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BRANNSTROM CleanTrack 1000 B User Manual

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Brannstrom Sweden AB
Uddevallagatan 14
416 70 Gothenburg, Sweden
Tel: +46 (0)31 195600
Fax: +46 (0)31 197790
Email: info@brannstrom.se
Operations and Technical manual for
Oil Discharge Monitoring Equipment
CleanTrack 1000 B
(Revision 2.20xd for Software version 2.20x)

Table of Contents

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BRANNSTROM CleanTrack 1000 B Specifications

General IconGeneral
BrandBRANNSTROM
ModelCleanTrack 1000 B
CategoryMeasuring Instruments
LanguageEnglish

Summary

1. Introduction

2. Important Notes

2.1. Component Replacement/Repair

Guidance on replacing and repairing critical components.

2.2. Disclaimer and Conditions

Information provided by Brannstrom Sweden AB and manual usage.

2.3. Main news in software version 2.20x compared to version 2.12.

Highlights new features in software version 2.20x.

2.4. Updates in this manual.

Details changes made in the manual compared to previous versions.

3. Specification

3.1. Description

Overview of the CleanTrack 1000 B system and its purpose.

3.1.1. Function and main parts

Explanation of the system's purpose and its primary components.

3.1.2. Measuring principle

Details the light transmission and scattering principle used for measurement.

3.2. Scope of Supply and System Supplies

Lists the components included in the CleanTrack 1000B system.

3.2.1. Parts always included in the Analyzing unit

Specifies components that are always part of the Analyzing unit.

3.3. System Interfaces

Lists electrical interfaces and signal setups within the system.

4. Installation

4.1. Computer Unit

Mechanical and electrical installation details for the computer unit.

4.1.1. Mechanical

Details for mounting the computer unit.

4.1.2. Electrical

Electrical connection and power requirements for the computer unit.

4.2. Converting Unit

Mechanical and electrical installation for the converting unit.

4.2.1. Mechanical

Mounting guidelines for the converting unit.

4.2.2. Electrical

Electrical connections and power supply for the converting unit.

4.3. Analyzing Unit

Details on installing the analyzing unit.

4.3.1. General drawings

Provides general arrangement drawings for the analyzing unit.

4.3.2. Mechanical

Mechanical mounting instructions for the analyzing unit.

4.3.3. Electrical

Electrical connection details for the analyzing unit.

4.3.4. Inlet probe and Outlet stub

Installation requirements for sample inlet probes and outlet stubs.

4.3.5. Piping of Sample Inlet and Outlet

Guidelines for sample inlet and outlet piping.

4.3.6. Piping for Fresh water (Option)

Installation details for optional fresh water piping.

4.3.7. Piping for Air motor (Air motor option only)

Details on piping for the air motor option.

4.4. Flow meter and Speed log

Information on flow meter and speed log requirements.

4.4.1. Flow meter general

General requirements and selection criteria for flow meters.

4.4.2. BRANNSTROM standard flow transmitter.

Details on the standard flow transmitter used by Brannstrom.

4.4.3. Speed log general

General requirements for the speed indication system.

4.5. Paper Printer

Details regarding the optional paper printer module.

4.6. Response time calculations

Explains how to calculate system response times and provides examples.

4.7. First Start up Checklist

A step-by-step checklist for initial system startup.

4.8. Pressure alarm settings

Guidance on setting pressure alarm limits to protect the sample pump.

4.9. Zener Barrier Instructions and Replacement

Instructions for handling and replacing Zener barriers.

4.10. Measuring Cell Instructions and Replacement

Procedures for installing and replacing the measuring cell.

4.10.1. Measuring Cell replacement (CTB10032)

Step-by-step guide for replacing the measuring cell.

4.11. Calculations on intrinsically safe arrangements

Guidance on demonstrating intrinsically safety margins for the installation.

5. Start/Stop procedure

5.1. General information before Start-up

Key safety and preparation points before starting the system.

5.2. Start-up procedure

Detailed steps for starting up the sample pump and system.

5.3. Close down procedure

Steps for safely shutting down the system.

5.4. Closing down for a longer time or preserving for sub-zero conditions

Procedures for extended shutdown or protection against freezing.

