Gas Sampling System

Salwico SW2020
User Manual, LPG version

çConsilium
The contents of this document are subject to revision without notice due to continued progress in
methodology, design and manufacturing. Consilium assumes no legal responsibility for any error or
damage resulting from the usage of this document.

Edition 2, 16 1 E, June 2016.

Part no: 070087

© 2008-2016, Consilium Fire & Gas AB

Consilium Marine AB
P.O. Box 8763
SE-402 76 GÖTEBORG
SWEDEN
Tel: +46-31-710 77 00, Fax: +46-31-710 78 00
E-mail: [email protected]
Internet: www.consilium.se
Contents
1. GENERAL INFORMATION A
1.1 DESCRIPTION OF THE SYSTEM
1.2 GENERAL BLOCK DIAGRAM

2. INSTALLATION B
2.1 CONTROL UNIT
2.2 ANALYZING UNIT
2.3 PIPE SYSTEM
2.4 FLAME TRAPS
2.5 MANUAL SHUT-OFF VALVES
2.6 SAMPLING PIPE ACCESSORIES
2.7 SAMPLING POINTS
2.8 ELECTRICAL CONNECTION
2.9 COMMISSIONING DOCUMENTS

3. OPERATION C
3.1 GENERAL PRINCIPLES
3.2 DISPLAY MODES
3.3 LISTS: ALARM, FAULT CODES, DISCONNECTION
3.4 SETUP - GENERAL SETTINGS
LEVEL 1 - SET TIME, DATE, TEST OF LEDS & BUZZER, ETC
LEVEL 2 - CALIBRATION, ETC
LEVEL 3 - SYSTEM SETUP AT START UP
3.5 SETUP - SAMPLING POINTS
3.6 GUIDELINES FOR DAILY HANDLING

4. TECHNICAL DATA D
4.1 INTERNAL CONNECTION
4.2 INTERNAL CONNECTION ON RIOK-40 AND RIOK-41
4.3 PNEUMATIC BLOCK DIAGRAM, ANALYSING UNIT
4.4 FLOW EXAMPLES
4.5 CALCULATION OF SAMPLING TIME
4.6 VACUUM PUMP
4.7 GAS DETECTORS

5. SPARE PARTS LIST E

6. PRODUCTS LIST F
7. MAINTENANCE G
 Salwico SW2020
General Information

1. GENERAL INFORMATION

A1
 Salwico SW2020
General Information

1.1 DESCRIPTION OF THE SYSTEM

Control Unit
The SW2020 Gas Sampling System is an automatically The control unit contains control functions and display for
scanning Gas Sampling System permanent installed for the system and is normally located in a cargo control
a number of sampling points. The gas detectors are room.
common for all sampling points, allowing the use of high
quality gas detectors with good accuracy. A gas sample Analysing Unit
is taken from each sampling point in turn, according to the The analysing unit contains all functions for detecting and
sampling sequence, and transported through the samp- transporting the test samples, as well as an internal
ling pipe to the gas detectors. The sampling time for each sampling point for monitoring of internal gas leakage. The
point is individually adjustable corresponding to the pipe analysing unit is installed in a ventilated area with controlled
length of each sampling point. This gives an optimally temperature above main deck level, normally the Cargo
short cycle time. Control Room.

The SW2020 Gas Sampling System is intended for Repeater Unit(s)

detection of explosive and toxic gases in cofferdams, pipe The repeater unit contains a clear text display for alarm
tunnels, stools, ballast tanks, slop tanks and other areas and fault messages. One unit is normally located in the
adjecent to cargo tanks. A pump room installation is Wheel House.
normally a separate system. The SW2020 is designed to
meet the requirements of IMO/SOLAS and classification Pipe System
rules. The pipe system transports the test samples from the
sampling points to the analysing unit. The pipe system
Individual sampling point settings includes shut off valves, flame traps, filters and cones (for
Each sampling point can easily be operated from the WB tanks).
control unit and it has individual settings for: Recommended pipe size: OD 8 mm, ID 6 mm.
– Sampling time as a function of pipe length.
– Gas detectors (up to 4 ) connected for monitoring
samples. For example %LEL, Vol% and ppm.
– Alarm levels for low and high alarm for each detector
and each sampling point..
– Clear text information.

Programmable scanning sequence

Each sampling point can easily be operated from the
control panel.

The SW2020 Gas Sampling System also gives the

possibility to define the sampling sequence enabling
certain points to be sampled more frequently.

A flow fault on a sample point will activate the Automatic

Pipe Cleaning System (APCS). The APCS will first attempt
to remove the cause of the flow fault by flushing the
sampling pipe and then try to obtain a new sample. The
sampling point is automatically disconnected and the fault
is transferred to the Fault List if the flow fault remains.

The last measured gas value for a sampling point can be

viewed in the Sampling Point List. Manual Measurement
and Purge on a selected sampling point are also done from
this list.

A test gas cylinder is connected to or built into the system

for calibration of the gas detectors.

The SW2020 system consists of four parts

A2
 Salwico SW2020
General Information

1.2 GENERAL BLOCK DIAGRAM

REPEATER UNIT

CONTROL UNIT

ALTERNATIVE: TWO SEPARATE WALL MOUNTED

CABINETS OR ONE SINGLE
CABINET

ANALYSING UNIT

MEASURING
POINT INSIDE
ANALYSING UNIT

S-4-005.285/E
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Installation

2. INSTALLATION

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 Salwico SW2020
Installation

2.1 CONTROL UNIT

DETECTOR

The control unit is the man-machine interface and controls the electronics in the
analysing unit. It consist of a LCD clear text Display, LED Display, LED's, keyboard,
microprocessor and memory for the software, definitions, additional texts etc. The unit
is normally made for wall mounting and should be placed in a well visible position e.g.
cargo control room. Electrical connection terminals to the analysing unit, the repeater
unit and the optional printer are placed in the bottom of the control unit cabinet.

As an alternative both the control unit and the analysing unit can be delivered in one
single cabinet.

The SW2020 control unit is divided into two parts; the gas alarm panel and the
operating panel.

The gas alarm panel is activated when a gas alarm situation is detected in the system.
The sampling point number, alarm level (LO or HI) and the actual gas detector in alarm
are displayed.

There are three keys on the operating panel. The Alarm Mute key is used to
acknowledge the gas alarm and the Alarm Reset key is used to reset the gas alarm.
The third key Alarms in Queue is used to toggle the sampling points in alarm.

The Operating Panel continuously shows, in the clear text display, sampling point and
the last measured value.

The Fault LED is lit and a fault message is shown in the clear text display when a fault
alarm is generated.

The List and Setup keys are used to manage the gas sampling system. The numeric
keypad is among other things used for value settings and clear text setup.

B2
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Installation

2.2 ANALYSING UNIT

The analysing unit contains all functions for detection and transport of the test
samples. Its components comprise: gas detectors, solenoid valves, sampling and
transport pump, flame traps, flow meter, remote I/O - PCB-boards, power supply unit
and terminals for power supply, alarm outputs connection to the control unit and
repeater unit as well as connections for all piping included in the system.

The analysing unit should be installed not less than 3 metres above the main deck in
order to avoid air locks in the pipes and ensure the correct work of the automatic flow
watching function. The area should be ventilated and temperature-controlled.

The analyzing unit is designed to be off a gas-tight construction and this needs to be
considered during installation of the equipment onboard when cables are entering
into the bottom of the cabinet.

There must not be an opening that could potentially ventilate Explosive or Toxic
gases to a safe area onboard.

For installation and for the future service work, there must be enough space, approx.
0.5m, at the pipe connection side, normally the left side.

There are removable plates intended for the installation of cable inlets on the
underside of the cabinet, for electrical connections.

The electrical connections are made in accordance with the electrical drawing in this
chapter.

Analysing Unit

Inlet instrument air 5-16 Bar

Pipe connections and flame

traps

Calibration gas

Bar

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Installation

2.2.1 PIPE CONNECTIONS

Suction Pipes
The sampling pipes from the manual shut-off valves are connected to the pre-mounted
and numbered flame trap on the side of the analysing unit by means of the stainless
steel connection nipples on the flame traps.

NB! These nipples should be tightened with a spanner, 1.25 turn only, from the hand-
tightening stop. If dismounted the nipple should be retightened to exactly the same
position during re-mounting.

The pipes between the analysing unit and the normal shut-off valves should be
mounted in such a way that air locks do not occur.

Also note that the pipes should be installed in such a way that service can be
performed on an individual flame trap as well as on On-Line Filters without
unnecessary dismounting of other pipes.

Exhaust Pipe
The exhaust pipe from the analysing cabinet is connected via a nipple at the intended
site and should be mounted with a slope towards the exhaust point. Refer to picture on
previous page.

