Labkotec SET-2000 Oil/Sludge User manual

Labkotec Oy
Myllyhaantie 6
FI-33960 PIRKKALA
FINLAND
Tel: + 358 29 006 260
Fax: + 358 29 006 1260 12.8.2019
Internet: www.labkotec.fi D15645AE-2
1/15
Copyright © 2019 Labkotec Oy We reserve the right for changes without notice
SET-2000 Oil/Sludge
110 VAC supply voltage
Alarm Device for Oil Separators
with SET/DM3AL and SET/S2 sensors
Installation and Operating Instructions

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 2/15 We reserve the right for changes without notice
TABLE OF CONTENTS
1GENERAL............................................................................................................ 3
2INSTALLATION ................................................................................................... 4
2.1 SET-2000 Oil/Sludge Control Unit ............................................................... 4
2.2 Sensor installation........................................................................................ 5
2.3 Junction box................................................................................................. 5
3OPERATION AND SETTINGS............................................................................ 6
3.1 Operation ..................................................................................................... 6
3.2 Factory settings............................................................................................ 8
4TROUBLE-SHOOTING ....................................................................................... 9
5REPAIR AND SERVICE.................................................................................... 10
6SAFETY INSTRUCTIONS................................................................................. 10
7 TECHNICAL DATA............................................................................................ 11
DECLARATION OF CONFORMITY....................................................................... 12
DECLARATION OF CONFORMITY....................................................................... 13
DECLARATION OF CONFORMITY....................................................................... 14
DECLARATION OF CONFORMITY....................................................................... 15
SYMBOLS
Warning / Attention
Pay attention to installations at potentially explosive atmospheres
Device is protected by double or reinforced insulation

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 3/15 We reserve the right for changes without notice
1 GENERAL
SET-2000 Oil/Sludge is an alarm device for monitoring the thickness of
the oil layer accumulating in the oil separator and the accumulation of
sludge or sand layer on the bottom of separator. Depending on the order,
the delivery consists of SET-2000 Oil/Sludge control unit, SET/DM3AL
sensor, SET/S2 sensor, junction box and installation supplies.
Figure 1. Oil separator alarm system with SET-2000 Oil/Sludge
The SET/DM3AL sensor is installed into the light liquid storage chamber
and gives an alarm when the chamber is filled to a pre-determined
degree. The function is based on the measurement of the electrical
conductivity of the surrounding liquid –water conducts electricity much
better than oil. The sensor is normally immersed in water.
SET/S2 sensor is installed in the separator or tank and it gives an alarm
when the sludge reaches the sensor. The principle of measurement is
ultrasonic. When sludge, sand or other solid particles accumulate
between the two sensor heads, the signal strength weakens, causing an
alarm. The sensor is normally immersed in water.
Oil separator is regarded as a potentially explosive (Ex) area. The
sensors can be installed in zone 0, 1 or 2 potentially explosive
atmosphere but the control unit must be mounted in a safe area.
The LED indicators, push buttons and interfaces of the device are
described in figure 2.
Figure 2. SET-2000 Oil/Sludge –features

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 4/15 We reserve the right for changes without notice
2 INSTALLATION
2.1 SET-2000 Oil/Sludge Control Unit
The SET-2000 Oil/Sludge 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. Installation of SET-2000 Oil/Sludge alarm device.

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 5/15 We reserve the right for changes without notice
2.2 Sensor installation
The sensor installation should be done as described in figure 3.
SET/DM3AL sensor gives an alarm when the upper electrode is in oil.
SET/S2 sensor gives an alarm when there is enough sand or sludge
accumulated between the two heads of the sensor. When the sludge
layer on the bottom of the separator or settling tank is pretty solid, the
correct installation depth can be adjusted based on the current level. In
case the level is not that clear, a tryout period of couple of days may be
useful.
Please check the correct installation depth also from the instructions of
the oil separator.
2.3 Junction box
If the sensor cable must be extended or there is need for equipotential
grounding, it can be done with the cable junction box. The cabling
between the SET-2000 control unit and the junction box should be done
with a shielded twisted pair instrument cable.
The cabling in figure 3 can be done with a two-pair shielded twisted pair
cable, whereupon both pairs are equipped with their own shields. Make
sure that the signal wires of the cables can never be connected to
each other.
LJB3 junction box enables cable extension in potentially explosive
atmospheres.
In figure 3 the shields and excess wires have been connected to the
same point in galvanic contact with metallic frame of the junction box.
This point can be connected to equipotential ground thru the ground
terminal. Other components of the system that need to be grounded can
also be connected to the same ground terminal.
The wire used for equipotential grounding must be min. 2.5 mm²
mechanically protected or, when not mechanically protected, the
minimum cross section is 4 mm².
Please make sure, that the sensor and the cable between SET-2000
control unit and the sensor do not exceed the maximum allowed
electrical parameters –see chapter 7 Technical data.
Detailed cabling instructions can also be found in the installation
instructions of SET/DM3AL and SET/S2 sensors.
Junction box of type LJB3 includes light alloy parts. When installing in
explosive atmosphere, make sure, that the junction box is located so,
that it can not be mechanically damaged or it will not be exposed to
external impacts, friction etc. causing ignition of sparks.
Make sure, that the junction is closed properly.

