3.2 Function ................................................................................................................................................. 4
3.3 List of Substances ............................................................................................................................... 5
8.4 Instructions 81 D-Ex … and 83 UV-… ........................................................................................ 38
8.5 Declaration of performance 81 D-Ex … .................................................................................... 41
8.6 Declaration of performance 83 UV-…....................................................................................... 42
8.7 TÜV test report 81 D-Ex … ............................................................................................................ 43
8.8 TÜV test report 83 UV-… ............................................................................................................... 45
translation are permitted only with the written consent of FAFNIR GmbH. FAFNIR GmbH
Table of Contents II
(4)
(5)
L
(1) (3)
Overfill Prevention Sensor
Overfill prevention device
(2)
E
1 Overview
Under the German Water Resources Act, vessels with water-polluting liquids must be equipped
with overfill prevention devices. In other countries, the corresponding national rules and regulations must be observed. In the case of storage tanks which are filled by tank vehicles, the
overfill prevention device consists of an Overfill Prevention Sensor (e-OPS) in the storage tank
and an Overfill Prevention Controller installed in the tank vehicle.
The Overfill Prevention Sensors 81 D-Ex and 83 UV-… approved to standard EN 13616, and the
Overfill Prevention Controller approved to prEN 16657 in the tank truck (tanker) provide this
overfill prevention device - see the Figure below:
At the lower end of the probe tube the Overfill Prevention Sensor contains a sensor (PTC thermistor). The measuring transducer transmits changes in resistance to the signal amplifier in
form of binary signals. According to the resistance value (liquid level in the tank), the actuator
in the tank truck is either opened so that the fuel can be filled or closed so that the fuel supply
is interrupted.
Connection between the Overfill Prevention Controller and the Overfill Prevention Sensor
The connection between the Overfill Prevention Controller on the tank truck and the Overfill
Prevention Sensor on the tank is made via a connecting cable with a socket coupler which is
inserted into the connection fitting (see Figure below). Depending on the tank filling method,
two different connection fittings are used for the connection to the Overfill Prevention Sensor:
1) Overfill Prevention Sensor with pipe fitting for the direct filling of individual tanks.
The socket coupler is inserted directly into the pipe fitting on the Overfill Prevention
Sensor.
2) Overfill Prevention Sensor with junction box and wall fitting for remote filling.
The socket coupler is inserted into the wall fitting which is connected to the Overfill
Prevention Sensor in the tank by an extension cable.
Page 1/46 Overview
Connection fitting
Socket coupler
Connection cable
Figure 1: Filling a tank from the tank truck
Security system
The Overfill Prevention Sensor can be used to install a security system which, as required by
prEN 16657, consists of the digital product identification device (PID) and the product recognition
device (PRD). The magnetic Cross Over Prevention (COP) and the analogue Filling Hose Safety
(FHS) are also used as an alternative. PID and PRD systems are third party products.
The magnetic Cross Over Prevention (COP) is used to prevent product mixes. In order to
achieve this, the Overfill Prevention Sensors are equipped with a coded connection fitting. The
particular code allocated to each product is read out by the Overfill Prevention Controller in
the tank truck. The liquid can only be released if the dispensing product coincides with the
product in the tank.
The analogue Filling Hose Safety (FHS) is used to monitor the hose. The connections of the fill-
ing hose and the vapour recovery are monitored via the connection cable of the Overfill Prevention Controller. The liquid can only be released when the hoses are securely connected.
Types
The following types of Overfill Prevention Sensors are available:
• 83 UV-C (as 83 UV-A, without junction box, with 5 m long cable)
• 81 D-Ex (as 83 UV-A, also for aviation fuels, solvents, etc. See list of substances)
• 81 D-Ex U (as 81 D-Ex, with voltage surge protection)
Overview Page 2/46
2 Safety instructions
The safety instructions in this manual are marked as follows:
If these safety instructions are not observed, it may result in the risk of accident or
damage to the device/system.
Useful information which ensures continued and correct operation of the system
and makes your work easier.
Overfill Prevention Sensors (e-OPS) are designed to monitor the filling procedures in static
tanks. Use the Overfill Prevention Sensors exclusively for this purpose. The manufacturer accepts no liability for any form of damage resulting from improper use.
The Overfill Prevention Sensors have been developed, manufactured and tested in accordance
with the latest good engineering practices and generally accepted safety standards. Nevertheless, hazards may arise from their use. For this reason, the following Safety Instructions must
be observed:
• The proper function of the Overfill Prevention Sensors is only guaranteed in combina-
tion with an approved Overfill Prevention Controller in the tank truck.
• Do not change or modify the Overfill Prevention Sensors or the overall system, or add
any equipment without the prior consent of the manufacturer.
• Only use original parts. These comply with the technical requirements specified by the
manufacturer.
• The installation, operation and maintenance of the Overfill Prevention Sensors must
only be carried out by expert personnel. Specialised knowledge must be acquired by
regular training.
• The Overfill Prevention Sensors must be checked and approved before commissioning
and also at regular intervals (see Section 4.5, Approval and testing obligations)
• Operators, installers and service technicians must observe all applicable safety regula-
tions. This also applies to any local safety and accident prevention regulations which
are not stated in this manual.
Page 3/46 Safety instructions
3 Structure and design
3.1 Description
The Overfill Prevention Sensors consist of a probe which extends into the tank and the height
of which can be adjusted, a screw-in unit which carries the probe and a connection fitting.
