Labkotec idOil-OIL User manual

idOil-OIL
Oil sensor
Installation and Operating Instructions EN
DOC001799-EN-1
9/11/2019

Table of contents
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1. General information about the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1. Markings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2. Conformity of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3. Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Safety and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1. General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2. Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3. Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6. Decommissioning and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1. Device operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2. Dimensions of the idOil-OIL oil sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1. General installation instructions for sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2. Installing the idOil-OIL sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1. idOil sensor connected to idOil control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2. idOil-OIL sensor connected to SET control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1. idOil-OIL sensor functional test with idOil control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2. idOil-OIL sensor functional test with SET control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1. idOil sensor troubleshooting with idOil control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2. idOil-OIL sensor troubleshooting with SET control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Technical specifications idOil-OIL oil sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Appendix EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1. General information about the manual
This manual is an integral part of the product.
Please read the manual before using the product.
Keep the manual available for the entire duration of the product’s life span.
Provide the manual to the next owner or user of the product.
Please report any errors or discrepancies related to this manual before commissioning
the device.
1.1. Markings and symbols
Safety-related markings and symbols
This marking warns of a possible hazard. Failing to observe the safety instructions in
question may result in injury or death.
This marking warns of a fault or hazardous situation. Failing to observe the safety
instructions in question may result in injury or device breakage.
This marking warns of a possible fault. Failing to observe the safety instructions in question
may result in device or system breakage or erroneous operation.
This marking emphasises an issue that requires special attention during installation and
when using the device in an explosive atmosphere.
Informative markings and symbols
This marking highlights essential information.
►This marking refers to a user measure.
1.2. Conformity of the product
The EU declaration of conformity and the product’s technical specifications are integral
parts of this document.
All of our products have been designed and manufactured with due consideration to the
essential European standards, statutes and regulations.
Labkotec Oy has a certified ISO 9001 quality management system and ISO 14001
environmental management system.
1.3. Limitation of liability
Due to continuous product development, we reserve the right to change these operating
instructions.
The manufacturer cannot be held liable for direct or indirect damage caused by neglecting
the instructions provided in this manual or directives, standards, laws and regulations
regarding the installation location.
The copyrights to this manual are owned by Labkotec Oy.
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2. Safety and the environment
2.1. General safety instructions
The plant owner is responsible for the planning, installation, commissioning, operation,
maintenance and disassembly at the location.
Installation and commissioning of the device may be performed by a trained professional
only.
Protection of operating personnel and the system is not ensured if the product is not used in
accordance with its intended purpose.
Laws and regulations applicable to the usage or the intended purpose must be observed.
The device has been approved for the intended purpose of use only. Neglecting these
instructions will void any warranty and absolve the manufacturer from any liability.
2.2. Intended use
The idOil-OIL sensor is intended to be used in oil separators to detect when the
accumulated oil in the separator has reached its maximum level. The sensor also detects if
the standard liquid layer in the separator drops unexpectedly e.g. in the case of leakage.
The sensor can be placed in a zone 0 explosive atmosphere, but the control unit connected
with have to be placed in a safe area.
A more specific description of the product’s operation, installation and use is provided
later in this manual.
The device must be used in accordance with the instructions provided in this
document. Other use is counter to the product’s purpose of use. Labkotec cannot be held
liable for any damage caused by using the device in violation of its purpose of use.
2.3. Installation and commissioning
The sensor can be installed in potentially explosive atmospheres of zones 0, 1 and 2.
In potentially explosive area installations, the national regulations and
appropriate standards IEC/EN 60079-25 Intrinsically safe electrical systems “i” and/or
IEC/EN 60079-14 Explosive atmospheres - Electrical installations design, selection and
erection must all
be followed..
If it is possible that static electricity can cause hazards in the measurement
environment, equipotential bonding must be attended according to the regulations
concerning potentially explosive atmospheres. Equipotential bonding is done by connecting
all conductive parts to the same potential e.g. in a junction box. Equipotential bonding
system must be grounded.
The instructions concerning the inspection and maintenance of Ex equipment contained
in the standards IEC/EN 60079-17 and IEC/EN 60079-19 should be observed
when executing service, inspection or repair procedures in potentially explosive
atmospheres.
