code switch “Measuring range”

A

Measuring electrode ORGS 11-1

B

Supporting flange

C

Drain valve (ball valve DN 12 L, PN 500)

D

Supply valve (ball valve DN 12 L, PN 500)

E

Non-return valve (ball valve DN 10 L, PN 500)

F

Deaerator

G

Sealing plug with lateral vent hole

H

Housing screws M4

I

Cable entry M16 x1.5 / M20x1.5

J

Housing cover

K

Plug

L

Thermal fuse T

M

Terminal strip ‘Test’

N

PE connection

O

Terminal strip

6

max

102 °C

Important Notes

Usage for the intended purpose

Use oil detector & alarm ORGS 11-2 only for signalling ingress of oil in cooling
water circuits.

Safety Note

The equipment must only be installed by qualified staff.
Qualified staff are those persons who – through adequate training in electrical

engineering, the use and application of safety equipment in accordance with
regulations concerning electrical safety systems, and first aid & accident prevention –
have achieved a recognised level of competence appropriate to the installation and
commissioning of this device.

Danger

When loosening the electrode hot cooling water might escape. This
presents the danger of severe scalding. It is therefore essential not to
dismantle the measuring electrode ORGS 11-1 unless the boiler pressure
is verified to be zero.

The terminal strip of the measuring electrode ORGS 11-1 is live during
operation.

This presents the danger of electric shock. Cut off power supply before
mounting/removing the housing cover.

7

Explanatory Notes

Scope of Supply

ORGS 11-2

1 Oil detector & alarm ORGS 11-2, PN 6
2 Sealing plugs for cable entry
1 Installation manual

Description

The oil detector & alarm ORGS 11-2 works according to the conductivity
measurement principle. The ORGS 11-2 has a switching controller integrated in its
terminal box which controls all functions. External switchgear is therefore not required.
A control and alarm system installed downstream of the equipment protects the
installation to be cooled and prevents ingress of oil.
The equipment features two channels and the contact relays are of the normally
closed type and will automatically signal alarm condition in the event of a malfunction.

Function

A water sample, taken downstream of the location at the highest point where ingress
of oil might occur, is fed from below into a measuring pot (see fig. 13 and 14,
page 17).

In the measuring pot the water-immiscible oil droplets precipitate and ascend, thereby
forming an oil film which forces the water level to drop accordingly.

The lowering of the water level is detected by the electrode rods since the oil, which is
non-conductive, interrupts the current flow between the two long and two short
electrode rods. Two volt-free relay contacts in the terminal box assess the information
and, if required, trigger an alarm and operate the associated switchgear.

The amount of oil necessary to raise an alarm depends on the design of the
measuring pot and the length of the electrode rods. The measuring pot is matched to
the electrode such that an alarm is given when the oil content limit of approx. 50 ml is
reached. The system can detect practically all insoluble, water-immiscible, non­emulsified matter with a lower density than water and a conductivity below the preset
response sensitivity.

Note

■

Rust preventing oils that are for instance emulsified in the cooling water
will not raise an alarm.

Design

ORGS 11-2:

Equipment module with three isolating valves and deaerator ready for connection,

Fig. 2
ORGS 11-1:

Measuring electrode as replacement for equipment module ORGS 11-2

8

Explanatory Notes – continued –

Technical Data

Oil detector & alarm ORGS 11-2
Test approval

ORGS 11-2: GL 17106-00 HH

Admissible service pressure

6 barg (87 psig)

Admissible service temperature

110°C (230 °F)

Flow velocity

100 – 300 l/h, recommended 200 l/h

Pressure drop

0.06 bar (under test conditions)

Raising of alarm

Oil content limit: approx. 50 ml

Water inlet, draining,

Ball valve, screwed EO 12 L

Water outlet

Ball valve, screwed EO 10 L

Weight

Approx. 7.4 kg

Electrode ORGS 11-1 (component of ORGS 11-2)
Connection

Screwed 1" BSP (DIN ISO 228-1)

Materials

Body: G AlSi8Cu3
Stem: 1.4571 CrNiMoTi 17 12 2
Electrode rods: 1.4571 CrNiMoTi 17 12 2
∅ of measuring electrodes: 5 mm

Protection

IP 65 to DIN EN 60529

Admissible ambient temperature

70 °C

Cable entry

Cable glands with integral cable clamps
M 16 x 1.5 (PG 19)
M 20 x 1.5 (PG 16)

Mains supply

115/230 V ± 10 %, 50/60 Hz
The transformer is of the split-bobbin
type according to VDE 0551