Fresh Air Pipe

The fresh air pipe to the analysing cabinet should be connected via a nipple at the
intended site. The air inlet can open up directly into the room where the analysing unit
is installed, provided that the atmosphere in the room is clean and temperature
controlled. Otherwise a pipe leading to such a space must be installed. Refer to picture
on previous page.

Calibration Gas Pipe

The calibration gas pipe from the calibration gas cylinder, with a relief valve and
pressure gauge, is connected to the analysing cabinet via a nipple at the intended site.
Refer to picture on previous page.
The pipe should be mounted in such a way that replacement of the calibration gas
cylinder can be made without unnecessary strain on pipes and couplings.

Instrument air 5 - 16 Bar inlet (only used when APCS function is present)
The inlet pipe for dry instrument air is connected to the analysing unit via a nipple at
intended site. Refer to picture on previous page.

2.2.2 CALIBRATION GAS CYLINDER

The calibration gas cylinder is mounted next to the analysing cabinet and fixed in the
conventional manner for pressure vessels. The gas cylinder can alternatively be
mounted inside the cabinet.

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Installation

2.3 PIPE SYSTEM

The pipe system transports the test samples from the sampling points to the analysing
unit. In addition to the piping, the system includes: shut-off valves, flame traps, pipe
couplings, sleeves, filters and pipe terminations.

When the sampling pipes are installed, care should always be taken that the pipes are
installed in such a way that the risk of air locks is avoided.

There are two main ways of installing the piping from the analysing unit to the various
sampling points; either the pipes are installed above deck or through the pipe tunnel,
or a combination of both methods. Note that pipes installed above deck must be
protected against mechanical damage. Refer to drawing Pipe installation example in
this chapter.

All pipe couplings with conical seals forming part of the pipe system should always be
sealed with Loctite 577. (NB! Not thread tape).

2.3.1 PIPE SUSPENSION

Suspension of the pipe assembly or individual pipes should be made in such a way
that the distance between the suspension points does not exceed 1 metre.

The pipes should also be fixed in such a way that vibrations or other similar actions do
not damage them. When installing the pipes, care should be taken not to allow them to
become deformed.

The drawing Suspension and fixing in this chapter shows a proposed method of
suspension and fixing.

2.3.2 SLEEVES AND BULKHEAD PASSAGES

Some type of passage arrangement must be used when passing through deck or
bulkhead plates. Such proposed units are shown on drawings Deck bulkhead passage
and Suspension and fixing in this chapter.

2.3.3 PIPE COUPLINGS

Efforts should be made to ensure that as few pipe couplings as possible are used for
each sampling pipe. This will avoid unnecessary air resistance in the pipes, caused by
turbulence due to unevenness of the joints, and also to reduce the possibility of
leakage to a minimum.

When a pipe cut is necessary, make sure that the pipe is not deformed at the cut and
that the airflow resistance is not increased. Also note that capillary connections have to
be carefully soldered to avoid unnecessary airflow resistance.

Each manufacturer’s individual recommendations on tightening should be observed

when installing those pipe couplings that must be used.

2.3.4 BENDING OF SAMPLING PIPES

In order to avoid unnecessary air resistance in the sampling pipes and risk of
deformation and the formation of fractures, a minimum bending radius of approx. 150
mm is recommended.

Refer to separate instructions for installation of other components of the pipe system.

B5
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Installation

- Flame Trap (analysing unit) - Chapter 2.5

- Manual shut-off valves - Chapter 2.6

2.3.5 PIPE INSTALLATION CHECK

NB. 1.
Before connection of the sampling pipes to the Analysing Unit and to the
On-Line-Filters:
Always flush the pipes with compressed air in order to clean them from dust and
water. After cleaning, finish the complete connection between the Analysing Unit,
Shut off Valves, On Line Filters and Pipe end Accessories.

NB. 2.
A test has to be performed on every sampling pipe to verify that there are no
leakages. Also verify that each sampling point is correctly connected to the
Analysing Unit. It is possible to do a test of the air tightness by disconnecting the
tubes one by one on the inside of the cabinet and perform the test by connecting
a manometer, shut-off valve and compressed air.

B6
 Salwico SW2020
Installation
SHUT-OFF VALVES

B7
 Salwico SW2020
Installation
DECK BULKHEAD PASSAGE

B8
 Salwico SW2020
Installation

SUSPENSION & FIXING

CLAMP FOR PIPE

on the deck/deckhouse

"JIRVA" PIPE FITTING

CLAMP FOR PIPE

in the pipe tunnel/
cofferdams etc.
ALTERNATIVE:

1 2

PIPE

PIPE

PIPE

B9
 ITEM No. DETECTOR POSITION ITEM No. DETECTOR POSITION ITEM No. DETECTOR POSITION

1 TANK 1 FWD PORT HOLD SPACE TOP 11 TANK 3 AFT PORT HOLD SPACE BOTTOM 21 FRESHWATER GLYCOL TANK BREATHER

2 TANK 1 FWD STBD HOLD SPACE TOP 12 TANK 3 AFT STBD HOLD SPACE BOTTOM 22 MOTOR ROOM TOP

3 TANK 1 AFT PORT HOLD SPACE BOTTOM 13 TANK 4 FWD PORT HOLD SPACE TOP 23 MOTOR ROOM BOTTOM

4 TANK 1 AFT STBD HOLD SPACE BOTTOM 14 TANK 4 FWD STBD HOLD SPACE TOP 24 COMPRESSOR ROOM TOP
FIXED INSTALLED ELECTRICAL TYPE GAS DETECTORS
5 TANK 2 FWD PORT HOLD SPACE TOP 15 TANK 4 AFT PORT HOLD SPACE BOTTOM 25 COMPRESSOR ROOM BOTTOM LOCATION OF DETECTION POINTS FOR GAS DETECTION FOR FL AMMABLE/TOXIC
6 TANK 2 FWD STBD HOLD SPACE TOP 16 TANK 4 AFT STBD HOLD SPACE BOTTOM 26 AIR INTAKE ACCOMODATION SPACE (IN DUCT) PRODUCTS WITH FIXED POINT GAS D ETECTORS.

7 TANK 2 AFT PORT HOLD SPACE BOTTOM 17 VENT MAST AFT 27 AIR INTAKE ENGINE ROOM (FAN ROOM, PORT)
SW2020 GAS SAMPLING SYSTEM DETECTION POINTS
8 TANK 2 AFT STBD HOLD SPACE BOTTOM 18 VENT MAST FWD 28 AIR INTAKE ENGINE ROOM (FAN ROOM, STBD)
LOCATION OF SAMPLE POINTS FOR GAS DETECTION FOR FLAMMABLE/TOXIC
9 TANK 3 FWD PORT HOLD SPACE TOP 19 AIRLOCK TOP 29 ENTRANCE CORRIDOR OF ACCOMODATION 'A' DECK PORT PRODUCTS WITH FIXED GAS SAMPLING SYSTEM.
10 TANK 3 FWD STBD HOLD SPACE TOP 20 AIRLOCK BOTTOM 30 ENTRANCE CORRIDOR OF ACCOMODATION 'A' DECK STBD

27 29 15 13 11 9 7 5 3 1

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A. P. 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260
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B .L. B.L.
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260
A. P. F.P.

B10
Installation
Salwico SW2020

16 15 12 11 8 7 4 3
 Salwico SW2020
Installation

2.4 FLAME TRAPS

The flame traps are normally supplied fitted to the analysing unit. Refer to the
installation instructions for the analysing unit in this chapter for pipe connection
instructions.

NB! The flame trap must be of an approved type.

R 1 / 4" Female thread

R 1 / 4" Female thread

Inlet instrument air 5-16 Bar

Pipe connections and flame traps

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Installation

2.5 MANUAL SHUT-OFF VALVES

The task of the manual shut-off valves is, where necessary, to shut off the pipe system
in an explosion risk zone from the system in a safe zone. This may occur when a
certain sampling area has a temporary high gas concentration or is filled with inert gas.
The shut-off valves should also be used for service needs, such as replacement of
flame traps, or if a certain sampling pipe is disconnected from the analysing unit.

Installation of the valves shall be made in the wall between the safe and explosive
zones. Holes are cut for the insertion of welding sleeves with an internal thread, the
shut-off valve then being screwed on from inside a safe zone by means of taper thread
couplings supplied and sealed with ”Loctite 577”.

NB!
All valves should be marked with the number of the corresponding sampling point.

It is important that the mutual distance between the valves is taken into consideration,
and that the sampling pipes from the analysing unit are installed in such a way that any
service on an individual shut-off valve can be carried out without any unnecessary
dismounting of other pipes.

Stainless steel type Brass type

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Installation

2.6 SAMPLING PIPE ACCESSORIES

2.6.1 FILTERS
Each individual sampling pipe should be protected with filters in order to avoid fouling
of both the pipes themselves as well as flame traps, valves, flow meter and detector.