The probe is sealed in the screw-in unit and can be moved and fixed within the adjustment
range. The screw-in unit is secured in place with a stuffing box fitting and additionally with a
locking screw. It is suitable for the pressure range from 0.67 – 2 bar (absolute). The sensor
(steel-enclosed PTC resistor) is located at the lower end of the probe. The PTC resistor in the
steel capsule is liquid-tight and gas-tight enclosed.
The connection fitting is a pipe fitting (direct filling) or a junction box with connection to the
wall fitting (remote filling). A 2-core connection cable (2 x 1 mm²) is installed from the junction
box to the wall fitting.
The Overfill Prevention Sensors are manufactured in probe lengths from 100 to 6,000 mm in
100 mm steps. The probe length is permanently engraved on the upper end of the probe tube
above the groove marking. The probe length represents the distance between the groove
marking on the upper end of the probe and the groove marking on the protective sleeve at
the height of the sensor.
3.2 Function
The PTC resistor is heated up after connecting the Overfill Prevention Sensor with the signal
amplifier of the Overfill Prevention Controller on the tank truck. After achieving a certain temperature, the change in resistance caused by this process prompts a signal in the signal amplifier "Overfill prevention device ready for operation".
The delivery of the liquid can now take place. As soon as the liquid reaches the sensor of the
Overfill Prevention Sensor, the heated PTC resistor is cooled down, thereby causing the resistance to change; this prompts a signal "close actuator" in the signal amplifier. The actuator is
automatically closed and the delivery therefore is stopped.
The reaction time for the closing process from the time the liquid is recognised to the end of
the product flow must not exceed 5.5 seconds: from the recognition of the liquid by the sensor
up to the output signal of the Overfill Prevention Controller max. 2.5 seconds, from the output
signal of the controller to the end of the product flow max. 3 seconds. [prEN16657, Section
5.4.2]
Structure and design Page 4/46
3.3 List of Substances
The Overfill Prevention Sensors (e-OPS) are suitable for use in tanks with the following liquids:
Overfill Prevention Sensor
List of Substances
83 UV 83 UV-A 83 UV-C 81 D-Ex 81 D-Ex U
• Fuel oil EL to DIN 51603
• Heating oil with FAME (fatty acid methyl
ester)
• Diesel fuel to DIN 51601/61606
such as e-OPS 83 ... plus:
• Petrol with up
• Aviationgaso-
• Diesel fuel with FAME (fatty acid methyl
ester)
• Aviation ker-
• Petrol to DIN 51600/51607
• Petrol with up to 60% ethanol
• Biodiesel
• Vegetable oils
• Industrial spirits
• Solvents
See the appendix for the detailed list of substances for the 81 D-EX Overfill Preven-
tion Sensor.
to 85 % ethanol
lines
osenes
The storage tanks must be approved for the liquids to be stored in them.
3.4.1 Overfill Prevention Sensor 83 UV with pipe fitting
Ø 24
35
42
Ø 60
18
150
Protective cage
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Adjustment dimension "x"
Plug insert
Pipe fitting
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Figure 2: Overfill Prevention Sensor 83 UV with pipe fitting
Structure and design Page 6/46
Ø 24
35
42
18
91
105
SW 55
Ø 60
Cable gland
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Adjustment dimension "x"
Protective cage
3.4.2 Overfill Prevention Sensor 83 UV with wall fitting
Plug insert
Wall fitting
Connection cable
(on site)
Junction box
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Figure 3: Overfill Prevention Sensor 83 UV with wall fitting
Page 7/46 Structure and design
3.4.3 Overfill Prevention Sensor 83 UV-A with pipe fitting
42
16
10
18
140
60
Protective cage
Dimensions in mm
Adjustment dimension "x"
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Plug insert
Pipe fitting
Earth connection
Type plate
Probe length engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Figure 4: Overfill Prevention Sensor 83 UV-A
Structure and design Page 8/46
79
16
10
SW 52
104
60
42
18
Probe length
(100 … 6,000
mm)
Control di-
mension "y"
Adjustment dimension "x"
Cable gland
Protective cage
Wall fitting
3.4.4 Overfill Prevention Sensor 83 UV-A with wall fitting
Plug insert
Connection cable
(on site)
Junction box
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Figure 5: Overfill Prevention Sensor 83 UV-A
Page 9/46 Structure and design
10
28
65
16
Adjustment dimension "x"
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Cable gland
Dimensions in mm
3.4.5 Overfill Prevention Sensor 83 UV-C
PG 9
Groove marking
Cylinder screw DIN 912, M4x6, VA
Gland screw, SW 27
Screw-in unit, SW 27
Thread G3/4"
Response point
Figure 6: Overfill Prevention Sensor 83 UV-C
Structure and design Page 10/46
Ø24
35
42
Ø 60
18
150
Protective cage
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Adjustment dimension "x"
(∅ 16)
∅ 24
(3)
35
3.4.6 Overfill Prevention Sensor 81 D-Ex with pipe fitting
Plug insert
Pipe fitting
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
Dimensions in mm
Figure 7: Overfill Prevention Sensor 81 D-Ex with pipe fitting
Page 11/46 Structure and design
3.4.7 Overfill Prevention Sensor 81 D-Ex with wall fitting
Ø24
35
42
18
91
105
SW55
Ø 60
Cable gland
Probe length
(100 … 6,000
mm)
Control dimen-
sion "y"
Adjustment dimension "x"
Protective cage
(on site)
(∅ 16)
24
(3)
35
(84)
91
(SW 58)
SW 55
Plug insert
Wall fitting
Connection cable
Junction box
Type plate
Probe length permanently engraved
Groove marking
Locking screw DIN 912, M6 x 8, SW 5
Gland screw, SW 36
Screw-in unit, SW 41
Thread G1"
Response point
∅
Dimensions in mm
Figure 8: Overfill Prevention Sensor 81 D-Ex with wall fitting
Structure and design Page 12/46
PG11
105
Ø60
66
Ø5 (2x)
29
PG 11
Dimensions in mm
3.5 Connection fitting
The connection fitting is the interface between the Overfill Prevention Sensor and tank truck.
