Aquametro Oil & Marine CONTOIL DN15 Service manual

Mounting and operating instructions
CONTOIL®DN15 - 50
VZO / VZOA
Table of contents
1Safety 2
2Product description 4
3Installation 6
4Operation 16
5Maintenance and Repair 17
6Troubleshooting 20
7Decommissioning, Dismantling and
Disposal 21
8Technical Data 22
9Appendix 23

2CONTOIL® DN15 - 50
1 Safety
1.1 Intended Use
The CONTOIL®flow meter is designed and solely intended for the flow measurement of Diesel
oil to Heavy Fuel Oil according to ISO 8217-2010
Improper or non-intended use may lead to the operational reliability of the device and is no
longer guaranteed. The manufacturer accepts no liability for any resulting damage to human
and material.
1.2 Notes on safety rules and symbols
The devices are designed to meet the latest safety requirements. They were tested and deliv-
ered in a condition that ensures safe operation. Improper or non-intended use of the devices,
can however, be dangerous. Therefore pay particular attention to the safety instructions within
this manual always shown by the following symbols:
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
NOTICE indicates a hazardous situation which, if not avoided, could result in
property damage.
NOTE
NOTE indicates helpful tips and recommendations, as well as information for
efficient and trouble-free operation.
See doc VDxxxx, page ## or
See section XX on page ## or
WEB link to QR code

CONTOIL® DN15 - 50 3
1.3 Safety rules and precautionary measures
The manufacturer accepts no responsibility if the following safety rules and precautions are
disregarded.
Modifications of the device implemented without preceding written consent from the
manufacturer, will result in the immediate termination of product liability and warranty
period.
Installation, operation, maintenance and decommissioning of this device must be car-
ried out by trained, qualified specialists, authorized by the manufacturer, operator or
owner of the facility. The specialist must have read and understood these Installation
and Operating Instructions and must follow the instructions here in.
Check the voltage and the information on the type plate before installing the device
Check all connections, settings and technical specifications of peripherals which may
be present.
Open the housing or parts of housings, which electric or electronic components in-
cluded, only when the electric power is turned off.
Do not touch any electronic components (ESD sensitivity).
Expose the system with respect to the mechanical load (pressure, temperature, IP
protection, etc.), only to a maximum of the specified classifications.
During operations that involve mechanical components of the system, release the
pressure in the pipe system or reduce the temperature of the medium to a safe level
for humans
None of the information stated here or elsewhere releases planners, installers and
operators from their own careful and comprehensive assessment of the respective
system configuration in terms of functional capability and operational safety
The local labor, safety laws and regulations must be adhered to.
1.4 About the operation manual
The manufacturer reserves the right to make changes to technical data without notice. The
latest information and versions of these operating instructions, can be requested at your local
dealer.
WARNING
The manufacturer accepts no responsibility if the instructions and
procedures as described in this manual are not followed!
NOTICE
This installation guide is intended for qualified personnel and therefore does
not include basic working steps.
Before operating the equipment or system, this Installation and Operating
Instructions must be completely read and understood.
Keep these instructions for later look up!

4CONTOIL® DN15 - 50
2 Product description
2.1 Scope of supply
1 Flow meter with mechanical counter.
1 mounting and operating instruction (this manual)
2.2 Flow meter configuration
The CONTOIL®flow meters consist of a hydraulic part, a coupling and an mechanical
counter.
The hydraulic part determines the nominal size of the flow meter.
The flow meters are calibrated before they leave the factory. Nevertheless, for optimal results
of differential measurement, flow meters of VZOA with special calibration (pairing) should be
used.
Mechanical counter VZO / VZOA
local mechanical display with or without pulse output
For details, see the dimensional drawings in
Appendix, chapter 9. on page 23
2.3 Handling, Transport and Storage
We congratulate you on purchasing this high-quality instrument. Please check all components
and parts delivered promptly after the receipt of goods.
FL: DN15 - 50
RC: DN15 - 40
Hydraulics
Display units