A filter has been developed for this purpose:

• On-line filter
for mounting on the pipe.

On-Line Filter
This filter is used for such sampling pipes where end-line filters cannot be used for a
variety of reasons, such as areas which may be temporarily water-filled or where
access is for other reasons, so difficult that necessary filter replacement may be
impaired or neglected.

Installation of on-line filters must be done in such a manner that the filter is easily
accessible for replacement, without causing unnecessary strain on pipes and
connections. The online filter should always be placed as close to the sampling point
as is practically feasible, but never in a safe zone. The nipples should be tightened in
accordance with pipe connections, see chapter 2.

We recommend that each individual filter should be marked with its corresponding
sampling point number.

R 1 / 4" Female thread

R 1 / 4" Female thread

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Installation

2.7 SAMPLING POINTS

2.7.1 PIPE TERMINATIONS

The pipe termination in the sampling area must be fixed so that the minimum distance
from a bulkhead frame is 0.1 m and approx. 0.15 m from the bottom. In filter
installation, e.g. end-line filter, the height above the bottom should be taken into
consideration with respect to this.

In certain areas care must be taken to prevent oil or water from being sucked into the
sampling pipes, and in such cases a height above the bottom of 0,5 m or more can be
allowed. Corners, where the air circulation is low, should be avoided. Note that the last
0.2 m of the pipe termination end must point downwards.

Each pipe termination should be marked with the corresponding sampling point
number.

Option

Refer to Chapter 2.7.2 for special pipe termination facility.

2.7.2 LOCATION OF THE SAMPLING POINTS

In accordance with the regulations and draft proposals that have been drawn up by the
classification societies, the following areas are to be monitored by the permanently
installed gas sampling system:

• Cofferdams
• Pipe tunnels
• Hold spaces around cargo tanks
• Other empty areas adjacent to slop tanks

In accordance with these rules it is essential that the planned number of sampling
points and their location including the pipe installation should be evaluated and
commented on by the classification societies prior to installation.

2.7.3 MARKING OF SAMPLING POINTS

Each sampling pipe must be marked with its number at the sampling point as well as
the manual shut-off valve. (Each sampling point is numbered at the flame trap on the
analysing unit.)

Salwico SW2020 has one sampling point for internal monitoring of the analysing
cabinet, normally the last sampling point.

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Installation

2.8 Electrical Connections

External connections

MAX. CON TACT LOAD:5A 250 VAC/24VDC

MD45 LV RS232/422/485

SYSTEM FAILURE GAS WARNING ( LOW ALARM) GAS ALARM (HIGH ALARM)
INPUT 230 VAC

NORM. ACT. NORM. ACT. RES ET WHEN RES ET WHEN RES ET WHEN RES ET WHEN
CONVE RTER

RES ET WHEN RES ET WHEN WARNING WARNING ALARM ALARM

FAIL. MUTED FAIL. RES ET MUTED RES ET MUTED RES ET
RL 1 RL 2 RL 3 RL 4 RL 5 RL 6
4A
4A
1
2
F
F

20

21

31

41

51

71
61
19

29

49
22
23

25
26
27
28

30

32

42
43

45
46
47
48

50

52

69
70

72
24

44

62
63

65
66
67
68
64
EMERG. POWER
INPUT 230VAC

MODBUS

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Installation

2.9 COMMISSIONING DOCUMENTS

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Installation
GAS SAMPLING SYSTEM SW2020, COMMISSIONING SET-UP
Ref no: SG- Yard: Hull no:
Start up time: sec Alarm delay time: sec Date:

ALARM LEVELS
Det #1: Low High Det#2: Low High
Det #3: Low High Det#4: Low High

SAMPLING POINTS SET-UP

POINT NO LOCATION DISTANCE SAMPL. TIME SET NOTE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

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Salwico SW2020 Gas Sampling System. Commissioning record.

To be used and filled in with signature by the personnel in charge of the installation.

Shipyard / Installation Company: Hull No: Ref.no:

SG-

Fill in
Description / Task / Check Sign./ Date:
data:

A. Pipe installation check.

1 Pipe dimension; sampling pipes on deck (diam. outer/inner)
2 Pipe material; sampling pipes on deck (Cu, CuNi, SS etc.)
3 Pipe dimension; sampling pipes in tank (diam. outer/inner)
4 Pipe material; sampling pipes in tank (Cu, CuNi, SS etc.)
5 Deck accessories material, stainless steel (SS) or brass (BR)
6 Sealing material Loctite 577 used, yes/no
7 Pipe dimension outlet pipe (diam. outer/inner)
8 Flushing of all sampling pipes with compressed air before connection to
cabinet and on-line-filters, yes/no.
9 Leakage test performed of all sampling points before connection to the
cabinet, yes/no.
10 Compressed Dry Instrument Air 5-16 Bar connected, yes/no.
11 Pressure Regulator set to 3.4 Bar, yes/no.
12 Sampling point commissioning performed and sheet B19 from
Installation Manual filled in and handed over to the ship owner, with a
copy stored in the SW2020 Control Unit, yes/no.

B. Electrical installation check.

13 Main Power Supply from Emergency switchboard, yes/no.
14 Repeater Unit working, yes/no.
15 External alarm functions test (Main Alarm, Typhoons, etc) yes/no.
16 External Alarm signal connected to EMS/AMS, yes/no.

C. Final hand over of the system to the ship owner.

17 Instructions on operation and maintenance given to ship’s crew,
yes/no.
18 Instruction Manuals and Spare parts handed over, yes/no.

When this document has been completed, two copies shall be made: one copy for the shipowner and one
copy to be sent to:

Consilium Marine AB
Attention: After Sales Department
P.O. Box 8763
SE-402 76 GÖTEBORG, SWEDEN

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Operation

3. OPERATION

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Operation

GAS
SAMPLING ALARM
POINT LEVEL

DETECTOR
F1 F2 F3 F4

7 8 9 FAULT
4 5 6 M
1 2 3 R
0

3.1 GENERAL PRINCIPLES

The Control Unit of the SW2020 Gas Sampling System is divided into two separate
parts.
The left-hand side consists of only three keys: ALARM MUTE, ALARM RESET and
ALARM IN QUEUE. The ALARM IN QUEUE key is used to find a gas alarm in the
gas alarm list and the two other keys to either mute or to reset an alarm (the gas
level is measured again to see if the alarm condition has disappeared).
The right-hand side is used for operation of the system. Just press one of the six
LIST and SETUP keys to start managing the system. All six keys will open a list of
items (sampling points, alarms etc.).
Use the four arrow keys to find the item you want and use the function keys to select
an action to perform.

3.1.1 CONTROL UNIT PANEL

The function of each individual push-button key on the control unit is described
below.

Button Function
LIST – List all sampling points in the system. Use Ç, È, PgÇ
SAMPLING POINTS and PgÈ to choose a sampling point.
LIST – List all disconnected sampling points, external control
DISCONNECTION’S and detectors.
Use Ç, È, PgÇ and PgÈ to choose an entry.
LIST – List all gas alarms in the system. Use Ç, È, PgÇ and
ALARMS PgÈ to choose an entry.
LIST – List all faults in the system. Use Ç, È, PgÇ and PgÈ to
FAULTS choose a fault.
SETUP – List all sampling points in the system. Use Ç, È, PgÇ
SAMPLING POINTS and PgÈ to choose a sampling point. Access level is
required to change settings.
SETUP – List all general settings in the system. An access level
GENERAL SETTINGS above 1 is required to change most settings.
F1 ,F2 ,F3, F4 Function keys. Push here to perform an action.
0, 1, 2 – 9 Numeric input buttons
↵ (ENTER) Used to accept a numeric input
ESC Go to the previous menu.

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Operation
HOME Go to the standby menu.
Ç List the next list entry. The LED is lit when the button is
active.
È List the previous list entry. The LED is lit when the
button is active.
Pg Ç Display the fifth list item to come (the list must have
more then 5entries).
Pg È Display the fifth previous list item.
M – FAULT MUTE Mute all faults in the system.
F – FAULT RESET Reset a fault in the fault list.
ALARM MUTE Mute all gas alarms in the system.
ALARM RESET Reset the displayed sampling point in alarm.
ALARM IN QUEUE Display the next gas alarm in the alarm list.

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3.2 DISPLAY MODES

3.2.1 NORMAL MODE

The control unit is in standby mode most of the time. The display below shows that
the measurement sequence is running. The system always displays the last
measurement.

** RUNNING ** <12:01:54>
sp5: Tank 2 FWD port hold space bottom
0 %LEL CxHy

The standby menu displays the system status. Another message could be:

** STARTUP ** <12:01:54>
Please wait -
System check in
progress...

The standby mode can be identified by the clock in the upper right corner and can be
reached by pressing the HOME key. The control unit will automatically return to
standby mode after 30 minutes of inactivity.

