Aquametro Oil & Marine Viscosity VC312 User manual

Version: VD 7-475 02.2021
VCS – Viscosity Controller
Installation and Operation Manual
Viscosity Control System
Viscosity Controller VC312/VC322/VC622/VC722
Fuel Viscosity System

2 VCS – Viscosity Controller
Content
1Introduction.................................................................................................................................. 3
1.1 Liability disclaimer ...............................................................................................................................................................................3
1.2 Safety precautions...............................................................................................................................................................................3
1.3 Receiving and storage requirements...........................................................................................................................................4
2Application.................................................................................................................................... 4
2.1 Description of Viscosity Controller ...............................................................................................................................................4
3Controller installation / implementation................................................................................... 5
3.1 General.....................................................................................................................................................................................................5
3.1.1 Planning ............................................................................................................................................................................................6
3.1.2 Installation........................................................................................................................................................................................7
3.1.3 Electrical wiring ..............................................................................................................................................................................8
4Controller operation .................................................................................................................... 8
4.1 Putting into operation .......................................................................................................................................................................8
4.2 Display and operation level .............................................................................................................................................................9
4.3 Display operating status (VC622/722 only)...............................................................................................................................9
4.4 Parameter settings level.................................................................................................................................................................10
4.5 Configuration level...........................................................................................................................................................................11
4.6 Manual optimization ....................................................................................................................................................................... 14
5Maintenance and repair............................................................................................................. 15
5.1 Calibration ........................................................................................................................................................................................... 15
5.2 Service maintenance........................................................................................................................................................................ 15
5.3 Spare parts .......................................................................................................................................................................................... 16
6Troubleshooting ......................................................................................................................... 17
6.1 Controller problems and recommended actions................................................................................................................. 17
6.2 Process troubleshooting................................................................................................................................................................ 18
7Decommissioning, dismantling and disposal.......................................................................... 20
7.1 Decommissioning............................................................................................................................................................................. 20
7.2 Dismantling ......................................................................................................................................................................................... 20
7.3 Return of materials........................................................................................................................................................................... 20
7.4 Disposal ................................................................................................................................................................................................ 21
8Technical data............................................................................................................................. 21
8.1 Hardware characteristics................................................................................................................................................................21
8.2 Dimensional drawings .................................................................................................................................................................... 22
8.3 Electrical connection diagrams ................................................................................................................................................... 22
8.3.1 VC312 controller connection................................................................................................................................................. 22
8.3.2 VC622 (322/622/722) controller connection................................................................................................................... 27

VCS – Viscosity Controller 3
1 Introduction
Thank you for your decision to work with Aquametro Oil & Marine Viscosity Control System (VCS).
This manual describes the installation, commissioning and use of Viscosity Control System. For additional
information, please contact your local sales agent [e-mail] / www.aquametro-oil-
marine.com.
1.1 Liability disclaimer
The manufacturer cannot monitor the compliance to this manual as well as the conditions and methods during
the installation, operation, usage and maintenance of the system regulator.
Improper installation can cause damages and endanger people. Therefore, we assume no responsibility and
liability for losses, damages or costs that result due to incorrect installation, improper operation, usage and
maintenance or in any manner associated therewith. Similarly, we assume no responsibility for patent right or
other right infringements of third parties caused by usage of this system regulator. The manufacturer reserves
the right, without prior notification, to make modifications concerning the product, technical data or installation
and operating manual.
1.2 Safety precautions
Viscosity Control System must only be used for its intended purpose and comply with local and international
safety regulations. All documentation is to be followed exactly. None of the information stated here or
elsewhere releases planners, installers and operators from their own careful and comprehensive assessment of
the respective plant configuration in terms of functional capability and operational safety.
Local applicable working regulations must be complied with, during all work on the plant and/or ship.
All safety-, installation- and operation instruction as described in this manual must be followed.
Sensors, actuators and control valves are sensitive instruments and should be treated carefully.
When removing or reinstalling sensors or components from the Viscosity Control System, safety instructions
in the respective operating manual must be followed.
Check the Viscosity Control System periodically for tightness of the connections and for proper functioning.
The unit must be installed to 110 VAC or 230 VAC according to wiring diagram.
Electrical wiring and installations are subject to statutory regulations, which must be taken into account
when planning the system.
Viscosity Control System is not for installation in zones subject to explosion hazards.
If work is to be done on the installation, before each intervention release the pressure in the installation
This manual provides instruction for installation, start-up and operation of Aquametro Oil & Marine Viscosity
Control System.
It is essential that this manual be thoroughly reviewed, with full comprehension of the
matters explained herein, before attempting installation and start-up.
The materials and workmanship incorporated into the Aquametro Oil & Marine Viscosity Control System are
designed to provide trouble-free service throughout the equipment lifetime. However, like any rotating
equipment, satisfactory performance depends on correct initial sizing, proper installation and periodic
inspection, monitoring of operating conditions (pressure, temperature, vibration, flow and electric power) and
prescribed maintenance. This manual has been prepared to assist the operator in understanding the workings of
the Viscosity Control System and provide direction for proper installation, start-up, operation and maintenance.

