fafnir 81 D-Ex Series Guide

FAFNIR GmbH • Schnackenburgallee 149 c • 22525 Hamburg • Tel.: +49 / 40 / 39 82 07–0 • Fax: +49 / 40 / 390 63 39
Technical Documentation
Overfill Prevention Sensor (e-OPS)
81 D-Ex… and 83 UV-…
Version: 5
Edition:
2019-02
Art. no.: 350237
FAFNIR
GmbH
DIN EN
13616

I Table of Contents
Table of contents
1Overview........................................................................................................................ 1
2Safety instructions........................................................................................................ 3
3Structure and design.................................................................................................... 4
3.1 Description............................................................................................................................................4
3.2 Function .................................................................................................................................................4
3.3 List of Substances...............................................................................................................................5
3.4 Structure ................................................................................................................................................5
3.4.1 Overfill Prevention Sensor 83 UV with pipe fitting................................................................6
3.4.2 Overfill Prevention Sensor 83 UV with wall fitting.................................................................7
3.4.3 Overfill Prevention Sensor 83 UV-A with pipe fitting ...........................................................8
3.4.4 Overfill Prevention Sensor 83 UV-A with wall fitting ............................................................9
3.4.5 Overfill Prevention Sensor 83 UV-C ..........................................................................................10
3.4.6 Overfill Prevention Sensor 81 D-Ex with pipe fitting ..........................................................11
3.4.7 Overfill Prevention Sensor 81 D-Ex with wall fitting ...........................................................12
3.5 Connection fitting ............................................................................................................................13
3.5.1 Pipe fitting ..........................................................................................................................................13
3.5.2 Wall fitting ..........................................................................................................................................13
3.5.3 Cross Over Prevention (COP).......................................................................................................14
3.5.4 Filling Hose Safety (FHS)................................................................................................................14
3.5.5 Product Identification Device (PID) ...........................................................................................14
3.5.6 Coding (example).............................................................................................................................14
4Installation .................................................................................................................. 16
4.1 Mounting.............................................................................................................................................16
4.2 Installation height ............................................................................................................................17
4.3 Mounting distance for installation in the manhole.............................................................18
4.4 Adjustment dimension...................................................................................................................19
4.4.1 Adjustment dimension X for cyl. horizontal tanks according to DIN 6608/ -16/ -17/
-24 and EN 12285 ............................................................................................................................19
4.4.2 Adjustment dimension X for standing tanks according to DIN 6619/-23........................20
4.4.3 Adjustment dimension X for tanks according to DIN 6618..................................................21
4.4.4 Adjustment dimension X for all other cylindrical tanks standing vertically ........................22
4.4.5 Tables of adjustment dimensions X ..........................................................................................23
4.5 Approval and testing obligations...............................................................................................29
5Maintenance and repair............................................................................................. 29
6List of figures .............................................................................................................. 30
7List of tables................................................................................................................ 30

Table of Contents II
8Appendix .....................................................................................................................31
8.1 List of Substances for the Overfill Prevention Sensors ......................................................31
8.2 EU Declaration of Conformity 81 D-Ex … and 83 UV-….....................................................34
8.3 EU-Type Examination Certificate 81 D-Ex … and 83 UV-…...............................................35
8.4 Instructions 81 D-Ex … and 83 UV-…........................................................................................38
8.5 Declaration of performance 81 D-Ex …....................................................................................41
8.6 Declaration of performance 83 UV-….......................................................................................42
8.7 TÜV test report 81 D-Ex … ............................................................................................................43
8.8 TÜV test report 83 UV-…...............................................................................................................45
© Copyright:
Reproduction and
translation are permitted only with the written consent of FAFNIR GmbH. FAFNIR GmbH
reserves the right to carry out product alterations without prior notice.

