INSTRUCTION MANUAL Oil level indicator with pointer

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INSTRUCTION MANUAL

Oil level indicator with pointer

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CONTENTS

1.

SAFETY ... 1

1.1 Safety instructions ... 1

1.2 Specified applications ... 1

1.3 Safety notes on the equipment operation ... 1

2.

DRAWINGS ... 2

2.1 OLI ... 2

2.2 eOLI ... 2

2.3 Mounting flange ... 3

2.3.1 OLI/eOLI (radial) ... 3

2.3.2 OLI/eOLI (axial) ... 3

2.3.3 OLI-22 / eOLI-22 (Radial) ... 3

2.3.4 OLI-22 / eOLI-22 (Axial) ... 4

2.4 L140 ... 4

2.4.1 Radial ... 4

2.4.2 Axial ... 5

2.5 Viewer ... 5

3.

OPERATING PRINCIPLE ... 6

3.1 Functioning ... 6

3.2 Outputs ... 6

3.3 Technical features ... 6

3.4 Tests ... 7

4.

INSTALLATION ... 8

4.1 Float assembly ... 8

4.1.1 LA version (radial) ... 8

4.1.2 LB version (axial) ... 8

4.2 Oil level indicator: General information ... 9

4.3 L140 ...10

4.4 OLI / eOLI...10

4.5 OLI-22 / eOLI-22 (with special flange) ...11

4.6 Viewer ...11

5.

ELECTRICAL CONNECTION ... 12

5.1 Micro-switches wiring ...12

5.2 Analog output and Modbus communication wiring (for eOLI and eOLI-22) ...13

5.2.1 Power voltage ...13

5.2.2 Analog output ...13

5.2.3 Modbus communication (optional) ...13

5.3 Viewer wiring ...13

5.3.1 Power voltage ...13

5.3.2 Analog input ...13

5.3.3 Viewer – eOLI connections ...13

5

OPERATION AND MAINTANENCE ... 14

6.1 Operation ...14

6.2 Maintenance ...14

6.3 Storage ...14

APPENDIX A: MODBUS COMMUNICATION ... 15

A1: MODBUS register ...15

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1. SAFETY

1.1 Safety instructions

Make sure that any person installing:

- Are technically qualified and competent. - Fully comply with these assembling instructions. Improper operations or misuse could cause danger to:

· Life and limb.

· To the equipm ent and other assets of the operator. · To the equipment proper, function.

Safety instructions in this manual are shown in three different forms to emphasize important information.

1.2 Specified applications

The oil level indicator is used in oil-insulated transformer to indicate the conservator tank oil level. Inside the device are usually installed up to four micro-switches to signal some critical oil levels. The micro-switches can give alarm or transformer power off signals.

It is important to observe the limit values indicated on the nameplate and in the manual before commissioning the device.

1.3 Safety notes on the equipment operation

Electrical installation is subject to the relevant national safety rules. It is mandatory to connect the grounding cable because of safety reason.

WARNING

This information indicates particular danger to life and health. Disregarding such a warning can lead to serious or fatal injury.

CAUTION

This information indicates particular danger to equipment and/or other property of the user. Serious or fatal injury cannot be excluded.

NOTE

This note gives important and specific information concerning the equipment.

CAUTION

Installation, electrical connection and fitting the device have to be carried out by qualified personnel and only in accordance to this instruction manual.

It is responsibility of the user to make sure that the device is used for specified application only. For safety matters, please avoid any unauthorized and improperly works.

WARNING

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2. DRAWINGS

2.1 OLI

2.2 eOLI

Fig. 1 Fig. 2

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2.3 Mounting flange

2.3.1 OLI/eOLI (radial)

2.3.2 OLI/eOLI (axial)

2.3.3 OLI-22 / eOLI-22 (Radial) Fig. 4

Fig. 3

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2.3.4 OLI-22 / eOLI-22 (Axial)

Fig.6

2.4 L140

2.4.1 Radial

Fig. 7

NOTE

Mounting flange may be designed in accordance with customer’s need: upon request, several hole patterns are available

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2.4.2 Axial

2.5 Viewer

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3. OPERATING PRINCIPLE

3.1 Functioning

The level gauge with magnetic joint is composed of a sturdy, watertight body made of aluminum alloy powder coated to protect against corrosion.

