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TRANSFORMER COMPONENTS

Liquid level indicator

Instruction manual

Contents

1. Safety

1.1 Safety instructions

1.2 Specified applications

1.3 Safety notes on the equipment operation

2. Drawings 3

2.1 Comem OLI

2.2 Comem eOLI

3

3

2.3 Mounting flange

2.3.1 Comem OLI/eOLI (radial)

2.3.2 Comem OLI/eOLI (axial)

2.3.3 Comem OLI22 / eOLI22 (radial)

4

5

4

4

2.3.4 Comem OLI22 / eOLI22 (axial)

2.4 Comem L140

2.4.1 Radial

2.4.2 Axial

2.5 Comem L220

2.6 Comem L340

2.7 Comem eViewer

5

6

6

7

8

9

2

2

2

2

3. Operating principle 10

3.1 Functioning 10

3.2. Outputs

3.3 Technical features

3.3.1 Microswitches

3.4 Tests

10

10

10

11

4. Installation 12

4.1 Float assembly

4.1.1 LA version (radial)

12

12

4.1.2 LB version (axial) 12

4.2 Liquid level indicator: general information 13

4.3 Comem L140

4.4 Comem OLI / eOLI

14

14

4.5 Comem OLI22 / eOLI22 (with special flange) 15

4.6 Comem L220 15

4.7 Comem L340

4.8 Comem eViewer

16

16

5. Electrical connection 17

5.1 Micro-switches wiring

5.2 Analog output and Modbus communication

18 wiring (for Comem eOLI and Comem eOLI22) 18

5.2.1 Power voltage 18

5.2.2 Analog output

5.2.3 Modbus communication (optional)

5.3 Comem eViewer wiring

5.3.1 Power voltage

5.3.2 Analog input 18

5.3.3 Comem eViewer – Comem eOLI connections 19

18

18

18

18

6 Operation and maintanence 20

6.1 Operation

6.2 Maintenance

6.3 Storage

20

20

20

A. Appendix A: MODBUS communication 21

A.1 MODBUS register

A.1.1 MODBUS address

21

21

2

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1. Safety

LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

1.1 Safety instructions

Make sure that any person installing:

• Are technically qualified and competent.

• Fully comply with these assembling instructions.

Improper operations or misuse could cause danger to:

• Life and limb.

• To the equipment and other assets of the operator.

• To the equipment proper, function.

Safety instructions in this manual are shown in three different forms to emphasize important information.

WARNING

1.2 Specified applications

The liquid level indicator is used in oil-insulated transformer to indicate the conservator tank oil level. Inside the device are usually installed up to four micro-switches to signal some critical oil levels.

The micro-switches can give alarm or transformer power off signals.

It is important to observe the limit values indicated on the nameplate and in the manual before commissioning the device.

1.3 Safety notes on the equipment operation

Electrical installation is subject to the relevant national safety rules.

It is mandatory to connect the grounding cable because of safety reason.

THIS INFORMATION INDICATES PARTICULAR

DANGER TO LIFE AND HEALTH. DISREGARDING

SUCH A WARNING CAN LEAD TO SERIOUS OR

FATAL INJURY.

CAUTION

CAUTION

THIS INFORMATION INDICATES PARTICULAR

DANGER TO EQUIPMENT AND/OR OTHER

PROPERTY OF THE USER. SERIOUS OR FATAL

INJURY CANNOT BE EXCLUDED.

INSTALLATION, ELECTRICAL CONNECTION AND

FITTING THE DEVICE HAVE TO BE CARRIED OUT

BY QUALIFIED PERSONNEL AND ONLY IN

ACCORDANCE TO THIS INSTRUCTION MANUAL.

IT IS RESPONSIBILITY OF THE USER TO MAKE

SURE THAT THE DEVICE IS USED FOR SPECIFIED

APPLICATION ONLY.

FOR SAFETY MATTERS, PLEASE AVOID ANY

UNAUTHORIZED AND IMPROPERLY WORKS.

