M118-完工图 BOSS 05T- 107 PDF

Final Document
完工资料
Oily Water Separator

油水分离器
Model: BOSS 5T-107
FOR
武穴市建达船舶制造有限公司
59M 平台供应船
Hull No.:SO1159-1
Version (A.0)
M118
2012.09
Date: 2012-02 Oily Water Separator
Rev: V2.0 BOSS 5T-107
VOLUME I TABLE OF CONTENTS
1. SYSTEM DESCRIPTION........................................................................................................................3
1.1. Components by System................................................................................................................3
1.1.1. BOSS Oil Water Separation System ...................................................................................3
1.1.2. Separator BOSS 107 filter system.......................................................................................3
1.1.4. Electrical/Controls ..............................................................................................................3
1.2. Process Description ......................................................................................................................3
1.2.1.Process pump: ......................................................................................................................3
1.2.4.Filter.....................................................................................................................................5
1.2.5.TPH or oil content monitor ..................................................................................................8
1.2.6. Additional Post Filter ..........................................................................................................8
1.3. System Features: ..........................................................................................................................9
1.4. Optional System Features: ..........................................................................................................9
1.5. System Specifications.................................................................................................................10
2. START UP ..............................................................................................................................................12
2.1. Factory Testing/Delivery ...........................................................................................................12
2.2. Installation ..................................................................................................................................12
2.3. Power Test...................................................................................................................................12
2.4. Initial Water Filling and testing:...............................................................................................14
2.5 Separator Level Switch Test: .....................................................................................................15
2.6. TPH TEST: .................................................................................................................................16
2.7. Set Flow Rate: ............................................................................................................................16
2.8. Verify Suction:............................................................................................................................16
2.9. STARTUP CHECK LIST:.........................................................................................................16
3. TROUBLE SHOOTING:........................................................................................................................17
3.1. Solenoid Valve ............................................................................................................................17
3.2. MOV............................................................................................................................................17
3.3. Filter............................................................................................................................................17
4. OPERATION ..........................................................................................................................................19
4.1. Normal Operation......................................................................................................................19
4.2. Alarm and Action Conditions....................................................................................................19
4.3. Draining the Separator..............................................................................................................20
4.4.Factory Startup and Acceptance Test Procedures....................................................................20
5. MAINTENANCE ...................................................................................................................................21
6.PARTS LIST AND RECOMMENDED SPARE PARTS .........................................................................23
6.1. BOSS 05 ......................................................................................................................................23
6.2. BOSS 05 ......................................................................................................................................23
6.3. Class I Div I and II: ...................................................................................................................23
6.4. Monitoring Equipment (all units are the same) ......................................................................23
6.5. Piping, fittings, miscellaneous ...................................................................................................25
6.6. Filter............................................................................................................................................25
O&M Manual – Volume I ATTACHMENT 3 -CALIBRATION SHEETS ................................................26
1.系统描述 .................................................................................................................................................28
1.1 系统部件 ......................................................................................................................................28
1.1.1 BOSS 油水分离系统........................................................................................................28
1.1.2 BOSS 107 分离器过滤系统.............................................................................................28
1.1.3 TPH 监测 ..........................................................................................................................28
1.1.4 电气/控制 ..........................................................................................................................28
1.2 工作过程描述.............................................................................................................................28
1.2.1 工作泵...............................................................................................................................28
1.2.2 前置滤器............................................................................................................................29
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1.2.3 油水分离...........................................................................................................................29
1.2.4 精过滤...............................................................................................................................29
1.2.5 TPH 油份浓度计 ..............................................................................................................30
1.2.6 终滤器 ...............................................................................................................................31
1.3 系统特征 ....................................................................................................................................31
1.4 可选系统特征..............................................................................................................................31
1.5 系统规格 .....................................................................................................................................31
2.启动 .........................................................................................................................................................33
2.1 工厂测试/交货...........................................................................................................................33
2.2 安装 .............................................................................................................................................33
2.3 电源测试 ....................................................................................................................................33
2.4 初次灌水和测试.........................................................................................................................34
2.5 分离器液位开关测试.................................................................................................................34
2.6 TPH 油份浓度计测试..................................................................................................................35
2.7 设定流量： .................................................................................................................................35
2.8 检验吸口压力：..........................................................................................................................35
2.9 启动检查清单..............................................................................................................................35
3.故障排除 .................................................................................................................................................37
3.1 电磁阀不工作...............................................................................................................................37
3.2 电动阀 ..........................................................................................................................................37
3.3 系统不排放合格水到船舷外.......................................................................................................37
4. 操作 .......................................................................................................................................................38
4.1 正常操作 .....................................................................................................................................38
4.2 报警 .............................................................................................................................................38
4.3 分离器泄放 .................................................................................................................................38
4.4 工厂启动和测试步骤..................................................................................................................39
5. 维护保养 ...............................................................................................................................................40
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1. SYSTEM DESCRIPTION
The BOSS-107oil water separation system includes the following basic components:
BOSS Oil Water Separator -fluids A&B
107 Oil Water Filter Separator -fluid C
TPH Monitoring
1.1. Components by System

1.1.1. BOSS Oil Water Separation System
F-101 Pre-filter y-strainer
CV-101 Inlet check valve
S-101 BOSS Oil Separator
P-101 Main process pump
G-101 Vacuum Gauge
LS-101 Oil level switch
V-001 BOSS Separator vent manual valve
SV-101 BOSS make-up water inlet control valve
CV-102 Oil discharge control valve
F-102 Oil discharge Y strainer
FI-101 Flow indicator
V-003 Flow control valve
V-004 Oil water Pump outlet manual valve
1.1.2. Separator BOSS 107 filter system
G-102 Pump discharge pressure gauge
V-002 Polisher vent valve
F-103 Fluid “C” post polisher
G-103 Pressure gauge after polisher
CV-103 Discharge check valve
CV-104 Discharge check valve
SV-102 Discharge water control valve
SV-103 Recycle water control valve
V-106 Backwash 3-way valve—polisher inlet (in normal position)
V-107 Backwash 3-way valve—polisher outlet (in normal position)
1.1.3. TPH Monitoring

V-005 TPH clean water inlet manual valve
FR-101 TPH flow restrictor
V-009 TPH Oil water outlet manual valve
TPH-101 TPH monitor
1.1.4. Electrical/Controls
P1 BOSS Control panel
1.2. Process Description

1.2.1.Process pump:
A process pump (P-101) is mounted on the outlet of the separator which pulls
water from the oily water sump through the pre-filter (F-101) and separator
(S-101). This placement reduces the formation of mechanical emulsification.
The standard pump will pull up to 10 feet (3 meters) of negative head or vertical
suction lift and still provide the design flow through the unit. The high lift
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model can pull up to 16 feet (5 meters) of negative head. The suction of the
pump is continuously flooded with a positive head so there is no need to prime
the pump. The pump is a stainless steel centrifugal pump and therefore does not
need a safety relief valve. Depending on suction and head requirements for a
given installation, the process pump is capable of pumping more than the
designed flow through the system.
The separation system operates in a negative pressure condition or vacuum. It is
critical that ALL connections to the oil water separator are airtight and properly
sized for the installation. If the connections are not air tight, air will be pulled
into the separator or if the inlet is restrictive it will cause the unit to cycle
between fill and discharge in a less than 30-minute cycle. The larger the leak or
greater the restriction the faster the cycle time.
1.2.2. Pre-filtration:
When the unit is turned on the main process pump (P-101) pulls water from the
sump through a pre-filter screen F-101 (Y-strainer). This strainer will remove
th
particulates larger than 1/20 of an inch in any dimension. The pre-filter screen
system includes a check valve (CV-101) to prevent water from back flowing
from the system when the unit is off or in the fill/oil discharge mode. If the flow
through the system becomes reduced it could be caused by a plugged pre-filter.
To unplug the filter, remove the screen, clean it and reinstall the screen.
1.2.3. Oil-water separation:
The oil water separator (S-101) is a coalescing type gravity separator that relies
on the difference in specific gravity of oil and water. The separator will not
remove aqueous fluids or fluids that have a specific gravity of near 1.0 or higher.
The oily water flows from the pre-filter into the bottom of the separator. The
separator has an inner and outer section. The water comes up through the center
section of the separator through an oleophilic media (polyethylene or
polypropylene). The media facilitates the separation of the oil from the water to
less than 15 PPM oil by providing a surface area that attracts droplets of oil and
holds them until they coalesce into larger droplets which rise rapidly to the
surface of the water in the separator. As oil collects in the top of the separator it
displaces the water and forces the water level in the separator downward. Any
gas vapor or air that enters the separator will rise rapidly to the top of the
separator where it collects with the oil. Air or vapor that collects in the separator
will be discharged with the oil. A level sensor (LS-101) in the top of the
separator detects the water level in the separator. When the water is displaced by
the collected oil to a predetermined low level, the pump P-101 turns off, SV-102
and SV-103 close, and SV-101 and MOV-101 (if applicable) open. Makeup
water is allowed into the separator through SV-101 raising the level of water in
the separator and pushing the oil out of the separator through the oil outlet valve
(MOV-101 or CV 102). Once the water reaches the high level, LS-101 causes
SV101and MOV-101 (if applicable) to close. The main pump (P-101) turns on
and SV-102 or SV-103 opens and normal operation resumes.
During normal operation oily water entering the system flows up through the
center section of the separator and over the top of the inner section where most
of the oil is separated from the water. The water then flows down through the
outer section of the separator, which contains additional media. The pass through
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the second stage of coalescing media helps remove any residual oil and provides
discharge water in most cases with less than 10-PPM oil content. Separated
water exiting the separator comes out the bottom of the outer section and is
pumped to the filter unit.
1.2.4.Filter
The primary purpose of MEPC 107(49) was to address the monitoring and
removal of emulsified oil. A coalescing separator will not remove chemical
emulsions and will only partially remove mechanical emulsions. Some form of
post treatment is necessary.
The BOSS 117 system includes a polyglass (Model 2T-107, 5T-107 and
10T-107) or steel (Model 25T-107 and 45T-107) filter vessel designed to hold
bulk media. The BOSS system is also certified to use standard cartridge filters of
Mycelx filters. The primary types of media are activated carbon and organoclay.
Each type has advantages and disadvantages depending on your specific needs.
Carbon generally works better than organoclay for most emulsions. Organoclay
works better than carbon for any free oil, BTEX, heavy metals or turbidity. The
mix of media can be adapted to fit any specific requirement. If you have a mix
that does not fit your specific requirements or is not performing as you think it
should, call the factory and we will work with you to design a mix that meets
your specific needs.
Bulk filters have certain advantages over cartridge filters. A cartridge filter for a
2 gpm system will hold about 5 ounces of oil. The same size cartridge filter that
has been treated with Mycelx coating will hold about 1.5 lbs. of oil. The BOSS
bulk media filter for a 2gpm system using organoclay will hold about 30 lbs.
of oil or about 100 times more than a 2 gpm cartridge. The other advantage is
that the media can be adapted easily to any situation. We can put sand in the
bottom to help remove turbidity. We can mix carbon and organoclay to address a
wider variety of situations. We can use all carbon or all organoclay. The
disadvantage of the bulk filter is that changing the media is more difficult than
with a cartridge. There are certain situations where we recommend using a
cartridge filter but in most cases the system will come with a bulk media filter
loaded with a base of sand covered by organoclay.
There are 2 types of filters that are supplied. The 2 and 5 gpm systems use a
fiberglass filter with a tube that goes down the center. The inlet and outlet are
both handled through the top distributor. The 25 and 45 gpm systems use a steel
vessel with an inlet distributor at the top and an outlet distributor at the bottom.
The 10 gpm system can use either a fiberglass or a steel vessel, depending on the
situation.
The fiberglass filters are rated for 125 psig pressure. With these filters we
oversize the pumps so that the same pump will work in almost any situation. The
systems are designed to handle up to 12” mercury suction vacuum and at
approximately 80 feet discharge head.
The steel filters are rated at 40 psig pressure unless a higher pressure is
requested up front. The pumps are sized to give no more than 40 psig under
normal operating conditions. If the situation demands a high suction lift and a
high discharge head and a stronger pump is needed then a higher pressure filter
will be required to accommodate the increased pressure.
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The fiberglass filter can either be configured in a Down Flow (water goes down
through the media and up the inner tube) or Up Flow (water goes down through
the inner tube and up through the media) mode.
a. Down Flow:
1. With a down flow configuration the inlet to the filter needs to have a vent valve
so the filter can be vented during the initial fill up of the system. This valve is
only needed when the filter is filled.
2. The back pressure across the filter is lower in a down flow configuration.
3. The filter will remove more turbidity from the water than with an up flow
configuration. Since the TPH monitor picks up turbidity a down flow
configuration will result in a slightly lower oil content reading if there is any
turbidity present.
4. The organoclay will remove more oil in ad down flow configuration
5. The back pressure can be reduced by filling the filter with coarse sand (40
mesh or coarser--#20) up to about 8” above the top of the bottom strainer
basket. Do not use fine sand because it will go through the strainer and could
possibly get into the discharge valves and cause the valves to stick. If you have
more turbidity you can use more sand and less media. You should not go above
50% sand, other wise the media will not have enough time to absorb the oil
6. In a down flow configuration the top strainer is not critical.
b. Up Flow:
1. No vent valve is necessary because the filter tank will vent through the
separator.
2. The back pressure across the filter is higher than with a down flow
configuration.
3. The organoclay media does not remove the turbidity as well so if there is
turbidity in the water the TPH monitor will read higher in an up flow
configuration.
4. The filter will remove less oil
5. Coarse sand will reduce the back pressure in the filter. Once again you should
not use fine sand.
6. In an up flow configuration the system will not work without the top strainer.
Without the strainer, organoclay particles will carry over and plug up the
valves and piping.
The system will work either way but the down flow has a couple of advantages.
In order to accommodate either configuration all systems come from the factory
with the top strainer in the filter, with a vent valve and with coarse sand at the
bottom of the filter. Since the downflow configuration is considered to have
more advantages, the standard factory configuration will be downflow.
The steel filter can only be piped up one way, as marked on the filter. With
organoclay, when the system first starts the back pressure across the filter may
gradually climb. This happens because the fines in the organoclay wash through
the organoclay to the sand interface and form a layer of fines on top of the sand.
This will depend on the type of organoclay that is used and how course it is.
After a few weeks of operation, if the backpressure goes up, you should reverse
the flow and backwash up through the media. This will cause the back pressure
to come back down and stabilize. To do this remove the flexible hoses at the
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top of the filter and reverse them and then run the system as normal. After 20 or
30 minutes turn the system off and change the flexible hoses back to their
original position. You should notice a drop in the back pressure. There is no
particular time when this procedure should be done and only needs to be done if
the pressure drop is too high and the design flow is not being achieved. (NOTE:
The systems with fiberglass filters come from the factory pre-piped with the
flexible hoses. The systems with the steel filters do not come with the filter
piped up and it is the customer’s responsibility to connect the filter to the
separator if the customer wants to be able to backwash. Backwashing is not
necessary, however, it is an effective tool to reduce pressure drop and extend the
life of the media and is recommended.)
During normal operation it is not uncommon for the water to form channels
through organoclay. Channeling can cause the TPH monitor to show higher oil
content readings than it should. If the oil content climbs you can backwash the
system to remove the channeling. This can be done in the same manner used to
backwash the system. Periodic backwashing of the filter will reduce both the
pressure drop and the channeling of the media and will extend the life of the
media. There is no set time to perform this procedure. It should be done when
the media is not meeting the required removal level. If the TPH has a high oil
content reading after the backwashing then it is time to replace the media.
It is not necessary to discharge the backwash water. You are not trying to
remove anything from the filter. You are simply mixing up the media to stop
channeling or to reduce pressure drop.
Activated carbon will have a lower pressure drop than organoclay and will not
channel like organoclay. With a carbon filter you will likely not need to
backwash the filter. The advantage of organoclay over carbon is that
organoclay will absorb about 5-7 times more oil and will therefore last longer
between media changes.
c. Startup
During the initial fill of the system with water, the air in the filter has no way of
venting itself. The air is pressurized when the pump runs and pushes back to
the pump when the pump is turned off causing the pump to lose its prime. Since
a vacuum is formed in the separator the vent valve on top of the separator will
need to be opened to allow water back into the pump... Therefore the procedure
for getting the air from the filter is to run the pump until water comes out of the
filter vent valve, close the vent valve, stop the pump, open the separator and
filter vent valves, wait for the water to settle, turn the pump back on until the air
is released from the filter. Once water comes out close the valve and repeat the
process. Repeat this process as many times as needed until no more air comes
out of the filter vent valve.
d. Recharging the Media

