S4600-WIO-001 Series

Transmitter for Moisture Content in Oil

Installation & Maintenance Manual

OMMXTS-W00064 - rev 4
 AMOT does not accept warranty and liability claims neither upon this publication
nor in case of improper treatment of the described products.

The document may contain technical inaccuracies and typographical errors. The
content will be revised on a regular basis. These changes will be implemented in
later versions. The described products can be improved and changed at any time
without prior notice.

© Copyright
All rights reserved.

USA
FCC notice:

This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference in a residential instal-
lation. This equipment generates, uses and can radiate radio frequency energy
and, if not installed and used in accordance with the installation manual, may
cause harmful interference to radio communications. However, there is no gua-
rantee that interference will not occur in a particular installation. If this equip-
ment does cause harmful interference to radio or television reception, which can
be determined by turning the equipment off and on, the user is encouraged to
try to correct the interference by one or more of the following measures:

- Reorient or relocate the receiving antenna.

- Increase the separation between the equipment and receiver.
- Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
- Consult the dealer or an experienced radio/TV technician for help.

Caution:
Any changes or modifications not expressly approved by the party responsible for
compliance could void the user's authority to operate this device.

CANADIAN
ICES-003 notification:

This Device B digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du
Canada.

OMMXTS-W00064 - rev 4 2
 TABLE OF CONTENTS
HARDWARE

1. GENERAL 4
1.1 Symbol assertion 4
1.2 Safety instructions 4
1.3 Environmental information 4

2. PRODUCT DESCRIPTION 5

3. INSTALLATION 5
3.1 Installation of the housing 5
3.2 Installation of the probe 5
3.2.1 General Safety instructions for installation 5
3.2.2 Installation of the probe directly in the process 6
3.2.3 Installation of the probe by utilizing the ball valve set 6

4. ELECTRICAL CONNECTIONS 7
4.1 Connection diagram 7

5. MAINTENANCE 8
5.1 Sensor cleaning 8
5.2 Self-diagnostics and error messages 8

6. REPLACEMENT PARTS / ACCESSORIES 8

7. TECHNICAL DATA 9

OMMXTS-W00064 - rev 4 3
 1. GENERAL

The manual is a part of the scope of supply and serves to ensure proper handling and optimum
functioning of the instrument. For this reason, the manual must be read before start-up.
This manual is for all personnel who require knowledge concerning transport, setup, operati-
on, maintenance and repair.

The manual must not be used for the purpose of competition without written consent and
must also not be forwarded to third parties. Copies for personal use are permitted.

All information, technical data and illustrations contained in these instructions are based on
information available at the time of publication.

1.1 Symbol assertion

This symbol indicates a safety instruction.

These safety instructions should always be followed carefully. By not following these instruc-
tions injuries of persons or material damage could happen. Therefore we do not accept liabi-
lity.

This symbol indicates a note.

These notes should be observed to achieve optimum functioning of the equipment.

1.2 Safety instructions

General Safety Instructions

• Excessive mechanical loads and incorrect usage should always be avoided.
• Take care when unscrewing the filter cap as the sensor element could be damaged.
• The sensor is an Electro Static Discharge sensitive component (ESD). When
touching the sensor element, ESD protective measures should be followed.
• Grip sensors only at the lead wires.
• Installation, electrical connection, maintenance and commissioning should
be performed by qualified personnel only.
• The devices are constructed for the operation of separated extra-low voltage (SELV).

Safety instructions for use of the alarm module with voltages >50V
• To insulate the optional alarm module from the low-voltage side of the transmitter, the
partition provided for this purpose must be fitted in the lower section.
• During operation of the instrument the modular housing must be completely closed.
• The protection class of an opened housing corresponds to IP00 and direct contact with
components carrying dangerous voltages is therefore possible. In general, work on live
components should be avoided and when absolutely necessary, should be performed
by qualified personnel only.

Safety instructions for use of the integrated power supply (option V01)
• During operation of the instrument the modular housing must be completely closed.
• The protection class of an opened housing corresponds to IP00. In general, work on
live components should be avoided and when absolutely necessary, should be
performed by qualified personnel only.

1.3 Environmental aspects

The equipment is developed with due consideration to all resultant environmental issues.
When you dispose of the equipment you should avoid environmental pollution. For disposal of
the transmitter the individual components must be sorted with care. The housing consists of
recyclable polycarbonate or metal (aluminium, Al Si 9 Cu 3). The electronics must be collec-
ted as electronic scrap and disposed of according to the regulations in force.

OMMXTS-W00064 - rev 4 4
 2. PRODUCT DESCRIPTION

Transmitter Series S4600-WIO-001 is specially designed for the measurement of water con-
tent in oil. The measured value is sent to the SPU over an RS485 link.