2.4. Transport and storage
Check the packaging and its content for any possible damage.
Ensure that you have received all the ordered products and that they are as intended.
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Keep the original package. Always store and transport the device in the original packaging.
Store the device in a clean and dry space. Observe the permitted storage temperatures. If
the storage temperatures have not been presented separately, the products must be stored
in conditions that are within the operating temperature range.
2.5. Repair
The device may not be repaired or modified without the manufacturer’s permission. If the
device exhibits a fault, it must be delivered to the manufacturer and replaced with a new
device or one repaired by the manufacturer.
2.6. Decommissioning and disposal
The device must be decommissioned and disposed of in compliance with local laws and
regulations.
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3. Product description
3.1. Device operation
The idOil-OIL sensor can be connected to Labkotec Oy analog (SET-1000 and SET-2000 -
product family) or digital (idOil-product family) control units.
The sensor issues an alarm signal when the accumulated oil layer in the separator reaches
the sensor and the sensor’s measuring electrode is covered in oil. The sensor issues an
alarm also when the liquid layer in the separator drops leaving the measuring electrode in
air e.g. due to a leakage.
Applications are oil separators.
The sensor has device classification 1 and it can be installed in zone 0, 1 and 2 hazardous
area.
3.2. Dimensions of the idOil-OIL oil sensor
A Measuring electrode
B Reference electrode
S Alarm switching point
Figure 1. Oil sensor idOil-OIL – structure and dimensions (mm)
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4. Installation
4.1. General installation instructions for sensors
idOil sensors can be installed in zone 0 explosive atmospheres. Do not remove the sensor
markings from the cables or sensor frames.
Read Section General safety instructions before installation.
Check the correct installation depth of the sensor in the instructions of the separator in
question.
For example, sensors can be installed suspended from their cable (see next figure). Leave
a sufficient length of the sensor or extension cable coiled inside the service well, so that
you can easily lift the sensor out for inspection and cleaning.
1Suspension
hook
2 Cable tie
Figure 2. Sensor suspension example Figure 3. Sensor mounting supplies
LMS-SAS5
4.2. Installing the idOil-OIL sensor
The sensor must be submerged at the desired installation depth when the liquid is at the
separator’s standard liquid level (L).
The exact installation depth depends on the following:
separator type
separator shape
volume and height of the separator’s oil compartment
The sensor must always be immersed in liquid. The alarm is activated when the lower
surface of the oil layer reaches the alarm switching point (S), i.e. when the sensor’s
measuring electrode is covered in oil.
The sensor activates the alarm when it is in contact with air. For this reason, the separator
must always be filled with water after draining.
1 idOil-OIL oil sensor
A Air
B Oil
C Water
L Standard liquid level
S Alarm switching point
X Maximum allowed oil layer thickness
Figure 4. Installing the idOil-OIL sensor
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5. Connections
5.1. idOil sensor connected to idOil control unit
Kuva 5 . Connecting idOil sensor(s) to idOil control units
A
B
Safe area
Hazardous area
The sensor connection is polarity free digital bus connection so the sensor can
be connected to any of the sensor connectors (sensor 1, sensor 2 or sensor 3).
Also, it doesn’t make any difference to which terminals of sensor connectors the
sensor wires are connected.
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1
2
Sensor connectors idOil-20, idOil-30/idOil-30 3G, idOil-30 Battery/idOil-30
Battery 3G
9
10
11
12
13
14
=
=
=
=
=
=
sensor 1, connection 1
sensor 1, connection 2
sensor 2, connection 1
sensor 2, connection 2
sensor 3, connection 1
sensor 3, connection 2
Sensor connectors idOil-D30
46
47
48
49
50
51
=
=
=
=
=
=
sensor 1, connection 1
sensor 1, connection 2
sensor 2, connection 1
sensor 2, connection 2
sensor 3, connection 1
sensor 3, connection 2
3Extension cable, e.g. protected, twisted-pair 2 x 0.5 mm2, maximum resistance
68 Ohm. Extra wires and shield must be cut and isolated carefully.
4Example cable connector LCJ1-1 for a single sensor
5Example cable connector LCJ121 for two sensors
6Example cable connector LCJ1-3 for three sensors
7Sensor(s)
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5.2. idOil-OIL sensor connected to SET control unit
The sensor of the idOil product family can be connected to the control unit of Labkotec Oy's
SET product family in place of the SET sensor. The difference is that the cable in the idOil
series sensors has no shielding and the polarity of the conductors does not matter because
the sensor connection is polarity-free.