The media will need to be replaced when the system will no longer keep the oil
content within acceptable limits. To remove the media it will be necessary to
vacuum out the media with a shop vac. The used media can generally be thrown
away in the same manner a spent oil filter is discarded or with the other
municipal waste from the vessel or facility. With organoclay it is necessary to
add coarse sand (40 mesh or coarser--#20) in the bottom of the filter to a level of
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about 8” above the top of the basket strainer. Fill the rest of the filter with media
up to about 8” from the top for the fiberglass filters and just below the top
distributor for the steel filters. With carbon, sand is optional and will help
remove turbidity if there is turbidity in the bilge. The filter should be filled to a
level of about 8” from the top for the fiberglass filters and just below the top
distributor for the steel filters.
e. Expected Resulds:
You can expect the following results from the system:
1. With no emulsions present and using organoclay in a down flow configuration,
the system will generally remove any free oil and the monitor will generally read
0 ppm. If you use an up flow configuration the monitor will read from 5 to
10ppm. Assuming no emulsions and carbon the oil content in the discharge will
be higher than organoclay.
2. The higher the volume of oil in the oily water the more oil the primary separator
will remove free oil to to <15ppm. However, with high concentrations of oil the
primary separator will pass more than 15ppm oil. The separator will handle
100% oil fro short periods of time. It will run 50% oil continuously. However, as
the oil concentration goes up so will the amount of oil in the water leaving the
separator. This is generally not a problem because the organoclay filter will take
out whatever the primary separator does not remove. The more oil in the
separator discharge the faster the post filter media will be consumed but the
system will accommodate such conditions.
3. Organoclay does not remove emulsion as well as carbon. Base on testing done
by REI, the organoclay filter removed fluid C to <10ppm, whereas carbon
removed fluid Cto <5ppm. A combination of carbon and organclay with a
sediment cartridge filter removed fluid C to <2ppm. These results will vary
depending o the type of emulsions.
1.2.5.TPH or oil content monitor

The BOSS 117 includes a Total Petroleum Hydrocarbon meter (“TPH”, also
sometimes called an Oil Content Monitor or “OCM”) as standard equipment.
This unit has the ability to automatically return non-conforming discharge water
back to the sump or bilge. The recycle solenoid valve (SV-103) and the oil in
water monitor (TPH) control the recycle action. The TPH unit is a 15 PPM oil
content alarm monitor that has been tested and approved in accordance with
IMO Resolution MEPC.107 (49). The TPH monitor is continually sampling the
process stream and is designed to react quickly to any changes in the oil content.
Normally we equips with Brannstrom BilgMon488 as standard supply
1.2.6. Additional Post Filter

An additional post filter may be required for the following purposes:
a) Remove turbidity. A sand filter can be used to remove turbidity out of the water.
If the water has an NTU of more than 35 it could cause the TPH monitor to give
a false alarm. Removal of the turbidity should help the TPH monitor provide
more accurate readings. If turbidity is a problem the most economical solution is
a post filter to remove the turbidity. The optional sand filter contains 0.45 to 0.55
mm filter sand which is designed to remove suspended particulate in the water.
b) Other.
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Filters can be used to achieve other post separation objectives, such as the
removal of iron, H2S, mercaptans, metals and other contaminants. Such other
filter options are offered on a project specific basis and will vary from project to
project. If there are space limitations, it is also possible to combine multiple
media types in the same filter vessel to create a multimedia filter.
c) Non detect oil content
It is possible to take the free oil content down to less than 1% or even non-detect.
This is generally achieved by combining an organoclay filter with a carbon filter.
1.3. System Features:

a. NEMA 4X controls and electrical
b. TEFC motor
c. Stainless Steel pump and impeller
d. Automatic operation
e. Completely self contained and operationally tested at the factory
f. IMO approval and US Coast Guard certification under MEPC 107 (49). The
system also has ABS type approval.
g. All piping is marine grade red brass, bronze fittings or stainless steel.
h. Total petroleum hydrocarbon monitoring.
i. Pressurized oil discharge with level control
j. Automatic control valves
k. Flow indicator
l. Marine grade paint coating system
m. All mounting hardware and panels are stainless steel.
n. Operates up to 30deg out of vertical for ship board application
o. Post filter for removing emulsions
1.4. Optional System Features:

a. Platform system. The platform system includes in addition to the standard
features a motorized ball valve on the oil discharge. Optionally it can also
include a stainless steel control box and armored cable.
b. Class I Div. II option. The system can be designed for a Class I Div. II
hazardous area classification. In this situation the control panel is NEMA
7X, the pump motor is explosion proof and the instruments are all properly
rated for this area classification. The electrical wiring is armored cable with
the properly approved connectors and seal offs. The standard TPH monitor
is from Northeast Controls and is in a NEMA 7X panel.
c. Class I Div I option. The system can be designed for a Class I Div I
hazardous area classification.
d. Turner Designs monitor for turbidity. The Turner monitor can also be Class
I Div II or Class I Div I.
e. If the inlet has a positive head then an MOV is required for the oil discharge.
Otherwise this feature is optional.
f. A skid is optional unless a Turner monitor is selected in which case it is
required.
g. Capacitance level switch.
h. Post separation filter; activated carbon or organoclay or sand
Page 10 of 46
1.5. System Specifications

Unit technical specification; Model: 05T-107
Specification / Treatment capacity 1.1m3/h

Height (cm) 153
Width (cm) 81
Depth (cm) 120
Dry weight (kg) 370
Filter sand (kg) 27
Organoclay/sand (.kg) 55
Pipe connection in/outlet 1/2”~1”
Common specification
Specification Value
IMO MEPC Compliance MEPC 107(49)
Test Pressure 0.33Mpa
Operating Pressure 0.11Mpa
Operating Temp Range 5~60 deg.
Max Free Oil Concentration 35%
Max Fluid “C” Oil Concentration (with filter) 6%
Oil in Water Discharge with TPH <15ppm
Max Amperage <15 amps
Design Negative Inlet Head (M) 3.5m
Level Sensor Conductance
Pump Centrifugal w SS Housing
Coalescing Media Polypropylene /HDPE
Hazardous Area Classification Nema 4X or Class I Div II
Coating Specification Epoxy /Urethane
Piping and Manual Valves Bronze/ Red Brass
Vessel Metallurgy Coated Carbon Steel
Page 11 of 46
Spare ：
ONE YEAR SPARE FOR PER SET OILY WATER SEPARATOR BOSS 05T-107
mechanical seal PC 1
solenoid coil only PC 1
disconnect switch & motor starter PC 1
fuses PC 4
lights PC 3
Page 12 of 46

2. START UP
2.1. Factory Testing/Delivery
Prior to delivery the system is tested in the manufacturers shop to verify that the system
is watertight and that all the pumps, valves, instrumentation and controls are operational.
When the system arrives at it final destination it should be carefully checked for damage
that may have been sustained during shipping. All damage should be noted and reported
to the shipping company and to the manufacturer. If replacement parts or components
are needed the manufacturer should be informed immediately.
2.2. Installation
The BOSS Oil Water Separator is a self-contained system that is fully tested and
operated under normal operating conditions at the factory. Within the system battery
limits no piping or wiring will be necessary unless the units are to be mounted separate
from each other. All that is normally required is to mount the system, make the
necessary piping connections to your application and bring power to the main panel, as
explained below. The power connections to the main power disconnect (see figure 1) are
shown on the electrical schematics attached as Attachment 5.
The unit has been set up for the proper voltage requirements at the factory as specified
by your purchasing department. Please insure that the voltage you are supplying matches
the voltage that the unit is designed to operate on. The voltage requirements are listed on
the wiring diagram supplied with the unit. This schematic is found inside the control
panel as well as within the attachment section of this manual (see attachment 5). All
piping connections to the system are listed in Attachment 2. It is critical that the
connecting pipe runs are sized to permit unrestricted operation of the unit. Piping that is
undersized can impair the operation of the system. To facilitate service and testing
procedures it is recommended that the customer install isolation valves at all piping
connections to the separator unit.
A hand valve (V-003) is included on all units just above the flow indicator
to adjust the flow so that it does not exceed the design flow rate. A flow
indicator has been installed on all newer model units. Both valves should
be positioned to keep the flow at the design rate. If the system does not
have a flow indicator we strongly suggest ordering one from the factory.
Without a flow indicator, to adjust the flow the customer will need to
measure the flow at the final discharge point. To accomplish this, fill a
known volume tank or bucket and measure the amount of time it takes to
fill it. Calculate the flow rate by dividing the tank capacity by the fill time.
Adjust the valve and repeat this process until the design flow is achieved.
The factory will provide an approximate pressure setting but the best
approach is to measure the flow into a bucket. Both the discharge and
recycle valves will need to be set the same.
2.3. Power Test
Before applying power to the unit, be sure all isolation valves to and from the system are
closed with the exception of the oil out valve after CV-102. If your BOSS unit is an “E”
series model there are no disconnects or circuit breakers. If you have a standard BOSS unit,
you will need to turn on the disconnect located on the control panel, and turn the selector
switch to on to begin operation. The “REM” position of the BOSS selector switch is for
remote on/off control. This would be for a remote controller or for a remote level switch
Page 13 of 46

in the bilge sump. The unit comes from the factory with a jumper on the REM position so
that the system will operate the same at the “ON” or “REM” positions. For any remote
operation, the customer will need to connect to the terminals provided. When the power
disconnect on the BOSS unit is turned on, the power light should come on, and the system
should go into “FILL & OIL DISCHARGE” mode. Leave the make up water isolation
valve closed until it has been verified that the pump is operating in the correct direction.
(see figure 2 on next page) The TPH monitor on the 107 unit should power up and perform
its self test mode. When the switch on the BOSS 117 is turned to ON, the recycle valve
should open and will stay open until the TPH unit senses less than 15 PPM oil content in
the water flow.
If your system is wired for 115 or 240 VAC SINGLE PHASE operation the following
procedure is NOT required. Follow this procedure ONLY if your system is wired for 3
PHASE operation. Power Test:
After the installation of power and BEFORE ANY WATER IS PUT IN
THE SYSTEM the pump should be checked for proper direction of rotation.
If pump rotation is checked after the system is filled, starting the pump in the
incorrect direction can cause the pump impeller to rotate off the motor shaft. If
this should occur the impeller could be severely damaged and the pump will
need major repair before operation. Checking rotation without water will
reduce the likelihood of this happening.
WARNING!!
An experienced and trained electrician or controls technician should do
this procedure, as potentially lethal voltages are present in the control
panel.
Page 14 of 46
Energize the pump by opening the control panel turning on the power disconnect by rotating
the disconnect shaft clockwise approx. 90 degrees. Momentarily push the contactor button
with a pencil or other non-metallic item. At the same time, watch the direction of the fan on
the rear of the pump. It should rotate in a clockwise direction as viewed from the back end
of the motor (see figure 2).
Power Connection
Disconnect Shaft
Contactor
Figure 1
Figure 2
Watch the direction of the fan on the rear of the pump. It should rotate in a clockwise
direction as viewed from the back end of the motor.
2.4. Initial Water Filling and testing:

Before the initial filling and testing isolate the supply of oily water and close the TPH
sample line valves. It is important that the system is tested BEFORE any oily water is
admitted into the separator. Verify that the clean water source has been turned on. Turn the
system switch to ON. The separator will start to fill and the Fill & Oil Discharge lights
should be on. Open the vent valve (V001) at the top of the separator. Doing this will cause
the separator to cycle between filling and discharging. Be sure to leave the sample line
valves to the TPH unit closed and turn the switch to ON. When the separator is full the fill
valve and oil discharge valve (MOV-101) will close (if your unit has the MOV option).
When the oil discharge valve is closed the water discharge valve or the recycle valve will
open and the pump will start. If the TPH Smartcell is dry, the unit will come up in a recycle
condition. Be sure to open any isolation valves that are installed on the recycle sump return
line and the discharge line.
While the system is filling leave the filter vent valve open. When water starts coming out
shut the vent valve. Let the system run for a short period of time and then shut off the pump,
open the separator and filter vent valves, wait for the water to settle, turn the pump back on
until the air is released from the filter. Once water comes out close the valve and repeat the
Page 15 of 46

process. Repeat this process as many times as needed until no more air comes out of the
filter vent valve.
During this time the entire flow will be returning back to the oily sump. Proper operation
can be verified by observing the pressure gauge located on the pump outlet. If the reading is
over 10 PSI and under 50 PSI the system is running normally. If the gauge is above 50 PSI it
is likely that a valve in the process stream is closed. If the gauge is reading less than 10 PSI
it is possible that it is not filled with water or the pump has lost its prime. To re-prime the
pump, open the vent valve V-001 until the unit goes into fill mode then close the valve and
the unit will return to normal operation.
When water is coming out of the vent, the filter is full and normal operation can begin. If
your filter is supplied with granulated activated carbon media, it will be necessary to allow
the filter unit to flush the residual dust from the media before the TPH will operate normally.
This process should take approximately 30 minutes. During this time the TPH sample lines
should remain closed. The entire stream will be diverted back to the bilge. Alternatively the
filter can also be rinsed with clean water by introducing a clean stream into the vent valve
and connecting a hose to the drain outlet and directing the flow directly overboard, the
carbon dust that is washed from the bed is not hazardous.
2.5 Separator Level Switch Test:
(No adjust is required for the level switch, the system is set at the factory)
Allow the system to run. During operation open the separator vent valve. With this
valve open the water level in the separator will cycle up and down. The low level
should not go below the bottom of the separator flange. The high level should not
discharge water from the vent when it is open. If the level switch needs to be reset
(capacitance switch only) refer to the Level Switch calibration Instruction sheet
(attachment 3) Otherwise minor adjustments can be made as follows; 1-Open the top of
the level switch. 2-Adjust the low level by turning the coarse adjustment clockwise to
raise the low level, counterclockwise to lower the low level. 3-Adjust the high level
by turning the differential adjustment clockwise to raise the high level,
counterclockwise to lower the high level. An adjustment of one turn will change the
level approximately 2 inches.
Run the system with the vent open for several cycles to verify that the level switch is
working and adjusted.
For the conductance level sensor the only way to adjust the level is to change the length of
the stainless steel probes. This would require ordering different length probes from the
manufacturer and replacing the original probe with the new probe.
Page 16 of 46

2.6. TPH TEST:
While the unit is breaking in, test the TPH with clean water. Open the return water sample
valve; (V-005) it is the one on the line that is connected to the top of the Smartcell. Turn on
the clean water supply isolation valve to the Cell and select the clean water option by
scrolling down the menu on the Smartcell control panel. The cell will fill with water and
the Smart cell will “zero” itself to the clean water. When the unit returns with a display of
“0” PPM the unit is ready for operation.
For further explanation of the TPH see the vendor O&M manual.
2.7. Set Flow Rate:

Turn the system on. Establish proper flow by adjusting the flow control valve until the flow
indicator shows the proper system flow rate. Observe the pressure gauge located on the
pump outlet.
2.8. Verify Suction:

Check the suction by reading the suction gauge on the inlet pipe. If the suction pressure
reads 0 there are most likely leaks in the piping. If the suction pressure is >10 inches Hg
there are either restrictions in the suction piping or the suction lift is too high. If you have
removed all restrictions and the vacuum gauge still reads >10inches Hg the system could
have difficulty achieving the design flow rate. In most cases the pump is oversized and the
system will accommodate a somewhat higher than normal suction head. If there is no foot
valve in the sump the system will drain every time it is shut of and will have a hard time
priming. Verify that there is a foot valve in the sump.
2.9. STARTUP CHECK LIST:

1. Connect piping. Make sure to install isolation valves before and after the unit and a foot
valve in the sump.
2. Connect power to the system. Verify proper voltage
3. Check pump rotation
4. Turn the system switch to the ON position
5. The system will automatically fill with clean water. Make sure no oily water is allowed
into the system.
6. Open the separator vent valve (V001)
7. Close the discharge and recycle isolation valves so the system will pressurize. This is to
help evacuate the air from the system.
8. Evacuate all air from the system. This may require running the pump one or more times.
9. Open the isolation valves.
10. turn system on.
11. Set the design flow rate.
12. Verify proper vacuum. Fix any piping leaks or remove any obstructions.
13. Open the valves to the TPH and verify proper operation of the TPH
14. The system is now ready for full operation and the oily water isolation valve can be
opened and normal operations can commence.
15. Observe several cycles of the system. You can shorten the cycle time by opening the
separator vent valve. This will pump air into the oil chamber and cause the system to go
into the fill mode.
Page 17 of 46

3. TROUBLE SHOOTING:
Pump disassembly
The following suggestions are provided for situations that have been encountered in the past:
3.1. Solenoid Valve