The movement of the float rod and the pointer takes place thanks to magnetic coupling and reaches a 120° angle. In this way, for every variation of the oil inside the conservator tank the movement of the float cause the rotation of the magnet joint with consequent variation of the indication on the dial of the gauge. The pointer indicate the level that the oil should reach at the temperatures printed on the dial.

The electronic version of the oil level gauge provide an analogical and a digital signal proportional to the oil level inside the conservator. These signals can be remote to : PLC, PC, integrated monitoring system, Remote Indicator.

An electronic level indicator equipped with 4..20 mA output signal can be coupled with the electronic Viewer. This device replicate the value of oil level (0-100%) at man-height.

3.2 Outputs

STANDARD CONFIGURATION

STANDARD

(OLI-L140) MICRO-SWITCHES 1, 2 or 4 change over contact (Fig.16)

OPTIONS (eOLI)

ANALOG OUTPUT 4-20 mA (terminals 41-44) (Fig.17)

(Minimum / Maximum resistance: 100 / 470 Ohm)

COMMUNICATION PORT RS-485 Modbus communication (terminals 3-4)) (Fig.17)

3.3 Technical features

Material All the external parts are resistant transformer oils, salt fog and UV rays.

Dial Tempered glass / Polycarbonate

Standard color White RAL 9002**

Ambient temperature -40°C ÷ +85°C

Oil temperature -40°C ÷ +120°C

Degree of protection IP65 according to EN60529 Standard cable gland 1 x M25x1.5 OLI – L140

3 x M25x1.5 eOLI

Wires Max 2.5mm2_{– advised 4x1mm}2_{o 6x1mm}2_{shielded twisted pair cable}

Electronic board features, only for eOLI

Power supply (terminals 1-2) 24 Vdc ±10% polarized

Power consumption 0,5 W

Analogical output (terminals 5-6) 4÷20 mA (dielectric strength between electronic card and analogical output:1kV)_{Minimum / Maximum resistance: 100 / 470 Ω} Distance for analogical output Max 30 m / 98 ft (for different demands contact COMEM)

Digital output (terminals 3-4) Serial RS485 Modbus RTU (for more inform ation contact COMEM assistance dept.) Distance for digital output Max 30 m / 98ft (for different demands contact COMEM)

Ventilation Valve n.2 to prevent the formation of condensation Micro-switches features

Power supply 24V ÷ 220V ac/dc

Power supply interruption

3A 125/250V ac (resistive)

0.5A 125V dc for inductive load L/R=40ms 0.25A 250V dc for inductive load L/R=40ms

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Electronic board features, only for Viewer

Power supply (terminals 1-2) 24 Vdc ±10% polarized

Analogical input (terminals 3-4) 4÷20 mA (dielectric strength between electronic card and analogical output:1kV)_{Minimum / Maximum resistance: 100 / 470 Ω} Distance for analogical input Max 30 m / 98 ft (for different demands contact COMEM)

** For critical environmental conditions please contact Comem

3.4 Tests

Description Reference standard Description Reference standard

Fast transient/burs immunity test IEC 61 000-4-4 Emission standard IEC 61 000-6-3 (EN 55022) Conducted disturbances IEC 61 000-4-6 Harmonic current emission EN 61000-3-2 Electrostatic discharge IEC 61 000-4-2 Voltage fluctuations and flicker EN 61000-3-3

Supply variation IEC 61 000-4-11 IP degree - IP 65 CEI EN 60259

Surge immunity test IEC 61 000-4-5 Vibration Test CEI EN 60721-3-4

(Class 4M4) Magnetic field immunity test IEC 61 000-4-3 Vibration Test IEC 60068-3-3 Power frequency magnetic field IEC 61 000-4-8

Table 2

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4. INSTALLATION

4.1 Float assembly

4.1.1 LA version (radial)

Screw the arm (Fig 9/A) into the hole of the backside shaft and block it with the M4 nut (Fig.9/B).

4.1.2 LB version (axial)

Insert the arm into the slot (Fig.10/A) on the backside shaft with and block it with the M5 nut (Fig.10/B).

CAUTION

The operating and the installation requirements described in this manual must be strictly following. If not, the device can be damaged or a malfunction can occur.

A

B

Fig. 9

A

Fig. 10

B

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4.2 Oil level indicator: General information

Depending on the conservator design, the level gauge can have different values of the parameters R and S (Fig.11) according to the table 4.

- “S”: parameter that indicates an offset from the vertical conservator axis [mm]. It is available for LA (radial) configuration. - “R”: parameter that indicates the length of the rod [mm]. It is available for LA (radial) and LB (axial) configurations. - “ØDC”: conservator diameter [mm].

NOTE

For the LB configuration COMEM advice to fit it in the center of the conservator (S=0 mm)

CAUTION

Verify contact surface of the conservator. It must be well leveled with a good degree of roughness (Ra=3.2 micrometer).

Verify and in case remove all welding burrs to ensure that the welding will not interfere with the housing flange holes.

During the flange assembly, COMEM advice to apply a few drops of cyanoacrylate glue on the gasket to fix it at the oil level flange. This action guarantees a good gasket positioning and it facilitates the assembly Apply a specific tightening torque (max 20 Nm) on the nuts following a cross sequence.

Table 4

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4.3 L140

Insert the arm with float through the machined hole on the conservator. Place the o-ring on the slot behind the gauge. Insert the device on the threaded pin of the conservator flange (Fig12/A). The oil level indicator has to be mounted using the items (Fig.12/B) showed in the table 5.

4.4 OLI / eOLI

Align the flange (Fig.13/C) with the threaded pins or holes (Fig.13/A) (depending on the conservator flange type) and positioning between the conservator and the flange the flat gasket (Fig.13/B). The oil level indicator has to be assembled on the flange using four screws M4x12 (Fig.13/D). The oil level indicator flange has to be assembled using the items showed in the table 5.

Q.ty Description Reference

standard

6 Ø6 plane washer UNI 6592

6 Ø6 grower washer UNI1751

6 M6 nut UNI5588 1 OR6362

-A

B

Fig. 12 Table 4 Fig. 13

A

B

D

C

Qty Description Reference

standard

4 M12 nut UNI5588

1 Flat gasket

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4.5 OLI-22 / eOLI-22 (with special flange)

Insert the arm with float through the machined hole on the conservator. Place the o-ring in the slot behind the flange (Fig.14/C). Insert the flange on the threaded pins (Fig.14/A) of the conservator flange and fix it with the items showed in the table 6 (Fig.14/B). Fix the gauge on the flange using 4 screws M4x12 (Fig.14/D)).

4.6 Viewer

Arrange the transformer with a dedicated place following the scheme in the figure 15. The connection can be done in two alternative way:

- threaded pin

-

screws

Q.ty Description Reference

standard

8 M10 nut UNI5588 1 OR221

-A

B

C

D

Table 6 Fig. 14 Fig. 15

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5. ELECTRICAL CONNECTION

Rem ove the cover from the terminal box unscrewing the 4 captive screws M4 (Fig.15/C)). Insert the wires through the cable gland (Fig.15/B) and wiring them following the electrical scheme (Fig.16-17).

5.1 Micro-switches wiring

Wire the electrical cables in accordance with the ordered model following the electrical scheme showed in the Figure 16. It is possible to identify the wiring diagram from the device part number:

E.g.: 1LB44X0000 – the 5th letter identify the wiring diagram of the micro-switches

CAUTION

Qualified and skilled personnel trained in the applicable health and safety regulations of the relevant country should only perform electrical connections.

WARNING

Dangerous electrical voltages!

It is imperative to deactivate the power supply during wiring of the device.

CAUTION

During the terminal box assembly, use caution not to damage the OR gasket (Fig.15/C). If this occurs, it must be substituted.

If you do not use all the cable glands, pay attention to close the free cable gland with a plug with gasket.

Fig. 15

B

C

A

DIAGRAM K DIAGRAM Y DIAGRAM X DIAGRAM W

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5.2 Analog output and Modbus communication wiring (for eOLI and eOLI-22)

5.2.1 Power voltage

Connect the power voltage (as written on the label on the terminal box cover) to terminals 1-2.

24 Vdc ±10% polarized

5.2.2 Analog output

Terminals for analog output 4-20 mA: 5-6 Minimum / Maximum resistance: 100 / 470 Ω 4 mA = 0% (minimum arrow position) 20 mA = 100% (maximum arrow position)

5.2.3 Modbus communication (optional) Digital output RS485: terminals 3-4

(for the Modbus register and address, see the Appendix A)

5.3 Viewer wiring

5.3.1 Power voltage

Connect the power voltage (as written inside the terminal box, fig.18) to terminals 1-2.

24 Vdc ±10% polarized

5.3.2 Analog input

Connect the analog signal (as written inside the terminal box, fig. 18) to terminals 3-4.

4..20 mA

5.3.3 Viewer – eOLI connections

The following schem e (fig.19) describes the connections for signal remoting between an electronic oil level indicator and the viewer. Fig. 17

Fig. 18

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5 OPERATION AND MAINTANENCE

The oil level indicator devices are ready for operation after installation, electrical connection and power supply.

6.1 Operation

It is possible to detect the conservator oil level observing the indicator dial: · Minimum level: when the pointer indicates the MIN position · Maximum level: when the pointer indicates the MAX position.

The electrical micro switches operate at an advance angle ≤ 5°, with respect to the min or max indications of the oil level in the conservator. When there is a double contact, for e.g. double MIN and/or double MAX (schemes Y o W) the second contact operates at about 5° after the first contact.

6.2 Maintenance

During regular maintenance on the transformer, we recommend performing the following checks on the oil level indicator:

·

Check the exterior condition of the device

· Remove dirt as necessary.

6.3 Storage

The oil level indicators can be handled without any tools. Handle the device with care.

When you install the device, please follow section 4, 5 and 6.

The oil level indicator must be stored in the original packing and in a dry place with temperature in the range -10÷40°C (14÷104 °F). Upon receiving the device, please check:

· The outer surface of the packaging to ensure that it is intact · That there are no breakages

If damages are found, please contact COMEM and provide the information from the shipping list and the serial number.

CAUTION

Not to paint the device. In this case any guarantees concerning the corrosion resistance decline.

Only mild soap and water should be used to clean the electrical box cover. Solvents must not be used for any reason as they will degrade the performance of the paint. Use of solvents on the unit will immediately void the warranty.

NOTE

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APPENDIX A: MODBUS COMMUNICATION

A1: MODBUS register

Register address

Operation

Notes

Operation for monitoring

0x2000 R Level value (0-100%)

0x2001 R Minutes from the last powering 0x2002 R Days from the last powering 0x2003 R Max level value (%) in the current day 0x2004 R Min level value (%) in the current day 0x2005 R Number of powering lost in the day

0x2006 R Minimum range value

0x2007 R Maximum range value

0x200A R Software version

Data logging

0x2100

R

Max level in the day 1

0x2101

R

Min level in the day 1

0x2102

R

0x2103

R

0x2104

R

0x2105

R

… … …

0x215C

R

Max level in the day X

0x215D

R

Min level in the day X

0x215E

R

Max level in the day Y

0x215F

R

Min level in the day Y

Events logging

0x2300

R

Events number

0x2301

R

Timestamp Hi [Event 1]*

0x2302

R

Timestamp Low [Event 1]*

0x2303

R

Event type: value 4=Change Date[Event 1]

0x2304

R

Level Value at the moment of the event [Event 1]

… … …

0x248D

R

Timestamp Hi [Event 100]*

0x248E

R

Timestamp Low [Event 100]*

0x248F

R

Event type: value 4=Change Date[Event 100]

0x2490

R

Level Value at the moment of the event [Event 100]

*Date and time of an event are calculated in this way:

Event Date/Time = Timestamp Hi (seconds) + (216_{) x Timestamp Low (seconds) + (01-Jan-2014 00hh:00min:00sec)} Table 7

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A1.1 MODBUS address

When are installed two or more units, it is necessary to differentiate the MODBUS address changing the dip-switches position

The available eOLI addresses are

· 128(default) to 143

4 3 2 1 ADDRESS

OFF OFF OFF OFF 128

OFF OFF OFF ON 129

OFF OFF ON OFF 130

OFF OFF ON ON 131

OFF ON OFF OFF 132

OFF ON OFF ON 133

OFF ON ON OFF 134

OFF ON ON ON 135

ON OFF OFF OFF 136

ON OFF OFF ON 137 ON OFF ON OFF 138 ON OFF ON ON 139 ON ON OFF OFF 140 ON ON OFF ON 141 ON ON ON OFF 142 ON ON ON ON 143 Table 8 Fig. 18

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Strada Regionale 11, Signolo 22 36054 Montebello Vic.No (VI) - Italy Tel. +39 0444 449311 - Fax -39 0444 449352 – 440359

http://www.comem.com e-mail:[email protected]