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BARTEC BENKE VISC-4 Operating Instructions Manual

Viscosity process analyzer
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Operating Instructions
Viscosity Process Analyzer VISC-4
401648MDHEN -
04/2016

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  • Page 1 Operating Instructions Viscosity Process Analyzer VISC-4 401648MDHEN - 04/2016...
  • Page 2 04/2016...
  • Page 3 BARTEC BENKE GmbH Borsigstraße 10 D-21456 Reinbek Tel.: +49 (0) 40 72703-0 Fax: +49 (0) 40 72703-363 E-Mail: service@bartec-benke.de Internet: www.bartec-benke.de...

  • Page 5: Table Of Contents

    Viscosity Process Analyzer VISC-4 Contents Contents General information................1 Information on the operating manual....................1 Explanation of symbols........................2 Duties of the operator ........................4 Limitation of liability ........................5 Copyright ............................. 5 Replacement parts........................6 Customer service.......................... 7 Safety....................9 Intended use ..........................
  • Page 6 Viscosity Process Analyzer VISC-4 Contents 2.9.1 Qualifications ........................39 2.9.2 General requirements ......................40 2.9.3 Unauthorized persons......................40 2.9.4 Instruction ..........................40 2.10 Personal protective equipment ....................41 2.11 Securing against being switched on again..................43 Technical data ..................45 Type plates ..........................51 Design and function ................53...
  • Page 7 Commissioning VISC-4 Ht or Hv ....................92 7.2.1 Switching on the power supply ....................92 7.2.2 Supplying the analyzer with product..................93 Commissioning VISC-4 Lt, Lv, Mt, and Mv .................. 94 7.3.1 Supplying the analyzer with product..................94 7.3.2 Switching on the power supply ....................95 Bleeding the differential pressure transmitter................
  • Page 8 Viscosity Process Analyzer VISC-4 Contents Safety ............................105 Fault analysis ........................... 107 Starting up after rectifying a fault....................112 Maintenance..................113 10.1 Safety ............................113 10.2 Maintenance plan........................116 10.3 Cleaning the touchscreen and other components................ 116 10.4 Rinsing and emptying product-carrying components ..............118 10.4.1...
  • Page 9 Viscosity Process Analyzer VISC-4 Contents 11.5 Removing fastenings......................... 153 11.6 Disposal ........................... 153 Index....................155 04/2016 V / VI...
  • Page 10 Viscosity Process Analyzer VISC-4 Contents VI / VI 04/2016...

  • Page 11: General Information

    Viscosity Process Analyzer VISC-4 General information General information Amongst other things, this section contains information on this operating manual, the symbols used, liability restrictions and contact persons in cus- tomer service. Information on the operating manual This operating manual provides important information on handling the analyz- er.

  • Page 12: Explanation Of Symbols

    Viscosity Process Analyzer VISC-4 General information Explanation of symbols Warnings Warnings are indicated in this operating manual by symbols. The warnings are introduced with signal words indicating the degree of danger at hand. Observe the instructions under all circumstances and work with care to avoid accidents, injuries to personnel and damage to property.
  • Page 13 Viscosity Process Analyzer VISC-4 General information Warning of a danger area Warning about poisonous substances Warning about flammable substances Warning about potentially explosive atmospheres Warning about dangerous electrical current Warning about potential hand injuries Warning about hot surfaces Warning about automatic start-up...

  • Page 14: Duties Of The Operator

    Viscosity Process Analyzer VISC-4 General information WARNING Risk of death due to unavailable explosion protection! ... indicates life-threatening situations in potentially explosive atmospheres. Failure to observe the safety instruction could result in serious injuries or death. FOR THIS REASON: ...

  • Page 15: Limitation Of Liability

    Viscosity Process Analyzer VISC-4 General information Limitation of liability All specifications and instructions in this operating manual have been com- piled under consideration of the applicable norms and regulations, the latest technological standards as well as our many years of experience and exper- tise.

