VAF instruments Viscosense 3, 775 Instructions For Installation, Operation Care And Maintenance

Technical Manual

Instructions for installation,
operation and maintenance

775

VISCOSENSE®3

Viscosity Sensor & Interface box

Valid for ViscoSense®3

Publication nr TIB-775-GB-0517
Supersedes TIB-775-GB-1216

CONTENTS

1.

PREFACE ....................................................................................... 2

1.1 General ........................................................................................................ 2

1.2 Symbols ....................................................................................................... 3

1.3 Copyright ..................................................................................................... 3

2. SYSTEM DESCRIPTION ................................................................ 4

2.1 System description ....................................................................................... 4

2.2 System components .................................................................................... 5

2.3 Principle of operation ................................................................................... 6

3. TECHNICAL SPECIFICATION ....................................................... 7

3.1 Sensor ......................................................................................................... 7

3.2 Sensor housing ............................................................................................ 7

3.3 Interface box ................................................................................................ 8

4. SAFETY INSTRUCTIONS .............................................................. 8

4.1 Safety precautions ....................................................................................... 8

5. UNPACKING .................................................................................. 9

6. INSTALLATION .............................................................................. 9

6.1 To record nameplate data ............................................................................ 9

6.2 Conditions for correct working of the ViscoSense®3 sensor ...................... 10

6.3 General installation recommendations ....................................................... 11

6.4 Mechanical installation ............................................................................... 11

6.4.1 ViscoSense®3 interface box .............................................................. 11

6.4.2 ViscoSense®3 housing ...................................................................... 11

6.4.3 To assemble ViscoSense®3 sensor .................................................. 13

6.5 Electrical installation .................................................................................. 15

6.6 Connection of sensor to interface box ........................................................ 16

6.7 Installation checklist version 1.0................................................................. 17

7. OPERATING INSTRUCTIONS ..................................................... 19

7.1 Initial start-up ............................................................................................. 19

7.2 Shut-down on heavy fuel oil ....................................................................... 19

7.3 Shut-down on diesel oil .............................................................................. 19

7.4 Routine start-up ......................................................................................... 19

8. MAINTENANCE ............................................................................ 20

8.1 Routine maintenance ................................................................................. 20

8.2 To clean the ViscoSense®3 sensor ............................................................ 20

8.2.1 General procedure ............................................................................ 20

9. REPAIR OR REPLACEMENT ...................................................... 21

9.1 Repair ........................................................................................................ 21

9.2 Replacement .............................................................................................. 21

9.3 Procedure for using the micro SD card ...................................................... 21

10. TAKE OUT OF SERVICE ......................................................... 22

11. REMOVAL AND STORAGE OF EQUIPMENT ......................... 23

12. MALFUNCTION AND SEND FOR REPAIR ............................. 23

1

13. ENVIRONMENT ....................................................................... 23

14. DISPOSAL ................................................................................ 23

15. TROUBLE SHOOTING ............................................................. 24

15.1 Disconnection the sensor ........................................................................ 24

15.2 General trouble shooting ......................................................................... 25

15.3 PI setting errors (for additional viscosity controller) ................................. 27

15.4 How to take a HFO sample for analysis .................................................. 27

15.5 Diagnostic information ............................................................................ 28

16. CERTIFICATES ........................................................................ 30

17. DRAWINGS .............................................................................. 31

17.1 ViscoSense®3 sensor and sensor housing ............................................. 31

17.1.1 ViscoSense®3 sensor housing with sensor installed ......................... 31

17.2 ViscoSense®3 interface box .................................................................... 32

17.2.1 ViscoSense®3 interface box .............................................................. 32

18. ABBREVIATIONS ..................................................................... 33

19. PARTS LISTS ........................................................................... 34

19.1 ViscoSense®3 sensor ............................................................................. 34

20. WARRANTY CONDITIONS ...................................................... 35

21. ENCLOSURE ........................................................................... 37

21.1 Recommendations for a good working booster unit ................................ 37

2

1. PREFACE

1.1 GENERAL

This manual contains instructions for installation, operation and maintenance (IOM) of the VAF

ViscoSense

®

3 viscosity sensor (VS3) and interface box.

For IOM information of associated equipment supplied by VAF Instruments, refer to the separate
manual supplied with those products.

