PAJ WIO 200B User manual

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3
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WIO 200B
Water in oil sensor
User manual Rev. 1.08
111881-944 Rev. 1.08 WIO200B User manual
Date: 04-02-2016

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3
03-01-0501-CRJ-04 Side 2 af 53
Table of contents
Table of contents .........................................................................................................................................................................................2
Introduction......................................................................................................................................................................................................3
Safety Advice ..................................................................................................................................................................................................4
Function...............................................................................................................................................................................................................6
Normal operation.........................................................................................................................................................................................7
Failure indication..........................................................................................................................................................................................8
Self test for alarm functions...............................................................................................................................................................9
Before installation ....................................................................................................................................................................................11
WIO Sensor dimensions in mm.....................................................................................................................................................14
Terminal box dimensions in mm..................................................................................................................................................16
WIO Integrated (WIOI) dimensions in mm ........................................................................................................................17
Technical data, Sensors ......................................................................................................................................................................19
Technical Data Terminal Box ..........................................................................................................................................................22
Technical Data Terminal Display Box.......................................................................................................................................23
Technical Data Terminal Box Alarm ..........................................................................................................................................26
Technical Data Terminal Box Alarm Buzzer........................................................................................................................29
Technical data, WIOI (WIO Integrated) ................................................................................................................................33
EC-Declaration of Conformity.........................................................................................................................................................39
Appendix A1: Install 1 Terminal Box with 1 display.......................................................................................................................42
Appendix A2: Install 1 Terminal Box with no display ....................................................................................................................43
Appendix A3: Install 2 Terminal Boxes with 2 display ..................................................................................................................44
Appendix A4: Install 2 Terminal Boxes with 1 display ..................................................................................................................45
Appendix A5: Install 2 Terminal Boxes with 1 display ..................................................................................................................46
Appendix A6: Install 3 Terminal Boxes with 3 display ..................................................................................................................47
Appendix A7: Install 3 Terminal Boxes with 2 display ..................................................................................................................48
Appendix A9: CABLE Specification .............................................................................................................................................49
Appendix A10: Error / failure FAQ..............................................................................................................................................50
Company Information...........................................................................................................................................................................53

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Introduction
This user manual provides technical data regarding the WIO (water in
lubrication oil, gear box oil, diesel oil, hydraulic oil or transformer oil) sensor
system. The system consist of a WIO Sensor, terminal box and cables. The
WIO Sensor is an insitu sensor which measures water content in lubrication oils
on ship engine or similar. The Terminal box connects the sensor to power
supply and to the ships surveillance system. The supplied cables are for
connection between the WIO Sensor and the Terminal box