NOTE

THIS NOTE GIVES IMPORTANT AND SPECIFIC

INFORMATION CONCERNING THE EQUIPMENT.

WARNING

ALL RELEVANT FIRE REGULATION MUST BE

STRICTLY OBSERVED.

TRANSFORMER COMPONENTS

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2. Drawings

2.1 Comem OLI

Figure 1

2.2 Comem eOLI

Figure 2

3

4 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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2. Drawings

2.3 Mounting flange

2.3.1 Comem OLI/Comem eOLI (radial)

Figure 3

2.3.2 Comem OLI/ Comem eOLI (axial)

Figure 4

TRANSFORMER COMPONENTS

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2. Drawings

2.3.3 Comem OLI22 / Comem eOLI22 (radial)

Figure 5

2.3.4 Comem OLI22 / Comem eOLI22 (axial)

Figure 6

NOTE

“4 HOLES” MOUNTING FLANGE MAY BE

DESIGNED IN ACCORDANCE WITH CUSTOMER’S

NEED: UPON REQUEST, SEVERAL HOLE

PATTERNS ARE AVAILABLE.

5

6 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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2. Drawings

2.4 Comem L140

2.4.1 Radial

Figure 7

2.4.2 Axial

Figure 8

TRANSFORMER COMPONENTS

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2. Drawings

2.5

Comem L220

2.5.1 Radial

Figure 9

2.5.1 Axial

Figure 10

7

8 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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2. Drawings

2.6

Comem L340

2.6.1 Radial

Figure 11

2.6.1 Axial

Figure 12

TRANSFORMER COMPONENTS

2.7

Comem eViewer

9

Figure 13

10 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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3. Operating principle

3.1 Functioning

The level gauge with magnetic joint is composed of a sturdy, watertight body made of aluminum alloy powder coated to protect against corrosion.

The movement of the float rod and the pointer takes place thanks to magnetic coupling and reaches a

120° angle. In this way, for every variation of the oil inside the conservator tank the movement of the float cause the rotation of the magnet joint with consequent variation of the indication on the dial of the gauge.

The pointer indicate the level that the oil should reach at the temperatures printed on the dial.

The electronic version of the oil level gauge provide an analogical and a digital signal proportional to the oil level inside the conservator. These signals can be remote to: PLC, PC, integrated monitoring system,

Remote Indicator.

An electronic level indicator equipped with 4-20 mA output signal can be coupled with the electronic

Viewer. This device replicate the value of oil level

(0-100%) at man-height.

3.2. Outputs

STANDARD

(Comem OLI-

ComemL140)

MICRO-SWITCHES

OPTIONS (Comem eOLI) ANALOG OUTPUT

COMMUNICATION PORT RS-485

Table 1

3.3 Technical features

STANDARD CONFIGURATION

1, 2 or 4 change over contact (Fig.16)

4-20 mA (terminals 6-7) (Fig.17)

Maximum resistance: 450 Ohm

Modbus communication (terminals 3-4) (Fig.17)

Material

Dial

Standard color

Ambient temperature

Oil temperature

Degree of protection

Standard cable gland

Wires

All the external parts are resistant transformer oils, salt fog and UV rays.

Tempered glass / Polycarbonate

RAL 7032**

-40°C up to +80°C

-40°C up to +120°C

IP66 according to EN60529 (Comem L340 available only IP65)

1 x M25x1.5 Comem OLI – Comem OLI22 – Comem L140 – Comem eViewer

3 x M25x1.5 Comem eOLI – Comem eOLI22

Max 2.5mm

2 – advised 4x1mm 2 o 6x1mm 2 shielded twisted pair cable

Electronic board features, only for eOLI

Power supply (terminals 1-2) 24 Vdc ±10% polarized

Power consumption

Analogical output (terminals 6-7)

Distance for analogical output

Digital output (terminals 3-4)

Distance for digital output

Ventilation Valve

1,5 W

4-20 mA (dielectric strength between electronic card and analogical output: 2kV)

Maximum resistance: 450 Ω

Accuracy : 2.5 % of full scale

Max 30 m / 98 ft (for different demands contact ABB)