  • Page 16: Replacement Parts

    FOR THIS REASON:  Only use replacement parts from BARTEC BENKE. Obtain replacement parts from authorised dealers or directly from BARTEC BENKE. For the address, see section 1.7 “Customer service” on page 7. WARNING No explosion protection due to using incorrect re-...

  • Page 17: Customer Service

    Viscosity Process Analyzer VISC-4 General information Customer service Should you require any technical information, our customer service depart- ment will be happy to help you. You can find information on the responsible contact partner at any time by telephone, fax, e-mail or on the Internet.
  • Page 18 Viscosity Process Analyzer VISC-4 General information 8 / 158 04/2016...

  • Page 19: Safety

    Do not make any modifications to the analyzer. Only use spare parts from BARTEC BENKE. Otherwise additional hazard may arise for which the safety fittings cannot provide sufficient protection. A more precise definition of the use of the products and the device-specific function can be found in Chapter 4 “Design and function”...

  • Page 20: Dangers And Risks

    Viscosity Process Analyzer VISC-4 Safety WARNING Danger from improper use! Any use which goes beyond and/or differs from the intended use of the unit can lead to dangerous situations. FOR THIS REASON:  The Analyzer is to be used only as intended.
  • Page 21 Viscosity Process Analyzer VISC-4 Safety Electrical current DANGER Danger of death due to electrical current! Touching voltage-conducting parts poses an immediate life- threatening hazard. Damage to the insulation or to individual components can cause fatal injury. FOR THIS REASON: ...
  • Page 22 Viscosity Process Analyzer VISC-4 Safety Hot operating materials WARNING Danger of burns due to hot operating materials! Operating materials can reach high temperatures during op- eration and cause burns upon contact. FOR THIS REASON:  Before handling operating materials, check whether they are hot.
  • Page 23 Viscosity Process Analyzer VISC-4 Safety WARNING Danger of death due to suspended loads! When lifting loads, falling or uncontrollably swinging compo- nents pose a danger to life and limb. FOR THIS REASON:  Never step beneath suspended loads.  Observe the specifications regarding the provided sus- pension points.
  • Page 24 Viscosity Process Analyzer VISC-4 Safety WARNING Danger of injury due to analyzer tipping over! Due to the high centre of gravity, the analyzer could tip over if transported incorrectly, which can lead to severe injuries and material damage. FOR THIS REASON: ...
  • Page 25 Viscosity Process Analyzer VISC-4 Safety Incorrect installation and commis- WARNING sioning Danger due to incorrect installation and commis- sioning! Installation and commissioning must be conducted by trained specialist personnel who have adequate experience. Errors in installation and commissioning can lead to life- threatening situations or considerable material damage.
  • Page 26 Viscosity Process Analyzer VISC-4 Safety Improper fault rectification WARNING Danger of injury due to improper fault rectification! Improper fault rectification can lead to serious personal injury and material damage. FOR THIS REASON:  Before starting work, ensure there is adequate space for the work.

  • Page 27: Hazardous Materials

    Viscosity Process Analyzer VISC-4 Safety Incorrect dismantling work WARNING Danger of injury due to incorrect dismantling work. Stored residual energy, components with sharp edges, points and corners in and around the analyzer or on the re- quired tools can cause injuries.
  • Page 28 Viscosity Process Analyzer VISC-4 Safety Poisonous substances WARNING Danger of injury from toxic substances! Swallowing, inhaling or contact with skin or eyes can lead to serious, permanent health damage or death. FOR THIS REASON:  Avoid direct contact.  Do not inhale vapours.

  • Page 29: Explosion Protection

    Viscosity Process Analyzer VISC-4 Safety Environmentally hazardous NOTICE substances Environmentally hazardous substances! Hazardous materials escaping during a malfunction are haz- ardous to the environment. FOR THIS REASON:  Prevent them from entering bodies of water, the sew- erage system or the ground, and/or install the analyzer...
  • Page 30 Viscosity Process Analyzer VISC-4 Safety Marking Meaning Materials which form a potentially explosive atmosphere and are gases, mist or vapors (not dust). Classification of gases and vapors into the sub- groups IIA, IIB and IIC depending on their potential to ignite. The explosion protection of the device permits use with subgroup IIC.

