Labkotec idOil-20 User manual

idOil®-20
Oil Separator Alarm Device
Installation and Operating Instructions EN
DOC001600-EN-5
10/12/2018

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. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4. Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6. Decommissioning and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1. Device operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2. Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1. Dimensions of the idOil control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2. Dimensions idOil-LIQ high liquid level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3. Dimensions of the idOil-OIL oil sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.4. Dimensions idOil-SLU sludge sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1. Installing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2. Sensor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1. Installing the idOil-LIQ high liquid level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2. Installing the idOil-OIL sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3. Installing the idOil-SLU sludge sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1. Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1. Connection with a single-sensor cable connector . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2. Connection with a two-sensor cable connector . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.3. Connection with a three-sensor cable connector . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2. Explanations of connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1. Sensor identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2. Factory settings of the idOil control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1. Local display and alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2. Resetting an alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3. Changing the buzzer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1. Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1. Test function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2. Functional test with sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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8.2. Maintenance measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1. Technical specifications for the idOil control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2. Technical specifications idOil-LIQ high liquid level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3. Technical specifications idOil-OIL oil sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4. Technical specifications idOil-SLU sludge sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1. APPENDIX A System digram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2. APPENDIX B 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 alarm system is intended for monitoring liquid levels particularly in oil and sand
separators.
The system consists of a control unit and connected sensors that have been installed in the
oil or sand separator. The sensors can be placed in a zone 0 explosive atmosphere, but the
control unit must be positioned 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. 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.
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.
2.4. Installation and commissioning
The device does not have a mains switch and therefore the supply voltage
wires near the device should be fitted with an isolating switch (250 VAC/12
VA), which disconnects the wires (L1, N), in order to facilitate service and
repair procedures. The switch must be labelled as the unit's isolating
switch. The external switch must adhere to the standard IEC/EN 60947-1
or IEC/EN 60947-3.
UL/CSA: Supply cable 3 x 1,5-2,1 mm2 (AWG16-AWG14). Supply voltage
max fuse size 10 A.
Other areas: Supply cable 3 x 1,5-2,5 mm2 (AWG16-AWG13). Supply
voltage max fuse size 16 A.
The supply voltage and local supply voltage tolerances must be taken into
account with regard to the cable’s maximum voltage.
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If the temperature in the installation environment is expected to exceed
+40°C, the temperature tolerance of the supply voltage and relay
connection cable must be at least +80°C. Otherwise, any cable that meets
the applicable electrical regulations can be used as the supply voltage and
relay connection cable.
Due to the overvoltage protection, the protective earth wire (PE) must be
connected to the supply voltage connector (see Section Connections).
The internal temperature of the device can be 10°C higher than the
ambient temperature. This must be taken into account in the cabling of the
device.
The voltage connected to the contacts of both relays must be in the same
voltage class (ELV/LV), considering the maximum values listed in the
technical specifications.
The idOil control unit must not be installed in potentially explosive areas,
but a sensor connected to it may 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.
See Technical specifications; Connection values and Appendix A System
diagram.
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
idOil® is an alarm system intended for monitoring liquid levels particularly in oil and sand
separators. The system consists of the idOil control unit and the idOil sensors installed in
the separator. The sensor cables can be extended with a cable connector or connection
box.
One to three different types of digital idOil sensors can be connected to the control unit. The
sensors can be used to monitor the following:
High liquid level (idOil-LIQ high liquid level sensor)
Oil layer detection (idOil-OIL oil sensor)
Sludge layer detection (idOil-SLU sludge sensor)
1 Control unit idOil-20
2 Cable connector LCJ1-3
3High liquid level sensor idOil-
LIQ
4 Oil sensor idOil-OIL
5 Sludge sensor idOil-SLU
A Air
B Oil
C Water
D Sludge
Figure 1. System description; idOil control unit, sensors and cable extension
The device’s indicator lights present sensor alarms and faults.
In alarm and fault situations, the buzzer sounds an alarm and the relays are switched to the
alarm position.
The relays are of the failsafe type, which means that they also enter the alarm state when
operating power is lost.
The operation of the product is described in more detail in the section Operation.