Serial RS485 Modbus RTU (for more information contact ABB)

Max 30 m / 98ft (for different demands contact ABB) n.1 to prevent the formation of condensation

Electronic board features, only for Viewer

Power supply (terminals 1-2) 24 Vdc ±10% polarized

Analogical input (terminals 3-4)

Distance for analogical input

Ventilation Valve

4-20 mA

Max 30 m / 98 ft (for different demands contact ABB) n.1 to prevent the formation of condensation

** For critical environmental conditions please contact ABB

Table 2

3.3.1 Microswitches

Breaking and making capacity

Voltage

24V DC to 220V DC

230 VCA

Table 3

Uninterrupted current (making capacity)

2A

2 A

Interrupted current (breaking capacity)

100mA L/R < 40

2 A cosφ > 0.5

TRANSFORMER COMPONENTS

— O I L LE V EL I N D I C ATO R - INSTRUCTION MANUAL

3. Operating principle

NOTE

FOR COMEM EOLI

EXPECTED USE : EXTERNAL

MAXIMUM ALTITUDE : 2000 M

MAXIMUM HUMIDITY : 80%

POLLUTION LEVEL : GRADE III

Other values may be agreed between purchaser and supplier. The minimum contact life shall be 1.000 operations.

3.4 Tests

Description

Fast transient/burs immunity test

(EN 55022)

Conducted disturbances

Electrostatic discharge

Surge immunity test

Magnetic field immunity test

Power frequency magnetic field

Reference standard

IEC 61 000-4-4

IEC 61 000-4-6

IEC 61 000-4-6

IEC 61 000-4-2

IEC 61 000-4-5

IEC 61 000-4-3

IEC 61 000-4-8

Description

Emission standard

Harmonic current emission

Harmonic current emission

Voltage fluctuations and flicker

Vibration Test

Vibration Test

-

Reference standard

IEC 61 000-6-3

EN 61000-3-2

EN 61000-3-2

EN 61000-3-3

CEI EN 60721-3-4 (Class 4M4)

IEC 60068-3-3

-

11

12 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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4. Installation

4.1 Float assembly

4.1.1 LA version (radial)

Screw the arm (Fig 14/A) into the hole of the backside shaft and block it with the M4 nut

(Fig.14/B).

A

B

Figure 14

4.1.2 LB version (axial)

Insert the arm into the slot (Fig.15/A) on the backside shaft with and block it with the M5 nut

(Fig.15/B).

CAUTION

THE OPERATING AND THE INSTALLATION

REQUIREMENTS DESCRIBED IN THIS MANUAL

MUST BE STRICTLY FOLLOWING. IF NOT, THE

DEVICE CAN BE DAMAGED OR A MALFUNCTION

CAN OCCUR.

Figure 15

A B

TRANSFORMER COMPONENTS

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4. Installation

4.2 Liquid level indicator: general

information

Depending on the conservator design, the level gauge can have different values of the parameters R and S (Fig.16) according to the table 4.

LA LB

Table 4a

CAUTION

VERIFY CONTACT SURFACE OF THE

CONSERVATOR. IT MUST BE WELL LEVELED

WITH A GOOD DEGREE OF ROUGHNESS (RA=3.2

MICROMETER).

VERIFY AND IN CASE REMOVE ALL WELDING

BURRS TO ENSURE THAT THE WELDING WILL

NOT INTERFERE WITH THE HOUSING FLANGE

HOLES.

DURING THE FLANGE ASSEMBLY, ABB ADVICE

TO APPLY A FEW DROPS OF CYANOACRYLATE

GLUE ON THE GASKET TO FIX IT AT THE OIL

LEVEL FLANGE. THIS ACTION GUARANTEES A

GOOD GASKET POSITIONING AND IT

FACILITATES THE ASSEMBLY

APPLY A SPECIFIC TIGHTENING TORQUE (MAX

20 NM) ON THE NUTS FOLLOWING A CROSS

SEQUENCE.