Page 1/46 Overview
1Overview
Under the German Water Resources Act, vessels with water-polluting liquids must be equipped
with overfill prevention devices. In other countries, the corresponding national rules and regu-
lations must be observed. In the case of storage tanks which are filled by tank vehicles, the
overfill prevention device consists of an Overfill Prevention Sensor (e-OPS) in the storage tank
and an Overfill Prevention Controller installed in the tank vehicle.
The Overfill Prevention Sensors 81 D-Ex and 83 UV-… approved to standard EN 13616, and the
Overfill Prevention Controller approved to prEN 16657 in the tank truck (tanker) provide this
overfill prevention device - see the Figure below:
1 Overfill Prevention Sensor 81 D-Ex… or 83 UV-…
2 Measuring transducer
3 Signal amplifier
4 Controller (Tank truck Management Computer TMC)
5 Actuator
Function
At the lower end of the probe tube the Overfill Prevention Sensor contains a sensor (PTC ther-
mistor). The measuring transducer transmits changes in resistance to the signal amplifier in
form of binary signals. According to the resistance value (liquid level in the tank), the actuator
in the tank truck is either opened so that the fuel can be filled or closed so that the fuel supply
is interrupted.
Connection between the Overfill Prevention Controller and the Overfill Prevention Sensor
The connection between the Overfill Prevention Controller on the tank truck and the Overfill
Prevention Sensor on the tank is made via a connecting cable with a socket coupler which is
inserted into the connection fitting (see Figure below). Depending on the tank filling method,
two different connection fittings are used for the connection to the Overfill Prevention Sensor:
1) Overfill Prevention Sensor with pipe fitting for the direct filling of individual tanks.
The socket coupler is inserted directly into the pipe fitting on the Overfill Prevention
Sensor.
2) Overfill Prevention Sensor with junction box and wall fitting for remote filling.
The socket coupler is inserted into the wall fitting which is connected to the Overfill
Prevention Sensor in the tank by an extension cable.
(4)
(5)
+ ϑ
L
(1)
(3)
Overfill Prevention Sensor
in the storage tank Overfill Prevention Controller in the tank truck
Overfill prevention device
(2)
E

Overview Page 2/46
Figure 1: Filling a tank from the tank truck
Security system
The Overfill Prevention Sensor can be used to install a security system which, as required by
prEN 16657, consists of the digital product identification device (PID) and the product recognition
device (PRD). The magnetic Cross Over Prevention (COP) and the analogue Filling Hose Safety
(FHS) are also used as an alternative. PID and PRD systems are third party products.
The magnetic Cross Over Prevention (COP) is used to prevent product mixes. In order to
achieve this, the Overfill Prevention Sensors are equipped with a coded connection fitting. The
particular code allocated to each product is read out by the Overfill Prevention Controller in
the tank truck. The liquid can only be released if the dispensing product coincides with the
product in the tank.
The analogue Filling Hose Safety (FHS) is used to monitor the hose. The connections of the fill-
ing hose and the vapour recovery are monitored via the connection cable of the Overfill Pre-
vention Controller. The liquid can only be released when the hoses are securely connected.
Types
The following types of Overfill Prevention Sensors are available:
•83 UV (for fuel oil, diesel, petrol, brass probe tube, pipe or wall fitting)
•83 UV-A (as 83 UV, stainless steel probe tube)
•83 UV-C (as 83 UV-A, without junction box, with 5 m long cable)
•81 D-Ex (as 83 UV-A, also for aviation fuels, solvents, etc. See list of substances)
•81 D-Ex U (as 81 D-Ex, with voltage surge protection)
Connection fitting
Socket coupler
Connection cable

Page 3/46 Safety instructions
2Safety instructions
The safety instructions in this manual are marked as follows:
If these safety instructions are not observed, it may result in the risk of accident or
damage to the device/system.
Useful information which ensures continued and correct operation of the system
and makes your work easier.
Overfill Prevention Sensors (e-OPS) are designed to monitor the filling procedures in static
tanks. Use the Overfill Prevention Sensors exclusively for this purpose. The manufacturer ac-
cepts no liability for any form of damage resulting from improper use.
The Overfill Prevention Sensors have been developed, manufactured and tested in accordance
with the latest good engineering practices and generally accepted safety standards. Neverthe-
less, hazards may arise from their use. For this reason, the following Safety Instructions must
be observed:
•The proper function of the Overfill Prevention Sensors is only guaranteed in combina-
tion with an approved Overfill Prevention Controller in the tank truck.
•Do not change or modify the Overfill Prevention Sensors or the overall system, or add
any equipment without the prior consent of the manufacturer.
•Only use original parts. These comply with the technical requirements specified by the
manufacturer.
•The installation, operation and maintenance of the Overfill Prevention Sensors must
only be carried out by expert personnel. Specialised knowledge must be acquired by
regular training.
•The Overfill Prevention Sensors must be checked and approved before commissioning
and also at regular intervals (see Section 4.5, Approval and testing obligations)
•Operators, installers and service technicians must observe all applicable safety regula-
tions. This also applies to any local safety and accident prevention regulations which
are not stated in this manual.