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Safety Advice
For your safety
The WIO200 (WIO) is designed as water in oil monitoring system, with a
relay switch-off function.
Before use please read the user manual and carefully store it in a safe
place. Install and operate the device only after reading and
comprehending the instruction manual, and after you are familiar with the
valid rules on work safety and accident prevention.
Please use the device only as specified. For this purpose please also note
the values in section “Technical data”.
During transport, storage and operation please adhere to the conditions
listed in “Technical data”.
IMPORTANT
Only qualified personnel may assemble start-up and maintain the unit
when it is in a zero voltage state. Only qualified electricians may work on
electrical installations.
The connection and instruction manual contains information that enables
the proper and efficient use of the WIO monitoring system. PAJ Sensors
A/S is not liable for damage caused be improper use of this device. This
manual is an integral part of the basic knowledge necessary for proper use
of the system.
Rights
PAJ Sensors A/S reserves the right to alter its products without prior
notice.
Copying and using the instruction manual for other purposes is only
allowed with the acceptance from PAJ Sensors A/S.
PAJ Sensors A/S accepts no responsibility for possible errors and
deficiencies in brochures, catalogues and other printed material.
PAJ Sensors A/S guarantees correct function as well as fulfillment of the
safety requirements only when connections are made in accordance with
instructions.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Safety observations
The comments about safety in this document will not discuss safety
observations of individual machine parts where safety devices (usually
safety relays) are applied. Here the respective instruction manuals will be
referenced! This document merely describes how to establish a WIO and
how to start it up.
WARNING
The monitoring system during machine operation cannot be guaranteed if
the system is connected incorrectly or not used as specified. This may lead
to fatal injuries. Interventions and changes to the WIO monitoring system
are not permitted, unless they are explicitly described in this user manual
or be written from PAJ Sensors A/S.
The regional legal regulations and conditions of the liability insurance of
the employer must be maintained.
Area of application
The WIO monitoring system is usually used in engines were a WIO will
monitor the water content in lubrication oil, gear box oil, diesel oil,
hydraulic oil or transformer oil.
The advantage of this monitoring system is the simple 4-20 mA interface
and the two relays indicating alarms, with digital readout.
Normally the WIO sensor is calibrated in Taro30 lubrication oil, if nothing
else are defined from customer.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Function
Short description of the function
PAJ Sensors A/S has developed a water in oil (WIO) monitoring system.
The fundamental idea of the WIO system is to easily and continuously
monitor the water activity (aw) in oil. The output is converted into a
standard 4-20 mA output.
The system also includes two relays indicating when too much water is
present in the oil. Default alarm values are set to 0,5 aw(high alarm) and
0,9 aw(high high alarm)
By use of the WIO-Software it is possible to change HHA and HA levels.
Furthermore you can continuously read out and graph the aw(or PPM) of
water in the oil.
WARNING
Do not use the sensor or relays to automatically enable/turn on or
disable/shut down engine. The decision to enable/turn on or disable/shut
down an engine, based on the sensor data, must be taken by proper
trained crew personnel, not by the sensor system.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Normal operation
Water activity (aw) provides the relative availability of water in oil where
pure oil has an activity of zero and oil saturated with distilled water has an
activity of exactly one. Under normal operation the WIO200 continuously
supplies an output analogue signal of 4 to 20 mA corresponding to 0.01 to
1.00 aw. Alarm indications with 0.03 awhysteresis via 2 relays are
provided for each sensor. These data can also be read out from the sensor
on the RS485 Modbus communication line.
Default alarm values are 0,5 awand 0,9 aw. Assumes these alarm values:
High alarm on at 0,50 aw(12 mA).
High alarm off at 0,47 aw(11,5 mA)
High high alarm on at 0,90 aw(18,4 mA).
High high alarm off at 0,87 aw(17,9 mA).
High high alarm will disable high alarm, thus only one alarm can be active.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Failure indication
Internal function failure will be indicated by activating both alarm relays at
the same time, or indicated as defined in the NAMUR NE43.
Internal failures includes:
Sensor reading out of range.
Sensor reading CRC error.
Unstable Sensor reading.
NAMUR NE43 is a German fault detection standard for 4-20mA analogue
signals. It allows the user to know if there is a fault within the instrument,
by sending analogue signal below 4mA and/or above 20mA. In accordance
with NAMUR NE43, the failure is indicated by:
Fault indicated by analogue output =<2,0 mA

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Self test for alarm functions
On the WIO Sensor there is a button for testing the alarm functions. By pushing the
Test button for 5 sec the high alarm relay turns on, and by pushing the Test button
for 10 sec the high alarm relay turns off and the high high alarm turns on. When the
Test button has been pushed continuously for more than 15 sec, it will be ignored by
the software, and the relays return to normal operation.
Test Button
Mode
Output Relay
Analogue
Output
Un-pressed
Normal operation
and no alarm
Relay 1 Open
Relay 2 Open
Normal
Pressed longer
than 5 sec
Test of high alarm
Relay 1 Closed
Relay 2 Open
Normal
Pressed longer
than 10 sec
Test of high high
alarm
Relay 1 Open
Relay 2 Closed
Normal
Pressed longer
than 15 sec
Normal operation
Normal
Normal

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
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Test Button
Mode
Output Relay
Analogue
Output
Un-pressed
Normal operation,
with high alarm
active
Relay 1 Closed
Relay 2 Open
Normal
Pressed longer
than 5 sec
Test of high alarm
Relay 1 Closed
Relay 2 Open
Normal
Pressed longer
than 10 sec
Test of high high
alarm
Relay 1 Open
Relay 2 Closed
Normal
Pressed longer
than 15 sec
Normal operation
Normal
Normal