13

NOTE

FOR THE LB CONFIGURATION ABB ADVICE TO FIT

IT IN THE CENTER OF THE CONSERVATOR (S=0

MM)

- “S”: parameter that indicates an offset from the vertical conservator axis [mm]. It is available for LA (radial) configuration.

- “R”: parameter that indicates the length of the rod [mm]. It is available for LA (radial) and LB (axial) configurations.

- “ØDC”: conservator diameter [mm].

Figure 16

14 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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4. Installation

4.3 Comem L140

Insert the arm with float through the machined hole on the conservator. Place the o-ring on the slot behind the gauge. Insert the device on the threaded pin of the conservator flange (Fig.17/A). The oil level indicator has to be mounted using the items

(Fig.17/B) showed in the table 4b.

6

6

Q.ty

6

1

Table 4b

Description

Ø6 plane washer

Ø6 grower washer

M6 nut

OR6362

Reference standard

UNI 6592

UNI1751

UNI5588

-

4.4 Comem OLI / Comem eOLI

Place the o-ring on the slot behind the gauge

(Fig.83/B) . Align the flange (Fig.18/C - stud length:

20±1 mm) with the threaded pins or holes (Fig.18/A)

(depending on the conservator flange type). The gauge has to be assembled on the flange using four screws M4x12 (Fig.18/D). The oil level indicator flange has to be assembled using the items showed in the table 5.

4

4

Q.ty

4

1

Table 5

Description

Ø12 plane washer

Reference standard

UNI 6592

Ø12 grower washer UNI1751

M12 nut / screw UNI5588

O-ring 6225 -

B

B

A

D

A

C

Figure 17 Figure 18

4

4

Q.ty

4

1

Description

Ø12 plane washer

Reference standard

UNI 6592

Ø12 grower washer UNI1751

M12 nut / screw UNI5588

O-ring 6225 -

TRANSFORMER COMPONENTS

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4. Installation

15

4.5 Comem OLI22 / Comem eOLI22 (with special flange)

Insert the arm with float through the machined hole on the conservator. Place the o-ring in the slot behind the flange (Fig.19/C). Insert the flange on the threaded pins (Fig.19/A) of the conservator flange and fix it with the items showed in the table 6

(Fig.19/B). Fix the gauge on the flange using 4 screws M4x12 (Fig.19/D).

8

8

Q.ty

8

1

Table 6

Description

Ø10 plane washer

Reference standard

UNI 6592

Ø10 grower washer UNI1751

M10 nut UNI5588

OR221 -

8

8

Q.ty

8

1

Table L220

4.6 Comem L220

Insert the arm with float through the machined hole on the conservator. Place the o-ring on the slot behind the gauge. Insert the device on the threaded pin of the conservator flange (Fig L220/A). The oil level indicator has to be mounted using the items

(Fig.L220/B) showed in the table L220.).

Description

Ø10 plane washer

Reference standard

UNI 6592

Ø10 grower washer UNI1751

M10 nut UNI5588

OR221 -

A

B

C

D

Figure 19

Figure L220

16 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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4. Installation

4.7 Comem L340

Q.ty

8

1

8

8

• Insert the arm with float through the machined hole on the conservator. Place the o-ring on the slot behind the gauge. Insert the device on the threaded pin of the conservator flange (Fig.

L340/A). The oil level indicator has to be mounted using the items (Fig.L340/B) showed in the table

L340.

Description Reference standard

Ø16 plane washer UNI 6592

Ø16 grower washer UNI1751

M16 nut

OR248

UNI5588

-

Table L340

4.8 Comem eViewer

Arrange the transformer with a dedicated place following the scheme in the figure 15. The connection can be done in two alternative way:

• threaded pin and nut M6

• screws M6

Figure 20

Figure L340

TRANSFORMER COMPONENTS

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5. Electrical connection

CAUTION

QUALIFIED AND SKILLED PERSONNEL TRAINED

IN THE APPLICABLE HEALTH AND SAFETY

REGULATIONS OF THE RELEVANT COUNTRY

SHOULD ONLY PERFORM ELECTRICAL

CONNECTIONS.