The modular housing enables an user-friendly operation and a quick replacement of the sen-
sor unit for service purposes. The construction of the transmitter makes field and local loop
calibration an easy task.

3. INSTALLATION

3.1 Installation of the housing

The necessary dimensions for the mounting holes can be found in the drawings below.

metal housing:
)
(6”
150
(2.2”)

(3.5”)
57

90
fig 1
3”)
(5.
135

3.2 Installation of the probe

Select a location with environmental conditions that permit an optimal measurement of the
process. The measuring medium (e.g.: oil) shall be as clean as possible i.e. without conta-
mination.

3.2.1 General safety instructions for installation

Because the sensing probe can be exposed to code “cable length”

very high pressures in the measurement environ- 194
32 (1.3”) 15 (0.59")
ment, there is the risk of sudden, unintentional
expulsion of the probe during or after improper
installation. Therefore, special precautions should
(0.51”)

be taken when working on the sensing probe or

∅13

in its vicinity. Bending over the sensing probe

should be avoided under any circumstances!
23 (1”)
minimum installation depth
During the installation of the sensor probe, make
sure that the surface of the sensing probe is not
damaged! Damaging the probe could lead to
damaged seals (consequence: leakage and pres- 64 (2.5”) resp. 164 (6.5”)
sure loss) and to problems during removal (jam-
ming). maximum installation depth

fig 2

OMMXTS-W00064 - rev 4 5
 3.2.2 Installation of the probe directly in the process

For direct probe installation, a stop valve should be provided on both sides of the probe
insert. This allows the sensor probe to be removed for maintenance and calibration wit-
hout any problems.

If the sensor probe is installed in a pressure chamber, make sure that the pressure in
the chamber and the ambient pressure are in equilibrium before you remove the probe.

Installation of the probe:

The temperature during installation may not fixed installation
vary more than ±40°C (±72°F) from the opera- (pressure tight up
ting temperature. to 20bar (300psi))

• 1st step: metal sealing ring

Install the probe with the stop valves closed. 1/2” ISO or 1/2“ NPT

• 2nd step: inside diameter

≥ 15 mm (0.6”) ≥ 13 mm (0.55”)
Insert the sensor probe into the process.
stop valve stop valve
• 3rd step:
To ensure a secure installation of the probe, the
lock nut must be tightened to a defined torque
of 30 Nm. If no torque-spanner is available
tighten the lock nut by hand as far as possible.
Continue to turn with an open-ended spanner
~50°. fig 3

3.2.3 Installation of the probe by utilising the ball valve set

The ball valve set allows for the removal of the probe without interrupting the process.
Install the balve valve perpendicular to the direction of flow. The pressure of the process
must be less than 10 bar (145psi). The two metal sealing rings (see fig 4) should be
replaced every time prior to re-installing the probe.

Installation of the probe:

The temperature during installation may not vary more

metal sealing ring
than ±40°C (±72°F) from the operating temperature. (as a standard contained
with the ball valve set)
metal sealing ring
• 1st step: (as a standard optional for ISO only
Install the probe with the ball valve closed. contained with
the probe)
optional for ISO only
• 2nd step:
Open the ball valve.
1/2” ball valve
• 3rd step:
Insert the sensor probe through the ball valve into the
process. A manual pressing tool is recommended at high
pressure.

• 4th step:
To ensure a secure installation of the probe, the lock nut
inside diameter
must be tightened to a defined torque of 30 Nm. If no ≥ 13 mm (0.55”)
torque-spanner is available tighten the lock nut by hand
as far as possible. Continue to turn with an open-ended
spanner ~50°.

fig 4

OMMXTS-W00064 - rev 4 6
 A too low torque results in a smaller tension force (fixing force) on the clamping sleeve. There is the risk
of injury due to sudden expulsion of the sensing probe. A too high torque can lead to permanent deforma-
tion of the clamping sleeve and the sensing probe. This can make the removal and re-installation difficult
or impossible.

Removing the probe:

• 1st step:
Firmly hold sensing probe. (Attention: do not bend con-
nection cable)
clamping
• 2nd step: sleeve
Slowly loosen the lock nut with a spanner (spanner
width 24) until the expulsion force acts on the probe. lock nut
sealing
In the installed state, never completely remove the element 2
lock nut, only unscrew it as much as necessary!
sealing
adapter
• 3rd step: element 1
body
After the sensor head has been pulled out of the pro-
cess up to the stop, close the ball valve.

• 4th step:
Probe can now be completely removed.