4 VCS – Viscosity Controller
IMPORTANT SAFETY INFORMATION
WORK SAFE SYMBOL
This symbol will appear in this manual at all remarks for operational safety, where risks
for health and life of personnel exist. Observe these points and proceed with caution in
these cases.
Cautions should be identified to other users
ATTENTION NOTICE
This symbol will appear in this manual where special attention must be paid in
order to maintain a correct operating procedure and to avoid damage to the
Viscosity Control System components and/or other plant equipment.
1.3 Receiving and storage requirements
Inspect Viscosity Control System components and separate delivered parts as soon as they are received.
Make notes and photos of damage (also package damages) or missing items.
File any claims with the transportation company immediately and notify vendor of the damages.
Normal packaging is designed to protect Viscosity Control System components and separate parts during
shipping and storage. Upon receipt at customers’ warehouse, store Viscosity Control System components and
separate parts indoors, in a sheltered and dry location.
2Application
The Aquametro Oil & Marine Viscosity Controller, with the scope of functionality from relays, several digital and
analog out- and inputs and other additional devices, is built to tackle the most demanding process and marine
applications for viscosity control systems.
The Viscosity Controller is a microprocessor-based industry controller series in panel mounting format
96 x 96 mm.
Design and operating elements are especially devised for easy and convenient handling and operation. The
controller is available as two or one channel controller with programmable proportional differential and integral
action. All relay contacts are potential free.
A Controller may be part of a complete Aquametro Oil & Marine Viscosity Control System. For instructions
covering the other components of this system, refer to the separate MBA as supplied with these components.
2.1 Description of Viscosity Controller
Scope of supply
Controller VC312
Three-point-step
switchable depending on the state of a binary input
2 information signal outputs (no galvanic isolation)
1 additional contact

VCS – Viscosity Controller 5
VC622
Continuous control or Three-point-step control
switchable depending on the state of a binary input
2 information signal outputs
2 additional contacts
Double continuous control optional
3Controller installation / implementation
3.1 General
Figure 4-1: Controller type - Display
1-Display for relay function
2-Descriptive text for displayed value
3-Digital value displays
4-Unit of display
5-Key for setpoint and parameter mode
6-Setpoint adjustment

6 VCS – Viscosity Controller
Measuring inputs / ranges:
ai1: Pt100 or standard signal, range 0 to 400°C resp. adjustable, preadjustment 4 to 20 mA / 0
to 50 cSt
ai2:
Pt100 or standard signal, range 0...400°C resp. adjustable, preadjustment 4 to 20 mA / 0
to 200 °C
ai3:
VC622/722 only
Remote resistance transmitter or standard signal preadjustment 4 to 20mA / 0 to 100 %
Binary input:
VC322/622/722
2 binary inputs, external voltage 0/24 VDC or potential free contact
0 V resp. contact open: status = 0;
24 V resp. contact closed: status = 1
b1: 0 = control channel 1 active; 1 = control channel 2 active
b2: 0 = continuous output(s) = 0%; 1 = auto. control
Relay output:
VC312
3 relays with potential-free changeover contacts incl. spark extinction, switch. power
250V 2A, preadjusted.:
K1 - Control function three point step (+)
K2 - Control function three point step (-)
K3 & K4 – Common relay switched by limit comparator assigned to actual value 1&2
VC322
4 relays with potential-free changeover contacts incl. spark extinction, switch. power
250V 2A, preadj.:
K1 - Control function three point step (+)
K2 - Control function three point step (-)
K3 - Relay switched by limit comparator assigned to actual value 1
K4 - Relay switched by limit comparator assigned to actual value 2
VC622/722
K1 – Relay switched by limit comparator assigned to actual value 1
K2 - Relay switched by limit comparator assigned to actual value 2
K3 -
K4 -
Analogue
outputs
4 signal- / continuous outputs 0/4..20 mA, galvanically isolated, preadjustment:
VC312
VC322
VC622
VC722
S1: Actual value 1 Actual value 1
Continuous Y1
Continuous Y1
S2: Actual value 2 Actual value 2 Actual value 1
Continuous Y2
S3:
Nil
Actual value 2
Actual value 1
S4:
Nil
Actual value 2
3.1.1 Planning
Topics covered in this chapter:
Installation checklist
Best practices
Power requirements
Other installation considerations
Recommended installations for the controller
Perform a pre-installation controller check

