Labkotec SET-1000 User manual

Labkotec Oy
Myllyhaantie 6
FI-33960 PIRKKALA
FINLAND
Tel.: [phone]
Fax: [phone].2019
Internet: www.labkotec.fi D15233FE-2
1/14
Copyright © 2019 Labkotec Oy We reserve the right for changes without notice
SET-1000
Level switch for one sensor
Installation and Operating Instructions

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 2/14 We reserve the right for changes without notice
TABLE OF CONTENTS
1GENERAL............................................................................................................ 3
2INSTALLATION ................................................................................................... 4
2.1 Cabling when using cable junction box........................................................ 5
2.2 Cabling when using cable joint .................................................................... 6
3OPERATION AND SETTINGS............................................................................ 7
3.1 Operation ..................................................................................................... 7
3.2 Altering settings............................................................................................ 8
4TROUBLE-SHOOTING ..................................................................................... 10
5REPAIR AND SERVICE.................................................................................... 11
6SAFETY INSTRUCTIONS................................................................................. 11
APPENDICES......................................................................................................... 12
Appendix 1 Technical data ................................................................................ 12
Appendix 2 Electrical parameters...................................................................... 13
SYMBOLS
Warning / Attention
Pay special attention to installations at explosive atmospheres
Device is protected by double or reinforced insulation

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 3/14 We reserve the right for changes without notice
1 GENERAL
SET-1000 is a one-channel level switch. Typical applications are high
level and low level alarms in liquid tanks, condensed water alarms, level
control and alarms in oil, sand and grease separators.
The LED indicators, push buttons and interfaces of the device are
described in figure 1.
Figure 1. SET-1000 level switch –features
SET-1000 can be used as a controller of a level sensor located in
potentially explosive atmosphere (zone 0,1 or 2) due to intrinsically safe
inputs of the device. The SET-1000 itself must be installed in a non-
hazardous area.
Figure 2. Typical application. High level alarm in a liquid vessel.

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 4/14 We reserve the right for changes without notice
2 INSTALLATION
The SET-1000 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. SET-1000 installation and connections of SET/OS2
sensor.

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 5/14 We reserve the right for changes without notice
2.1 Cabling when using cable 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-1000 control unit and the junction box should be done
with a shielded twisted pair instrument cable.
LJB2 junction box enables cable extension in potentially explosive
atmospheres.
In examples in figure 4 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 protected, the minimum cross
section is 4 mm².
Please make sure, that the cable between SET-1000 and the sensor
does not exceed maximum connection values –see appendix 2.
Detailed cabling instructions can be found in the instructions of particular
Labkotec SET sensors.
Figure 4. Level sensor cabling with a junction box for cable
extension.
Junction box of type LJB2 include 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 box is closed properly.

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 6/14 We reserve the right for changes without notice
2.2 Cabling when using cable joint
Figure 5. Cable joint
Connections of the sensor cable inside the cable joint are explained in
figure 8. Cable shields and possible excess wires need to be connected
to the same point in galvanic contact.
Please make sure, that the sensor and cable between SET-1000 control
unit and the sensor do not exceed the maximum allowed electrical
parameters –see appendix 1 Technical data.
IP rating of the cable joint is IP68. Make sure, that the cable joint is closed
properly.
If the sensor 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 SET-1000 control unit and the junction box should be done
with a shielded twisted pair instrument cable.
Figure 6.
Cable installation example
Figure 7.
Installation accessories
Figure 8.
Level sensor cabling with a
cable joint for cable extension.