Structure and design Page 4/46
3Structure and design
3.1 Description
The Overfill Prevention Sensors consist of a probe which extends into the tank and the height
of which can be adjusted, a screw-in unit which carries the probe and a connection fitting.
The probe is sealed in the screw-in unit and can be moved and fixed within the adjustment
range. The screw-in unit is secured in place with a stuffing box fitting and additionally with a
locking screw. It is suitable for the pressure range from 0.67 – 2 bar (absolute). The sensor
(steel-enclosed PTC resistor) is located at the lower end of the probe. The PTC resistor in the
steel capsule is liquid-tight and gas-tight enclosed.
The connection fitting is a pipe fitting (direct filling) or a junction box with connection to the
wall fitting (remote filling). A 2-core connection cable (2 x 1 mm²) is installed from the junction
box to the wall fitting.
The Overfill Prevention Sensors are manufactured in probe lengths from 100 to 6,000 mm in
100 mm steps. The probe length is permanently engraved on the upper end of the probe tube
above the groove marking. The probe length represents the distance between the groove
marking on the upper end of the probe and the groove marking on the protective sleeve at
the height of the sensor.
3.2 Function
The PTC resistor is heated up after connecting the Overfill Prevention Sensor with the signal
amplifier of the Overfill Prevention Controller on the tank truck. After achieving a certain tem-
perature, the change in resistance caused by this process prompts a signal in the signal ampli-
fier "Overfill prevention device ready for operation".
The delivery of the liquid can now take place. As soon as the liquid reaches the sensor of the
Overfill Prevention Sensor, the heated PTC resistor is cooled down, thereby causing the re-
sistance to change; this prompts a signal "close actuator" in the signal amplifier. The actuator is
automatically closed and the delivery therefore is stopped.
The reaction time for the closing process from the time the liquid is recognised to the end of
the product flow must not exceed 5.5 seconds: from the recognition of the liquid by the sensor
up to the output signal of the Overfill Prevention Controller max. 2.5 seconds, from the output
signal of the controller to the end of the product flow max. 3 seconds. [prEN16657, Section
5.4.2]

Page 5/46 Structure and design
3.3 List of Substances
The Overfill Prevention Sensors (e-OPS) are suitable for use in tanks with the following liquids:
Overfill Preven-
tion Sensor
83 UV 83 UV-A 83 UV-C 81 D-Ex 81 D-Ex U
List of Sub-
stances
•Fuel oil EL to DIN 51603
•Heating oil with FAME (fatty acid methyl
ester)
•Diesel fuel to DIN 51601/61606
•Diesel fuel with FAME (fatty acid methyl
ester)
•Petrol to DIN 51600/51607
•Petrol with up to 60% ethanol
•Biodiesel
•Vegetable oils
such as e-OPS 83 ... plus:
•Petrol with up
to 85 % ethanol
•Aviationgaso-
lines
•Aviation ker-
osenes
•Industrial spirits
•Solvents
See the appendix for the detailed list of substances for the 81 D-EX Overfill Preven-
tion Sensor.
The storage tanks must be approved for the liquids to be stored in them.
3.4 Structure
Overfill Preven-
tion Sensor
83 UV 83 UV-A 83 UV-C 81 D-Ex 81 D-Ex U
Probe tube Brass Stainless
steel
Stainless
steel
Stainless
steel
Stainless
steel
Probe tube
length [mm]
100 - 6000 100 - 6000 100 - 6000 100 - 6000 100 - 6000
Probe tube Ø
[mm]
24 x 2 16 x 1.5 16 x 1.5 24 x 1 24 x 1
Screw-in unit Brass Brass Brass Brass/stain
less steel
Brass/stain
less steel
Screw-in unit
thread [inch]
G1 G1 G¾ G1 G1

Structure and design Page 6/46
3.4.1 Overfill Prevention Sensor 83 UV with pipe fitting
Figure 2: Overfill Prevention Sensor 83 UV with pipe fitting
Ø 24
35
42
Ø 60
18
150
Protective cage
Plug insert
Pipe fitting
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Adjustment dimension "x"