If a solenoid valve does not work the most likely cause is a failure of the coil or a loose wire.
You can verify the electrical continuity from the control panel. To replace the coil, turn off
the power to the system, disconnect the wiring, remove the cover and replace the coil.
NEVER remove the coil with the power still connected. You will destroy the coil instantly if
the coil is separated from the valve and the power somehow is either left on or gets turned
on.
If the valve needs a new gasket or O ring turn off the power and make sure there is no power
to the coil. Then loosen the nut just above the valve and remove the coil section. Replace the
gasket/ O-ring and reassemble the valve. Do not turn the power back on until the valve is
fully reassembled.
3.2. MOV
When the system goes into Fill Mode, if the MOV opens but the Fill Valve does not open
then it is possible that the MOV switch is faulty. If the switch does not make complete
contact then the MOV will open but SOV 101will not do anything. If this happens you have
a bad switch on the MOV and need to replace the switch.
3.3. Filter
There are a number of situations that can occur with the filter:
a. If there is turbidity in the water the TPH monitor can give a false oil content reading. If
this happens a sediment filter may be needed to remove turbidity. You can either add a
sand filter or cartridge filter to remove the turbidity. You can also change the loading in
the filter to include more sand in the bottom of the filter and less media.
b. If you have high levels of emulsions and the organoclay is not removing the oil
adequately, you may need to use carbon instead of organoclay or you can use a
combination of carbon and organoclay. Carbon will work better fro emulsions and
organoclay will work better fore free oil. If you use the combination you should load a
bed of sand first, then carbon and then organoclay. The water goes down through the
media. It is best to go through the organoclay first and then the carbon.
c. If you are running high concentrations of oil the primary separator may pass more than
15ppm oil. The system will handle up to 100% slugs of oil and will handle 25% or more
on a continuous basis. However, the water coming out of the separator will also go up in
oil content. This is generally not a problem because the organoclay filter will remove the
oil. However, the organoclay media will fill up faster and the media will need to be
changed more often.
d. The organoclay works best in a downflow configuration, where the water goes down
Page 18 of 46

through the media. The oil content will be at least 5 ppm lower in a down flow
configuration.
e. In most situation the organoclay will remove 100% of the free oil that goes through the
filter. As the organoclay fills up with oil the ppm oil in the discharge will rise until the
monitor goes into alarm. When this happens reverses the hoses and go up through the
organoclay for 10-15 minutes and then reverse them back again. Sometimes the
organoclay will channel. This will loosen up the organoclay, reduce the back pressure
and get red of the channels. In most cases this process can be repeated several times,
which will extend the life of the organoclay. When this process no longer reduces the oil
content below 15 ppm it is time to change the media.
f. In the case of carbon there is no channeling and when it no longer will stay below
15ppm it is time to change the media
g. When it is time to change the media open the top of the filter housing and vacuum out
the media. This can be done with a shop vacuum. You will need to keep the media wet
in order to vacuum it out. To replace the media, dump sand in the bottom up to about 6’
above the bottom distributor, then add organoclay to about 8’ from the top. Any
combination of sand, carbon and organoclay is possible depending on your situation. If
you have a lot of turbidity add more and (up to half). If you have more emulsions add
more car bon. If you have high concentrations of oil use more organoclay. You can
purchase pre-measured buckets of sand/carbon/organoclay from the factory or your
distributor.
You can also hir a local filter company (such as US Filter) to change the media. They
will come out and vacuum out the filter and replace the media.
You can also order a replacement filter, swap out the new filter for the old filter and
return the old filter for a credit to the factory or to your distributor.
h. Sometimes a high TPH reading has nothing to do with the filter and is simply caused by
a dirty TPH cell. The glass in the cell should be cleaned on a regular basis. This should
be the first thing checked when the monitor is in alarm mode.
Page 19 of 46

4. OPERATION
4.1. Normal Operation
After all of the specified testing has been completed and the system has run satisfactorily
with the water flowing through the filter, then the system can be put in normal operation.
Turn the switch to ON and open the sample lines to the TPH. The unit will then monitor
the outlet stream and automatically switch between discharge and recycle as needed.
The system is designed to operate without operator interface except in certain conditions
as described below.
4.2. Alarm and Action Conditions
The only alarm condition that requires operator action is when the filter has reached
maximum hydrocarbon saturation. This is determined by the inability of the separator
and filter to clean the stream below 15 PPM. At this point, the TPH monitor will not be
discharging water overboard but is in a continuous recycle mode.
The Smartcell should be cycled several times through the clean water and clean the cell
glass with the cell plunger located on the top of the cell, before it is determined that the
filter is full. You should also backwash the filter to make sure there is no channeling in
the organoclay. If, after cleaning the cell, the TPH level is still above the 15-PPM limit
and you have backwashed the filter to remove any channeling, it is time to change the
filter media.
There is 1 alarm condition and 4 action conditions that require operator response.
a. Oil in Discharge Water Alarm—If the oil in the discharge water is greater than
15 PPM the TPH monitor will alarm. A TPH alarm will cause the system to
automatically go into recycle mode until the condition no longer exists. The
alarm light on the TPH panel indicates that the system is in recycle and that oil
greater then 15 PPM has been detected in the water. There is an adjustable 020
sec. delay timer in the TPH that is met before the recycle valve is actuated.
b. Plugged filter—If the pre-filter or post-filter (if applicable) are plugged the
pump will not pull the design flow of water through the system. When this
happens it is time to clean the filter(s). A better approach would be to set up a
routine schedule to clean the filter(s). The timing for cleaning the filters will
be determined by the customer based on operating conditions.
c. Short-cycle condition—If the inlet pump is pulling air into the system from
leaks in the piping, air will collect in the top of the separator and force the oil
down. This will cause the level sensor to read hi oil level and will cause the
system to short cycle between oil discharge and normal operation. A cycle
time of less than 30 min. in most cases is an indication of this problem
This is also a possible indicator that the external sump low level switch is
faulty, and the system is sucking the sump dry. Check the sump level switch
or adjust the system flow rate. If the inlet line is plugged, or the pre-filter is
plugged, the separator will likely short cycle. Remove the restriction. If the
process flow is greater than the design it can also cause a short-cycle
condition. See the next paragraph.
d. Excess flow condition—The system is designed to process the oily water at a
specific flow rate. The pump is capable of pumping more than the design flow
rate to accommodate many possible variables with suction and discharge lift that
may be encountered with each application or installation. The flow adjustment
valve (V-003) must adjusted to the designed separator flow for your unit.
Page 20 of 46

Processing more than the design flow will reduce the effectiveness of the
separator and cause a TPH alarm condition. An excessive flow rate could also
cause other problems in the system such as a short cycle condition. When the
system is initially started up the flow rate should be adjusted to achieve the
design flow, and periodically checked if there is a possibility that the position of
the flow adjustment valve V-003 has been changed.
4.3. Draining the Separator
Before draining the separator, cycle the system between fill and normal operation several
times in succession to eject as much oil as possible from the top of the separator. To cycle
the unit place the system in normal operation, close the inlet valve that is located on the inlet
side of F-101 and open the vent valve (V001). The unit will go into fill mode as soon as the
fluid level in the top of the unit is pumped down to the low-level sensor. This should
happen in approximately 30 – 60 seconds. The unit will cycle between fill and normal
operation as long as the vent is open and the inlet is closed. Three cycles should be enough
to dilute and reject as much oil as possible. Then proceed to open the drain plugs D1 & D2.
This will drain both of the internal sections of the unit. Leave the vent open to facilitate the
draining process. To refill the unit follow the procedure outlines in
4.4.Factory Startup and Acceptance Test Procedures

A factory startup and acceptance test is not required for the system, however, it is a good
idea and one that we highly recommend. If we do a factory startup we will perform the
following procedures. If the customer does their own startup they will need to follow these
same procedures. If the customer initially elects to do their own startup and then changes
their mind the factory startup can be done at any time. The cost for a factory startup is
$2,400 plus out of pocket expenses in North America and $2,800 plus out of pocket
expenses elsewhere for any of the standard systems. The factory startup can also be
performed by your distributor if they have a factory trained technician. Check with your
distributor to determine if they have a factory trained technician. The fee charged by the
distributor’s technician will be determined by the distributor.
1 Verify that the installation of the system has been done properly.
2 Make any installation corrections required.
3 Verify the power and voltage to the system
4 Proceed through the startup procedures as described above.
5 Pressure test the system from the inlet valve to the discharge valve. This has
already been done at the factory but it should be checked again to make sure nothing
has changed during installation.
6 Set the discharge flow to the design gpm.
7 Proceed through the startup procedures for the TPH
8 Once everything has been tested satisfactorily with clean water the system is ready to
introduce process water.
9 Operate the system at design conditions for the required test period.
10 Simulate alarm and warning conditions to verify that they function properly.
11 Make any adjustments that are appropriate.
12 Provide a training class for the system operator(s). This training will include
theoretical training on the system, functional training and training on how to
maintain the equipment.
Page 21 of 46

5. MAINTENANCE
The separator system may require periodic maintenance on or replacement of the
components shown in the spare parts list below in section 5. The following items may
require periodic maintenance at specific intervals.
A. Pump—The pump installed on the system does not require lubrication. The mechanical
seal should be replaced periodically or when it fails.
B. Valves—The valves installed on the system are high quality marine grade valves and do
not require lubrication. If sand particles get into the solenoid valves it can cause them to
leak and they will need to be cleaned. The coils and gasket will need to be replaced
periodically or when they fail.
C. TPH Monitor—The TPH will need a periodic check of zero against clean water, and
frequent cleaning of the glass sample cell. The dessicator will need to be replaced whenever
the color indicator is not blue. It is possible to bake out the dessicators in an oven at low
temperature. A spare parts kit is recommended for the TPH. Anything not covered by the
standard spare parts kit for the TPH will require the unit to be sent back to the factory for
repair.
D. Coalescing Media—The coalescing media in the separator should last for several years.
It does not require specific maintenance or replacement under normal operating conditions.
If the media is damaged by adding chemicals to the water or for some unusual reason you
should do the following in order to change out the media:
1 Remove the old media. This is easier if you make a hook using a small diameter rod.
Shove the rod down the side of the media. Turn 90 degrees so the hook part is
under the media and use the hooked rod to pull the media up.
2 The media should come packaged with an inner section and an outer section. The
inner section should come partially shoved inside the outer section. Remove the
inner section.
3 It doesn’t matter which section you install first. Place the media in the proper section
and get it started, making sure not to damage the edge of the media trying to force it
in place. The media should be tight but not too tight. If the section is too large you
may need to trim a small amount off the roll. To do this just cut off the excess with
a utility knife.
4 It is easier to push the media into the vessel with 2 people. Both people can help get
the media started about 1/3 of the way. Then use the round piece of wood to put on
top of the media and push down uniformly.
5 Repeat the same process for the other section of media. The inner section should be
pushed down about 1-2 inches below the weir. The outer section should be pushed
down just below the weir.
E. Filter Media—The filter media will need to be changed when the oil content monitor
will not go below 15 ppm AND you have cleaned the cell AND you have backwashed
the post filter. High oil content can be caused by using surfactants and other cleaning
chemicals that cause hard to remove chemical emulsions. We recommend the use of
cleaners that do not cause emulsions. A list of factory recommended cleaners can be
obtained from your factory representative or directly from the factory.
F. Controls components—The control components are designed for marine application.
They should be replaced when they fail. We have indicated on the spare parts list which
items we recommend to spare.
Page 22 of 46

G. Flow indicator— The flow indicator is a low-cost direct reading industrial class flow
indicator that is simple to use and install. It provides an excellent way to measure the
flow through the system without having to use an expensive meter. The disadvantage of
the flow indicator is that it is not as rugged as more expensive meters might be. The
flow indicator is made from high impact polysulfone plastic and has excellent structural
integrity for a plastic device. However, it will break if put under too much stress or it
impacted directly. To replace a broken flow indicator, remove the broken indicator.
Apply pipe thread compound that is compatible with plastic. We recommend “Blue
Magic Industrial Grade” made by Whitlam. We have found that Teflon tape does not
work as well and is hard to seal. Do not over tighten. Over tightening will cause the
indicator to break. Tighten until snug—you should have 4-5 thread showing when you
are down. If you use the right pipe thread compound you will get a good seal without
over tightening. We also highly recommend that you maintain a spare flow indicator at
all times. If the flow indicator breads and you do not have a spare, simply replace the
indicator with a similar length threaded nipple, order a replacement and install the new
indicator when it arrives. The system will function perfectly fine without the flow
indicator. The only impact is that you will not know exactly what the flow rate is.
Page 23 of 46

6.PARTS LIST AND RECOMMENDED SPARE PARTS
The following lists show the recommended spare parts for each model of separator to be
kept on hand for routine maintenance and repair of the Recovered Energy Boss oil/water
separator. In the case of pumps, valves and TPH, we recommend that the customer spare
a complete assembly plus rebuild components. That way if a component breaks down
the spare assembly can be installed and the rebuild kit can be used to repair the
component that failed and the customer will always have a functioning spare.
Description Part Number (*)(*) indicates this is a recommended spare.
Pumps –
6.1. BOSS 05
a. Complete pump assembly including motor:
P-101 Separator pump (3 phase) ................................JEU 806
(110 vac single phase)..........................................SBS 1200511
b. Pump repair kit for 3 phase

(complete pump assembly kit minus seal) (*)
Mechanical seal for 3 phase pump ......... (*)
Minimum repair parts (o-ring, impeller, plug kit) ......... (*)
Pump repair kit for 110 V (standard kit, including seal) .........
6.2. BOSS 05
a. Complete valve assembly for each type of valve SOV-101 18N42 1/2” ....... (*)
SOV-102, SOV-103 18A42 1/2” ........ (*)
MOV-101 DM9933-FTTS-075/ER1-2.5-4-120/60............
b. Valve repair/rebuild kits:

Solenoid coil only: SOV-101,102,103 A2-120vac ........ (*)
Valve gasket: SOV-101 18N42 1/2”-S ....... (*)
Valve disc and gasket: SOV-102,103 18A42-3/4”-S ....
6.3. Class I Div I and II:
For Class I Div II and Class I Div I units the valves are all rated Class I Div I
Group C and D so the same valves are used for both applications.
½” SOV F18A42 ............ F18A42
¾” SOV F18A43 ............ F18A43
1” SOV F18A44 ............ F18A44
1.5” SOV F35A46 ............ F35A46
MOV DM9933-FTTS-075/ER 1-2.5-7-120/60............
6.4. Monitoring Equipment (all units are the same)

a. Complete units: Conductance level probe
Conductance level probe 3E3B ............
Capacitance level relay 16MM1A0001............
Flow indicator FI-101

b. Controls Parts List and Recommended Spares (standard units):
Page 24 of 46

Contactor ....................................................... GH15BN-3-10A (*)
Circuit breaker (if used) .......................................... WMS1D03Control box
10x8x6 w/ subpanel................. HW-100806CHQRControl box
12x10x6 .................................. HW-121006CHQRControl box
14x12x8 .................................. HW-141208CHQRControl box
sticker ................................................................... Disconnect
handle ...................................................... SD-HRY (*)
Disconnect shaft .......................................................... SD-200 (*)
Disconnect switch ................................................. SD1-025BR (*)
Fuses (set) (if used)......................................................... HCTR (*)
Fuse holders................................................................... Lights (set of 1
green and 1 red)................................................ (*)
Motor starter.................................................................... MS25 (*)
Relay -set (if used)............................................... 782-2C or 4C (*)
Switch 3 position selector .................................... E22XBG1RR (*)
Surge suppressors (set of 4) ............................ GH15BN-3-10A (*)
Terminal kit ..............................................................................
Transformer..............................................................................
TPH monitor (Dekma) ..............................................................
TPH repair kit (Dekma) (dessicator (2), O-ring, fuses (2), brush) (*)
TPH dessicator.......................................................................... (*)
TPH brush ................................................................................ (*)
Stainless tube fitting kit (4 ferrule & connector set).................. (*)
c. Controls Parts List and Recommended Spares (Class I Div I & Class I Div II):
Armored cable .........................................................................Cable glands
(set of 2) ............................................... 711A 1/2 (*)
Contactor ....................................................... GH15BN-3-10A (*)
Circuit breaker ....................................................... WMS1D03Circuit breaker
molded case ....................................... G FrameConduit
box ............................................................................. Control box NEMA
7X..................................... EXB12188N34Control box mounting
pan ........................................................ Control box labels
(set)............................................................. Fuses
(set) ................................................................................ (*)
Fuse holder ............................................................................... Lights (set of 1
green and 1 red)................................................ (*)
Motor starter.................................................................... MS25 (*)
Switch disconnect handle.......................................................... (*)
Switch 3 position selector ......................................................... (*)
Surge suppressors (set of 4) ............................ GH15BN-3-10A (*)
Terminal kit ..............................................................................
Transformer..............................................................................
Stainless tube fitting kit (4 ferrule & connector set)................... (*)
Page 25 of 46
6.5. Piping, fittings, miscellaneous

a. Miscellaneous BOSS filter
media Maintenance paint quart kit urethane and hardener.....SW14109
Top flange gasket for 2 GPM separator................. 1210.02NEO (*)

b Pipe fittings—BOSS 2 & 5
Bronze ball valve ½” .......(*)
Bronze threaded ball valve 3/4” ......(*)
Bronze union ¾” ........(*)
Bronze threaded spring check valve 3/4” ........(*)
Bronze threaded spring check valve 1” (5only) ........(*)
Bronze union 1” (5 only) .......(*)
Bronze Y strainer ¾” .......(*)
6.6. Filter
BOSS 2-107 Filter tank Filter basket strainers (set of 2) (*)
Filter riser (*)
Filter top distributor (*)
Charge of media (*)
Page 26 of 46
O&M Manual – Volume I ATTACHMENT 3