Pay attention to the sealing element 1 while mounting

or removing the probe. This sealing element has to be
put in a proper form. fig 5

4. ELECTRICAL CONNECTIONS
4.1 Connection diagram

serial data output

RS485

supply

fig 6

OMMXTS-W00064 - rev 4 7
 5. MAINTENANCE

5.1 Sensor cleaning

Cleaning of humidity and temperature sensors from oil residue:

1) Remove filter cap carefully, do not touch the sensors

2) Emerge the measuring head in N-HEPTAN and swirl for approx. 30 seconds
3) Remove excess liquid and allow to air dry for approx. 30 minutes
4) Screw on filter cap carefully

Cleaning of the measuring head is recommended before emerging in other oil and before a
calibration.

5.2 Self diagnostics and error messages

Self diagnostics via LEDs on the circuit board:
• Green LED flashing ⇒ Supply voltage applied/Microprocessor is active

• Red LED
constantly lit ⇒ Humidity sensor element damaged
flashing ⇒ Humidity sensor element accruing moisture (condensation!)

• Transmitter failure
no supply voltage
⇒ Check wiring and supply voltage
⇒ only green LED is illuminated continuously ⇒ Electronics defect
⇒ contact AMOT

6. REPLACEMENT PARTS / ACCESSORIES

Description Order Code

- Stainless steel filter TLXZZ0001

- Housing cover in metal TLXZZ0002

- Replacement probe - for S4600-WIO-001 with 5m cable TLXZZ0003

- Ball valve set TLXZZ0004

OMMXTS-W00064 - rev 4 8
 7. TECHNICAL DATA

Measuring values:
Water activity:

Measuring range: 0 ... 1aw

Accuracy incl. hysteresis and non-linearity in air:

Special calibration
against certified standards: ± 0.01aw (0...0.9aw) ± 0.02aw (0.9...1aw)
Standard calibration: ± 0.02aw (0...0.9aw) ± 0.03aw (0.9...1aw)
Traceable to intern. standards, administered by NIST, PTB, BEV

Temperature dependence
of electronics: typ. ± 0.0001 [1/°C] (typ. ± 5.6 * 10-5 [1/°F])

Temperature dependence
of sensing probe: typ. ± (0.00002 + 0.0002 x aw) x ∆T [°C] ∆T = T - 20°C

Response time with stainless

steel filter at 20°C/t90: typ. 10min in still oil

Temperature:

Working range sensing probe: -40...180°C -40...356°F

Accuracy:

∆°C

°C

Temperature dependence
of electronics: typ. ± 0.005°C/°C
Adjustable measurement
range:

Water activity: aw from 0 up to 1 units

General:
Supply voltage: 8 ..35V DC

Current consumption: for 24V DC: typ. 80 mA

Pressure range sensing probe: 0.01 ...10 bar 0.15 ... 145 psi

Housing/protection class: AI Si 9 Cu 3/IP65; Nema 4

Sensor cable length: 5 m

Cable gland: M16 x 1.5 cable dia 4.5 - 10 mm (0.18 - 039")

Electrical connection: Screw terminals up to max. 1.5mm2 (AWG 16)

Sensor protection: Stainless steel filter

Sensor fluid connection: 1/2" NPT male standard (ISO 228-1/G 3/4" adaptor also provided)

Sensor ball valve set: Provided as standard 1/2" NPT

Operating temp. range of

electronics: -40 ... 60°C -40 ... 140°F

Storage temperature: -40 ... 60°C -40 ... 140°F

Electromagnetic compatibility EN61000-6-2 EN61000-6-3 ICES-003 Class B

according to: EN61326-1+A1+A2 FCC Part 15 Class B

OMMXTS-W00064 - rev 4 9
Europe, Middle East and Africa Americas

AMOT AMOT USA

Western Way 8824 Fallbrook Dr
Bury St Edmunds Houston, TX 77064
Suffolk, IP33 3SZ USA
England
Tel +1 (281) 940 1800
Tel +44 (0) 1284 762222 Fax +1 (713) 559 9419
Fax +44 (0) 1284 760256 Email general: [email protected]
Email [email protected] orders: [email protected]
customer service: [email protected]

AMOT Controls GmbH

Rondenbarg 25
22525 Hamburg
Germany
Tel +49 (0) 40 8537 1298
Fax +49 (0) 40 8537 1331
Email [email protected]

AMOT Russia
#34 Shabolovka Street
Building 2
Moscow 115419
Russia
Tel +7 495 617 12 93
Fax +7 495 913 97 65
Email [email protected]

Asia and Australasia

AMOT Shanghai
Rm 308, Building No A8
Jiahua Business Center
808 Hongqiao Road
Shanghai 200030
China
Tel +86 (0) 21 6447 9708
Fax +86 (0) 21 6447 9718
Email [email protected]

AMOT Singapore
10 Eunos Road 8 #12-06
Singapore Post Centre
Singapore 408600
Tel +65 6408 6265
Fax +65 6293 3307
Email [email protected]

www.amot.com
www.bearingwear.com