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 7/14 We reserve the right for changes without notice
3 OPERATION AND SETTINGS
The SET-1000 control unit is initialized at the factory as follows. See a
more detailed description in chapter 3.1 Operation.
Channel 1
Alarm takes place when the level hits the sensor (high level alarm)
Relay 1
Relay de-energizes in alarm and fault situations (so-called fail-safe
operation).
Relay 1 is resettable with the Reset button.
Relay 2
Relay de-energizes in alarm and fault situations (so-called fail-safe
operation).
Operational delay for both relays is set to 5 seconds. The trigger level is
normally at the middle of the sensor’s sensing element.
3.1 Operation
The operation of a factory-initialized SET-1000 is described in this
chapter.
If the operation is not as described here, check the settings (chapter 3.2.)
and the operation (chapter 4) or contact a representative of the
manufacturer.
Normal mode –no alarms
The level in the tank is below the sensor.
Mains LED indicator is on.
Other LED indicators are off.
Relays 1 and 2 are energized.
High level alarm
The level has hit the sensor (sensor in the medium).
Mains LED indicator is on.
Alarm LED indicator is on.
Buzzer on after 5 sec delay.
Relays de-energize after 5 sec delay.
Fault alarm
Sensor cable break, short circuit or a broken sensor, i.e. too low or too
high sensor signal current.
Mains LED indicator is on.
Sensor cable Fault LED indicator is on after 5 sec delay.
The relays de-energize 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.
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 SET-1000 level switch and the function of other
equipment, which is connected to SET-1000 via its relays.
Attention ! Before pressing the Test button, make sure that the change
of relay status does not cause hazards elsewhere !

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 8/14 We reserve the right for changes without notice
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.
Alarm on
When pressing the Test push button:
Fault LED indicator is immediately on.
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 Altering settings
If the default situation described above does not apply to the site being
measured, the following device settings can be changed.
Operating direction
High level or low level function (increasing or decreasing level).
Operation delay
Two alternatives: 5 sec or 30 sec.
Trigger level
Trigger point of an alarm in the sensor’s sensing element.
Sensor selection
Buzzer
SET/DM3AL sensor or other Labkotec SET series sensor.
The buzzer can be disabled.
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 9. Altering settings

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 9/14 We reserve the right for changes without notice
The settings are changed using the upper circuit board’s switches
(MODE and DELAY) and potentiometer (SENSITIVITY) and the lower
circuit board’s jumpers (Sensor selection and Buzzer). The switches are
displayed in their default setting in the circuit board figure (figure 9).
OPERATING DIRECTION (MODE)
Switch S1 is used to set the operating direction. When the
switch is in its low position, Alarm LED indicator as well as
buzzer is on and relays de-energize when the liquid level is
beneath the trigger level of the sensor (low level mode).
This setting is also used, when an alarm of an oil-layer on
water is required.
When the switch is in its high position the Alarm LED indicator
as well as buzzer will be on and relays de-energize when the
liquid level is above the sensor’s trigger level (high level
mode).
OPERATIONAL DELAY SETTING (DELAY)
Switch S2 is used to set the operational delay of the device.
When the switch is in low position relays operate and buzzer
is on after 5 seconds after the level reaches trigger level, 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 sensor current value and trigger level
without delay. Fault LED has a fixed delay of 5 sec.
TRIGGER LEVEL SETTING (SENSITIVITY)
Trigger level setting is executed as follows:
1. Immerse the sensor’s sensing element to the
medium to the desired height –see sensor
instructions, if needed.
2. Rotate the potentiometer so, that the Alarm LED is
on and the relay de-energizes –please pay attention
to the operational delay.
3. Check the function by lifting the sensor to the air and
immersing it back to the medium.
SENSOR SELECTION
If the sensor in use is a conductive SET/DM3AL sensor, then
the jumper beside the channel 1 connector must be short-
circuited.

