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

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height (this is the height where the OFP should react) and tightened to its place. Left over
aluminum pipe should be shortened to a proper length.
IMPORTANT! The connection must be covered and protected from heavy sunlight and rain with a
correctly certified protective cover.
IMPORTANT! While mounting the sensor to its place, should be taken into consideration that the
sensor and the pipe material is aluminum. So there is a possibility of igniting sparks.
3.3. Mounting instruction for bottom sensor
Mounting of the bottom sensor is almost the same process than with the top sensor, only its
location is different. The bottom sensor installation spot is presented in Figure 2.The bottom sensor
must also be placed so that its connection is protected from heavy sunlight and rain. While placing
the sensor into the pipe, the prism should be facing away from the sunlight, because sunlight might
cause false detections.

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4. Electrical installation of the GateWay v10 Level Surveillance System
When making the electrical connections, general requirements for installation and maintenance of
explosion proof electrical equipment shall be considered. (EN/IEC 60079-14 and EN/IEC 60079-17
in European countries within CENELEC).
4.1. General information and the inlets
There are no pre-made inlets on the GateWay v10-unit. EX-“e”(EN/IEC 60079-7) certified inlets
must be used and they need to be installed by ATEX certified manufacturer in ATEX certified
facility. Generally, it is suggested that a minimum amount of inlets should be used. This will ensure
that the integrity of the enclosure will stay intact. Use weather-tight cable strain reliefs or liquid-tight
(IP65 minimum) conduit fittings to keep out the external moisture. The use of weather-tight cable
strain reliefs with the sensor and the socket housings as well is also imperative for moisture
resistant system. It is required the use of high quality stranded and tinned copper wire with a
minimal thickness of 1.0mm² for all electrical connectors to the GateWay v10. Trim approximately
5 mm of the insulation off the end of each wire that will be connected to terminal blocks of the
GateWay v10-unit. The orange terminal blocks on the GateWay v10 are the Ex-“e”safety
connections and the green terminal blocks are EX-“I” (EN/IEC 60079-11) protected connections.
Usage of orange terminal block: Insert trimmed wire into the desired slot and tighten the screw.
Before inserting the wire, make sure that the tightening screw is open.
Exe-e marking of the orange terminal block:
Usage of the green terminal block: Insert the trimmed wire into the desired slot (nothing else is
needed to be done, the connection is self-closing). When detaching connection from the terminal,
push gently with the screwdriver (or with some other suitable tool) at the orange lever on top of the
terminal and gently pull out the wire. Proper color coding will save time when installing and
repairing the system. Remember to make notes of your installation for the maintenance purposes.
IMPORTANT! Due to the vibrations, which occurs on the tank trucks, it is very important ensure
that the connections will hold. If unwanted connections are formed, it is possible for dangerous
situations to emerge.
In Figure 4 there is one suggestion about how to position the inlets to the GateWay v10. Amongst
the installers, it has been considered a positive thing if all inlets have been fitted on the bottom side
of the GateWay v10-unit.
Eex e II II 2 GD 175V 1,5mm
Demko 03 ATEX 134439 U

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Figure 4. Ex-safe Inlet example *
(*For more instructions and bigger drawings, refer to the last pages of this document to Annex 8.)
4.2. Wiring instructions − Power
IMPORTANT! POWER MUST BE OFF WHEN INSTALLING OR REMOVING POWER LEADS TO
THE GATEWAY V10. THE POWER WIRES FOR THE BATTERY MUST BE KEPT SEPARATE
FROM THE SENSOR AND SOCKET WIRING! THEY CANNOT BE RUN TOGETHER IN SAME
CONDUIT! This is important when maintaining safe current levels in the intrinsically safe sensors,
auxiliary switches, and socket wiring.
Do not apply power to the GateWay v10-unit without reading this manual thoroughly and checking
all the connections first. The GateWay v10 is designed to operate on truck systems with the
nominal power of 24VDC (20VDC min. to 32VDC max.) If the power supply is not within this range
contact your retailer before powering up the GateWay v10 system. GateWay v10 has extensive
power supply protections; however, by using some pulse supplies or other same kinds of charges,
it may end up permanently damaging the GateWay v10-unit.
GateWay v10 has a fuse build inside, but it is not replaceable on site. For this reason the power
supply for the GateWay v10 -unit should include fuse of 1 Amps. The fuse should be located at the
truck cabin in the fuse box. Because the power cord of the GateWay v10-unit passes through the
zone 1, the used cable must be approved cable for said zone. For the power cord, there has to be

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an independent housing on the GateWay v10-unit, else it will violate the safety approvals of the
GateWay v10 product.
It is suggested to be turned off the GateWay v10-unit when a) it is not in use, and b) the tank truck
is in motion.
Previous suggestion is presented because the moving liquid in the tank may cause false
detections, especially if “sealed” compartment function is in use. Turning off when not used, can be
accomplished with a power switch which is connected to the protecting door or with some similar
application.
Attach the (fused) wire from the truck battery to the GateWay v10-units input terminals shown in
Figure 5. The connectors are Ex –“e”(EN/IEC 60079-7) class certified.
Figure 5. Electrical wiring of the Power *
(*For more instructions and bigger drawings, refer to the last pages of this document to Annex 1)
4.3. Wiring instructions − Sensors
Make all 2-wire wiring connections as defined in Figure 6. Be sure to double check that your wiring
connections are correct. It has been found a small amount of non-corrosive sealant or electrical
crease in each crimp connection will prevent corrosion and provide very reliable wire connections.