CONTOIL® DN15 - 50 5
2.4 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 declara-
tion and/or cleaning will be charged to the delivering company or the operator.
For a device that is sent back to Aquametro Oil & Marine AG for repair or calibration the fol-
lowing point are an absolute must:
Always quote type and serial number when contacting an Aquametro Oil & Marine AG
office or a 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 AG, equipment must be returned in the
unpurified state. In this case also the contact person at Aquametro Oil & Marine AG,
which has granted the approval to return a crude device must be stated.
Only then Aquametro Oil & Marine AG can transport, examine and repair a returned device.
Use form FO0451e_Declaration of Decontamination
and FO0301e_Return Form

6CONTOIL® DN15 - 50
3 Installation
CAUTION
The surfaces of the device and the medium may be hot.
Risk of burns!
Carry out work only on cooled systems.
Work may only be performed by authorized specialists in
accordance with the applicable regulations.
Use appropriate protective equipment.
WARNING
The pipe and the device may be under pressure.
Risk of severe injury!
Carry out work only on non-pressurized systems.
When working on the device 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.

CONTOIL® DN15 - 50 7
3.1 Mounting
Flow meter installation
Easy access for reading the flow meter and controlling the ancillary equipment is important.
Provided that the arrow on the housingis in the direction offlow, the flow meter can be installed
in any position without any special modifications. The mechanical counter can be turned to the
desired position
Exception: upside down installation.
Flow conditioners are unnecessary.
NOTE
The layout of piping must ensure that the flow meter is filled with liquid at all
times and that no inclusions of air, foam or gas may occur.
Aquametro Oil & Marine AG recommends to install bypass valves.
The quantities from all consumers must be registered by the flow meter.
Tank
Pump
Non-Return
Valve
Flow meter
Flow meter
Tank

8CONTOIL® DN15 - 50
Correct layout of flow meter and accessories
If the flow meter is used for viscosities higher than 5 mPa.s, or if it is mounted on the suction
side of a pump, the pressure loss and the flow rate that can still be attained should be deter-
mined with the help of the pressure loss curves provided in CONTOIL® Technical Information.
In addition, the pressure loss due to installed filters must be taken into consideration.
Select the flow meter and ancillaries according to the working conditions listed below:
Flow meters must be selected according to the maximum flow rate and not according
to the pipe diameter. If necessary, adjust the pipeline.
Flow rate (maximum expected application flow rate = maximum-continuous flow rate of
flow meter Qcont)
Material compatibility with medium
Operating pressure and temperature
Ambient temperature
The flow meters must selected according to the flow rate and not according to the pipe diame-
ter. If necessary, adapt the pipework.
Non-Return-Valves
In order to avoid backflow and draining, Non-Return-Valves must be mounted after the flow
meter. Backflow and draining can cause faulty measurements and may damage the flow meter.
Filter
Non-Return-Valve
Flow meter
Pump
Tank

CONTOIL® DN15 - 50 9
Dirt filter, Safety filter
Filters should be fitted to prevent any damage to the flow meter from impurities in the oil.
NOTICE
The filter mounted in the flow meter inlet is only a safety filter and can not
act as a dirt filter.
Risk of malfunction or damage.
If the medium contains dirt always have a dirt filter installed
upstream of the flow meter.
Heat insulation
The electronic or mechanical counter must not be insulated. This could cause its permitted
temperature range to be exceeded.
The permitted temperature ranges for the flow meter must be observed.
Maximum mesh width for filters
Nominal
Flow meter type
size
VZO
VZOA
DN15
0.250mm
0.100mm
DN20
0.400mm
0.100mm
DN25
0.400mm
0.250mm
DN40
0.600mm
0.250mm
DN50
0.600mm
0.250mm
No heat insulation in
this area
Heating coil (winding)
Pipe
Heat insulation

