VAF instruments Viscosense 3 Maintenance manual

Technical Manual

Instructions for installation,

operation and maintenance

775

VISCOSENSE

Viscosity Sensor & Interface box

Valid for ViscoSense®3

Publication nr TIB-775-GB-0517

Supersedes TIB-775-GB-1216

CONTENTS

1. PREFACE....................................................................................... 2

1.1 General ........................................................................................................2

1.2 Symbols .......................................................................................................3

1.3 Copyright .....................................................................................................3

2. SYSTEM DESCRIPTION................................................................ 4

2.1 System description.......................................................................................4

2.2 System components ....................................................................................5

2.3 Principle of operation ...................................................................................6

3. TECHNICAL SPECIFICATION ....................................................... 7

3.1 Sensor .........................................................................................................7

3.2 Sensor housing............................................................................................7

3.3 Interface box ................................................................................................8

4. SAFETY INSTRUCTIONS .............................................................. 8

4.1 Safety precautions .......................................................................................8

5. UNPACKING .................................................................................. 9

6. INSTALLATION .............................................................................. 9

6.1 To record nameplate data............................................................................9

6.2 Conditions for correct working of the ViscoSense®3 sensor ......................10

6.3 General installation recommendations.......................................................11

6.4 Mechanical installation...............................................................................11

6.4.1 ViscoSense®3interface box..............................................................11

6.4.2 ViscoSense®3 housing......................................................................11

6.4.3 To assemble ViscoSense®3 sensor ..................................................13

6.5 Electrical installation ..................................................................................15

6.6 Connection of sensor to interface box........................................................16

6.7 Installation checklist version 1.0.................................................................17

7. OPERATING INSTRUCTIONS..................................................... 19

7.1 Initial start-up .............................................................................................19

7.2 Shut-down on heavy fuel oil.......................................................................19

7.3 Shut-down on diesel oil..............................................................................19

7.4 Routine start-up .........................................................................................19

8. MAINTENANCE............................................................................ 20

8.1 Routine maintenance .................................................................................20

8.2 To clean the ViscoSense®3 sensor............................................................20

8.2.1 General procedure ............................................................................20

9. REPAIR OR REPLACEMENT ...................................................... 21

9.1 Repair ........................................................................................................21

9.2 Replacement..............................................................................................21

9.3 Procedure for using the micro SD card ......................................................21

10. TAKE OUT OF SERVICE ......................................................... 22

11. REMOVAL AND STORAGE OF EQUIPMENT......................... 23

12. MALFUNCTION AND SEND FOR REPAIR ............................. 23

13. ENVIRONMENT ....................................................................... 23

14. DISPOSAL................................................................................ 23

15. TROUBLE SHOOTING............................................................. 24

15.1 Disconnection the sensor........................................................................24

15.2 General trouble shooting.........................................................................25

15.3 PI setting errors (for additional viscosity controller).................................27

15.4 How to take a HFO sample for analysis..................................................27

15.5 Diagnostic information ............................................................................28

16. CERTIFICATES........................................................................ 30

17. DRAWINGS .............................................................................. 31

17.1 ViscoSense®3 sensor and sensor housing .............................................31

17.1.1 ViscoSense®3sensor housing with sensor installed.........................31

17.2 ViscoSense®3interface box....................................................................32

17.2.1 ViscoSense®3interface box..............................................................32

18. ABBREVIATIONS..................................................................... 33

19. PARTS LISTS........................................................................... 34

19.1 ViscoSense®3 sensor .............................................................................34

20. WARRANTY CONDITIONS...................................................... 35

21. ENCLOSURE ........................................................................... 37

21.1 Recommendations for a good working booster unit ................................ 37

1. PREFACE

1.1 GENERAL

This manual contains instructions for installation, operation and maintenance (IOM) of the VAF

ViscoSense®3 viscosity sensor (VS3) and interface box.

For IOM information of associated equipment supplied by VAF Instruments, refer to the separate

manual supplied with those products.

This manual contains important information for the installer, the operator and for your maintenance

department.

Never use the equipment outside its specifications or beyond common engineering practice

nor use the equipment for other applications or make connections to other equipment than

explicitly described in the order acknowledgement and/or technical manuals of VAF

Instruments.

It is not allowed to make any modifications to the sensor or the interface box without prior

written permission of VAF Instruments BV.

To ensure safe and correct installation and operation, read this manual completely before

installing the equipment and starting operations.

ViscoSense®2and ViscoSense®3 sensor (from serial numbers 70000) and interface box

(from serial numbers 1480000) are not interchangeable with previous model ViscoSense®.

ViscoSense®2and ViscoSense®3 sensor and interface box are interchangeable.

For any additional information contact:

VAF Instruments B.V. Tel. +31 78 618 3100

Vierlinghstraat 24, 3316 EL Dordrecht Fax +31 78 617 7068

P.O. Box 40, NL-3300 AA Dordrecht E-mail: [email protected]

The Netherlands Internet: www.vaf.nl

Or your local authorized VAF dealer.

Their addresses can be found on www.vaf.nl

1.2 SYMBOLS

The following symbols are used to call attention to specific types of information.

A warning to use caution! In some instances, personal injury or damage to the

ViscoSense®3 unit or control system may result if these instructions are not followed

properly.

An explanation or information of interest.

Warning for hazardous voltages. Symbol is used on the interface box in combination with

the requirement to switch of the power supply to the box before opening it, in order to

avoid personal injury.

1.3 COPYRIGHT

While every precaution has been taken in the preparation of this manual, no responsibility for errors or

omissions is assumed. Neither is any liability assumed for damages resulting from the use of the

information contained herein. Specifications can be changed without notice.

ViscoSense®is a registered trademark of VAF Instruments B.V.

