Vaf Lorcon Manila

Pneumatic System Components For Viscotherm

T E C H N I C A L M A N U A L 773 INSTRUCTIONS FOR INSTALLATION, OPERATION AND MAINTENANCE

Publ. Nr. TIB-773-GB-0107 Supersedes TIB-773-GB-0305

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CONTENTS

1. PREFACE....................................................................................................4 1.1 General.......................................................................................................................4 1.2 Sysmbols....................................................................................................................4 1.3 Copyright ...................................................................................................................4 1.4 To record import serial numbers ...............................................................................5

2. SYSTEM DESCRIPTION ..........................................................................6 2.1 System arrangement diagram ....................................................................................6 2.2 System components ...................................................................................................7

3. OPERATING PRINCIPLE SYSTEM COMPONENTS ............................8 3.1 Viscosity control station ............................................................................................8 3.2 Control valve ...........................................................................................................11 3.3 Alarm pressure swich (option) ................................................................................11 3.4 Airfilter-regulator ....................................................................................................12 3.5 Viscosity recorder (option)......................................................................................13 3.6 Analog viscosity indicator (option) .........................................................................13

4. TECHNICAL SPECIFICATION SYSTEM COMPONENTS.................14 4.1 Viscosity Control Station.........................................................................................14 4.2 Airfilter-regulator ....................................................................................................14 4.3 Analog viscosity indicator (option) .........................................................................15 4.4 Alarm pressure switch (option) ...............................................................................15 4.5 Starter box (option)..................................................................................................15

5. INSTALLATION PROCEDURES SYSTEM COMPONENTS..............16 5.1 Viscosity control station ..........................................................................................16

5.1.1 Mechanical installation..................................................................................16 5.1.2 Pneumatic connections ..................................................................................16

5.2 Airfilter-regulator ....................................................................................................18 5.3 Viscosity recorder....................................................................................................19 5.4 Analog viscosity indicator .......................................................................................19 5.5 Alarm pressure switch .............................................................................................21 5.6 Starter box................................................................................................................23

6. DIMENSIONS...........................................................................................24 6.1 Viscosity control station ..........................................................................................24 6.2 Airfilter-Regulator ...................................................................................................26 6.3 Alarm pressure switch .............................................................................................27

6.3.1 Alarm pressure switch ...................................................................................27 6.3.2 Alarm pressure switch ...................................................................................27

6.4 Analog viscosity indicator .......................................................................................28 6.4.1 Indicator with alarm contracts .......................................................................28 6.4.2 Indicator without alarm contacts ...................................................................28

6.5 Starter box................................................................................................................29

7. OPERATING INSTRUCTIONS...............................................................30 7.1 Viscosity control station ..........................................................................................30

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7.1.1 Adjustment of control parameters .................................................................30 7.1.2 Manual operation...........................................................................................31

7.2 Initial start-up ..........................................................................................................32 7.3 Tuning to process.....................................................................................................32 7.4 Routine start-up and shut down ...............................................................................33

8. MAINTENANCE......................................................................................33 8.1 General.....................................................................................................................33 8.2 Maintenance schedule..............................................................................................33 8.3 "A" Maintenance checks..........................................................................................34 8.4 "B" Maintenance checks..........................................................................................34 8.5 "C" Maintenance checks..........................................................................................35 8.6 Maintenance of viscosity control station.................................................................36

8.6.1 Daily servicing...............................................................................................36 8.6.2 Annual servicing............................................................................................36

8.7 Maintenance of airfilter regulator............................................................................39 8.7.1 Daily servicing...............................................................................................39 8.7.2 Annual servicing............................................................................................39

8.8 Maintenance of analog viscosity indicator ..............................................................40 8.9 Maintenance of pressure alarm switch ....................................................................40 8.10 Maintenance of starter box...................................................................................40

9. TROUBLE SHOOTING ...........................................................................41 9.1 General.....................................................................................................................41 9.2 Viscosity signal too low ..........................................................................................41 9.3 Viscosity signal too high .........................................................................................41 9.4 No or negative viscosity signal................................................................................42 9.5 Output pressure from control station to control valve remains high .......................42 9.6 Unstable viscosity control (process is hunting) ....................................................43 9.7 Viscosity indication slowly drifting from setpoint ..................................................44 9.8 Viscosity system can not be brought into automatic control...................................44 9.9 Residual offset can not be eliminated......................................................................44 9.10 Problems in other system components .................................................................45

9.10.1 Viscosity control station ................................................................................45 9.10.2 Airfilter-regulator ..........................................................................................45 9.10.3 Alarm pressure switch, analog viscosity indicator, starter box .....................45 9.10.4 Control valve .................................................................................................45

10. PARTS LISTS .........................................................................................46 10.1 Recommended spare parts KIts............................................................................46 10.2 Viscosity control station.......................................................................................47 10.3 Air Filter Regulator ..............................................................................................52 10.4 Analog Viscosity Indicator...................................................................................53 10.5 Alarm pressure switch ..........................................................................................54

11. MAINTENANCE RECORD...................................................................56 12. WARRANTY CONDITIONS.................................................................57

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1. PREFACE

1.1 GENERAL This manual contains instructions for installation, operation and maintenance of the control components supplied with a VAF Viscotherm pneumatic fuel viscosity control system Series V12. This manual supplements the IOM instructions for the Viscotherm Sensor/Pneumatic Transmitter Assembly, as published in Technical Manual No. 766. For IOM information of the control valve for steam or thermal oil, and the viscosity recorder (if this option is supplied), refer to the separate manuals supplied with these system components.

To ensure safe and correct installation and operation of your Viscotherm system read this manual completely before starting operations.

For any additional information contact: VAF Instruments B.V. Tel. +31 78 618 3100 Vierlinghstraat 24, NL-3316 EL Dordrecht Fax +31 78 617 7068 P.O. Box 40, NL-3300 AA Dordrecht E-mail: [email protected] The Netherlands Internet: www.vaf.nl Or your local authorized VAF dealer. Their addresses can be found on www.vaf.nl

1.2 SYSMBOLS The symbols below are used to call attention to specific types of information.

A warning to use caution! In some instances, personal injury or damage to the Viscotherm unit or control system may result if these instructions are not followed properly.

An explanation or information of interest.

1.3 COPYRIGHT This 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. Viscotherm is a registered trademark of VAF Instruments B.V.

