VAF instruments T-SENSE Technical Manual

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Technical Manual
Instructions for installation, operation and maintenance
T-SENSE®
Optical Torque M eas uring systems and PEM4 stand alone
Publication nr
TIB-669-GB-1117
Supersedes
-
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TABLE OF CONTENTS
1. PREFACE .................................................................................................................... 3
1.1General ................................................................................................................... 3
1.2Symbols .................................................................................................................. 3
1.3Copyright................................................................................................................. 3
2. SYSTEM DESCRIPTION ............................................................................................. 4
2.1PEM4 TOUCH SCREEN ........................................................................................ 4
2.2System security ....................................................................................................... 4
3. TECHNICAL SPECIFICATIONS .................................................................................. 5
3.1PEM4 TOUCH SCREEN ........................................................................................ 5
4. SAFETY INSTRUCTIONS ........................................................................................... 5
5. UNPACKING ................................................................................................................ 5
6. INSTALLATION AND FIRST USE ............................................................................... 5
6.1To record nameplate data ....................................................................................... 7
6.2Installation diagram ................................................................................................. 8
6.3Installation of the PEM4 touch screen .................................................................... 9
6.4Cable specifications .............................................................................................. 13
7. OPERATING PRINCIPLES ........................................................................................ 14
7.1General ................................................................................................................. 14
7.2Displayed parameter and engineering units ......................................................... 14
7.3Explanation of the parameters .............................................................................. 14
7.3.1 Torque ......................................................................................................... 14
7.3.2 Shaft speed ................................................................................................. 14
7.3.3 Power .......................................................................................................... 14
7.3.4 Thrust (option) ............................................................................................. 14
7.4Operating instructions PEM4 touchscreen
............................................................ 15
7.4.1 Operating menus......................................................................................... 15
7.5How to operate the touch screen .......................................................................... 15
7.5.1 Home menu................................................................................................. 15
7.5.2 Propulsion menu ......................................................................................... 16
7.5.3 Settings menu ............................................................................................. 16
7.5.4 Alarm screen ............................................................................................... 18
7.6Method of calculations .......................................................................................... 19
8. MAINTENANCE ......................................................................................................... 20
9. REPAIR ...................................................................................................................... 20
10. TAKE OUT OF SERVICE ..................................................................................... 20
11. REMOVAL AND STORAGE OF EQUIPMENT ..................................................... 20
12. MALFUNCTION AND SEND FOR REPAIR ......................................................... 20
13. ENVIRONMENT ................................................................................................... 20
14. DISPOSAL ............................................................................................................ 20
15. TROUBLE SHOOTING ......................................................................................... 21
15.1 PEM4 malfunction ............................................................................................. 21
15.2 No torque signal ................................................................................................ 21
16. CERTIFICATES .................................................................................................... 21
16.1 EMC classifications of the PEM4 ....................................................................... 21
17. DRAWINGS .......................................................................................................... 22
18. ABBREVIATIONS ................................................................................................. 25
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19. SPARE PARTS ..................................................................................................... 25
20. WARRANTY CONDITIONS .................................................................................. 26
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1. PREFACE
1.1 GENERAL
The PEM4 touch screen is a microprocessor based instrument, which is able to fulfil standard torque, shaft speed and power calculations within narrow limits. Thrust and thrust/power calculations can be performed when thrust measurements are available.
The T-Sense
®
torque sensor is the measuring instrument providing torque, speed and power as input
for the PEM4 touch screen. The TT-Sense
®
additionally provides thrust measurements as input. This
completely unique and compact total solution can be used for simple to complicated configurations.
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.
To ensure safe and correct installation and operation, read this manual completely before installing the equipment and starting operations.
For any additional information contact:
VAF Instruments B.V.
Tel. +31 78 618 3100
Vierlinghstraat 24, 3316 EL Dordrecht Fax +31 78 617 7068 P.O. Box 40, NL-3300 AA Dordrecht E-mail: sales@vaf.nl The Netherlands Internet: www.vaf.nl
Or your local authorized VAF dealer. Their addresses can be found on www.vaf.nl
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 torque sensor or control system may result if these instructions are not followed properly.