-CALIBRATION SHEETS
Level Switch Calibration Adjustment Sheet for Capacitance Level Sensor Procedure for
setting the Level Switch
Dip switch settings from left to right – ON – OFF – ON – OFF. Up is
ON. Down is OFF.
With the water level below the bottom of the probe or at the Low setpoint:
Adjust the Differential full CCW. (20 turns or until a clicking sound is heard) If the
LED is on turn the Course CCW until the LED turns off.
Adjust the Course CW until the LED just turns on.
The light will come on while turning CW.
Turn the Course adjustment another 1/8 of a turn past where the LED just comes ON.
Adjust the Differential fully CW. (20 turns or until a clicking sound is heard)
Raise the water level to the High setpoint. Adjust the Differential CCW until the LED turns
off.
Page 27 of 46

O&M Manual – Volume I ATTACHMENT 4 – PARTS
IDENTIFICATION
Page 28 of 46

1.系统描述
BOSS -107 系列油水分离装置包括以下基本部件：
·油水分离装置－液体 A&B
·107 油水过滤装置－液体 C
·TPH 检测
1.1 系统部件
1.1.1 BOSS 油水分离系统
F-101 前过滤装置
CV-101 进口止回阀
S-101 油分离器
P-101 主工作泵
G-101 真空表
LS-101 油位开关
V-001 分离器手动通气阀
SV-101 补充水进口控制阀
CV-102 排油控制阀
F-102 排油 Y 型滤器
FI-101 流量计
V-003 流量控制阀
V-004 真空泵出口取样手动阀
1.1.2 BOSS 107 分离器过滤系统
G-102 滤器前压力表
V-002 滤器透气阀
F-103 C 液体过滤器
G-103 滤器后压力表
CV-103 处理出口止回阀
CV-104 真空破坏阀
SV-102 107 分离器排放控制阀
SV-103 107 分离器循环控制阀
V-106 T 型三通阀（工作状态油水进入滤器）
V-107 T 型三通阀（工作状态油水出滤器）
1.1.3 TPH 监测
V-005 TPH 清洁水进口手动阀
FR-101 TPH 节流阀
V-009 TPH 取样水手动阀
TPH-101 TPH 分析器
1.1.4 电气/控制
P1 BOSS 控制面板
1.2 工作过程描述
1.2.1 工作泵
一台工作泵(P-101)安装在分离桶的出口，该泵从前置滤器(F-101)和分离器(S-101)中抽
吸水。这种布置减少了机械乳化。该泵能够产生 10 英尺（3 米）的负压头且能够给整个
装置提供设定流量。高吸力型号能够产生 16 英尺（5 米）的负压头。泵的吸口持续注满
正压的水，这样不需要将泵灌满水。该泵为不锈钢离心泵，因此不需要安全阀。取决于
吸口和压头的安装，工作泵有能力泵送比设计的流量更大的流量。
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分离系统工作在一个负压或者真空的状态。在安装的时候，所有的油水分离器的连接和
合理的尺寸都是至关重要的。如果连接处没有气密，空气便会拉至分离器或者进口受限
制，将会引起整个单元在加注和排放之间进行小于 30 分钟的循环，泄漏越大或受限越大，
循环便会越快。
1.2.2 前置滤器
当装置供电时，工作泵(P-101)通过一个前置滤器 F-101(Y 型滤器)从污水舱中抽吸水。该
滤器将会除去任何大于 1/20 英寸的颗粒。该前置滤器包括一个止回阀 CV-101 去防止系
统断电或排油模式下水回流。当流量减小时，很可能是前置滤器堵塞，拆下滤器，清洁。
1.2.3 油水分离
油水分离器 S-101 是一个聚合式的重力分离器，主要依赖于油与水的比重的不同。该油
水分离器不能够清除比重接近 1.0 或者更高的液体。油水经过前置滤器进入到分离器的
底部。分离器有一个内筒和外筒，水沿着分离器的中间部分向上，通过一个亲油介质（聚
乙烯、聚丙烯）。该介质有助于油从水中分离达到 15PPM，在介质表面区域吸收油份颗粒
并且让其聚合成大的油滴，这样将会加速上升到分离器中水的表面。当油聚集到分离器
的顶部，油便会置换水且迫使水往分离器的下部。任何的气体和空气进入到分离器，都
会加速上升至分离器的顶部聚集。聚集在顶部的空气和气体将会和油一起排出。一个液
位传感器 LS-101 在分离器的顶部，用来探测分离器中水的液位。当水被聚集的油置换到
预定的低液位时，泵 P-101 将会关闭，SV-102 和 SV-103 关闭，且 SV-101 和 MOV-101（如
应用）将会打开。补充水将通过 SV-101 进入分离器提升分离器中的水位，并且将油通过
油出口阀 MOV-101 或 CV-102 排出分离器。一旦水位到达高位，LS-101 开启且 SV-102 或
SV-103 开启，恢复至正常工作状态
在正常工作状态下，油水通过分离器的中间部分流向上方，并且到达内筒的顶部，在那
里大部分的油从水中分离出来。然后水沿着外筒流向下，外筒有额外的介质过滤。通过
含有聚合介质的第二级，有助于清除任何残留油份且提供油份浓度小于 10PPM 的排放水。
在分离器中分离的水从外筒的底部被泵送到过滤器单元。
1.2.4 精过滤
5T-107 油水分离器装有一过滤器，该过滤器设计成可以清除乳化物和其它的非常难以在
分离筒中分离器的 C 液体。该滤器使用了集中型式的亲油介质，主要的型式是活性碳。
有两种型式的滤器可提供，2 和 5gpm 系统是一个玻璃纤维滤器，进口和出口都是在分
配器上手动操作的。25 和 45gpm 系统用的是钢容器，该容器是进口分配器在顶部而出口
分配器在底部。10gpm 系统既可使用玻璃纤维也可使用钢容器，依据情况而定。
玻璃纤维滤器设定的压力为 125psig,和这些滤器使用的是大型号的泵，这样就可以适应
多种情况，该系统设计可处理 12〞水银柱吸口真空度和大约 80 英尺的排出压头。
钢滤器设定成 40psig 压力，该系统中泵压力正常情况下不会超过 40psig。如果情况要
求一个高的吸高和高的排出压头，一个功率更大的泵是需要的，并且一个高压的滤器也
是应该与此相配套。
A, 流向向下
1．流向向下的架构需要滤器的进口装有一个透气阀，这样滤器可以在初次充满水
前放气，这个阀只有在灌水的时候才需要。
2．流向向下的结构通过滤器的背压比较低。
3．流向向下的结构滤器能够清除更多的混浊相比较流向向上的结构。
4．通过将滤器填充粗砂到滤器上部 8〞可以降低背压。不要用精细的滤砂，因为
细滤砂容易穿过滤器到排出口，从而导致阀被卡死。
5．在流向向下的结构中，顶部的滤器不是起关键作用的。
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B,流向向上
1．透气阀不需要安装。
2．背压较高。
3．亲油介质不能完全清除乳化物质。
4．滤器中的粗砂能够降低背压，同样不能使用细矿砂。
5．在流向向上的结构中，顶部的滤器是必不可少的。
系统可以在两种方式上工作，但是流向向下的有一系列的优点，为了适两种结构，所有
从工厂出来的系统都配有顶部滤器，透气阀和在滤器底部的粗纱，因为流向向下的结构
有诸多优点，故标准的出厂结构为流向向下的结构
由于聚合材料，当系统初次启动时，滤器的背压有可能逐渐升高。在使用过几周工作之
后，如果背压升高，需要反冲洗。这样就能使背压降下来并且稳定，反冲洗时移去滤器
顶部的软管并且反方向，再正常启动系统。20 至 30 分钟后，将系统关闭，并且将软管
装回到原位置。这样就会达到背压降低，实际上没有一个特定的时间去做此工作，仅需
在压降太大和设计流量达不到时需要。（须知：配备玻璃纤维滤器的系统出厂前已经预装
好了软管，而所配钢筒的滤器没有配备，所以客户如果需要反冲洗的时候，需要自己去
接分离器的滤器。反冲洗不是必需的，但是却是一个减少压降和延长过滤介质的非常有
效的手段）
在正常工作条件下，水会穿过聚合物形成通道，通道会引起 TPH 浓度监测器显示比实际

的要高一些。如果油份浓度攀升，需要反冲洗系统清除该通道。定期的反冲洗滤器会减
少压降和过滤介质通道的形成，并且有助于延长过滤介质的使用寿命。没有一个设定的
时间来实行该措施。如果反冲洗后浓度读数很高，就需要更换过滤介质了。
没有必要将反冲洗的水排出，不需要将滤器中的任何东西排出。可以简单的混合一下过
滤介质去减少压降。
活性碳会有一个相对于聚合物来说比较小的压降，也不会像聚合物那样形成通道，对于
活性碳滤器来说，不要反冲洗滤器。聚合物材料相对于活性碳滤器的优点就是聚合物能
够吸收 5－7 倍的油份，因此更换介质的间隔时间会长很多。
C 启动
在系统初次充满水的时候，滤器中的空气没有办法自己放气，当泵工作的时候，
空气被压缩，并且当泵停的时候空气会压回到泵，这样会引起泵失去自吸能力。
所以在分离器中的真空形成的时候位于分离器顶部的透气阀需要打开，允许水
进到泵中。因此排出空气的步骤是泵运转至出气口有水出来，关闭放弃阀，停
泵，打开分离器和滤器的放气口，等水沉淀，启动泵直至空气从滤器中释放。
一旦水溢出，关闭阀并且重复操作该程序。不断的重复该程序多次，直至没有
空气从滤器的放气孔出来。
D 重新填充介质
当系统不能够保持油份浓度在可接受的限度内，介质就需要更换掉。移出介质
要将介质的真空破坏。用过的介质与其它的油滤器可同等对待处理。
1.2.5 TPH 油份浓度计

BOSS 107 系列包含一个总石油类碳氢表（TPH,有时也叫做油份浓度计或者 OCM）作为标
准设备。这套装置能够自动的将不合格的水排放至污水井或污水舱。循环用电磁阀 SV-103
和油份浓度计 TPH 控制循环动作。油份浓度计 TPH 是一个 15PPM 油份浓度报警监测器并
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且已经通过 IMO MEPC.107(49)测试和认可。TPH 浓度监测器持续的取样处理液体并且对
任何油份浓度的变化反应迅速。
1.2.6 终滤器
一个加装的终滤器可以用来有如下作用：
a) 清除混浊
一个砂滤可以用来清除出水中的混浊，如果水的 NTU 值超过 35，将会引起 TPH
监测器给出错误读数，移除这些混浊能够有利于 TPH 监测器的精确读数。如果混
浊是一个问题的话，那么最经济的解决方案就是使用终滤器。可选择的砂滤包含
0.45 － 0.55mm 的滤砂，这样可以清除掉水中的悬浮颗粒。
b) 其它
滤器可以用来达到其它的分离目的，比如清除铁、氢硫化物、硫醇、金属和其它
污染物。像其它的滤器可以根据项目的不同来进行不同的选择。如果有空间限制，
可以把不同的介质放在同一个滤筒中形成一个多介质过滤器
c) 无油份
将油份浓度降至 1ppm 或 0 油份是可能的，可以通过将聚合材料和活性碳滤器联
合使用。
1.3 系统特征
A: NEMA 4X 控制和电气
B: TEFC 马达
C: 不锈钢泵和叶轮
D: 自动操作
E: 系统完整和工厂测试
F: IMO 和美国海岸警卫队认可，满足 107(49)规范。ABS 认可。
G: 所有管路为船用等级铜配件和不锈钢
H: 油份浓度监测
I: 液位控制压力排油
J: 自动控制阀
K: 流量计
L: 船用漆涂层
M: 所有装配件和面板为不锈钢
N: 可在实船操作中 30 度范围内操作
O: 终滤器用来清除乳化
1.4 可选系统特征
1.5 系统规格
BOSS 05T-107
高度 (inch/cm) 60 / 153
宽度 (inch/cm) 32 /81
深度 (inch/cm) 47 / 120
干重 (lbs./kilogram) 825/ 370
容量 GPM (m3/hour) 5 /（1.1）
活性碳充填(lbs./kg) 120 /55
石英砂充填(lbs./kg) 60 / 27
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Common specification 公共规格
Specification 规格 Value
IMO MEPC Compliance 规范 MEPC 107(49)
Test Pressure 试验压力 0.33Mpa
Operating Pressure 工作压力 0.11Mpa
Operating Temp Range 工作温度 5~60 deg.
Max Free Oil Concentration 最大含油量 35%
Max Fluid “C” Oil Concentration (with filter)最大 “C”类含油量 6%
Oil in Water Discharge with TPH 处理水排放含油量 <15ppm
Three Phase Power 电源 380VAC
Frequency 频率 50Hz
Max Amperage 最大电流 <15 amps
Design Negative Inlet Head (M)吸高 3.5m
Level Sensor 油位电极 Conductance
Pump 泵 Centrifugal w SS Housing
Coalescing Media 分层过滤介质 Polypropylene /HDPE
Hazardous Area Classification 区域使用等级 Nema 4X or Class I Div II
Coating Specification 涂层规格 Epoxy /Urethane
Piping and Manual Valves 管路及手动阀材质 SS316/Bronze/ Red Brass
Vessel Metallurgy 桶体材料 Marine Coated Carbon Steel
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2.启动
2.1 工厂测试/交货
在交货之前，系统都会通过工厂测试，检验系统的水密性和泵的性能，阀和控制系统。
在系统到达目的地之后，需要仔细检查是否在海运途中损坏。所有的损坏都要报告给
海运公司和生产厂家。如果替代部件和零件需要的话，需要立即通知生产厂家。
2.2 安装
BOSS 油水分离器是一个完整的系统，在工厂里进行了完全的测试和操作。所有正常
要求要做的就是安装系统，连接相应的管路，接电源至主配电板，电气接线图请见附
件。
在购买的时候，装置已经设定好了合适的电压要求。请确认该电压是否匹配。电压要
求在电气图中已经列出。控制箱内部可以发现有示意图。所有的管路连接也可在附件
中发现。所有的管路连接不会对装置产生限制作用是很关键的。在规格以内的管路会
消弱整个系统的工作。
在所有系统中，在流量计的上方有一个手动阀 V-002，用来调节流量不要超过设定系
统流量。在新的单元上面都会装有一流量计。阀要在设定的流量的位置工作。如果
系统没有配有流量计，我们强烈推荐向厂家订购。没有流量计的话，用户需要测量
最终排出口的流量来调节流量，去实现该操作，需要充满一个已知的容器来测量充
满所需要的时间。调节阀并且不断的重复该操作直到达到设计流量。工厂会提供一
个大约的压力设定值，但是最好的办法是测量流进桶中的流量。排出阀和循环阀两
个都要同时调节。
2.3 电源测试
当装置供电前，确定除了 CV-102 后油出口阀以外，所有进出系统的隔离阀都处于关闭
状态。如果购买的是 BOSS 的 E 系列产品，将没有断路器。如果购买的是标准的 BOSS
系列，需要将位于控制面板上的断路器合上。BOSS 选择开关上的 REM 位置是为了遥
控的启动/停止控制。是一个遥控控制器或是一个污水井的遥控液位开关。装置可以工
作在 ON 或者 REM 位。对于任何遥控操作用户都需要连接已提供的接线端子。当电源
供电，装置供电时，电源指示灯会亮，并且系统会进入充油 & 排油模式。让步水隔
离阀关闭直至验证泵在正常方向上工作。TPH 浓度监测器供电，并且进入测试模式。
在装置供电的情况下，循环阀将会打开，并且保持打开，直至检测到油份浓度小于
15PPM。
如果系统电源是 110V 或者 240VAC 单相电时，下面的步骤不必要求。如果系统是 3