  • Page 31: Types Of Protection And Certificates

    Viscosity Process Analyzer VISC-4 Safety Meaning of the marking Marking Meaning according to NEC 505 / CEC section Class I Classification of potentially explosive atmospheres in classes I (combustible gases, vapors and mist), II (dusts) and III (fibers and lint).
  • Page 32 Viscosity Process Analyzer VISC-4 Safety Pressurization (Ex p) The penetration of an external, potentially explosive atmosphere into the hous- ing of electrical components is prevented by a protective gas (in this case, air) maintained in the housing interior under overpressure in relation to the sur- rounding atmosphere.

  • Page 33: Special Conditions

    Viscosity Process Analyzer VISC-4 Safety NOTICE You will find the list of explosion-protected components and subassemblies used, as well as the corresponding certifi- cates, in the customer folder under Manufacturer Data Re- cord Book section 5 "Certificates". The risk assessment shows that the combination of explosion-proof compo- nents and subassemblies does not create additional ignition hazards.

  • Page 34: Safety Devices

    Viscosity Process Analyzer VISC-4 Safety Safety devices WARNING Danger of death due to non-functioning safety devices Safety is only guaranteed if the safety devices are intact. FOR THIS REASON:  Before starting work, check whether the safety devices are correctly installed and fully functional.

  • Page 35: Overview Of The Safety Equipment On The Analyzer

    Viscosity Process Analyzer VISC-4 Safety 2.5.1 Overview of the safety equipment on the analyzer Figure 2.1: Locations of the safety equipment Lock for measuring unit enclosure cover Key switch Lock on the power supply box Ground Catch Catch with safety bolt...

  • Page 36: Control Box (Ex P)

    Viscosity Process Analyzer VISC-4 Safety 2.5.2 Control box (Ex p) The control box (Ex p) contains operating equipment without its own igni- tion protection type and therefore contains potential ignition sources. Explosion protection is provided for the control box by the pressurization type of protection (Ex p).
  • Page 37 Viscosity Process Analyzer VISC-4 Safety WARNING Explosion protection is not provided when the pres- sure monitor is switched off! The control box contains ignition sources. Operating the de- vice when the pressure monitor of the control box is switched off can result in explosions in potentially explosive atmo- spheres.
  • Page 38 Viscosity Process Analyzer VISC-4 Safety WARNING Danger of explosion due to open sources of igni- tion! The control box contains ignition sources. Opening in poten- tially explosive atmospheres can cause explosions. FOR THIS REASON:  If there is a potentially explosive atmosphere present, disconnect the voltage supply of the analyzer and wait 5 minutes before opening.

  • Page 39: Junction Boxes (Ex E)

    Viscosity Process Analyzer VISC-4 Safety 2.5.3 Junction boxes (Ex e) The signal junction box (1) contains terminals for connecting the signal lines. Caution! The covered terminal connections are live even when switched off. The signal junction box only offers explosion protection in closed condition through the increased safety protection type (Ex e).

  • Page 40: Main Switch And Emergency Off Equipment

    Viscosity Process Analyzer VISC-4 Safety of the safety equipment on the analyzer” on page 25. 2.5.5 Main switch and emergency off equipment Main switch and integration in an The analyzer has neither its own main switch nor its own emergency off de- emergency off concept required vice.

  • Page 41: Signs

    Viscosity Process Analyzer VISC-4 Safety Signs The following safety instructions and signs giving orders must be attached di- rectly to the device. They must be attached in the position in which they are delivered and must be clearly legible. WARNING...