3.2.2 MANUAL MEASUREMENT

You could for instance make a manual measurement on sampling point number 5
(SP5) by first pressing LIST – SAMPLING POINTS, then choose SP5 with the arrow
keys and finally press F3 (MEASURE) to start measuring on SP5. The display should
now look like below.

sp5 - Tank 2 FWD port hold space bottom

Current: 5 New: _
Enter manual measurement time in minutes
MEASURE

Some menus require a numerical input. Manual measurement is one of them. Enter
a new value with the numerical keyboard. Press ENTER to change the new value
into the current value and press F1 to start measuring.
Just press F1 if you want to start measuring using the default value (5-minutes).
The display will now show the measurement value on the selected sampling point.

sp5 - Tank 2 FWD port hold space bottom

Remaining measurement time 4:43
12 %LEL CxHy

The system used in the examples in this manual consists of 60 sampling points and
one detector measuring hydrocarbon gases (CxHy).

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3.2.3 GAS ALARM
With reference to the alarm list:

1. When the “Alarm Mute” button is pressed, the acoustic alarm stops and all alarm
outputs with mute functionality are deactivated. The scanning cycle continues and
will give new alarms for each sampling point exceeding the alarm level. The alarms
are stored in the Alarm List and the SP of the last occurred alarm is shown as well as
the alarm level “LO” or “HI”.
2. Activation of the “Alarm Reset” button starts a revaluation of the SP in alarm. An
“Alarm Reset” request will stop the sampling sequence and make a new
measurement. This revaluation is to be able to accept an alarm reset on the SP if the
level is now below the alarm level. If You push the “Alarm in Queue” button and
make a Reset of all SP’s in alarm, the system will start re-evaluating these SP’s one
by one. It may therefore take a while to complete alarm reset for several SP’s.

The revaluation sequence can be interrupted by manual measurement or purge.

(See the Sampling Point List).

3.2.4 FAULT ALARM

With reference to the Fault list:

1. An Analyse pump, flow failure is caused by the flow switch FS and stops the pump
and scanning sequence if the system does not have the pump redundancy option.
The FS is detecting that the pump pressure is too low. The cause is probably a
membrane leakage of the pump or a fault of the FS itself. Service is needed if the
fault cannot be reset.
3. Analyse Pump or Internal Leakage is indicated when the automatic leakage
control fails. This control is automatically done once per 24 hours by closing all the
sampling valves, running the analysing pump and checking that the vacuum switch
VS1 is activated. If the VS1 is not activated the cause is a leakage at the vacuum
side of the pump from pipes, solenoid valves, pipe couplings or the VS1 itself.
4. Calibration. This fault indicates that zero or span calibration is not completed due to
a value that is out of range, either due to a gas detector fault or a test gas fault. The
bottle might be empty or the test gas mixture is not corresponding to the value that is
set for span calibration.
5-8. Gas Detector 1-4. Indicates a fault depending on which type of detector that is in
use. There might be a loss of power, a dirty mirror in an IR-detector or a sensor
failure etc.
10. Fault compressed instrument air. Indicates that the pressure from the pressure
regulator is below 2.8 Bar.

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12. Flow fault on SP#. Indicates a flow fault on the SP listed. Before indication of a flow
fault the automatic pipe cleaning function first attempt to remove the cause of the
flow fault by flushing the sampling pipe during 15 seconds and then tries to obtain a
new sample. If the flow fault still remains the sampling point is automatically
disconnected and a flow fault alarm is generated and listed in the fault list. The
scanning cycle continues to the next sampling point. As long as the flow fault for a
certain sampling point is listed in the fault list the fault remains. To be able to reset
the flow fault the cause has to be removed. If a mistake was done concerning a SP
in a ballast tank that should normally had been disconnected before ballasting the
SP has to be disconnected via “List Sampling Point” Key.
13. Fuse fault as indicated. Switch off the main power and change the broken fuse.
14. Low 5 volt in control unit. Service or exchange of the unit might be necessary.
17. Analysing unit no answer, indicates that there is no contact with the PCB –RIOK-
40. The reason might be a function fault, power fault, fuse fault or a cable brake.
18. Analysing unit booted, indicates that the fault message according to 17 is reset.
19. No custom set-up, using factory (default) set-up, indicates that custom related
settings are not done. This normally only occurs the first time the system is started at
the workshop.
20. Flash memory error in control unit indicates a faulty flash memory. Exchange of
the same might be necessary. Consult the service department for assistance.
21-24.Negative drift, analyser 1-4 (Abnormal condition). Calibrate the detector.

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3.3 LISTS
All operations required by the average user can be performed from the four lists in
the system.

3.3.1 ALARM LIST

The left-hand side of the control unit always displays the sampling point in alarm (1-
60) and the alarm level (Hi or Low).
Mute gas alarms by pressing ALARM MUTE and reset gas alarms by pressing
ALARM RESET. Press ALARMS IN QUEUE to display the next gas alarm (if any).

When you want more detailed information about an alarm press LIST ALARMS on
the right-hand side of the control unit. This list is opened automatically when a new
gas alarm is detected. Use the arrow keys to display the next and previous alarms.
The display below shows the first alarm of three. The alarm occurred on sampling
point 1 and 43 %LEL CxHy (Alarm level ’Hi’) was measured.

** ALARM LIST 1(3) **

sp1: Tank 1 FWD port hold space bottom
43 %LEL CxHy(Hi)

3.3.2 FAULT LIST

Press LIST FAULTS, on the right-hand side of the control unit, to display the faults in
the system. This list is automatically opened when the system detects a fault.
The display below shows the first fault of two. Fault code 15 with an explanatory text
is displayed.

** FAULT LIST 1(2) **

Fault(1) Analyse pump, flow failure

Mute faults by pressing the FAULT MUTE key and reset faults by pressing the
FAULT RESET key.

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3.3.2.1 Fault codes

The following faults can be detected. See section C, part 3.7, for a more thorough
explanation of the fault codes

(1) Analyse pump, flow failure

(3) Analyse Pump or Internal Leakage
(4) Calibration
(5) Detector 1, (Gas type + type of detector
fault)
(6) Detector 2, (Gas type + type of detector
fault)
(7) Detector 3, (Gas type + type of detector
fault)
(8) Detector 4, (Gas type + type of detector
fault)
(10) Fault compressed instrument air
(12) Flow fault on SP #
(13) Fuse fault in control unit
(14) Low 5 volt in control unit
(17) Analyse unit no answer
(18) Analyse unit booted
(19) No custom setup, using factory (or default)
setup
(20) Flash memory error in control unit
(21) Negative drift, analyser 1 (Abnormal
condition)
(22) Negative drift, analyser 2 (Abnormal
condition)
(23) Negative drift, analyser 3 (Abnormal
condition)
(24) Negative drift, analyser 4 (Abnormal
condition)

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3.3.3 SAMPLING POINT LIST

Press LIST SAMPLING POINTS to enter the Sampling Point List.

Select a sampling point with the arrow keys (sampling point 5 is selected in the
example below) and then use the function keys to perform an action.

** SAMPLING POINT 5(60) **

sp5: Tank 2 FWD port hold space bottom

VALUES DISCONNECT MEASURE PURGE

The following actions can be performed on a sampling point:

• VALUE – Display the value of the last gas measurement

• DISCONNECT – Disconnect for a period of time or forever (OFF). Before
ballasting: Always disconnect the corresponding sampling points. The counter
pressure will automatically engage for sampling points with this feature.
• MEASURE – Start measuring the gas concentration. Make a prompt check of the
actual gas concentration on the selected sampling point. The measurement time
can be set in minutes but newer below the set-up time (depending on the pipe
length). The gas value(s) are continuously updated during the measurement and
a Gas Alarm (high or low) will be generated if the corresponding value is still
exceeded when the measurement value is stable.
• PURGE – Clean the pipe for that particular SP during 2 minutes. An automatic
decompression is done through the internal SP in order to protect the pressure
switch and pump membrane before commencing the measurement sequence.
The decompression time is 10 seconds.

Actions such as purge and manual measure can not be performed on disconnected
sampling points. The only allowed action on a disconnected sampling point is
RECONNECT.

After a MEASURE or PURGE manoeuvre, the normal measurement sequence is

commenced at the SP that was interrupted.

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3.3.3.1 Sampling Point Groups (option)

Sampling point groups are used in installations with many sampling points to make
the daily handling with disconnecting and reconnecting sampling points more
efficient.

Sampling point 1 to 8 are members of group 1 in the example below. The group
members and the free text on row 2 (STB Water ballast tanks, SP 1-8) are
configurable in SETUP but requires access level 2.