相电时，遵守下面的步骤。电源测试：
在电源安装之后，在系统没进水之前，要检查泵的转向是否正确。在系统充满水之后
如果检查泵的转向，如果泵的转向是错误的，将导致泵的叶轮会从泵轴上脱落。如果
发生这样的事情，那么泵的叶轮会损坏的非常严重并且在工作前泵要进行大的修理。
在没有水的情况下检测转向会减少发生的可能性！
警告！！
只有有经验的、受过训练的电气工程师和控制技术人员才能够进行这种工作，因为控
制箱中存在致命电压！
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打开控制面板，合上电源断路器，通过顺时针旋转断路器轴 90 度给泵电压。用铅笔或
其它非金属即刻按一下接触器按钮。同时观察泵后部的风扇转向。从马达后面观察应
该是按顺时针方向转动。
2.4 初次灌水和测试
在初次灌水和测试前，隔离油水供应和关闭 TPH 取样阀。在任何油水进入分离器以前
对系统进行测试是非常重要的。检查清洁水源已经接上。将系统开关旋至 ON 位，分
离器将要充水并且补充/排油指示灯开始变亮。打开位于分离器顶部的放气阀 V001，
这样分离器开始在补充和排油之间循环。确定让取样管路至 TPH 单元的阀关闭，且将
开关旋至 ON 位，当分离器充满的时候，补充阀和排油阀 MOV-101 将会关闭（如果装
置有 MOV 选择的话）。当排油阀关闭时，排水阀或者循环阀将要打开并且泵会启动。
如果 TPH 的感光干的话，装置进入再循环条件。确定打开所有的安装在污水循环和排
放管路上的隔离阀。
当系统充满的过程中，滤器的放气阀要保持开，
，当水流出时关闭放气阀。让系统运转
一小段时间，然后关闭泵，打开分离器和滤器的放气阀，等一段时间让水沉淀，启动
泵直至滤器中有空气逸出。一旦水溢出，关闭阀并重新操作该流程。重复操作该流程
多次直至没有空气从滤器的放气口逸出。
在这段时间，整个的流量将会返回到污水井中，工作时要观察位于泵出口的压力表检
查是否工作正常。如果读数高于 10 PSI 并且低于 50 PSI，系统工作正常。如果压力表
读数高于 50 PSI,有可能管路出现堵塞，如果读数小于 10 PSI，很可能没有充满水或者
泵失去自吸能力。让泵重新产生自吸，打开放气阀 V-001 直至装置进入加注模式然后
关闭该阀，装置返回到正常工作状态。
当水从放气孔溢出时，滤器已经充满并且开始正常工作。如果滤器提供的是成粒状的
活性碳，在 TPH 油份浓度计正常工作前冲洗介质中的灰尘是必需的。这个过程大概要
持续 30 分钟左右。在这个过程中，TPH 的取样管路要保持关闭状态。整个系统水回流
至污水井中。
2.5 分离器液位开关测试
Page 35 of 46
让系统运转起来，在操作过程中打开分离器的放气阀。这个阀打开后分离器中的液位
就会循环的高和低。低液位的时候不能低于分离器底部的法兰。高液位不能从打开的
放气阀中排出。如果液位开关需要重新设定（只适用于电容式）请参考液位开关计算
说明（附件 3）其它的微调可通过下面实现：
1－打开液位开关的顶部
2－调节低位，通过顺时针转动粗调，升高低液位，反方向为降低低液位
3－调节高位，通过顺时针转动调节差值，升高高液位，逆时针为降低高液
位
一次转动相当于调节液位大概 2 英寸在放气阀开的情况下运转系统几次来检验液位
开关的工作和调整。对于电导式的液位探测器，只有一种方法来调节液位，那就是改
变不锈钢探头的长度。这就要从厂家订购不同长度的探头来用新的探头取代以前的探
头
2.6 TPH 油份浓度计测试

油份计调零其方法是：首先要想油分计通入清水，打开接在清水进口的阀门 V-005，然后
调节油分计的面板按钮使油分计工作在清水测试模式下。但清水通过油分计的探头后油分
计就会显示 0ppm。接下来油分计就可以工作。
因为在此过程中要启动电磁阀等。具体要求和说明见油份计操作手册
2.7 设定流量：
打开系统。通过流量调节阀直调节泵出口的压力和流量到系统设定值。这些数可以通过安
装在泵出口的压力表和流量计直接观察。
2.8 检验吸口压力：
检查设备吸口的压力。如果吸口的压力读数为 0Mpa 那么有可能管路有泄漏。如果吸口
压力大于负压 0.1Mpa 那么有可能是管路堵塞或者是吸程过高。如果是吸程过高，那将
导致真空泵出口难以达到设计流量。在大多数情况下，泵的设计压头是比工作状态下高
的，为了保证设备在停机后能迅速启动我们在进口装了单向阀。
2.9 启动检查清单
1．连接管道。关闭隔离球阀（不在设备中）确保前后管路连接正确。
2．连接电源，验查系统电压。
3．检查泵的旋转。
Page 36 of 46

4．使系统的开关旋转到 ON 位置。
5．系统会自动填充清洁的水，这时不准许油水进入系统。
6．打开分离桶体上的排气阀（v001）
7．关闭排放电磁阀使系统加压。这是帮助排放过滤桶体内的空气。
8．要排放完全系统内的空气。需要反复间断运行真空泵。
9．打开隔离阀（不在设备中）。
10．启动系统。
11．调节节流阀到设计流量和压力。
12．检查系统的真空度。解决任何管道泄漏问题。
13．打开阀门 V-005 调试油份计 0 值。
14．系统已准备好油水分离工作可以正常运行。
15．观察系统分离排油运行情况。
Page 37 of 46
3.故障排除
下面是设备可能遇到的故障
3.1 电磁阀不工作
如果电磁阀不能工作，最有可能的原因是控制它的中继坏了，或者是接线松脱。你可以检
测以下控制箱内的中继，更换中继时，要关闭系统，切断电源，拆卸下罩壳换上中继线圈。
注意不要在带电的状态下取下线圈，这有可能永久性的破坏线圈，这时把线圈从阀上取下
来，电源也无法再次判断阀是开还是关.
更换新垫片或 O 型密封圈时，关闭电源确保线圈不带电，接下来松开电磁阀顶部螺栓取下
电磁阀盖，更换新垫片和 O 型圈，盖上端盖，在电磁阀没有换好前不要通电。
3.2 电动阀
当装在系统的可选电动阀打开，冲水电磁阀打开，系统进入冲水模式，如果电动阀打开，
而冲水阀没有打开，可能是冲水阀坏掉了。如果电动阀没有动作，你就需要更换电动阀。.
3.3 系统不排放合格水到船舷外
a. 当浑浊的油水通过油份计的检查装置时，油份计的读数就会混乱，如果是这样工况，
你就需要去除水中的浊度。你需要加装一个砂滤器在重力分离器和过滤装置之间，或
者是在过滤器的下部增加砂的比例但是这是不推荐的一种方式。
b. 如果进入设备的污水含有胶状物比较多，而膨润土又不能完全过滤出油，这时你就
需要用活性炭来代替膨润土，或者是两者混合使用来，因为活性炭对胶状物很有效，
膨润土对乳化油有效，这样可以提高过滤材料的综合性能。但在在使用这两者混合材
料做过滤材料时，也要在过滤桶底部加上一些砂，
c. 如果你的设备运行的工况是高含有量的油水环境时，你的油分计一直处在 15ppm 以
上，但是系统依然把油水中的百分之百的大分子油分离出来，同时过滤桶中的膨润土
过滤油水中的百分之 25 小分子油
d. 在大多数情况下过滤桶中的膨润土能过滤掉通过它的所有小分子油份，除非是膨润
土材料过滤饱和，油份计就会发出油份升高的报警，这时你就需要更换过滤材料。
e.个别短暂的油份计报警可能是油份计的探头太脏引起的，油份计报警时你首先要做的
就是拔出油份计探头灯检查是否有污物覆盖，
f.其中一个很重要的检查是看流量计的流量是否超过了设计流量，因为如果流量大，这
就会减少油水在第一重力分离桶中的停留时间，这会降低油份从水中分离出来的比例。
流量小就会使油水在重力分离桶中的分离时间变长，提高了分离比，这样进入下级过
滤器中的油水的含油量就比较低。
Page 38 of 46
4. 操作
4.1 正常操作
当所有规定的测试完成后并且水可以开始通过滤器时，系统令人满意的进行工作，这
时系统可以投入正常使用。旋动开关至 ON 位，并且打开通往 TPH 的取样管路，装置
开始检测出口并且会在排放和循环之间自动切换。系统设计成无人工作模式除非出现
以下集中情况：
4.2 报警
唯一需要操作人员处理的报警是当滤器达到碳氢饱和时，这时分离器和过滤器没有能
力去清洁液体到 15PPM 以下。这时候，TPH 不会把水排放至舷外而只是不停的在循环
模式。
光敏电阻玻璃管需要用位于电池上方的柱塞清洁。还需要反冲洗滤器来确保在聚合物
中没有通道。如果在清洁光敏电阻后 TPH 油份浓度计的读数超过了 15PPM，并且已经
反冲洗了滤器，那么就到了应该更换过滤介质的时候了。
下面一种报警情况和 4 种动作条件需要操作人员反应
A: 排出水中有油警报――如果排出的水中油的浓度超过了 15PPM，TPH 警报就

会发出。TPH 警报会引起整个系统自动进入循环模式直到该情况不在存在。 TPH
面板上会有警报灯亮，指示系统在进行循环模式并且油份大于 15PPM 被监测
到。这里有一个在循环阀动作前 0－20 秒的延迟时间在 TPH 中。
B: 滤器堵塞――如果前置滤器和终滤器被堵塞了，那么泵的流量就不会达到设计
的流量。这个时候就需要清洁滤器了。一个比较好的方案就是定期清洁滤器，
清洁滤器的时间取决于用于依据于实际的操作条件。
C: 短时间循环――如果泵进口抽进了来自于管路泄漏的空气，空气会在分离器顶
部聚集，并且会迫使油往下，这样会引起液位探测器探测到一个油位高，因此
系统开始在正常工作和排放之间短时间的循环工作。循环的时间少于 30 分钟
的情况，大部分都是因为这个原因造成的。
还有一种情况可能是污水井上的低液位开关故障，并且系统将污水井吸干了。
检查一下污水井的液位开关或者调节一下系统的流量。如果进口出现了堵塞，
或者前置滤器堵塞，分离器就会很可能开始短时间循环。移除限制物。如果处
理流量大于设计流量，也会引起短时间的循环。见下一段。
D: 流量大情况该系统是设计成在处理油污水时有一个特定的流量。泵是有能力来
泵送更大的流量以此来适应进口和排出口的可能性的变化。流量调解阀 V-003
必须调节至设定的分离器流量来适应所用的装置。处理量大会导致减少分离器
的效率并且会影响到 TPH 的工作环境。过多的流量也会引起系统中其它的问
题，比如短时间的循环。当系统初次启动时，流量要调节到达到设定的流量。
并且定期的检查流量调解法 V-003 是否改变了位置。
4.3 分离器泄放
在泄放分离器之前，系统在加注和排放之间循环几次来尽可能的从分离器的顶部排
出最多的油。如要循环，将系统置于正常工作条件下。关闭位于 F-101 进口处的进口
阀并且打开透气阀 V001，这样装置从顶部的液位到低液位时进入加注模式，这个过
程大概是 30－60 秒。整个装置会在加注和正常工作模式下不停的循环只要保持透气
Page 39 of 46

阀打开和进口阀关闭。三个循环已经足够可以排出尽可能多的油。然后打开泄放柱塞
D1&D2，这样可以泄放装置的内外腔体的液体。保持透气阀打开有助于泄放过程。
4.4 工厂启动和测试步骤
对于该系统来说并不要求工厂启动和接受测试，但是尽管如此，依然是一个好办法而
且我们推荐。如果我做工厂启动的话，我们将要遵守以下步骤。如果用户想要他们自
己启动也同样要遵守这些步骤。如果用户开始选择他们自己启动而后来改变想法做工
厂启动，那么工厂启动可以在任何时间进行。但是需要收费。
1. 检查系统的安装是否合适。
2. 确保每个安装都按照要求正确安装
3. 检查系统的电源和电压
4. 按照上面描述的步骤启动
5. 检查进口到出口阀间的系统工作压力，虽然这些已经在工厂测试好，但是
还是应该在安装时重新检查一下
6. 设定出口流量至设计流量
7. 按照启动步骤启动 TPH 油份浓度计
8. 当系统用清洁水测试成功后可以开始正常处理水工作
9. 在设定的条件下操作系统
10. 激活报警并检查报警条件，检验功能是否正常
11. 调整调节系统
12. 给操作人员提供培训课程。这个培训包括系统的理论培训，功能培训并且
培训如何维护设备
Page 40 of 46
5. 维护保养
油水分离器系统要求定期的维护或者更换部件。下面的事项需要明确的时间间隔定期的维
护保养
A: 泵――装在系统上的泵不需要润滑。机械轴封需要定期的或故障时予以更换
B: 阀――装在系统上的阀是船用等级的高质量的阀，并且不需要润滑。如果砂颗粒进
入到电磁阀中会引起阀泄漏，这时需要进行清洁。线圈和密封圈需要定期的或者
损坏时更换
C: TPH 油份浓度计――TPH 需要定期的用清洁水检测是否为零，并且经常的清洁玻璃

管。无论何时颜色指示器不是蓝色时干燥剂都要更换。也可以在烤箱里低温烘烤。
推荐一个 TPH 的备件箱，任何没有在 TPH 备件箱中没有的东西都要求返回到工
厂维修。
D: 聚合介质――分离器中的聚合介质可以使用几年。在正常工作条件下没有要求明确
的维护和更换。如果由于一些不常见的原因通过加化学物质到水中而破坏了介
质，那么需要按照一下程序更换介质
1：清除原介质。
2：内部和外部的介质都是包装的。里面的部分要在外部的内部挤压。清
除内部。
3：对于先装哪个部分是没有关系的。将介质放置在合适的位置并且启动，
确保不要破坏介质。介质需要压紧但不要太紧。
4：要两个人将介质装进桶中比较容易。
5：对于另外一部分的介质重复该程序。
E: 滤器介质――当油份浓度不能小于 15PPM 时，且已经清洁了光敏电阻并且已经

反冲洗了终滤器，那么就需要更换滤器的介质了。高油份浓
度可能是使用了表面活性剂和其它的清洁化学物质引起的。我们建议不要使用引
起乳化的清洁品。一份工厂推荐的清洁品可以从工厂的代表或者直接从工厂处获
得。
F: 控制部分――控制部分设计成船用，当故障时需要更换，我们已经有一个我们推
荐备件的备件清单。
G：流量指示――流量大小是一个常规的工业参数。方便读取流量，安装简单，价格
便宜这是本流量计被选择用在设备上的理由，如果流量计上的玻璃变的模糊或者
破碎，你可以非常方便的打开流量计的外壳，更换上一个新的玻璃罩，流量计里
面的弹簧维护更换也很方便只要拆掉外壳和玻璃罩就可以更换了，但每个型号的
流量计其弹簧规格不同、如果流量计失效不能工作，系统也不会受到多大的影响
还是可以工作在某一个流量下的。如果流量大整个设备的处理量就大，如果流量
小设备的处理量就低，对国际海洋环境组织来说知道某个时间的流量大小没有必
要，只要排放的水含油量达标就可以了
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JEU
Model JEU EBARA Stainless Steel Self Priming Jet Pumps
Contents
Model No. Specifications Selection Performance Pump Sectional View

Chart Curve Dimensions
JEU806-3/4HP
JEU1506-11/2HP 502 503 504 505 506
*Note: NSF/ANSI 61 Annex G listed

Certified to
NSF/ANSI 61, ANNEX G
EBARA Fluid Handling

www.pumpsebara.com 500
(t) 803 327-5005 • (f) 803 327-5097 rev. 03/12
JEU
Model Designation
JE U 806 7 D 1 G
MoDEl TyPE
JE – Jet Pump
GEoGRAPHIC DESIGNATIoN
U – U.S.A. market
HoUSING AND IMPEllER NUMBER

806
1506
RATED KW
7 – 3/4 HP
10 – 1HP
15 – 11/2 HP
20 – 2HP
MoToR TyPE
D = oDP motor
T = TEFC motor
PHASE
1 – single phase
3 – three phase
MECHANICAl SEAl
G – General service mechanical seal

(t) 803 327-5005 • (f) 803 327-5097 rev. 08/01
JEU
Specifications
Standard Optional
Size
Suction 11/4'' NPT thread
Discharge 1'' NPT thread
Range of HP /4 HP to 2HP
3
Range of Performance
Capacity 1.5 to 18.5 GPM at 3450 RPM
Head 63 to 190 Feet at 3450 RPM
Liquid handled
Type of liquid Clean water
Temperature Maximum: 113˚F (45˚C)
Suction Lift Maximum 25 Ft. at 68˚F (20˚C)
Maximum working pressure 125 PSI (9 Bar)
Materials
Casing 304L Stainless Steel
Impeller (closed type) 304L Stainless Steel
Shaft Stainless Steel
Ejector Noryl plus 20% Fiberglass
Diffuser Noryl plus 20% Fiberglass
Bracket Aluminum
Shaft Seal Mechanical Seal – Type 21
Bearing Ball Bearing
Direction of Rotation Clockwise when viewed from motor end
Motor
Type NEMA 56J Frame
Speed 60 Hz, 3450 RPM (2 poles)
Single Phase TEFC – 1 HP and 2 HP
ODP – 3/4 HP and 11/2 HP, 115/230V
Three Phase TEFC – 1 HP and 2 HP
ODP – 3/4 HP and 11/2 HP, 208-230/460V
Motor Protection Built-in overload protection (single phase)

(t) 803 327-5005 • (f) 803 327-5097 rev. 08/01
JEU
Selection Chart
60 Hz Synchronous Speed: 3450 RPM
l /MIN
10 20 30 40 50 60 70
Ft.
200
60M
180
50
160
140
25
TOTAL HEAD
40
20
120
15
100 30
10
25 3
80
20
15 20
60
10
3
40
0 2 4 6 8 10 12 14 16 18 20
CAPACITY IN GPM
NOTE: Figures in selection chart indicate suction lift (Ft.).