  • Page 42: Overview Of Signs

    Viscosity Process Analyzer VISC-4 Safety 2.6.1 Overview of signs Figure 2.6: Warnings Warning about hot surfaces Warning sign: “Danger of injury due to liquids and gases under overpressure” Warning sign: “Danger of explosion due to electrostatic charge” Command sign: Use hand protection Command sign: Use eye protection Warning sign: “Danger of explosion due to electrostatic charge”...

  • Page 43: Warnings

    Viscosity Process Analyzer VISC-4 Safety 2.6.2 Warnings Stickers 1 and 8 (see page 32) Warning about hot surface. Sticker 2 (see page 32) WARNING Danger of injury due to liquids or gases under pres- sure! Lines are under overpressure even when switched off. In the case of defective or leaky lines, escaping liquids or gases could cause serious injuries.
  • Page 44 Viscosity Process Analyzer VISC-4 Safety Sticker 7 (see page 32) WARNING Danger of injury due to analyzer tipping over! Due to the high center of gravity, the analyzer could tip over if transported incorrectly, which can lead to severe injuries and material damage.

  • Page 45: Command Signs

    Viscosity Process Analyzer VISC-4 Safety Sticker 11 (see page 32) WARNING Danger of explosion due to ignitions sources within! Hot surfaces and residual charges of electronic components inside the control box can ignite a potentially explosive at- mosphere. FOR THIS REASON: ...

  • Page 46: Safety Measures At The Installation Location

    Viscosity Process Analyzer VISC-4 Safety Safety measures at the installation location  Workspace conditions Ensure that the working area is adequately ventilated.  Observe the emission limits. Install an exhaust-air cleaning system if necessary.  Do not direct suctioned-off air back into the work room.
  • Page 47 Viscosity Process Analyzer VISC-4 Safety WARNING Danger of explosions due to escaping petrochemi- cal products! Petrochemical products can leak. The liquid evaporates and forms an explosive atmosphere when it mixes with air. Or es- caping gas can form an explosive atmosphere with the air.

  • Page 48: Personnel Requirements

     Do not make any technical modifications to the analyzer without prior written consent from the manufacturer.  Only use replacement parts from BARTEC BENKE. Ignition sources of operating WARNING material outside the analyzer Danger of explosion due to open ignition sources of...

  • Page 49: Qualifications

    Viscosity Process Analyzer VISC-4 Safety 2.9.1 Qualifications WARNING Danger of injury due to inadequate qualifica- tions! Improper handling can lead to considerable personal in- jury and material damage. FOR THIS REASON:  Have all tasks performed only by qualified person- nel.

  • Page 50: General Requirements

    Viscosity Process Analyzer VISC-4 Safety 2.9.2 General requirements Completed instruction must be logged and confirmed by the persons respon- sible for instruction and by the persons receiving instruction. Employees must be persons who can be expected to perform their work reli- ably.

  • Page 51: Personal Protective Equipment

    Viscosity Process Analyzer VISC-4 Safety 2.10 Personal protective equipment Wearing personal protective equipment while working is required in order to minimise health hazards.  Always wear the protective equipment required for the corresponding tasks.  Follow the instructions posted in the work area regarding personal protective equipment.
  • Page 52 Viscosity Process Analyzer VISC-4 Safety Respiratory protection, filter devices Protect against hazardous gases, vapours, dusts and similar materials and media. If a permissible threshold value is exceeded by a factor of 100, self-contained respiratory protection apparatus must be used. Respiratory protection may only be used when there is an oxygen content of at least 17% in the air.

  • Page 53: Securing Against Being Switched On Again

    Viscosity Process Analyzer VISC-4 Safety 2.11 Securing against being switched on again DANGER Danger of death due to unauthorised restarting! During work in danger areas, there is the danger that the power supply can be switched on without authorisation. This poses a life-threatening hazard for the persons in the danger area.
  • Page 54 Viscosity Process Analyzer VISC-4 Safety 44 / 158 04/2016...