An explanation or information of interest.
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.
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2. SYSTEM DESCRIPTION
2.1 PEM4 TOUCH SCREEN
The PEM4 touch screen is able to calculate several output data. Functions, which can be performed with this PEM4 touch screen are:
Measurement and display of torque, shaft speed, power and thrust (optional). Calculation of average shaft power, shaft speed and torque during the last 1, 4 and 24 hours. Calculation of total energy and total revolutions including reset. Calculation of average thrust/quotient when thrust measurement (optional) is provided. Displaying of parameters.
The PEM4 touch screen can be installed in a control cabinet or control panel.
Remark: Optional 4-20 mA analogue output can be integrated in the stator control box near the T­Sense
®
torque sensor. Please read section 6.5 in TIB-661 for detailed information or read
TIB-664 section 6.5 in case of TT-Sense
®
torque/thrust sensor.
2.2 SYSTEM SECURITY
Besides checking the status of the torque measurement system the PEM4 system also checks itself continuously for program and configuration data integrity, normal program flow and power supply conditions. Alarm messages will be logged in a dedicated alarm screen.
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3. TECHNICAL SPECIFICATIONS
3.1 PEM4 TOUCH SCREEN
Supply voltage 115-230 VAC to power supply unit Dimensions
235 x 150 x 44 (w x h x d)
Cut out
217,6 x 128,6 mm (w x h)
Cut out depth
38 mm
Front panel thickness
7 mm
Connections
RJ45 Ethernet connection on the ba ck-bottom side of the pa nel
Temperature range
-20ºC – 60ºC
Display
Color TFT LCD, PCAPTouch screen 7,0” (1024 x 600 dots) with adjustable LED backlight
Power consumption
8 W
Processor (CPU)
i.MX 6 DualLite at 1 GHz, 2 GB DDR3 on board memory
Net weight
1,3 kg
Figure 1 – PEM4 touch screen
4. SAFETY INSTRUCTIONS
There are no special safety instructions for the equipment.
5. UNPACKING
Let the equipment acclimatize inside the closed box for at least one hour at the location where the system will be installed. When the equipment is taken out of the box, please leave the special protection supplied with the equipment as long as possible in place to avoid any damage. The special protection should be stored for the unlikely event the equipment has to be sent for repair. Dispose of the packing material should be done according to the laws of the country where the equipment is installed, or according to the rules that are applicable on the vessel.
Be careful when unpacking the electronic equipment. The content is fragile. Do not press on the PEM2 touch screen.
6. INSTALLATION AND FIRST USE
The PEM4 touch screen will be delivered with the software and correct data settings installed. First connect the Ethernet cables to the control box and the touch screen. The wires for power supply should be connected at last.
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Check if the inputs show any errors. If that is the case the connection(s) or connected equipment should be checked and corrected.
6.1 TO RECORD NAMEPLATE DATA
This information is required when contacting the supplier for any reason.
Date of delivery: xx xx xxxx Serial number: xxxx Stator version: xxxx Interface version: xxxx Hull number: xxxx Type: PEM4 touch screen
Above information can be found at the PEM4 info screen.
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6.2 INSTALLATION DIAGRAM
The PEM4 touch screen can be connected to the stator control box as shown in Figure 2 and Figure 3. The maximum number of touch screens, which can be connected by Ethernet connection is two.
Figure 2 – T-Sense® torque sensor connected to one PEM4 touch screen
Figure 3 – Example of T-Sense® torque sensor connected to two PEM4 touch screens
Remark: When a TT-Sense
®
Thrust & Torque sensor is installed it can be connected in the same
way as above mentioned T-Sense
®
equipment.
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6.3 INSTALLATION OF THE PEM4 TOUCH SCREEN
1. Install the PEM4 touch screen in a control cabinet or control panel in the ECR or on the bridge, where it will be free as possible from moisture, large fluctuations of temperature and particularly of vibration shock. Also influences such as large magnetic fields caused by transformers, relays or electromagnets must be avoided.
