Pneumatic System Components

For Viscotherm
TECHNICAL

MANUAL

773

INSTRUCTIONS FOR INSTALLATION, OPERATION

AND MAINTENANCE

Publ. Nr.
Supersedes

TIB-773-GB-0107
TIB-773-GB-0305

CONTENTS
1. PREFACE....................................................................................................4
1.1
1.2
1.3
1.4

General.......................................................................................................................4
Sysmbols....................................................................................................................4
Copyright ...................................................................................................................4
To record import serial numbers ...............................................................................5

2. SYSTEM DESCRIPTION ..........................................................................6

2.1
2.2

System arrangement diagram ....................................................................................6

System components ...................................................................................................7

3. OPERATING PRINCIPLE SYSTEM COMPONENTS ............................8

3.1
3.2
3.3
3.4
3.5
3.6

Viscosity control station ............................................................................................8

Control valve ...........................................................................................................11
Alarm pressure swich (option) ................................................................................11
Airfilter-regulator ....................................................................................................12
Viscosity recorder (option)......................................................................................13
Analog viscosity indicator (option) .........................................................................13

4. TECHNICAL SPECIFICATION SYSTEM COMPONENTS.................14

4.1
4.2
4.3
4.4
4.5

Viscosity Control Station.........................................................................................14

Airfilter-regulator ....................................................................................................14
Analog viscosity indicator (option) .........................................................................15
Alarm pressure switch (option) ...............................................................................15
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

2

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
10.2
10.3
10.4
10.5

Recommended spare parts KIts............................................................................46

Viscosity control station.......................................................................................47
Air Filter Regulator ..............................................................................................52
Analog Viscosity Indicator...................................................................................53
Alarm pressure switch ..........................................................................................54

11. MAINTENANCE RECORD ...................................................................56

12. WARRANTY CONDITIONS.................................................................57

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.
Vierlinghstraat 24, NL-3316 EL Dordrecht
P.O. Box 40, NL-3300 AA Dordrecht
The Netherlands
Or your local authorized VAF dealer.
Their addresses can be found on www.vaf.nl

Tel. +31 78 618 3100

Fax +31 78 617 7068
E-mail: sales@vaf.nl
Internet: 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.

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

Viscosity Control Station

Airfilter-Regulator
Starter Box
Analog Viscosity Indicator
Viscosity Recorder
Alarm Pressure Switch
Control valve

Nameplate data

2. SYSTEM DESCRIPTION
2.1 SYSTEM ARRANGEMENT DIAGRAM

Figure 1

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.

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.

Figure 3 Operation schematic of the viscosity control station

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).

10

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

11

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

12

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

13

4. TECHNICAL SPECIFICATION SYSTEM COMPONENTS

4.1 VISCOSITY CONTROL STATION
Air supply
Input signal
Output signal
Pneumatic connections
Control mode
Proportional band
Reset time
Viscosity scale
Control accuracy
Static air consumption
Materials
Measuring element
Encasing
Protection class
Mounting
Mounting hardware
Max. static working pressure
Overrange protection
Ambient temperature limits
Weight

1.4 bar (140 kPa; 20 psi)

0.2-1.0 bar (20-100 kPa; 3-15 psi) from dP-transmitter
0.2-1.0 bar (20-100 kPa; 3-15 psi) to control valve
6 mm pipe couplings, 1/4" NPT female
PI (proportional + reset);
reverse (standard) or direct acting;
automatic or manual operation.
2-200% (factory adjusted to 35 %)
0.03 - 5 minutes (factory adjusted to 5 minutes)
see dial of instrument
1% of full scale
3 Nl/min
phosphor bronze bellows
die-cast aluminium
IP65, weatherproof, tropically resistant
wall or flush panel
mounting brackets and rubber vibration dampeners supplied with
instrument.
1 bar (100 kPa; 15 psi)
1 bar (100 kPa; 15 psi)
-40 to 100C (-40 to 212F)
3.5 kilos

