VAF instruments Viscosense 3 Maintenance manual

Technical Manual
Instructions for installation,
operation and maintenance
775
VISCOSENSE
®
3
Viscosity Sensor & Interface box
Valid for ViscoSense®3
Publication nr TIB-775-GB-0517
Supersedes TIB-775-GB-1216

CONTENTS
1. PREFACE....................................................................................... 2
1.1 General ........................................................................................................2
1.2 Symbols .......................................................................................................3
1.3 Copyright .....................................................................................................3
2. SYSTEM DESCRIPTION................................................................ 4
2.1 System description.......................................................................................4
2.2 System components ....................................................................................5
2.3 Principle of operation ...................................................................................6
3. TECHNICAL SPECIFICATION ....................................................... 7
3.1 Sensor .........................................................................................................7
3.2 Sensor housing............................................................................................7
3.3 Interface box ................................................................................................8
4. SAFETY INSTRUCTIONS .............................................................. 8
4.1 Safety precautions .......................................................................................8
5. UNPACKING .................................................................................. 9
6. INSTALLATION .............................................................................. 9
6.1 To record nameplate data............................................................................9
6.2 Conditions for correct working of the ViscoSense®3 sensor ......................10
6.3 General installation recommendations.......................................................11
6.4 Mechanical installation...............................................................................11
6.4.1 ViscoSense®3interface box..............................................................11
6.4.2 ViscoSense®3 housing......................................................................11
6.4.3 To assemble ViscoSense®3 sensor ..................................................13
6.5 Electrical installation ..................................................................................15
6.6 Connection of sensor to interface box........................................................16
6.7 Installation checklist version 1.0.................................................................17
7. OPERATING INSTRUCTIONS..................................................... 19
7.1 Initial start-up .............................................................................................19
7.2 Shut-down on heavy fuel oil.......................................................................19
7.3 Shut-down on diesel oil..............................................................................19
7.4 Routine start-up .........................................................................................19
8. MAINTENANCE............................................................................ 20
8.1 Routine maintenance .................................................................................20
8.2 To clean the ViscoSense®3 sensor............................................................20
8.2.1 General procedure ............................................................................20
9. REPAIR OR REPLACEMENT ...................................................... 21
9.1 Repair ........................................................................................................21
9.2 Replacement..............................................................................................21
9.3 Procedure for using the micro SD card ......................................................21
10. TAKE OUT OF SERVICE ......................................................... 22
11. REMOVAL AND STORAGE OF EQUIPMENT......................... 23
12. MALFUNCTION AND SEND FOR REPAIR ............................. 23

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13. ENVIRONMENT ....................................................................... 23
14. DISPOSAL................................................................................ 23
15. TROUBLE SHOOTING............................................................. 24
15.1 Disconnection the sensor........................................................................24
15.2 General trouble shooting.........................................................................25
15.3 PI setting errors (for additional viscosity controller).................................27
15.4 How to take a HFO sample for analysis..................................................27
15.5 Diagnostic information ............................................................................28
16. CERTIFICATES........................................................................ 30
17. DRAWINGS .............................................................................. 31
17.1 ViscoSense®3 sensor and sensor housing .............................................31
17.1.1 ViscoSense®3sensor housing with sensor installed.........................31
17.2 ViscoSense®3interface box....................................................................32
17.2.1 ViscoSense®3interface box..............................................................32
18. ABBREVIATIONS..................................................................... 33
19. PARTS LISTS........................................................................... 34
19.1 ViscoSense®3 sensor .............................................................................34
20. WARRANTY CONDITIONS...................................................... 35
21. ENCLOSURE ........................................................................... 37
21.1 Recommendations for a good working booster unit ................................ 37

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1. PREFACE
1.1 GENERAL
This manual contains instructions for installation, operation and maintenance (IOM) of the VAF
ViscoSense®3 viscosity sensor (VS3) and interface box.
For IOM information of associated equipment supplied by VAF Instruments, refer to the separate
manual supplied with those products.
This manual contains important information for the installer, the operator and for your maintenance
department.
Never use the equipment outside its specifications or beyond common engineering practice
nor use the equipment for other applications or make connections to other equipment than
explicitly described in the order acknowledgement and/or technical manuals of VAF
Instruments.
It is not allowed to make any modifications to the sensor or the interface box without prior
written permission of VAF Instruments BV.
To ensure safe and correct installation and operation, read this manual completely before
installing the equipment and starting operations.
ViscoSense®2and ViscoSense®3 sensor (from serial numbers 70000) and interface box
(from serial numbers 1480000) are not interchangeable with previous model ViscoSense®.
ViscoSense®2and ViscoSense®3 sensor and interface box are interchangeable.
For any additional information contact:
VAF Instruments B.V. Tel. [phone]
Vierlinghstraat 24, 3316 EL Dordrecht Fax [phone]
P.O. Box 40, NL-3300 AA Dordrecht E-mail: [email protected]
The Netherlands Internet: www.vaf.nl
Or your local authorized VAF dealer.
Their addresses can be found on www.vaf.nl

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1.2 SYMBOLS
The following symbols are used to call attention to specific types of information.
A warning to use caution! In some instances, personal injury or damage to the
ViscoSense®3 unit or control system may result if these instructions are not followed
properly.
An explanation or information of interest.
Warning for hazardous voltages. Symbol is used on the interface box in combination with
the requirement to switch of the power supply to the box before opening it, in order to
avoid personal injury.
1.3 COPYRIGHT
This technical manual is copyrighted with all rights reserved.
While every precaution has been taken in the preparation of this manual, no responsibility for errors or
omissions is assumed. Neither is any liability assumed for damages resulting from the use of the
information contained herein. Specifications can be changed without notice.
ViscoSense®is a registered trademark of VAF Instruments B.V.