  • Page 55: Technical Data

    Viscosity Process Analyzer VISC-4 Technical data Technical data Parameters Specification Device type VISC-4 Variable Kinematic viscosity Measuring range Variable Derived values Kinematic viscosity Dynamic viscosity (cP) Ρ = 850 kg/m³ 0.7...3 0.6...2.55 1...5 0.85...4.25 2...10 1.7...8.5 6...30 5.1...25.5 10...50 8.5...42.5 20...100...
  • Page 56 50 to 100 °C Additional heating of the measuring unit enclo- sure (122 to 212 °F) Viscosity (cSt) 0.7...30 10...1000 The variant name is determined by the temperature range and measuring range of the viscosity, such as VISC-4 Mt. 46 / 158 04/2016...
  • Page 57 Viscosity Process Analyzer VISC-4 Technical data Parameters Specification Ex marking Marking according to ATEX Variants Lt, Lv, Mt, Mv II 2 G IIC T4 Gb Variants Ht, Hv II 2 G IIC T3 Gb Marking according to NEC/CEC Variants Lt, Lv, Mt, Mv...
  • Page 58 Viscosity Process Analyzer VISC-4 Technical data Inlet temperatures Measuring temperature Inlet temperature [°C] [°F] [°C] [°F] 5...30 41...86 Variants Lt, Lv, Mt, Mv (up to 10 cSt: 5...40) (up to 10 cSt: 41...104) 5...50 41...122 (up to 10 cSt: 5...60) (up to 10 cSt: 41...140)
  • Page 59 Viscosity Process Analyzer VISC-4 Technical data Parameters Specification Optional Automatic cleaning (cleaning medium) Consumption 3.8...10 l/h Filtering, mesh width 10 μm Inlet pressure (depending on the viscosity at 3...14 bar (43.5...203 psi) the product inlet) Back-pressure (depending on the viscosity at Below primary pressure maximum 3 bar (43.5 psi)
  • Page 60 Viscosity Process Analyzer VISC-4 Technical data Parameters Specification Digital outputs Voltage 24 VDC Current 0.5 A Total signal currents, max. 0.8 A Reference potential 0 V / ground Voltage High: 15...28 VDC Low: 0...4 VDC Auxiliary voltage Voltage 24 VDC Current, max.

  • Page 61: Type Plates

    Viscosity Process Analyzer VISC-4 Technical data Type plates The following figures are example type plates in line with ATEXT: Analyzer The primary type plate is located on the cover of the power supply box and contains the following information: ...
  • Page 62 Viscosity Process Analyzer VISC-4 Technical data Junction boxes The type plate for the junction boxes is on a side of the junction boxes and contains the following specifications:  Manufacturer  Type  Ex marking  Certificate number  Serial number Figure 3.3: Type plate...

  • Page 63: Design And Function

    Viscosity Process Analyzer VISC-4 Design and function Design and function This chapter provides an overview of the most important functions and the de- sign of the analyzer. Overview Figure 4.1: Analyzer overview Measuring unit enclosure Power supply box Touchscreen Rack...

  • Page 64: Brief Description

    Viscosity Process Analyzer VISC-4 Design and function Brief description The device is used to measure the viscosity of petrochemical or similar fluids. The device is a process analyzer. It measures the viscosity of a petrochemical fluid fully automatically in the corresponding precalibrated measuring range.

  • Page 65: Viscosity And Measuring Principle

    Viscosity Process Analyzer VISC-4 Design and function Viscosity and measuring principle Newton’s friction law When a fluid is in flow, internal friction occurs between the layers of the fluid. The friction force F between two fluid layers depends on the contact area A, the distance dx, and the difference in speed dv between adjacent layers.
  • Page 66 Viscosity Process Analyzer VISC-4 Design and function Hagen-Poiseuille law If there is a laminar flow of Newtonian fluid through a narrow pipe with the ra-  dius R and a length l, then the volume flow can always be determined dV dt with Newton’s friction law:...