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1.4 TO RECORD IMPORT SERIAL NUMBERS For identification purposes it is recommended to record also nameplate data of all Viscotherm system components as ordered for your typical installation. Always quote the instrument serial number when contacting the factory or local service representative. Component

Nameplate data

Viscosity Control Station

Airfilter-Regulator

Starter Box

Analog Viscosity Indicator

Viscosity Recorder

Alarm Pressure Switch

Control valve

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2. SYSTEM DESCRIPTION

2.1 SYSTEM ARRANGEMENT DIAGRAM

Figure 1

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2.2 SYSTEM COMPONENTS The control components shown in figure 1 are: Viscosity sensor and differential pressure transmitter The capillary type viscosity sensor measures the dynamic viscosity of Newtonian liquids. The differential pressure transmitter converts the measured viscosity value into a 0.2-1.0 bar (3-15 psi) control signal. Viscosity control station The viscosity control station receives the 0.2-1.0 (3-15 psi) signal from the differential pressure transmitter and compares this signal with the desired (setpoint) viscosity value. Any deviation between the actual fuel viscosity and the desired viscosity results in a corrective air signal to the control valve. Control valve The control valve regulates the amount of steam or thermal liquid to the fuel heater. For more information refer to the technical manual supplied with the valve. Airfilter-regulator The airfilter-regulator provides regulated air supply to the differential pressure transmitter, the viscosity controller and the analog viscosity indicator (of this option if supplied). STANDARD OPTIONS Viscosity recorders Records the viscosity of the fuel oil. The input of the recorders is the 0.2-1.0 bar (3-15 psi) signal from the differential pressure transmitter, Analog viscosity indicator The remote indicator is used to provide viscosity indication in the control room or on the bridge. The instrument can be supplied with adjustable low and high viscosity alarm contracts which can be connected to the ships alarm system. Alarm pressure switch The non-indicating pressure switch is pneumatically connected to the viscosity control signal from the differential pressure transmitter and has two micro-switches to signalize low and high viscosity levels via the ships alarm system. Starter box and motor switch The starter box or the motor switch is used for on-off control of the electromotor of the Viscotherm sensor. The motor switch is a simple on-off switch for installation close to the sensor. The starter box is equipped with a thermal relay for protection of the electromotor.

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3. OPERATING PRINCIPLE SYSTEM COMPONENTS

3.1 VISCOSITY CONTROL STATION Measuring section (Fig. 3) The output signal from the dP-transmitter, which is proportional to the viscosity of the fuel oil, enters through the "process" connection and actuates a metal diaphragm pressure element. Element motion is carried on to the black indicating pointer and the flapper assembly via mechanical linkages. The black pointer indicates the actual viscosity of the fuel oil on the direct reading viscosity scale. The desired viscosity is set by means of the set point knob and is indicated by the red set pointer. Control action The standard control action for Viscotherm systems using steam or thermal oil operated fuel heaters is such, that an increase in viscosity (fuel oil becoming thicker will result in a decreasing pneumatic output signal of the controller unit, opening the control valve (if this has the standard air-to-close action) to add more steam or thermal liquid. This is called the reverse acting control mode. For air-to-open valves, the action can be altered into direct mode, i.e. an increase in viscosity will result in an increasing output pressure.

Figure 2 Viscosity control station Relay The low bleed relay is in balance (neither feeding nor exhausting air) as long as the process is not changing. At balance condition, the force exerted by the nozzle diaphragm equals the force exerted by the output diaphragm. A change in the process causes a variation in the flapper-nozzle gap, thus producing a change in the nozzle back pressure (P1). The force exerted by the nozzle diaphragm causes the pilot valve to either open the inlet port, allowing supply air to enter the output, or to open the exhaust valve, exhausting output air (P2). Either of these changes continues until the force developed by the output diaphragm balances the force on the nozzle diaphragm and equilibrium is restored. Reset action The function of the reset action is to eliminate the proportional offset between the measuring process and the setpoint without creating instability in the proportional control action. When the reset valve is set to a particular restriction, pressure P2 is fed directly into the feedback bellows and flows more slowly into the reset chamber via the reset valve. This creates a differential pressure across the bellows which at first delays the balance across the capsule, but within a well-defined time period produces equilibrium and restores the process to the set point.

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Figure 3 Operation schematic of the viscosity control station

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Auto/manual switch By means of the AUTO/MANUAL transfer switch of the bypass panel, the controlling pressure for the pneumatic relay can be switched between the flapper-nozzle and the output of the manual regulator. Thus a choice can be made between automatic control of the output and manual control. Description of proportional + reset action of controller (refer to figure 3) With a decrease in the measured actual viscosity (fuel becoming thinner) the following occurs: 1. The output of the differential pressure transmitter also decreases, causing the measuring diaphragm of the

controller to collapse.

2. The black pointer rotates counter clockwise.

3. The flapper moves toward the nozzle as a result of the downward motion of link assembly ABC, causing the flapper to restrict the nozzle flow and increasing nozzle back pressure P1.

4. Air supply pressure feeding through the restrictor expands the nozzle diaphragm.

5. The inlet port of the pneumatic relay opens and the exhaust port closes.

6. The output pressure P2 increases (as indicated on the output gauge).

7. The feedback bellows expand, moving link JL to the right.

8. Proportional link FG, pivoting around F, causes link GD to move upward.

9. Lever assembly E also moves upward, turning the flapper away from the nozzle.

10. Determined by the setting of the reset valve, the pressure inside the reset bellows increases slowly, moving link JL to the left. This results in a slow further increase of the output pressure (reset action). The reset action will continue until the measured value is back at the setpoint and the bellows is in equilibrium.

11. The increasing output pressure P2 (step 6) is sent to the control valve, resulting in less steam or thermal liquid supplied to the heater (assuming the control valve is 'air-to-close'), to increase the viscosity of the fuel oil (fuel becoming thicker).

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3.2 CONTROL VALVE The standard control valve for steam or thermal liquid is a straight-through 2-way globe valve with pneumatic spring and diaphragm type actuator. The valve is equipped with an auxiliary handwheel operator. The valve for thermal liquid is equipped with an extended bonnet with bellows seal. The size of the control valve depends on the quantity of fluid to be controlled, the inlet pressure and the pressure drop across the valve, as well as on the specific gravity of the liquid or the properties of the steam. Calculation of the suitable valve is done by VAF Instruments on the basis of the information supplied by the customer. For more information refer to the technical manual supplied with the valve.

3.3 ALARM PRESSURE SWICH (OPTION) The non-indicating pressure switch (Figure 4A or 4B) is pneumatically connected to the viscosity measuring signal from the differential pressure transmitter. The instrument opens an electrical switching element if any of the following occurs: The Viscotherm sensor motor malfunctions The differential pressure transmitter malfunctions The supply air fails The supply current fails The alarm signal can be connected to the engine room alarm system.

Figure 4A Viscosity alarm switch Figure 4B Viscosity alarm switch

Check which model has been supplied

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3.4 AIRFILTER-REGULATOR This pressure-reducing regulator (Figure 5) is a simple automatic device which controls the downstream pressure by balancing the force set by a spring against the force produced by the desired output pressure acting on a diaphragm. When the spring force is greater than the output pressure force, the diaphragm assembly moves downward and the inlet supply valve opens, permitting the controlled pressure to increase. When the regulated pressure force is greater than the force set by the spring, the diaphragm assembly moves upward, closing the pilot valve and uncovering the relief port. The air then escapes to atmosphere through the relief opening in the bonnet until the spring and pressure forces are balanced. The required output pressure is set by turning the range adjust screw and is indicated on the pressure gauge. A spring loaded drain valve is used for periodic draining of the liquid which collects in the bowl.