Depending on the method used to fill the tank, different connection fittings are used for the
connection to the Overfill Prevention Sensor: pipe fitting and wall fitting. The connection fitting
can also be equipped with a security system (COP/FHS, see following chapters).
3.5.1 Pipe fitting
If the supply connection and the Overfill Prevention Sensor are located in the manhole, the
connection fitting for the Overfill Prevention Sensor is to be a pipe fitting.
Figure 9: Pipe fitting type 907 with plug insert type 901
3.5.2 Wall fitting
If the supply connection is at a distance from the tank (e.g. in a remote filling pit), the Overfill
Prevention Sensor with junction box and wall fitting is used. The connection between junction
box and wall fitting must be installed with a cable/wire of 2 x 1 mm² with a maximum length of
150 m. In the case of 2 x 1.5 mm² cables, the maximum length is 250 m.
Figure 10: Wall fitting type 907 with plug insert type 901
Page 13/46 Structure and design
3.5.3 Cross Over Prevention (COP)
Code 1 = Super E10
Code 4 = Super Plus
Code 2 = Diesel fuel
Code 5 = not currently used
Code 3 = Super E5
Code 6 = not currently used
Code N = Neutral, FHS without COP
The Overfill Prevention Sensors may be equipped with a coded connection fitting. A specific
code is allocated to each product; this is read out by the Overfill Prevention Controller in the
tank truck via the socket coupler FP 903/FHS/K, and only approves the liquid delivery when the
product to be delivered coincides with the stored product. The coding is carried out via the
type FP 901 plug insert.
3.5.4 Filling Hose Safety (FHS)
The connection fitting can be used to monitor the hose. A signal is transmitted via connection
cable from the Overfill Prevention Controller of the tank truck to the Overfill Prevention Sensor
and then via the hoses back to the Overfill Prevention Controller. Only when the filler hose (for
petrol also the vapour recovery hose) is safely connected the delivery can take place. Contact is
made via the type FP 901 FHS plug insert.
3.5.5 Product Identification Device (PID)
If a connection cable with a type FP 903 FHS socket coupler is used and the connection fitting
has a type FP 901 FHS plug insert, the digital product identification PID (third party product)
can also be used.
3.5.6 Coding (example)
Structure and design Page 14/46
Cross Over Prevention (COP)
plug insert type FP 901/1-6
Filling Hose Safety (FHS):
plug insert type FP 901/1-6 FHS
Cross Over Prevention (COP)
plug insert type FP 901/1-6
Filling Hose Safety (FHS):
plug insert type FP 901 H/1-6 FHS
PG7
PG11
Ø5 (2x)
105
Ø60
29
66
PG11
PG7
M6 (2x)
105
Ø60
29
84
Dimensions in mm
Pipe fitting type 907 with
Pipe fitting type FP 907/FHS with
Wall fitting type FPW 907 with
Wall fitting type FPW 907/FHS with
Figure 11:
Page 15/46 Structure and design
Pug insert with COP/FHS
locking system
4 Installation
Gland screw (max. 40 Nm)
Locking screw (max. 8 Nm)
Hexagon nut (max. 40 Nm)
Thread
4.1 Mounting
When working on tanks for storage of flammable liquids, all local safety and accident
prevention regulations must be observed as a matter of principle.
When filling static tanks with water-polluting liquids, the tanks may only be filled up
to their permitted level (see the German Water Resources Act resp. corresponding
national rules and regulations).
Installation in protective tubes or dipstick pipes is not permitted.
(1)The Overfill Prevention Sensor must always be installed in a vertical position in the
tank. Installation is via a screw-in unit. Provide the thread of the screw-in unit with a
suitable sealant and screw into the tank coupling. Release the locking screw and the
stuffing box (see Figure below). To obtain the correct position, the Overfill Prevention
Sensor can be moved upwards and fixed in position.
Figure 12: Screw-in unit
(2) Determine the adjustment dimension "x" for the Overfill Prevention Sensor (see Sec-
tion 4.4). The adjustment dimension "x" is the distance between the hexagon nut seat
of the screw-in unit and the groove marking on the sensor's protective sleeve at the
lower end of the probe.
(3) Set the height of the Overfill Prevention Sensor to the control dimension "y" (see Sec-
tion 4.2). The control dimension "y" is the distance between the hexagon nut seat of
the screw-in unit and the upper groove marking on the probe tube.
(4) Then re-tighten the stuffing box and locking screw.
Installation Page 16/46
x
y
Probe length
a = manway nozzle height
a
h
4.2 Installation height
In the case of tanks to the DIN standard, the response height "h" and the adjustment dimension "x" needed for this can be taken from the tables in the Section "Adjustment dimension".