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Before installation
IMPORTANT
Only qualified personnel may assemble and maintain the unit. Only
qualified personnel may install the unit.
Screw in probe pressure-tight directly in the center of the oil pipe where
the measurement is to take place. The threads should be sealed with
Loctite® 271. The sensor should be mounted with max. torque of 35 Nm.
Connect the cables from the WIO sensor to the Terminal box. Use a
hexagon wrench size 30.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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To sensor Power and Alarms
IMPORTANT
Only qualified personnel may assemble start-up and maintain the terminal
box(s) when it is in a zero voltage state. Only qualified electricians may
work on electrical installations.
Install +24 VDC and GND into the terminal box and connect the 4-20 mA
to an external device if needed. Connect the relay to external device if
needed.
If the terminal box has a (aw) or PPM display, there must be a short circuit
between terminals 11 and 12. This short circuit produces the needed
closed loop for mA measurement.
If the terminal box has a °C or °F display, there must be a short circuit
between terminals 9 and 10. This short circuit produces the needed closed
loop for mA measurement. Only for WIO and WIOI 300/400/500
After installing the WIO-Software can PC and terminal box be connected
through DB9 connector. Only for WIO and WIOI 300/400/500
Last connect the cables from the Terminal box to the sensor.
It is allowed (but not necessary) to connect screw terminal 10 and 12 “-
4-20 mA” to screw terminal 14 “GND”, thus creating common ground for
the output and the power.
Terminal boxes with display. Screw terminal pin 11 and 12 or screw
terminal pin 9 and 10 can be connected to external equipment, but only in
a closed loop for mA measurement.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Terminal Box Connection
Contact Assignment
There is only one connector CN3 for using of the terminal box contacts.
For
con
nection more than one terminal box please refer to:
-Appendix A1
-Appendix A2
-Appendix A3
Contact-
Number
Description
9
+4 –20 mA positive analog output signal for indication of temperature in oil.
This option is not available for WIO200
Only for WIO and WIOI 300/400/500
10
-4 –20 mA return analog signal for indication of temperature in oil.
This option is not available for WIO200
Only for WIO and WIOI 300/400/500
11
+4 –20 mA positive analog output signal for indication of awor PPM in oil.
12
-4 –20 mA return analog signal for indication of awor PPM in oil.
13
Power supply, 24VDC ±10% and with max. residual voltage ripple 10%
14
Power supply ground terminal contact
15
Relay contact for HH Alarm
16
Relay contact for HH Alarm
17
Relay contact for H Alarm
18
Relay contact for H Alarm

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
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WIO Sensor dimensions in mm
WIO Standard ½” thread Sensor, Short dimensions in mm:
30mm Wrench max. torque 35 Nm
WIO Standard ¾” thread Sensor, Short dimensions in mm:
30mm Wrench max. torque 35 Nm

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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WIO Ball Valve pipe ½” thread Sensor, Long dimensions in mm:
30mm Wrench max. torque 35 Nm
WIO Ball Valve pipe ¾” thread Sensor, Long dimensions in mm:
30mm Wrench max. torque 35 Nm

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]
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Terminal box dimensions in mm

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
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WIO Integrated (WIOI) dimensions in mm
WIOI Sensor, short pipe, ½” thread, dimensions in mm:
WIOI Sensor, long pipe, ½” thread, dimensions in mm:

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WIOI Sensor, long pipe, ¾” thread, dimensions in mm:

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
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Technical data, Sensors
WIO Standard ¾” (ISO 228-1 G¾”), Short
WIO Standard ½” (ISO 228-1 G½”), Short
WIO Ball Valve pipe, Long
Output
Analogue output (galvanic isolated)
4 –20 mA for aw
Max. Load (analogue output)
< 500Ω
Measurement Range (4 –20 mA)
0,01 –1,00 aw
Accuracy (0,05-0,95 aw)
± 0,03 aw
Accuracy (outside 0,05-0,95 aw)
± 0,05 aw
Resolution
< 0,004 aw
Input
Supply nominal voltage
24V DC ± 10%
Max. residual voltage ripple
10%
Maximum Load current
200 mA
Max. Power input
< 4,8 VA

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg
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Relays
Contact arrangement
2 x Normally Closed (NC)
Rated voltage
60V
Rated current (40C)
1A
Max. DC Load breaking capacity
Relay 1
„High Alarm“
Relay 2
„High High Alarm“
Default High Alarm
0,50 aw
Default High High Alarm
0,90 aw
Socket specification
Connector design
1x male socket, 1x female socket
Connector locking system
Screw-locking, M12x1
Wire gauge
0,25 mm2
Contacts
8 Pol
Rated voltage
60V
Rated current (40C)
1A
Cable specification
Cable design
Multipair overall screened cable
Outlet diameter
9,9 mm
Voltage class
0,6/1kV
Wires
4x2 twisted pair
Wire gauge
0,75 mm2
Media for measurement
Lubrication oil
Grade SAE 30/TBN 5-10
Max. Oil temperature
90°C
Max. Oil pressure
Sensor mounting method in application:
Ball valve mounted: Max. 10 Bar
Thread mounted: Max. 20 Bar