Optolevel GATEWAY v10 Instruction Manual

GATEWAY v10
LEVEL SURVEILLANCE SYSTEM
INSTALLATION INSTRUCTIONS
Manufacturer:
Optolevel Oy
Puomikatu 3
37150 Nokia, Finland

Optolevel®GW10 system rev2.0 en Page 2 of 25
DECLARATION OF CONFORMITY
We hereby confirm that the electrical apparatus manufactured by us, meets the demands of following directives, in the
way that has been defined in this document, EMC-directive 2004/108/EC and ATEX-directive 94/9/EC.
MANUFACTURER Optolevel Oy
CONTACT INFORMATION Puomikatu 3, 37150 Nokia, Finland,
Tel. [phone], [email protected]
DESCRIPTION OF THE DEVICE Surveillance- and control-unit for tank truck loading systems.
PRODUCT NAME, MODEL Optolevel® GateWay v10
SERIAL NUMBER Serial number indicates manufacturing order. It can be found inside the
device written on the heatsink. Each product has its manufacturing date
and patch number stored in our database.
STRUCTURE OF THE APPARATUS OBSERVES FOLLOWING UNIFORMED SAFETY STANDARDS:
EN 60079-10 Electrical Apparatus for Explosive Gas Atmospheres Part 10: Classification of
Hazardous Areas. Environment class: II, Device class: 2.
EN/IEC 60079-0:2004 Electrical apparatus for potentially explosive atmospheres. General
requirements.
EN/IEC 60079-7:2004 Electrical apparatus for potentially explosive atmospheres. Increased safety “e”
EN/IEC 60079-11:2004 Electrical apparatus for potentially explosive atmospheres. Intrinsic safety "i".
EN/IEC 60079-18:2004 Electrical apparatus for potentially explosive atmospheres.
Encapsulation 'm'.
EN 13922:1995 Tanks for transport of dangerous goods. Service equipment for tanks. Overfill
prevention systems for liquid fuels.
EMC
EMISSION:
EN/IEC 61000-6-3:1996 General emission standard. Part 1: Residential, commercial and light
industrial environments. Class B.
EN/IEC 61000-6-4:1997 General emission standard. Part 2: Industrial environments. Class B.
IMMUNITY:
EN/IEC 61000-6-1:1997 General emission standard. Part 1: Residential, commercial and light
industrial environments. Class A.
EN/IEC 61000-6-2:1999 General emission standard. Part 2: Industrial environments. Class A.
ISO 7637-1&-2:2004 Road vehicles -- Electrical disturbances from conduction and coupling.
Quality of our products is guaranteed by our production line, which has certification of the following standards ISO
9001:2000, EN 13980 and ATEX 94/9/EC by DNV Certification OY/AB. Device has been CE-marked on year 2008.
II 2(1)G At Hämeenkyrö 18th April 2008.
Ex emb [ia] IIB T3 Gb
VTT 08 ATEX 035X Optolevel Oy.

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Table of Contents
Table of Contents........................................................................................................................3
Table of figures and drawings......................................................................................................4
1. Product description..................................................................................................................5
1.1. Operational description of GateWay v10 Level Surveillance System.................................6
1.2. The Optic sensors.............................................................................................................6
1.3. Overfill protection..............................................................................................................6
1.4. Product mixing prevention.................................................................................................7
2. Mounting of the GateWay v10 .................................................................................................8
2.1. General information...........................................................................................................8
2.2. Mounting information.........................................................................................................8
2.3. Mounting instructions........................................................................................................9
2.4. Use, maintenance.............................................................................................................9
3. Sensor mounting...................................................................................................................10
3.1. Mounting information.......................................................................................................10
3.2. Mounting instructions for top sensor................................................................................10
3.3. Mounting instruction for bottom sensor ...........................................................................11
4. Electrical installation of the GateWay v10 Level Surveillance System ...................................12
4.1. General information and the inlets...................................................................................12
4.2. Wiring instructions − Power.............................................................................................13
4.3. Wiring instructions − Sensors..........................................................................................14
4.4. Wiring instructions − Optic loading rack output................................................................16
4.5. Wiring instructions − Thermal loading rack output...........................................................17
4.6. Wiring instructions − Magnetic valves .............................................................................18
4.7. Wiring instructions − I-Current.........................................................................................19
4.8. Wiring instructions − Interlock, Loading, Acknowledge....................................................20
4.9. Wiring instructions − CAN-bus ........................................................................................21
4.10. Wiring instructions - Unloading OFP .............................................................................22
4.11. Serial port –instructions................................................................................................23
5. Additions Notes.....................................................................................................................24
5.1 Warranty..........................................................................................................................24
6. Troubleshooting and maintenance.........................................................................................25
6.1 Maintenance test..............................................................................................................25
6.2 Troubleshooting...............................................................................................................25