Figure 5 Sectional view of airfilter-regulator

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3.5 VISCOSITY RECORDER (OPTION) The air input signal of this single pen strip chart recorder is connected to the pneumatic viscosity output signal of the differential pressure transmitter of the Viscotherm system. The air signal enters through the inlet fitting and actuates a bellows element. Element motion is transferred to a pen arm with cartridge pen. The chart roll has a direct reading scale in viscosity units and is actuated by a spring-wound or electric clock. High and/or low electric alarm contacts are available as standard option. Alarms can be adjusted throughout the full range of the instrument and can be connected to the ships alarm system. For more information refer to the Technical Manual supplied with the recorder.

3.6 ANALOG VISCOSITY INDICATOR (OPTION) The air input signal is connected to the pneumatic viscosity signal of the differential pressure transmitter of the Viscotherm system and actuates a bourdon tube pressure element. Element motion is carried to a pointer which indicates the actual viscosity on a direct reading scale. The instrument can optionally be equipped with high and low alarm contacts for connection to the ships alarm system. Figure 6

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4. TECHNICAL SPECIFICATION SYSTEM COMPONENTS

4.1 VISCOSITY CONTROL STATION

Air supply 1.4 bar (140 kPa; 20 psi) Input signal 0.2-1.0 bar (20-100 kPa; 3-15 psi) from dP-transmitter Output signal 0.2-1.0 bar (20-100 kPa; 3-15 psi) to control valve Pneumatic connections 6 mm pipe couplings, 1/4" NPT female Control mode PI (proportional + reset); reverse (standard) or direct acting; automatic or manual operation. Proportional band 2-200% (factory adjusted to 35 %) Reset time 0.03 - 5 minutes (factory adjusted to 5 minutes) Viscosity scale see dial of instrument Control accuracy 1% of full scale Static air consumption 3 Nl/min Materials Measuring element phosphor bronze bellows Encasing die-cast aluminium Protection class IP65, weatherproof, tropically resistant Mounting wall or flush panel Mounting hardware mounting brackets and rubber vibration dampeners supplied with

instrument. Max. static working pressure 1 bar (100 kPa; 15 psi) Overrange protection 1 bar (100 kPa; 15 psi) Ambient temperature limits -40 to 100C (-40 to 212F) Weight 3.5 kilos

4.2 AIRFILTER-REGULATOR Type reducing-relief type automatic regulator Maximum supply pressure 20 bar (2,000 kPa; 300 psi) Regulated output pressure 0-2.5 bar/ 0-35 psi (0-250 kPa) Air output capacity max. 34 Nm/h Connections 1/4" NPT Materials Housing die-cast aluminium Valve plug stainless steel Range spring cadmium plated carbon steel Diaphragm Nylon reinforced Buna-N Filter element sintered stainless steel Filter mesh width 0.005 mm Ambient temperature range -50 to 65C (-58 to 150F) Accessories supplied wall mounting bracket and output pressure gauge Weight 0.58 kilos

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4.3 ANALOG VISCOSITY INDICATOR (OPTION)

Type edge scale manometer Mounting flush panel Measuring element bourdon tube Input air signal 0.2-1.0 bar (3-15 psi) Materials Measuring element CuSn Encasing steel Reading units direct reading in viscosity units Accuracy class 1% F.S. Protection class IP55 Alarm device (option) 2 adjustable NO/NC change-over switches Max. voltage 250 V Max. current 3 Amp AC / 500 VA ; 2 Amp DC / 50 W Weight 1.2 kilos

4.4 ALARM PRESSURE SWITCH (OPTION)

Type non-indicating pressure switch Mounting wall, post or front panel Measuring element two SPDT diaphragm pressure switches Input air signal 0.2-1.0 bar (3-15 psi) Material Housing die-cast aluminium Contact rating 250 VA, 5A or 10A (check your model) Protection class IP54 (NEMA 4) Weight 0.95 kilos

4.5 STARTER BOX (OPTION)

Type on-off switch for electric motor (make Marbaise) of Viscotherm sensor Mounting wall or post Protection class IP65 Operating voltage same as electric motor of sensor Ambient temperature max. 55C (122F) Motor protection thermal relay Power consumption 90 VA Switching current Part No Motor, type Marbaise Current

0399-0309PH 220 480 V, 3 ph 0.40 - 0.63 A 220/240 V, 1 ph 0.63 - 1 A

Weight: 0.4 kilos

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5. INSTALLATION PROCEDURES SYSTEM COMPONENTS

5.1 VISCOSITY CONTROL STATION

5.1.1 Mechanical installation

1. Install viscosity control station in upright position to a wall or in a control panel.

2. Installation place must be free from moisture, large fluctuations of temperature, vibration and shock.

3. When installing instrument to a wall, the vibration dampers supplied should be used on the mounting brackets.

4. When installing instrument in a control panel, refer to figure 15 or 16 for panel cutout dimensions.

To install:

a) disconnect pneumatic connections between controller section and auto-manual station section.

b) remove auto-manual station from mounting bracket.

c) remove mounting bracket from controller.

d) install controller and auto-manual station in panel.

e) re-install pneumatic connections.

5.1.2 Pneumatic connections

(see figure 7) Use 6x1 mm or tubing or piping for making pneumatic connections.

1. Make sure that the I-port on the back of the controller has been connected to the I-port of the auto-manual station. The internal I-tube clamp should be tightened (figure 8).

2. Connect supply port (E) of the auto-manual station to a regulated 1.4 bar (20 psi) air supply tapped from the OUT port of the airfilter-regulator.

3. Connect output port V of the auto-manual station to the air connection of the steam, or thermal oil, control valve.

4. Connect NPTF process port M1 to the OUT port of the differential pressure transmitter. Also see Technical Manual 766 supplied with the sensor/transmitter assembly).

The maximum air pressure applied to M1 should never exceed 100 kPa (1 bar; 15 psi).

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Figure 7 Pneumatic connections of control station with low mounted auto-manual station (left) and side

mounted auto-manual station (right)

Figure 8 I-clamp to close integral air connection

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5.2 AIRFILTER-REGULATOR

1. Install the airfilter-regulator in an upright position, using the bracket provided. Required mounting parts: two (2) bolts, nuts and washers, M6 or 1/4".

2. Leave sufficient clearance to remove the lower bowl for servicing.

3. Make pneumatic connections as shown in figure 9, using 6 x 1 mm or tubing.

a) Connect the IN port to a compressed air supply with a maximum air pressure of 20 bar (300 psi).

b) Connect the OUT port to the IN connection of the dP-transmitter and to the supply port E of the viscosity control station.

The two remaining taps (stamped "G") are reduced pressure outlets. One is used by the pressure gauge, the other one is plugged.

Figure 9 Airfilter-regulator

Regulate to 20 psi (1.4 bar)

NPT female IN (2x) Mtg. hole 16 x 8,7 mm

Mtg. bracket screw to wall

Supply air from compressor max. 20 bar (300 psi)

Output pressure gauge

NPT OUT Connect to:

Supply port E of control station IN connection of dP-

transmitter

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5.3 VISCOSITY RECORDER

(If supplied) 1. Install recorder vertically to a wall or in a control panel, where it will be free as possible from vibration,

moisture and large fluctuations of temperature. Four (4) tapped M8 mounting holes are provided at the corners of the instrument. For installation to a 2 pipe a mounting support is available as optional extra.