10 CONTOIL® DN15 - 50
Special requirements - differential measurements
For differential measurements, one flow meter is installed in the supply line pipe and one in the
return line pipe. The flow difference between these meters determines the consumption.
If ordered with the "differential measurement" option, VZOA flow meters are calibrated in ac-
cordance with the indicated supply and return flow volumes. The flow meters are labeled
“SUPPLY” and “RETURN”. Make sure that these flow meters are installed in the correct pipe-
line, i.e. the supply flow meter shall be installed in the supply line pipe and the return flow meter
shall be installed in the return line pipe.
Special requirements - ships
On ships, attention is required to ensure that the engine can continue to operate at full power
even if there is heavy filter contamination or if the flow meter is damaged. A pressure switch
can be used to switch over to the bypass and to draw attention for servicing. The engine then
continues to operate but without consumption measurements.
Ship classification societies require the installation of bypass pipes. The relevant regulations
must be followed.
Flow meter
Flow meter
Return
Supply
Pump
Filter
Engine
Tank

CONTOIL® DN15 - 50 11
Installation of the flow meter on the suction side of a pump
If the flow meter is installed on the suction side of a pump, consideration must be given to avoid
air-intake or foam.
Installation of the flow meter on the pressure side of a pump
Flushing of pipes
If the pipes are to be flushed at a later stage, stop valves shall be provided on both sides of the
flow meter.
NOTICE
Accumulation of debris will occure in front of the stop-valve during flushing.
To eliminate this, replaced the flow meter with a spool piece.
Special requirements - filling and dosing units
For filling and dosing, the valve must be fitted between flow meter and discharge.
The shorter the pipe section between valve and discharge, the higher the accuracy.
Avoid water hammer if fast closing valve is installed.
Filter
Pump
Flow meter on pressure side
Filter
Flow meter on suction side
Pump
Filter
Valve
Flow meter
Pump
flushing
measuring

12 CONTOIL® DN15 - 50
3.2 Mechanical installation
WARNING
Leakage or rupture due to connections being made using force.
Risk of severe injury!
Risk of substantial property damage!
Never attempt to overcome misalignments (lateral, angular,
longitudinal, torsional) using force.
Make sure the pipings are flexible enough, if not: use compensators.
Consider the effects of thermal contraction and expansion.
WARNING
Leakage or rupture due to misuse of the mounting material.
Risk of severe injury!
Risk of substantial property damage!
Regarding mechanical strength, with bolts, screws and nuts, use the
prescribed dimensions.
Use the full number of bolts, screws and nuts.
Observe the prescribed thread lubrication (grease or dry!).
Tighten the bolts and nuts in the proper sequence to the specified
torque.
If using flanged connections, the correct number of connector elements must be fitted and they
must be tightened with the correct torque in accordance with the screw manufacturer’s instruc-
tions. Comply with the permissible operating data as defined on the type plate. Make sure that
no hazardous fumes can build up in the piping and in the flow meter during commissioning,
decommissioning and dismantling. The flow meter must at all times be completely filled with
liquid during operation. Check the flow meter periodically for tightness of the connections and
for proper functioning. If work is to be done on the installation, before each intervention: release
the pressure in the installation if hazardous liquids are used, wear protective clothing and safety
goggles, place a collecting tray underneath the installation.

CONTOIL® DN15 - 50 13
Preparing for installation
Check flow meters and installation material.
Compare the data of the flow meter name plate with the expected maximum conditions of the
installation. They may not exceed the flow meter specifications:
•Continuous flow rate (Qcont l/h)
•Maximum operating pressure (PN bar)
•Maximum temperature (°C)
•Appropriate connections( threaded, or flanged) and seals (gaskets)
•Fasteners for the flow meter
•Resistance to liquid to be metered and temperature
CAUTION
Unauthorized start-up while mounting.
Risk of injury!
Make sure that unauthorized start-up is not possible while
mounting.
Comply with the appicable working regulations during all work on the
system.
NOTE
When existing systems are altered:
Take the flow meter out of operation in order to flush the system clean of
debris. Flushing information on page 11.
Trial operation
Start trial operation (without flow meter); open the stop valves slowly when doing this.
Carry out a pressure test in the plant.
Check for leaks and tightness of all bolts
Flush the pipework until clean (flow meter out of pipeline)
Release the pressure and stop the system again.
This trial operation ensures that the pipework is tight and clean.