The diameter, nominal capacity (particularly for multi-chamber tanks) and the height of the
manway nozzle height including the tank lid are important in calculating the adjustment dimension "x".
The installation height is adjusted using the control dimension "y" (see Figure below):
Control dimension "y" = probe length - adjustment dimension "x"
x = adjustment dimension
y = control dimension
h = response height
Figure 13: Control dimension "y"
If the Overfill Prevention Sensor is mounted in tanks that are not detailed in the ta-
bles, it must be ensured that the maximum filling ratio (volumes) of 95% for aboveground and 97% for underground tanks (minimum 300 mm earth covering) is not
exceeded.
The adjustment dimension "x" cakes into consideration a manway nozzle height of
100 mm for tanks according to DIN 6608, 6616, 6618, and EN 12285, and 60 mm for
tanks according to DIN 6619, 6623 and 6624, as well as an overall thickness of
20 mm of the tank lid including sealing (see Tables of adjustment dimensions). In
the case of different heights, the adjustment dimension "x" must be amended correspondingly.
The response height "h" and the adjustment dimensions "x" detailed in the tables
take into consideration shutdown volumes (due to switching delays in the control
circuit of the controller) for permanently installed fill pipes up to 20 m in length. For
tanks with permanently installed fill pipes over 20 m in length, the adjustment di-
Page 17/46 Installation
mensions "x" must be increased by an amount that corresponds to the additional
volumes in the pipe.
4.3 Mounting distance for installation in the manhole
When installing Overfill Prevention Sensors in manholes, the distance between the top edge of
the connection fitting and the lower edge of the manhole cover should not be less than 20
mm and not more than 300 mm.
Installation Page 18/46
x
b
h
D
y
Figure
Probe length
y = probe length – x
4.4 Adjustment dimension
4.4.1 Adjustment dimension X for cyl. horizontal tanks according to DIN
6608/ -16/ -17/ -24 and EN 12285
(See Tables 1, 2, 3 or 7)
For tanks, the diameters of which are not detailed in the tables, the adjustment
dimension must be selected for the next largest tank diameter.
14: Tanks in accordance with DIN 6608, 6616, 6617, 6624 and EN 12285
b = distance between the tank bottom and the tank lid (hexagon nut seat)
h = max. filling height / response height (see tables 1–3, 7)
D = tank diameter
x = Overfill Prevention Sensor adjustment dimension (see tables 1–3, 7)
y = control dimension to check the position of the Overfill Prevention Sensor
Page 19/46 Installation
4.4.2 Adjustment dimension X for standing tanks according to DIN 6619/-23
x
b
h
y
Probe length
y = probe length – x
DIN 6619 see Tables 4 or 5
DIN 6623 see Table 6
For tanks, the diameters of which are not detailed in the tables, the adjustment
dimension must be selected for the next largest tank diameter.
Figure 15: Tanks in accordance with DIN 6619 and 6623
b = distance between the tank bottom and the tank lid (hexagon nut seat)
h = max. filling height / response height (see tables 4–6)
D = tank diameter
x = Overfill Prevention Sensor adjustment dimension (see tables 4–6)
y = control dimension to check the position of the Overfill Prevention Sensor
Installation Page 20/46
xy
h
b
a
c
Probe length
4.4.3 Adjustment dimension X for tanks according to DIN 6618
DIN 6618 see Tables 7 or 8
Abbildung 16: Tanks nach DIN 6618
a = Response height
b = distance between the tank bottom and the tank lid (hexagon nut seat)
c = auxiliary distance dimension (upper edge of tank shell up to hexagon nut seat)
h = max. filling height / response height (see tables 7-8)
x = Overfill Prevention Sensor adjustment dimension (see tables 7-8)
y = control dimension
(1) Use value „a“ from table 8
(2) Measuring the auxiliary distance c (upper edge of tank shell up to hexagon nut seat)
Calculate the adjustment dimension "x": x = a + c
(3) If the determination of the adjustment dimension "x" is not possible by this proce-
dure, following method can also be used: Measure value „b“ by dipping (middle of the
tank) and use value „h“ from the table 7. Calculate the adjustment dimension "x":
x = b –h
Page 21/46 Installation
4.4.4 Adjustment dimension X for all other cylindrical tanks standing vertically
x
y
h
H
b
c
Probe length
Figure 17: Tanks in accordance with DIN 4119
b = distance between the tank bottom and the tank lid (hexagon nut seat)
c = auxiliary distance dimension (upper edge of tank shell up to hexagon nut seat)
h = max. filling height / response height
H = shell height
x = Overfill Prevention Sensor adjustment dimension
y = control dimension
(1) Measuring the "H" shell height. The "H" dimension represents the distance between the
bottom plate and the upper edge of the tank shell.
(2) Calculating the filling height "h", which corresponds to the permitted filling ratio.
h = H • 0.95
(3) Measuring the vertical auxiliary distance dimension "c".