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Sensor sockets are intrinsically safe (EN/IEC 60079-11) connections, which have the following
properties.
Uo = 13.6V
Io = 22mA
Co = 5.2µF
Lo = 0.2H
The color coding of the used wire is presented in Annex 2. This coding is standardized in
EN 13922:2003, Table A.16.
The circuit connected to these terminals should comply with demands for intrinsic safety
(EN 60079-11). The circuit must be separated from other not intrinsic safe circuits.
IMPORTANT! Resistance of each wire for 2-wire optic sensor system cannot exceed value of 0,3Ω
and resistance of each connection cannot exceed value of 0,5Ω. (EN 13922:2003)
Figure 6. Electrical wiring of the sensors *
(*For more instructions and bigger drawings, refer to the last pages of this document, to Annex 2)

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4.4. Wiring instructions − Optic loading rack output
The optic loading rack output should be connected to the optic socket. This socket should be
located near the loading pipes because it is needed when the optic socket is used in the loading
process. Check installation instructions from Figure 6.
This is intrinsically safe (EN/IEC 60079-11) connection, which has galvanic separation. Connection
is compliant with accordance of the standard 13922:2003.
The color coding of the used wire is presented in Annex 3. This coding is standardized in
EN 13922:2003, Table A.16.
The circuit connected to these terminals should comply with the demands for intrinsic safety
(EN 60079-11). The circuit must be separated from other non-intrinsic safe circuits.
IMPORTANT! The resistance of each wire used for the 5-wire system cannot exceed the value of
5Ωand the resistance of each connection cannot exceed the value of 0,5Ω. (EN 13922:2003)
Figure 7. Electrical wiring of the Optic socket *
(*For more instructions and bigger drawings, refer to the last pages of this document, to Annex 3)

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4.5. Wiring instructions − Thermal loading rack output
The thermal loading rack output should be connected to the thermal socket which should be
located near the loading pipes because it is needed on the loading process. The thermal socket
has galvanic separation protection. Check the connection instructions from Figure 7.
This is intrinsically safe (EN/IEC 60079-11) connection, which has galvanic separation protection.
Connection values are in accordance to certificate EN 50020.
The circuit connected to these terminals should comply with demands for intrinsic safety
(EN 60079-11).The circuit must be separated from other non-intrinsic safe circuits.
Vi = 20,5V
Ii = 190mA
Ci = 1,33µF
Li = 0,2H
IMPORTANT! The connection resistance from the thermistor socket and the loading rack must not
exceed the value of 10Ω(SFS 5684). So if 2x1mm² cable is used, then its maximum length is 50m.
Figure 8. Electrical wiring of the Thermistor socket *
(* For more instructions and bigger drawings, refer to the last pages of this document, to annex 4)

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4.6. Wiring instructions − Magnetic valves
There are two different magnetic valve controls, which are associated with different operations.
The unloading magnetic valve controls and loading magnetic valve controls.
These connections are inputs, with EX-“e” (EN/IEC 60079-7) sockets.
As the magnetic valve controls are only inputs, it will need a safe power supply to be able to create
a working circuit. Check Figure 8 or Annex 5 for more information.
Maximum values for this connection:
Un = 24V nominal
Imax =3A
Pmax =7W
Note that the maximum current and voltage combinations are limited by informed maximum power
(7W), which should not be exceeded.
Figure 9. Electrical wiring of the Magnetic valve *
(* For more instructions and bigger drawings, refer to the last pages of this document, to Annex 5)

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4.7. Wiring instructions − I-Current
I-Current can provide 24V voltage or 156mA current. The main use for this connection is to offer
safe operating voltage for Optolevel®iLED or for future Optolevel®released products.
These are intrinsically safe (EN/IEC 60079-11) connections, which have following properties.
Uo = 25V
Io = 178mA
Co = 0,85µF
Lo = 4mH
The circuit connected to these terminals should comply with demands for intrinsic safety
(EN60079-11). The circuit must be separated from other non-intrinsic safe circuits.
Voltage response to this connection is almost linear and is presented in Figure 10.
0
5
10
15
20
25
156
122
100
80
60
40
20
10
5
1
iCurrent
I-Virta
Figure 10. i-Current voltage response

Optolevel®GW10 system rev2.0 en Page 20 of 25
Figure 11. Electrical wiring of the i-Current *
(*For more instructions and bigger drawings, refer to the last pages of this document, to Annex 6)
4.8. Wiring instructions − Interlock, Loading, Acknowledge
Interlock, loading, and acknowledge should be connected as shown in Figure 12. They are
protected from the voltage of the wrong polarity
These are intrinsically safe (EN/IEC 60079-11) connections, which have the following properties.
Uo = 6,5V
Io = 6,5mA
Co = 500µF
Lo = 1H
The circuit connected to these terminals should comply with demands for intrinsic safety
(EN60079-11). The circuit must be separated from other non-intrinsic safe circuits.