14 CONTOIL® DN15 - 50
Installing the meter in the pipe
Remove the protection plugs or caps from the flow meter (inlet and outlet).
Insert the flow meter into the pipeline in the prescribed position and flow direction. The arrow
on the flow meter should correspond with the direction of flow. Install mating flanges parallel
and without tension in the pipe.
NOTICE
Mechanical connection of flow meter into the pipe systems.
Risk of leackage
Always use appropriate sealing material as per connection type.
For pipes made of copper or thin-walled steel pipes, the flow meter requires additional fas-
tening. Use appropriate fasteners.
Meter with flanged ends
Meter with threaded ends
X
X

CONTOIL® DN15 - 50 15
3.3 Electrical Installation
NOTICE
Electrical connection to the supply voltage and / or connections to other systems.
Risk of malfunction or damage
Review of technical data, chapter 8.1, on page 22.
3.4 Electrical connection
Display unit options VZO, VZOA
Pulser RV
Cable; 3 m, Polarity: in any order
Pulser IN/INA
Pay attention to polarity when connecting the plug.
See document VD4-345.
Control /
monitoring System
pulse value see type plate
connection cable min. 2 x 0.35 mm2 and 4 - 6 mm
external cable diameter on plug
supplied with product or use optional
part no. 80019 with prefabricated
cable
connection detail can be found on cable mount instruction
delivered with the product (VD4-345def)
Totalizer
pulse value see type plate

16 CONTOIL® DN15 - 50
3.5 Engineering notes
Parameterizing ancillary devices
Some ancillary units require programming of pulse values or frequency (see the relevant
operating instructions). Pulse values of the VZO(A) flow meters: see type plates.
The maximum frequency is calculated with the following formula:
𝑚𝑎𝑥. 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑖𝑛 𝑙𝑖𝑡𝑒𝑟𝑠/ℎ𝑜𝑢𝑟
𝑝𝑢𝑙𝑠𝑒 𝑣𝑎𝑙𝑢𝑒 𝑖𝑛 𝑙𝑖𝑡𝑒𝑟𝑠 𝑥 3600 = 𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 𝑖𝑛 𝐻𝑧
4 Operation
NOTE
Modification of operation settings may result in faulty or wrong
measuring results.
4.1 Operation and startup
Startup and commissioning of mechanical part of flow meter (VZO, VZOA). Open valves slowly,
fill pipework gradually. Vent the installation well.
Water hammer must be avoided in order not to damage the flow meter. Inclusions of air cause
measuring errors in all types of flow meter and can damage them during operation.
Check the tightness of the connections watch for leakages. Check if the flow rate of the
installation correspond to the specification of the flow meter.
Roller counter type flow meter (VZO and VZOA): measure the flow volume for
30 - 60 seconds, the flow rate is calculated using the following formula:
𝑡𝑜𝑡𝑎𝑙𝑖𝑠𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑖𝑛 𝑙𝑖𝑡𝑒𝑟𝑠 𝑥 3600
𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑡𝑖𝑚𝑒 𝑖𝑛 𝑠𝑒𝑐𝑜𝑛𝑑𝑠 = 𝑙𝑖𝑡𝑒𝑟𝑠 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟
Should the established flow rate be greater than the specification of the flow meter (Qcont),
either a flow control valve (throttle) must be inserted behind the flow sensor or a larger size
flow meter must be used.
For RV and IN(A) pulse sensors: Check function of connected accessories.

CONTOIL® DN15 - 50 17
5 Maintenance and Repair
5.1 Calibration
All our flow meters are calibrated in the factory.
An accuracy check and recalibration is offered at Aquametro Oil & Marine AG, this is usually
dependent on customer, operator or regulation requirements. This interval depends largly on
the operating conditins, process liquid and the application the flow meter 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 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 googles
NOTICE
Use of unsuitable cleaning agents and procedures.
Risk of malfunction or damage
Follow the cleaning instructions on the next page.
NOTICE
Warranty will be void, if the flow meter is being opened during the warranty
period by a non Aquametro Oil & Marine AG certified person.