2. Connect air connection on recorder to "OUT" port of differential pressure transmitter using 6x1 mm or tubing or piping. (For connection at dP-transmitter see Technical Manual 766 supplied with the viscosity sensor/transmitter).

5.4 ANALOG VISCOSITY INDICATOR (If supplied)

1. Install indicator in a panel, where it will be free as possible from moisture, vibration and large fluctuations of temperature. For ease of reading it is recommended to install the instrument in the engine control room or on the bridge. Clamp instrument to panel using two mounting fixtures supplied.

2. Connect NPT female connection on indicator to OUT port of differential pressure transmitter

3. Using 6x1 mm or tubing or piping. Figure 10.

4. If gauge is equipped with alarm feature, connect alarm contacts through Pg 13.5 connector to the ships alarm system, in accordance with figure 11.

Unless expressly specified on the purchase order, the alarm settings are not adjusted in the factory. Low and high alarm points can be individually set by removing window and moving alarm pointers with finger.

Figure 10 Connections at rear of analog viscosity indicator

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500 V 3A 250V 50 W= 2A= Figure 11 Electrical connections of indicator equipped with alarm contacts.

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5.5 ALARM PRESSURE SWITCH (If supplied: Figure 12A or Figure 12B

1. Install switch in a place where it will be free as possible from moisture, vibration and large fluctuations of temperature.

2. Connect pressure port of switch to output of differential pressure transmitter.

3. Make electrical connections to ships alarm system in accordance with figure 13.

Unless expressly specified on the purchase order, the alarm settings are not adjusted in the factory. Low and high alarm points can be individually set by screwdriver adjustment after removing lid on top of instrument.

Figure 12A Connections of pressure switch Figure 12A Connections of pressure switch

Check your model

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Figure 13A Electrical connections to ships alarm system (model as figure12A)

Figure 13B Electrical connections to ships alarm system (model as figure12B)

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5.6 STARTER BOX

(If supplied) 1. Install starter box in a convenient location near the Viscotherm sensor. Remove lid and mount box to

wall or post using the two 4.5 mm press-through mounting holes.

2. Make electrical connections to the main power supply and to the electric motor on the Viscotherm sensor, in accordance with figure 14. Use cable with a wire diameter of 1.5 or 2.5 mm2 and a cable diameter of max. 10 mm.

Figure 14 Connections at starter box

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6. DIMENSIONS

6.1 VISCOSITY CONTROL STATION

Figure 15 Viscosity controller with low mounted auto-manual station

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Figure 16 Viscosity controller with side mounted auto-manual station

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6.2 AIRFILTER-REGULATOR

Figure 17 Airfilter-regulator

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6.3 ALARM PRESSURE SWITCH

6.3.1 Alarm pressure switch

(Check your model supplied)

Figure 18A Alarm pressure switch 6.3.2 Alarm pressure switch

(Check your model supplied)

Figure 18B Alarm pressure switch

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6.4 ANALOG VISCOSITY INDICATOR

6.4.1 Indicator with alarm contracts

6.4.2 Indicator without alarm contacts

Figure 19

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6.5 STARTER BOX

Figure 20

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7. OPERATING INSTRUCTIONS

7.1 VISCOSITY CONTROL STATION

7.1.1 Adjustment of control parameters

The desired, or setpoint, viscosity value is indicated by the red pointer (3, Fig. 21). To adjust this pointer, turn the setpoint adjustment knob (1) until the red pointer is at the desired viscosity. The proportional band can be adjusted by means of the graduated dial (2). The proportional band value is indicated by the red arrow at the left hand side of the dial (partially covered by the setpoint pointer) The dial has two areas with the same scale division, one area for direct and one for reverse control action. Figure 21 Inside view of viscosity control station

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3

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Check the control action, which is determined by the position of the proportional band dial. It should be - in reverse position when the control valve action is air to close, - in direct position when the control valve action is air to open. Unless ordered otherwise the control parameters are preset in the factory as follows: proportional band 35 %, control action reverse, reset time 5 minutes. Refer to section 8.3 in case one or more of these parameters must be altered. 7.1.2 Manual operation

To switch over from automatic to manual control, simply turn knob A of the auto-manual station (Fig. 22)

from to The output pressure to the control valve will now graduately be adjusted to match the setting of knob B. By turning knob B, the air output pressure to the control valve can be adjusted. This pressure is indicated by gauge C.

To switch back to automatic operation, simply turn knob A back to the position, where after the output signal will graduately be adjusted to the actual controller setting.

A C B Figure 22 Auto-manual station

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7.2 INITIAL START-UP Before starting up the system, the following procedures must be followed:

1. Check that all instruments are installed in accordance with the instructions in this manual and in Technical Manual 766 supplied with the Viscotherm sensor/dP-transmitter.

2. Make sure that the pressure adjustment screw on the airfilter-regulator is turned fully counter clockwise, then turn on the air supply to the airfilter-regulator.

3. Slowly increase the output pressure of the airfilter-regulator to 1.4 bar (20 psi). Lock the adjustment screw with the locking nut.

4. Observe the reading of the viscosity at the viscosity control station and/or the analog viscosity indicator (if supplied). If the indication is not zero (positive or negative), adjust the zero setting of the differential pressure transmitter as described in Section 9.2 of Technical Information Bulletin IB-766 supplied with the Viscotherm sensor/dP-transmitter. Adjustment of the indicating pointer of the analog viscosity indicator is made by the adjustment screw at the rear of the instrument (Fig. 19).

5. Switch the viscosity control station to MANUAL using knob A (Fig. 22). Using knob B check the action and the performance of the steam or thermal liquid control valve. First set the output to 0.2 bar (3 psi) and then to 1 bar (15 psi). For a valve with 'air to open' action this should correspond with the fully closed position and the fully open position. For an 'air to close' valve these pressures should correspond with the fully open and the fully closed positions. Switch the viscosity control station back to AUTOMATIC control.

6. Check that the control action of the viscosity control station is in accordance with the action of the valve. See paragraph 7.1.1 if necessary to reverse the control action.

7. Set the red setpoint pointer of the viscosity control station to the desired viscosity as specified by the engine manufacturer.

8. Adjust the settings of the alarm pressure switch and/or the analog viscosity indicator and start the driving motor of the viscosity recorder (if these options have been supplied).

9. Follow the initial start-up instructions in section 8.1 of Technical Manual 766 supplied with the Viscotherm sensor/dP-transmitter.

7.3 TUNING TO PROCESS When the fuel system is completely filled with HFO and the viscosity control station is in the automatic mode, the behaviour of the system has to be checked and, if necessary, be adjusted. This is best done by observing the viscosity control process directly after a substantial change in the fuel consumption of the main engine. A good control behaviour is characterised by a fast return of the measured value to the setpoint value, with only one or two oscillations around the setpoint. When the process is hunting (the viscosity is oscillating around the setpoint value), increase the proportional band setting and/or increase the reset time until the process behaves properly. When the viscosity returns very slowly to the setpoint value, decrease the proportional band setting and/or decrease the reset time until the process behaves properly. When the process, despite continued adjustment, cannot be brought into good control, refer to the trouble shooting section in chapter 10.

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7.4 ROUTINE START-UP AND SHUT DOWN Refer to sections 8.2 and 8.3 of Technical Manual 766 supplied with the Viscotherm sensor/dP-transmitter.

8. MAINTENANCE

8.1 GENERAL Under normal conditions the Viscotherm system requires a minimum of maintenance. "Normal" conditions means:

a) A clean operating environment.

b) Viscotherm system components installed in accordance with the installation instructions given.

c) Operation of the viscosity control system in accordance with this manual and other related publications issued by VAF Instruments B.V.

d) The air supply for pneumatic system components is free from oil, moisture and dirt.

e) Uninterrupted electric power supply at the normal specified values.

8.2 MAINTENANCE SCHEDULE To ensure many years of trouble-free and dependable operation, the Viscotherm system requires periodical maintenance. The maintenance record on the last page of this manual may be used to record maintenance operations. The maintenance schedule should be established using the check lists on next pages as a guideline. This preventive maintenance can be split up into 3 types, each with its recommended performance time interval: "A" maintenance checks: Operators daily and periodical maintenance, according the schedule given in paragraph 8.3. "B" Maintenance checks: Bi-annual (or every 10,000 operating hours) field maintenance by official VAF Instruments service engineer. See paragraph 9.4 for details. "C" Maintenance checks: Complete overhaul of the system, after every 4 to 6 years. This overhaul will be performed aboard ship or in suppliers nearest service shop, as required. See paragraph 8.5 for details.

All maintenance and repair to be carried out under the warranty conditions in this manual.

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8.3 "A" MAINTENANCE CHECKS Operators daily and periodical maintenance. Time interval Check and/or action to be performed

Daily Drain bowl of airfilter-regulator.

Observe pressure gauge of airfilter-regulator to check that the

instrument air supply pressure is 1.4 bar (20 psi).

Weekly Wind-up clockwork of a viscosity recorder with spring-drive.

Check writing pen of viscosity recorder.

Monthly Replace chart roll of viscosity recorder.

Annually Clean viscosity control station.

8.4 "B" MAINTENANCE CHECKS Bi-annual (or every 10,000 operating hours) field check by authorized VAF service engineer. These checks may also be performed by an other qualified instrument engineer. The required service parts are available from the factory. VAF Instruments B.V. will, however, not assume responsibility for the performed service operations. Viscosity control station Inspection of key parts. Verification of process pointer calibration, range and span. General performance test.

DP-transmitter Calibration check and general performance test.

Alarm pressure General performance test.

Gauge or pressure switch Complete system Running test to determine if the system may be operated for

another service period.

Further disassembly, inspection and repair of the Viscotherm system instruments will only be carried out if, in the opinion of our service engineer, the maintenance work and running trials have indicated a failure.

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8.5 "C" MAINTENANCE CHECKS The "C" maintenance checks are recommended every 4 to 6 years and comprise a full overhaul of the complete system. This overhaul should be carried out by an official VAF Instruments service engineer. These checks may also be performed by another qualified instrument engineer, provided that the required replacement parts are correctly ordered from the factory. VAF Instruments B.V. will, however, not assume responsibility for the performed service operations. The "C" maintenance checks include: All relevant "A" and "B" maintenance checks. Complete inspection and cleaning of all instruments supplied by VAF Instruments B.V. Replacement of worn and defective parts. Re-installation of rebuilt instruments, and performance test runs to determine if the system may be

operated for another service period. The service work will be done on site as much as possible. However, if field repair of a part is not possible, our service engineer may advise to have this part overhauled in the factory or the nearest approved repair facility. For service operations aboard ship, our service engineer must be provided with all necessary facilities as indicated in the warranty conditions in this manual. VAF Instruments warranty conditions shall apply to all service work performed by their official service engineers.

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8.6 MAINTENANCE OF VISCOSITY CONTROL STATION

8.6.1 Daily servicing

Daily the following actions and checks must be performed:

a) Verify the viscosity indication of the control station and the viscosity of the fuel.

b) Check connections inside and outside the instrument and check mounting bolts for tightness, specially under vibration conditions.

8.6.2 Annual servicing

Alignment of the control station Annually, the operation and alignment of the control station must be checked as follows:

a) Supply the controller with instrument air at 1.4 bar (20 psi).

b) Set red and black pointer a little shifted, if possible around the middle of the scale. Set the I-action screw (I, Figure 23) on a high value (5-6).

c) Set the proportional band (D, Fig. 23) at a value giving an output signal of 0.6 bar (9 psi). After about 1 minute of stability, turn the I-action screw to 0 repeats/minute. A pressure of 0.6 bar (9 psi) is now enclosed into the integral bellows.

d) Set the proportional band to infinite.

Figure 23 Proportional and reset function parts

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e) Check that the output signal is still 0.6 bar; if not, slightly loosen the two screws M (figure 23) and

gradually move the plate supporting the nozzle/flapper assembly until the required output signal is obtained.

f) Adjust the proportional band to 10% direct action, and thereafter to 10% reverse action. Check whether the output signal of the controller remains at 0.6 bar (9 psi) with a maximum deviation of 0.03 bar (0.5 psi). If so, the controller is properly aligned; otherwise, proceed as follows:

g) Should the control signal deviate from 9 psi when adjusting the proportional band as indicated in step f with a same difference, but of opposite sign (plus and minus) on direct and reverse action (p.E.: signal is 9 + 2 = 11 psi on reverse action and 9 - 2 = 7 psi on direct action), turn slowly and gradually screw H (figure 23) to adjust the output signal at 9 psi. After this adjustment, repeat step f.

The reset screw is protected by a threaded plug. Take out this protection before adjusting.

h) Should the control signal deviate from 9 psi when adjusting the proportional band with unequal

difference of opposite sign on direct and reverse action (p.E.: signal is 9 + 3 = 12 psi on reverse action and 9 - 1 = 8 psi on direct action), adjust the proportional band to 10% direct acting.If on this position the deviation is higher than on reverse action, turn flapper nut (figure 24), clockwise until half of the deviations algebraic addition is eliminated. Example: For the above mentioned, this would be (3 + (-1)):2 = 1 psi. To eliminate this value, rotate the flapper nut until the output is 12 - 1 = 11 psi. Should the deviation be lower on reverse than on direct action, turn the flapper nut counter-clockwise.

i) After every operation on the flapper as described under step h, repeat steps e through h.

Flapper nut Figure 24 Nozzle / flapper assembly

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To clean amplifying relay and nozzle (Refer to figure 25) 1. Shut-off air supply to the viscosity control station.

2. Carefully, remove the air connection (S) from the relay.

3. The capillary orifices (O and P) are incorporated in the relay. To reach these orifices remove the amplifying relay body by unscrewing two slot screws (Q).

4. Pull out the orifices which are press fitted on the side of the relay, facing the base plate, by using the threaded end of the extractor/cleaner tool (1, Fig. 29) supplied with the instrument.

5. Clean the two orifices using the thin steel wire fitted on one end of the extractor/cleaner tool and blowing with dry and clean compressed air.

6. Before reassembling orifices lubricate O-ring with a thin film of silicone grease. Replace O-ring if necessary. Each orifice has a different bore; use special attention when reassembling orifices into their corresponding seats. Check that reference numbers (1 and 2) on orifices correspond with numbers on relay body.

7. To clean nozzle set proportional band at 10% on direct action, keeping the measuring index at the beginning of the scale and positioning the setpoint red index at the end of the scale. These operations are necessary to keep the flapper elastic plate away from the nozzle. Blow clean air at 1-2 bar (15-30 psi) into the tube (S) to remove any presence of water, oil or dirt from nozzle and tube.

8. To clean the diaphragm and other inner relay parts remove two hexagonal socket screws R.

Figure 25 Amplifying relay i) When reassembling the relay, check that positioning of mounting holes on diaphragms and gaskets is

correct. Notice the reference marks engraved on all components; these should coincide with the reference marks on the base plate.

j) Re-install the relay in the control station and re-connect the air connection.

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8.7 MAINTENANCE OF AIRFILTER REGULATOR

8.7.1 Daily servicing

1. Drain bowl of airfilter-regulator by pushing on drain valve (5), while the instrument is in line under pressure.

2. Check air connections for tightness and leaks.

3. Check that output pressure of the airfilter-regulator is 1.4 bar (20 psi). Adjust if necessary.

4. Check air leakage through relief opening in bonnet. Excessive air leakage indicates a ruptured diaphragm and replacement of the airfilter-regulator is needed.

8.7.2 Annual servicing

1. Lubricate range adjustment screw (1) with an anti-seize compound.

2. Remove bolt (4) and slide off bowl sub-assembly (3).

3. Remove filter element (2) and clean filter with a suitable solvent. Let element dry thoroughly.

4. Re-assemble airfilter-regulator in reverse order.

Figure 26 Airfilter-regulator

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8.8 MAINTENANCE OF ANALOG VISCOSITY INDICATOR The following checks should be performed every month:

a) Zero check of the dP-transmitter (see Technical Manual TIB-766).

b) Check that the reading of the analog viscosity indicator is identical to the viscosity reading of the viscosity control station. An excessive deviation indicates instrument failure or leakage of the pneumatic piping.

8.9 MAINTENANCE OF PRESSURE ALARM SWITCH The alarm switch requires no maintenance.

8.10 MAINTENANCE OF STARTER BOX

The starter box requires no maintenance.

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9. TROUBLE SHOOTING

9.1 GENERAL Before using the trouble shooting tables in this section make sure that: the bunker fuel has the correct standard viscosity; all by-pass and block valves of the Viscotherm system are in correct positions (either open or closed, as

specified in this manual and in Technical Manual 766 supplied with the Viscotherm sensor/dP- transmitter;

the supply of steam or thermal liquid to the fuel heater is sufficient; the spring-loaded valve in the return line from the engine to the mixing tank is working properly and is

set to the correct value; all pneumatic pipings and process connections are not leaking or clogged. all electric connections are in good order. Some system problems, arising as errors in viscosity indication, are due to disturbances of the viscosity sensor/dP-transmitter assembly. Refer to the trouble-shooting section of Technical Manual 766 supplied with the Series V12 sensor/dP-transmitter.

9.2 VISCOSITY SIGNAL TOO LOW

(May be indicated by incorrect temperature of the fuel). POSSIBLE CAUSE CORRECTIVE ACTION Air piping between output connection of Repair the leak. dP-transmitter and M1 port of viscosity control station leaking at high pressure (+) side.

The problem is in the sensor/dP-transmitter. See trouble shooting in Technical Manual 766.

9.3 VISCOSITY SIGNAL TOO HIGH

(May be indicated by incorrect temperature of the fuel). POSSIBLE CAUSE CORRECTIVE ACTION Fuel too cold during start-up. Start system up in accordance with the procedures in

Section 8 of this manual and Technical Manual 766.

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9.4 NO OR NEGATIVE VISCOSITY SIGNAL

POSSIBLE CAUSE CORRECTIVE ACTION Pneumatic piping between dP-transmitter and viscosity control station leaking.

Repair leak.

Air supply pressure to viscosity control station and/or other instruments too low.

Check that air supply is at 1.4 bar and/or check piping for leaks.

Measuring element of viscosity control station defective or overranged

Contact VAF Instruments for replacement.

Loose or leaking air tubings in viscosity Check and replace if necessary. Control station.

Wrong control action of viscosity control station.

Check that control action is as described in paragraph 4.1.

Orifices (O and/or P, Fig. 25) in viscosity control station dirty or clogged.

Clean orifices as described in to clean amplifying relay and nozzle of paragraph 8.6.2.

Diaphragm of control valve perforated or leaking.

Refer to technical manual supplied with valve.

9.5 OUTPUT PRESSURE FROM CONTROL STATION TO CONTROL VALVE REMAINS HIGH

POSSIBLE CAUSE CORRECTIVE ACTION Wrong setpoint of viscosity control station. Adjust setpoint to desired viscosity value.

Amplifying relay and/or nozzle of viscosity control station clogged, or loose orifices in relay

Clean relay, tighten orifices and/or nozzle as described in paragraph 8.6.2.

Loss of air through gaskets of orifices (O and/or P, Fig. 25) of viscosity control station.

Replace gasket(s).

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9.6 UNSTABLE VISCOSITY CONTROL (PROCESS IS HUNTING) This difficulty will manifest itself by the appearance of process hunting when there had been none before. Before proceeding with any other check, increase (widen) the proportional band adjustment by turning the PB-dial until the process is just stable. Increasing the proportional band will result in a slower, but more stable control. Decreasing the proportional band effects a faster, but less stable control. If widening the band does not help, the feedback may be inoperative due to a clogged tube or a broken feedback capsule. If the control operation continues to hunt, set the proportional band adjustment back to its initial value and decrease the reset time. When continued adjustment fails to bring the process into control, it is best to look for erratic behaviour of the process or other system components. POSSIBLE CAUSE CORRECTIVE ACTION Proportional band setting of = viscosity control station too narrow.

Increase proportional band.

Reset time setting of viscosity control station too fast.

Decrease reset time.

Reset valve of viscosity control station fully closed or clogged.

Check reset valve and adjust setting if necessary.

Wrong values of proportional band and/or integrating action.

Re-adjust P-band and/or I-action as described in Paragraph 7.3.

Friction in the mechanical linkages of the viscosity control station.

Eliminate frictions by cleaning.

Friction in the control valve, or valve oversized.

Refer to technical manual supplied with control valve.

Integral air tubing in viscosity control station (A, Figure 27) leaking.

Tighten screw B (Fig. 27) or replace tubing.

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9.7 VISCOSITY INDICATION SLOWLY DRIFTING FROM SETPOINT

POSSIBLE CAUSE CORRECTIVE ACTION Proportional band setting of viscosity control station too wide.

Reduce proportional band.

Low speed of I-action.

Increase number of repeats per minute.

Capillary orifice (O, Fig. 25) partially clogged.