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2. SYSTEM DESCRIPTION
2.1 SYSTEM DESCRIPTION
ViscoSense®3 is, besides other applications, intended for use in fuel oil treatment systems to obtain a
correct measurement and control of the fuel oil viscosity.
Figure 1 shows a typical fuel treatment system with return line from the engine. In this system, the
degassing/mixing tank operates as a fuel buffer, ensuring gradual changes of viscosity which results
in a stable control of the viscosity. The ViscoSense®3 sensor is used to measure the actual viscosity
of the fuel oil. The signal from the sensor is compared to the setpoint of a viscosity controller, which
regulates the output of the fuel heater via a control element (steam or thermal oil valve, or electric
heater cabinet).
Figure 1 Typical example of an automatic control system using steam or thermal oil heater

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2.2 SYSTEM COMPONENTS
The ViscoSense®3 viscosity system consists of:
the combined viscosity and temperature measuring sensor
the sensor housing
Interface box
The sensor housing is made of ductile iron and has flanges for direct mounting in the fuel line. The
sensor itself is made of stainless steel and is mounted in the housing. The sensor head has a special
DLC coating and it is mechanically protected by a stainless steel flow tube with 3 oval slits. It is
supplied with 5 metres of signal cable for connection to the interface box.
The ViscoSense®3 Interface box is a wall mount electronic unit, processing the signals to and from
the sensor. It provides 4...20 mA signals for remote read-out of viscosity and temperature for a
flowcomputer, controller or other system elements. See separate technical manuals for a description
of these components.
Figure 2 ViscoSense®3 components (sensor in housing and interface box)

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2.3 PRINCIPLE OF OPERATION
The operating principle of the sensor is that of a torsion pendulum. The sensor consists of a stainless
steel driver / sensor head (1), attached to the base plate (2) by means of a tubular torsion spring (3).
In the head, one pair of piezo elements (driver piezos) (4) actuates the pendulum at its torsional
resonance frequency, while another pair (the receiver piezos) probes the actual movement of the
head. In a low viscosity medium, like air the resonance frequency is in the range of 1600 Hz. In a high
viscosity medium the movement of the head is damped by the liquid. Consequently, the resonance
frequency slightly shifts towards lower frequencies, whilst the width of the resonance peak increases,
which is a measure for the viscosity.
A flow tube (5) is placed around the pendulum, to protect it against mechanical damage.
The flow tube is machined with a smooth surface, as well as with a triplet of oval slits. These slits
increase the refreshing rate between sensor and flow tube.
Figure 2 ViscoSense®3 sensor (VS3)

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3. TECHNICAL SPECIFICATION
3.1 SENSOR
Sensor type nr. 0279-0096
Viscosity range 0 - 25/50 mPa.s (other ranges on request)
Temperature range 0-200°C
Maximum operating temperature 180C
Temperature transmitter PT 100 element
Accuracy
Viscosity +/- 2% instantaneous or 0.5 mPa.s
Temperature ± 1C
Material
Sensor Stainless steel 316L
Coating Diamond Like Carbon (DLC)
Signal cable length 5 metres, integrated with sensor
Protection class IP65
Weight 1 kg
Warning
For hazardous zone I and II, the ViscoSense®3 Ex d version is required.
(See separate technical manual TIB-777)
3.2 SENSOR HOUSING
Material housing ductile iron
Flange connections DN 50 mm (2”), DIN, ANSI or JIS
DN 65 mm (2,5”), DIN, ANSI or JIS
DN 80 mm (3”), DIN, ANSI or JIS
DN 100 mm (4”), DIN, ANSI or JIS
Maximum pressure rating 40 bar
Weight 2” approx. 10 kg
2,5” approx. 11 kg
3” approx. 12 kg
4” approx. 13 kg

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3.3 INTERFACE BOX
Interface box type nr. 0279-0112
Supply voltage 100-230 VAC, 50/60 Hz
(Fluctuations should not exceed ±10% of the nominal value)
Power consumption 6 Watt
Internal battery Lithium coin type 3V rechargeable, 5 mAh, 6,8 mm
(Do not exchange without prior consulting VAF Instruments)
Output
Viscosity Isolated active output 4…20 mA, current loop, max. load 400Ω
Range typ. 0 - 25/50 mPa.s (depending on selected range)
Temperature Isolated active output 4…20 mA, current loop, max. load 400Ω
Range typ. 0 - 200° C
Response time Depending on application
Resolution 0,1 mPa.s and 0,1 g/l
Ambient temperature -20 .. + 55 C
Humidity range 0-95% RH
Protection class IP 66
Mounting Wall mounting
Cable connections
Power supply M20 x 1,5, Ø9-13 mm
Output signals M20 x 1,5, Ø9-13 mm
Sensor M16 x 1,5, Ø5-9 mm, integrated with sensor cable
Cable wire
Power supply 3 x 1.5 mm², double isolated heavy duty PVC
Output signals 3 x 2 x 0,50 mm², twisted pair, individually screened, braid shielded
Ventilation requirements No special requirements
Weight 2,0 kg
Max. altitude for use 2000 m above sea-level
4. SAFETY INSTRUCTIONS
4.1 SAFETY PRECAUTIONS
To ensure the safety of personnel and equipment:
Always follow the safety and installation recommendations in this manual.
Always use personal protective means when working with hot, aggressive and toxic process
liquids.
Always use insulated tools when working on electrical installations.
Ensure that local safety regulations are met when installing and operating the equipment.
All personnel who operate and service the equipment should read this manual completely and
make themselves acquainted with the equipment before installing or operating the equipment.
The ViscoSense®3 sensor body will heat up to the process temperature; do not touch the body
housing while process is running!