BARTEC BENKE VISC-4 User manual

Viscosity Process Analyzer VISC-4
Operating Instructions
401648MDHEN -
04/2016

04/2016 2

BARTEC BENKE GmbH
Borsigstraße 10
D-21456 Reinbek
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.bartec-benke.de

Viscosity Process Analyzer VISC-4
Contents
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Contents
1 General information.............................................................................. 1
1.1 Information on the operating manual.............................................................................................. 1
1.2 Explanation of symbols.................................................................................................................. 2
1.3 Duties of the operator ................................................................................................................... 4
1.4 Limitation of liability ...................................................................................................................... 5
1.5 Copyright ..................................................................................................................................... 5
1.6 Replacement parts........................................................................................................................ 6
1.7 Customer service.......................................................................................................................... 7
2 Safety.................................................................................................... 9
2.1 Intended use ................................................................................................................................ 9
2.1.1 Improper use........................................................................................................................... 9
2.2 Dangers and risks....................................................................................................................... 10
2.3 Hazardous materials ................................................................................................................... 17
2.4 Explosion protection.................................................................................................................... 19
2.4.1 Marking ................................................................................................................................ 19
2.4.2 Types of protection and certificates ........................................................................................ 21
2.4.3 Special conditions ................................................................................................................. 23
2.5 Safety devices ............................................................................................................................ 24
2.5.1 Overview of the safety equipment on the analyzer.................................................................... 25
2.5.2 Control box (Ex p) .................................................................................................................. 26
2.5.3 Junction boxes (Ex e)............................................................................................................. 29
2.5.4 Potential matching................................................................................................................. 29
2.5.5 Main switch and emergency off equipment ............................................................................. 30
2.5.6 Signs and safety warnings ..................................................................................................... 30
2.6 Signs ......................................................................................................................................... 31
2.6.1 Overview of signs .................................................................................................................. 32
2.6.2 Warnings .............................................................................................................................. 33
2.6.3 Command signs .................................................................................................................... 35
2.7 Safety measures at the installation location .................................................................................. 36
2.8 Safety information on explosion protection.................................................................................... 36
2.9 Personnel requirements .............................................................................................................. 38

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2.9.1 Qualifications ........................................................................................................................ 39
2.9.2 General requirements ............................................................................................................ 40
2.9.3 Unauthorized persons............................................................................................................ 40
2.9.4 Instruction ............................................................................................................................ 40
2.10 Personal protective equipment .................................................................................................... 41
2.11 Securing against being switched on again....................................................................................43
3 Technical data .....................................................................................45
3.1 Type plates ................................................................................................................................ 51
4 Design and function ...........................................................................53
4.1 Overview.................................................................................................................................... 53
4.2 Brief description ......................................................................................................................... 54
4.3 Viscosity and measuring principle................................................................................................ 55
4.4 Measuring procedure.................................................................................................................. 57
4.5 Description of subassemblies ...................................................................................................... 58
4.5.1 Measuring unit...................................................................................................................... 58
4.5.2 Controller.............................................................................................................................. 59
4.5.3 Fluid technology.................................................................................................................... 61
4.5.4 Junction boxes...................................................................................................................... 62
4.5.5 Sample conditioning system (optional) .................................................................................... 63
4.6 Optional extensions .................................................................................................................... 64
4.7 Connections ............................................................................................................................... 65
4.8 Operating elements .................................................................................................................... 65
5 Transport, packaging, and storage .....................................................69
5.1 Safety ........................................................................................................................................ 69
5.2 Safety instructions for transport................................................................................................... 69
5.3 Symbols on the packaging .......................................................................................................... 71
5.4 Transport inspection ................................................................................................................... 71
5.5 Packaging.................................................................................................................................. 72
5.6 Center of gravity and suspension................................................................................................. 73
5.7 Transport ................................................................................................................................... 74
5.8 Storage...................................................................................................................................... 75