(4) Calculate the adjustment dimension "x" according to the figure above:
b = H + c; x = b – h
Installation Page 22/46
Tank diameter D
Nominal volume tank or
Maximum filling
[mm]
Adjustment dimen-
[mm]
1,000
1
795
320
1,250
3
1,095
270
1
990
375
1,600
16
1,465
250
13
1,460
255
10
1,455
260
7
1,440
275
5
1,430
285
3
1,395
320
2
1,355
360
2,000
30
1,840
275
25
1,835
280
20
1,830
285
16
1,825
290
13
1,820
295
10
1,815
300
7
1,795
320
5
1,775
340
2,500
60
2,305
310
50
2,305
310
40
2,300
315
30
2,295
320
25
2,290
325
20
2,285
330
10
2,255
360
2,900
100
2,675
335
80
2,670
340
60
2,670
340
50
2,665
345
40
2,665
345
20
2,645
365
4.4.5 Tables of adjustment dimensions X
The adjustment dimension "x" cakes into consideration a manway nozzle height of
100 mm for tanks according to DIN 6608, 6616, 6618, and EN 12285, and 60 mm for
tanks according to DIN 6619, 6623 and 6624, as well as an overall thickness of
20 mm of the tank lid including sealing. In the case of different heights, the adjust-
Table 1: Adjustment dimension X for cylindrical horizontal tanks according to DIN 6608
for underground storage with more than 300 mm earth covering
ment dimension "x" must be amended correspondingly.
[mm]
compartment [m³]
height "h"
sion "x"
Page 23/46 Installation
Table 2: Adjustment dimension X for cylindrical horizontal tanks according to DIN 6608,
Tank diameter D
Nominal volume tank or
Maximum filling
Adjustment dimen-
[mm]
1,000
1
775
340
1,250
3
1,065
300
1
965
400
1,600
16
1,420
295
13
1,415
300
10
1,410
305
7
1,400
315
5
1,385
330
3
1,355
360
2
1,320
395
2,000
30
1,785
330
25
1,780
335
20
1,775
340
16
1,770
345
13
1,765
350
10
1,760
355
7
1,745
370
5
1,725
390
2,500
60
2,235
380
50
2,230
385
40
2,230
385
30
2,225
390
25
2,220
395
20
2,215
400
10
2,185
430
2,900
100
2,595
415
80
2,590
420
60
2,590
420
50
2,585
425
40
2,585
425
20
2,560
450
6616, and 6617
for underground storage with less than 300 mm earth covering,
as well as above ground and partially-aboveground tanks
[mm]
compartment [m³]
height "h"
sion "x"
Installation Page 24/46
Tank diameter D
[mm]
Nominal volume of tank
or compartment [m³]
Maximum filling
height "h" [mm]
Adjustment
dimension "x" [mm]
1,000
3.0
855
220
2.0
835
240
1.5
815
260
1.0
780
295
1,250
5.0
1,085
240
3.5
1,075
250
3.0
1,065
260
2.0
1,040
285
Tank diameter D
[mm]
Nominal volume of tank
or compartment [m³]
Maximum filling
height "h" [mm]
Adjustment
dimension "x" [mm]
2,000
7.0
2,145
385
5.0
1,500
385
2,500
11.5
2,240
460
2,900
15.0
2,230
505
Tank diameter D
[mm]
Nominal volume of tank
or compartment [m³]
Maximum filling
height "h" [mm]
Adjustment
dimension "x" [mm]
1,250
1.7
1,325
230
1,600
5.0
2,430
275
3.8
1,850
240
2.8
1,375
215
2,000
6.0
1,910
240
Tank diameter D
[mm]
Nominal volume of tank
or compartment [m³]
Maximum filling
height "h" [mm]
Adjustment
dimension "x" [mm]
1,000
0.7
910
245
1,250
0.6
665
230
0.4
420
215
1.0
780
205
Table 3: Adjustment dimension X for cylindrical horizontal tanks according to DIN 6624
For above ground storage
Table 4: Adjustment dimension X for standing tanks according to DIN 6619 :1981-10/
1982-09/ 1989-09
Table 5: Adjustment dimension X for standing tanks according to DIN 6619 :1968-07
Table 6: Adjustment dimension X for standing tanks according to DIN 6623
Page 25/46 Installation
Table 7: Adjustment dimension X for cylindrical standing tanks according to DIN 6618
Tank diameter D
[mm]
Nominal volume of tank
[m³]
Maximum filling
height "h" [mm]
Response height a
[mm]
1.600
16
7.800
765
13
6.350
605
10
4.895
450
7
3.460
275
2.000
25
7.856
678
20
6.313
641
2.500
40
8.066
727
30
6.100
558
2.900
60
9.026
550
50
7.565
826
Tank diameter D
[mm]
Nominal volume of tank
[m³]
Adjustment
dimension "x" [mm]
1.600
16
7.800
13
6.350
10
4.895
7
3.460
2.000
25
7.856
20
6.313
2.500
40
8.066
30
6.100
2.900
60
9.026
50
7.565
:1968-07
Table 8: Adjustment dimension X for cylindrical standing tanks according to DIN 6618
:1981-10, Part 1–4
Installation Page 26/46
Tank diam-
Nominal
[m³]
95 %
97 %
98 %
Maximum
height "h"
Adjustment
dimension
Maximum
Adjustment
dimension
Maximum
height "h"
Adjustment
dimension
900
1
660
355
675
340
685
330
1,000
1
730
385
750
365
760
355
1,250
1
910
455
930
435
940
425
1.5
970
395
995
370
1,010
355
2
1,005
360
1,030
335
1,045
320
3
1,040
325
1,070
295
1,080
285
1,600
2
1,280
435
1,315
400
1,330
385
2.5
1,310
405
1,340
375
1,360
355
3
1,325
390
1,360
355
1,380
335
4
1,350
365
1,390
325
1,405
310
5
1,370
345
1,410
305
1,425
290
7
1,385
330
1,425
290
1,445
270
10
1,400
315
1,440
275
1,465
250
13
1,405
310
1,450
265
1,475
240
16
1,410
305
1,455
260
1,480
235
1,900
4
1,595
420
1,640
375
1,665
350
5
1,620
395
1,665
350
1,690
325
7
1,640
375
1,690
325
1,715
300
10
1,660
355
1,710
305
1,735
280
13
1,670
345
1,720
295
1,745
270
15
1,675
340
1,725
290
1,750
265
20
1,680
335
1,730
285
1,760
255
25
1,685
330
1,735
280
1,765
250
30
1,690
325
1,740
275
1,770
245
Table 9: Adjustment dimension X for cylindrical horizontal tanks according to EN 12285
for underground storage with less than 300 mm earth covering, as well as aboveground and
partly-aboveground tanks with maximum filling level of 95%, 97% and 98%.