Special voltage

24 V ± 10 %, 50/60 Hz

∆∆

∆p

∆∆

v

9

Explanatory Notes – continued –

Technical Data – continued –

Power consumption

5 VA

Fuse

Thermal fuse T

Sensitivity

Range 1: 10 µS/cm
Range 2: 0.5 µS/cm
Code-switch selectable

Electrode voltage

10 V

ss

Outputs for control circuit

Two volt-free relay contacts,
contact material AgNi 0.15 hard gold plated.
Max. contact rating with switching voltages of 24/115/230 V a.c. 8 A resistive/
inductive.
Max. contact rating with a switching voltage of 24 V d.c.: 8 A

Energizing and de-energizing delays

3 seconds, factory set

Indicators and adjustors

Two red LEDs to indicate
“Electrode rod submerged and
output relay energized” status: “No ingress of oil”
One four pole code switch for
selection of sensitivity range

= 102°C

max

Installation

Installation requirements

The water sample taken from the cooling water cycle must flow continuously
through the oil detector & alarm ORGS 11-2. We recommend a flowrate of 200 l/h.

The sampling of the cooling water should take place downstream of the location of
a potential oil leakage at the highest point and, if possible, in a horizontal line.
Since the oil flows in the upper part of the pipe we recommend the installation of a
welding pocket according to DIN 2618 for collecting the oil droplets. The line
leading to the measuring pot of the ORGS 11-2 should be vertically ascending,
running directly into the bottom part of the measuring pot. Avoid any narrow parts
in the supply line since they could give rise to undesired emulsification of the oil.

If space is a consideration and the measuring pot has to be installed at a lower
point make sure that the line leading to the measuring pot features sufficiently
sized bends in order to prevent emulsification.

10

Installation – continued –

Installation requirements – continued –

To achieve the recommended flowrate of approx. 200 l/h provide the main cooling
water line with a standard orifice plate in order to throttle the flow velocity between
the water sampling location and its re-entry point.

The pressure drop
The pressure drops of the connecting lines depend on the design and layout of the

installation and must be ascertained individually. The calculated resistance
coefficient ζ can be used to determine the opening ratio and, consequently, the
required diameter d for the opening of the standard orifice plate.

For more information on the sizing and layout of fluid dynamic systems please refer
to the corresponding technical literature and relevant standards.

ORGS 11-2

∆∆

∆p

across the measuring pot is 0.06 bar.

∆∆

v

1. Use supporting flanges to install the oil detector ORGS 11-2 in a suitable place.

B

2. Connect the supply line, the return line and the drain line with the cutting ring
screwed unions of the ball valves in a pressure-tight manner.

3. Close ball valve and open ball valves and . If the cooling water line is under
pressure the rapid-action deaerator will vent the ORGS 11-2.

C D E

F

Note

■ Please pay attention to the examples of installation on page 17

(figs. 13 and 14).

Tools

■ Open-end spanner, 22 mm A. F., to DIN 894

■ Open-end spanner, 27 mm A. F., to DIN 894

11

Wiring

Measuring electrode ORGS 11-1

Use multi-core flexible control cable with min. conductor size 1.5 mm² for wiring.

1. Undo screws and remove the housing cover , Fig. 3

2. Unscrew union nuts of cable entries .

3. Slacken plug with 17 mm open-end spanner but do not remove it. Fig. 4

H

I

K

J

The electrode terminal can be turned through +/– 180°.

4. Turn electrode terminal into desired direction (+/– 180°).

5. Tighten plug slightly.

6. Remove terminal strip from board.

7. Connect terminal strip according to wiring diagram, establish PE connection.

K

H

N

8. Plug in terminal strip.

9. Mount housing cover , fasten screws and install cable entry .

J

H

I

Wiring diagram

Fig. 5

Position of contacts: de-energized, alarm, LEDs 1 and 2 not illuminated

Tools

■ Screwdriver for cross head screws, size 1

■ Screwdriver for slotted screws, size 2.5, completely insulated according to

VDE 0680

■ Open-end spanner 17 mm A. F. to DIN 894

12

Standard Setting

Factory setting

The equipment features the following factory set default value:

■ Measuring range ≥ 10 µS/cm

Switch selection of measuring range

The measuring range can be switch-selected between ≥ 0.5 µS/cm and ≥ 10 µS/cm
by means of a code switch :

1. Undo screws of the electrode terminal and remove housing cover , fig. 3.

H

5

J

Code switch 1 - 4 OFF Measuring range ≥ 0.5 µS/cm

Code switch 1 - 4 ON Measuring range ≥ 10 µS/cm

2. Mount housing cover and fasten screws .

J H

Attention

■ Make sure not to damage the electronic components when setting

the code switch.