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6 Installation and preparation for commissioning ................................ 77
6.1 Safety ........................................................................................................................................ 77
6.2 Requirements for the installation location ..................................................................................... 79
6.3 Fixing to the floor........................................................................................................................ 80
6.4 Connecting pipe connections....................................................................................................... 80
6.5 Connecting the voltage supply and signal lines ............................................................................. 83
6.6 Preparing for commissioning ....................................................................................................... 85
6.6.1 Rinsing the instrument air supply lines....................................................................................85
6.6.2 Supplying with instrument air ................................................................................................. 86
6.6.3 Rinsing the product supply lines ............................................................................................. 86
6.6.4 Rinsing the coolant supply line ............................................................................................... 88
6.6.5 Fill the chiller and provide it with coolant................................................................................. 88
7 Commissioning ................................................................................... 90
7.1 Safety ........................................................................................................................................ 90
7.2 Commissioning VISC-4 Ht or Hv ................................................................................................. 92
7.2.1 Switching on the power supply............................................................................................... 92
7.2.2 Supplying the analyzer with product........................................................................................93
7.3 Commissioning VISC-4 Lt, Lv, Mt, and Mv .................................................................................. 94
7.3.1 Supplying the analyzer with product........................................................................................94
7.3.2 Switching on the power supply............................................................................................... 95
7.4 Bleeding the differential pressure transmitter................................................................................ 96
7.5 Monitoring and operation............................................................................................................. 97
8 Operation ............................................................................................ 99
8.1 Safety ........................................................................................................................................ 99
8.2 Switching on ............................................................................................................................ 100
8.3 Operation ................................................................................................................................. 100
8.4 Switching off ............................................................................................................................ 101
8.5 Shutting down in an emergency................................................................................................. 101
8.6 Conduct in the event of danger.................................................................................................. 103
9 Faults................................................................................................ 105

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9.1 Safety ...................................................................................................................................... 105
9.2 Fault analysis ........................................................................................................................... 107
9.3 Starting up after rectifying a fault............................................................................................... 112
10 Maintenance......................................................................................113
10.1 Safety ...................................................................................................................................... 113
10.2 Maintenance plan..................................................................................................................... 116
10.3 Cleaning the touchscreen and other components........................................................................ 116
10.4 Rinsing and emptying product-carrying components................................................................... 118
10.4.1 Products with low to normal viscosity ................................................................................... 118
10.4.2 Highly viscous products (special case of the variants Ht or Hv) ............................................... 120
10.5 Cleaning of product-carrying components (highly viscous products) ............................................. 124
10.6 General visual inspection........................................................................................................... 124
10.7 Checking the safety equipment.................................................................................................. 126
10.8 Checking the pressure monitor.................................................................................................. 127
10.9 Bleeding the differential pressure transmitter ............................................................................. 128
10.10 Replace the Peltier elements ..................................................................................................... 129
10.11 Turning out the swing arm with the measuring unit..................................................................... 134
10.12 Replacing the mass flow meter.................................................................................................. 136
10.12.1 Removing the mass flow meter ............................................................................................ 136
10.12.2 Installing a mass flow meter ................................................................................................ 137
10.13 Replacing the capillary unit........................................................................................................ 138
10.13.1 Removing the insulation container........................................................................................138
10.14 Turning the swing arm back and fixing it in place ....................................................................... 145
10.15 Checking the residual-current device (RCD)................................................................................ 146
10.15.1 Measures after the RCD has triggered .................................................................................. 147
10.15.2 Measures in case of troubles ............................................................................................... 147
10.16 Replacing the battery on the industry PC.................................................................................... 148
10.17 Measures after maintenance ..................................................................................................... 149
11 Dismantling .......................................................................................151
11.1 Safety ...................................................................................................................................... 151
11.2 Preparing for dismantling .......................................................................................................... 152
11.3 Disconnecting electrical connections.......................................................................................... 152
11.4 Disconnecting pipe connections ................................................................................................ 152

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11.5 Removing fastenings................................................................................................................. 153
11.6 Disposal................................................................................................................................... 153
12 Index................................................................................................. 155