4.2 AIRFILTER-REGULATOR
Type
Maximum supply pressure
Regulated output pressure
Air output capacity
Connections
Materials
Housing
Valve plug
Range spring
Diaphragm
Filter element
Filter mesh width
Ambient temperature range
Accessories supplied
Weight

reducing-relief type automatic regulator

20 bar (2,000 kPa; 300 psi)
0-2.5 bar/ 0-35 psi (0-250 kPa)
max. 34 Nm/h
1/4" NPT
die-cast aluminium
stainless steel
cadmium plated carbon steel
Nylon reinforced Buna-N
sintered stainless steel
0.005 mm
-50 to 65C (-58 to 150F)
wall mounting bracket and output pressure gauge
0.58 kilos

14

4.3 ANALOG VISCOSITY INDICATOR (OPTION)

Type
Mounting
Measuring element
Input air signal
Materials
Measuring element
Encasing
Reading units
Accuracy class
Protection class
Alarm device (option)
Max. voltage
Max. current
Weight

edge scale manometer

flush panel
bourdon tube
0.2-1.0 bar (3-15 psi)
CuSn
steel
direct reading in viscosity units
1% F.S.
IP55
2 adjustable NO/NC change-over switches
250 V
3 Amp AC / 500 VA ; 2 Amp DC / 50 W
1.2 kilos

4.4 ALARM PRESSURE SWITCH (OPTION)

Type
Mounting
Measuring element
Input air signal
Material Housing
Contact rating
Protection class
Weight

non-indicating pressure switch

wall, post or front panel
two SPDT diaphragm pressure switches
0.2-1.0 bar (3-15 psi)
die-cast aluminium
250 VA, 5A or 10A (check your model)
IP54 (NEMA 4)
0.95 kilos

4.5 STARTER BOX (OPTION)

Type
Mounting
Protection class
Operating voltage
Ambient temperature
Motor protection
Power consumption
Switching current

Weight:

15

on-off switch for electric motor (make Marbaise) of Viscotherm sensor

wall or post
IP65
same as electric motor of sensor
max. 55C (122F)
thermal relay
90 VA
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
0.4 kilos

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).

16

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

17

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.
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 dPtransmitter
Figure 9 Airfilter-regulator

18

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

19

500 V

3A
250V

50 W=

2A=

Figure 11 Electrical connections of indicator equipped with alarm contacts.

20

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

21

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

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

22

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

23

6. DIMENSIONS
6.1 VISCOSITY CONTROL STATION

Figure 15 Viscosity controller with low mounted auto-manual station

24

Figure 16 Viscosity controller with side mounted auto-manual station

25

6.2 AIRFILTER-REGULATOR

Figure 17 Airfilter-regulator

26

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

27

6.4 ANALOG VISCOSITY INDICATOR

6.4.1 Indicator with alarm contracts

6.4.2 Indicator without alarm contacts

Figure 19

28

6.5 STARTER BOX

Figure 20

29

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.

1
2

Figure 21 Inside view of viscosity control station

30

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)
to
The output pressure to the control valve will now graduately be adjusted to match
from
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
output signal will graduately be adjusted to the actual controller setting.

A
Figure 22 Auto-manual station

31

position, where after the

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.

32

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.

33

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.

34

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.

35

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

36

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

37

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.

38

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

39

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.

40

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/dPtransmitter;
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

dP-transmitter and M1 port of viscosity
control station leaking at high pressure (+)
side.

Repair the leak.

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.

41

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

Control station.

Check and replace if necessary.

Wrong control action of viscosity control station.

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

Check that control action is as described in paragraph

4.1.
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).

42

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.

43

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.

44

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

45

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

0390-1061
kit
for 2-year operation

26

Recommended spare parts kits for airfilter regulator

0670-0005
1
Airfilter-regulator assy
0673-0031
5
Filter element

46

10.2 VISCOSITY CONTROL STATION

Figure 28 Viscosity control station

47

Table 2: Viscosity control station

Item No.
Fig. 28

Qty.

1*
2
3
4
6
7
8
9
10
11
12*
13
14*
15
16
17
--

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

19

Part Name

Air tubing, internal I-action

Indicating pointer, black
Setpoint indicator, red
Proportional band dial
Flapper/nozzle assy (not shown, hidden behind PB dial)
Setpoint knob
Feedback bellows assy
I-action belows assy
I-action setpoint screw
Adjustment screw for output signal
Link
Air tubing, proportional signal
Output pressure gauge
Air tubing, process signal
Process bellows support
Process bellows assy
Process link
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% **
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.

48

Fig. 29 Pneumatic relay of viscosity control station

Table 3: Pneumatic relay of viscosity control station
Item No.
Fig. 29
1*
505
506
508 *
509 *+
510 +
511 *
512
513
514
515
516 *
517
518
519 *
520
556 *
585

Qty.

1
2
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1

Part Name

Extractor/orifice cleaner tool (stored in door of controller)

Screw
Screw
Upper diaphragm
Lower diaphragm, seat and disc
Intermediate plate
Spring
Seat ring
Lower plate
Relay valve
Valve guide
Flat spring
Spring
O-ring
Screw with capillary orifice
Screw with capillary orifice
Gasket
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.

49

Fig. 30, Auto/manual bypass station

Table 4: Auto/manual bypass station

Item No.
Fig. 30
1
2
3
4
5*
6
7
8
9*
10
11
12
13
14
15
16
17
18
19
20
21 *
22
23

Qty.
4
1
1
1
1
1
1
2
2
1
2
2
1
1
1
1
1
1
1
4
2
1
1

Part Name
Screw M4 x 35
Upper plate
Valve spring
Intermediate plate
Diaphragm assy
Loading spring
Spring guide
Screw M4 x 10
O-ring
Air connector
Mounting pillar
Fixing plate
Base plate
Pressure adjusting knob
O-ring
Gauge holding plate
Pressure gauge output signal
Switch knob
Name plate
Screw M4 x 10
O-ring
Distributor
Switch block

* Recommended spare parts. Refer to table 6 for contents of spare parts kit.

50

Figure 31 Side view of viscosity control station

Table 5: Viscosity controller rear parts

Item No.
Fig. 31

Qty

Part Name

21
22
23

4
kit
1

Mounting bar with vibration dampener

External pneumatic tubing
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

51

1x

1x

1x

1x

1x

10.3 AIR FILTER REGULATOR

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

Qty

Part Number

Part Name

0670-0005

1*
2
3

1
1
1

0673-0031
1419-0007
0653-0002

Airfilter-regulator (without mounting bracket and pressure

gauge)
Filter element
Wall mounting bracket
Pressure gauge 0-2.5 bar/0-35 psi

* Recommended spare part

52

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
1

0653-0059
0653-0062

Viscosity indicator
Viscosity indicator with NO/NC alarm contacts

No loose spare parts available.

53

10.5 ALARM PRESSURE SWITCH

Figure 34 Alarm pressure switch

54

Table 9: Alarm pressure switch

Fig. 34
Item. No
*
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
18
19
23
24
27
28
29
30
31
32
33
34
35
36
37
38
39
60
64
65

Qty
1
4
2
1
2
2
2
2
2
2
4
4
1
1
1
1
1
4
1
1
4
2
2
1
1
1
1
1
4
2
1
1
1
1
1
1
1

Part. Name

Part. No.

Pressure switch, Model No. D2T-H18

Screw, bracket
Screw, adjusting
Bracket assembly
Spring, overload
Thrust washer, adjusting screw
Stop nut, adjusting screw
Bracket, limit switch
Limit switch assembly
Insulator, limit switch
Nut, limit switch screw
Washer, limit switch screw
Nameplate, electrical
Base plate
Gasket, base plate
Diaphragm capsule assembly
Cover plate
Screw, cover plate
Bracket, mounting
Tag, wire code
Screw, limit switch
Nameplate, identification
Screw, adjustment cover
Cover, adjustment
Gasket, adjustment cover
Housing
Nameplate, trademark
Gasket, housing
Screw, terminal block cover
Screw, terminal block
Terminal block
Marker, terminal strip
Gasket, terminal block cover
Cover, terminal block
Ground screw, slotted
Nameplate, duty to warn
Nameplate, caution

0610-0008

* Recommended spare part. Repair parts not available

55

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
Hours

Check*

Date

Remarks

Authorized
Signature

Months
ABC
ABC
ABC
ABC
ABC
ABC
ABC
ABC
ABC
ABC
ABC
ABC

* Check each operation as performed

56

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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