A group can be disconnected:

** GROUP 1(3) **
Grp1: FWD port hold spaces, SP1-8

DISCONNECT

And reconnected again, the user will be asked to automatically purge all sampling
points in the group (recommended). Take care when reconnecting a whole group -
make sure that all areas are empty and do not require IG Mode (if that option is
implemented).

** GROUP 1(3) **
Grp1: FWD port hold spaces, SP1-8

RECONNECT

Sampling points belonging to a group can still be disconnected or reconnected

individually, this makes the situation below valid since the SP’s in a group can have
mixed disconnection status.

** GROUP 1(3) **
Grp1: FWD port hold spaces, SP1-8

RECONNECT DISCONNECT

3.3.4 DISCONNECTIONS LIST

Press LIST DISCONNECTIONS to enter the Disconnection List.

Disconnected sampling points are listed here. Reconnect the chosen sampling point
by pressing F1 (RECONNECT).

** DISCONNECTION LIST 1(3) **

sp 5 disconnected
sp5: Tank 2 FWD port hold space bottom
RECONNECT

Disconnected sampling points and activated external control off are listed here.
It is possible to deactivate the external control by pressing F1 (RECONNECT).

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3.4 SETUP – GENERAL SETTINGS

The system changes the access level and enters CONFIGURATION MODE when
the correct access code for level 2, 3 or 4 is entered. The system will not start until
the user chooses to start the system again (the access level is automatically
changed back to 1) or the user timeout expires after 30 minutes.

Choose a menu with the Arrow Keys. The menu numbers in this document are
shown between brackets in each header.

3.4.1 GENERAL SETTINGS - ACCESS LEVEL 1

Change access level (1)

Enter a 4-digit access code and push ↵. The result of the operation is displayed on
row 3. The sampling sequence is stopped when the access level is changed to 2 or
higher.

(1) Change access level

Current: **** New:
Enter a 4-digit access code

Change access level code (2)

Enter the access level you want to change access code for, push ↵ and then F1 to
continue. The code can only be changed for access levels lower or the same as the
current access level (level 2 in the example below).

(2a) Change access level code

Current: 2 New:
Enter an access level (1-3)
CONTINUE

Enter the new 4-digit access code, push ↵ and then F1 to continue.

(2b) Change access level code

Current: New:
Enter the 4 digit access code
CONTINUE

Enter the same access code again and push ↵. The result of the operation is
displayed on row 3.

(2c) Change access level code

Current: New:
Enter the same 4 digit code again

Change time of day (3)

Enter the time of day (HHMMSS, 24-hour clock) and push ↵. The result is displayed
on row 3.

(3) Change time of day

Current: 121629 New:
Enter a new time of day (HHMMSS)

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Change the date (4)

Enter the date (YYYYMMDD) and push ↵. The result is displayed on row 3.

(4) Change the date

Current: 19970101 New:
Enter a new date ...... (YYYYMMDD)

Change LED intensity (5)

Enter a new intensity and then push ↵ to change the intensity of the LED’s.

(5) Change LED intensity

Current: 5 New:
Enter a new value (1..5)

Print the system configuration (6)

Push F1 to print the system configuration. Printing the systems configuration can,
needless to say, only be done when there’s a printer in the system.

(6) Print the systems configuration

PRINT

Test pixels and LEDs (7)

Push F1 to test LED’s and pixels on the control unit.

(7) Test pixels and LED's

TEST

Test the local buzzer (8)

Push F1 to test the local buzzer.

(8) Test the local buzzer

TEST

External Control Off (9)

The External Control Off disables steering of external output of type GAS ALARM.
Start the External Control Off functionality by pressing F1. Default timeout values is
5 minutes but can be changed by the numeric keys.
Deactivate the External Control Off by pressing F2 when it is running.
After the timeout has expires the External Control Off is deactivated automatically.

(9) External Control Off

Current: 5 New:
Enter a new time in minutes (5..30)
START

If the External Control Off is activated it shows up in the disconnection list.

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Check the valves for internal leakage (10)

Push F1 to check the system (valves and connections) for internal leakage.

(10) Start checking the valves

Status: ABORTED

START STOP

3.4.2 GENERAL SETTINGS - ACCESS LEVEL 2

Restart the system, save current setup (11)

Push F1 to restart the sampling sequence. The system will change back to access
level 1 and save the current system configuration.

(11) Restart the system

- Save the current setup,
return to access level 1
RESTART

Restart the system without saving (12)

Push F1 to restart the sampling sequence. The system will change back to access
level 1 but will NOT save the current system configuration. All changes to the system
configuration will be lost.

(12) Restart system without saving

- Don't save the current setup,
return to access level 1
RESTART

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3.4.2.1 Span and zero calibration of gas detectors

Calibrate span on a gas detector (12)

Gas detectors must be adapted and calibrated to the system on the A/D inputs with
two different gas concentrations: Zero and a Span gas value determined by the user
(the span gas value must be in the area 25-100% off the highest measurement for
the gas detector).

Calibration of span is only accepted when dS, in figure 1, is below a certain value
depending on the brand and type of gas detector.

Successful calibration of a detector will result in correct presentation of gas values

on the control unit.

M e a s u re d
G a s -v a lu e Id e a l g r a p h

S pan
dS R e a l g ra p h

0
d0

0 Span
E x p e c te d
G a s - v a lu e

F i g u r e 1 : T w o -p o in t c a lib ra tio n . “ G a s -v a lu e s ” b e lo w 0 a re in t e r p r e te d
a s “n e g a tiv e d rift ” o r a s a fa u lt c o n d itio n .

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Select one detector (1-4) to calibrate by entering a numeric input and ↵. Push F1 to
continue.

(12a) Calibrate span on a gas detector

Current: (1)CxHy New:
Enter detector no (1 - no of detectors)
CONTINUE

Enter the concentration of the span-gas. Push F1 to continue. Note that the
procedure for calibrating span for Oxygen will differ.

(12b) Calibrate span on a gas detector

Current: 50 New:
Enter test gas value in %LEL
CONTINUE

Open the valve(s) connecting the test-gas bottle to the test-gas tube in the analysing
unit. Push F1 to continue.

(12c) Calibrate span on a gas detector

Open test gas valve to start calibration

START

Start the calibration procedure and change to menu 12d by pushing F1. The
measured gas-value can now be seen on row 2.

Wait until the measured gas-value has stabilised and then calibrate the detector with
F1.

If calibration fails:
• Check that the test gas bottle is not empty.
• Check the tube to the test gas bottle.
• Calibrate the gas detector manually according to the calibration procedure
(The procedure depends on the brand and type of gas detector).

Exit menu 12d with F2.

(12d) Calibrate span on a gas detector

Measured: 49 %LEL CxHy

CALIBRATE EXIT

Close the test-gas valve(s) and exit with F1.

(12e) Calibrate span on a gas detector

Remember to close the test gas valve(s)

EXIT

Note: After a successful calibration, finish by saving the current setup (10).

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Adjust zero on a gas detector (13)

Calibration of zero in the system on the A7D inputs for a gas detector is done with air
from the fresh air inlet (except for O2, described separately below).

(13a) Adjust zero on a gas detector

Current: (1)CxHy New:
Enter detector no (1 – no of detectors)
CONTINUE

Select one detector (1-4) to calibrate by entering a numeric input and ↵. Push F1 to
continue.

(13b) Adjust zero on a gas detector

Measured: 1 %LEL CxHy

ADJUST

Calibrate the detector with F1 when the measured value is stabilised.

If zero calibration fails:

• Make sure the fresh air inlet is not blocked.
• Calibrate the gas detector manually according to the calibration procedure
(the procedure depends on the brand and type of gas detector).

Exit with ESC.

Note: After a successful calibration, finish by saving the current setup (10).

Undo calibration on a gas detector (14)

Select one detector (1-4) to undo calibration by entering a numeric input and ↵. Push
F1 to undo calibration of the chosen detector. The previous value is presented on the
control unit.

(14) Undo calibration on a gas detector

Current: (1)CxHy New:
Enter detector no (1 - no of detectors)
UNDO

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3.4.2.2 Calibration procedure for gas detectors with 4-20 mA output signal.

Gas detectors of type GD10 IR:

These types of detectors are factory calibrated. They have a continuous self-test
function and report dirty optics and fault by setting the output signal:
4 mA +/- 0,3 mA: Normal zero level
1 mA for 3 sec at 5 min intervals: Early indication of dirt accumulation on windows.
1 mA continuously: Dirt accumulation on windows
0 mA: Internal Malfunction

Check the output signal by connecting an Ampere meter measuring the current in the
range 0-30 mA DC in serial with the electric cable from terminal 3 on the detector
and the system terminal 353.

Gas detectors type ST600 EX Catalytic:

The following described calibration procedure is performed during the zero and span
set-up calibration from the control panel.
Remove the cover from the detector. Connect an Ampere meter measuring the
current in the range 0-30 mA DC on terminal M1(+) and M2(-) at the PCB.