VCS – Viscosity Controller 7
3.1.1.1 Installation checklist
Verify the contents of the product shipment to confirm that you have all parts and information
necessary for the installation.
Make sure that all electrical safety requirements are met for the environment in which the controller will
be installed.
Make sure that the local ambient temperatures and pressure are within the limits of the controller.
Make sure that you will have adequate access to the controller for verification and maintenance.
Verify that you have all equipment necessary for your installation. Depending on your application, you
may be required to install additional parts for optimal performance of the controller.
3.1.1.2 Best practices
The following information can help you get the most from your Controller.
Handle the Controller with care. Follow local practices for lifting or moving the meter.
Always store and transport the Controller in its original packaging.
Do not expose the Controller to excessive vibration (greater than 0.5 g continuously). Vibration levels in
excess of 0.5 g can affect the meter accuracy.
3.1.1.3 Power requirements
Following are the DC power requirements to operate the controller:
Power supply: 100 to 250 VAC, approx. 14 VA
alternative 24 V AC / DC
Power cable recommendations for explosion-proof/flameproof controller
3.1.1.4 Other installation considerations
Numerous external factors can affect the meter's successful operation. To ensure that your system works correctly,
consider the factors covered in this section when designing your installation.
Select a location away from electrical and magnetic fields.
3.1.2 Installation
Before installation inspect the controller for any visible signs of damage caused during transport. Check power
supply acc. to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind with the fastening devices
supplied.
The controller is designed for panel mounting, a panel thickness of 2.5 mm is required.
To panel-mount the controller
1. Cut a hole of the correct size (96.8 x 96.8 mm)
2. Insert the controller
3. Mount and fix the clamps
Do not overtighten the screws and allow sufficient space for cable installation and service.

8 VCS – Viscosity Controller
3.1.3 Electrical wiring
Plug bar on the back face of the controller; connect up the controller at the rear following the wiring diagram;
wire cross section max. 1.5 mm2
To avoid cross interference all low voltage measuring lines and pilot wires must be encased
in a shielded cable (the shielding must be earthed one-sided)
The control leads must be fused externally to protect the output relays.
Phase wire and neutral wire must not be transposed.
Refer to chapter “8.3 Electrical connection diagrams” to connect all cables in accordance to the electrical
connection plan.
4Controller operation
Default values
Default values for your meter are configured at the factory. The specific values are determined by the options
that were specified on the purchase order. These are provided on the configuration sheet that was shipped with
your meter.
4.1 Putting into operation
Switch on power supply. Digital display and control lamps (if available) will light up according to the setpoint
after some seconds. If nothing happens check the fine-wire fuse (if available) on the back panel of the controller
and the electrical wiring. Adjust set value and check other adjustments.
Operating status
The upper display shows the actual value (channel / measuring input 1), the lower display remains empty
or (depending on the version and settings) shows
the attendant unit of measure (°C, °F, %...)
an additional actual value, the setpoint value or the controller output value Y
or the additional actual value only when the key is pressed.
Alternative type:
Switch over the upper display to the several actual values by pressing the key, the lower display
shows the number of the attendant measuring input.
Setpoint value setting
Press key shortly (do not hold down)
The upper display shows the abbreviation of the activated setpoint adjustment mode, the lower display
shows the adjusted value.
The indicated value can now be changed by the (lower) and (higher) -keys.
Each variation of the set value is immediately active, without any more operating steps.
The arrow keys have a built-in accelerator mode: longer pressing causes faster alterations.
Return to operating level
Press key shortly (or automatically after 30 seconds without any key-action)
optional: Press key shortly again: *SP =set values of further control loops (*=no.) /
SP* =further set values of the control loop / SPE =external setpoint (display mode only);
flashing display signifies that the function is not active at the moment

