Labkotec OilSET-1000 User manual

Labkotec UK Ltd
Shentonfield Road
Manchester
M22 4SD
ENGLAND
Tel: [phone].2008
Fax: [phone] D15399_e
E-mail: [email protected]
Internet: www.labkotec.co.uk 1/10
Copyright © 2008 Labkotec Oy We reserve the right for changes without notice
OilSET-1000
Oil Separator Alarm Device
Installation and Operating Instructions

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 2/10 We reserve the right for changes without notice
TABLE OF CONTENTS
1GENERAL............................................................................................................ 3
2INSTALLATION ................................................................................................... 4
2.1 OilSET-1000 control unit.............................................................................. 4
2.2 SET DM/3 probe .......................................................................................... 5
2.3 Cable joint .................................................................................................... 5
3OPERATION AND SETTINGS............................................................................ 6
3.1 Operation ..................................................................................................... 6
3.2 Factory settings............................................................................................ 7
4TROUBLE-SHOOTING ....................................................................................... 8
5REPAIR AND SERVICE ...................................................................................... 9
6SAFETY INSTRUCTIONS................................................................................... 9
7TECHNICAL DATA............................................................................................ 10
SYMBOLS
Warning / Attention
Pay special attention to installations at explosive atmospheres
Device is protected by double or reinforced insulation

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 3/10 We reserve the right for changes without notice
1 GENERAL
OilSET-1000 is an alarm device for monitoring the thickness of the oil
layer accumulating in an oil separator. Depending on the order, the
delivery consists of OilSET-1000 control unit, SET DM/3 probe and a
cable joint.
Figure 1. Oil separator alarm system
SET DM/3 probe is installed into the light liquid storage chamber and
gives an alarm when the chamber is filled to a pre-determined degree.
The probe is normally immersed in water.
The function is based on the measurement of the electrical
conductivity of the surrounding liquid – water conducts electricity
much better than oil.
Oil separator is regarded as potentially explosive (Ex) area. SET DM/3
probe can be installed in a zone 0, 1 or 2 potentially explosive area
but the control unit must be mounted in a safe area.
The LED indicators, push buttons and interfaces of the OilSET-1000
control unit are described in figure 2.
Figure 2. OilSET-1000 control unit - features

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 4/10 We reserve the right for changes without notice
2 INSTALLATION
2.1 OilSET-1000 control unit
OilSET-1000 control unit can be wall-mounted. The mounting holes
are located in the base plate of the enclosure, beneath the mounting
holes of the front cover.
The connectors of the external conductors are isolated by separating
plates. The plates must not be removed. The plate covering the
connectors must be installed back after executing cable connections.
The cover of the enclosure must be tightened so, that the edges touch
the base frame. Only then do the push buttons function properly and
the enclosure is tight.
Before installation, please read the safety instructions in chapter 6 !
Figure 3. OilSET-1000 alarm device installation.

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 5/10 We reserve the right for changes without notice
2.2 SET DM/3 probe
SET DM/3 probe should be installed as described in figure 3.
The probe gives an alarm earliest when the upper electrode is in oil
and latest when the probe is totally immersed in a non-conductive
liquid - in other words, it is totally away from the water.
Please check the correct installation depth also from the instructions
of the oil separator.
2.3 Cable joint
Fig. 4 Cable joint SK-3-2500
Connections of the probe cable inside the cable joint are explained in
figure 3. Cable shields and possible excess wires need to be
connected to the same point in galvanic contact.
Please make sure, that the probe and cable between OilSET-1000
control unit and the probe do not exceed the maximum allowed
electrical parameters – see chapter 7 Technical data.
IP rating of the cable joint is IP 67. Make sure, that the cable joint is
closed properly.
If the probe cable must be extended and there is a need for
equipotential grounding, it should be done with the junction box LJB2.
The cabling between the OilSET-1000 control unit and the junction
box should be done with a shielded twisted pair instrument cable e.g.
SY or CY Screened 2 Core 0.5 mm2.
Fig. 5. Cable installation example Fig. 6. Installation accessories