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Table of figures and drawings
Figure 1. Optolevel® optic sensors Ex-marking.........................................................................6
Figure 2. Optolevel® Level Surveillance System on tank truck.................................................8
Figure 3. Assembly instructions for cable connection *..........................................................10
Figure 4. Ex-safe Inlet example * ...............................................................................................13
Figure 5. Electrical wiring of the Power *..................................................................................14
Figure 6. Electrical wiring of the sensors *...............................................................................15
Figure 7. Electrical wiring of the Optic socket * .......................................................................16
Figure 8. Electrical wiring of the Thermistor socket *..............................................................17
Figure 9. Electrical wiring of the Magnetic valve *....................................................................18
Figure 11. Electrical wiring of the i-Current *............................................................................20
Figure 12. Installation of interlock, acknowledge and loading. *.............................................21

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1. Product description
This manual describes the operation, installation and troubleshooting of the GateWay v10 Level
surveillance system. Its intended use is to help operators and maintenance men to understand the
operation and potential of this system.
Optolevel® GateWay is a tank truck and trailer mounted onboard Level Monitoring System with
sensors mounted in the top and on the bottom of each tank compartment. GateWay v10 can be
connected to the loading rack control. It monitors the digital data flow from the sensor and detects
and informs the status of each sensor. GateWay v10 can be configured to act with desirable way
on different scenarios. This document only goes through the most basic functions where GateWay
v10 is used for. GateWay v10 can be connected to all used sockets for loading and unloading
procedures. It will help make these processes safer, faster and more reliable.
GateWay v10 can be used to create these features:
- Overfill monitor and prevention
- Product mixing monitor and prevention
- Unloading overfill prevention up to three compartments.
And
- For advanced users, GateWay v10 is a tool which can be molded to fit several other
customer specified applications.
GateWay v10 has connections for 24 two-wire sensor sockets, which is enough for truck with 8
tank compartments. Each tank can be equipped with 3 sensors. (Note that GateWay v10 can also
be made to work with switches)
GateWay v10 controller is able to drive 8 magnetic valves, which can be configured to act the way
that is needed on the application.
GateWay v10 controller is designed to be used with Optolevel® optical sensor and is not
guaranteed to be compatible with sensors from other manufacturers.

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1.1. Operational description of GateWay v10 Level Surveillance System
GateWay uses self checking functions and will indicate faulty sensors with a blinking of a red LED
light. This is accomplished with constant digital data exchange between GateWay v10 and
Optolevel®optic sensors. If the information flow is interrupted or disturbed, it will be indicated with
LEDs, which are located at the front panel of the GateWay v10-unit.
1.2. The Optic sensors
The GateWay v.10.2 is designed to operate with two wire optic sensors. Every sensor needs two
wires to be connected to GateWay v10-unit. The GND (ground) wire can be shared to save on the
total number of the wires.
GateWay v10 communicates several hundred times in a second with each sensor, this guarantees
a fast response time for overflow prevention and gives you more safety for the loading and
unloading processes.
Both top and bottom sensors operate with the same principle, and they are approved for use in
Zone 0 hazardous locations. Refer to www.optolevel.fi for more approval details. The optic sensor
has a label as shown in Figure 1.
OPTOLEVEL®
Finland
Model: Ui = 14V
Optolevel 2480/2 Ii = 420 mA
Ci = 2nF
0575 II 1/2 G Li = 0,01 mH
EEx ia IIC T6
VTT 04 ATEX 051X Max. pressure 25 bar.
Serial No. is on top of the prism Year of production: 200_
Figure 1. Optolevel®optic sensors Ex-marking
1.2.1. GateWay v10 Sensor indications
GateWay v.10 controller provides connections for 8 overfill (top) sensors, 8 retain (bottom) sensors
and 8 P2 (level 2) sensors for extra safety. The state of each these sensors is indicated with
individual red diagnostic LED. The sensor indicates a broken or shorted connection with blinking
LED, a wet sensor with solid light and a dry sensor is indicated without a light. This way separate
field testers are not required when searching for faulty sensors or connections.
1.3. Overfill protection
OFP (Over Fill Prevention) is a common feature in level monitoring systems and is a very useful
safety feature.
Common overfill prevention operation: If any moment the top sensor becomes wet during the
loading process, the thermistor and the optic loading rack outputs become immediately non-
permissive and the controller will also indicate this by lighting up the corresponding compartments
LED.