VCS – Viscosity Controller 9
4.2 Display and operation level
Setpoint value setting
Briefly press the button (do not hold)
A flashing frame with the description SP shows the activated setpoint level. The upper text display shows
the parameter name “SP=” and the adjusted value, the lower text display optionally shows a description
text.
The displayed value can now be changed using the and buttons.
A setpoint change is effective immediately, without any further operational steps.
‘Arrow’ button acceleration effect: longer pressing causes faster changing.
Return to operating mode
briefly press the button (or automatic after > 30 sec)
Manual operation: (optional)
MAN.
Press and hold the button, then additionally press the button, then release both.
(For multi-channel controllers, first select the channel number CH..
using the up/down buttons and continue with the P button, after which:)
The display shows “MAN or Hand", plus the setting variable, if it exists.
The control function is switched off.
Manual control is now possible using the and keys
Return to operating mode: only with button, no automatic switching back from
manual operation!
Optional: Start self-optimisation (see chapter Optimisation): press the button >5 sec
whilst in manual control function; the lower display jumps to "-Ad-".
Abort: press the button again >5 sec
4.3 Display operating status (VC622/722 only)
Graphical representation: Briefly press the button (do not hold). Actual- and setpoint values of the controller
are displayed as a continuous diagram. The actual recording cycle is signalised by an ongoing red dot.
Vertical yellow lines with grey background for date and time represent recording interruptions.
Optional: To switch on the cursor press button briefly:
The cursor is moved along the time axis with the (earlier) / (later) buttons, the values of the cursor
position are shown in accordance to the date and time.
Briefly press the button to switch off the cursor

10 VCS – Viscosity Controller
4.4 Parameter settings level
Access from the operating level
Depending on the controller type, the operating level has to be unlocked with a switch on
the back panel of the device.
After polling (see instructions for level PARA 1 / 2), a flashing frame with the description PAR1 / PAR2 shows the
activated parameter level.
The upper text display shows the first parameter name and the adjusted value, the lower text display optionally
shows a description text.
Continue to the next parameter and/or confirm entry:
briefly press the button each time.
To change the setting displayed: Press the buttons:
Settings in detail:
(existence depends on version and type):
PARA 1
Polling: press and hold the button >5 sec,
release it after the display reacts.
Factory
setting Notes
COD2
Code number 2 (password) for parameter levels (1 to 9999)
1
CH..
(only) for multi-channel controllers: Selection of desired channel (no.)
P
Proportional range Xp (%) (for more details, see “Optimisation”)
35.0
I
Integral action time Tn (min) (for more details, see “Optimisation”)
6.0
D
Rate time Tv (min) (for more details, see “Optimisation”) 0.2
SH
Response sensitivity (“dead zone”) Xsh (%)
0.1
SA
Setpoint distance (absolute) for following switching contact no
5.0 / 3.0
SP
Independent setpoint for switching contact no.
0.0
SD
Hysteresis (switching difference on/off) for switching contact no
3.0
return to operating mode:
briefly press the button (or automatic after > 30 sec)
PARA 2
Polling: press and hold the button, additionally press the
button, hold both buttons for >5 sec, release them after
the display reacts:
Factory
setting
Notes
COD2
Code number 2 (password) for parameter levels (1 to 9999)
1
Unit
Switches the unit of display (°C / °F) °C
*BLO/*BHI
(only) for voltage / current input: start / end of display range
#
*ELO/*EHI
(only) for external setpoint: start / end of setpoint range
#
*SLO/*SHI
(only) for information signal output: start / end of range
#
NST
Number of decimal places of the display (0 / 1 / 2, depending
on range)
0
*Lo / *HI
Setpoint setting range, lower / upper limit
#
CRST
Contrast setting for display (0 to 20)
32