Clean orifice as described in paragraph 8.6.2.

Control valve for steam or thermal liquid Incorrectly sized.

Refer to technical manual supplied with valve.

9.8 VISCOSITY SYSTEM CAN NOT BE BROUGHT INTO AUTOMATIC CONTROL

POSSIBLE CAUSE CORRECTIVE ACTION Loose connections or leak in nozzle line of Viscosity control station.

Check nozzle line for leakage or loose connections.

Nozzle in viscosity control station clogged.

Remove and clean nozzle as described in section 8.6.2.

Flapper in control station bent or not seating. Contact VAF Instruments or nearest service representative.

Loose internal mechanical linkages in viscosity control station.

Check for loose linkages.

Loose air hoses in viscosity control station. Check for loose air hoses.

9.9 RESIDUAL OFFSET CAN NOT BE ELIMINATED

POSSIBLE CAUSE CORRECTIVE ACTION I-action needle valve of viscosity control station (9, Figure 28 ) clogged.

Clean or replace needle valve.

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9.10 PROBLEMS IN OTHER SYSTEM COMPONENTS

9.10.1 Viscosity control station

When the viscosity control station is fitted with an auto-manual station, tubing A (fig. 27) is locked in the factory by applying pressure on plate C using screw B. Tighten screw B, or replace tubing when leaking which is shown by hunting of the control process.

Figure 27 Device to close integral air connection 9.10.2 Airfilter-regulator

Excessive air leakage through the bleed hole and failing regulated pressure signal usually indicates a ruptured diaphragm. Replace airfilter-regulator when defective. 9.10.3 Alarm pressure switch, analog viscosity indicator, starter box

When the difficulties are in these components, contact VAF Instruments or nearest service representative for replacement. 9.10.4 Control valve

The control valve for steam or thermal liquid must be correctly sized. It should be large enough to maintain the process for most load conditions. If it operates near the full open position continually, it is probably undersize and does not have sufficient control. If it operates near the closed position continually, it is probably oversize. For valve sizing formulas and further trouble shooting instructions refer to the technical manual supplied with the valve

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10. PARTS LISTS

10.1 RECOMMENDED SPARE PARTS KITS Recommended Service Replacement Parts Kits for most frequently ordered Viscotherm system components are listed in Table 1. Refer to the parts lists in this section for the contents of each kit. Spares for other Viscotherm system components can be ordered from Tables 2 through 9. Table 1: Standard spare parts kits Part No Qty. Description For contents see table

Recommended spare parts kit for viscosity control station 2 6 0390-1061 kit for 2-year operation

Recommended spare parts kits for airfilter regulator 7 0670-0005 1 Airfilter-regulator assy 0673-0031 5 Filter element

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10.2 VISCOSITY CONTROL STATION

Figure 28 Viscosity control station

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Table 2: Viscosity control station Item No. Fig. 28

Qty. Part Name

1 * 1 Air tubing, internal I-action 2 1 Indicating pointer, black 3 1 Setpoint indicator, red 4 1 Proportional band dial - 1 Flapper/nozzle assy (not shown, hidden behind PB dial) 6 1 Setpoint knob 7 1 Feedback bellows assy 8 1 I-action belows assy 9 1 I-action setpoint screw 10 1 Adjustment screw for output signal 11 1 Link 12* 1 Air tubing, proportional signal 13 1 Output pressure gauge 14* 1 Air tubing, process signal 15 1 Process bellows support 16 1 Process bellows assy 17 1 Process link -- 1 Scale plate (not shown) 025 mPas / 0..25 cSt 025 mPas / 0..110 sR1 025 mPas / 0-3.5 Engler 050 mPas / 0..50 cSt 050 mPas / 0..110 sR1 050 mPas / 0-7 Engler 0..100% ** 19 1 Pneumatic relay. Refer to figure 29 and table 6 for details. * Recommended spare parts. Refer to table 6 for contents of spare parts kit. ** When ordering specify: 0 to 100 % = 0 to .. mPas, sR1, cSt or Engler.

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Fig. 29 Pneumatic relay of viscosity control station Table 3: Pneumatic relay of viscosity control station Item No. Fig. 29

Qty. Part Name

1 * 1 Extractor/orifice cleaner tool (stored in door of controller) 505 2 Screw 506 2 Screw 508 * 1 Upper diaphragm 509 *+ 1 Lower diaphragm, seat and disc 510 + 1 Intermediate plate 511 * 1 Spring 512 1 Seat ring 513 1 Lower plate 514 1 Relay valve 515 1 Valve guide 516 * 1 Flat spring 517 1 Spring 518 2 O-ring 519 * 1 Screw with capillary orifice 520 1 Screw with capillary orifice 556 * 1 Gasket 585 1 Upper plate * Recommended spare parts. Refer to table 6 for contents of spare parts kit. + The diaphragm of item 509 must be led through the hole in the intermediate plate, item 510.

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Fig. 30, Auto/manual bypass station Table 4: Auto/manual bypass station Item No. Fig. 30

Qty. Part Name

1 4 Screw M4 x 35 2 1 Upper plate 3 1 Valve spring 4 1 Intermediate plate 5 * 1 Diaphragm assy 6 1 Loading spring 7 1 Spring guide 8 2 Screw M4 x 10 9 * 2 O-ring 10 1 Air connector 11 2 Mounting pillar 12 2 Fixing plate 13 1 Base plate 14 1 Pressure adjusting knob 15 1 O-ring 16 1 Gauge holding plate 17 1 Pressure gauge output signal 18 1 Switch knob 19 1 Name plate 20 4 Screw M4 x 10 21 * 2 O-ring 22 1 Distributor 23 1 Switch block * Recommended spare parts. Refer to table 6 for contents of spare parts kit.

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Figure 31 Side view of viscosity control station Table 5: Viscosity controller rear parts Item No. Fig. 31

Qty Part Name

21 4 Mounting bar with vibration dampener 22 kit External pneumatic tubing 23 1 Mounting bracket for auto/manual bypass panel Table 6: Contents of spare parts kit Item No:

Figure 28 1 12 14

Figure 29 1 508 509 511 516 556

Figure 30 5 9 21

Kit Part No: 0390-1061 (2 years)

1x 1x 1x

1x 1x 1x 1x 1x 1x

1x 1x 1x

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10.3 AIR FILTER REGULATOR

Figure 32 Airfilter-regulator Table 7: Airfilter-regulator Item No. Fig. 32

Qty Part Number Part Name

* 1 0670-0005 Airfilter-regulator (without mounting bracket and pressure gauge)

1 * 1 0673-0031 Filter element 2 1 1419-0007 Wall mounting bracket 3 1 0653-0002 Pressure gauge 0-2.5 bar/0-35 psi * Recommended spare part

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10.4 ANALOG VISCOSITY INDICATOR

Figure 33 Analog viscosity indicator with alarm contacts Table 8: Analog viscosity indicator Item.No Fig. 33

Qty Part Number Part Name

- 1 0653-0059 Viscosity indicator - 1 0653-0062 Viscosity indicator with NO/NC alarm contacts No loose spare parts available.

