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 13.8.2019
Internet: www.labkotec.fi D15349AE-1
1/15
Copyright © 2019 Labkotec Oy We reserve the right for changes without notice
SET-2000
110 VAC supply voltage
Level switch for two sensors
Installation and Operating Instructions

SET-2000 (110 VAC) D15349AE-1
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 Cabling when using cable junction box........................................................ 5
2.1.1 Level sensors in the same area and zone....................................... 5
2.1.2 Level sensors in different areas and zones ..................................... 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 Cabling and electrical parameters.................................................. 13
SYMBOLS
Warning / Attention
Pay attention to installations at potentially explosive atmospheres
Device is protected by double or reinforced insulation

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 3/15 We reserve the right for changes without notice
1 GENERAL
SET-2000 is a two-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-2000 level switch –features
SET-2000 can be used as a controller of level sensors located in
potentially explosive atmospheres (zone 0,1 or 2) due to intrinsically
safe inputs of the device. The SET-2000 itself must be installed in a
non-hazardous area.
The level sensors, which are connected to SET-2000, can be installed
in zones of different classification, because the channels are
galvanically isolated from each other.
Figure 2. Typical application. High level and low level alarm
in a liquid vessel.

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 4/15 We reserve the right for changes without notice
2 INSTALLATION
The SET-2000 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-2000 installation and connections of SET/OS2
and SET/TSH2 sensors.

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 5/15 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-2000 control unit and the junction box should be
done with a shielded twisted pair instrument cable.
LJB2 and LJB3 junction boxes enable cable extension in explosive
atmospheres.
In examples in figures 4 and 5 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 ground 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 cables do not exceed the
maximum allowed electrical parameters –see appendix 2.
Detailed cabling instructions can be found in the instructions of
particular Labkotec SET sensors.
2.1.1 Level sensors in the same area and zone
In the example in figure 4 the level sensors are located in the same
area and in the same explosion-hazardous zone. Cabling can be
made with one two-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.
Figure 4. Level sensor cabling with a junction box when the
level sensors are in same area and same zone.

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 6/15 We reserve the right for changes without notice
2.1.2 Level sensors in different areas and zones
Level sensors in figure 5 are located in separate areas and zones.
Connections must then be made with separate cables. Also the
equipotential grounds can be separate.
Figure 5. Cabling with a cable junction box when sensors
are located in separate areas and zones.
Junction boxes of types LJB2 and LJB3 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 is closed properly.

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 7/15 We reserve the right for changes without notice
3 OPERATION AND SETTINGS
The SET-2000 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)
Channel 2
Alarm takes place when the level leaves the sensor (low level alarm)
Relays 1 ja 2
Relays de-energize in respective channels’ alarm and fault situations (so-
called fail-safe operation).
Operational delay 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-2000 is described in this
chapter.
If the operation is not as described here, check the settings and
operation (chapter 3.2) or contact a representative of the
manufacturer.
Normal mode –no alarms
The level in the tank is between the two sensors.
Mains LED indicator is on.
Other LED indicators are off.
Relays 1 and 2 are energized.
High level alarm
The level has hit the high level sensor (sensor in the medium).
Mains LED indicator is on.
Sensor 1 Alarm LED indicator is on.
Buzzer on after 5 sec delay.
Relay 1 de-energizes after 5 sec delay.
Relay 2 remains energized.
Low level alarm
The level is below low level sensor (sensor in the air).
Mains LED indicator is on.
Sensor 2 Alarm LED indicator is on.
Buzzer on after 5 sec delay.
Relay 1 remains energized.
Relay 2 de-energizes after 5 sec delay.
After removal of an alarm, the respective alarm LED indicators and
buzzer will be off and respective relay will be energized after 5 sec delay.
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 cable Fault LED indicator is on after 5 sec delay.
The relay of 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 level switch and the function of other
equipment, which is connected to SET-2000 via its relays.

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 8/15 We reserve the right for changes without notice
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.
High level or low level 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.
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).
Operational 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 6. Altering settings

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 9/15 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
6).
OPERATING DIRECTION SETTING (MODE)
Switches S1 and S3 are used to set the operating direction.
When the switch is in its low position Alarm LED indicator as
well as buzzer are on and the relay de-energizes 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 by using a capacitive Labkotec SET sensor.
When the switch is in its high position the Alarm LED
indicator as well as buzzer will be on and the relay de-
energizes when the liquid level is above the sensor’s trigger
level (high level mode).
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 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 LEDs follow the sensor current value and trigger level
without delay. Fault LED has a fixed 5 sec delay.
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 type sensor,
then the jumper beside the respective connector must be
short-circuited.

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 10/15 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:
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 7.
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/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 !
Channel 1
Poles
10 [+] and 11 [-]
Channel 2
Poles
13 [+] and 14 [-]
Short circuit
20 mA –24 mA
20 mA –24 mA
Sensor in the air
<7mA
< 7 mA
Sensor in the liquid
(r 2)
>8mA
> 8 mA
Sensor in the water
> 10 mA
> 10 mA
Figure 7. Sensor current measurement Table 1. Sensor currents

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 11/15 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-2000 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 ground 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 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 12/15 We reserve the right for changes without notice
APPENDICES
Appendix 1 Technical data
SET-2000
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
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
2 pcs. of Labkteco SET series sensors
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
Channel 1 / Channel 2
375V (IEC/EN 60079-11)
EMC
Emission
Immunity
IEC/EN 61000-6-3
IEC/EN 61000-6-2
Ex-classification
Special conditions(X)
II (1) G [Ex ia] IIC
VTT 04 ATEX 031X
(Ta = -25 C…+50 C)
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
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)

SET-2000 (110 VAC) D15349AE-1
Installation and Operating Instructions
Copyright © 2019 Labkotec Oy 13/15 We reserve the right for changes without notice
Appendix 2 Cabling and electrical parameters
When installing the device, make sure that the electrical values of the cable
between SET-2000 and sensors never exceed maximum electrical
parameters.
The cabling between SET-2000 control unit and cable extension junction box
must be executed as in figures 5 and 6. 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:
Determining 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 is (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.