(t) 803 327-5005 • (f) 803 327-5097 rev. 08/01
JEU
Performance Curves
JEU806–3/4 HP Synchronous Speed: 3450 RPM Size: 1 x 11/4 x 41/2

CURVE NO.: JE-C601-9601
1" NPT DISCH. x 11/4" NPT SUC.
IMP. DIA. 4 1/2" (115mm)
1.00 SPEC. GRAVITY
140
40
120
50 30 100 T.D.H.
Suc. .Lift (Ft.)) 25
40 80
20
KW SHAFT POWER
HP SHAFT POWER
20 .
30 60
PUMP EFF 15
10 1
TOTAL HEAD
TOTAL HEAD
EFFICIENCY
3
20 40 SHAFT POWER 1
Ft
0.5
%
0.5
CAPACITY 0 5 10 15 20
USGPM
CAPACITY 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
m3/min
JEU1506–11/2 HP Synchronous Speed: 3450 RPM Size: 1 x 11/4 x 53/16

CURVE NO.: JE-C603-9601
1" NPT DISCH. x 11/4" NPT SUC.
IMP. DIA. 5 3/16" (132mm)
1.00 SPEC. GRAVITY
60 200
180
50
160
140 T.D.H
40 Suc.. Lift (Ft.) 25 .
120 20
50 30 100 15
10
3
40 80
KW SHAFT POWER
HP SHAFT POWER
20 1.5
30 60 SHAFT POWER
1
TOTAL HEAD
TOTAL HEAD
EFFICIENCY
20 40 EFF. 1
PUMP
Ft
0.5
%
0.5
CAPACITY 0 5 10 15 20
USGPM
CAPACITY 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
m3/min

(t) 803 327-5005 • (f) 803 327-5097 rev. 08/01
JEU
Dimensions
Priming Plug A
PF /4"
1
Discharge 83/16"
21/8"
Suction
85/16"
61/8"
83/16"
Drain Plug 315/16" 51/8"
1
PF /4"
69/16" 2-Anchor Hole 93/16"
ø3/8"
Pump Size-NPT Dimension Unit Weight (lbs.)

(inch) (inch)
Model Size Single Phase Three Phase
Suction Discharge A
oDP TEFC oDP TEFC
JEU806-3/4HP 1×11/4 ×41/2 11/4 1 155/8 Max. 37 41 39 43
JEU1506-11/2HP 1×11/4×53/16 11/4 1 191/8 Max. 42 46 44 48

(t) 803 327-5005 • (f) 803 327-5097 rev. 03/12
JEU
Sectional View
018
120-2
022
021 800
212-1 150
115-2
135-1 120-3
115-3
120-4
011
111
135-2
048
160
115-1
115-4 001 120-1

212-2
Part No. Part Name Material No. for 1 Unit

001 Casing 304L Stainless 1
011 Casing cover 304L Stainless 1
018 Bracket Aluminum 1
021 Impeller 304L Stainless 1
022 Guide vane Noryl GFNZ 1
048 Impeller nut 304L Stainless 1
111 Mechanical seal – 1 set
115-1 O-Ring Viton 1
120-1 Bolt 304L Stainless 8
135-1 Washer 304L Stainless 1
135-2 Washer 304L Stainless 1
150 Diffuser & Venturi Tube Noryl GFNZ 1
160 Base Steel 1
212-1 Plug 304L Stainless 1
212-2 Plug 304L Stainless 1
800 Motor NEMA 56J Frame 1

(t) 803 327-5005 • (f) 803 327-5097 rev. 08/01
No.:
Date: 10/5/2011
Customer :
TECHNICAL PROPOSAL
Three-phase induction motor - Squirrel cage rotor
Product line : Jet Pump - NEMA 56 : Three-Phase - Threaded - TEFC (IP55)
Catalog Number : .7536ES3EJPR56J

List Price :
Notes:
Jet Pump - NEMA 56 : Three-Phase - Threaded - TEFC (IP55)
Performed by: Checked:

No.:
Date: 10/5/2011
DATA SHEET
Customer :
Frame : B56
Output : 0.75 HP
Frequency : 60 Hz
Poles : 2
Full load speed : 3440
Slip : 4.44 %
Voltage : 208-230/460 V
Rated current : 2.30-2.19/1.10 A
Locked rotor current : 17.1/8.54 A
Locked rotor current (Il/In) : 7.8
No-load current : 1.18/0.590 A
Full load torque : 1.13 lb.ft
Locked rotor torque : 400 %
Breakdown torque : 350 %
Design : A
Insulation class : F
Temperature rise : 80 K
Locked rotor time : 15 s (hot)
Service factor : 1.15 (1.00 at 208V)
Duty cycle : S1
Ambient temperature : -20°C - +40°C
Altitude : 1000 m
Degree of Protection : IP55
Approximate weight : 26 lb
Moment of inertia : 0.03156 sq.ft.lb
Noise level : ---
D.E. N.D.E. Load Power factor Efficiency (%)

Bearings 6203 2RS 6202 2RS 100% 0.83 77.0
Regreasing interval --- --- 75% 0.78 72.5
Grease amount --- --- 50% 0.67 66.5
Notes:

No.:
Date: 10/5/2011
PERFORMANCE CURVES RELATED TO RATED OUTPUT

100 1.0 0.0
C - Slip
C
90 0.9 2.0
80 0.8 4.0
70 0.7 6.0
60 0.6 A
B 8.0
50 0.5 10.0
D - Current at 230V (A)

40 0.4 4
3
A - Efficiency (%)
B - Power factor
2
D
1
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Percent of rated output (%)
Customer :
Output : 0.75 HP Locked rotor current (Il/In) : 7.8

Frame : B56 Duty cycle : S1
Full load speed : 3440 Service factor : 1.15 (1.00 at 208V)
Frequency : 60 Hz Design : A
Voltage : 208-230/460 V Locked rotor torque : 400 %
Insulation class : F Breakdown torque : 350 %
Notes:

No.:
Date: 10/5/2011
CHARACTERISTIC CURVES RELATED TO SPEED

5.0 10.0
B - Current related to rated current (I/In)

4.5 9.0
4.0 B 8.0
A - Torque related to rated torque (C/Cn)
A
3.5 7.0
3.0 6.0
2.5 5.0
2.0 4.0
1.5 3.0
1.0 2.0
0.5 1.0
0.0 0.0
0 10 20 30 40 50 60 70 80 90 100
Speed related to rated speed (%)
Customer :
Output : 0.75 HP Locked rotor current (Il/In) : 7.8

Frame : B56 Duty cycle : S1
Full load speed : 3440 Service factor : 1.15 (1.00 at 208V)
Frequency : 60 Hz Design : A
Voltage : 208-230/460 V Locked rotor torque : 400 %
Insulation class : F Breakdown torque : 350 %
Notes:

1 2 3 4 5 6 7 8
Notes:
E
Performed by:
Checked:
Customer:
Jet Pump - NEMA 56 : Three-Phase - Threaded - TEFC (IP55)
F P N-W U AB AA
7.323 1.874 0.6250 5.433 NPT 1/2"
Flange AJ AK BD BF
FC-149 5.874 4.500 6.535 UNC 3/8"x16-2B Three-phase induction motor 10/5/2011
BB BC AH Frame B56 - IP55
0.157 --- 2.563
BilgMon488 Instruction Manual vQ 1/49
INSTRUCTION MANUAL
操作说明书
BilgMon488
15 ppm Bilge Alarm
15 ppm 舱底报警
Brännströms Elektronik AB
Uddevallagatan 14
416 70 Göteborg
Tfn: +46 31 19 56 00
Fax: +46 31 19 77 90
info@brannstrom.se ♦ www.brannstrom.se
Table of Contents 目录
1. Table of validity........................................................................................................... 3
2. Introduction 介绍.......................................................................................................5
3. Construction 施工...................................................................................................... 5
4. Operation 操作.......................................................................................................... 7
5. Caution 警告............................................................................................................... 7
6. Specification 说明书....................................................................................................8
6.1. General 概要........................................................................................................8
6.2. Specific 115/230 V AC model 具体 115/230V 交流模式................................. 10
6.3. Specific 24 V AC/DC model.............................................................................. 10
7. Installation 安装........................................................................................................ 11
8. Operating Instructions 操作说明书.......................................................................... 19
9. Simulation.................................................................................................................. 31
10. Contrast................................................................................................................... 31
11. Automatic stopping device test 自动停止装置试验................................................32
11.1. While separator is active.................................................................................... 32
11.2. While separator is not active............................................................................. 32
12. Response test 响应测试.......................................................................................... 32
12.1. Step 1................................................................................................................32
12.2. Step 2................................................................................................................32
12.3. Alternative........................................................................................................ 33
13. Calibration check (40 NTU)..................................................................................... 34
14. Maintenance............................................................................................................. 34
15. Log entries............................................................................................................... 35
16. Troubleshooting....................................................................................................... 37
17. Certificates............................................................................................................... 39
1. Table of validity 有效性列表
The following table describes the software and hardware versions on which this
document was based.下表是基于文档描述的软件和硬件版本。
Doc version MASTER MASTER PCB ver. SENSOR SW SENSOR PCB ver.
文档版本 SW ver. 主印刷电路板版本 ver. 传感器印刷电路板版本
主开关版本传感器开关版本
vN A3 Bilgbas_H.1/ F Bilgemon H.1
Bilgbaslv_C.1
Bilgemaster L.1
vO, vP A4 Bilgbas_H.1/ B2 Bilgemon J.1
Bilgbaslv_D.1
Bilgemaster L.1
vQ A4 Bilgbase_H.1/ B2 Bilgemon J.1
Bilgbaslv_D.1/
Bilgbasco_A
Bilgemaster L.1
2.Introduction 介绍
The BilgMon488 bilge alarm has been designed specifically for use in conjunction
with 15 ppm oil-water separator units. BilgMon488 performance meets the
requirements of the International Maritime Organisation specifications for 15 ppm
bilge alarms contained in resolution MEPC. 107(49).
BilgMon488 舱底警报特别针对 15ppm 油水分离器而设计。BilgMon488 遵循国
际海事组织制定的 15ppm 舱底报警的 MEPC. 107(49)决议。
BilgMon488 is equipped with 2 adjustable alarms that are triggered when the oil-
content of the processed sample exceeds the set limit (1 – 15 ppm, works-adjusted to
15ppm). Alarm outputs consist of relays and indicator LEDs. Additionally a 0(4) – 20
mA current output signal (corresponding to 0 – 30 ppm) is available to enable
remote surveillance and recording of oil contents.
BilgMon488 配备两个可调整的报警触发点：当含油量超过设定值（1-15ppm，
工装设定为 15ppm）。报警输出由继电器和发光二极管组成。一个 0（4）-20
毫安的电流输出信号（对应于 0-30ppm）能够很细微的记录含油量。
Downloading the operating log of BilgMon488 can be done through a USB-interface.

This requires driver software and cables that can be supplied on demand.
BilgMon488 能够通过一个 USB 接口下载操作日志，我方可按要求提供安装驱
动程序和电缆。
3.Construction 解释说明
BilgMon488 consists of two main parts, the MASTER unit (housing with LCD,
buttons and LEDs) and the SENSOR unit (housing with pipe fittings).
BilgMon488 由两个主要部分组成，主单元（机壳上有液晶面板，按键和发光二
极管）和信号单元（机壳上有相应管件）。
The MASTER unit contains all the electronics used for control and data storage of the
bilge alarm. Mounted in the lid of the MASTER housing is the main memory
containing the bilge alarm log.
主单元包含所有电气元件用于舱底报警的控制和数据保存。主存储器包含舱底
报警记录安装在主机壳的面板上。
The SENSOR unit contains electronics for measuring the sample stream. The
SENSOR unit also holds the measurement calibration data. Communication with the
MASTER unit is done wireless hence the SENSOR unit is hermetically sealed and
shall not be opened.
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信号单元所包含的电气元件用来检测流动水样。信号单元同样也要保持测量校
准数据。通信是由无线方式做到的，因此信号单元是被密封的，不能够将其打
开。
4.Operation 操作方法
Optical sensors monitors the amount of light scattered and absorbed by the oil
droplets in the sample stream. Sensor signals are processed by a microprocessor to
produce a corresponding oil content (ppm) output. The output is communicated to the
MASTER unit where it is processed. The MASTER unit takes action, such as alarm
activation, logging etc., depending on the oil content and the separator signal.
当水样中含有油滴，光电传感器射出的光线会产生折射和聚焦。这个光学信号
通过微处理器进行计算然后转化为相应的含油量（ppm）输出。输出信号传递
到主单元进行处理。主单元依靠含油量进行诸如报警、记录等工作。
Settings that affect the behaviour of the bilge alarm are described in detail in
the“Operating Instructions”section.
如何设置舱底报警详细描述查看“操作说明书”。
Zero point calibration can be re-adjusted on site whereas full sensor calibration
according to IMO-requirements is performed by manufacturer.
尽管所有信号刻度遵循 IMO 要求由厂商执行，但 0 刻度要在指定机构重新设
定。
5.Caution 注意事项
The lid of the MASTER unit contains a small battery (watch battery). This battery
enables the BilgMon488 to keep track of time and date (real time clock, RTC).
主单元面板包含一块小电池（纽扣电池）。该电池能够维持 BilgMon488 的时间
和数据（实时时钟）。
Do NOT under any circumstance remove this battery as it will cause a unrecoverable
error (“RTC check FAILED!!”).
禁止任何情况下拆除此电池，否则将导致不可恢复的错误（实时时钟时间丢
失）
Do NOT open the SENSOR unit as this will invalidate the calibration.
禁止打开信号单元，否则将导致刻度失效
Do NOT open the MASTER unit when it is energized. Hazardous voltages are
present inside.
禁止主单元工作时把其打开。谨防触电。
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6.Specification 说明书
6.1 General 概要
Measurement 参数:
Oil range 含油范围: 0 – 30 ppm
Resolution 精度: 0.1 ppm
Accuracy 决议: According to IMO MEPC.107(49)
遵循 IMO MEPC.107(49)
Response time 响应时间: < 3 sec
Alarms 警报:
Alarm 1 (valve control) delay: 0-10 sec user adjustable
警报 1（阀们控制）延迟 0－10 秒用户可调
Alarm 2 (annunciation) delay: 0-600 sec user adjustable
警报 2（通报）延迟 0－600 秒用户可调
Alarm points 1 and 2: 1-15 ppm user adjustable
报警点 1 和 2 1-15 ppm 用户可调
Alarm hysteresis: 0.5 ppm (below alarm point)
报警滞后： 0.5ppm(低于报警点)
Data storage and retrieval:数据存储和

检索
Calibration storage: Stored in sensor housing.
刻度存储：保存在信号单元机壳内
IMO required data: Stored in BilgMon488 main housing
国际海事组织要求数据： (sensor housing may be replaced with data
remaining on board).
保存在 BilgMon488 主机壳内（在数据
保留在主板的情况下信号机壳能更换）
IMO required data retrieval: Via LCD display, RS232 or removable
国际海事组织要求的数据检索 memory.
通过液晶显示屏，RS232 或存储器
User interface:用户界面
LCD display: 2x16 alphanumeric display
液晶显示器 2 x16 数字显示
Control: 4 button keypad
控制 4 个按键
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6.2 Specific 115/230 V AC model 具体 115/230V 交流模式

Input/Output 输入/输出：
Current output: 0 – 20 mA or 4 – 20 mA for 0 – 30 ppm
输出电流 0－30ppm 时为 0 – 20 mA 或 4 – 20 mA
Communications: RS232 serial communication (separate
通信 adapter)
RS232 串口（独立适配器）
Alarm outputs: 2 x relays (0.25A)
报警输出 2x 继电器（0.25A）
Clean water solenoid valve output: 1 x relay (0.5A, supply voltage)
清水电磁阀输出 1x 继电器（0.5A，电源电压）
Switch input: 1 x switch input for separator status
开关输入 1x 开关输入用于分离状态
System and supply 系统电源:

Supply: 1 A, 115 or 230 V AC, 50 – 60 Hz
电源 1 A, 115 或 230 V AC, 50 – 60 Hz
Power consumption electronics: 10 VA
电源功率 10 VA
Power consumption solenoid: 18 VA
线圈功率 18 VA
6.3 Specific 24 V AC/DC model 交/直流点模式细节
Input/Output 输入/输出:
Current output: 0 – 20 mA or 4 – 20 mA for 0 – 30 ppm
电流输出 0－30ppm 时为 0 – 20 mA 或 4 – 20 mA
Communications: RS232 serial communication (separate
通信 adapter)
RS232 串口（独立适配器）
Alarm outputs: 2 x relays (1A)
报警输出： 2x 继电器（1A）
Clean water solenoid valve output: 1 x relay (1A, supply voltage)
清水电磁阀输出： 1x 继电器（1A，电源电压）
Switch input: 1 x switch input for separator status
开关输入： 1x 开关输入用于分离状态
System and supply:

Supply: 1.5 A, 24 V AC (50 – 60 Hz) or 24 V DC
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System and supply:

电源： 1.5 A, 24 V AC (50 – 60 Hz) 或 24 V DC
Power consumption electronics: 10 VA
电源功率： 10 VA
Power consumption solenoid: 18 VA
线圈功率： 18 VA
7. Installation 安装
Mechanical 机械
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Tube arrangement alt 1 管束排列方案
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3-way solenoid valve mounting (Tube arrangement alt 1).