6. Menu operations

6.1. Main Menu and Top of Page indications

Overview of the main menu and status indicators.

6.2. Edit Numeric values

How to change numerical settings using the interface.

6.3. Keys

Explanation of the function of various keys on the interface.

6.4. Password

Information on accessing functions using passwords.

6.5. Measuring Cell - Indications and Keys

Details on the indicators and keys on the Measuring Cell front.

7. Menu layout

7.1. Main Menu

Overview of the main menu options and their functions.

7.1.1. Start page

Description of the default screen shown after inactivity.

7.2. Operation

Details on operating the system and its various modes.

7.2.1. Running

Information displayed and settings for the 'RUNNING' mode.

7.2.2. Running Settings

Configuration options before starting a discharge.

7.2.2.1. "Discharge line"

Selection of the discharge line for operation.

7.2.2.2. "Oil type"

Selection of oil type, including bio-fuel blends.

7.2.3. Manual Override

Allows insertion of manual values during equipment malfunction.

7.2.4. Status

Displays system status for immediate discharge readiness.

7.3. Alarm Table

Lists and explains system alarms and their status.

7.4. Recorded data

Information on how recorded data is stored and managed.

7.4.1. Recorded data examples

Examples of recorded data lines and their meanings.

7.5. USB

Information on using USB memory sticks for data transfer.

7.5.1. USB-Memory stick

Details on attaching and recognizing a USB memory stick.

7.5.2. Save Printouts on USB stick

Procedure for saving printouts to a USB stick.

7.6. On-board Test

Describes functional tests to verify system operation.

7.7. Measuring Cell Check/Calibration

Procedures for checking and calibrating the measuring cell.

7.7.1. Zero Calibration Status

Indicates the zero calibration status of the connected measuring cell.

7.7.2. Zero Calibration Prepare

Prepares the system for zero calibration using manual or auto flush.

7.7.3. Zero Calibration Take Zero

Initiates the zero calibration process for the measuring cell.

7.7.4. Replace Measuring Cell

Instructions on how to replace the measuring cell.

7.8. Setup of parameters

Allows configuration of various system parameters.

7.8.1. Line of discharge

Configuration of discharge lines and overboard valve control.

7.8.2. ZF1 (Zener barrier flow input 1)

Setup for Zener barrier flow input 1.

7.8.3. ZF2

Setup for Zener barrier flow input 2.

7.8.4. CVF

Setup for CVF flow input.

7.8.5. Pressure

Configuration of pressure settings and alarms.

7.8.5.1. Static Pressure/Water function

Explains pressure alarm functions for sample and water.

7.8.6. Motor (Optional Extended Converting unit I/O PCB)

Settings for optional motor features on the converting unit.

7.8.7. Speed

Configuration of speed input sources and limits.

7.8.8. System Configuration, Standard

Standard system configuration settings.

7.8.9. System Configuration, Alarms&Extras

Configuration of alarms and extra system features.

7.9. Computer

Details about the computer unit's functions.

7.9.1. USB-Memory stick

Instructions for using USB memory sticks.

7.9.2. Real Time Clock

Setting the system's real-time clock.

7.9.3. IP-address

Configuration of static or DHCP IP addresses.

7.9.4. Touch Screen Calibration

Procedure for calibrating the touch screen display.

7.10. System Check

Procedures for checking system communication and components.

7.10.1. Main

Overview of printed circuit boards in the system.

7.10.2. Test

Enables manual activation of relay outputs for testing.

7.10.3. GPS (NMEA 0183 receiver)

Displays transmitted NMEA sentences from the GPS.

7.10.4. Paper Printer _(Optional)

Details about the optional paper printer module.

7.10.5. Expiry (Trial period)

Information on the trial period and its activation/deactivation.

7.10.6. Power (Computer unit Power supply)

Details on the computer unit's power supply.

7.10.7. CUIO (Computer unit I/O PCB)

Information on the Computer unit's Input/Output PCB.

7.10.8. CVCT/Standard (Converting unit I/O PCB)

Information on the Converting unit's Standard I/O PCB.

7.10.9. CVCT/Extended (Optional Extended Converting unit I/O PCB)

Information on the optional Extended Converting unit I/O PCB.