Kuva 6. Connecting idOil-OIL to SET control units
A
B
Safe area
Hazardous area
The sensor connection is polarity free so the sensor wires can be connected to
any of the sensor terminals (+ or -).
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1 Sensor connector OilSET-1000
9
10
11
=
=
=
SHD
+
-
Shield is not connected to the control unit. Extra wires and shield must be cut and
isolated carefully.
2Junction box LJB2-78-83 for a single sensor. Extra wires and possible shield are
connected to the earthing connector of the junction box.
3Cable connector LCJ1-1 for a single sensor. Extra wires and shield must be cut
and isolated carefully.
4 Sensor connector SET-2000 Hi Level/Oil
12
13
14
=
=
=
SHD
+
-
Shield is not connected to the control unit. Extra wires and shield must be cut and
isolated carefully.
5Junction box LJB3-78-83 for two sensors. Extra wires and possible shield are
connected to the earthing connector of the junction box.
6Cable connector LCJ1-2 for two sensors. Extra wires and shield must be cut and
isolated carefully.
7Extension cable, e.g. protected, twisted-pair 2 x 0.5 mm2, maximum resistance
68 Ohm.
8idOil-OIL sensor
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6. Functional test
Always check the correct operation of the alarm after the installation and after making the
connections. You should also check the operation every time the separator is emptied or at
least once every six months.
6.1. idOil-OIL sensor functional test with idOil control unit
Functional test:
1. The sensor is in the water. The control unit should be in normal mode; indicator lights
are off (idOil-20) and there are no alarm notifications on the screen (idOil-30 and idOil-
D30), the relays are energised and the buzzer is silent.
2. Lift the sensor in the air or the oil. The control unit’s Oil chamber full indicator light
should light up or an alarm notification should appear on the screen within 10
seconds, after which the relay(s) should be de-energised, the buzzer should let out an
alarm sound and the local screen’s backlight should start blinking after the set delay.
3. Lower the sensor back into the water. The indicator light should turn off or the alarm
notification should disappear within 10 seconds and the relay(s) and the buzzer
should revert to their normal state after the set delay.
Clean the sensor of any contaminants that it might have accumulated during the functional
test before placing it back in the separator.
If the sensor does not function as described, check the device settings from the control
unit’s installation and operating instructions or contact the representative of the
manufacturer.
6.2. idOil-OIL sensor functional test with SET control unit
Functional test:
1. The sensor is in the water. The control unit should be in normal mode; indicator lights
are off, the relays are energised and the buzzer is silent.
2. Lift the sensor in the air or the oil. The control unit’s Oil chamber full indicator light
should light up within 10 seconds, after which the relay(s) should be de-energised and
the buzzer should let out an alarm sound after the set delay.
3. Lower the sensor back into the water. The indicator light should turn off within 10
seconds and the relay(s) and the buzzer should revert to their normal state after a
delay.
Clean the sensor of any contaminants that it might have accumulated during the functional
test before placing it back in the separator.
If the sensor does not function as described, check the device settings from the control
unit’s installation and operating instructions or contact the representative of the
manufacturer.
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7. Maintenance
The sensor should be cleaned every time the separator is emptied and at least once every
six months during mantenance inspection. For cleaning the sensor you can use e.g.
dishwashing detergent and brush.
Do not use corrosive substances to clean the sensors.
The idOil sensors do not have wearing or replaceable parts.
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8. Troubleshooting
8.1. idOil sensor troubleshooting with idOil control unit
EXPLOSION HAZARD!
Observe the installation and maintenance instructions for explosive atmospheres!
The measuring device must be Exi classified if the sensor is in an explosive area.
idOil-30, idOil-D30: Remember to set the device in maintenance mode so that the alarms
during the maintenance measures are recorded in the inspection log instead of the alarm
log. For detailed instructions on how to set the device in maintenance mode, please refer to
the control unit’s operation and installation manual.
The sensor cable wires are not numbered because the voltage polarity (+ or -) makes no
difference.