3 通电磁阀（管束排列方案 1）
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NOTE (115/230 VAC model): There are two coils delivered with the BilgMon 488
one to be used with 110 VAC (marked 96 V) and one to be used with 220 VAC
(marked 205 V). Be sure to install the proper one for the choosen voltage.
注意（115/230V 交流模式）：BilgMon 488 交货时附带两个线圈，一个用于
110V 交流电(标记为 96 伏)，另一个用于 220V 交流电（标记为 205V）。安装
使用时务必确认所选择的电压。
NOTE (24 VAC/DC model): Only one coil delivered with this model (marked 24 V).
注意（24V 交流/直流模式）：该模式只供应 1 个线圈（标记为 24 伏）
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Tube arrangement alt 2 管束排列方案 2
Uddevallagatan 14
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Uddevallagatan 14
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Tube arrangement alt 3 管束排列方案 3
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Electrical connections 电气连接

115VAC/230VAC
24V AC/DC
8. Operating Instructions 操作说明书
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The menu system of BilgMon488 is organised into 4 top menus:

1. Main menu.
2. Info menu.
3. Log menu.
4. Cleaning/test menu.
5. Settings menu.
Some of the menus also contain submenus for displaying or setting the properties of
the apparatus.
BilgMon488 菜单系统分 4 个 1 级菜单：
1. 主菜单
2. 信息菜单
3. 日志菜单
4. 清洗/测试菜单
5. 设置菜单
一些菜单还包含一些用于显示或设置设备性能的子菜单。
Navigating the menus is done by using the 4 push buttons located beneath the LCD
display. In this document they are referred to as (from left to right) MINUS, PLUS,
ABORT and ENTER. LONG_ENTER means keeping the ENTER button pressed for
more than 2 seconds. By using the above mentioned buttons the user is able to
navigate menus, enter values and activate different functions of the BilgMon488 .
通过使用液晶显示器下的 4 个按钮来操作菜单。在文档中提到的（从左到右）
MINUS, PLUS, ABORT 和 ENTER，LONG-ENTE R 意思是长按 ENTER 键超
过 2 秒。用户通过使用上述提到的按钮来操作菜单，输入设定函数使
BilgMon488 在不同的功能下运作。
Main menu 主菜单

After start the display will show the main menu. The apparatus can only be activated
when the display shows the main menu hence the user has to be sure that the
apparatus is left in the main menu state after performing settings, cleaning, tests etc.
Contrast of the LCD screen can be adjusted by holding the ABORT button while
adjusting with PLUS and MINUS when in main menu. Note that the apparatus will
return to the main menu after 5 min of no activity (no pressed buttons). The bilge
alarm can only be activated when in main menu. In all other menus the overboard
valve will be closed.
打开显示器后将看见主菜单。该仪器只有当显示器显示主菜单时才能工作，因
此用户必须确保该仪器是留在主菜单状态上进行设置，清洗，测试等。液晶显
示屏的对比度可以通过在主菜单同时按住 ABORT 与 PLUS 和 MINUS 键来调
整。请注意，该设备若 5 分钟未操作（未按下任何按钮）将会返回主菜单（未
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按下按钮）。舱底报警只有在主菜单发出。在其他菜单模式下，舷外阀门都将
关闭。
Info menu 信息菜单
The submenus of info menu show information about the master unit (software version
and part ID) and the sensor unit (part ID, SW version, sensor birth date and date of
last calibration check). Note that entering the submenus also puts the apparatus in an
alarm state.
信息菜单的子菜单显示主控制单元（软件版本和零件号）和信号单元资料（零
件号，开关版本，传感器生产日期和最近次刻度校核日期）的信息。请注意，
进入子菜单仪器还是在报警状态中。
Log menu 日志菜单
The log menu contains functionality for searching and stepping the logged IMO
required data.
日志菜单包含的功能用于搜索和分步记录国际海事组织要求的数据。
Cleaning & test menu 清洗和测试菜单

The cleaning & test menu and its submenus provide measures for calibrating, cleaning
and testing the apparatus.
清洗和测试菜单和子菜单提供校准，清洗和仪器测试措施
Settings menu 设置菜单

Settings menu contains adjustable settings of parameters such as ppm-limits,
alarm/valve time delays, autoflush settings, clock and current output (curro) mode.
设置菜单包含如 ppm 参数范围设置，报警/阀门延时，自动冲洗设置，时间和
电流输出模式。
The menu system of BilgMon 488 is depicted in the following figure:

BilgMon 488 的菜单系统如下图所述：
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Contrast Forced valve close
MAIN INFO LOG CLEANINNG & TEST SETTINGS
Simulation Master info Step log Clean cell Valve
Sensor info Check 40NTU cal Alarm
Test outputs Autoflush
Clock
(solid) navigate using PLUS and MINUS

(dashed) navigate using ENTER and ABORT
Curro mode
(dotted) navigate using LONG_ENTER if sep is active
Curro max
The following table shows the different menus and submenus of the BilgMon488 and
detailed instructions on how to operate them.
下表详细说明了如何操作 BilgMon488 中不同的菜单和子菜单。
050327 10:06:00
PPM=07.2 SPL
The“main menu” is
displayed at startup.
启动后显示主菜单
The values shown in this
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menu are date, time, the

measured oil-content of the
sample in parts per million
(ppm) and the position of
the clean water valve (SPL
= sample, WTR = clean
water).
在此菜单中显示的值是日
期，时间，测得的样本中
的含油量（ppm）和净水
阀门的位置（SPL＝样
本，WTR＝净水）。
Press PLUS to go to next
menu.
按 PLUS 键到下一个菜单
Return to this menu by
pressing ABORT several
times.
按 ABORT 键数次可返回
此菜单。
If the second row shows
“Lost sensor com!” se
section Troubleshooting.
如果第二行显示“失去信
号端口”本身疑难解答。
If the alarm is on (when
unit is active) the user can
acknowledge it by pressing
one of the buttons.
如果报警开启，（当部件
启动），用户可通过按下
其中一个按钮确认。
Acknowledging will turn
off the alarm output but
the alarm led will remain
lit until the PPM-value is
below the set alarm limit.
确认将关闭报警输出，但
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报警指示灯将持续闪亮直
到 PPM 值低于设定报警
上限。
Info Master info
信息主要信息
The “info menu” and its Continuous cycles with Master info
submenus contain information about the
information about the master unit (se right
system such as software column). Master ID:
versions, ID-numbers etc. 关于主单元的连续周期的 AC02-2321
信息菜单和子菜单包含了信息。（右栏）
系统软件翻译信息，数字 Press MINUS to go to Master SW ver:
ID 等。 previous submenu. 000A
To enter the info 按 MINUS 返回上一菜单
submenus press ENTER.按 Press PLUS to go to next
ENTER 进入信息子菜 submenu.
单。按 PLUS 进入下一个菜单
Press PLUS to go to next Press ABORT to exit the
menu.按 PLUS 进入下一 submenu.
个菜单按 ABORT 退出菜单
Return to this menu by
pressing ABORT several
times.按 ABORT 数次退
出此菜单
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Sensor info
传感器信息
Continuous cycles with Sensor info
information about the
sensor unit (se right
column). Sensor ID:
关于传感器单元的连续周 CD12-4541
期的信息。（右栏）
Press MINUS to go to Sensor SW ver:
previous submenu. 按 000B
MINUS 返回上一菜单
Sensor date:
Press ABORT to exit the 050219 15:20:00
submenu. 按 ABORT 退
出菜单 Cal. checked:
050220 10:00:00
T:25.3 Dry:60
V3:3.20 V03:.312
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Log Log: PPM > 15 Log: Search for:

1043 entries 050223 13:32:12 050223 13:32:12
The “log menu” shows the The “step log menu” lets The “search log menu” lets
number of events/entries the user step through the the user search for a
currently available in the apparatus log displaying specific date in the log.
log memory. the event, date and time of Note that a cursor is shown
日志菜单显示在内存中目 the log entries. under the item currently
前可用的日志和条目。步骤日志菜单让用户通过 edited.
To enter the log submenu 仪器的日志显示事件，日搜索日志菜单让用户在日
press ENTER (only 期和日志的时间。志中搜索具体日期。请注
possible if log is not Step backwards (in time) 意,光标是在当前正在编
empty). by pressing MINUS and 辑的项目下显示。
按 ENTER 键进入日志子 forward by pressing PLUS. Move cursor by pressing
菜单(如果日志不是空的) 返回按 MINUS，离开按 ENTER.
Press PLUS to go to next PLUS。通过 ENTER 键移动光
menu or MINUS to go to Enter search mode by 标。
previous. pressing ENTER (se right). Increase/decrease value by
按 PLUS 键进入下一菜单 Return to “log menu” by pressing PLUS/MINUS.
或按 MINUS 返回。 pressing ABORT. 按 PLUS/MINUS 键增加/
进入搜索模式按减少数值。
ENTER。返回日志菜单 Commit search by pressing
按 ABORT。 LONG_ENTER (return to
When returning from this “step log menu” with result
menu the user will be of search).
asked “Send log?”. This 按 LONG_ENTER 提交搜
provides the possibility to 索（返回搜索日志菜单）
send data to the USB port Abort search by pressing
of the apparatus. Answer ABORT (return to“step log
the question by pressing menu”).
the button corresponding to 按 ABORT 键中止搜索
the desired answer.
（返回到步骤日志菜
当返回这个菜单，用户会
单）。
被询问“发送日志”。这可
能将数据发送到设备的
USB 端口。通过按所需
答案的相应按钮来回答这
个问题。
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Cleaning & test Clean cell: Zero value: 040%

START WTR ZERO
清洁和测试
To enter the “cleaning and Press ENTER to enter the The cleaning mode lets the
test” submenus press cleaning mode (se right). user unscrew the cap of the
ENTER. Press PLUS to go to next sensor housing and clean
按 ENTER 键进入“清洁 submenu and ABORT to the sensor using water and
和测试”子菜单。 exit the submenu. a soft brush.
Press PLUS to go to next 按 ENTER 进入清洁模清洗模式可以让用户松开
menu or MINUS to go to 式。按 PLUS 进入下一个传感器并且用水和软刷清
previous. ABORT returns 子菜单，按 ABORT 退出洁传感器。
to “main menu”. 子菜单。 The water valve can be
按 PLUS 进入下一菜单或 opened and closed by
MINUS 返回。ABORT 返 pressing MINUS.
回主菜单。按 MINUS 可开启和关闭
水阀门。
When the sensor tube is
clean enough the “zero
value” will be below 50%
when running clean water
through the sensor.
当清洁水通过传感器，传
感器管足够干净（零值）
将低于 50％。
Pressing ENTER when
“ZERO” is displayed zero
calibrates the sensor.
按下 ENTER 键，
“ZERO”显示传感器零校
准。
Check 40NTU cal: Cal value: 083%
START OK
Press ENTER to enter the Fill the sensor with 40NTU

check 40NTU calibration reference fluid. If the
mode (se right). sensor is correctly
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按 ENTER 进入检查 calibrated the calibration

40NTU 校准模式。 value displayed should be
Press PLUS to go to next above 80%.
submenu or MINUS to go 把传感器装满 40NTU 参
to previous. 考液体。如果传感器校准
按 PLUS 键进入下一子菜正确，那么校准值将显示
单或者按 MINUS 返回上在 80％以上。
一级菜单。 Pressing ENTER (OK)
Press ABORT to exit the when the calibration value
submenu. is displayed sets the
按 ABORT 键退出子菜 calibration check date
单。 (shown in “sensor info”
submenu) to current date.
按 ENTER(确定)时，当
校准值显示设置校准检查
日期为当前日期（在传感
器信息子菜单中显示）。
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Test outputs: ALM VLV WTR C

START OFF 09 OFF EXIT
Press ENTER to enter the The test outputs lets the

automatic cleaning mode user toggle the relay
(se right). outputs of the BilgMon
按 ENTER 进入自动清洗 488.
模式。测试允许用户切换的
Press MINUS to go to BilgMon488 继电器输
previous submenu. 出。
按 MINUS 返回上一级菜 Press
单。 MINUS/PLUS/ABORT to
Press ABORT to exit the toggle the states of valve-
submenu. /alarm-/water-relay.
按 ABORT 键退出子菜按 MINUS/PLUS/ABORT
单。来切换阀－/报警－/水－
继电器。
Note that a time limit is
used for the water- and
valve-relays.
请注意水－和阀－继电器
有时间限制。
Two relays can not be
activated simultaneously.
两个继电器不能同时激
活。
In the top right corner of
the LCD an indication of
the input signal is shown
(“C” means closed and “O”
means open).
在 LCD 的右上角显示输
入信号指示（“C”指关
闭，“O”指打开）。
Exit by pressing ENTER.
退出按 ENTER.
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Settings Valve settings Valve settings

ppm:15.0 t:000s ppm:15.0 t:000s
设置值设置
Ppm:15.0 t:000s
To enter the “settings” Valve settings menu show Move cursor by pressing
submenus press ENTER. the values set for Alarm 1 ENTER.
按 ENTER 进入设置子菜 (valve control). 按 ENTER 键移动光标。
单。阀门设置菜单显示报警 1 Increase/decrease value by
Press PLUS to go to next （阀门控制）的设置值。 pressing PLUS/MINUS.
menu or MINUS to go to There are two editable 按 PLUS/MINUS 来增加/
previous. values, the ppm limit 减少值。
按 PLUS 键进入下一子菜 (“ppm:”) and the time Commit value by pressing
单或者按 MINUS 返回上 delay (“t:”) of the alarm. LONG_ENTER.
一级菜单。有 2 个可编辑的值，ppm 按 LONG_ENTER 提交
的限制(“ppm:”)和报警的值。
时间延迟(“t:”) Abort edit by pressing
Press ENTER to edit the ABORT.
valve settings (se right). 中止编辑按 ABORT。
按 ENTER 键编辑阀门设
置。
submenu and ABORT to
exit the submenu.
按 PLUS 进入下一子菜
单，按按 ABORT 键退出
子菜单。
Alarm settings Alarm settings
ppm:15.0 t:010s ppm:15.0 t:010s
Alarm settings menu show Move cursor by pressing

the values set for Alarm 2 ENTER.
(annunciation). 按 ENTER 键移动光标。
报警设置菜单显示报警 2 Increase/decrease value by
（阀门控制）的设置值. pressing PLUS/MINUS.
There are two editable 按 PLUS/MINUS 键增加/
values, the ppm limit 减少。
(“ppm:”) and the time Commit value by pressing
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delay (“t:”) of the alarm. LONG_ENTER.