VCS – Viscosity Controller 11
BRGH
Brightness display (30 to 100)
50
DSP1
Variable shown in first display line (10 mm) (OFF / SP / Y / IST..)
DSP2
Variable shown in second display line (10 mm) (OFF / SP / Y /
IST..)
DSP3
Variable shown in third display line (10
mm if DSP4=OFF,
otherwise 3 mm) (OFF / SP / Y / IST..)
DSP4
Variable shown in fourth display line (3 mm) (OFF / SP / Y / IST..)
EIN1..4
(SP = setpoint, Y=setting variable, Ist * = Actual value channel
/ measuring input*)
Unit of measurement for corresponding display line (°C / °F / %
/ bar / mbar / mPas / cSt / Kgm3/ mm / KPa / L / m3/h) Note:
no conversion! C
Text1/2/3/4
Description text for corresponding display line1..4: choose from
a predefined list (ACT.VAL.,SETPOINT, SUPPLY,RETURN)
resp. 1 additionally editable text; *changeable by PKS-software,
1=ACT.VAL1
2=
ACT.VAL2
3=
SETPOINT
Return
to operating mode:
briefly press the P button (or automatic after > 30 sec)
* = ID number in case of several measuring inputs or control
loops
.# = corresp. range
4.5 Configuration level
Access from the operating level
Depending on the controller type, the operating level has to be unlocked with a switch on
the back panel of the device.
Polling: press and hold the button, additionally press the button, hold both buttons for >5 sec, release
them after the display reacts:
A flashing frame with the description CONF shows the activated parameter level. The upper text display shows
the first parameter name and the adjusted value, the lower text display optionally shows a description text.
continue to the next parameter and/or confirm entry:
briefly press each time the button
To change the setting displayed:
Number values: Press the buttons, text values: press the button
Settings in detail:
(existence depends on version and type):
Factory
setting
Notes
CODE
Code number for configuration level (1 to 9999),
Alternatively: Hold the button for more than 10 sec after code
entry
1
COD1
Possibility of setting the code number for the configuration level
(option).
1
COD2
Possibility of setting the code number for the parameter levels
(option).
1

12 VCS – Viscosity Controller
LNG
Language selection of the menu text (Deutsch, English, User def, Off)
English
CONF
Selection of the configured controller function (if existent)
return to operating mode: Briefly press the button
or: continue to the following settings: press the -button and hold
it > 5 sec:
Note: when continuing after changing a function, the display first
flashes for a few seconds, only then does the desired switching over
or back take place
SPEF
Configuration external/second setpoint “BIN” (activation by binary
input)
/ “MENU” (activation from the setpoint level) / “SP2” / “AUS”=OFF
MENU
AIN*
Input type for input no.*: "RTD / 0 to 20 / 4 to 20(mA) / 0 to10 /
2 to 10 (V) / AUS=OFF" (note different terminals for I/U!)**
4 to 20
mA
IST*
Correction value for changing the controller display (+/-)
SP 2/E
Type of effect of second / external setpoint: "Add/ Sub/ AbS"
(adding / subtracting / absolute value) AbS
*YM
Setting time of the controlled drive “6 to 600” (sec)
60 sec
*CY' '
Switching frequency in two-point controllers: "2 to 120" (sec.)
20 sec
*OUT
Setting output signal "0 to 20 / 4 to 20" (mA) /0 to 10 / 2 to 10 (V)“
4 to 20
mA
*OUT
Setting output characteristic: direct / inverse "di / in"
(with 2 outputs: "in in / in di / di in / di di")
in
in in
0
*td
For 2 outputs: dead zone between outputs 1 and 2 “0…10%”
0.0
*AP
Output signal working point (-100 to +100)
50
FG A/E
Automatic adjustment of remote transmitter input (see extra sheet 99ar)
Sou*
Assignment of inform. output signal(s)* (act. value/setp., setting var..)
Ist1
Sou*
Type of information output signal(s)* “0 to 20/4 .to 20(mA)/
0 to 10/2 to 10(V)”
(* Sout= Signal 1; Sou2 = Signal 2)
*Y_S
Behaviour of the setting output in the event of measurement line
error:
Relay position: "rel1 / rel2 / OFF"
Continuous output: "0...100" (%)
rel2(70.)
rel1(20.)
bin.Ein
g
Sub-menu for binary input configurations
Polling: press the button and hold it > 5 sec
BIN*
Direction of control action binary input* direct / inverse (di/in)
di
BIN*
Assignment of collective relay: Stat=none, SREL= collective relay
Stat
BIN*
Switch-on delay (0…300 sec)
0
REL*
Function mode of additional contact (relay no.)
LCA / LCE
REL*
Measuring input / control loop assigned to additional contact
IST 1
REL*
Add. contact – relay pos. in event of meas. line error "SiE/SiA"(on/off)
Si A
DSPL
Display representation: NORM (grey / black), INV (black / white)
NORM
Adr
if equipped with interface: bus address (number)
5
BAUD
if equipped with interface: baudrate (9600/ 19200/ 38400)
38400
return to operating mode: briefly press the button again
* = ID number in case of several inputs / outputs or control loops.
**= Rtd input of ain2 is additionally usable if equipped with ext. setpoint and activation using SP-F