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 6/15 We reserve the right for changes without notice
3 OPERATION AND SETTINGS
SET-2000 Oil/Sludge is initialized at the factory. The operation of the
device should always be checked after the installation. The operation
should also be checked always when emptying the separator or at least
once every six months.
Functionality test
Oil alarm (SET/DM3AL sensor)
1. Immerse the sensor into water. The device should be in normal mode
(see chapter 3.1).
2. Lift the sensor up in the air or oil. Oil alarm should occur. (see chapter
3.1).
3. Immerse the sensor back into water. Alarm should go off after 5 sec
delay.
Functionality test
Sludge alarm (SET/S2 sensor)
1. Immerse the sensor into water. The device should be in normal mode.
2. Lift the sensor up in air or sink it into sludge. An alarm should be
generated after 30…40 seconds (see chapter 3.1).
3. Immerse the sensor back into water. The alarm should go off after a
delay of 30…40 seconds.
Clean up the sensors before placing them back into the 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 SET-2000 Oil/Sludge is described
in this chapter.
Normal mode –no alarms
SET/DM3AL sensor is totally in water and the two heads of the SET/S2
sensor are totally immersed in water.
Mains LED indicator is on.
Other LED indicators are off.
Relays 1 and 2 are energized.
Oil alarm
SET/DM3AL sensor is in oil. The sensor gives an alarm when the upper
electrode is in oil.
(Note! The same alarm takes place when SET/DM3AL sensor is in the
air)
Mains LED indicator is on.
Oil Alarm LED indicator is on.
Buzzer on after 5 sec delay.
Relay 2 remains energized.
Relay 1 de-energizes after 5 sec delay.
After removal of an Oil alarm, the alarm LED indicator and buzzer will be
off and relay 1 will be energized after 5 sec delay.
Sludge alarm
The two heads of the SET/S2 sensor are immersed in sludge or sand.
Mains LED indicator is on.
Alarm LED indicator is on after approx. 5 sec. delay. (Delay of the
sensor.)
Buzzer is on after 30…40 sec delay. (30 sec delay of the control unit incl.)
Relay 1 remains energized.
Relay 2 de-energize after 30...40 sec delay.
(Note. The same alarm takes place when SET/S2 sensor is in the air.)

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 7/15 We reserve the right for changes without notice
The operational delay of SET/S2 (30…40 sec) prevents false alarms from
occurring when garbage or other obstacles, which weaken the
measurement signal momentarily, pass across the sensors heads.
Note! When testing SET/S2 sensor operation in a separate vessel, the
water put into the vessel should stand for about 30 minutes before testing.
This prevents false alarms caused by the attachment of air bubbles on the
sensor heads.
After removal of Sludge alarm (the two heads of the sensor are in water),
the Alarm LED indicator will be off and relay 2 will be energized and
buzzer will be off after a delay of 30…40 sec.
Fault alarm
A broken sensor, sensor cable break or short circuit, i.e. too low or too
high sensor signal current.
Mains LED indicator is on.
Sensor circuit Fault LED indicator is on after 5 sec delay.
The relay of the respective channel de-energizes after 5 sec delay.
Buzzer is on after 5 sec delay.
Reset of an alarm
When pressing the Reset push button.
Buzzer will go off.
Relays will not change their status before 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 SET-2000 Oil/Sludge and the function of other equipment,
which is connected to SET-2000 via its relays.
Attention ! Before pressing Test button, make sure that the change of
relay status does not cause hazards elsewhere !
Normal situation
When pressing the Test push button:
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.
Sludge or Oil alarm on
When pressing the Test push button:
Fault LED indicators are immediately on.
The Alarm LED indicator of the alarming channel remains on and the
respective relay remains de-energised.
Alarm LED indicator of the other channel is on and the relay de-
energizes.
Buzzer remains on. If it has been reset earlier, it will return to be on.
When the Test push button is released:
The device returns without delay to the preceding status.
Fault alarm on
When pressing Test push button:
The device does not react with regards to the faulty channel.
The device reacts as described above with regards to the functional
channel.