This manual contains important information for the installer, the operator and for your maintenance
department.

Never use the equipment outside its specifications or beyond common engineering practice
nor use the equipment for other applications or make connections to other equipment than
explicitly described in the order acknowledgement and/or technical manuals of VAF
Instruments.

It is not allowed to make any modifications to the sensor or the interface box without prior
written permission of VAF Instruments BV.

To ensure safe and correct installation and operation, read this manual completely before
installing the equipment and starting operations.

ViscoSense

®

2 and ViscoSense®3 sensor (from serial numbers 70000) and interface box

(from serial numbers 1480000) are not interchangeable with previous model ViscoSense

®

.

ViscoSense

®

2 and ViscoSense®3 sensor and interface box are interchangeable.

For any additional information contact:

VAF Instruments B.V.

Tel. [phone]

Vierlinghstraat 24, 3316 EL Dordrecht Fax [phone]
P.O. Box 40, NL-3300 AA Dordrecht E-mail: [e-mail]
The Netherlands Internet: www.vaf.nl

Or your local authorized VAF dealer.
Their addresses can be found on www.vaf.nl

3

1.2 SYMBOLS

The following symbols are used to call attention to specific types of information.

A warning to use caution! In some instances, personal injury or damage to the

ViscoSense

®

3 unit or control system may result if these instructions are not followed

properly.

An explanation or information of interest.

Warning for hazardous voltages. Symbol is used on the interface box in combination with
the requirement to switch of the power supply to the box before opening it, in order to
avoid personal injury.

1.3 COPYRIGHT

This technical manual is copyrighted with all rights reserved.
While every precaution has been taken in the preparation of this manual, no responsibility for errors or

omissions is assumed. Neither is any liability assumed for damages resulting from the use of the
information contained herein. Specifications can be changed without notice.

ViscoSense

®

is a registered trademark of VAF Instruments B.V.

4

2. SYSTEM DESCRIPTION

2.1 SYSTEM DESCRIPTION

ViscoSense®3 is, besides other applications, intended for use in fuel oil treatment systems to obtain a

correct measurement and control of the fuel oil viscosity.

Figure 1 shows a typical fuel treatment system with return line from the engine. In this system, the
degassing/mixing tank operates as a fuel buffer, ensuring gradual changes of viscosity which results

in a stable control of the viscosity. The ViscoSense

®

3 sensor is used to measure the actual viscosity

of the fuel oil. The signal from the sensor is compared to the setpoint of a viscosity controller, which
regulates the output of the fuel heater via a control element (steam or thermal oil valve, or electric
heater cabinet).

Figure 1 Typical example of an automatic control system using steam or thermal oil heater

5

2.2 SYSTEM COMPONENTS

The ViscoSense®3 viscosity system consists of:

 the combined viscosity and temperature measuring sensor
 the sensor housing
 Interface box

The sensor housing is made of ductile iron and has flanges for direct mounting in the fuel line. The
sensor itself is made of stainless steel and is mounted in the housing. The sensor head has a special
DLC coating and it is mechanically protected by a stainless steel flow tube with 3 oval slits. It is
supplied with 5 metres of signal cable for connection to the interface box.

The ViscoSense

®

3 Interface box is a wall mount electronic unit, processing the signals to and from

the sensor. It provides 4...20 mA signals for remote read-out of viscosity and temperature for a
flowcomputer, controller or other system elements. See separate technical manuals for a description
of these components.

Figure 2 ViscoSense®3 components (sensor in housing and interface box)

6

2.3 PRINCIPLE OF OPERATION

The operating principle of the sensor is that of a torsion pendulum. The sensor consists of a stainless
steel driver / sensor head (1), attached to the base plate (2) by means of a tubular torsion spring (3).
In the head, one pair of piezo elements (driver piezos) (4) actuates the pendulum at its torsional
resonance frequency, while another pair (the receiver piezos) probes the actual movement of the
head. In a low viscosity medium, like air the resonance frequency is in the range of 1600 Hz. In a high
viscosity medium the movement of the head is damped by the liquid. Consequently, the resonance
frequency slightly shifts towards lower frequencies, whilst the width of the resonance peak increases,
which is a measure for the viscosity.

