INSTRUCTION MANUAL Oil level with pointer indicator

INSTRUCTION MANUAL Oil level with pointer indicator 5COL868200 REV.B I

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 3.3.1 Microswitches... 7 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... 15 6.1 Operation...15 6.2 Maintenance...15 6.3 Storage...15 APPENDIX A: MODBUS COMMUNICATION... 16 A1: MODBUS register...16 A1.1 MODBUS address...17

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 equipment 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. 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

2.1 OLI 2. DRAWINGS 2.2 eoli Fig. 1 2 Fig. 2

2.3 Mounting flange 2.3.1 OLI/eOLI (radial) 2.3.2 OLI/eOLI (axial) Fig. 3 2.3.3 OLI-22 / eoli-22 (Radial) Fig. 4 3 Fig. 5

2.3.4 OLI-22 / eoli-22 (Axial) NOTE 4 holes mounting flange may be designed in accordance with customer s need: upon request, several hole patterns are available Fig.6 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) OPTIONS (eoli) MICRO-SWITCHES ANALOG OUTPUT COMMUNICATION PORT RS-485 1, 2 or 4 change over contact (Fig.16) 4-20 ma (terminals 6-7) (Fig.17) Maximum resistance: 450 Ohm Modbus communication (terminals 3-4)) (Fig.17) 3.3 Technical features Table 1 Material Dial All the external parts are resistant transformer oils, salt fog and UV rays. Tempered glass / Polycarbonate Standard color White RAL 9002** Ambient temperature Oil temperature Degree of protection Standard cable gland Wires Electronic board features, only for eoli Power supply (terminals 1-2) Power consumption Analogical output (terminals 6-7) Distance for analogical output Digital output (terminals 3-4) Distance for digital output Ventilation Valve Electronic board features, only for Viewer -40 C +80 C -40 C +120 C IP65 according to EN60529 1 x M25x1.5 OLI OLI-22 L140 Viewer 3 x M25x1.5 eoli eoli-22 Max 2.5mm 2 advised 4x1mm 2 o 6x1mm 2 shielded twisted pair cable 24 Vdc ±10% polarized 0,5 W 4 20 ma (dielectric strength between electronic card and analogical output: 2kV) Maximum resistance: 450 Ω Accuracy : 2.5 % of full scale Max 30 m / 98 ft (for different demands contact COMEM) Serial RS485 Modbus RTU (for more information contact COMEM assistance dept.) Max 30 m / 98ft (for different demands contact COMEM) n.1 to prevent the formation of condensation Power supply (terminals 1-2) 24 Vdc ±10% polarized Analogical input (terminals 3-4) 4 20 ma Distance for analogical input Max 30 m / 98 ft (for different demands contact COMEM) Ventilation Valve n.1 to prevent the formation of condensation ** For critical environmental conditions please contact Comem 6 Table 2

3.3.1 Microswitches Breaking and making capacity Voltage Uninterrupted current (making capacity) Interrupted current (breaking capacity) 24V DC to 220V DC 2A 100mA L/R < 40 230V AC 2A 2A cosφ > 0.5 Other values may be agreed between purchaser and supplier. The minimum contact life shall be 1.000 operations. Only in case that the device has to operate in a system at 24V DC and making capacity up to 0.5VA, the switches shall be able to make a low current down to 100mA even after one year of non-operation. 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 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 B 6 Ø6 plane washer UNI 6592 6 Ø6 grower washer UNI1751 6 M6 nut UNI5588 A 1 OR6362 - Table 4 Fig. 12 4.4 OLI / eoli Place the o-ring on the slot behind the gauge (fig.13/b). Align the flange (Fig.13/C) with the threaded pins or holes (Fig.13/A) (depending on the conservator flange type). The gauge 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. B Qty Description Reference standard 4 Ø12 plane washer UNI 6592 A 4 Ø12 grower washer UNI1751 4 M12 nut / screw UNI5588 1 O-ring 6225 - D Table 5 C 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 A 8 M10 nut UNI5588 1 OR221 - Table 6 B C 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 and nut M6 - screws M6 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/A). 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. Remove 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 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 Fig. 15 12

DIAGRAM K DIAGRAM Y DIAGRAM X DIAGRAM W 5.2 Analog output and Modbus communication wiring (for eoli and eoli-22) Fig. 16 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: 6-7 Maximum resistance: 450 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% 5.3.2 Analog input Connect the analog signal (as written inside the terminal box, fig. 18) to terminals 6-7 : 4..20 ma. Terminal 3 in the VIEWER with terminal 6 in the eoli. Terminal 4 in the VIEWER with terminal 7 in the eoli. Fig. 18 5.3.3 Viewer eoli connections The following scheme (fig.19) describes the connections for signal remoting between an electronic oil level indicator and the viewer. 13

14 Fig. 19

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. 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. 15

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 Max level in the day 2 0x2103 R Min level in the day 2 0x2104 R Max level in the day 3 0x2105 R Min level in the day 3 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 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] Events logging 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) 16

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 Fig. 18 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 17

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 21