7.10.10. ZBCT (Converting unit Zener Barrier PCB)

Information on the Converting unit's Zener Barrier PCB.

7.10.11. MC (Measuring Cell)

Displays readings from the measuring cell.

7.10.12. External Modbus RTU (Optional CUIO)

Details on optional Modbus RTU communication.

7.11. Approvals

Displays the approvals granted to the CleanTrack 1000B unit.

8. Fault-finding

8.1. Malfunction of Computer/Converting unit

Troubleshooting steps for computer or converting unit malfunctions.

8.2. List of displayed alarms

A comprehensive list of system alarms and their descriptions.

8.3. System file errors

Troubleshooting for errors related to system files.

8.4. System communications errors

Troubleshooting for communication errors between system components.

8.5. External sensor alarms

Alarms related to external sensors like GPS and flow meters.

8.6. Measurement alarms

Alarms triggered by measurement results exceeding limits.

8.7. Measurement sample alarms

Alarms related to sample pressure and water conditions.

8.8. Paper Printer alarms

Troubleshooting for issues with the optional paper printer.

8.9. Extended Converting unit Motor alarms (Optional)

Optional motor alarms for the extended converting unit.

8.10. Miscellaneous Sample pump and Overboard Valve alarms.

Alarms related to sample pump feedback and valve status.

8.11. Indications on PCB's

Visual indicators on the various PCBs of the system.

8.11.1. Computer unit I/O PCB indications

LED indicators on the Computer unit I/O PCB.

8.11.2. Converting unit I/O PCB indications

LED indicators on the Converting unit I/O PCB.

8.11.3. Extended Converting unit I/O PCB indications (Optional)

LED indicators for the optional Extended Converting unit I/O PCB.

8.11.4. Zener barrier PCB indications

LED indicators on the Zener barrier PCB.

9. Maintenance, Spare parts and Consumables

9.1. Software upgrading

Procedure for upgrading the system software via USB.

9.2. Battery replacement

Instructions for replacing the computer unit's internal battery.

9.3. Saving Printouts and Settings on a USB memory stick

How to save recorded data and settings to a USB stick.

9.4. Periodic Checks and Servicing

Regular checks and servicing schedule for the system.

9.5. Verification of accuracy and access to restricted parts

Details on accuracy verification and restricted access to the measuring cell.

9.6. Cleaning of Inlet Filter

Instructions for cleaning the sample pump's inlet filter.

9.7. Sample Pump Shaft seal oil refilling

Procedure for refilling oil in the sample pump shaft seal.

9.8. Spare parts

Lists of spare parts for different system units.

9.8.1. Computer Unit

List of spare parts for the computer unit.

9.8.2. Converting Unit

List of spare parts for the converting unit.

9.8.3. Analyzing Unit

List of spare parts for the analyzing unit.

9.8.4. Sample pump

List of spare parts for various sample pump models.

9.8.5. Fuses

List of fuses for the power supply unit and converting units.

9.9. Recommended Spare parts

Recommendations for essential spare parts to keep on hand.

9.10. Consumables

Details on consumable items like batteries and printer rolls.

9.11. Storage before installation

Guidelines for storing the unit before installation.

10. Figures and Drawings

10.1. Computer Unit

Drawings related to the computer unit's mounting.

10.2. Converting Unit

Drawings showing the dimensions of the converting unit.

10.3. Analyzing Unit

Diagrams for various analyzing unit configurations.

10.3.1. Analyzing Unit skid with Ex. motor Sample pump

Arrangement drawing for skid-mounted Ex. motor sample pump.

10.3.2. Analyzing Unit with external Sample pump

Drawings for analyzing unit with an external sample pump.

10.3.3. Analyzing Unit with Freestanding items for External Sample pump

Diagrams for analyzing unit with freestanding external pump items.

10.3.4. Analyzing Unit with Air motor Sample pump

Arrangement drawings for analyzing unit with air motor sample pump.

10.4. SPP-100 Sample pump with Ex. Motor

Dimensional drawings of the SPP-100 sample pump with Ex. motor.

10.5. Nikuni Sample pump for Bulkhead mounting

Drawings for Nikuni sample pump mounted on a bulkhead.