Zero adjustment: Apply clean air and adjust on the potentiometer P2 to 4 mA.

Due to the fact that this detector is a catalytic type and the sample is taken from an
inert gas area, the sample needs to be diluted with 50% air. The detecting range for
the detector is 0-100% LEL. If the detector is reading 25% LEL (diluted), the actual
value of the sampled gas is 50% LEL. Consequently, every reading is doubled in the
panel. When the detector is system calibrated, the calibration gas is not diluted. A
calibration gas of 45% LEL will show 90% LEL on the display.

Span calibration: Apply calibration gas. Adjust the output current on potentiometer
P3.
The current can be calculated using the following formula:

Current I mA = ((16 mA/full scale gas) x (calibration gas concentration x 2)) + 4 mA

Propane or methane detector, range 0-200 % LEL (dilution):

Calibration gas 50 % LEL => 16/200 x 50 x 2 + 4 = 12 mA

Gas detectors type ST400 Electrochemical:

Since the gas is diluted with 50% air, every reading is doubled in the panel. When
the detector is system calibrated, the gas is not diluted. A calibration gas of 45% will
correctly indicate 90% on the display.

The following described calibration procedure is performed during the zero and span
set-up calibration from the control panel.
Remove the cover from the detector. Connect an Ampere meter measuring the
current in the range 0-30 mA DC on terminal M1(+) and M2(-) at the PCB.

Zero adjustment: Apply clean air. OBS for zero calibration of oxygen detectors, use
our combined calibration gas with Nitrogen (N2) base or 100 % N2.
Adjust on the potentiometer P3 to 4 mA.

Span calibration: Apply calibration gas. Adjust the output current on potentiometer
P1.
The current can be calculated using the following formula:

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Current I mA = ((16 mA/full scale gas) x (calibration gas concentration x 2)) + 4 mA

Note!
After the calibration and in order to set the new values, always finish in menu 11.
“Restart the system, save the current set-up”.

3.4.2.3 No of groups in the system (15)

Change the current number of groups with a numeric input and ↵. A group is a
collection of Sampling Points, the groups defined in this menu are configured
individually in the Sampling Points Setup, see 3.5.

(15) No of groups in the system

Current: 0 New:
Enter the number of groups (0..8)

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3.4.3 GENERAL SETTINGS - ACCESS LEVEL 3

Change the start-up time (16)

Change the current start-up time with a numeric input and ↵. The start-up time
determines how long the SW2020 will wait after power-on before starting the
sampling sequence (to allow warm-up of gas detectors).

(16) Change the startup time

Current: 10 New:
Enter startup time in seconds

Change the alarm delay time (17)

Change the current alarm delay time with a numeric input and ↵. The alarm delay
time determines how long the SW2020 waits before measuring after gas from the
correct Sampling Point has arrived at the detector(s).

Measurement Alarm delay

time time

Get gas Measure gas

from the SP concentration

Figure 2: Measurement on a
sampling point.

This time should be equal to the reaction time of the slowest gas detector in the
system

(17) Change the alarm delay time

Current: 5 New:
Enter alarm delay time in seconds

Same measurement time all SPs (18)

Change the current measurement time for all sampling points with a numeric input
and ↵. The measurement time for a Sampling Point is the time it takes for the gas to
arrive from the SP to the detector(s). See figure 2

Observe that measurement times for individual measurement points will be lost.

(18) Same measurement time all SP's

Current: 11 New:
Enter the measurement time in seconds

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Same alarm level all SPs (19)

Change the current alarm level for all sampling points. Observe that alarm levels for
individual measurement points will be lost.

Choose a gas detector with a numeric input and ↵. Continue with F1.

(19a) Same alarm level all SP's

Current: (1)CxHy New:
Enter detector no (1 - no of detectors)
CONTINUE

Choose the alarm level to change (High or Low) with F2 and ↵. Continue with F1.

(19b) Same alarm level all SP's

Current: Lo New:
Toggle the alarm level with <F2>
CONTINUE TOGGLE

Enter the new alarm level with a numeric input and ↵. Exit with F1.

(19c) Same alarm level all SP's

Current: 20 New:
Enter Lo alarm level for det. 1 in %LEL
DONE

Change the sampling sequence (20)

Enter the new sampling sequence length with a numeric input and ↵. Continue with
F1.

(20a) Change the sampling sequence

Current: 24 New:
Enter the sequence length
CONTINUE

Menu 20b is a list where the index in the sampling sequence is chosen with the
arrow keys; the current sequence index can be seen on row 3. The sampling point
corresponding to a sequence index is changed with a numeric input and ↵. Abort
definition of the sampling sequence with F1 and save the current sequence with F2.

(20b) Change the sampling sequence

Current: 1 New:
Enter a SP for sequence index no: 1
ABORT SAVE SEQ

Restart with factory settings (21)

Push F1 to change back to access level 1 and restart the sampling sequence with
the configuration that was defined at the factory.

All custom settings (changes in the configuration after delivery) will be lost.

(21) Restart with factory settings

- WARNING, all custom settings
will be lost !
RELOAD

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3.5 SETUP - SAMPLING POINTS (ACCESS LEVEL 2)

Push SETUP - Sampling Points and then use the Arrow Keys to choose the
sampling point (or group) to configure. Access level 2 is required to enter the
Sampling Points Setup.

3.5.1 CONFIGURING A SAMPLING POINT

Use the Arrow Keys to select a sampling point.

** SAMPLING POINT SETUP 3(6) **

sp3: Water ballast tank 2 STB

TEXT ALARM LVL M.TIME DET.ON/OFF

Push F1, F2, F3 or F4 to configure the chosen Sampling Point.

Change the free text associated with a sampling point (TEXT)

Push F1 to change the free text.

Change free text

Now: Water ballast tank 2 STB

CONTINUE

Push F1 again to change the free text.

Change free text

New: _

ABORT SAVE

The new text is entered with the alpha - numeric keyboard and the backspace button
(←).

Push an alpha - numeric button until you see the desired symbol and then wait for
the timer to expire (about one second) to add the symbol to the free text.

The symbols associated with each alpha – numeric button are written on the buttons.
Note that upper and lower case letters as well as the numeric itself is available for
each button.

Save the new free text with F2 or return to previous menu without saving with F1 (or
ESC).

Note:
Leave the setup mode with (10) if the new settings should be saved.

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Change the alarm levels for a detector (ALARM LVL)

Push F2 to change the alarm level. Choose a detector with a numeric input and ↵.
Push F1 to continue.

Sp3: Water ballast tank 2 STB

Current: (1)CxHy New:
Enter detector no (1 - no of detectors)
CONTINUE

Choose the alarm level to change with F2 and ↵. Push F1 to continue.

3(6) Water ballast tank 2 STB

Current: Lo New:
Toggle the alarm level with <F2>
CONTINUE TOGGLE

Enter a new alarm level with numeric input and ↵. Push F1 to finish.

3(6) Water ballast tank 2 STB

Current: 20 New:
Enter Lo alarm level for det. 1 in %LEL
DONE
Change the measurement time for a sampling point (M.TIME)

Push F3 to change the measurement time. Enter a new measurement time with
numeric input and ↵. Push ESC to finish.

The measurement time for a Sampling Point is the time it takes for the gas to arrive
from the SP to the detector(s). See figure 2.

sp3: Water ballast tank 2 STB

Current: 11 New:
Enter new measurement time in seconds

Disconnect a gas detector for a certain SP (DET.ON/OFF)

Push F4 to disconnect a detector. Choose a detector with a numeric input and ↵.

Push F1 to disconnect the chosen detector for that particular Sampling Point. The
detector is reconnected again by pushing F1 one more time.

sp3: Water ballast tank 2 STB

Current: (1)CxHy New:
Enter detector no (1 - no of detectors)
DISCONNECT

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3.5.2 CONFIGURING A GROUP
If a number of groups are configured in the system (see 3.4.), they will be present in
the Sampling Point List. Use the Arrow Keys to select a Group.

** GROUP SETUP 3(3) **

grp3: Water ballast tanks STB

TEXT DEFINE

Push F1 or F2 to configure the chosen Group.

Change the free text associated with a group (TEXT)

Push F1 to change the free text.

Change free text

Now: Water ballast tanks STB

CONTINUE

Push F1 again to change the free text.

Change free text

New: _

ABORT SAVE

The new text is entered with the alpha - numeric keyboard and the backspace button
(←).

Push an alpha - numeric button until you see the desired symbol and then wait for
the timer to expire (about one second) to add the symbol to the free text.

The symbols associated with each alpha – numeric button are written on the buttons.
Note that upper and lower case letters as well as the numeric itself is available for
each button.

Save the new free text with F2 or return to previous menu without saving with F1 (or
ESC).