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 6/10 We reserve the right for changes without notice
3 OPERATION AND SETTINGS
The OilSET-1000 alarm device is initialized at the factory.
The operation of the alarm device should be checked always after the
installation.
Functionality test 1. Immerse the probe into water. The device should be in normal mode.
2. Lift the probe up in air or oil. An Oil alarm should be generated (see
chapter 3.1 for more detailed description).
3. Immerse the probe back into water. The alarm should go off after a
delay of 5 sec. Clean up the probe if necessary before placing it back
into the oil separator.
A more detailed description of the operation is provided in chapter 3.1.
If the operation is not as described here, check the factory settings
(chapter 3.2.) or contact a representative of the manufacturer.
3.1 Operation
The operation of a factory-initialized OilSET-1000 is described in this
chapter.
Normal mode – no alarms SET DM/3 probe is totally immersed in water.
Mains LED indicator is on.
Other LED indicators are off.
Relays 1 and 2 are energized.
Oil alarm SET DM/3 probe is immersed in oil. (The probe gives an alarm earliest
when the upper electrode is in oil and latest when the probe is totally
immersed in a non-conductive liquid, in other words it is totally away from
the water.)
Mains LED indicator is on.
Oil Alarm LED indicator is on.
Buzzer on after 5 sec delay.
Relays de-energize after 5 sec delay.
(Note. The same alarm takes place when SET DM/3 probe is in the air.)
After removal of an alarm, the Oil Alarm LED indicator and buzzer will be
off, and relays will be energized after a fixed delay of 5 sec.
Fault alarm Probe cable break, short circuit or a broken probe, i.e. too low or too high
probe signal current.
Mains LED indicator is on.
Probe circuit Fault LED indicator is on after 5 sec delay.
Buzzer is on after 5 sec delay.
The relays de-energize after 5 sec delay.
Reset of an alarm When pressing the Reset push button.
Buzzer will go off.
Relay 1 energizes.
Relay 2 will stay de-energized until the actual alarm or fault is off.
TEST FUNCTION
Test function provides an artificial alarm, which can be used to test the
function of the OilSET-1000 alarm device and the function of other
equipment, which are connected to OilSET-1000 via its relays.
Attention! Before pressing the Test button, make sure that the change
of relay status does not cause hazards elsewhere!

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 7/10 We reserve the right for changes without notice
Normal situation When pressing the Test push button:
Oil Alarm and Fault LED indicators are immediately on.
Buzzer is immediately on.
Relays de-energize after 2 sec of continuous pressing.
When the Test push button is released:
LED indicators and buzzer go immediately off.
Relays energize immediately.
Alarm on When pressing the Test push button:
Fault LED indicator is immediately on.
Oil Alarm LED indicator remains on.
Buzzer remains on. If it has been reset earlier, it will return to be on.
If relay 1 was already reset, it will de-energize again after 2 sec. of
continuous pressing.
Test will not affect relay 2, because it is already in alarm status.
When the Test push button is released:
The device returns without delay to the preceding status.
Fault alarm on When pressing the Test push button:
The device does not react to the test at all.
3.2 Factory settings
If the operation of OilSET-1000 is not as described in the previous
chapter, check that the device settings are as in figure 7. Change the
settings according to the following instructions if needed.
The following tasks must only be executed by a person with proper
education and knowledge of Ex-i devices.
We recommend, that when altering the settings the mains voltage is
off or the device is initialized before the installation is executed.
Figure 7. Factory settings
The settings are made with switches (MODE and DELAY) and
potentiometer (SENSITIVITY) located in the upper printed circuit
board, and the jumper located in the lower board (figure 7). In figure 7,
the switches are as set in the factory.
Switch S2 is used to set the operational delay of the control unit. When the switch is in low
position, relays operate and buzzer is on after 5 seconds after the level has reached the
trigger level, and if the level still remains on the same side of the trigger level.
When the switch is in high position, the delay is 30 seconds.
Delays are operational in both directions (energizing, de-energizing). Alarm LED follows the
probe current value and trigger level without delay. Fault alarm takes place after a fixed delay
of 5 sec.