18 CONTOIL® DN15 - 50
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 flow meter:
do not use any aggressive solvents
rinse hydraulic part of flow meter thoroughly
Aquametro Oil & Marine AG recommends to use the following cleaning solvents:
Gasoline used for cleaning purposes
Cleaner’s naphtha
Petroleum ether
Dirt filter (not safety filter of flow meter)
Dirt filters must be cleaned periodically, initially at short intervals to keep fuel system free of
dirt and debris.
To restart the system:
slowly open the stop valves, avoiding pressure surges (“water hammer”)
vent the pipe well
check tightness
Maintenance
NOTICE
Warranty will be void, if the flow meter is being opened during the warranty
period by a non Aquametro Oil & Marine AG certified person.
Check connections periodically for tightness and if necessary retighten. For control and clean-
ing, the measuring chamber and the ring piston of the flow meters DN15-50 can be removed
without dismantling the flow meter from the pipe.
Torque of measuring chamber screws
Flow meter
Screws
Torque
DN 15,20
M 6
6 Nm
DN 25
M 8
16 Nm
DN 40
M 12
47 Nm
DN 50
M 16
100 Nm

CONTOIL® DN15 - 50 19
The cleaning and revision cycle depends largely on the conditions of operation. Under
favourable conditions 5-10 years suffice. Check the devices for corrosion.
Recommended revision cycle
Flow meter.
Totalizer Volume
Time
DN 15
20‘000 m3
7 years
DN 20
50‘000 m3
DN 25
100‘000 m3
DN 40
300‘000 m3
DN 50
1‘000‘000 m3
The responsibility of the revision cycles lies with the operator.
NOTICE
If opening is necessary:
Risk of malfunction!
Observe positions during disassembly
Follow assembly instructions
Check proper function at start up
Recalibration is recommended after service
For more information about maintenance, request document VI 14-419.
Opening and closing
For instruction on opening and closing the flow meter please refer to our webpage.
See Spare part list and Maintenance instructions VI14-419
5.3 Spareparts
NOTICE
Use of wrong Spare parts
Risk of malfunction or damage
Use only original spare parts, supplied by Aquametro Oil & Marine AG
Spare part list and Maintenance instructions VI14-419 may be
requested from Aquametro Oil & Marine AG.

20 CONTOIL® DN15 - 50
6 Troubleshooting
6.1 For all CONTOIL®flow meter
Fault symptoms
Possible causes
Procedures 1)
Pointers on roller
counter rotate
irregularly
This is normal at high flow
rates and has no effect on
accuracy of measurement
No action required
Counter runs
backwards
Meter mounted in wrong di-
rection
Install meter with arrow point-
ing in flow direction
Counter not running
Indicated quantity or
flow rate too small
Flow rate outside allowed
range (below Qmin or above
Qmax of meter)
Check flow rate
If too high, reduce flow or
install larger meter
If too low, increase flow or in-
stall smaller meter
Moving parts heavily worn
out due to continuous
overload
install larger meter
Dirt trap / filter heavily
soiled
Clean dirt trap, replace filter
Safety filter in meter intake
clogged
Replace safety filter
Install dirt trap / filter with
correct mesh size
Moving parts jammed
clean measuring chamber,
replace defective parts
Alignment of inner parts
align cover and measuring
chamber (rip to rip)
Separating plate broken by
oPressure hammer
oGas inclusions
Check and rectify operating
conditions and meter position
Fill pipes slowly
De-aerate pipes thoroughly
Indicated quantity or
flow rate too high
Meter positioned wrongly
(e.g. at highest point)
Gas or air inclusion in fluid
Check and rectify operating
conditions and meter position
De-aerate pipes carefully
pressure drop at
meter too high
Dirt trap or filter heavily
soiled
Clean dirt trap, replace filter
Flow meter’s safety filter
heavily soiled
Clean safety filter of flow
meter
No pulse output
signal
Legend:
1) Consult operating in
structions
2) pulser type IN / INA
only
3) pulser type RV only
No flow
Check flow using Indication
Pulser sensor defective 2)
Replace sensor
Pulser module defective 2)
Remove sensor and check if
pulser disk does rotate
Pulser disk does not rotate
2)
Remove pulser module, place
counter on first module, and
check flow indication
If indication is positive, replace
pulser module
otherwise see ‘Counter not
running’
Reed pulser defective 3)
Replace roller counter