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General information
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1 General information
Amongst other things, this section contains information on this operating
manual, the symbols used, liability restrictions and contact persons in cus-
tomer service.
1.1 Information on the operating manual
This operating manual provides important information on handling the analyz-
er. Adherence to all safety and operating instructions given is prerequisite for
work safety.
Furthermore, the locally applicable accident prevention regulations and
general safety instructions for the area of application of the analyzer
must be observed.
Read the operating manual prior to beginning any work! It is a compo-
nent part of the product and must be stored in the immediate vicinity of
the analyzer and must be accessible for operating personnel at all times.
If the analyzer is handed over to a third party, the operating manual must also
be handed over.
For the purposes of clarity, the figures in this operating manual are not nec-
essarily illustrated to scale and may deviate slightly from the actual analyzer
model.
In addition to the operating manual and the software handbook, all other doc-
uments contained in the customer folder are applicable.
Observe the safety instructions listed there! An overview can be found in the
table of contents in the customer folder.
NOTICE
i
This operating manual is supplemented by the software
manual.
It provides a detailed explanation of the operation of the
software for controlling the analyzer. It also contains in-
formation on the measuring process.

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General information
1.2 Explanation of symbols
Warnings Warnings are indicated in this operating manual by symbols. The warnings are
introduced with signal words indicating the degree of danger at hand.
Observe the instructions under all circumstances and work with care to avoid
accidents, injuries to personnel and damage to property.
Symbols used in the manual and on
the analyzer
The safety warnings on the analyzer are also highlighted with warning sym-
bols. The following section explains the warning symbols used on the analyzer
and in the operating manual.
DANGER
… indicates an immediate hazard which, if not avoided, will
result in serious injury or death.
WARNING
… indicates a possible hazard which, if not avoided, could
result in serious injury or death.
CAUTION
… indicates a possible hazard which, if not avoided, could
result in minor injuries.
NOTICE
… indicates a possible hazard which, if not avoided, could result in damage
to equipment or property.

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General information
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Examples of special warning signs
Warning of a danger area
Warning about poisonous substances
Warning about flammable substances
Warning about potentially explosive atmospheres
Warning about dangerous electrical current
Warning about potential hand injuries
Warning about hot surfaces
Warning about automatic start-up
(in use with some analyzers only)
Warning about cold
(in use with some analyzers only)
DANGER
Danger of death due to electrical current!
... indicates life-threatening situations due to electrical cur-
rent. Failure to observe the safety instruction could result in
serious injuries or death.
FOR THIS REASON:
The work to be performed may only be carried out by
an electrician.

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Tips and recommendations
1.3 Duties of the operator
The analyzer is used in commercial enterprises. The operator of the analyzer
is therefore under legal obligation to ensure work safety. The applicable na-
tional standards and laws must be observed.
In addition to the work safety instructions in this operating manual, the safety,
accident prevention and environmental protection regulations applicable in
the area of application of the analyzer must be observed.
Further to this, the operator is responsible for ensuring that the analyzer is al-
ways in a technically perfect working condition. Therefore the following ap-
plies:
The operator must ensure that all maintenance intervals specified in
this operating manual are adhered to.
The operator must have all safety equipment inspected regularly to
ensure it is fully functional and complete.
The operator must make the necessary safety equipment available to person-
nel.
WARNING
Risk of death due to unavailable explosion
protection!
... indicates life-threatening situations in potentially explosive
atmospheres. Failure to observe the safety instruction could
result in serious injuries or death.
FOR THIS REASON:
Work may only be performed by a specialist for poten-
tially explosive atmospheres.
NOTICE
i
… indicates useful tips and recommendations as well as in-
formation for efficient and trouble-free operation.

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1.4 Limitation of liability
All specifications and instructions in this operating manual have been com-
piled under consideration of the applicable norms and regulations, the latest
technological standards as well as our many years of experience and exper-
tise.
The manufacturer assumes no liability for damages due to the following:
Failure to observe the instructions in the operating manual
Improper use
Deployment of untrained personnel
Structural modifications made without prior consent
Technical modifications
Use of non-approved replacement parts
The actual scope of delivery of special models can differ from the explanations
and diagrams used in this manual if additional options are ordered or due to
the latest technical changes.
Otherwise, the obligations agreed upon in the delivery contract, the general
terms and conditions and the delivery terms of the manufacturer apply, as well
as any legal regulations valid at the time the contract was concluded.
1.5 Copyright
The operating manual is to be treated confidentially. It is intended exclusively
for personnel engaged to work with the analyzer. Making the operating man-
ual available to third parties is not permitted without the manufacturer's writ-
ten consent.
Reproductions of any type - including excerpts - as well as the application
and/or imparting of the content is prohibited without a written statement from
the manufacturer. Infringements will be met with a claim for compensatory
damages. The right to make further claims is reserved.
NOTICE
i
The information, texts, diagrams, images and other illustra-
tions of the contents are copyright protected and subject to
commercial protective rights. Every instance of misuse may
result in prosecution.