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10.5 ALARM PRESSURE SWITCH

Figure 34 Alarm pressure switch

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Table 9: Alarm pressure switch Fig. 34 Item. No Qty Part. Name Part. No.

* 1 Pressure switch, Model No. D2T-H18 0610-0008 1 4 Screw, bracket 2 2 Screw, adjusting 3 1 Bracket assembly 4 2 Spring, overload 5 2 Thrust washer, adjusting screw 6 2 Stop nut, adjusting screw 7 2 Bracket, limit switch 8 2 Limit switch assembly 9 2 Insulator, limit switch 10 4 Nut, limit switch screw 11 4 Washer, limit switch screw 13 1 Nameplate, electrical 14 1 Base plate 15 1 Gasket, base plate 16 1 Diaphragm capsule assembly 17 1 Cover plate 18 4 Screw, cover plate 19 1 Bracket, mounting 23 1 Tag, wire code 24 4 Screw, limit switch 27 2 Nameplate, identification 28 2 Screw, adjustment cover 29 1 Cover, adjustment 30 1 Gasket, adjustment cover 31 1 Housing 32 1 Nameplate, trademark 33 1 Gasket, housing 34 4 Screw, terminal block cover 35 2 Screw, terminal block 36 1 Terminal block 37 1 Marker, terminal strip 38 1 Gasket, terminal block cover 39 1 Cover, terminal block 60 1 Ground screw, slotted 64 1 Nameplate, duty to warn 65 1 Nameplate, caution * Recommended spare part. Repair parts not available

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11. MAINTENANCE RECORD To prove that the Viscotherm system has been properly maintained, retain records such as work orders and receipts, showing that scheduled maintenance has been performed. The form on this page should be kept and updated and presented to our service engineer prior to a B or C maintenance check.

MAINTENANCE PERFORMANCE RECORD Interval

Check* Date Remarks Authorized Signature

Hours Months

A B C

A B C

A B C

A B C

A B C

A B C

A B C

A B C

A B C

A B C

A B C

A B C

* Check each operation as performed

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12. WARRANTY CONDITIONS

1. Without prejudice to the restrictions stated hereinafter, the contractor guarantees both the soundness of the product delivered by him and the quality of the material used and/or delivered for it, insofar as this concerns faults in the product delivered which do not become apparent during inspection or transfer test, which the principal shall demonstrate to have arisen within 12 months from delivery in accordance with subarticle 1A exclusively or predominantly as a direct consequence of unsoundness of the construction used by the contractor or as a consequence of faulty finishing or the use of poor materials.

1A. The product shall be deemed to have been delivered when it is ready for inspection (if inspection at the premises of the contractor has been agreed) and otherwise when it is ready for shipment.

2. Articles 1 and 1a shall equally apply to faults which do not become apparent during inspection or transfer test which are caused exclusively or predominantly by unsound assembly/installation by the contractor. If assembly/installation is carried out by the contractor, the guarantee period intended in article 1 shall last 12 months from the day on which assembly/installation is completed by the contractor, with the understanding that in this case the guarantee period shall end not later than 18 months after delivery in accordance with the terms of subarticle 1A.

3. Defects covered by the guarantee intended under articles 1, 1A and 2 shall be remedied by the contractor by repair or replacement of the faulty component either on or off the premises of the contractor, or by shipment of a replacement component, this remaining at the discretion of the contractor. Subarticle 3A shall equally apply if repair or replacement takes place at the site where the product has been assembled/installed. All costs accruing above the single obligation described in the first sentence, such as are not restricted to shipment costs, travelling and accommodation costs or disassembly or assembly costs insofar as they are not covered by the agreement, shall be paid by the principal.

3A.If repair or replacement takes place at the site where the product has been assembled/installed, the principal shall ensure, at his own expense and risk, that:

a. the employees of the contractor shall be able to commence their work as soon as they have arrived at the erection site and continue to do so during normal working hours, and moreover, if the contractor deems it necessary, outside the normal working hours, with the proviso that the contractor informs the principal of this in good time;

b. suitable accommodation and/or all facilities required in accordance with government regulations, the agreement and common usage, shall be available for the employees of the contractor;

c. the access roads to the erection site shall be suitable for the transport required;

d. the allocated site shall be suitable for storage and assembly;

e. the necessary lockable storage sites for materials, tools and other goods shall be available;

f. the necessary and usual auxiliary workmen, auxiliary machines, auxiliary tools, materials and working materials (including process liquids, oils and greases, cleaning and other minor materials, gas, water, electricity, steam, compressed air, heating, lighting, etc.) and the measurement and testing equipment usual for in the business operations of the principal, shall be available at the correct place and at the disposal of the contractor at the correct time and without charge;

g. all necessary safety and precautionary measures shall have been taken and adhered to, and all measures shall have been taken and adhered to necessary to observe the applicable government regulations in the context of assembly/installation;

h. the products shipped shall be available at the correct site at the commencement of and during assembly.

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4. Defects not covered by the guarantee are those which occur partially or wholly as a result of:

A. non-observance of the operation and maintenance instructions or other than foreseeable normal usage;

B. normal wear and tear;

C. assembly/installation by third parties, including the principal;

D. the application of any government regulation regarding the nature or quality of the material used;

E. materials or goods used in consultation with the principal;

F. materials or goods provided by the principal to the contractor for processing;

G. materials, goods, working methods and constructions insofar as are applied at the express instruction of the principal, and materials or goods supplied by or on behalf of the principal;

H. components obtained from third parties by the contractor insofar as that party has given no guarantee to the contractor.

5. If the principal fails to fulfil any obligation properly or on time ensuing from the agreement concluded between the principal and the contractor or any agreement connected to it, the contractor shall not be bound by any of these agreements to any guarantee regardless of how it is referred to. If, without previous written approval from the contractor, the principal commences disassembly, repair or other work on the product or allows it to be commenced, then every agreement with regard to guarantee shall be void.

6. Claims regarding defects must be submitted in writing as quickly as possible and not later than 14 days after the discovery of such. All claims against the contractor regarding faults shall be void if this term is exceeded. Claims pertaining to the guarantee must be submitted within one year of the valid complaint on penalty of invalidity.

7. If the contractor replaces components/products under the terms of his guarantee obligations, the replaced components/products shall become the property of the contractor.

8. Unless otherwise agreed, a guarantee on repair or overhaul work carried out by the contractor or other services shall only be given on the correctness of the manner in which the commissioned work is carried out, this for a period of 6 months. This guarantee only covers the single obligation of the contractor to carry out the work concerned once again in the event of unsound work. In this case, subarticle 3A shall apply equally.

9. No guarantee shall be given regarded the inspection conducted, advice given and similar matters.

10. Alleged failure to comply with his guarantee commitments on the part of the contractor shall not absolve the principal from his obligations ensuing from any agreement concluded with the contractor.

11. No guarantee shall be given on products which form a part of, or on work and services on, goods older than 8 years.

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Revision 0305: 1. Alarm pressure switch (Figure 12A, 13A and 18A) added Revision 0107: 7.1.1 Corrected red pointer is 3, knob is 1, graduated dial is 2.

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