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With the GateWay v10, the user can add extra safety by using additional sensors. The sensors are
located slightly lower than the overfill prevention (top) sensors. With GateWay v10 unique
configurable* action, the user is able to assign different properties for different situations. For
example, the user in here can assign its extra sensor for magnetic valve outputs on the GateWay
v10 -unit, and use them to drive bottom valves on tank compartments. This ensures that if the first
safety system fails, there is a backup system to prevent the expensive and time-consuming
accidents from happening. This is a level of safety that one can only achieve with the GateWay
v.10 -Level surveillance system.
(* Help with configuration, refer to configuration instructions manual.)
1.4. Product mixing prevention
PMP (Product Mixing Prevention) is a useful feature, which can save a lot of time when used right.
When starting the loading process, the GateWay v10 will inspect if opening the bottom valves have
caused the bottom sensor to get wet. If the bottom valve is opened and the sensor gets wet, the
corresponding compartment LED is lit, both the thermistor and the optic loading rack outputs will
go on non-permissive state until the tank have been checked, and the wet sensor acknowledged.
This feature is beneficial when multiple loads are loaded at the same tank. Extra attention has to
be given to prevent different products from mixing.*
(* remember that one can also use switches instead of sensors to create similar features more
suitable for your application.)

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2. Mounting of the GateWay v10
Figure 2. Optolevel®Level Monitoring System on tank truck.
2.1. General information
GateWay v10 is manufactured in reinforced ATEX-certified Fibox cover, which can be installed in
potentially explosive atmospheres at Zone 1 (For detailed information of the certification and
allowed surroundings, refer to www.optolevel.fi ). Although the GateWay v10 is an ATEX certified
product, it is still recommended that the user will locate it so that it is protected from impacts. Only
competent persons are allowed to carry out installation and maintenance of the device. All official
health and safety instructions and regulations must be followed carefully to avoid the risk of
accidents, and to protect the environment.
2.2. Mounting information
Ensure that the chosen place for the installation of the device is located on the same zone or zone
with lower demands that the device is certified for. When installing the device in potentially
explosive atmospheres all regulations and instructions pertaining to the installation are to be
followed rigidly. When there is a risk that device may be subjected to heavy sunlight, rain,
temperature fluctuations etc., care must to be taken to ensure that the device is adequately
protected.

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2.3. Mounting instructions
There are no pre-drilled mounting holes on the bottom of the GateWay v10-unit; however, the
GateWay v10-unit must be installed trough screw places on the bottom of the unit. The GateWay
v10-unit should be bolted on the metal base.
IMPORTANT! Installation in accordance to certificate supposes that GateWay v10 is installed in a
place where it is not susceptible to impacts.
2.4. Use and maintenance
During the lifetime of the installation, the condition of the unit needs to be maintained. The
operational test described in Chapter 6.1 should be done twice a year to ensure flawless operation
of this safety equipment. Cleaning of the enclosure must only be carried out with a wet cloth. To
ensure the integrity of the enclosure material only neutral washing agents must be used.
WARNING! GateWay MUST be disconnected if any welding is done on tank/truck. If this is not
done you may render your unit useless.

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3. Sensor mounting
The sensors are a vital part of the Level Monitoring System and they should be installed in the
locations presented in the Figure 2.
3.1. Mounting information
The Optolevel®sensor is designed to be mounted with a pearl pipe set such as VSH-24-SUPER-
EN1254 which is manufactured by Onninen. You can also use Wennstroms sensor cover 15-3387
and 15-3390 or can be used some other third party mounting equipment.
The sensor has been certified to be used with other compatible mounting equipment if they are Ex-
certified for this type of use. The choice of the mounting equipment is not limited to a certain
manufacturer.
For detailed information of the physical sensor mounting, refer to the mounting equipments manual
or documentation.
Figure 3. Assembly instructions for cable connection *
(*Picture is a shrunken version of annex 10 which can be located from the end of this document.)
3.2. Mounting instructions for top sensor
The sensor should be mounted the way that is presented in Figure 2. The sensor with the
extension pipe (top sensor) should be lowered from the top of the tank compartment to its right