Define Group Members (DEFINE)

Push F1 to ADD a Sampling Point to the Group. Push F2 to remove the last
Sampling Point from the Group and push F3 to exit the menu.

Define group 3
Sp:1,2,3

ADD SP REMOVE LAST DONE

Push F1 to ADD Sampling Point 4 to the group or enter a new Sampling Point with
numeric input and ↵. The ESC button will return to the previous menu without adding
a new sampling point.

Add Sampling Point to Group no 3

Current: 4 New:

ADD

C23
 Salwico SW2020
Operation

3.6 GUIDE LINES FOR DAILY HANDLING

Important notes:
The Pressure Air to the system must never be shut off!
The manual shut-off valves shall remain open during normal operation.

Alarm levels:
See this manual chapter 3 Gas alarm.
There are two alarm levels in the SW2020:
- At 99% L.E.L., Low alarm will occur
- At 100% L.E.L., High alarm will occur

Fault Alarms:
See this manual chapter 3 Fault alarm.

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 Salwico SW2020
Technical Data

4.TECHNICAL DATA

D1
 Salwico SW2020
Technical Data

4.1 INTERNAL CONNECTION

D2
 Salwico SW2020
Technical Data

4.2 INTERNAL CONNECTIONS ON RIOK-40 AND RIOK-41

Analogue inputs on RIOK-40

Input Terminal Pos Description
AN1 19-20 Gas Detector 1
AN2 21-22 Detector 2 (option)
AN3 23-24 Detector 3 (option)
AN4 25-26 Detector 4 (option)

Digital inputs on RIOK-40

Input Terminal Pos Description
0 1-2 PS 1 Fault Analysing Pump
1 3-4 PS2 Fault Presuction Pump (option)
3 5-6 VS1 Fault Analysing Flow
4 7-8 VS2 Fault Presuction Flow (option)
5 9-10 Fault Gas Detector (option)
6 11-12 Fault Moisture (option)
7 13-14 PS Fault instrument air low pressure
8 15-16 Fault Power (option)

Digital outputs from RIOK-40

Output Terminal Pos Description
0 35 RL1 Fault alarm with mute function
1 37 RL2 Fault alarm
2 39 RL3 Gas alarm Low level with mute function
3 41 RL4 Gas alarm Low level
4 43 RL5 Gas alarm High level with mute function
5 45 RL6 Gas alarm High level
6 47 V1 Soleniod valve
7 49 V2 Soleniod valve
8 51 V3 Soleniod valve
alt. V8 Soleniod valve. Pump redundance. (option)
9 53 V4 Soleniod valve
10 55 V5 Soleniod valve
11 57 V6 Soleniod valve for Two pump system
12 59 V7 Soleniod valve for Two pump system
13 61 V9 Soleniod valve. Water trap drainage (option)
14 63 RL7 Controller Relay for Analysing Pump
15 65 RL8 Controller Relay for Presuction Pump (option)

D3
 Salwico SW2020
Technical Data

Outputs on RIOK-41´s
Output Terminal Position Description
16 2 V101 Solenoid Valve Sampling Point 1
17 4 V102 Solenoid Valve Sampling Point 2
18 6 V103 Solenoid Valve Sampling Point 3
19 8 V104 Solenoid Valve Sampling Point 4
20 10 V105 Solenoid Valve Sampling Point 5
21 12 V106 Solenoid Valve Sampling Point 6
22 14 V107 Solenoid Valve Sampling Point 7
23 16 V108 Solenoid Valve Sampling Point 8
24 2 V109 Solenoid Valve Sampling Point 9
25 4 V110 Solenoid Valve Sampling Point 10
. .
. .
. .
n Vn Solenoid Valve Sampling Point n

D4
 Salwico SW2020
Technical Data

4.3 Pneumatic diagram, Analysing unit

4.3.1 One pump system

SP1 SP2 SP3 SP4 SP5 SP6 SPi

FA FA FA FA FA FA FA
FA FA FA FA FA FA FA
A A A A A A A

V101 P P V103 P V104 P V105 P V106 P Vi(109) P

V102

V3 A
S

DILUTION FM3
PUMP 15L 150

0
FS FA
P2 FS2
VS
VS1 M
S1 ANALYZING FM3 ST600 VCM ST400 NH3
PUMP 15L 150 0-100%LEL 0-100%±PM

A P 0
FS FA
P1 FS1
P G1 G2
M V4 A

V2 A
P R
V5 FA
S

FRESH AIR
INLET TEST GAS OUTLET
INLET

D5
 Salwico SW2020
Technical Data

4.4 Flow examples

4.4.1 One pump system
Normal operation, sampling and analysing of sampling point no 2 (SP2)

SP1 SP2 SP3 SP4 SP5 SP6 SPi

FA FA FA FA FA FA FA
FA FA FA FA FA FA FA
A A A A A A A

V101 P P V103 P V104 P V105 P V106 P Vi(109) P

V102

V3 A
S

DILUTION FM3
PUMP 15L 150

0
FS FA
P2 FS2
VS
VS1 M
S1 ANALYZING FM3 ST600 VCM ST400 NH3
PUMP 15L 150 0-100%LEL 0-100%±PM

A P 0
FS FA
P1 FS1
P G1 G2
M V4 A

V2 A
P R
V5 FA
S

FRESH AIR
INLET TEST GAS OUTLET
INLET

D6
 Salwico SW2020
Technical Data

4.4.2 One pump system

Pipe cleaning function on sampling point no 2 (SP2). Pump connected to fresh air inlet.

D7
 Salwico SW2020
Technical Data

4.4.4 One pump system

Calibration with test gas.

SP1 SP2 SP3 SP4 SP5 SP6 SPi

FA FA FA FA FA FA FA
FA FA FA FA FA FA FA
A A A A A A A

V101 P P V103 P V104 P V105 P V106 P Vi(109) P

V102

V3 A
S

DILUTION FM3
PUMP 15L 150

0
FS FA
P2 FS2
VS
VS1 M
S1 ANALYZING FM3 ST600 VCM ST400 NH3
PUMP 15L 150 0-100%LEL 0-100%±PM

A P 0
FS FA
P1 FS1
P G1 G2
M V4 A

V2 A
P R
V5 FA
S

FRESH AIR
INLET TEST GAS OUTLET
INLET

D8
 Salwico SW2020
Technical Data

4.5 CALCULATION OF SAMPLING TIME

120

100

80
Sampling time, second

60

40

20

0
0m 50m 100m 150m 200m 250m 300m
Pipe length, meter

Sampling pipe length, m 0 25 50 75 100 125 150 175 200 225 250 275 300
Sampling time, sec 10 15 22 28 35 43 52 61 70 80 91 105 120

Diagram for calculation of the optimal sampling time is 6 mm. For a SW2020-system with two pumps the sum
corresponding to the sampling point length. The pump of presuction and analysing time is the total sampling
capacity is 15 L/min and the sampling pipe inner diameter time to insert in the setup for the sampling points.

D9
 Salwico SW2020
Technical Data

4.6 Vacuum Pump

The vacuum pump 107 CCD20 used in the SW2020 Gas Sampling System is a
membrane pump designed for a high degree of efficiency when it is used for
vacuum.
It is designed for continuous operation with permanently lubricated bearings, a
long life Buna “N” diaphragm, stainless steel valves and aluminum valve plate.
The pump is balanced for low vibration operation and in addition mounted on
shock absorbers.
The diagram for calculation of sampling time previous in this manual is a result
from real tests on vacuum pump 107 CCD20, with sampling pipes of inner
diameter 6 mm.
The flow meter and the flow switch monitor the flow capacity of the pump.
The system vacuum guard or the flow switch supervises the tightness of the
pump membrane.

DATA:

Model: Thomas 107 CCD20

Motor voltage/frequency 220/50-230/60
Power 130 Watt
Current 1,0 Amp
Flow at free flow 19 L/min
Flow at –0.2 Bar (vacuum) 14 L/min
Flow at –0.4 Bar (vacuum) 9 L/min

MAINTENANCE:

Below procedures refer to the drawing and part list found on the next page.

The maintenance of the pump is mainly to exchange diaphragm and valve

flappers after they have been worn-out. By removing of the pump head with the
four screws (item 13), this service is easily accessible.

Exchange the diaphragm (item 3) by removing the diaphragm hold down plate
(item 5) with the four screws (item 4).

Exchange or cleaning of the valve flappers:

Remove the valve plate (item 24). Unscrew the valve flapper screw and remove
the valve flappers (item 20), one on each side of the valve plate. Be careful not
do damage or contaminate the surface where the flappers are working. Clean
the flappers and the surface carefully with alcohol and then blow dry. Make sure
that the flappers are pressing tight towards the valve plate, otherwise the
capacity of the pump will be reduced.

Our Spare part set for the pump Art. No. 7360, contains diaphragm, valve
flappers and valve plate gasket (item 3, 20 and 23).