2. All cable connections should be made using cables as specified in section 6.4.
3. Connect the RJ45 Ethernet from the stator control box and power supply to the backside bottom of the PEM4 touch screen in accordance with Figure 4.
Figure 4 – ON/OFF switch and communication ports at backside bottom of PEM4 touch screen
4. Check for correct power supply and integrity of external wiring connections. Turn on power and observe several readings, like torque, shaft speed, power etc.
Important notes
Never connect cable shields at both ends to ground, but at one end only,
to avoid
earth loops.
To avoid interference on the signal cables, such cables must be installed as far as
possible from electric power cables used for power supply and stator.
Ensure that the ambient temperature at the PEM4 never exceeds 55°C.
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5. Only applicable if an additional (second) touch screen is connected to the T-Sense® system. Additional touch screens are connected to the system as described in Figure 5. For the use of two PEM4 screens a Ethernet switch is necessary. Check for correct power supply and integrity of external wiring connections. Turn on power and
observe several readings, like torque, shaft speed, power etc.
Figure 5 – Example of T-Sense® torque sensor connected to two PEM4 touch screens
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6. IP settings of the PEM4 display In order to have no malfunction of the system the IP settings of the PEM4 display have to be set up
correctly. The next steps will explain how to adjust the IP settings of the system. Switch off the power supply of the PEM4 display. Wait for 1 minute and then repower the PEM4.
Enter password “5678” end press login. The screen below will appear.
Change the Address to http://168.0.0.120 (this is the default IP address of the stator control box) and press “Save setting”. Then Press “Ethernet settings”. The screen below will appear.
Press “Ethernet settings”. The next screen will appear.
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Ensure the IP address is 168.0.0.110 for the first PEM4 display. In case a second PEM4 display is installed the second screen should have IP address 168.0.0.111. If this is correct press “Next”. Set the DNS address to 255.255.255.0 and press “Done”. The screen below will appear.
Press “Confirm” to save settings. Next, switch of the power supply of the PEM4, wait for 1 minute and repower the PEM4 display. The screen below will appear.
Press “Start Application” or wait until the timer has gone to zero, the application will start at the home screen, see screen below.
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6.4 CABLE SPECIFICATIONS
Specification for the input, output and power supply cables connected to the PEM4 touch screen.
Figure 6 – Specification of input and output cables at the stator control box and PEM4 touch screens
Cable specification:
IC-01 Integrated antenna cable 5m, VAF supply IC-02 Integrated stator cable 5m, VAF supply IC-04 Power supply (115 / 230 VAC) cable, 3 x 1,5 mm
2
, flex strands
IC-05 Power supply (24 VDC) cable, 1x2x0,5 mm
2
, flex strands
IC-11 Connection cable Ethernet, CAT5e, Braid Shielded, RJ45
Remark: When a TT-Sense
®
Thrust & Torque sensor is installed it can be connected in the same
way as above mentioned T-Sense
®
equipment.
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7. OPERATING PRINCIPLES
7.1 GENERAL
A zero setting procedure is always necessary in order to obtain a correct measurement and reading. For more detailed information see paragraph 6.4 in TIB 661 of the T-Sense
®
torque sensor.
The PEM4 touch screen is easy to operate and provides the operator with a standard selection of torque, shaft speed and power data. A number of conditional messages will inform you about error/fault conditions if applicable. Setups determining functionality are only possible via the access code 1234. All setups and computations are stored in a battery backup RAM. The PEM4 system is self-checking as for correct functioning of its memories, program run and existence of supply voltage.