eter D
[mm]
volume
tank
tank com-
partment
filling
[mm]
"x“
[mm]
filling
height "h"
[mm]
"x"
[mm]
filling
[mm]
"x"
[mm]
Page 27/46 Installation
Tank diam-
Nominal
ment [m³]
95 %
97 %
98 %
Maximum
[mm]
Adjustment
dimension
[mm]
Maximum
[mm]
Adjustment
dimension
[mm]
Maximum
[mm]
Adjustment
dimension
[mm]
2,000
4
1,675
440
1,720
395
1,745
370
5
1,700
415
1,750
365
1,775
340
7
1,725
390
1,775
340
1,805
310
10
1,745
370
1,795
320
1,825
290
13
1,755
360
1,805
310
1,840
275
15
1,760
355
1,815
300
1,845
270
16
1,760
355
1,820
295
1,845
270
20
1,765
350
1,825
290
1,850
265
25
1,770
345
1,830
285
1,855
260
30
1,775
340
1,835
280
1,860
255
2,500
5
2,100
515
2,160
455
2,195
420
10
2,170
445
2,240
375
2,275
340
15
2,195
420
2,260
355
2,300
315
20
2,205
410
2,275
340
2,315
300
25
2,215
400
2,285
330
2,325
290
30
2,220
395
2,290
325
2,330
285
40
2,225
390
2,295
320
2,335
280
50
2,230
385
2,300
315
2,340
275
60
2,230
385
2,300
315
2,340
275
2,900
10
2,500
510
2,580
430
2,625
390
20
2,550
460
2,635
375
2,680
330
30
2,565
445
2,650
360
2,695
315
40
2,575
435
2,660
350
2,705
305
50
2,580
430
2,665
345
2,710
300
60
2,585
425
2,665
345
2,710
300
80
2,585
425
2,670
340
2,715
295
100
2,590
420
2,670
340
2,720
290
3,000
10
2,580
530
2,660
450
2,710
400
20
2,635
475
2,720
390
2,770
340
30
2,655
455
2,740
370
2,790
320
40
2,665
445
2,750
360
2,795
315
50
2,670
440
2,755
355
2,800
310
60
2,670
440
2,755
355
2,805
305
80
2,675
435
2,760
350
2,810
300
100
2,680
430
2,765
345
2,815
295
eter D
[mm]
volume
tank or
compart-
filling
height "h"
"x"
filling
height "h"
"x"
filling
height "h"
"x"
Installation Page 28/46
4.5 Approval and testing obligations
A mounting diagram must be delivered to the operator, in which the tank diameter, capacity,
nozzle height, manhole cover thickness and the dimensions "x" and "y" as well as the Overfill
Prevention Sensor type with approval code can be seen.
Testing obligations in accordance with §§ 15 and 16 of the German Industrial Safety
Regulations (BetrSichV) and § 1 of the German Regulations on Equipment Handling
Substances Hazardous to Water (WasgefStAnlV). In other countries, the corresponding national rules and regulations must be observed.
Storage facilities for static tanks, filler points, petrol stations, airport refuelling equipment, and their components, e.g. Overfill Prevention Sensors, must be tested by an
approved inspection agency prior to commissioning, re-commissioning (after modifications subject to testing) as well as repeatedly at specific testing intervals.
The system parts, e.g. Overfill Prevention Sensors, must be tested at regular intervals
by the operator or an authorised person as required by the manufacturer's operating
instructions, e.g. by using the FAFNIR Overfill Prevention Sensor tester ME 6.
5 Maintenance and repair
The Overfill Prevention Sensor is maintenance-free.