Page 7/46 Structure and design
3.4.2 Overfill Prevention Sensor 83 UV with wall fitting
Figure 3: Overfill Prevention Sensor 83 UV with wall fitting
Ø 24
35
42
18
91
105
SW 55
Ø 60
Cable gland
Junction box
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Adjustment dimension "x"
Protective cage
Plug insert
Wall fitting
Connection cable
(on site)

Structure and design Page 8/46
3.4.3 Overfill Prevention Sensor 83 UV-A with pipe fitting
Figure 4: Overfill Prevention Sensor 83 UV-A
42
16
10 18
140
60
Protective cage
Plug insert
Pipe fitting
Earth connection
Type plate
Probe length engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Adjustment dimension "x"
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"

Page 9/46 Structure and design
3.4.4 Overfill Prevention Sensor 83 UV-A with wall fitting
Figure 5: Overfill Prevention Sensor 83 UV-A
79
16
10
SW52
104
60
42
18
Probe length
(100 … 6,000
mm)
Control di-
mension "y"
Adjustment dimension "x"
Cable gland
Junction box
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Protective cage
Plug insert
Wall fitting
Connection cable
(on site)

Structure and design Page 10/46
3.4.5 Overfill Prevention Sensor 83 UV-C
Figure 6: Overfill Prevention Sensor 83 UV-C
10 28
65
16
Adjustment dimension "x"
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Cable gland
PG 9
Groove marking
Cylinder screw DIN 912, M4x6, VA
Gland screw, SW 27
Screw-in unit, SW 27
Thread G3/4"
Response point
Dimensions in mm

Page 11/46 Structure and design
3.4.6 Overfill Prevention Sensor 81 D-Ex with pipe fitting
Figure 7: Overfill Prevention Sensor 81 D-Ex with pipe fitting
Ø 24
35
42
Ø 60
18
150
Protective cage
Plug insert
Pipe fitting
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Adjustment dimension "x"
(
∅
16)
∅24
(3)
35

Structure and design Page 12/46
3.4.7 Overfill Prevention Sensor 81 D-Ex with wall fitting
Figure 8: Overfill Prevention Sensor 81 D-Ex with wall fitting
Ø 24
35
42
18
91
105
SW 55
Ø 60
Cable gland
Junction box
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Adjustment dimension "x"
Protective cage
Plug insert
Wall fitting
Connection cable
(on site)
(
∅
16)
∅
24
(3)
35
(84)
91
(SW 58)
SW 55

Page 13/46 Structure and design
3.5 Connection fitting
The connection fitting is the interface between the Overfill Prevention Sensor and tank truck.
Depending on the method used to fill the tank, different connection fittings are used for the
connection to the Overfill Prevention Sensor: pipe fitting and wall fitting. The connection fitting
can also be equipped with a security system (COP/FHS, see following chapters).
3.5.1 Pipe fitting
If the supply connection and the Overfill Prevention Sensor are located in the manhole, the
connection fitting for the Overfill Prevention Sensor is to be a pipe fitting.
Figure 9: Pipe fitting type 907 with plug insert type 901
3.5.2 Wall fitting
If the supply connection is at a distance from the tank (e.g. in a remote filling pit), the Overfill
Prevention Sensor with junction box and wall fitting is used. The connection between junction
box and wall fitting must be installed with a cable/wire of 2 x 1 mm² with a maximum length of
150 m. In the case of 2 x 1.5 mm² cables, the maximum length is 250 m.
Figure 10: Wall fitting type 907 with plug insert type 901
PG11
105
Ø60
66
Ø5 (2x)
29
PG 11
Dimensions in mm

Structure and design Page 14/46
3.5.3 Cross Over Prevention (COP)
The Overfill Prevention Sensors may be equipped with a coded connection fitting. A specific
code is allocated to each product; this is read out by the Overfill Prevention Controller in the
tank truck via the socket coupler FP 903/FHS/K, and only approves the liquid delivery when the
product to be delivered coincides with the stored product. The coding is carried out via the
type FP 901 plug insert.
3.5.4 Filling Hose Safety (FHS)
The connection fitting can be used to monitor the hose. A signal is transmitted via connection
cable from the Overfill Prevention Controller of the tank truck to the Overfill Prevention Sensor
and then via the hoses back to the Overfill Prevention Controller. Only when the filler hose (for
petrol also the vapour recovery hose) is safely connected the delivery can take place. Contact is
made via the type FP 901 FHS plug insert.
3.5.5 Product Identification Device (PID)
If a connection cable with a type FP 903 FHS socket coupler is used and the connection fitting
has a type FP 901 FHS plug insert, the digital product identification PID (third party product)
can also be used.
3.5.6 Coding (example)
Code 1 = Super E10
Code 4 = Super Plus
Code 2 = Diesel fuel
Code 5 = not currently used
Code 3 = Super E5
Code 6 = not currently used
Code N = Neutral, FHS without COP