  • Page 67: Measuring Procedure

    Viscosity Process Analyzer VISC-4 Design and function Measuring procedure  After the fluid to be analyzed enters the device, the pressure and flow of the sample are set.  With the variants Lt, Lv, Mt, Mv, the sample flows into a tempering sys- tem.

  • Page 68: Description Of Subassemblies

    Viscosity Process Analyzer VISC-4 Design and function Description of subassemblies 4.5.1 Measuring unit Figure 4.2: Example of subassemblies inside the measuring unit enclosure Swing arm Zero-point valve Insulated container with capillary unit Pressure differential transmitter Coriolis mass flow meter Control valve for flow...

  • Page 69: Controller

    Viscosity Process Analyzer VISC-4 Design and function Cooling unit The temperature on the inside of the insulated container is set precisely by adding heat with a heater. Prerequisite for this is that the ambient temperature is sufficiently low. An additional cooling unit is required for measuring the vis- cosity below or close to the ambient temperature.
  • Page 70 Viscosity Process Analyzer VISC-4 Design and function The pressurized control box contains all electrical and electronic components necessary for controlling the analyzer. The electrical and electronic components are:  The industry PC that provides the user interface, controls and monitors all processes and performs external communications.

  • Page 71: Fluid Technology

    Viscosity Process Analyzer VISC-4 Design and function 4.5.3 Fluid technology The fluid technology subassembly contains components for regulating the pressure and filtering the required instrument air and for filtering the coolant if the cooling unit option is installed. Figure 4.4: Fluid technology (example)

  • Page 72: Junction Boxes

    Viscosity Process Analyzer VISC-4 Design and function 4.5.4 Junction boxes The analyzer is connected to the supply and signal voltages via two separate junction boxes: The signal junction box (1) contains terminals for connecting the signal lines. The Ex e type of protection of only guaranteed as long as the signal junction box is closed.

  • Page 73: Sample Conditioning System (Optional)

    Viscosity Process Analyzer VISC-4 Design and function 4.5.5 Sample conditioning system (optional) Overview Figure 4.6: Sample preparation system in heating cabinet (example) Thermometer (sample) Fine filter Pressure gauge Drain Heating cabinet Heating element Thermometer (cabinet) Bypass valve Product inlet Fine filter...

  • Page 74: Optional Extensions

    Viscosity Process Analyzer VISC-4 Design and function NOTICE Your sample conditioning system may differ from the one de- scribed here. You can find the exact details of its specifica- tions in the supplied technical documentation. Should you have any questions, please do not hesitate to contact BARTEC BENKE.

  • Page 75: Connections

    Viscosity Process Analyzer VISC-4 Design and function Connections Figure 4.7: Connections Product inlet Coolant inlet Product outlet (drain) Instrument air inlet Coolant outlet Operating elements To prevent potentially explosive atmospheres from entering, overpressure is created with the aid of instrument air in the interior of the control box.
  • Page 76 Viscosity Process Analyzer VISC-4 Design and function WARNING Explosion protection is no longer provided when the pressure monitor is switched off! The control box contains ignition sources. Operating the device when the pressure monitor of the control box is deactivated can result in explosions in potentially explo- sive atmospheres.
  • Page 77 Viscosity Process Analyzer VISC-4 Design and function Pressure regulator with coalescer and filter unit for adjusting the pri- mary pressure for instrument air. The pressure regulator protects against par- ticles and moisture entering the instrument air in the event of a fault.
  • Page 78 Viscosity Process Analyzer VISC-4 Design and function 68 / 158 04/2016...

  • Page 79: Transport, Packaging, And Storage

    Viscosity Process Analyzer VISC-4 Transport, packaging, and storage Transport, packaging, and storage The following transport and storage conditions must be observed. Safety Personnel The transport work described here may only be performed by trained special- ists or by employees of the manufacturer.
  • Page 80 Viscosity Process Analyzer VISC-4 Transport, packaging, and storage Tipping over of the analyzer WARNING Danger of injury from transport item tipping over! If it is set down the transport load on an uneven surface or surface with an insufficient load-bearing capacity, the load will tip over.