VCS – Viscosity Controller 13
Selectable switching functions (depending on version):
For setting please refer to configuration level under
REL*
Switching functions for trailing contacts:
LC A
Break contact on either side of setpoint
(Limit comparator). Relay drops out as
deviation increases (Aus = off)
LC E
Make contact on either side of setpoint
(Limit comparator). Relay picks up as
deviation increases (Ein = on)
Su A
Break contact below setpoint. Relay drops out
as actual value decreases (Aus = off)
Su E
Make contact below setpoint. Relay picks
up as actual value decreases (Ein = on)
So A
Break contact above setpoint. Relay drops
out as actual value increases (Aus = off)
So E
Make contact above setpoint. Relay picks
up as actual value increases (Ein = on)
St A
Heating stage below setpoint. Relay
drops out as actual value increases
(Aus = off)
Switching functions for independent contacts:
Hysteresis below:
US A
Relay drops out with increasing actual value (Aus
= off)
US E
Relay picks up with increasing actual
value (Ein = on)
Hysteresis above:
USCA
Relay picks up as actual value decreases
USCE
Relay drops out with decreasing actual value

14 VCS – Viscosity Controller
4.6 Manual optimization
An optimum adaptation of the control parameters (P, I, D) is necessary in order to balance an appearing
deviation as quickly, non-oscillating and exactly as possible, according to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be replaced
by this brief information.
The following information is for help purpose only:
P = proportional band Xp (%):
lower value = longer impulses, more sensitive reaction
higher value = shorter impulses, less sensitive reaction
Examples: - Oscillating temperature without distinct initial overshot: Xp too low;
- The setpoint is reached very slowly after initial exceeding: Xp too high.
I = integral action time Tn (min):
lower value = shorter impulse gaps, faster balancing
higher value = longer impulse gaps, slower balancing
Examples: - the set value is reached very slowly without overshooting: Tn too high;
- high initial overshot followed by fading oscillation: Tn too low.
D = rate time Tv (min):
increases the controller reaction in case of fast actual value or setpoint alterations
(adjust only if necessary). Higher values cause higher increase
Empirical dimensioning of Xp / Tn / Tv
Based on the actual value curves, the control loop can be re-optimized:
-:Actual value is only slowly approaching the set point.
Setting rule: Increase proportional component. If this leads to an improvement, then reduce the integration time.
This repeat to one satisfactory regulator result is achieved.
-: Actual value slowly approaches the set point with slight oscillations.
Setting rule: Increase proportional component. If this leads to an improvement, then reduce the
-: Actual value approaches the set point without significant overshoot.
Optimal controller behavior for processes that do not allow overshoot.
-: Actual value is approaching the set point with a slight muted overshoot.
Optimal controller behavior for fast control and compensation of Interference components. ()
Setting rule: The first overshoot should not be 10% of the setpoint step exceed.
-: Actual value approaches the setpoint quickly, but oscillates far over. The Vibrations are
damped and thus just barely stable
Setting rule: reduce proportional component. If this is an improvement leads, then increase the integration time.
This repeat to one satisfactory regulator result is achieved.