■ Do not use a pencil to set the code switch!

Tools

■ Screwdriver for cross head screws, size 1

■ Screwdriver for slotted screws, size 2.5; completely insulated according to

VDE 0680

13

Commissioning

Danger

The terminal strip of the ORGS 11-1 is live during operation.
This presents the danger of electric shock.
Cut off power supply before removing or replacing the housing cover.

Check wiring

1. Check whether the system has been wired according to wiring diagram, fig. 5.

2. Check whether mains supply is in accordance with the wiring of the equipment.

Apply mains voltage

1

1. LEDs and serve as visual checks for the operating modes, fig. 4. To check the

2

correct functioning of the LEDs remove the housing cover. See “Wiring”.

Operate Valves

E

1. Close ball valve and open ball valves and . If the cooling water line is under

C

pressure the rapid-action deaerator will vent the ORGS 11-2.

D

F

Operation

Normal operation, oil alarm

1. If the measuring pot is vented and completely filled with cooling water the red LEDs

1 2

1 and are illuminated.

2. Under certain conditions air or gases that have been dissolved in the cooling water
can accumulate in the upper part of the measuring pot. The rapid-action deaerator

F

F will automatically vent the measuring pot during normal operation.

3. If oil accumulates in the upper part of the measuring pot and the electrode rods of
the measuring electrode are completely covered with oil, an oil alarm will be raised

2

and the LEDs and extinguish.

1

4. If an oil alarm has been triggered although there is no oil in the cooling water
system, please refer to the fault-finding list on page 15.

14

Annex

Danger

The terminal strip of the ORGS 11-1 is live during operation.
This presents the danger of electric shock.
Cut off power supply before removing or replacing the housing cover.

Fault finding list

Oil alarm raised but no oil in cooling water cycle

Fault:
Remedy:

Fault:
Remedy:

Fault:

Remedy:
Fault:

Remedy:
Fault:

Remedy:

Fault:
Remedy:

Mains voltage has not been applied.
Apply mains voltage. Wire equipment according to the wiring diagram.

The thermal fuse has been triggered.
No voltage across terminal if the thermal fuse is defective.

L

Replace defective thermal fuse (stock code 051629).
The ambient temperature must not exceed 70°C.

Air or gases that have been dissolved in the cooling water have
accumulated in the measuring pot.
Check rapid-action deaerator and replace it if necessary.

The electrical conductivity is too low.
Set code switch to ≥ 0.5 µS/cm.

5

The electrode housing does not have earth connection to the boiler.
Clean seating surfaces and insert metal joint ring (of stainless steel

1.4301) D 33 x 39 to DIN 7603.
Do not insulate the measuring electrode with hemp or PTFE tape!

Electronic board is defective.
Replace board (stock code 391422).

If faults occur that are not listed above or cannot be corrected, please contact our
service centre or authorized agency in your country.

15

Annex – continued –

Declaration of Conformity

We hereby declare that the equipment ORGS 11-2 conforms to the following
European guidelines.

■ LVD 73/23/eec version 93/68/eec

■ EMC guideline 89/336/eec version 93/68/eec

which are based on the following harmonised standards:

■ LV standard DIN EN 50178

■ EMC standard DIN EN 50 081-2, DIN EN 61000-6-2

This declaration is no longer valid if modifications are made to the equipment
without consultation with us.

Bremen, 14th March 2003

GESTRA GmbH

Head of the Design Dept.

Uwe Bledschun

(Academically qualified engineer)

Key

1

1 Automatically operated rapid-action deaerator

2

2 Return valve (ball valve DN 10 L, PN 500)

3 Discharge line DN 12

3

4

4 Standard orifice plate

5

5 Main engine, diesel fuel, oil cooler etc.

6

6 Drain valve (ball valve DN 12 L, PN 500)

7

7 Supply line DN 14

8

8 Supply valve (ball valve DN 12 L, PN 500)

9

9 Measuring pot ORGS 11-1

Quality Assurance Manager

Lars Bohl

(Academically qualified engineer)

16

Examples of installation

1

Cooling water
cycle

Fig. 13

9

8

7

5

1

9

8

7

2

6

4

3

2

6

Cooling water
cycle

Fig. 14

5

4

3

17

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810801-00/503cs · © 2003 GESTRA GmbH · Bremen · Printed in Germany