A flow tube (5) is placed around the pendulum, to protect it against mechanical damage.
The flow tube is machined with a smooth surface, as well as with a triplet of oval slits. These slits

increase the refreshing rate between sensor and flow tube.

Figure 2 ViscoSense®3 sensor (VS3)

7

3. TECHNICAL SPECIFICATION

3.1 SENSOR

Sensor type nr. 0279-0096
Viscosity range 0 - 25/50 mPa.s (other ranges on request)
Temperature range 0-200°C
Maximum operating temperature

180C
Temperature transmitter PT 100 element
Accuracy

Viscosity +/- 2% instantaneous or 0.5 mPa.s
Temperature

± 1C
Material

Sensor Stainless steel 316L

Coating Diamond Like Carbon (DLC)
Signal cable length 5 metres, integrated with sensor
Protection class IP65
Weight 1 kg

Warning
For hazardous zone I and II, the ViscoSense

®

3 Ex d version is required.

(See separate technical manual TIB-777)

3.2 SENSOR HOUSING

Material housing ductile iron

Flange connections DN 50 mm (2”), DIN, ANSI or JIS

DN 65 mm (2,5”), DIN, ANSI or JIS
DN 80 mm (3”), DIN, ANSI or JIS
DN 100 mm (4”), DIN, ANSI or JIS

Maximum pressure rating 40 bar

Weight 2” approx. 10 kg

2,5” approx. 11 kg
3” approx. 12 kg
4” approx. 13 kg

8

3.3 INTERFACE BOX

Interface box type nr. 0279-0112
Supply voltage 100-230 VAC, 50/60 Hz

(Fluctuations should not exceed ±10% of the nominal value)
Power consumption 6 Watt
Internal battery Lithium coin type 3V rechargeable, 5 mAh, 6,8 mm

(Do not exchange without prior consulting VAF Instruments)
Output

Viscosity Isolated active output 4…20 mA, current loop, max. load 400Ω
Range typ. 0 - 25/50 mPa.s (depending on selected range)
Temperature Isolated active output 4…20 mA, current loop, max. load 400Ω

Range typ. 0 - 200° C
Response time Depending on application
Resolution 0,1 mPa.s and 0,1 g/l
Ambient temperature

-20 .. + 55 C
Humidity range 0-95% RH
Protection class IP 66
Mounting Wall mounting
Cable connections

Power supply M20 x 1,5, Ø9-13 mm

Output signals M20 x 1,5, Ø9-13 mm
Sensor M16 x 1,5, Ø5-9 mm, integrated with sensor cable
Cable wire

Power supply 3 x 1.5 mm², double isolated heavy duty PVC

Output signals 3 x 2 x 0,50 mm², twisted pair, individually screened, braid shielded
Ventilation requirements No special requirements
Weight 2,0 kg
Max. altitude for use 2000 m above sea-level

4. SAFETY INSTRUCTIONS

4.1 SAFETY PRECAUTIONS

To ensure the safety of personnel and equipment:

 Always follow the safety and installation recommendations in this manual.
 Always use personal protective means when working with hot, aggressive and toxic process

liquids.

 Always use insulated tools when working on electrical installations.
 Ensure that local safety regulations are met when installing and operating the equipment.
 All personnel who operate and service the equipment should read this manual completely and

make themselves acquainted with the equipment before installing or operating the equipment.

 The ViscoSense

®

3 sensor body will heat up to the process temperature; do not touch the body

housing while process is running!

9

5. UNPACKING

Let the instruments acclimatize in the location where they are going to be installed for at least one
hour inside their shipment box. This is to avoid moisture buildup inside the instrument, or on the
connectors and wires.

When the equipment is taken out of the box, please leave the transport locking cap and the outside
protection, in place as long as possible to avoid any damage.

The ViscoSense

®

3 sensor has a special DLC coating on the pendulum.

Damage of the coating will influence the working of the sensor.

Special care should be taken not to scratch or damage the DLC coating.

The transport locking cap and the outside protection should be stored, in the unlikely event the
equipment has to be returned 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.

Figure 4 Transport locking cap Figure 5 Outside protection

6. INSTALLATION

6.1 TO RECORD NAMEPLATE DATA

Before installing a ViscoSense®3 system, record type and serial numbers as stamped on the

ViscoSense

®

3 sensor and interface box.