PROBLEM: Fault alarm is on:
idOil-20: The sensor alarm indicator light is flashing red and the fault
indicator light is red (cable cut or loose) or the alarm indicator lights of all
sensors and the fault indicator light are red (short circuit).
idOil-30, idOil-D30: Fault alarm on (the backlight of the display is
flashing).
Explanation: The sensor cable is short-circuited, cut or disconnected from the
connector. The sensor could also be damaged.
Action: 1. Measure voltage separately from that sensor's sensor connectors.
The voltage should be 9.0–11.5 V.
2. If the voltage is correct, measure the current drawn by the sensor
as follows:
2.1 Disconnect the sensor wire from the control unit’s left-hand side
sensor connector.
2.2 Connect an mA meter as shown in the figure below.
2.3 SENSOR connectors can have 1–3 sensors connected to it, with a
single sensor drawing 6.0–8.0 mA of current.
2.4 Reconnect the disconnected wire after the measurement.
The measurement can also be carried out on the separator end by opening the cable
extension.
A Ex-classified mA current meter
B idOil-20, idOil-30 control unit’s sensor connectors 9–10 or 11–12 or 13–14
C idOil-D30 control unit’s sensor connectors 46–47 or 48–49 or 50–51
D idOil sensor(s)
Figure 7 . Measuring sensor current; idOil control unit - idOil sensor(s)
If problems occur, contact Labkotec Oy's service department.
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8.2. idOil-OIL sensor troubleshooting with SET control unit
EXPLOSION HAZARD!
Observe the installation and maintenance instructions for explosive atmospheres!
The measuring device must be Exi classified if the sensor is in an explosive area.
The sensor cable wires are not numbered because the voltage polarity (+ or -) makes no
difference.
PROBLEM: Fault alarm is on:
The sensor circuit’s Fault indicator light is on and the buzzer is
sounding.
Explanation: The sensor cable is short-circuited, cut or disconnected from the
connector. The sensor could also be damaged.
Action: 1. Measure voltage separately from that sensor's sensor connectors.
The voltage should be 10.0 - 12.0 V.
2. If the voltage is correct, measure the current drawn by the sensor
as follows:
2.1 Disconnect the sensor wire from the central unit’s + sensor
connector.
2.2 Connect an mA meter as shown in the figure below.
2.3 The current value should settle within 10 seconds as follows:
- sensor in water 10–14 mA
- sensor in air/oil 6–8 mA
2.4 Reconnect the disconnected wire after the measurement.
The measurement can also be carried out on the separator end by opening the cable
extension / junction box.
1. Ex-classified mA current meter
2. SET-1000/2000 series control unit’s sensor connector
3. idOil-OIL sensor
Figure 8 . Measuring sensor current; SET-1000/2000 control unit - idOil-OIL sensor
If problems occur, contact Labkotec Oy's service department.
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9. Technical specifications idOil-OIL oil sensor
TECHNICAL SPECIFICATIONS idOil-OIL
Operating principle Conductance
Enclosure Enclosure class: IP 68
Materials: PVC, AISI 316, PA, CR, NBR
Weight 395 g (incl. 5 m cable)
Temparature Operation: 0ºC…+60ºC
Environment: -30ºC…+60ºC
Supply voltage 7,5...16 V DC
Cable 2 x 0.75 mm2 PUR
EMC IEC/EN 61000-6-2
IEC/EN 61000-6-3
ATEX and IECEx
Ex classification
Special terms (X)
Exi connection values
See system diagram Appendix A
EESF 19 ATEX 001X
IECEx EESF 19.0001X
II 1 G Ex ia IIA T5 Ga (idOil-OIL)
II 1 G Ex ia IIB T5 Ga (idOil-OIL-S)
Ta = -30°C…+60°C
Ui = 16 V, Ii = 80 mA, Pi = 400 mW
Ci < 5.2 nF, Li < 1.6 mH
Manufacturing year:
Please see the serial number on the type
plate.
xxxxxxx x xxx xx YY x
where YY = manufacturing year
(e.g. 18 = 2018)
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10. Appendix EU Declaration of Conformity
Installation and Operating Instructions | idOil-OIL 17/18
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Installation and Operating Instructions | idOil-OIL 18/18
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