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 8/10 We reserve the right for changes without notice
4 TROUBLE-SHOOTING
Problem: MAINS LED indicator is of
f
Possible reason: Supply voltage is too low or the fuse is blown. Transformer or MAINS LED
indicator is faulty.
To do: 1. Check if the two pole mains switch is off.
2. Check the fuse.
3. Measure the voltage between poles N and L1. It should be 230 VAC + 10 %.
Problem: No alarm when probe in oil or air, or the alarm will not go of
f
Possible reason: The SENSITIVITY setting is wrong in the control unit (see figure 7), or probe is
dirty.
To do: 1. Clean-up the probe and lift it up in the air or immerse it into oil.
2. Turn the SENSITIVITY potentiometer slowly anticlockwise until the probe gives
an alarm.
3. Immerse the probe into water and wait until the alarm goes off. If the alarm does
not go off, turn the potentiometer slowly clockwise until the alarm goes off.
4. Lift the probe up in the air or oil. The probe should give an alarm again.
Problem: FAULT LED indicator is on
Possible reason: Current in probe circuit too low (cable break) or too high (cable in short circuit).
The probe might also be broken.
To do: 1. Make sure, that the probe cable has been connected correctly to the OilSET-
1000 control unit. See probe specific instructions.
2. Measure the voltage separately between the poles 10 and 11. The voltages
should be between 10,3….11,8 V.
3. If the voltage is correct, measure the probe current. Do as follows:
3.1 Disconnect probe’s [+] wire from probe connector (pole 10).
3.2 Measure short circuit current between [+] and [-] poles.
3.3 Connect mA-meter as in figure 8.
Make a comparison to the values in Table 1.
3.4 Connect the wire back to the connector.
If the problem can not be solved with the above instructions, please contact
Labkotec Oy’s local distributor or Labkotec Oy’s service.
Attention! If the probe is located in an explosive atmosphere, the multimeter must
be Exi-approved!
SET DM/3, channel 1
Poles 10 [+] ja 11 [-]
Shortcircuit 20 mA – 24 mA
Probe in the air 9 – 10 mA
Probe in oil (εr .2) 9 – 10 mA
Probe in the water 2 – 3 mA
Factory setting for
alarm point
approx. 6.5 mA
Figure 8. Probe current measurement Table 1. Probe currents

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 9/10 We reserve the right for changes without notice
5 REPAIR AND SERVICE
The probe should be cleaned and the operation should also be tested
when emptying the oil storage chamber or at least once every six
months. The easiest way to check the operation is to lift the probe up
in the air and to put it back to the separator. The operation is
described in chapter 3.
For cleaning, a mild detergent (e.g. washing-up liquid) and a
scrubbing brush can be used.
The mains fuse (marked 125 mAT) can be changed to another glass
tube fuse 5 x 20 mm / 125 mAT complying EN 60127-2/3. Any other
repair and service works on the device may be carried out only by a
person who has received training in Ex-i devices and is authorized by
the manufacturer.
In case of queries, on site commissioning and service contract details,
please contact Labkotec Oy’s service:
[e-mail].
Environment-Agency Pollution Prevention Guidelines (PPG3):
“Any electrical device used within a separator or used to monitor sensors
placed within a separator must be intrinsically safe and certified to a
suitable explosion protection standard. The location of the monitoring
device, such as the alarm or 'separator management system' control panel,
must be located within a safe area and conform to the requirements of BS EN
60079-10. For this reason it is important to always use qualified technicians
who are familiar with the installation, calibration and servicing of intrinsically
safe equipment. Regular maintenance and testing of equipment is
essential.”
6 SAFETY INSTRUCTIONS
OilSET-1000 control unit must not be installed in potentially explosive
atmosphere. Probes connected to it may be installed in zone 0, 1 or 2
potentially explosive atmospheres.
In case of installations in explosive atmospheres the national
requirements and relevant standards as EN 50039 and/or EN 60079-
14 must be taken into account.
If electrostatic discharges can cause hazards in the operating
environment, the device must be connected into equipotential ground
according to requirements with regards to explosive atmospheres.
Equipotential grounding is made by connecting all conductive parts
into same potential e.g. at the cable junction box. Equipotential ground
must be earthed.
The device does not include a mains switch. A two pole mains switch
(250 VAC 1 A), which isolates both lines (L1, N) must be installed in
the main power supply lines in the vicinity of the unit. This switch
facilitates maintenance and service operations and it has to be marked
to identify the unit.
When executing service, inspection and repair in explosive
atmosphere, the rules in standards EN 60079-1 and EN 60079-19
about instructions of Ex-devices must be obeyed.