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3.2. Products
Control unit:
Type name Description
idOil -20 Control unit, 100-240 V AC
Sensors:
Type name Description
idOil -LIQ High liquid level sensor to sense excessively high liquid level
idOil -OIL Oil sensor to detect the thickness of the oil layer
idOil -SLU Sludge sensor to detect the thickness of the sludge layer
Accessories:
Type name Description
LCJ1-1 Cable connector for one sensor
LCJ1-2 Cable connector for two sensors
LCJ1-3 Cable connector for three sensors
LMS-SAS2 Mounting kit for control unit
LMS-SAS5 Mounting kit for sensor
3.3. Dimensions
3.3.1. Dimensions of the idOil control unit
Figure 2. Dimensions of the idOil control unit (mm)
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3.3.2. Dimensions idOil-LIQ high liquid level sensor
A Sensor’s sensing element
S Alarm switching point
Figure 3. High liquid level sensor idOil-LIQ – structure and dimensions (mm)
3.3.3. Dimensions of the idOil-OIL oil sensor
A Measuring electrode
B Reference electrode
S Alarm switching point
Figure 4. Oil sensor idOil-OIL – structure and dimensions (mm)
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3.3.4. Dimensions idOil-SLU sludge sensor
T Sensor gap
S Alarm trigger point
Figure 5. Sludge sensor idOil-SLU – structure and dimensions (mm)
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4. Installation
4.1. Installing the control unit
The idOil control unit is wall mounted. Installation holes are located at the bottom part of the
box under the mounting holes for the cover.
The cover of the box must be tightened so that the edge touches the bottom part. This
ensures that the reset and test button functions well and the enclosure is tight.
The control unit must be installed in a safe (non-Ex) space.
Read Section General safety instructions before installation.
1 Cable glands M16 grey, 3 pcs
2 Cable glands M16 blue, 2 pcs
3Fastening holes Ø4.5 mm, 4
pcs
Installation dimensions 160 x
110 mm
Figure 6. Installing the idOil control unit
4.2. Sensor installation
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.
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1Suspension
hook
2 Cable tie
Figure 7. Sensor suspension example Figure 8. Sensor mounting supplies
LMS-SAS5
4.2.1. Installing the idOil-LIQ high liquid level sensor
The sensor is normally in air, and it issues an alarm when the sensing element is
submerged in liquid. The sensor is installed at a suitable height above the standard liquid
level (L) so that the overflow alarm is activated once the liquid level reaches the sensing
element.
Overflow is possible in the following cases, for example:
if the filter is dirty
if the automatic closure device is blocked
or if some other situation causes blockage in the discharge pipe
1 idOil-LIQ high liquid level sensor
A Air
B Oil
C Water
L Standard liquid level
S Sensor switching point
XLiquid alarm limit (maximum surface
level)
Figure 9. Installing the idOil-LIQ high liquid limit sensor
4.2.2. 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.
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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 10. Installing the idOil-OIL sensor
4.2.3. Installing the idOil-SLU sludge sensor
The sensor issues an alarm on sludge, sand or other solids accumulated at the bottom of
the separator.
The sensor’s exact installation depth depends on the following:
separator type
separator shape
maximum allowed sludge layer thickness
The sensor must always be immersed in liquid. The alarm is activated when the sludge
layer reaches the alarm switching point (S), which is located inside the sensor gap (T).
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.
Figure 11. Installing the idOil-SLU
sludge sensor
1 idOil-SLU sludge sensor
A Air
B Oil
C Water
D Sludge
L Standard liquid level
S Alarm switching point
X Maximum allowed sludge layer height
T Sensor gap
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5. Connections
Read Section General safety instructions before installation.
Make the connections when the device is de-energised.
The legends for the connection diagrams can be found in the section
following the diagrams.
5.1. Connection diagrams
5.1.1. Connection with a single-sensor cable connector
Figure 12. Connection with a single-sensor cable connector
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5.1.2. Connection with a two-sensor cable connector
Figure 13. Connection with a two-sensor cable connector
5.1.3. Connection with a three-sensor cable connector
Figure 14. Connection with a three-sensor cable connector
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5.2. Explanations of connection diagrams
1 Supply voltage 100–240 V AC
(N.B. The device does not include a mains switch, see Section General safety
instructions)
PE = protective earth connector
N = neutral connector
L1 = phase connector
UL/CSA: Supply cable 3 x 1,5-2,1 mm2 (AWG16-AWG14). Supply
voltage max fuse size 10 A.
Other areas: Supply cable 3 x 1,5-2,5 mm2 (AWG16-AWG13).
Supply voltage max fuse size 16 A.