2. SYSTEM DESCRIPTION

2.1 SYSTEM DESCRIPTION

ViscoSense®3 is, besides other applications, intended for use in fuel oil treatment systems to obtain a

correct measurement and control of the fuel oil viscosity.

Figure 1 shows a typical fuel treatment system with return line from the engine. In this system, the

degassing/mixing tank operates as a fuel buffer, ensuring gradual changes of viscosity which results

in a stable control of the viscosity. The ViscoSense®3 sensor is used to measure the actual viscosity

of the fuel oil. The signal from the sensor is compared to the setpoint of a viscosity controller, which

regulates the output of the fuel heater via a control element (steam or thermal oil valve, or electric

heater cabinet).

Figure 1 Typical example of an automatic control system using steam or thermal oil heater

2.2 SYSTEM COMPONENTS

The ViscoSense®3 viscosity system consists of:

the combined viscosity and temperature measuring sensor

the sensor housing

Interface box

The sensor housing is made of ductile iron and has flanges for direct mounting in the fuel line. The

sensor itself is made of stainless steel and is mounted in the housing. The sensor head has a special

DLC coating and it is mechanically protected by a stainless steel flow tube with 3 oval slits. It is

supplied with 5 metres of signal cable for connection to the interface box.

The ViscoSense®3 Interface box is a wall mount electronic unit, processing the signals to and from

the sensor. It provides 4...20 mA signals for remote read-out of viscosity and temperature for a

flowcomputer, controller or other system elements. See separate technical manuals for a description

of these components.

Figure 2 ViscoSense®3 components (sensor in housing and interface box)

2.3 PRINCIPLE OF OPERATION

The operating principle of the sensor is that of a torsion pendulum. The sensor consists of a stainless

steel driver / sensor head (1), attached to the base plate (2) by means of a tubular torsion spring (3).

In the head, one pair of piezo elements (driver piezos) (4) actuates the pendulum at its torsional

resonance frequency, while another pair (the receiver piezos) probes the actual movement of the

head. In a low viscosity medium, like air the resonance frequency is in the range of 1600 Hz. In a high

viscosity medium the movement of the head is damped by the liquid. Consequently, the resonance

frequency slightly shifts towards lower frequencies, whilst the width of the resonance peak increases,

which is a measure for the viscosity.

A flow tube (5) is placed around the pendulum, to protect it against mechanical damage.

The flow tube is machined with a smooth surface, as well as with a triplet of oval slits. These slits

increase the refreshing rate between sensor and flow tube.

Figure 2 ViscoSense®3 sensor (VS3)

3. TECHNICAL SPECIFICATION

3.1 SENSOR

Sensor type nr. 0279-0096

Viscosity range 0 - 25/50 mPa.s (other ranges on request)

Temperature range 0-200°C

Maximum operating temperature 180C

Temperature transmitter PT 100 element

Accuracy

Viscosity +/- 2% instantaneous or 0.5 mPa.s

Temperature ± 1C

Material

Sensor Stainless steel 316L

Coating Diamond Like Carbon (DLC)

Signal cable length 5 metres, integrated with sensor

Protection class IP65

Weight 1 kg

Warning

For hazardous zone I and II, the ViscoSense®3 Ex d version is required.

(See separate technical manual TIB-777)

3.2 SENSOR HOUSING

Material housing ductile iron

Flange connections DN 50 mm (2”), DIN, ANSI or JIS

DN 65 mm (2,5”), DIN, ANSI or JIS

DN 80 mm (3”), DIN, ANSI or JIS

DN 100 mm (4”), DIN, ANSI or JIS

Maximum pressure rating 40 bar

Weight 2” approx. 10 kg

2,5” approx. 11 kg

3” approx. 12 kg

4” approx. 13 kg

3.3 INTERFACE BOX

Interface box type nr. 0279-0112

Supply voltage 100-230 VAC, 50/60 Hz

(Fluctuations should not exceed ±10% of the nominal value)

Power consumption 6 Watt

Internal battery Lithium coin type 3V rechargeable, 5 mAh, 6,8 mm

(Do not exchange without prior consulting VAF Instruments)

Output

Viscosity Isolated active output 4…20 mA, current loop, max. load 400Ω

Range typ. 0 - 25/50 mPa.s (depending on selected range)

Temperature Isolated active output 4…20 mA, current loop, max. load 400Ω

Range typ. 0 - 200° C

Response time Depending on application

Resolution 0,1 mPa.s and 0,1 g/l

Ambient temperature -20 .. + 55 C

Humidity range 0-95% RH

Protection class IP 66

Mounting Wall mounting

Cable connections

Power supply M20 x 1,5, Ø9-13 mm

Output signals M20 x 1,5, Ø9-13 mm

Sensor M16 x 1,5, Ø5-9 mm, integrated with sensor cable

Cable wire

Power supply 3 x 1.5 mm², double isolated heavy duty PVC

Output signals 3 x 2 x 0,50 mm², twisted pair, individually screened, braid shielded

Ventilation requirements No special requirements

Weight 2,0 kg

Max. altitude for use 2000 m above sea-level

4. SAFETY INSTRUCTIONS

4.1 SAFETY PRECAUTIONS

To ensure the safety of personnel and equipment:

Always follow the safety and installation recommendations in this manual.

Always use personal protective means when working with hot, aggressive and toxic process

liquids.

Always use insulated tools when working on electrical installations.

Ensure that local safety regulations are met when installing and operating the equipment.

All personnel who operate and service the equipment should read this manual completely and

make themselves acquainted with the equipment before installing or operating the equipment.

The ViscoSense®3 sensor body will heat up to the process temperature; do not touch the body

housing while process is running!

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