Page 15/46 Structure and design
Cross Over Prevention (COP)
Pipe fitting type 907 with
plug insert type FP 901/1-6
Filling Hose Safety (FHS):
Pipe fitting type FP 907/FHS with
plug insert type FP 901/1-6 FHS
Cross Over Prevention (COP)
Wall fitting type FPW 907 with
plug insert type FP 901/1-6
Filling Hose Safety (FHS):
Wall fitting type FPW 907/FHS with
plug insert type FP 901 H/1-6 FHS
Figure 11: Pug insert with COP/FHS locking system
PG7
PG11
Ø5 (2x)
105
Ø60
29
66
PG11
PG7
M6 (2x)
105
Ø60
29
84
Dimensions in mm

Installation Page 16/46
4Installation
4.1 Mounting
When working on tanks for storage of flammable liquids, all local safety and accident
prevention regulations must be observed as a matter of principle.
When filling static tanks with water-polluting liquids, the tanks may only be filled up
to their permitted level (see the German Water Resources Act resp. corresponding
national rules and regulations).
Installation in protective tubes or dipstick pipes is not permitted.
(1) The Overfill Prevention Sensor must always be installed in a vertical position in the
tank. Installation is via a screw-in unit. Provide the thread of the screw-in unit with a
suitable sealant and screw into the tank coupling. Release the locking screw and the
stuffing box (see Figure below). To obtain the correct position, the Overfill Prevention
Sensor can be moved upwards and fixed in position.
Figure 12: Screw-in unit
(2) Determine the adjustment dimension "x" for the Overfill Prevention Sensor (see Sec-
tion 4.4). The adjustment dimension "x" is the distance between the hexagon nut seat
of the screw-in unit and the groove marking on the sensor's protective sleeve at the
lower end of the probe.
(3) Set the height of the Overfill Prevention Sensor to the control dimension "y" (see Sec-
tion 4.2). The control dimension "y" is the distance between the hexagon nut seat of
the screw-in unit and the upper groove marking on the probe tube.
(4) Then re-tighten the stuffing box and locking screw.
Gland screw (max. 40 Nm)
Locking screw (max. 8 Nm)
Hexagon nut (max. 40 Nm)
Thread

Page 17/46 Installation
4.2 Installation height
In the case of tanks to the DIN standard, the response height "h" and the adjustment dimen-
sion "x" needed for this can be taken from the tables in the Section "Adjustment dimension".
The diameter, nominal capacity (particularly for multi-chamber tanks) and the height of the
manway nozzle height including the tank lid are important in calculating the adjustment di-
mension "x".
The installation height is adjusted using the control dimension "y" (see Figure below):
Control dimension "y" = probe length - adjustment dimension "x"
Figure 13: Control dimension "y"
If the Overfill Prevention Sensor is mounted in tanks that are not detailed in the ta-
bles, it must be ensured that the maximum filling ratio (volumes) of 95% for above-
ground and 97% for underground tanks (minimum 300 mm earth covering) is not
exceeded.
The adjustment dimension "x" cakes into consideration a manway nozzle height of
100 mm for tanks according to DIN 6608, 6616, 6618, and EN 12285, and 60 mm for
tanks according to DIN 6619, 6623 and 6624, as well as an overall thickness of
20 mm of the tank lid including sealing (see Tables of adjustment dimensions). In
the case of different heights, the adjustment dimension "x" must be amended cor-
respondingly.
The response height "h" and the adjustment dimensions "x" detailed in the tables
take into consideration shutdown volumes (due to switching delays in the control
circuit of the controller) for permanently installed fill pipes up to 20 m in length. For
tanks with permanently installed fill pipes over 20 m in length, the adjustment di-
mensions "x" must be increased by an amount that corresponds to the additional
volumes in the pipe.
xy
Probe length
a = manway nozzle height
x = adjustment dimension
y = control dimension
h = response height
a
h