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 8/15 We reserve the right for changes without notice
3.2 Factory settings
If the operation or SET-2000 Oil/Sludge is not as described in the
previous chapter, check that the device settings are as in figure 4.
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 Exi devices.
We recommend, that when altering the settings the mains voltage is off
or the device is initialized before the installation is executed.
Figure 4. Factory settings of SET-2000 Oil/Sludge
The settings are made with switches (MODE and DELAY) and
potentiometers (SENSITIVITY) located in the upper printed circuit board
(figure 4) and with the jumpers located in the lower board. Switches in
figure 4 are as set in the factory.
OPERATIONAL DELAY SETTING (DELAY)
Switches S2 and S4 are used to set the operational delay of the device.
When the switch is in low position relays de-energize and buzzer is on after
5 seconds after the sensor current 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
LEDs follow the sensor current value and trigger level without delay. Fault
alarm takes place after a fixed delay of 5 sec.

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 9/15 We reserve the right for changes without notice
4 TROUBLE-SHOOTING
Problem:
MAINS LED indicator is off
Possible reason:
Supply voltage is too low or the fuse is blown. Transformer or MAINS LED
indicator 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 110 VAC ± 10 %.
Problem:
No alarm when SET/DM3AL sensor in oil or air, or the alarm will not go off
Possible reason:
The SENSITIVITY setting is wrong in the control unit (see figure 4), or sensor dirty.
To do:
1. Clean-up the sensor and lift it up in the air or immerse it into oil.
2. Turn the SENSITIVITY potentiometer slowly anticlockwise until the sensor gives
an alarm.
3. Immerse the sensor 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 sensor up in the air or oil. The sensor should give an alarm again.
Problem:
No alarm when SET/S2 sensor in sludge or air, or the alarm will not go off
Possible reason:
The SENSITIVITY setting is wrong in the control unit (see figure 4).
To do:
1. Lift the sensor up in the air or immerse it into sludge and wait 10 seconds.
2. Turn the SENSITIVITY potentiometer slowly anticlockwise until the sensor gives
an alarm.
3. Immerse the sensor 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 sensor up in the air or sink into sludge. The sensor should give an alarm
again.
Problem:
FAULT LED indicator is on
Possible reason:
Current in sensor circuit too low (cable break) or too high (cable in short circuit).
The sensor might also be broken.
To do:
1. Make sure, that the sensor cable has been connected correctly to the SET-2000
control unit. See sensor specific instructions.
2. Measure the voltage separately between the poles 10 and 11 as well as 13 and
14. The voltages should be between 10,3….11,8 V.
3. If the voltages are correct, measure the sensor current one channel at a time.
Do as follows:
3.1 Disconnect sensor’s [+] wire from sensor connector (poles 11 and 13).
3.2 Measure short circuit current between [+] and [-] poles.
3.3 Connect mA-meter as in figure 5.
Make a comparison to the values in Table 1.
3.4. Connect the wire/wires back to respective connector(s).
If the problems can not be solved with the above instructions, please contact
Labkotec Oy’s local distributor or Labkotec Oy’s service.
Attention ! If the sensor is located in an explosive atmosphere, the multimeter must
be Exi-approved !

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 10/15 We reserve the right for changes without notice
SET/DM3AL, Channel 1
Poles 10 [+] and 11 [-]
SET/S2, Channel 2
Poles 13 [+] and 14 [-]
Shortcircuit
20 mA - 24 mA
20 mA - 24 mA
Sensor in the air
9 - 11 mA
13 - 14 mA
Sensor in the oil
9 - 11 mA
---
Sensor in the sludge or sand
---
12 - 14 mA
Sensor in the water
3 - 4 mA
5 - 7 mA
Factory setting for alarm point
approx. 6.5 mA
approx. 11 mA
Figure 5. Sensor current measurement Table 1. Sensor currents
5 REPAIR AND SERVICE
The sensors should be cleaned and the operation of the alarm device
should 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
sensors up in the air and put them 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 IEC/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 Exi devices and is authorized by the
manufacturer.
In case of queries, please contact Labkotec Oy’s service.
6 SAFETY INSTRUCTIONS
SET-2000 Oil/Sludge must not be installed in potentially explosive
atmosphere. Sensors connected to it may be installed in zone 0, 1 or 2
potentially explosive atmosphere.
In case of installations in explosive atmospheres the national
requirements and relevant standards as IEC/EN 60079-25 and/or
IEC/EN 60079-14 must be taken into account.
Warning! If the cabling is voltage-tested, the sensor must be
disconnected.
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,
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 IEC/EN 60079-17 and IEC/EN 60079-19 about
instructions of Ex-devices must be obeyed.