Always quote the instrument serial number and the variant number when contacting the
factory or local service representative.

Never exceed the temperature and pressure limits specified on the nameplate of the

ViscoSense

®

3. Consult the factory if the ViscoSense®3 must be used for a different

process liquid than originally ordered.

A ViscoSense

®

3 unit may be part of a complete VAF viscosity control system. For information and

instructions covering the other components of this system, refer to the separate technical manuals as
supplied with these components.

10

For identification purposes it is recommended to record also nameplate data of

other ViscoSense

®

3 system components here.

Housing

Serial number: ……………………………

Variant: ……………………………………

Sensor

Serial number: ……………………………

Interface box

Serial number: ……………………………

Model: ……………………………………

6.2 CONDITIONS FOR CORRECT WORKING OF THE VISCOSENSE®3 SENSOR

The flow is recommended to be in-between the maximum and minimum fluid flow rate as mentioned
in chapter 21.1.

The ViscoSense

®

3 housing should be placed in such a way, that no air can be trapped in the housing.

This can easily happen if the inner diameter of the piping is smaller than the inner diameter of the

ViscoSense

®

3 housing, if it has been installed horizontally.

If the inner diameter of the piping is smaller than the inner diameter of the ViscoSense

®

3 housing, the

transitions between the two diameters should be tapered. The inner diameter of the ViscoSense

®

3

housing should not be smaller than the piping.
The fluid should be homogenous.
It should not contain any air bubbles or foam.

THE FLUID SHOULD NOT CONTAIN ANY CHEMICALS OR SOLID PARTICALS THAT
CAN DAMAGE THE DLC COATING

THE FUEL SHOULD BE IN COMPLIANCE WITH ISO 8217:2010
(SPECIFICATIONS OF MARINE FUELS)

11

6.3 GENERAL INSTALLATION RECOMMENDATIONS

 Mount the ViscoSense®3 housing as low as possible, in the fuel system.

 Compare your process variables with the specifications. Make sure these are compatible!
 Pressure pulsations and variations should be avoided as much as possible.
 Mechanical vibrations should be avoided as much as possible.

 No special tools are required to install the ViscoSense

®

3. Ensure that your standard tools

are fit for the job.

 Make sure that the working environment is clean. Ensure that no dirt can enter the sensor.
 Insulate the pipes and the sensor housing well, to avoid any temperature loss of the fluid.
 When fuel viscosity is 500 mPa.s or thicker it is recommended to wrap steam tracing with

sufficient capacity, or 20 Watts/metre resistance wiring around the ViscoSense

®

3 housing.

 VAF ViscoSense

®

3 sensor and interface box are precision instruments. Handle them with

care

.

Do not unscrew the cable gland on the top of the ViscoSense®3 sensor or disconnect the
cable from the sensor. This will violate the correct operation of the ViscoSense

®

3 sensor.

Take care that the pendulum is not damaged and the torsion tube not bent by
mechanical force.

This will violate the ViscoSense

®

3 signal.

6.4 MECHANICAL INSTALLATION

6.4.1 ViscoSense®3 interface box

1. Install the ViscoSense

®

3 interface box in a suitable location, free from excessive vibrations,

humidity and excessive temperature variations.

2. The maximum distance between sensor and the interface box is determined by the cable length

from the sensor, being approx. 5 metres.

3. Allow sufficient space for installation of cables and for servicing.

4. The surface on which the interface box is mounted should at least be able to bear a weight of 10

kg.

6.4.2 ViscoSense®3 housing

1. Remove dust caps from sensor housing and install housing stress-free, with shut-off valves and

bypass valve in the fuel piping as illustrated in figure 6. Take care that the flow direction is in

accordance with the indication on the housing (inlet, outlet and arrow) as illustrated in figure 8.

Support inlet and outlet piping sufficiently.

These shut-off valves and bypass valve are not furnished by VAF Instruments.

2. Note that the distance between fuel heater and sensor housing inlet should not exceed 4 metres.

3. To protect the instrument from excessive vibrations, which can cause malfunctioning of the

instrument, it is recommended to:

Install the ViscoSense

®

3 as low as possible in the fuel system close to a solid structure or beam.

Install suitable pipe clamps at both sides of the ViscoSense

®

3 sensor housing.