Page 29/46 Maintenance and repair
6 List of figures
Figure 1: Filling a tank from the tank truck ........................................................................................................ 2
Figure 9: Pipe fitting type 907 with plug insert type 901 ........................................................................... 13
Figure 10: Wall fitting type 907 with plug insert type 901......................................................................... 13
Figure 11:
Figure 12: Screw-in unit .......................................................................................................................................... 16
Figure 13: Control dimension "y" ........................................................................................................................ 17
Figure 15: Tanks in accordance with DIN 6608, 6616, 6617, 6624 and EN 12285 ............................ 19
Figure 16: Tanks in accordance with DIN 6619 and 6623 .......................................................................... 20
Abbildung 16: Tanks nach DIN 6618 .................................................................................................................. 21
Figure 17: Tanks in accordance with DIN 4119 .............................................................................................. 22
Pug insert with COP/FHS
locking system .............................................................................. 15
7 List of tables
Table 1: Adjustment dimension X for cylindrical horizontal tanks according to DIN 6608 ........... 23
Table 2: Adjustment dimension X for cylindrical horizontal tanks according to DIN 6608, 6616,
and 6617 ....................................................................................................................................................................... 24
Table 3: Adjustment dimension X for cylindrical horizontal tanks according to DIN 6624 ........... 25
Table 4: Adjustment dimension X for standing tanks according to DIN 6619 :1981-10/ 1982-09/
Table 8: Adjustment dimension X for cylindrical standing tanks according to DIN 6618 :1981-
10, Part 1–4 .................................................................................................................................................................. 26
Table 9: Adjustment dimension X for cylindrical horizontal tanks according to EN 12285 .......... 27
Table 10: List of Substances I - Fuels and Oils ................................................................................................ 31
Table 11: List of Substances II - Aviation gasolines ...................................................................................... 31
Table 12: List of Substances III - Aviation kerosenes ................................................................................... 32
Table 13: List of Substances IV - Special benzines, solvents, alcohols .................................................. 33
List of figures Page 30/46
List of Substances I
for Overfill Prevention Sensors 83 UV-…
List of Substances II
Supplements List of Substances I for Overfill Prevention Sensors 81 D-Ex and 81 D-Ex U
Aviation
fuels
in accordance with specification
Abbreviations
Bundesrepublik
United
USA
Bundesrepublik
Code)
United
USA
Aviation
80 [82 UL]
MIL G-5572 F
AVGAS
AVGAS
80 [82 UL]
Aviation
100
DERD
Edition 8
AVGAS 100
AVGAS
Aviation
100 LL
DERD
Edition 8
MIL G-5572 F
F 18
AVGAS
AVGAS
LL
Aviation
115/145
VTL-9130-004/2c
DERD
Edition 8
MIL G-5572 F
F 22
AVGAS 115
AVGAS
8 Appendix
8.1 List of Substances for the Overfill Prevention Sensors
List of Substances
• Fuel oil EL to DIN 51603
• Heating oil with FAME (fatty acid methyl ester)
• Diesel fuel to DIN 51601/61606
• Diesel fuel with FAME (fatty acid methyl ester)
• Petrol to DIN 51600/51607
• Petrol with up to 60% ethanol
• Biodiesel
• Vegetable oils
Table 10: List of Substances I - Fuels and Oils
Deutschland [Federal Republic of
Germany]
(Nato-Code)
Kingdom
Deutschland
[Federal Re-
public of Ger-
many] (Nato-
Kingdom
Gasoline
Gasoline
Gasoline
Gasoline
Table 11: List of Substances II - Aviation gasolines
Page 31/46 Appendix
2485
2475
2485
80 [82 UL]
100 LL
Grade
Grade 100
Grade 100
Grade 115
List of Substances III
Supplements List of Substances I for Overfill Prevention Sensors 81 D-Ex and 81 D-Ex U
Aviation
fuels
in accordance with specification
Abbreviations
Aviation
[Jet A-1]
VTL-9130-006/4
DERD 2494
F 34 1)
AVTUR
JP 1
Aviation
type Jet B
VTL-9130-006/4
DERD 2454
MIL-T-5624 L
F 40 2)
AVTAG
JP 4
Aviation
type
VTL-9130-007/4
DERD 2452
MIL-J-5624 L
F 44
AVCAT
JP 5
Jet fuel
MIL-J-25656 B
(USAF)
JP 6
Turbine
volatility
MIL-T-38219
JP 7
Aviation
type Jet A-1
DERD 2453
MIL-T-83133 D
F 34
AVTUR/FSII
JP 8
turbine fuel,
kerosene,
type Jet A
turbine fuel,
wide cut,
turbine fuel,
high flash,
fuel, low
respective
VTL-9130-010/2
Edition 8
Edition 8
Edition 8
F 35
F 45
(USAF)
turbine fuel,
kerosene,
1)
F34 = F35 with ice formation inhibitor
2)
F40 = F45 with ice formation inhibitor
Table 12: List of Substances III - Aviation kerosenes
Appendix Page 32/46
List of Substances IV
Special benzines
Supplements List of Substances I for Overfill Prevention Sensors 81 D-Ex and 81 D-Ex U
Petrol with up to 85% ethanol
Petrol-ether to DIN 51 630
Boiling point benzines to DIN 51 631
Test benzines to DIN 51 632
Safety lamp benzines to DIN 51 634
FAM regular gasolines to DIN 51 635
Lighting, burning and solvent petroleum to DIN 51 636
Benzene, tuluol xylol
Solvent naphta (light) to DIN 51 63
Alcohols
Propanol
Butanol
Ethanol
Table 13: List of Substances IV - Special benzines, solvents, alcohols
Page 33/46 Appendix
Instructions in accordance with Directive 2014/34/EU TÜV 00 ATEX 1656 X
Overfill Prevention Sensor Type 81 D-Ex ... and 83 UV-...
Level detector LS 300 ...
High-level sensor type SEPARIX-T … Edition: 09.2018
I Range of application
The sensors are intrinsically safe operating equipment for use in explosion hazardous area and serve for
detecting the limit level. The Overfill Prevention Sensors serve as part of a filling safety device. The level
detector is used as part of an overfill prevention system, dry run protection or filling control. The highlevel sensor is used to detect a fluid back pressure within a light liquid separator.
II Standards
The sensors are designed in accordance with the following European standards
EN 60079-0: 2012 + A11:2013 Equipment - General Requirements
EN 60079-11: 2012 Equipment protection by intrinsic safety "i"
EN 60079-26: 2015 Equipment with Equipment Protection Level (EPL) Ga
III Instructions for safe …
III.a … use
The sensors are designed as intrinsically safe equipment and are suitable for use in potentially explosive
areas. The level detectors LS 300 … C (coated with plastic) are suitable for the gas groups IIA and IIB. All
other level detectors are suitable for all gas groups (IIA, IIB and IIC).
The approval applies to device versions 81 D-Ex …, 83 UV-…, LS 300 … and SEPARIX-T …
III.b … assembling and dismantling
Assembling and dismantling must solely be carried out with the power disconnected!
For sensors with connection housing the cover of the connection housing may be removed for the
electrical installation. After installation, the connection housing must be locked again.
III.c … installation
The wiring must be carried out only with the power disconnected. Special rules and regulations, including EN 60079-14 and local installation regulations, must be observed.
The sensors can be installed completely inside Zone 0. If the integrated overvoltage protection is used,
e. g. LS 300 U, the terminal compartment with overvoltage protection must be installed outside Zone 0.
General information (see also EN 60079-14:2014, section 16.3 or EN 60079-25:2010, section 12):
The overvoltage protection device must be installed outside, but as close to the border of Zone 0
as technically possible, preferably at a distance of up to 1 m.
If a screw-in unit is used, it must be provided with a suitable sealing material and screwed into the tank
coupling. If the sensor tube is permanently connected with a flange, the installation length cannot be
changed. The flange shall be provided with a suitable seal and fixed with flange bolts or nuts.
By the process connection, there may be an opening in the boundary wall to the area requiring EPL "Ga".
Then, there is the risk of flammable gases release and flame entrance.
If the sensor is supplied without process connection, the installer is responsible for compliance with the
EX requirements.
General information (see also EN 60079-26, section 4.3):
Attention must be paid, if the sensor is installed in the separating wall between Zone 0 and Zone 1.
Then a protection class of at least IP66 or IP67 must be achieved after installation.
When wiring the sensor to the measuring transducer (preferably blue coloured cable), the approved
inductance and capacitance of the measuring transducer must not be exceeded.
The sensors have a two-pole screw or plug connection or cable tail. Attention does not need to be paid
to polarity.
The integration of the sensors without overvoltage protection into the equipotential bonding is not
required. For integration of the sensors with overvoltage protection into the equipotential bonding, a
PA terminal is provided.
III.d … adjustment
No Ex-relevant adjustments are required for operation of the sensors.
III.e … putting into service
Before putting into service, all devices must be checked of right installation and connection. The electrical supply, as well as connected devices, must be checked.
III.f … maintenance (servicing and emergency repair)
The sensors are generally maintenance-free. In case of a defect, the sensors must be sent back to the
manufacturer or one of its representations.
The sensors, in particular the probe tip, may be cleaned. Grease-dissolving cleansing agents can be used
to remove any firmly clinging grease or oil residues. Sharp-edged objects are unsuitable for the purpose
of cleaning since they could damage the sensor.
When performing an insulation test of the intrinsically safe circuit with 500 V under well-controlled conditions, according to EN 60079-25, section 12 it is necessary to disconnect sensors with overvoltage
protection since there is no compliance with the requirements for dielectric strength according to
EN 60079-11, section 6.3.13. For all other sensors, there is compliance between the intrinsically safe
circuit and the chassis or, if present, other intrinsically safe circuits with 500 V
The following electrical input values apply to the sensors:
≤30 V
U
i
I
≤ 200 mA
i
P
≤1 W
i
The effective internal capacitance and inductance that are externally effective, are negligibly small. If the
sensors are supplied with integrated cable, then the electrical characteristics are:
= 200 pF/m
C
c
L
= 1 µH/m
c
L
= 30 µH/Ω
c/Rc
The sensors may be used in the following ambient temperature range:
= -40 °C … +110 °C
T
a
When using a sensor with overvoltage protection, the maximum temperature is +90 °C for the sensor
head.
General information (see also EN 60079-0, section 1):
Zone 0 exists only under atmospheric conditions:
Temperature range: -20 °C … +60 °C
Pressure range: 0.8 bar to 1.1 bar
Oxidants: Air (oxygen content approx. 21 %)
The sensors achieve a housing protection of:
Degree of protection: IP68
The following technical data apply to sensors with overvoltage protection:
The nominal DC spark-over voltage amounts to:
U = 350 V ± 20 %
The nominal impulse discharge current amounts to:
I = 20 kA (10 × Wave 8/20 µs)
The nominal alternating discharge current amounts to:
I = 20 A (10 × @ 50 Hz, 1 s)
The insulation resistance of an overvoltage arrester amounts to:
R > 10 GΩ
VI Specific conditions for use
1. Overfill Prevention Sensor and Level detectors with overvoltage protection do not comply with the
dielectric strength requirements according to EN 60079-11, section 6.3.13. When performing an insulation test of the intrinsically safe circuit it is therefore necessary to disconnect the device.
2. When using the integrated overvoltage protection, integration into the equipotential bonding is re-