D10
Salwico SW2020
Technical Data

D11
 Salwico SW2020
Technical Data

4.7 Gas Detectors

LIST OF RECOMMENDED GAS DETECTORS FOR SW2020

GAS SAMPLING SYSTEMS:

Gas Name Range Gas Type Art.no.

detector
C3H8 Propane 0-100% LEL GD 10 IR Infrared 4253
C3H8 Propane 0-100% VOL GD 10 IR Infrared
CH4 Methane 0-100% LEL GD 10 IR Infrared 4253-ME
CH4 Methane 0-100% VOL GD 10 IR Infrared 4243-ME
C3H8 Propane 0-100% LEL ST600 EX Catalytic 4460
CH4 Methane 0-100% LEL ST600 EX Catalytic 4460
NH3 Ammonia 0-10% LEL ST600 EX Catalytic 4480
NH3 Ammonia 0-100 ppm ST400 Electrochemical
O2 Oxygen 0-25% VOL ST400 Electrochemical 4461
H2S Hydrogen 0-25 ppm ST400 Electrochemical 4462
sulfide
CO Carbon 0-250 ppm ST400 Electrochemical 4463
monoxide

For technical data, see additional information in project working

drawings.

Other type of gas detectors for other gases can be installed by

request.

D12
 Salwico SW2020
Spare Parts List

5 SPARE PARTS LIST

E1
 Salwico SW2020
Spare Parts List

Standard Spare Part Set

ART.NO 1720

Description Qty Art.No.

Solenoid valve 3-way 6014-T 1 4652
Solenoid valve 2-way 6013-A 1 4654
Flame trap FTH-1/4 / On-line filter 1 4227
Filter for 4227 10 4229
Teflon hose 6/4 mm 1 4219
Repair kit for 15 l pump 7350 1 7360
Fuse 500 mAT 10 8200
Fuse 100 mAT 10 8218
Fuse 315 mAT 10 8219
Fuse 4 AT 10 8225

Extended Spare Part Set

ART.NO 1710

Description Qty Art.No.

Solenoid valve 3-way 6014-T-2.0 / 6014-D-2.0 1 4652
Solenoid valve 2-way 6013-A-2.0 1 4651
Solenoid valve 2-way 6013-A-2.0 5 W 1 4654
Manual shut-off valve 1 4232
Flame trap FTH-1/4 1 4227
On-line filter SS 1 4227
Filter element 10 4229
Hose coupling 6/4 - 1/8” 5 4270
Loctite 577 1 4236
Teflon hose 6/4 2m 4219
Viton hose 7/5 0.2 m 4220
Vacuum meter 1 4246
Gasket set for 15 L pump 7350 1 7351
Pressure Guard 1 7303
Relay 24V / 2P-5A 2 12015
Fuse 500 mAT, 5 x 20 10 8200
Fuse 100 mAT 5 x 20 10 8218
Fuse 315 mAT 5 x 20 10 8219
Fuse 3.15 AT 5 x 20 10 8204
Fuse 4 AT 5 x 20 10 8225

Consilium Marine AB, P.O.Box 8763, SE-40276 GÖTEBORG, SWEDEN

Tel: +46-31 710 77 00, Fax: +46-31 710 78 00
E-mail: [email protected]
WEB: www.consilium.se

E2
 Salwico SW2020
Products list

6. PRODUCTS LIST

F1
 ANALYZING UNIT

Pos Description Code Type Data Art. No

1 Pump P1, P2 107 CCD20 15 l/min, 230V 50/60 Hz 7350

2 Solenoid Valve V1 (one pump syst.) 6013-A-2.0 24 V=,8W,0-10 kp 4651
3 Solenoid Valve V1 (two pump syst.) 6014-T-2.0 24 V=,5W,0-6kp 4652
4 Solenoid Valve V2 6013-A-2.0 24 V=,5W,0-10 kp 4654
5 Solenoid Valve V3 6013-A-2.0 24 V=,8W,0-10 kp 4651
6 Solenoid Valve V4 6013-A-2.0 24 V=,5W,0-10 kp 4654
7 Solenoid Valve V5 6014-T-2.0 24 V=,5W,0-6kp 4652
8 Solenoid Valve V6 6014-T-2.0 24 V=,5W,0-6kp 4652
9 Solenoid Valve V7 6014-T-2.0 24 V=,5W,0-6kp 4652
10 Solenoid Valve V8 6014-T-2.0 24 V=,5W,0-6kp 4652
11 Solenoid Valve V9 330-D-2.0 24 V=,8W,0-10 kp 4655
12 Solenoid Valve V101 - V104 6013-A-2.0 24 V=,8W,0-10 kp or 5W,0-6kp 4651/4652
13 Solenoid Valve Vx 6013-A-2.0 24 V=,8W,0-10 kp or 5W,0-6kp 4651/4652
14 Solenoid Valve Vx+1 6013-A-2.0 24 V=,8W,0-10 kp or 5W,0-6kp 4651/4652
15 Solenoid Valve Vi n-1 6013-A-2.0 24 V=,8W,0-10 kp or 5W,0-6kp 4651/4652
16 Solenoid Valve Vi n 6013-A-2.0 24 V=,8W,0-10 kp or 5W,0-6kp 4651/4652
17 Pressure Guard PS1 620.9100 2-8 mbar 7303
18 Vacuum Guard VS1, VS2 VSM1 7317
19 Choke Valve S1, S2, S3 RT 0,5 mm 7342
20 Flow Meter FM Brooks GT1355 0-300 l/h / 7-70 l/h 7318
21 Detectors Custom designed Required

F2
Products list
Salwico SW2020
 Pos Description Code Type Data Art. No

22 Filter/Pressure Reg. PR N1204-D00 0 - 4 Bar 7307

23 Pressure Instrument PRI M043 0 - 4 Bar 7308
24 Filter F N204-F00 7309
25 Choke Valve S4, S5-Sx SCO - 604 - 1/8”/ 8290 - 1/8" Adjustable 7241
26 Flame Trap Outlet FT FTH - 1/4 4227
27 Flame Trap Sampling Point FT FTH - 1/4 4227
28 Power Supply Unit SP - 100 SP-100 / 27 85 - 264VAC / 24 VDC 53030
29 Automatic Fuse E21 12250 4A 12001
30 Relay RL1 - RL8 E40 06823 24VDC 2P5A 12015
31 Remote Input/Output PCB RIOK - 40 RIOM - 40 19240
32 Remote Output PCB RIOK - 41 RIOM - 41 19241
33 Flow Switch FS LPH - 125-1 7319
34 Pressure Switch PS2 PMN 10A 0 - 7 Bar 34030-0010

CONTROL UNIT ME400

35 Control panel GSM - 3150 GSM - 3150 51000
36 I/O board IKK - 4 IKK - 4 52000
37 Comm. board AKK - 2 AKK - 2 52100

F3
Products list
Salwico SW2020
 Salwico SW2020
Maintenance

7. MAINTENANCE

G1
 Salwico SW2020
Maintenance

General
The SW2020 gas sampling system has no parts that need daily maintenance
and since the central continuously supervises itself it will generate a fault
message if something is malfunctioning.
The daily handling of the system is described in the document “Guidelines for
the daily handling of Salwico SW2020”. It is essential to follow these guidelines
in order to have a reliable and functional system.

Maintenance

Detector & pipes (3-6 months)

Every 3-6 months it is recommended to test and if possible calibrate the gas
detector(s) inside the analyzing unit.
This should be done according to chapter 3.4 “General Settings menu 12” in
this manual.

Every 3-6 months it is also recommended to visually check that the sampling
pipes from the central cabinet to the deck passage are not broken in any way.

Pump(s) (12-15 months)

The sampling pump(s) is/are working constantly ,and the membrane inside the
pump(s) will be worn-out after a period.
-When the central is equipped with one pump the recommendation is that the
membrane should be replaced once every 12-15 months. However, the central
is always supervising the flow from the pump, which means that if the
membrane becomes weak or is broken there will be a pump fault alarm.
The recommendations are to always have a spare membrane in the spare part
set.
-When the central is equipped with two pumps and redundancy function, there
will always be one pump that can handle the sampling cycle even though one
pump is not working. Therefore the recommendation in this case is to replace
the membrane when it is broken or every 12-15 months. The central is always
supervising the flow from the pumps and if one does not work properly there
will be a pump fault alarm.
The recommendations are to always have two spare membranes in the spare
part set.

Additional information
There is an online filter on each sampling line and it might get filled with dust or
dirt etc. If such a filter is blocked the remedy is to replace the filter.
The central will generate a sampling point flow fault alarm any filter is blocked.

On-line filter
The online filter has an internal sinter filter, which is replaceable.

The recommendations are to always have some spare filters in the spare part
set.

G2