WARNING

PROVIDE TO THE EDEVICE A POWER SUPPLY

DISCONNECTION THROUGH AN EXTERNAL

SWITCH (IF THE DEVICE IS INSTALLED IN A

FIXED POSITION).

WARNING

DANGEROUS ELECTRICAL VOLTAGES!

IT IS IMPERATIVE TO DEACTIVATE THE POWER

SUPPLY DURING WIRING OF THE DEVICE.

WARNING

THE EDEVICE MUST BE POWERED BY A POWER

SUPPLY PROTECTED FROM OVERLOAD

(IMAX<340 MA)

CAUTION

DURING THE TERMINAL BOX ASSEMBLY, USE

CAUTION NOT TO DAMAGE THE OR GASKET

(FIG.15/A). IF THIS OCCURS, IT MUST BE

SUBSTITUTED.

IF YOU DO NOT USE ALL THE CABLE GLANDS,

PAY ATTENTION TO CLOSE THE FREE CABLE

GLAND WITH A PLUG WITH GASKET.

Remove the cover from the terminal box unscrewing the 4 captive screws M4 (Fig.21/C). Insert the wires through the cable gland (Fig.21/B) and wiring them following the electrical scheme (Fig.22-23).

17

C

A

B

Figure 21

18 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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5. Electrical connection

5.1 Micro-switches wiring

Wire the electrical cables in accordance with the ordered model following the electrical scheme showed in the figure 22.

DIAGRAM K DIAGRAM Y DIAGRAM X DIAGRAM W

Figure 22

5.2 Analog output and Modbus communication wiring

(for Comem eOLI and Comem

eOLI22)

5.2.1 Power voltage

Connect the power voltage (as written on the label on the terminal box cover) to terminals 1-2.

24 Vdc ±10% polarized

5.2.2 Analog output

Terminals for analog output 4-20 mA: 6-7

Maximum resistance: 450 Ω

4 mA = 0% (minimum arrow position)

20 mA = 100% (maximum arrow position)

5.2.3 Modbus communication (optional)

Digital output RS485: terminals 3-4

(for the Modbus register and address, see the

Appendix A)

5.3 Comem eViewer wiring

5.3.1 Power voltage

Connect the power voltage (as written inside the terminal box, fig.18) to terminals 1-2.

24 Vdc ±10%

5.3.2 Analog input

Connect the analog signal (as written inside the terminal box, Fig. 24) to terminals 6-7 : 4-20 mA.

Negative Comem eViewer (3) with negative Comem eOLI (7). Positive Comem eViewer (4) with positive

Comem eOLI (6).

5.3.3 Comem eViewer – Comem eOLI connections

The following scheme (Fig.24) describes the connections for signal remoting between an electronic liquid level indicator and the eViewer.

1 + POWER SUPPLY

2 - 24 V DC

3 - ANALOG INPUT

4 + 4..20 mA

Figure 24

Figure 23

TRANSFORMER COMPONENTS

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5. Electrical connection

Figure 25

19

20 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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6. Operation and maintanence

The liquid level indicator devices are ready for operation after installation, electrical connection and power supply.

6.3 Storage

The liquid level indicators can be handled without any tools. Handle the device with care.

6.1 Operation

It is possible to detect the conservator oil level observing the indicator dial:

• Minimum level: when the pointer indicates the MIN position

• Maximum level: when the pointer indicates the

MAX position.

The electrical micro switches operate at an advance angle ≤ 5°, with respect to the min or max indications of the oil level in the conservator. When there is a double contact, for e.g. double MIN and/or double

MAX (schemes Y o W) the second contact operates at about 5° after the first contact.

NOTE

COMEM ADVICES TO DISCONNECT THE EOLI/

EOLI-22/VIEWER DURING THE ELECTRICAL

TRANSFORMER ROUTINE TEST.

CAUTION

NOT TO PAINT THE DEVICE. IN THIS CASE ANY

GUARANTEES CONCERNING THE CORROSION

RESISTANCE DECLINE.