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1.6 Replacement parts
Obtain replacement parts from authorised dealers or directly from
BARTEC BENKE. For the address, see section 1.7 “Customer service” on
page 7.
The replacement parts list can be found in the customer folder.
WARNING
Risk of injury due to incorrect replacement parts!
Incorrect or defective replacement parts can result in dam-
ages, faults or total failures as well as impairments to safety.
FOR THIS REASON:
Only use replacement parts from BARTEC BENKE.
WARNING
No explosion protection due to using incorrect re-
placement parts!
Some optionally used replacement parts are modified by
BARTEC BENKE for a particular purpose. The use of non-
modified original replacement parts of the relative manufac-
turer can cause loss of explosion protection.
FOR THIS REASON:
Only use replacement parts from BARTEC BENKE.

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1.7 Customer service
Should you require any technical information, our customer service depart-
ment will be happy to help you.
You can find information on the responsible contact partner at any time by
telephone, fax, e-mail or on the Internet.
Furthermore, our employees are always eager to receive any new information
and experiences arising from use and which could be valuable for the im-
provement of our analyzers.
Service-address BARTEC BENKE GmbH
Borsigstraße 10
D-21456 Reinbek, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.bartec-benke.de

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General information

Viscosity Process Analyzer VISC-4
Safety
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2Safety
This section provides an overview of all important safety aspects for optimal
protection of personnel as well as safe and trouble-free operation.
Failure to observe the operating and safety instructions in this manual can re-
sult in considerable dangers.
This chapter describes all the safety and warning signs in line with the risk as-
sessment of the analyzer. The measures for avoiding the respective dangers
are described in detail in this chapter. The following chapter will only present
the safety and warning signs in shortened form.
Example of shortened safety or
warning message
2.1 Intended use
The analyzer is designed exclusively as a process analyzer for the fully auto-
matic measurement of fossil and regenerating energy sources and/or petro-
chemical products (hereafter referred to as product). The analyzer is only to
be used for stationary operation. It is suitable for use in potentially explosive
atmospheres.
Do not make any modifications to the analyzer. Only use spare parts from
BARTEC BENKE. Otherwise additional hazard may arise for which the safety
fittings cannot provide sufficient protection.
A more precise definition of the use of the products and the device-specific
function can be found in Chapter 4 “Design and function” on page 53.
2.1.1 Improper use
The following uses of the device are prohibited.
Feeding other liquids, vapors, or gases into the device; in particular this
applies to an external vent drain system. Adding oxygen or hydrogen
can result in the risk of explosions.
Rinsing with steam. High temperatures and pressures damage device
components.
Feeding liquid gas into the device.
DANGER
Danger of death due to electrical current!
Touching voltage-conducting parts poses an immediate life-
threatening hazard. Damage to the insulation or to individual
components can cause fatal injury.
Avoidance measures
see chapter 2 “Safety”.

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Safety
Claims of any type for damages due to improper use are disallowed.
The operating company is solely responsible for all damages arising from im-
proper use.
2.2 Dangers and risks
The following section names residual risks that have been established in a risk
analysis.
Adhere to the safety instructions and observe the warnings in the follow-
ing sections of this operating manual to reduce health risks and avoid
dangerous situations.
WARNING
Danger from improper use!
Any use which goes beyond and/or differs from the intended
use of the unit can lead to dangerous situations.
FOR THIS REASON:
The Analyzer is to be used only as intended.
Strict compliance with all specifications in this operat-
ing manual is mandatory.