VCS – Viscosity Controller 15
5Maintenance and repair
5.1 Calibration
All our Viscomaster Systems are calibrated in the factory.
An accuracy check and recalibration is offered at Aquametro Oil & Marine, this is usually dependent on
customer, operator or regulation requirements. This interval depends largely on the operating conditions,
process liquid and the application the system is installed in.
5.2 Service maintenance
CAUTION
The surfaces of the device/system and the medium may be hot.
Risk of burns!
Carry out work only on cooled devices/systems.
Work may only be performed by authorized specialists in accordance with
the applicable regulations.
Use appropriate protective equipment.
WARNING
The device/system may be under pressure.
Risk of severe injury!
Carry out work only on non-pressurized devices/systems.
When working on the device/system watch out for leaking medium.
Work may only be performed by authorized specialists in accordance with
the applicable regulations.
Use appropriate protective equipment, particularly safety goggles
WARNING
The device/system may be under high voltage.
Risk of severe injury!
Carry out work only on non-powered devices/systems.
When working on the device/system watch out for faulty isolation or open
cable cores and ends.
Work may only be performed by authorized specialists in accordance with
the applicable regulations.
Use appropriate protective equipment
Use of unsuitable cleaning agents and procedures.
Risk of malfunction or damage!
Follow the cleaning instructions on the next page.

16 VCS – Viscosity Controller
Before working on the hydraulics:
put the system or section out of operation
close the stop valves
release the pressure
put a suitable tray underneath the connection to be worked on
be prepared for spillage, have absorbent at hand
Cleaning of Viscosity Controller:
do not use any aggressive solvents
rinse hydraulic part of flow meter thoroughly
Aquametro Oil & Marine recommends to use the following cleaning solvents:
Gasoline used for cleaning purposes
Cleaner’s naphtha
Petroleum ether
Bevor working on the electronic
For repair remittance remove plug board with connected leads on the rear side, loosen fastening
devices and remove controller from the panel.
In case of remittance, please give precise details of the fault to reduce time and cost of repair.
To restart the system:
slowly open the stop valves, avoiding pressure surges (“water hammer”)
vent the pipe well check tightness
Maintenance
Use of unsuitable cleaning agents and procedures.
Risk of malfunction or damage!
Follow the cleaning instructions on the next page.
Check connections periodically for tightness and if necessary retighten.
Check insulation periodically for completeness and functionality and reattach if necessary.
Steam valve spindle has to be kept clean and lubricated, if necessary, lubricate the spindle with Molykote
including grease.
Following the initial temperature and pressure load, retighten the screws of all flange connections (also cover
and connection piece flanges), the valve cone should be located in the center
All electronic controllers in the product range of the manufacturer are virtually maintenance-free.
Provided that the controller is correctly installed and put into operation and is protected against mechanical
damage and inadmissible operating conditions, it should give years of trouble-free service. In case of faults
repair work by the customer should be restricted to the externally accessible leads and connections and
components the customer is expressly permitted to deal with himself (bridge circuits, fuses).
All further work, especially on internal components will terminate warranty, makes subsequent inspection and
fault repair more difficult and can cause considerable damage to the circuitry.
5.3 Spare parts
Use of wrong Spare Parts
Risk of malfunction or damage!
Use only original spare parts, supplied by Aquametro Oil & Marine
Spare part list and Maintenance instruction may be requested from Aquametro Oil & Marine.

VCS – Viscosity Controller 17
6Troubleshooting
6.1 Controller problems and recommended actions
Problem
Possible causes
Recommended actions
Err 1...6
Fault on measuring input nr. …
check measuring lines
for short circuit or
breakage
check measuring input
by connecting a RTD
Err 55
Fault on loading the parameter;
press any key, the
controller starts in
emergency operation
mode,
configuration of the
parameters has to be
checked
Err 50
Hardware error in program section
no further operation
possible, remit
controller for repair
Err 52
Hardware error in data section
no further operation possible, remit controller for repair
no further operation
possible, remit
controller for repair
Err 58
Err 59
Err 60
Err 61
Binary inputs out of function (status = 0),
Digital outputs out of function (switched off),
Relay outputs out of function (switched off),
Analogue outputs out of function (0 %),
remit controller for
repair
Err 62
Err 63
Data connection to the modular fault detector 826..
interrupted,
Data connection to the hardware expansion modules
interrupted,
check cables
Error messages during self-adaptation:
Err 202 Ambient conditions are not suitable for self-adaptation; adjust parameter
manually
Err 205
routine exceeded the setpoint
raise setpoint or lower
actual value and start
adaptation again
Err 206 Fault on measuring input during adaptation; check the wiring and
start adaptation again