The supply voltage and local supply voltage tolerances must be
taken into account with regard to the cable’s maximum voltage.
2 Sensor connectors
9 = sensor 1, connection 1
10 = sensor 1, connection 2
11 = sensor 2, connection 1
12 = sensor 2, connection 2
13 = sensor 3, connection 1
14 = sensor 3, connection 2
The sensor connection is a polarity-free digital bus, which means
that it does not matter which sensor terminal the wires are
connected to.
3 Relay outputs
RELAY 1
3 = Relay common contact
4 = Contact that opens in an alarm situation
5 = Contact that closes in an alarm situation
RELAY 2
6 = Relay common contact
7 = Contact that opens in an alarm situation
8 = Contact that closes in an alarm situation
The maximum values presented in the technical specifications must
be taken into account.
4 Cable connector:
LCJ1-1 for a single sensor
LCJ1-1 for two sensors
LCJ1-3 for three sensors
5 Sensors
6Extension 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.
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7 Protection plate
The connectors for the external connections are separated with
separator walls on the protection plate. The separator walls must not
be removed. The protection plate covering the connectors must be
reinstalled after connecting the cables.
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6. Commissioning
6.1. Sensor identification
Ensure that the sensors have been installed and connected in the control unit in
accordance with the instructions in the previous paragraphs.
DANGER OF ELECTRICAL SHOCK! Please observe the safety
instructions below!
Open the cover of the control unit and
ensure that the protection plate is in place!
Connect power to the control unit.
The voltage supply and fault indicator lights
(see Section Operation) are lit in green.
The sensor indicator lights are off.
Press the sensor identification button
briefly (1).
Figure 15. Sensor identification button.
The sensor identification function is initiated and the fault indicator light flashes green.
Once a sensor has been identified, the indicator light of the sensor in question becomes
green.
When all connected sensors have been identified, the lights of the connected sensors are
green and the fault indicator light stops flashing.
Close the cover of the enclosure.
The separator alarm system is now operational.
If the control unit does not identify all connected sensors.
Check the sensor connections.
After the check, press the sensor identification button again.
The control unit will look for the sensors for approx. 2 minutes, unless it
has already found three sensors.
The sensor identification can be stopped by pressing the sensor
identification button for 5 seconds.
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6.2. Factory settings of the idOil control unit
Alarm
settings
Alarm buzzer on
Alarm repeat (24h) on
Alarm delay for all sensors 10 s
Alarm reset button on
Relay
settings
Relay 1
Connected sensors All sensors connected to the
control unit
function function upon sensor alarm
relay is restored
when alarm is reset no
Relay 2
Connected sensors All sensors connected to the
control unit
function function upon sensor fault
relay is restored
when alarm is reset no
Installation and Operating Instructions | idOil-20 19/34
DOC001600-EN-5

7. Operation
After installation and commissioning, the idOil separator alarm system functions entirely
independently and does not require constant monitoring.
The alarm information can be connected to automation systems through relays.
All of the system’s connections and functions are described in the figure below and in more
detail in the following sections.
1 High liquid level sensor alarm indicator
light
2 Oil sensor alarm indicator light
3 Sludge sensor alarm indicator light
4 Fault indicator light
5 Voltage supply indicator light
6 Alarm reset and test button
7 Inlet for power supply
8 Relay output lead-throughs 2 pcs
9 Sensor connections 2 pcs (blue)
Figure 16. Features of the idOil control unit
7.1. Local display and alarms
Local display
The device features LED lights for indicating alarms and faults.
Alarms
In alarm and fault situations:
The indicator lights for alarm and/or fault situations are switched on.
After the alarm delay (10 s):
The buzzer lets out an alarm sound.
The relays are switched to the alarm position. Relay 1 is de-energised in an alarm
situation and relay 2 is de-energised in a fault situation. The relays are of the failsafe
type, which means that they also enter the alarm state when operating power is lost.
The alarms can be divided into two groups: level and fault alarms.
In a level alarm the sensor in the separator has detected that the liquid level being
monitored has reached the alarm limit (high liquid level, oil or sludge).
In a fault alarm the control unit has detected a fault in the sensor circuit. The monitoring
covers the communication between the control unit and sensor as well as short circuits
and breaks.
The indicator lights are used to indicate the status of the control unit and sensors. The
section below presents the operation of the indicator lights, buzzer and relays in various
situations:
Installation and Operating Instructions | idOil-20 20/34
DOC001600-EN-5