INSTRUCTION MANUAL
Oil level indicator with pointer
5COL868200 – REV.01
I
II
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
A1.1 MODBUS address .......................................................................................................................16
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 equipm ent proper, function.
Safety instructions in this manual are shown in three different forms to emphasize important information.
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.
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.
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
All relevant fire regulation must be strictly observed.
1
2. DRAWINGS
2.1 OLI
Fig. 1
2.2 eOLI
2
Fig. 2
2.3 Mounting flange
2.3.1 OLI/eOLI (radial)
2.3.2 OLI/eOLI (axial)
Fig. 3
Fig. 4
2.3.3 OLI-22 / eOLI-22 (Radial)
Fig. 5
3
2.3.4 OLI-22 / eOLI-22 (Axial)
Fig.6
NOTE
Mounting flange may be designed in accordance with customer’s need: upon request, several hole patterns
are available
2.4 L140
2.4.1 Radial
Fig. 7
4
2.4.2 Axial
Fig. 8
2.5 Viewer
5
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)
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)
OPTIONS
(eOLI)
Table 1
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 2.5mm 2 – 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 information 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
6
Electronic board features, only for Viewer
Power supply (terminals 1-2)
Analogical input (terminals 3-4)
Distance for analogical input
24 Vdc ±10% polarized
4÷20 mA (dielectric strength between electronic card and analogical output:1kV)
Minimum / Maximum resistance: 100 / 470 Ω
Max 30 m / 98 ft (for different demands contact COMEM)
** For critical environmental conditions please contact Comem
Table 2
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
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
EN 61000-3-2
Table 3
7
4. INSTALLATION
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.
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).
A
B
Fig. 9
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).
Fig. 10
A
B
8
4.2 Oil level indicator: General information
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.
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.
Table 4
Fig. 11
-
“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)
9
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.
Q.ty
Description
Reference
standard
6
Ø6 plane washer
UNI 6592
6
Ø6 grower washer
UNI1751
6
M6 nut
UNI5588
1
OR6362
-
B
A
Table 4
Fig. 12
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.
Qty
Description
Reference
standard
4
Ø12 plane washer
UNI 6592
4
Ø12 grower washer
UNI1751
4
M12 nut
UNI5588
B
1
Flat gasket
-
C
Table 5
D
A
Fig. 13
10
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)).
Q.ty
Description
Reference
standard
8
Ø10 plane washer
UNI 6592
8
Ø10 grower washer
UNI1751
8
M10 nut
UNI5588
1
OR221
-
A
B
C
Table 6
D
Fig. 14
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
Fig. 15
11
5. ELECTRICAL CONNECTION
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.
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).
C
A
B
Fig. 15
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
DIAGRAM K
DIAGRAM Y
DIAGRAM X
DIAGRAM W
Fig. 16
12
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)
Fig. 17
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
Fig. 18
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. 19
13
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.
NOTE
Comem advices to disconnect the eOLI/eOLI-22/Viewer during the electrical transformer routine test
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.
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.
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.
14
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
0x2101
0x2102
0x2103
0x2104
0x2105
R
Max level in the day 1
Min level in the day 1
Max level in the day 2
Min level in the day 2
Max level in the day 3
Min level in the day 3
…
…
…
0x215C
0x215D
0x215E
0x215F
R
R
R
R
Max level in the day X
Min level in the day X
Max level in the day Y
Min level in the day Y
R
R
R
R
R
Events logging
0x2300
0x2301
0x2302
0x2303
0x2304
…
0x248D
0x248E
0x248F
0x2490
R
Events number
Timestamp Hi [Event 1]*
Timestamp Low [Event 1]*
Event type: value 4=Change Date[Event 1]
Level Value at the moment of the event [Event 1]
…
…
R
R
R
R
R
R
R
R
Timestamp Hi [Event 100]*
Timestamp Low [Event 100]*
Event type: value 4=Change Date[Event 100]
Level Value at the moment of the event [Event 100]
Table 7
*Date and time of an event are calculated in this way:
Event Date/Time = Timestamp Hi (seconds) + (2 16 ) x Timestamp Low (seconds) + (01-Jan-2014 00hh:00min:00sec)
15
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
Fig. 18
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
16
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:comem@comem.com
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