7.2 DISPLAYED PARAMETER AND ENGINEERING UNITS
The following parameters are available at the PEM4 touch screen: Torque
(kNm)
Shaft speed
(rpm)
Shaft power
(kW)
Total energy
(kWh, MWh, GWh)
Time-base
(hours, minutes, seconds)
When a TT-Sense
®
Thrust & Torque measurement system is applied the PEM4 touch screen will
display below parameters in addition: Propeller thrust
(kN)
Thrust power quotient
(kN/MW)
7.3 EXPLANATION OF THE PARAMETERS
7.3.1 Torque
The torque signal, measured in the rotor part, is sent wireless via the stator antenna to the electronics in the control box. In this control box the signal is converted to a Ethernet, which signal is connected to the PEM4 touch screen. Zero torque adjustment will be done during commissioning of the T-Sense
®
rotor and control box.
7.3.2 Shaft speed
The shaft speed is measured via a gravity sensor in the T-Sense
®
rotor part. This rotor part is connected wireless to the stator electronics in the control box. The stator electronics are connected to the PEM4 touch screen via Ethernet.
7.3.3 Power The power is calculated by multiplying the above measured shaft speed and torque. The output values
are submitted to the PEM4 touch screen via the same Ethernet connection.
7.3.4 Thrust (option) In case a TT-Sense
®
is installed, which additionally measures the axial displacement due to propeller thrust, the thrust values are converted to an Ethernet signal in the same way as the torque and shaft speed outputs.
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7.4 OPERATING INSTRUCTIONS PEM4 TOUCHSCREEN
7.4.1 Operating menus The PEM4 touch screen includes with the following operating menus:
7.4.1.1 The user mode
For daily use: In this mode all relevant system menus are displayed. Different pages could be selected by tapping the page at the top of the screen.
7.4.1.2 The settings mode (settings menu) for users
Only displayed after choosing the “Settings Menu” page and entering your password (1234).
7.5 HOW TO OPERATE THE TOUCH SCREEN The PEM4 touch screen screens are designed in such a way that they are easy to operate and self
explaining. By pressing at the touch screen buttons/text fields/characters/pages are selected. Browsing through the menus by tapping on the different pages at the top of the touch screen will help
you to find the information you are looking for. In the “Settings Menu” you will be able to change specific values via a numeric keypad. This keypad will be displayed after pressing the values in the grey sections at the touch screen.
In the following sections several examples of PEM4 screens are shown and a description of the main PEM4 functions is added.
7.5.1 Home screen
Figure 7 – Home screen
This is the “Home” submitting information about the actual torque, propeller speed and power at the propeller. Note that thrust and thrust power quotient (propeller) are only visible if a TT-Sense
®
is
installed.
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7.5.2 Propulsion screen
Figure 8 – Propulsion screen
This page is showing the average propulsion data over the last 1, 4 and 24 hours. When the propeller shaft is rotating the PEM4 is continuously recalculating these average values. In case the propeller shaft is not rotating the average values stay as they are.
Total Energy” consumed by the propeller and the “Total Revolutions” made by the shaft are available at the lower part of the screen. The “Total Energy” value jumps from kW to MW to GW (min. 0,000 kW and max. 9999 GW). The “Total Revolutions” value jumps from E3 to E6 to E9 (respectively 1000, 1x10
6
and 1x109 revolutions). These total values can be set to zero anytime by pushing the “Reset” buttons.
After resetting “Total Energy” and “Total Revolutions” the previous displayed values are lost.
7.5.3 Settings menu
Figure 9 – Settings menu
This “Settings Menu” is accessible by entering the 4-digit password 1234 in the login screen. This screen is your entrance to adjustment of settings.
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7.5.3.1 Settings menu, torque inversion
Figure 10 – Settings menu, torque inversion
When the touch screen is showing a negative torque value, when sailing ahead, you are able to convert this negative value to positive by pushing the “Standard” button once. “Standard” will now change to “Inverse”. Pushing “Inverse” will change the button back to “standard” again.
7.5.3.2 Settings menu, clock
Figure 11 – Settings menu, clock
7.5.3.3 Settings menu, Ethernet settings
Figure 12 – Settings menu, Ethernet settings
In this menu it is possible to change the Ethernet settings of the stator control box. Via “Get settings” the current settings are shown.
Remark: Please double check changes before pressing changing settings. Incorrect settings might cause malfunctioning of the complete system.