OilSET-1000 Oil Separator Alarm Device D15399_e
Installation and Operating Instructions
Copyright © 2008 Labkotec Oy 10/10 We reserve the right for changes without notice
7 TECHNICAL DATA
OilSET-1000 control unit
Dimensions 175 mm x 125 mm x 75 mm (L x H x D)
Enclosure IP 65, material polycarbonate
Ambient temperature -25 ºC…+50 ºC
Supply voltage 230 VAC ± 10 %, 50/60 Hz
Fuse 5 x 20 mm 125 mAT (EN 60127-
2/3)
The device is not equipped with a mains
switch
Power consumption 2 VA
Probes One SET probe (SET DM/3)
Max. impedance of the
current loop between the
control unit and a probe
75 .
Relay outputs Two potential-free relay outputs
250 V, 5 A, 100 VA
Operational delay 5 sec or 30 sec.
Relays de-energize at trigger point.
Operation mode selectable for increasing
or decreasing level.
Electrical safety EN 61010-1, Class II , CAT II / III
Insulation level
Probe / Mains supply voltage
375V (EN 50020)
EMC
Emission
Immunity
EN 61000-6-3
EN 61000-6-2
Ex-classification
Special conditions (X)
II (1) G [EEx ia] IIC
VTT 04 ATEX 031X
(Ta = -25 °C…+50 °C)
Electrical parameters
Characteristic curve of the
output voltage is trapezoidal
See table 2.
Uo = 14,7 V Io = 55 mA
Po = 297 mW R = 404 
Due to non-linear characteristics of the probe voltage, the interaction of
both, capacitance and inductance, must be taken into account. The
table below indicates the connecting values in explosion groups IIC and
IIB. In explosion group IIA the values of the group IIB can be applied.
Max. permissible value Combined Co and Lo
Co Lo Co Lo
II C 608nF 10 mH
568nF
458 nF
388 nF
328 nF
258 nF
0,15 mH
0,5 mH
1,0 mH
2,0 mH
5,0 mH
II B 3,84F 30 mH
3,5 µF
3,1 µF
2,4 µF
1,9 µF
1,6 µF
0,15 mH
0,5 mH
1,0 mH
2,0 mH
5,0 mH
Lo/Ro= 116,5 µH/(IIC) and 466 µH/(IIB)
Table 2. OilSET-1000 electrical parameters
SET DM/3 probe
Principle of operation Measurement of conductivity
Enclosure IP68, materials: AISI 316 and PVC
Ambient temperature -20 ºC…+70 ºC
Supply voltage Approx. 12 VDC from SET control unit
Cable Fixed oil resistant PVC cable 3 x 0,5
mm2, standard length 5 m.
EMC
Emission
Immunity
EN 50081-1
EN 50082-1
Ex-classification II 1 G EEx ia IIA T4
VTT 02 ATEX 012X
Electrical parameters Ui = 16,5 V Ii = 80 mA
Pi= 330 mW Ci = 700 pF
Li = 10 H
Special conditions concerning Ex-classification (X):
- Ambient temperature -20 ºC…+70 ºC
- Shielded probe cable shall be connected to equipotential ground
- If probe cable have to be extended, please use LJB2-78-83
junction box. The junction box shall also be connected to
equipotential ground.
Figure 9. Dimensional drawing of SET DM/3 probe