10.6. Matre Sample pump for Bulkhead mounting

Drawings for Matre sample pump mounted on a bulkhead.

10.7. Connection box

Drawings for the system connection box.

10.8. Measuring Cell replacement

Diagrams related to the measuring cell replacement procedure.

10.9. GA-plans

General arrangement (GA) plans for system configurations.

10.9.1. Partnames of typical arrangement

Identifies parts in a typical system arrangement drawing.

10.9.2. GA-plan with Ex. motor Sample pump

GA plan for skid-mounted Ex. motor sample pump system.

10.9.3. GA-plan with bulkhead penetrating Sample pump

GA plan for bulkhead penetrating sample pump systems.

10.9.4. GA-plan with Air motor Sample pump

GA plan for systems with an air motor sample pump.

10.9.5. GA-plan with pilot-controlled Air motor Sample pump

GA plan for systems with a pilot-controlled air motor sample pump.

10.10. Electrical

Electrical cable diagrams for system components.

10.10.1. Electrical cable diagram for electrical Ex. motor sample pump

Cable diagram for electrical Ex. motor sample pump.

10.10.2. Electrical cable diagram for bulkhead mounted sample pump

Cable diagram for bulkhead mounted sample pump.

10.10.3. Electrical cable diagram for air motor sample pump

Cable diagram for air motor sample pump.

10.10.4. Internal cable diagram for electrical sample pump motor

Internal wiring diagram for electrical sample pump motor.

10.10.5. Internal cable diagram for Extended SPP-100 sample pump motor (Optional)

Internal wiring for optional extended SPP-100 sample pump motor.

10.11. Sample probes

Installation arrangements for sample probes.

10.11.1. Sample probes installation arrangements 1”

Arrangements for 1-inch sample probes.

10.12. Flow meter

Diagrams for the CleanTrack flow meter unit.

11. Approval Certificates

11.1. Certificate: MED-D

EC Type Examination Certificate (MED-D).

11.2. Type Approval, DNV

DNV Type Approval certificate for the system.

11.3. Type Approval, Germany

German Type Approval certificate for the system.

11.4. IMO Certificate, CCS

China Classification Society (CCS) IMO Certificate.

11.5. Type Approval, CCS

China Classification Society (CCS) Type Approval.

11.6. Type Approval, NK

Nippon Kaiji Kyokai (NK) Type Approval.

11.7. Type Approval, RMRS

Russian Maritime Register of Shipping (RMRS) Type Approval.

12. ATEX Certificates and Instructions

12.1. Declaration of Conformity

EU Declaration of Conformity for the equipment.

12.2. ATEX Certificate Zener Barrier PCB

EC Type Examination Certificate for the Zener Barrier PCB.

12.3. ATEX Certificate Measuring Cell

EC Type Examination Certificate for the Measuring Cell.

12.4. Pressure transmitter, Danfoss

Technical brochure for Danfoss pressure transmitters.

12.5. Pressure transmitter, Siemens

Manufacturer's Declaration of Conformity for Siemens pressure transmitters.

12.5.1. Declaration of Conformity

Siemens EU Declaration of Conformity for pressure transmitters.

12.5.2. ATEX Certificate

EC Type Examination Certificate for Siemens ATEX pressure transmitters.

12.6. Flow meter, Siemens

EU-Type-Examination Certificate for Siemens flow meters.

12.7. Flow meter, Fuji

EC-Type Examination Certificate for Fuji electronic pressure transmitters.

12.8. Sample Pump, SPP-100 with Elprom explosion proof motor

Instructions for Elprom explosion proof motors.

12.8.1. Elprom instructions

Detailed instructions for Elprom motors.

12.8.2. Elprom Certificate, EPT 17 ATEX 2588 X

EC Type Examination Certificate for Elprom motors.

12.8.3. Elprom Certificate, EUM1 10 ATEX 0350

EC Type Examination Certificate for Elprom motors.

12.9. Sample Pump, Speck pump with Gast air motor

Information on obtaining ATEX certificates for Speck pumps.

13. Appendix, Work shop test and Calibration Certificate

Work shop test

Contains detailed workshop test procedures.

Calibration Certificate

Includes a calibration certificate for the equipment.

14. Project specific drawings and data sheets