SET-2000 Oil / Sludge (110 VAC) D15645AE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 11/15 We reserve the right for changes without notice
7TECHNICAL DATA
SET-2000 Oil/Sludge
Dimensions
175 mm x 125 mm x 75 mm (L x H x D)
Enclosure
IP 65, material polycarbonate
Operation temperature
-25 ºC…+50 ºC
Supply voltage
110 VAC ± 10 %, 50/60 Hz
Fuse 5 x 20 mm 125 mAT (IEC/EN
60127-2/3)
The device is not equipped with a mains
switch
Power consumption
4 VA
Sensors
Labkotec SET/S2 and SET/DM3AL
Max. resistance of the
current loop between the
control unit and a sensor
75 Ω.
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
IEC/EN 61010-1, Class II , CAT II /
III
Insulation level
Sensor / Mains supply
voltage
375V (IEC/EN 60079-11)
EMC Emission
Immunity
IEC/EN 61000-6-3
IEC/EN 61000-6-2
Ex-classification
Special conditions (X)
ATEX
IECEx
II (1) G [Ex ia] IIC
(Ta = -25 C…+50 C)
VTT 04 ATEX 031X
IECEx VTT 10.0003X
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 Ω
Manufacturing year:
Please see the serial number
on the type plate
xxx x xxxxx xx YY x
where YY = manufacturing year
(e.g. 19 = 2019)
Due to non-linear characteristics of the sensor 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
3,84μF
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/Ω (IIC) and 466 µH/Ω (IIB)
Table 2. SET-2000 Oil/Sludge electrical parameters
SET/DM3AL sensor (Oil alarm)
Principle of operation
Measurement of conductivity
IP-classification
IP68
Material
AISI 316, PVC (black), NBR, PA
Temperature
Operation: 0 ºC…+60 ºC
Safety: -30 ºC…+60 ºC
Supply voltage
Approx. 12 VDC from SET control unit
Cable
Fixed, oil resistant, shielded cable 2 x
0,75 mm2, standard length 5 m.
EMC: Emission
Immunity
IEC/EN 61000-6-3
IEC/EN 61000-6-2
Ex-classification
Special conditions (X)
ATEX
IECEx
II 1 G Ex ia IIA T5 Ga
(Ta -30 ºC…+60 ºC)
- The risk of electrostatic charge must be
observed !
EESF 19 ATEX 004X
IECEx EESF 19.0004X
Electrical parameters
Ui= 16 V Ii= 80 mA Pi = 400 mW
Ci= 3500 pF Li= 85 μH
Manufacturing year:
Please see the serial
number on the type plate
x xxx x xxxxx xx YY x
where YY = manufacturing year
(e.g. 19 = 2019)
SET/S2 sensor (Sludge alarm)
Principle of operation
Ultrasonic
IP-classification
IP68
Material
PP, AISI304, AISI 316, PVC and NBR
Temperature
Operation: 0 ºC…+60 ºC
Safety: -25 ºC…+60 ºC
Supply voltage
Approx. 12 VDC from SET control unit
Cable
Fixed, oil resistant shielded cable 3 x 0,5
mm2, standard length 5 m.
EMC: Emission
Immunity
IEC/EN 61000-6-3
IEC/EN 61000-6-2
Ex-classification
Special conditions (X)
ATEX
IECEx
II 1 G Ex ia IIB T5 Ga
(Ta -25 ºC…+60 ºC)
- The risk of electrostatic charge must be
observed !
VTT 07 ATEX 051X
IECEx 10.0002X
Electrical parameters
Ui= 16 V Ii= 80 mA Pi = 320 mW
Ci= 3000 pF Li= 80 μH
Manufacturing year:
Please see the serial
number on the type plate
xxx x xxxxx xx YY x
where YY = manufacturing year
(e.g. 19 = 2019)
Figure 6.
Dimensional
drawings of
SET/DM3AL and
SET/S2 sensors

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY