PAJ WIO 200B User Manual

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

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WIO 200B

Water in oil sensor

User manual Rev. 1.08

111881-944 Rev. 1.08 WIO200B User manual

Date: 04-02-2016

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Table of contents

Table of contents ......................................................................................................................................................................................... 2

Introduction ...................................................................................................................................................................................................... 3

Safety Advice .................................................................................................................................................................................................. 4

Function ............................................................................................................................................................................................................... 6

Normal operation ......................................................................................................................................................................................... 7

Failure indication .......................................................................................................................................................................................... 8

Self test for alarm functions ............................................................................................................................................................... 9

Before installation .................................................................................................................................................................................... 11

WIO Sensor dimensions in mm..................................................................................................................................................... 14

Terminal box dimensions in mm .................................................................................................................................................. 16

WIO Integrated (WIOI) dimensions in mm ........................................................................................................................ 17

Technical data, Sensors ...................................................................................................................................................................... 19

Technical Data Terminal Box .......................................................................................................................................................... 22

Technical Data Terminal Display Box ....................................................................................................................................... 23

Technical Data Terminal Box Alarm .......................................................................................................................................... 26

Technical Data Terminal Box Alarm Buzzer ........................................................................................................................ 29

Technical data, WIOI (WIO Integrated) ................................................................................................................................ 33

EC-Declaration of Conformity ......................................................................................................................................................... 39

Appendix A1: Install 1 Terminal Box with 1 display ....................................................................................................................... 42

Appendix A2: Install 1 Terminal Box with no display .................................................................................................................... 43

Appendix A3: Install 2 Terminal Boxes with 2 display .................................................................................................................. 44

Appendix A4: Install 2 Terminal Boxes with 1 display .................................................................................................................. 45

Appendix A5: Install 2 Terminal Boxes with 1 display .................................................................................................................. 46

Appendix A6: Install 3 Terminal Boxes with 3 display .................................................................................................................. 47

Appendix A7: Install 3 Terminal Boxes with 2 display .................................................................................................................. 48

Appendix A9: CABLE Specification ............................................................................................................................................. 49

Appendix A10: Error / failure FAQ .............................................................................................................................................. 50

Company Information ........................................................................................................................................................................... 53

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

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Introduction

This user manual provides technical data regarding the WIO (water in
lubrication oil, gear box oil, diesel oil, hydraulic oil or transformer oil) sensor
system. The system consist of a WIO Sensor, terminal box and cables. The
WIO Sensor is an insitu sensor which measures water content in lubrication oils
on ship engine or similar. The Terminal box connects the sensor to power
supply and to the ships surveillance system. The supplied cables are for
connection between the WIO Sensor and the Terminal box

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Safety Advice

For your safety

The WIO200 (WIO) is designed as water in oil monitoring system, with a
relay switch-off function.

Before use please read the user manual and carefully store it in a safe
place. Install and operate the device only after reading and
comprehending the instruction manual, and after you are familiar with the
valid rules on work safety and accident prevention.

Please use the device only as specified. For this purpose please also note
the values in section “Technical data”.

During transport, storage and operation please adhere to the conditions

listed in “Technical data”.

IMPORTANT

Only qualified personnel may assemble start-up and maintain the unit
when it is in a zero voltage state. Only qualified electricians may work on
electrical installations.

The connection and instruction manual contains information that enables
the proper and efficient use of the WIO monitoring system. PAJ Sensors
A/S is not liable for damage caused be improper use of this device. This
manual is an integral part of the basic knowledge necessary for proper use
of the system.

Rights

PAJ Sensors A/S reserves the right to alter its products without prior
notice.

Copying and using the instruction manual for other purposes is only
allowed with the acceptance from PAJ Sensors A/S.

PAJ Sensors A/S accepts no responsibility for possible errors and
deficiencies in brochures, catalogues and other printed material.

PAJ Sensors A/S guarantees correct function as well as fulfillment of the
safety requirements only when connections are made in accordance with
instructions.

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Safety observations

The comments about safety in this document will not discuss safety
observations of individual machine parts where safety devices (usually
safety relays) are applied. Here the respective instruction manuals will be
referenced! This document merely describes how to establish a WIO and
how to start it up.

WARNING

The monitoring system during machine operation cannot be guaranteed if
the system is connected incorrectly or not used as specified. This may lead
to fatal injuries. Interventions and changes to the WIO monitoring system
are not permitted, unless they are explicitly described in this user manual
or be written from PAJ Sensors A/S.

The regional legal regulations and conditions of the liability insurance of
the employer must be maintained.

Area of application

The WIO monitoring system is usually used in engines were a WIO will
monitor the water content in lubrication oil, gear box oil, diesel oil,
hydraulic oil or transformer oil.

The advantage of this monitoring system is the simple 4-20 mA interface
and the two relays indicating alarms, with digital readout.

Normally the WIO sensor is calibrated in Taro30 lubrication oil, if nothing
else are defined from customer.

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Function

Short description of the function

PAJ Sensors A/S has developed a water in oil (WIO) monitoring system.
The fundamental idea of the WIO system is to easily and continuously
monitor the water activity (aw) in oil. The output is converted into a
standard 4-20 mA output.

The system also includes two relays indicating when too much water is
present in the oil. Default alarm values are set to 0,5 aw (high alarm) and
0,9 aw (high high alarm)

By use of the WIO-Software it is possible to change HHA and HA levels.
Furthermore you can continuously read out and graph the aw (or PPM) of
water in the oil.

WARNING

Do not use the sensor or relays to automatically enable/turn on or
disable/shut down engine. The decision to enable/turn on or disable/shut
down an engine, based on the sensor data, must be taken by proper
trained crew personnel, not by the sensor system.

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Normal operation

Water activity (aw) provides the relative availability of water in oil where
pure oil has an activity of zero and oil saturated with distilled water has an
activity of exactly one. Under normal operation the WIO200 continuously
supplies an output analogue signal of 4 to 20 mA corresponding to 0.01 to

1.00 aw. Alarm indications with 0.03 aw hysteresis via 2 relays are
provided for each sensor. These data can also be read out from the sensor
on the RS485 Modbus communication line.

Default alarm values are 0,5 aw and 0,9 aw. Assumes these alarm values:

High alarm on at 0,50 aw (12 mA).
High alarm off at 0,47 aw (11,5 mA)
High high alarm on at 0,90 aw (18,4 mA).
High high alarm off at 0,87 aw (17,9 mA).
High high alarm will disable high alarm, thus only one alarm can be active.

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Failure indication

Internal function failure will be indicated by activating both alarm relays at
the same time, or indicated as defined in the NAMUR NE43.

Internal failures includes:

 Sensor reading out of range.
 Sensor reading CRC error.
 Unstable Sensor reading.

NAMUR NE43 is a German fault detection standard for 4-20mA analogue
signals. It allows the user to know if there is a fault within the instrument,
by sending analogue signal below 4mA and/or above 20mA. In accordance
with NAMUR NE43, the failure is indicated by:

 Fault indicated by analogue output =<2,0 mA

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Self test for alarm functions

On the WIO Sensor there is a button for testing the alarm functions. By pushing the
Test button for 5 sec the high alarm relay turns on, and by pushing the Test button
for 10 sec the high alarm relay turns off and the high high alarm turns on. When the
Test button has been pushed continuously for more than 15 sec, it will be ignored by
the software, and the relays return to normal operation.

Test Button

Mode

Output Relay

Analogue
Output

Un-pressed

Normal operation
and no alarm

Relay 1 Open
Relay 2 Open

Normal

Pressed longer

than 5 sec

Test of high alarm

Relay 1 Closed
Relay 2 Open

Normal

Pressed longer

than 10 sec

Test of high high
alarm

Relay 1 Open
Relay 2 Closed

Normal

Pressed longer

than 15 sec

Normal operation

Normal

Normal

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Test Button

Mode

Output Relay

Analogue
Output

Un-pressed

Normal operation,
with high alarm
active

Relay 1 Closed
Relay 2 Open

Normal

Pressed longer

than 5 sec

Test of high alarm

Relay 1 Closed
Relay 2 Open

Normal

Pressed longer

than 10 sec

Test of high high
alarm

Relay 1 Open
Relay 2 Closed

Normal

Pressed longer

than 15 sec

Normal operation

Normal

Normal

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Before installation

IMPORTANT

Only qualified personnel may assemble and maintain the unit. Only
qualified personnel may install the unit.

Screw in probe pressure-tight directly in the center of the oil pipe where
the measurement is to take place. The threads should be sealed with
Loctite® 271. The sensor should be mounted with max. torque of 35 Nm.
Connect the cables from the WIO sensor to the Terminal box. Use a
hexagon wrench size 30.

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To sensor Power and Alarms

IMPORTANT

Only qualified personnel may assemble start-up and maintain the terminal
box(s) when it is in a zero voltage state. Only qualified electricians may
work on electrical installations.

Install +24 VDC and GND into the terminal box and connect the 4-20 mA
to an external device if needed. Connect the relay to external device if
needed.

If the terminal box has a (aw) or PPM display, there must be a short circuit
between terminals 11 and 12. This short circuit produces the needed
closed loop for mA measurement.

If the terminal box has a °C or °F display, there must be a short circuit
between terminals 9 and 10. This short circuit produces the needed closed
loop for mA measurement. Only for WIO and WIOI 300/400/500

After installing the WIO-Software can PC and terminal box be connected
through DB9 connector. Only for WIO and WIOI 300/400/500

Last connect the cables from the Terminal box to the sensor.

It is allowed (but not necessary) to connect screw terminal 10 and 12 “­4-20 mA” to screw terminal 14 “GND”, thus creating common ground for
the output and the power.

Terminal boxes with display. Screw terminal pin 11 and 12 or screw
terminal pin 9 and 10 can be connected to external equipment, but only in
a closed loop for mA measurement.

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Terminal Box Connection

Contact Assignment

There is only one connector CN3 for using of the terminal box contacts.

For
con

nection more than one terminal box please refer to:

- Appendix A1

- Appendix A2

- Appendix A3

Contact­Number

Description

9

+4 – 20 mA positive analog output signal for indication of temperature in oil.
This option is not available for WIO200

Only for WIO and WIOI 300/400/500

10

-4 – 20 mA return analog signal for indication of temperature in oil.
This option is not available for WIO200

Only for WIO and WIOI 300/400/500

11

+4 – 20 mA positive analog output signal for indication of aw or PPM in oil.

12

-4 – 20 mA return analog signal for indication of aw or PPM in oil.

13

Power supply, 24VDC ±10% and with max. residual voltage ripple 10%

14

Power supply ground terminal contact

15

Relay contact for HH Alarm

16

Relay contact for HH Alarm

17

Relay contact for H Alarm

18

Relay contact for H Alarm

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WIO Sensor dimensions in mm

WIO Standard ½” thread Sensor, Short dimensions in mm:

30mm Wrench max. torque 35 Nm

WIO Standard ¾” thread Sensor, Short dimensions in mm:

30mm Wrench max. torque 35 Nm

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WIO Ball Valve pipe ½” thread Sensor, Long dimensions in mm:

30mm Wrench max. torque 35 Nm

WIO Ball Valve pipe ¾” thread Sensor, Long dimensions in mm:

30mm Wrench max. torque 35 Nm

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Terminal box dimensions in mm

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WIO Integrated (WIOI) dimensions in mm

WIOI Sensor, short pipe, ½” thread, dimensions in mm:

WIOI Sensor, long pipe, ½” thread, dimensions in mm:

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WIOI Sensor, long pipe, ¾” thread, dimensions in mm:

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Technical data, Sensors

WIO Standard ¾” (ISO 228-1 G¾”), Short

WIO Standard ½” (ISO 228-1 G½”), Short

WIO Ball Valve pipe, Long

Output

Analogue output (galvanic isolated)

4 – 20 mA for a

w

Max. Load (analogue output)

< 500Ω

Measurement Range (4 – 20 mA)

0,01 – 1,00 aw

Accuracy (0,05-0,95 aw)

± 0,03 a

w

Accuracy (outside 0,05-0,95 aw)

± 0,05 aw

Resolution

< 0,004 aw

Input

Supply nominal voltage

24V DC ± 10%

Max. residual voltage ripple

10%

Maximum Load current

200 mA

Max. Power input

< 4,8 VA

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Relays

Contact arrangement

2 x Normally Closed (NC)

Rated voltage

60V

Rated current (40C)

1A

Max. DC Load breaking capacity

Relay 1

„High Alarm“

Relay 2

„High High Alarm“

Default High Alarm

0,50 aw

Default High High Alarm

0,90 aw

Socket specification

Connector design

1x male socket, 1x female socket

Connector locking system

Screw-locking, M12x1

Wire gauge

0,25 mm2

Contacts

8 Pol

Rated voltage

60V

Rated current (40C)

1A

Cable specification

Cable design

Multipair overall screened cable

Outlet diameter

9,9 mm

Voltage class

0,6/1kV

Wires

4x2 twisted pair

Wire gauge

0,75 mm2

Media for measurement

Lubrication oil

Grade SAE 30/TBN 5-10

Max. Oil temperature

90°C

Max. Oil pressure

Sensor mounting method in application:
Ball valve mounted: Max. 10 Bar
Thread mounted: Max. 20 Bar

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Response times

Delay before valid data from start-up

< 30 s

Delay before valid data from installation
(first use)

10 minutes
Device Failure Indication

Analogue output

< 2 mA

Manual test

Press sensor test button for 5 seconds

High Alarm turns on for 5 seconds

Press sensor test button for 10 seconds

High Alarm turns off
High High Alarm turns on for 5 seconds

Press sensor test button for 15 seconds

Normal operating and test button ignored

Miscellaneous

Ambient Temperature, running / storage

0 - 90°C / -30 - +95°C

Relative humidity for running and storage

10% up to 95%, no condensation

Re calibration

Recommended with max 3 years interval

Warranty

2 years

Approvals

Germanischer Loyd

WIO products are EU approval under 75 965 –
09 HH date 2009-11-30

Enclosure

Weight for WIO standard

650 grams

Weight for WIO Ball valve pipe

790 grams

Connection (mechanical)

ISO 228-1 G ½” or ¾” thread
2 x 8-pole connectors, male and female,

M12x1 thread

Enclosure material

Stainless Steel/Aluminum EN44100 (Former

4261)

Protective type

IP66

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Technical Data Terminal Box

FUNCTIONING

Terminal box shall be provided with 24vdc.
Terminal box supply 24vdc on to WIO sensor.
WIO sensor delivers mA, digital values and relay status to the terminal
box.

Output

Analogue output

See the specifications for sensor’s analogue
output

Digital output

See the specifications for sensor’s digital

output

Input

Supply nominal voltage

24V DC ± 10%

Max. residual voltage ripple

10%

Maximum Load current

200 mA

Max. Power input

< 4,8 VA

Relays

Contact arrangement

2 x Normally Open (NO)

Rated voltage

250 VAC

Max. switching voltage

400VAC

Rated current

2A

Breaking capacity max.

1250VA

Enclosure

Weight

650 grams

Connection to sensor (mechanical)

2 x 8-pole connectors, male and female,
M12x1 thread

Connection (mechanical)

2 x M20 gland, cable diameter 6 to 12 mm

Enclosure material

Aluminum

Protective type

IP66

Warranty

2 years

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Technical Data Terminal Display Box

Output

Analogue output

See the specifications for sensor’s analogue output

Digital output

See the specifications for sensor’s digital output

Input

Supply nominal voltage

24V DC ± 10%

Max. residual voltage ripple

10%

Maximum Load current

200 mA

Max. Power input

< 4,8 VA

Relays

Contact arrangement

2 x Normally Open (NO)

Rated voltage

250 VAC

Max. switching voltage

400VAC

Rated current

2A

Breaking capacity max.

1250VA

Display version - aw (water activity from 0,01 to 1,00)

Accuracy (0,05-0,95 aw)

± 0,03 aw

Resolution

<0,004 aw

Display version - PPM (H20)

Accuracy (0,05-0,95 aw)

±30%

Resolution

1 PPM

Enclosure

Weight

650 grams

Connection to sensor (mechanical)

2 x 8-pole connectors, male and female, M12x1 thread

Connection (mechanical)

2 x M20 gland, cable diameter 6 to 12 mm

Enclosure material

Aluminum

Protective type

IP66

Warranty

2 years

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FUNCTIONING

Terminal box shall be provided with 24vdc.
Terminal box supply 24vdc on to WIO sensor.
Terminal box measuring mA from the sensor, and convert it to aw or PPM
value.
WIO sensor delivers mA, digital value and relay status to the terminal box.

IMPORTANT

The display is an indication of the water level in the oil. Display can be
shipped as PPM or aw.

Upon ordering a PPM display the customer must specify the water
saturation point in PPM of the used oil at the preferred working
temperature of the oil. The saturation point is typically between 3000­10000 PPM. Alternatively the customer can ship 10 liters of oil to PAJ
Sensor A/S for inspection including specification of the working oil
temperature.

WARNING

All displays will show from positive values when operating properly. There
will appear a negative value during start-up, after 5 seconds the value will
be in positive measurement range. Otherwise, if a negative value is
present the Terminal box might have been installed incorrectly.

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NOTE

WIO200 uses 3 different units for the measurement of water in oil:

1) a

w

: WIO measures humidity in aw. The range is 0.01…1.00 aw.

2) %RH (relative humidity) is identical to the unit a

w

multiplied by

100. The range is 1…100 %RH

3) ppm: WIO can convert a

w

to ppm. In this case the saturation point,
at a given temperature, must be known. Output in ppm is only
reliable at this temperature.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 26 af 53

Technical Data Terminal Box Alarm

Output

Analogue output

See the specifications for sensor’s analogue output

Digital output

See the specifications for sensor’s digital output

Input

Supply nominal voltage

24V DC ± 10%

Max. residual voltage ripple

10%

Maximum Load current

200 mA

Max. Power input

< 4,8 VA

Relays

Contact arrangement

2 x Normally Open (NO)

Rated voltage

250 VAC

Max. switching voltage

400VAC

Rated current

2A

Breaking capacity max.

1250VA

Buzzer

Oscillation frequency

3000±500 Hz

Sound pressure level

85db by open housing

Tone

Pulsed

Button with LED

Blink frequency

2 Hz

Color

RED

Enclosure

Weight

530 grams

Connection to sensor (mechanical)

2 x 8-pole connectors, male and female, M12x1 thread

Connection (mechanical)

2 x M20 gland, cable diameter 6 to 12 mm

Enclosure material

Aluminum

Protective type

IP66

Warranty

2 years

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 27 af 53

FUNCTIONING

Terminal box shall be provided with 24vdc.
Terminal box supply 24vdc on to WIO sensor.
Terminal box indicate the relay status from the WIO sensor.
WIO sensor delivers mA, digtal values and relay status to the terminal
box.

H-Alarm LED is for indication of the High Alarm relay state from the WIO
sensor. When the alarm condition is generated by the WIO sensor, then
the High Alarm relay is open and the H-Alarm LED flash red ON/OFF
sequence to show the High Alarm state, and the alarm signal buzzer will
be switched ON.

HH-Alarm LED is for indication of the High High Alarm relay state from the
WIO sensor. When the alarm condition is generated by the WIO sensor,
then the High High Alarm relay is open and the HH-Alarm LED flash red
ON/OFF sequence to show the High High Alarm state, and the alarm signal
buzzer will be switched ON.

The H-Alarm LED or HH-Alarm LED will stay in blinking mode until the H­Alarm or HH-Alarm button is pressed, then the LED constantly turned on.
The alarm signal buzzer will stay on until the H-Alarm or HH-Alarm button
is pressed.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 28 af 53

Abstract representation of the H-Alarm and HH-Alarm button and LED
function:

t

0,5

0,9

a

w

HA-LED

off

HHA-LED

off

flashing

HA-Button pressed

HHA-Button pressed

ON

OFF

flashing

flashing

ON

flashing

H-Alarm Relay

HH-Alarm Relay

Figure 1: H-Alarm and HH-Alarm button function

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 29 af 53

Technical Data Terminal Box Alarm Buzzer

Output

Analogue output

See the specifications for sensor’s analogue

output

Digital output

See the specifications for sensor’s digital

output

Input

Supply nominal voltage

24V DC ± 10%

Max. residual voltage ripple

10%

Maximum Load current

200 mA

Max. Power input

< 4,8 VA

Relays

Contact arrangement

2 x Normally Open (NO)

Rated voltage

250 VAC

Max. switching voltage

400VAC

Rated current

2A

Breaking capacity max.

1250VA

Display version - aw (water activity from 0,01 to 1,00)

Accuracy (0,05-0,95 aw)

± 0,03 aw

Resolution

<0,004 aw

Display version - PPM (H20)

Accuracy (0,05-0,95 aw)

±30%

Resolution

1 PPM

Buzzer

Oscillation frequency

3000±500 Hz

Sound pressure level

85db by open housing

Tone

pulsed

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 30 af 53

FUNCTIONING

Terminal box shall be provided with 24vdc.
Terminal box supply 24vdc on to WIO sensor.
Terminal box measuring mA from the sensor, and convert it to aw or PPM
value.
WIO sensor delivers mA, digital values and relay status to the terminal
box.

H-Alarm LED is for indication of the High Alarm relay state from the WIO
sensor. When the alarm condition is generated by the WIO sensor, then
the High Alarm relay is open and the H-Alarm LED flash red ON/OFF
sequence to show the High Alarm state, and the alarm signal buzzer will
be switched ON.

HH-Alarm LED is for indication of the High High Alarm relay state from the
WIO sensor. When the alarm condition is generated by the WIO sensor,
then the High High Alarm relay is open and the HH-Alarm LED flash red
ON/OFF sequence to show the High High Alarm state, and the alarm signal
buzzer will be switched ON.

The H-Alarm LED or HH-Alarm LED will stay in blinking mode until the H­Alarm or HH-Alarm button is pressed, then the LED constantly turned on.
The alarm signal buzzer will stay on until the H-Alarm or HH-Alarm button
is pressed.

Button with LED

Blink frequency

2 Hz

Color

RED

Enclosure

Weight

650 grams

Connection to sensor (mechanical)

2 x 8-pole connectors, male and female,
M12x1 thread

Connection (mechanical)

2 x M20 gland, cable diameter 6 to 12 mm

Enclosure material

Aluminum

Protective type

IP66

Warranty

2 years

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 31 af 53

Abstract representation of the H-Alarm and HH-Alarm button and LED
function:

t

0,5

0,9

a

w

HA-LED

off

HHA-LED

off

flashing

HA-Button pressed

HHA-Button pressed

ON

OFF

flashing

flashing

ON

flashing

H-Alarm Relay

HH-Alarm Relay

Figure 2: H-Alarm and HH-Alarm button function

IMPORTANT

The display is an indication of the water level in the oil. Display can be
shipped as PPM or aw.

Upon ordering a PPM display the customer must specify the water
saturation point in PPM of the used oil at the preferred working
temperature of the oil. The saturation point is typically between 3000­10000 PPM. Alternatively the customer can ship 10 liters of oil to PAJ
Sensor A/S for inspection including specification of the working oil
temperature.

WARNING

All displays will show from positive values when operating properly. There
will appear a negative value during start-up, after 5 seconds the value will
be in positive measurement range. Otherwise, if a negative value is
present the Terminal box might have been installed incorrectly.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 32 af 53

NOTE

WIO200 uses 3 different units for the measurement of water in oil:

1) a

w

: WIO measures humidity in aw. The range is 0.01…1.00 aw.

2) %RH (relative humidity) is identical to the unit a

w

multiplied by

100. The range is 1…100 %RH

3) ppm: WIO can convert a

w

to ppm. In this case the saturation point,
at a given temperature, must be known. Output in ppm is only
reliable at this temperature.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 33 af 53

Technical data, WIOI (WIO Integrated)

Output

Analogue output (galvanic isolated)

4 – 20 mA for a

w

Max. Load (analogue output)

< 500Ω

Measurement Range (4 – 20 mA)

0,01 – 1,00 aw

Accuracy (0,05-0,95 aw)

± 0,03 aw

Accuracy (outside 0,05-0,95 aw)

± 0,05 a

w

Resolution

< 0,004 aw

Input

Supply nominal voltage

24V DC ± 10%

Max. residual voltage ripple

10%

Maximum Load current

200 mA

Max. Power input

< 4,8VA

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 34 af 53

Relays

Contact arrangement

2 x Normally Open (NO)

Rated voltage

250VAC

Max. switching voltage

400VAC

Rated current

2A

Breaking capacity max.

1250VA

Max. DC Load breaking capacity

Relay 1

„High Alarm“

Relay 2

„High High Alarm“

Default High Alarm

0,50 aw

Default High High Alarm

0,90 aw

Cable specification

Cable design

Multipair overall screened cable

Outlet diameter

9,9 mm

Voltage class

0,6/1kV

Wires

4x2 twisted pair

Wire gauge

0,75 mm2

Media for measurement

Lubrication oil

Grade SAE 30/TBN 5-10

Max. Oil temperature

90°C

Max. Oil pressure

Sensor mounting method in application:
Ball valve mounted: Max. 10 Bar
Thread mounted: Max. 20 Bar

Response times

Delay before valid data from start-up

< 30 s

Delay before valid data from installation
(first use)

10 minutes

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 35 af 53

Device Failure Indication

Analogue output

< 2 mA

Manual test

Press sensor test-button for 5 seconds

High Alarm turns on for 5 seconds

Press sensor test-button for 10 seconds

High Alarm turns off
High High Alarm turns on for 5 seconds

Press sensor test-button for 15 seconds

Normal operating and test button ignored

Display version - aw (water activity from 0,01 to 1,00)

Accuracy (0,05-0,95 aw)

± 0,03 aw

Resolution

<0,004 aw

Display version - PPM (H20)

Accuracy (0,05-0,95 aw)

±30%

Resolution

1 PPM

Buzzer

Oscillation frequency

3000±500 Hz

Sound pressure level

85db by open housing

Tone

pulsed

Button with LED

Blink frequency

2 Hz

Color

RED

Enclosure

Weight

4000 grams

Connection (mechanical)

ISO 228-1 G ½” or ¾” thread
2 x gland M20, cable diameter 6 to 12 mm

Enclosure material

Stainless Steel/Aluminum EN44100 (Former

4261)

Protective type

IP66

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 36 af 53

FUNCTIONING

Terminal box shall be provided with 24vdc.
Terminal box supply 24vdc on to WIO sensor.
Terminal box measuring mA from the sensor, and convert it to aw or PPM
value.
WIO sensor delivers mA, digital values and relay status to the terminal
box.

H-Alarm LED is for indication of the High Alarm relay state from the WIO
sensor. When the alarm condition is generated by the WIO sensor, then
the High Alarm relay is open and the H-Alarm LED flash red ON/OFF
sequence to show the High Alarm state, and the alarm signal buzzer will
be switched ON.

HH-Alarm LED is for indication of the High High Alarm relay state from the
WIO sensor. When the alarm condition is generated by the WIO sensor,
then the High High Alarm relay is open and the HH-Alarm LED flash red
ON/OFF sequence to show the High High Alarm state, and the alarm signal
buzzer will be switched ON.

The H-Alarm LED or HH-Alarm LED will stay in blinking mode until the H­Alarm or HH-Alarm button is pressed, then the LED constantly turned on.
The alarm signal buzzer will stay on until the H-Alarm or HH-Alarm button
is pressed.

Miscellaneous

Ambient Temperature, running / storage

0 - 90°C / -30 - +95°C

Relative humidity for running and storage

10% up to 95%, no condensation

Re calibration

Recommended with max 3 years interval

Warranty

2 years

Approvals

Germanischer Loyd

WIO products are EU approval under 75 965 –
09 HH date 2009-11-30

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 37 af 53

Abstract representation of the H-Alarm and HH-Alarm button and LED
function:

t

0,5

0,9

a

w

HA-LED

off

HHA-LED

off

flashing

HA-Button pressed

HHA-Button pressed

ON

OFF

flashing

flashing

ON

flashing

H-Alarm Relay

HH-Alarm Relay

Figure 2: H-Alarm and HH-Alarm button function

IMPORTANT

The display is an indication of the water level in the oil. Display can be
shipped as PPM or aw.

Upon ordering a PPM display the customer must specify the water
saturation point in PPM of the used oil at the preferred working
temperature of the oil. The saturation point is typically between 3000­10000 PPM. Alternatively the customer can ship 10 liters of oil to PAJ
Sensor A/S for inspection including specification of the working oil
temperature.

WARNING

All displays will show from positive values when operating properly. There
will appear a negative value during start-up, after 5 seconds the value will
be in positive measurement range. Otherwise, if a negative value is
present the Terminal box might have been installed incorrectly.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 38 af 53

NOTE

WIOI200 uses 3 different units for the measurement of water in oil:

1) a

w

: WIO measures humidity in aw. The range is 0.01…1.00 aw.

2) %RH (relative humidity) is identical to the unit a

w

multiplied by

100. The range is 1…100 %RH

3) ppm: WIO can convert a

w

to ppm. In this case the saturation point,
at a given temperature, must be known. Output in ppm is only
reliable at this temperature.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 39 af 53

EC-Declaration of Conformity

PAJ Group, Grundtvigs Allé 163, DK-6400 Sønderborg, Denmark

Manufactory
Declare under our sole responsibility that the product:

unit identification: product classification:

WIO200 – WIO300 – WIO400 – WIO500 Water In Oil measuring instrument

is a safety tested component according to EC Guideline:

2004/108/EC Electromagnetic compatibility
2006/95/EC Low voltage directive

to which this declaration relates is in conformity with the following standard(s) or other normative documents(s):

IEC 61326-1:2006-11-03, EN 61010-1:2001, EN 60529 Edition 2.1 2001-02,
IEC 60068-1:1988, IEC 60068-2-2:2007, IEC 60068-2-1:2007, IEC 60068-2-30:2005,
IEC 60068-2-6:2007, IEC 61000-4-16:1998-01, IEC 61000-4-6:2007, IEC 61000-4-3:2006,
IEC 61000-4-5:2005, IEC 61000-4-2:2001, IEC 61000-4-4:2004

The described product corresponds to the following European Directives:

2004/108/EC Electromagnetic compatibility
2006/95/EC Low voltage directive

Consistency of a production sample device with the marked product in accordance with the Directives No:

2004/108/EC Electromagnetic compatibility
2006/95/EC Low voltage directive

Notified agency/Address: Germanischer Lloyd AG Head Office
Deputy Head of Department

Automation, Navigation and Communication (MC-EA)
Vorsetzen 35

D-20459 Hamburg/Germany

75 956 – 09 HH 2009-11-30

Certification number Date of issue

The marked product is consistent with the examined production sample device.

Technical documentation:

Poul Jessen

______________________________________________________________________
Grundtvigs Allé 163 • DK-6400 Sønderborg • Tel: [phone] • E-Mail: [e-mail]

Sønderborg, 15.04.2011 Poul Jessen, Managing Director

Date of issue Name and signature

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 40 af 53

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 41 af 53

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 42 af 53

Appendix A1: Install 1 Terminal Box with 1 display

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 43 af 53

Appendix A2: Install 1 Terminal Box with no display

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 44 af 53

Appendix A3: Install 2 Terminal Boxes with 2 display

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 45 af 53

Appendix A4: Install 2 Terminal Boxes with 1 display

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 46 af 53

Appendix A5: Install 2 Terminal Boxes with 1 display

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 47 af 53

Appendix A6: Install 3 Terminal Boxes with 3 display

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

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03-01-0501-CRJ-04 Side 48 af 53

Appendix A7: Install 3 Terminal Boxes with 2 display

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

Tel: [phone] • Fax: [phone] • CVR: 3459-1229 • www.paj.dk • e-mail: [e-mail]

APPROVALS: ISO 9001, ISO 14001, ISO 13485, IEC 61340-51 & IPC-A-610 CLASS 3

03-01-0501-CRJ-04 Side 49 af 53

Appendix A9: CABLE Specification

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

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03-01-0501-CRJ-04 Side 50 af 53

Appendix A10: Error / failure FAQ

Failure
type

Description

Possible reasons

PPM display
failure

Display shows only negative
numbers

1. Sensor is not connected.

2. The error caused by missing
jumper in terminal box pin 11 and
pin 12. See Appendix A1

3. Check that the jumper is
properly installed, it is seen that
the jumper has been installed but
the jumper had no proper
connection

4. The wires are reversed in
terminal box pin 7 and pin 8 lower
part. After changing and there is no
change in the display, then the
fault is either 1, 2 or 3.

a

w

display

failure

Dispay shows only negative
numbers

1. Sensor is not connected.

2. The error caused by missing
jumper in terminal box pin 11 and
pin 12. See Appendix A1

3. Check that the jumper is
properly installed, it is seen that
the jumper has been installed but
the jumper had no proper
connection

4. The wires are reversed in
terminal box pin 7 and pin 8 lower
part. After changing and there is no
change in the display, then the
fault is either 1, 2 or 3.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

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03-01-0501-CRJ-04 Side 51 af 53

Dead
display

Display indicate nothing

Maybe is 24V dc supply interrupted
to the display. There shall be 24V
dc at this connector.

Relay

Relay-state while alarm is on

Sensor

How to check the mA output from
sensor?

Remove jumper in pin 11 and pin

12. In order to ensure that there
can be measured mA must pin 11
and pin 12 must be screwed.
Remember to set the measuring
instrument in dc mA and connect
test leads correctly in the
measuring instrument. Sensor is
alright when measuring a value
between 4 and 20 mA. Is the result
about 2 mA then there is an
internal sensor error, so the sensor
must be sent for repair. Is the
result 0 mA, tjek if the sensor get
24 Vdc power.

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

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03-01-0501-CRJ-04 Side 52 af 53

Dip Switch

a

w

Are the dip switches still
positioned correctly?

Correct positions:

Dip Switch
PPM

Are the dip switches still
positioned correctly?

Correct positions:

Broken
cables
between
Sensor and
terminal
box

No mA will can be measured on:

Analog 1: Terminal 11 and 12
and
Analog 2: Terminal 9 and 10

PAJ Sensor A/S • Grundtvigs Allé 163 • DK-6400 Sønderborg

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03-01-0501-CRJ-04 Side 53 af 53

Company Information

PAJ Sensor A/S
Grundtvigsallé 163
DK-6400 Sønderborg
Tel: [phone]
Mail: [e-mail]