ONLY MILD SOAP AND WATER SHOULD BE USED

TO CLEAN THE ELECTRICAL BOX COVER.

SOLVENTS MUST NOT BE USED FOR ANY

REASON AS THEY WILL DEGRADE THE

PERFORMANCE OF THE PAINT. USE OF

SOLVENTS ON THE UNIT WILL IMMEDIATELY

VOID THE WARRANTY.

The liquid level indicator must be stored in the original packing and in a dry place with temperature in the range -10°C up to 40°C (14°F up to 104°F).

Upon receiving the device, please check:

• The outer surface of the packaging to ensure that it is intact

• That there are no breakages

If damages are found, please contact ABB and provide the information from the shipping list and the serial number.

6.2 Maintenance

During regular maintenance on the transformer, we recommend performing the following checks on the oil level indicator:

• Check the exterior condition of the device

• Remove dirt as necessary.

TRANSFORMER COMPONENTS

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Appendix A: MODBUS communication

A1 MODBUS register

Operation Register address

Operation for monitoring

0x2000

0x2001

0x2002

0x2003

0x2004

0x2005

0x2006

0x2007

0x200A

R

R

R

R

R

R

R

R

R

Notes

Level value (0-100%)

Minutes from the last powering

Days from the last powering

Max level value (%) in the current day

Min level value (%) in the current day

Number of powering lost in the day

Minimum range value

Maximum range value

Software version

Data logging**

0x2100

0x2101

0x2102

0x2103

0x2104

0x2105

…

0x215C

0x215D

0x215E

0x215F

R

R

R

R

R

R

R

R

…

R

R

Max level in the day -1

Min level in the day -1

Max level in the day -2

Min level in the day -2

Max level in the day -3

Min level in the day -3

…

Max level in the day -23

Min level in the day -23

Max level in the day -24

Min level in the day -24

Events log

0x2300

0x2301

0x2302

0x2303

0x2304

…

0x248D

0x248E

0x248F

0x2490

R

R

R

R

R

…

R

R

R

R

Events number

Timestamp Hi [Event 1]*

Timestamp Low [Event 1]*

Event type: value 4=Change Date[Event 1]

Level Value at the moment of the event [Event 1]

…

Timestamp Hi [Event 100]*

Timestamp Low [Event 100]*

Event type: value 4=Change Date[Event 100]

Level Value at the moment of the event [Event 100]

*Date and time of an event are calculated in this way:

Event Date/Time = Timestamp Hi (seconds) + (216) x Timestamp Low (seconds) + (01-Jan-2014 00hh:00min:00sec)

** The daily maximum and minimum data were saved starting from the nearest day, in registers 0x2100 and 0x2101, at the farthest day, in registers

0x215E e0x215F.

Table 7

21

22 LI Q U I D LE V EL I N D I C ATO R - INSTRUCTION MANUAL

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Appendix A: MODBUS communication

A1.1 MODBUS address

When are installed two or more units, it is necessary to differentiate the MODBUS address changing the dip-switches position.

The available Comem eOLI addresses are

• 128 to 143 (default).

ON

ON

ON

ON

ON

OFF

ON

ON

ON

4

OFF

OFF

OFF

OFF

OFF

OFF

OFF

Table 8

ON

OFF

OFF

OFF

OFF

ON

ON

ON

ON

3

OFF

OFF

OFF

OFF

ON

ON

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

2

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

1

OFF

ON

OFF

ON

OFF

ON

OFF

132

131

130

129

128

136

135

134

133

140

139

138

137

ADDRESS

143

142

141

Figure 26

TRANSFORMER COMPONENTS 23

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ABB Power Grids Italy S.p.A.

COMEM Operating Unit

Strada Regionale 11, Signolo 22

36054 Montebello Vicentino (VI) - ITALY www.abb.com/transformercomponents

The data and illustrations are not binding. We reserve the right to modify the contents of this document without prior notice following technical and product developments.

© Copyright 2020 ABB. All rights reserved.