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7.5.3.4 Settings menu, info
Figure 13 – Settings menu, info
This screen is displaying all essential data in case you to have to contact VAF Instruments regarding your T-Sense
®
torque measuring system.
7.5.4 Alarm screen
Figure 14 – Alarm Screen
In case the PEM4 touch screen detects that output data is missing the system will showing the alarm message “Communication Fail”.
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7.6 METHOD OF CALCULATIONS
Shaft power is calculated from the measured torque and the revolutions of the shaft.
Shaft power

∙ 
9.945
P = Shaft power [kW] M = Torque [kNm] n = rotations per minute [rpm]
Total energy is calculated from the integrating shaft power over time
Total energy
∆∙∆
E = Total energy [kWh]
The thrust quotient indicates the amount of thrust generated per MW propulsion power. The thrust quotient is an indicator of propeller efficiency. Be aware that propeller thrust and ship speed influence each other.
Thrust quotient
  
1000
T = Thrust [kN] P = Shaft power [kW]
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8. MAINTENANCE
No special maintenance is needed for the PEM4 touch screen. The touch screen can be cleaned with a dry and clean cloth. Do not use any cleaning product or chemical on the screen.
9. REPAIR
Nothing on the PEM4 touch screen can be repaired on site.
10. TAKE OUT OF SERVICE
Switch off the power supply.
11. REMOVAL AND STORAGE OF EQUIPMENT
Switch off the power supply. Make sure that all wires that are connected to the PEM4 are labelled correctly so that re-installation of the PEM4 can be done without any errors. Disconnect all the input and output wires.
Store the PEM4 in a box in a cool and dry place, so that the PEM4 cannot be damaged.
12. MALFUNCTION AND SEND FOR REPAIR
If the PEM4 stops working completely contact VAF Instruments for instructions. VAF Instruments is working with a RMA (return material authorisation), in the event the PEM4 has to be sent back for repair, you can contact VAF Instruments, by email: service@vaf.nl
for further instructions.
13. ENVIRONMENT
The PEM4 touch screen has no negative influence on the environment during normal operation.
14. DISPOSAL
The PEM4 touch screen is made out of metal and electronics. It should be disposed according to local laws of the country.
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15. TROUBLE SHOOTING
15.1 PEM4 MALFUNCTION
If the PEM4 does malfunction, power the PEM4 down, check all wiring and power the PEM4 back up again. This will restart the program.
15.2 NO TORQUE SIGNAL
The connection between the PEM4 and the stator control box is broken.
Check wires for damage. Check the connections in the stator control box or at the PEM4 touch screen.
16. CERTIFICATES
For a torque measuring system no classification certificates are required.
16.1 EMC CLASSIFICATIONS OF THE PEM4
PEM4 Efficiency Monitor is tested in accordance with:
General Vibration Strain, IEC 68-2-64 compliant. Shock, IEC 68-2-64 compliant.
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17. DRAWINGS
Drawing 1 – 0815-1023
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Drawing 2 – 0815-2037
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Drawing 3 – 0815-2038
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18. ABBREVIATIONS
PEM4 Touch screen for Ethernet communication SPU3 Signal Processing Unit, part of the PEM4 efficiency monitoring system CPU Central Processing Unit TFT Thin Film Transistor - Liquid Crystal Display PCAP Projected Capacitive LED Light Emitting Diode LCD Liquid Crystal Display PT100 Temperature sensor type PT100 PT2 Type of flowmeter with Hall sensor and PT100 output
19. SPARE PARTS
A recommended spare part list is not applicable.
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20. 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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VAF Instruments B.V.
Vierlinghstraat 24, 3316 EL Dordrecht, The Netherlands P.O. Box 40, 3300 AA Dordrecht, The Netherlands T +31 78 618 3100 sales@vaf.nl, www.vaf.nl
Specifications subject to change without notice. VAF Instruments B.V. is an ISO 9001 Certified Company. Agents and distributors in more than 50 countries.
Represented by
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