18 VCS – Viscosity Controller
6.2 Process troubleshooting
Problem
Possible causes
Recommended actions
Viscosity reading
oscillating
Normal process noise
Two-phase flow
Deposition or coating, especially
asphaltenes, on the tines
Contaminants in the process fluid
Vibration in the pipeline
Check your process conditions.
Check for two-phase flow,
stratification, or settling. Install a
pump. Check for environmental
conditions that produce stratification
(e.g., a heat source).
Increase back pressure to minimize
bubble formation.
Clean the tines.
Minimize vibration in the pipeline.
Energy level in heating system to low
Check whether other consumers
cyclically draw energy
Steam Valve oscillating Wrong adjustments of control loop
Adapt control loop (Increase P – check
if necessary increase I / small steps for
the changes)
Viscosity signal
too low /
Temperature not
reached
Air entrapped in fuel oil system
Vent the system at the bypass valve
Heat Valve not fully opened
Adapt Control Loop parameter
Heat Valve close to max. Position
Steam system power at max
Viscosity Signal
remains at
maximum Value
Fuel too cold during start up
Check fuel line trace heating ans or fuel
heater
Fuel too cold during normal operation
due to insufficient heating
Increase output signal of controller to
hear exchanger.
Consult AOM if this does not solve the
problem
No Viscosity
/Temperature
Signal
Air entrapped in fuel oil system
Vent the system
No Electrical supply to viscosity sensor Check main Supply
Check fuses of control unit/power
supply unit
Check integrity of electrical
connection
Current loop connection broken
Check electrical wiring of 4-20mA
output signal
Viscosity sensor malfunction
Contact AOM
To balance any appearing deviation as quickly a non-oscillation operation conditions of the PID Loop is required.

VCS – Viscosity Controller 19
P = proportional band Xp (%):
Lower value = longer impulses (three-point step control), more sensitive reaction,
Higher value = shorter impulses (three-point step control), less sensitive reaction.
Examples:
Oscillating temperature/viscosity without distinct initial overshoot:
P (Xp) too low
Setpoint is reached very slowly after initial overshooting:
P (Xp) to high
I = Integral action time Tn (min):
Lower value = shorter impulse gaps (three-point step control), faster balancing
Higher value = longer impulse gaps (three-point step control), slower balancing
Examples:
the set value is reached very slowly without overshooting:
I (Tn) too high
high initial overshot followed by fading oscillation:
I (Tn) to low
D = rate time Tv (min):
Increases the controller reaction in case of fast actual or setpoint alterations (adjust only if necessary).
Higher values cause higher increase.

20 VCS – Viscosity Controller
7Decommissioning, dismantling and disposal
CAUTION
The surfaces of the device/system and the medium may be hot.
Risk of burns!
Carry out work only on cooled devices/systems.
Work may only be performed by authorized specialists in accordance with
the applicable regulations.
Use appropriate protective equipment.
WARNING
The device/system may be under pressure.
Risk of severe injury!
Carry out work only on non-pressurized devices/systems.
When working on the device/system watch out for leaking medium.
Work may only be performed by authorized specialists in accordance with
the applicable regulations.
Use appropriate protective equipment, particularly safety goggles
7.1 Decommissioning
Disconnect all sources of energy.
Remove the devices from the system.
Pay particular attention to the disposal instructions in section 7.4.
7.2 Dismantling
Not required.
7.3 Return of materials
Never send a device/system back if you are not absolutely certain that all traces of hazardous substances have
been removed, e.g. substances which have penetrated crevices or diffused through plastic.
Costs incurred for waste disposal and injury (burns, etc.) due to inadequate declaration and/or cleaning will be
charged to the delivering company or the operator.
For a device that is sent back to Aquametro Oil & Marine for repair or calibration the following point are an
absolute must:
Always quote type and serial number when contacting an Aquametro Oil & Marine office or an
Aquametro representative.
Always enclose a duly completed "Declaration of decontamination” form (FO0451e).
Only in special cases (e.g. for the reconstruction of causes of errors) and only with the prior consent of
the Aquametro Oil & Marine, equipment must be returned in the impurified state. In this case also the
contact person at Aquametro Oil & Marine, which has granted the approval to return a crude device
must be stated.