有 2 个可编辑的值，ppm 按 LONG_ENTER 提交。
的限制(“ppm:”)和报警的 Abort edit by pressing
时间延迟(“t:”) ABORT.
Press ENTER to edit the 按 ABORT 键退出编辑。
alarm settings (se right).
按 ENTER 编辑报警设
置。
submenu or MINUS to go
to previous.
按 PLUS 键进入下一子菜
单或者按 MINUS 返回上
一级菜单。
Press ABORT to exit the
submenu.
按 ABORT 键退出退出子
菜单。
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Autoflush ( on) Autoflush ( on)

t:20s int:24h t:20s int:24h
Autoflush lets the user set Move cursor by pressing

the duration (“t:”) in ENTER.
seconds and the interval 按 ENTER 键移动光标。
(“int:”) in hours of the Increase/decrease value by
automatic sensor flush pressing PLUS/MINUS.
function. 按 PLUS/MINUS 键增加/
传感器冲洗的自动冲洗功减少。
能可让用户设置持续时间 Commit value by pressing
（S）和间隔时间（h）。 LONG_ENTER.
Press ENTER to edit the 按 LONG_ENTER 提交。
autoflush settings (se Abort edit by pressing
right). ABORT.
按 ENTER 键编辑自动冲按 ABORT 键退出编辑。
洗设置（右栏）。 Setting the duration to 0
Press PLUS to go to next seconds turns the autoflush
submenu or MINUS to go feature off.
to previous. 设置持续时间 0 秒关闭自
按 PLUS 键进入下一子菜动冲洗功能。
单或者按 MINUS 返回上
一级菜单。
submenu.
按 ABORT 键退出子菜
单。
Set clock: Set clock:
050327 11:34:05 050327 11:34:05
Set clock shows the date Move cursor by pressing

and time as displayed in ENTER.
the main menu. 按 ENTER 键移动光标。
设置在主菜单中显示的日 Increase/decrease value by
期和时间。 pressing PLUS/MINUS.
Press ENTER to edit/set 按 PLUS/MINUS 键增加/
the date and time. 减少。
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按 ENTER 键编辑/设置日 Commit value by pressing

期和时间。 LONG_ENTER.
Press PLUS to go to next 按 LONG_ENTER 提交。
submenu or MINUS to go
to previous. Abort edit by pressing
按 PLUS 键进入下个子菜 ABORT.
单或按 MINUS 键返回上按 ABORT 键退出编辑。
一级。 Time format is ”yymmdd
Press ABORT to exit the hh:mm:ss”.
submenu. 时间格式为“年月日时:
按 ABORT 键退出子菜分：秒”。
单。
Curro mode Curro mode
0 to 20 mA 0 to 20 mA
Curro mode shows the set Toggle value by pressing

mode of the current output. PLUS/MINUS.
Curro 模式显示当前输出按 PLUS/MINUS 键切
设置模式。换。
Press ENTER to edit/set Commit value by pressing
the mode。 LONG_ENTER.
按 ENTER 键编辑/设置模按 LONG_ENTER 提交。
式。 Abort edit by pressing
Press PLUS to go to next ABORT.
submenu or MINUS to go 按 ABORT 键退出编辑。
to previous.
按 PLUS 键进入下个子菜
单或按 MINUS 键返回上
一级。
Press ABORT to exit.
按 ABORT 键退出。
Curro 20mA cal. Curro 20mA cal.
59100 59100
This menu lets the user Measure the output using a

change the calibration of ampere-meter and adjust
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the current output port. the output to 20mA by

此菜单允许用户改变当前 pressing PLUS/MINUS.
输出端口校准。使用安培－米测量输出和
Press ENTER to edit/set 按 PLUS/MINUS 调整输
the calibration value. 出至 20mA。
按 ENTER 键编辑/设置校 Commit value by pressing
准值。 LONG_ENTER.
Press PLUS to go to next 按 LONG_ENTER 提
submenu or MINUS to go 交。
to previous. Abort edit by pressing
按 PLUS 键进入下个子菜 ABORT.
单或按 MINUS 键返回上按 ABORT 键退出编辑。
一级。
submenu.
按 ABORT 键退出子菜
单。
9. Simulation 模拟
By holding the ENTER button pressed while in main menu lets the user simulate
different ppm values and separator input states. In this mode the The following table
shows the display in the simulation mode.
在主菜单中，通过按住输入按钮让用户模拟不同的 PPM 值和分隔输入状态。
在这种模式下，下表显示了在模拟模式中的屏幕。
Simulation SPL
PPM=07.0 SEP_ON
PPM=03.0 ACT
Pressing the MINUS

button decreases the PPM
value by 1.0. Pressing the
PLUS button increases the
PPM value by 1.0. Pressing
the ABORT button toggles
the simulated separator
input (SE
P_OFF = separator off,
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SEP_ON = separator on).

按 MINUS 键降低
1.0PPM 值.按 PLUS 键升
高 1.0PPM 值。按
ABORT 键切换分离器的
模拟输入（SE
P_OFF＝分离器关闭，
SEP_ON＝分离器打
开）。
In the upper right corner of
the display an indication is
given of the clean water
valve position.
在显示屏的右上角显示了
清洁水阀门的位置。
10. Contrast 对比度

By holding the ABORT button pressed while in main menu lets the user set the
contrast of the LCD screen. The following table shows the display when as seen when
adjusting the contrast.
通过按中止按钮。用户可在主菜单设置显示屏的对比度。下表说明了当调整对
比度时的屏幕显示。
Contrast: 010%
Pressing the MINUS

button decreases the
contrast value by 10%.
Pressing the PLUS button
increases the contrast value
by 10%.
按 MINUS 键减少 10％对
比度值。按 PLUS 键增加
10％对比度值。
11. Automatic stopping device test 自动停止装置试验
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11.1 While separator is active.当分离器启动

If the separator is active and the automatic stopping device is not activated (overboard
valve open) it is possible to force the activation of the stopping device for a short
period of time (10 s) by pressing LONG_ENTER in the main menu. This allows
testing that the automatic is correctly connected.
如果分离器启动和自动停止装置未启动（舷外阀门开启），则可以短时间按住
主菜单的长输入键（10 秒）来强制停止装置。这可以用来测试自动装置是否正
确连接。
11.2 While separator is not active.当分离器关闭

To check that the automatic stopping device is correctly connected see chapter
“12.2.Step 2”.
检查自动停止装置是否正确连接见第二章（12.2 第 2 节）
12. Response test 响应测试

12.1 Step 1 第一步
To check that the sensor responds to objects in the measuring path unscrew the
cleaning cap (top of SENSOR housing) and insert a long plastic rod or something
similar into the measuring path. Do not use anything that might scratch or in other
ways damage the glass tube inside the SENSOR housing (as for example
screwdrivers). If the sensor is working properly the display should read “PPM>30.0”
(main menu). Note that the air-detection feature of the SENSOR requires the glass
tube to be filled with water during this test for it to work.
检查传感器在测量路径中的响应对象松清洁帽的螺钉并在测量路径中插入一个
长的塑料棒或类似的东西。不能使用任何可能划伤或以其他方式损害信号机壳
内部玻璃管的物品（例如螺丝刀）。如果传感器正常工作那么显示屏有
PPM>30.0 的字样（主菜单）。请注意传感器空气检测功能需要玻璃管测试工作
时充满水。
12.2 Step 2 第二步
Testing alarms and valves are done in simulation mode (see “9. Simulation”) or in the
“Test outputs” submenu of the cleaning & test menu (see page 23) since this doesn't
require opening the MASTER housing.
在模拟模式（见“9.模拟”）或者在清洗及测试菜单中的“测试输出”子菜单
（见 23 页）检测报警和阀门，因为这不需要开放的主机罩壳。
12.3 Alternative 替代
To make step 1 of the response test affect alarms and valves the apparatus needs to be
active. Bilgmon 488 is activated (flashing green led) when in main menu and the
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separator input signal is active. Activation can be done by strapping connections 10

and 11 (see “Electrical connections”). This method is not recommended since there is
an obvious risk of forgetting the strap and that it requires opening the MASTER unit.
为了应对测试的步骤 1 影响的仪器报警和阀门必须有效。当主菜单和分隔输入
信号激活，Bilgmon 488 也激活（绿色指示灯闪烁）。可以通过捆绑连接 10 和
11 来激活（见“电气连接”）。因为会忘记捆带而造成危险且还需要打开主单
元因此这个方法不建议。
13. Calibration check (40 NTU) 校准检查（40NTU）

Enter the “Check 40NTU cal” submenu of the cleaning & test menu (see page 22).
Press enter to start the calibration test. The clean water valve will now be opened.
Close the clean water supply. Drain the sensor and fill it with 40NTU calibration fluid.
The display should now show a value between 80% and 100%. If this is the case an
“OK” will be shown over the RETURN button. Press the RETURN button to set the
“Cal checked” date as shown in the “Sensor info” submenu.
输入“检查 40NTU cal”清洗和测试菜单的子菜单（见第 22 页）。按回车键开
始校准测试。净水阀门现在打开，关闭净水供给，沥干传感器并填充 40NTU 的
标准液。显示器现在显示值在 80％至 100％之间。如果是这种情况那么在回车
键之后显示 OK。按下回车键在子菜单显示的“传感器信息”中设置“cal 检
查”日期。
14．Maintenance 保养
The BilgMon488 can be set to autoflush (see page 25). This means that the sensor
tube is flushed with clean water at durations and intervals as set in the settings menu.
Autoflush is only active when in main menu and BilgeMon488 is not active.
该 BilgMon488 可以设置为自动冲洗（见第 25 页）。这意味着在设置菜单中可
设置在持续时间和间隔时间用清水冲洗该传感器管。自动冲洗仅在主菜单有
效，BilgeMon488 无效。
Cleaning the measurement unit should be done using a soft bottle-brush and mild
detergent. Note that there is a glass tube inside the SENSOR unit so don't use
anything that might scratch or damage the glass (i.e. metal objects). If the glass tube is
layered with rust or similar try using low concentrated acid (for example hydrochloric
acid). Rinse well and make sure you protect your eyes, skin and airways if using
acidic substances.
清洁计量元件应当使用软瓶刷和温和的清洁剂。注意传感器元件里面有个玻璃
管，不要使用任何可能划伤或损坏玻璃的物体（即金属物体）。如果玻璃管附
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着锈层或类似物质可尝试使用低浓度酸（例如盐酸）。如果使用酸性物质，请
冲洗干净，并保护好您的眼睛，皮肤和呼吸道。
15. Log entries 日志条目

The following entries are stored in the log of BilgMon488:
以下条目记录在 BilgMon488 的日志里：
Type Example Explanation
举例解释
POWER ON Log: POWER ON Power was turned on at given date
电源开 060102 11:36:32 and time (yymmdd hh:mm:ss).
日志：电源开电源在给定的日期和时间打开
06 年 1 月 2 日，11：36：（年月日时：分：秒）
32
POWER OFF Log: POWER OFF Power was turned off.
电源关 060102 14:06:10 电源被关闭
日志：电源关
06 年 1 月 2 日，14：06：
10
SEP ON Log: SEP ON Separator signal input turned from
分离器信号开启 060102 12:10:12 not activated to activated.
分离器信号输入从无效到有效
SEP OFF Log: SEP OFF Separator signal input turned from
分离器信号关闭 060102 12:23:34 activated to not activated.
分离器信号输入从有效到无效
PPM ABOVE Log: PPM > 15 Measured ppm went from below
060102 12:15:13 set valve ppm level to above (in
example valve setting is 15 ppm).
测量 ppm 从低的阀门 ppm 等级
到高的（例如阀门设置为
15ppm）
PPM BELOW Log: PPM < 15 Measured ppm went from above
060102 12:17:42 set valve ppm level to below (in
example valve setting is 15 ppm).
测量 ppm 从高的阀门 ppm 等级
到低的（例如阀门设置为
Uddevallagatan 14
416 70 Göteborg
Tfn: +46 31 19 56 00
Fax: +46 31 19 77 90
Type Example Explanation

举例解释
15ppm）
PPM SET Log: PPM SET 05 Valve ppm level setting was
PPM 设置 060102 13:10:07 changed to indicated value (in
example to 5 ppm).
阀门 ppm 的等级设置改为显示
值（例如为 5ppm）
SIM ON Log: SIM_ON Simulation was turned on.
模拟打开 060102 12:09:50 模拟打开
SIM OFF Log: SIM_OFF Simulation was turned off.

模拟关闭 060102 12:24:19 模拟关闭
TIME SET Log: TIME SET Clock was altered (in settings
时间设置 +0:59:46 menu). Offset to BilgMon builtin
realtime clock in hours, minutes
and seconds is shown.
时钟改变了（在设置菜单）。
调整 BilgMon 内置以小时，
分，秒显示的实时时钟偏差。
RTC SET Log: RTC SET BilgMon builtin realtime clock
实时时钟设置 051021 09:47:29 was set (logged once at factory).
BilgMon 内置实时时钟已设置
（记录曾在工厂设置过）
PPM AVG Log: PPM AVG 04 PPM average when below set
PPM 平均值 051021 09:47:29 valve ppm limit since latest SEP
ON signal.
自最新离合器开启信号以来,
PPM 平均值低于设置阀门 PPM
限制以下。
16. Troubleshooting 疑难解答
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416 70 Göteborg
Tfn: +46 31 19 56 00
Fax: +46 31 19 77 90
Symptom Possible reason Servicing

征兆可能原因维修
BilgMon488 is switched Power supply is erroneous. Check connections
on but LCD remains blank. 电源错误 internally, externally and
BilgMon488 开启，但液 power supply voltages.
晶显示器仍然空白。检查内外部连接和电源电
or 压。
LCD monitor is broken. Order replacement part.
液晶显示器坏了订购更换零件。
or
Automatic fuses blown. Disconnect externals that
自动保险丝烧断 might have caused the
short-circuit (f.ex.
water/sample-valve).
断开可能造成短路的外部
连接（不包括清水/取样
阀）。
Wait until fuses have
cooled down power up
the unit again.
等到保险丝降温再重新开
机
PPM value remains high Dirty sensortube Clean the sensor tube and
PPM 值仍然很高传感器管很脏 re-zero.
Or 或者清洁传感器管并重新调零
Air present in sample Correct cause of air
当前样本中空气 presence. Clean sensor and
re-zero.
纠正空气存在的原因。清
Or 或洁传感器并重新调零。
Excessive contaminates Correct cause of
present in sample (rust, contamination. Clean
bacteria etc...) sensor and re-zero.
目前样本中存在过多污染纠正污染原因。清洁传感
（铁锈，细菌等）器并重新调零
LCD display show: Memory malfunction Order replacement part.
MEMORY ERROR, 内存故障订购更换零件
Uddevallagatan 14
416 70 Göteborg
Tfn: +46 31 19 56 00
Fax: +46 31 19 77 90

MEMORY WRITE Or 或
ERROR, Memorychip not present Order replacement part.
ERASE ERROR 记忆芯片不存在订购更换零件
液晶显示屏显示：
内存错误，
内存编写错误
擦除错误

LCD display show: Dirty or damaged Part MASTER and
Lost sensor com! MASTER-SENSOR SENSOR units. Clean
液晶显示屏显示：失去信 contact area. contact surface with mild
号主信号单元接触面脏污或 detergent.
损坏主单元和信号部分单元。
用温和清洁剂清结接触
面。
LCD display show: Real time clock stopped. Order replacement part.
RTC check: FAILED! 实时时钟停止订购更换的零件
液晶显示屏显示：
RTC 检查：失败
Uddevallagatan 14
416 70 Göteborg
Tfn: +46 31 19 56 00
Fax: +46 31 19 77 90
17.Certificates 证书
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416 70 Göteborg
Tfn: +46 31 19 56 00
Fax: +46 31 19 77 90
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Final Document

Oily Water Separator

Model: BOSS 5T-107

Rev: V2.0 BOSS 5T-107

VOLUME I TABLE OF CONTENTS

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

1.1. Components by System

1.1.3. TPH Monitoring

1.2. Process Description

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

d. Recharging the Media

Rev: V2.0 BOSS 5T-107

1.2.5.TPH or oil content monitor

1.2.6. Additional Post Filter

Rev: V2.0 BOSS 5T-107

1.3. System Features:

1.4. Optional System Features:

Rev: V2.0 BOSS 5T-107

1.5. System Specifications

Specification / Treatment capacity 1.1m3/h

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

2.4. Initial Water Filling and testing:

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

2.7. Set Flow Rate:

2.8. Verify Suction:

2.9. STARTUP CHECK LIST:

Rev: V2.0 BOSS 5T-107

3.1. Solenoid Valve

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

4.4.Factory Startup and Acceptance Test Procedures

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

b. Pump repair kit for 3 phase

b. Valve repair/rebuild kits:

6.4. Monitoring Equipment (all units are the same)

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

6.5. Piping, fittings, miscellaneous

Rev: V2.0 BOSS 5T-107

O&M Manual – Volume I ATTACHMENT 3

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

在正常工作条件下，水会穿过聚合物形成通道，通道会引起 TPH 浓度监测器显示比实际

1.2.5 TPH 油份浓度计

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107

如果系统电源是 110V 或者 240VAC 单相电时，下面的步骤不必要求。如果系统是 3

Rev: V2.0 BOSS 5T-107

Rev: V2.0 BOSS 5T-107