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 10/14 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 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:
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-1000 control unit. See sensor 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 voltages are correct, measure the sensor current. Do as follows:
3.1 Disconnect sensor’s [+] wire from sensor connector (pole 10).
3.2 Measure short circuit current between [+] and [-] poles.
3.3 Connect mA-meter as in figure 10.
Make a comparison to the values in Table 1. More detailed current
values are to be found in the instructions of specific sensor’s
instructions. E.g. SET/DM3AL sensor’s current is 3 - 4 mA when
the sensor is fully immersed in water and it is 9 - 11 mA when
sensor is in the air.
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 sensor is located in an explosive atmosphere, the
multimeter must be Exi-approved !
Channel 1
Poles 10 [+] and 11 [-]
Short circuit
20 mA –24 mA
Sensor in the air
< 7 mA
Sensor in the liquid
(r 2)
> 8 mA
Sensor in the water
> 10 mA
Figure 10. Sensor current measurement Table 1. Sensor currents

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 11/14 We reserve the right for changes without notice
5 REPAIR AND SERVICE
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 Ex-i devices and is authorized by the
manufacturer.
In case of queries, please contact Labkotec Oy’s service.
6 SAFETY INSTRUCTIONS
SET-1000 level switch must not be installed in explosive atmosphere.
Sensors connected to it may be installed in explosive atmosphere zone
0,1 or 2.
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.
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 IEC/EN 60079-17 and IEC/EN 60079-19 about
instructions of Ex-devices must be obeyed.

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 12/14 We reserve the right for changes without notice
APPENDICES
Appendix 1 Technical data
SET-1000
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 (IEC/EN 60127-2/3)
The device is not equipped with a mains switch
Power consumption
2 VA
Sensors
One Labkotec SET sensor
Max. resistance of the current loop
between the control unit and a
sensor
75 Ω. See more in appendix 2.
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.
IIC
IIB
Attention ! See appendix 2.
Uo = 14,7 V Io = 55 mA Po = 297 mW R = 404 Ω
Co = 608 nF Lo= 10 mH Lo/Ro= 116,5 µH/Ω
Co = 3,84 µF Lo= 30 mH Lo/Ro= 466 µH/Ω
Year of manufacture
See serial number from the type
plate
xxx x xxxxx xx YY x
where YY = year of manufacture
(e.g. 19 = 2019)

SET-1000 D15233FE-2
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 13/14 We reserve the right for changes without notice
Appendix 2 Electrical parameters
When installing the device, make sure that the electrical values of the cable
between SET-1000 and sensor never exceed maximum electrical parameters.
The cabling between SET-1000 control unit and cable extension junction box /
cable joint must be executed as in figure 4 / 8 Extension cable should be shielded
paired twisted instrument cable.
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 followed.
Uo= 14,7 V Io= 55 mA Po= 297 mW R= 404 Ω
The characteristics of the output voltage is trapezoidal.
Max. permissible value
Both 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 H/(IIC) and 466 H/(IIB)
Table 2.Electrical parameters
Maximum length of the sensor cable is determined by the resistance (max. 75 Ω)
and other electrical parameters (Co, Lo and Lo/Ro) of the sensor circuit.
Example:
Determing the maximum cable length
Instrument cable with following characteristics is used:
-DC resistance of a twin wire at + 20°C is approx. 81 Ω/ km.
- Inductance is approx. 3 μH / m.
- Capacitance is approx. 70 nF/km
Influence of resistance
Estimate for additional resistances in the circuit is 10 Ω. The max length of the
cable is then (75 Ω- 10 Ω) / (81 Ω / km) = 800 m.
The influence of inductance and capacitance of a 800 m cable is:
Influence of inductance
Total inductance is 0,8 km x 3 μH/m = 2,4 mH. The sum value of the cable and
e.g. SET/OS2 sensor [Li = 30 μH] is 2,43 mH. L/R ratio is thus 2,4 mH / (75 –10)
Ω= 37 μH/Ω, which is less than the maximum allowed value 116,5 μH/Ω.
Influence of capacitance
Cable capacitance is 0,8 km x 70 nF/km = 56 nF. Combined value of the cable
and the e.g. SET/OS2 sensor [Ci = 3 nF] is 59 nF.
When compared to the values in table 2, we can summarize that above values do
not limit the use of this particular 800 m cable in explosion groups IIB or IIC.
Feasibility of other cable types and sensors for different distances can be
calculated accordingly.