  • Page 81: Symbols On The Packaging

    Viscosity Process Analyzer VISC-4 Transport, packaging, and storage Symbols on the packaging This way up   The arrows indicate the top side of the packaged item. They must always point upwards, otherwise the content can be damaged. Protect against moisture Protect the packaged items against moisture and store in a dry place.

  • Page 82: Packaging

    Viscosity Process Analyzer VISC-4 Transport, packaging, and storage  Do not accept the delivery or only with reservations.  Note the extent of damage on the transport documents or on the delivery note of the carrier.  File a claim.

  • Page 83: Center Of Gravity And Suspension

    Viscosity Process Analyzer VISC-4 Transport, packaging, and storage Center of gravity and suspension Figure 5.1: Center of gravity Suspension eyebolt Center of gravity: (HxWxD): approx. 1960 x 570 x 370 mm 04/2016 73 / 158...

  • Page 84: Transport

    Viscosity Process Analyzer VISC-4 Transport, packaging, and storage Transport Transport with a forklift The analyzer can be transported with a forklift under the following conditions: (Analyzer is in its packaging)  The analyzer must be in its packaging (wooden box or wooden crate with integrated pallet).

  • Page 85: Storage

    Viscosity Process Analyzer VISC-4 Transport, packaging, and storage Storage  Only store the analyzer where the following conditions are fulfilled:  Only store in the original packaging.  Do not store outdoors.  Store in a dry and dust-free location.
  • Page 86 Viscosity Process Analyzer VISC-4 Transport, packaging, and storage 76 / 158 04/2016...

  • Page 87: Installation And Preparation For Commissioning

    Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning Installation and preparation for commissioning The installation and commissioning of the analyzer must be performed profes- sionally in order to ensure smooth operation. This section describes important steps and conditions as well as the safety instructions that must be observed.
  • Page 88 Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning Electrical current GEFAHR Danger of death due to electrical current! Touching voltage-conducting parts poses an immediate life- threatening hazard. Damage to the insulation or to individual components can cause fatal injury.

  • Page 89: Requirements For The Installation Location

    Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning Requirements for the installation location Environmental conditions The analyzer is solely intended for use at a fixed location in an analysis build- ing that provides protection against the elements. The following conditions...

  • Page 90: Fixing To The Floor

    Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning NOTICE If a vortex cooler is in use for the control box, make sure that at the very most drip water can hit the analyzer in compliance with EN 60529. Make sure that the hot air discharge of the vortex cooler is not hindered.
  • Page 91 Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning Liquids and gases WARNING under pressure Danger of injury due to liquids or gases under pres- sure! Lines are under overpressure even when switched off. In the case of defective or leaky lines, escaping liquids or gases could cause serious injuries.
  • Page 92 Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning  When the power is off, the control valve of the analyzer opens fully. To limit the product flow, you can install a needle valve at the product inlet downstream from the pressure regulator. Make sure that the product pressure and flow are sufficient for safe operation of the analyzer.

  • Page 93: Connecting The Voltage Supply And Signal Lines

    Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning Kühlung mit Kühlmittel NOTICE Die am Ausgang Kühlmittel angeschlossene Leitung kann heiß werden. Isolieren Sie daher die Leitung mit geeignetem Wärmedämmmaterial. Connecting the voltage supply and signal lines  This work should only be performed by a qualified electrician.
  • Page 94 Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning Preparation WARNING Danger of explosion due to open ignition sources of operating material outside the analyzer Operating materials operated in intrinsically safe circuits can cause explosions if they are not connected in line with the manufacturer's specifications.

  • Page 95: Preparing For Commissioning

    Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning  Connecting electric signal lines Unscrew the cover of the signal junction box.  Dismantle the flange plate and drill holes for the cable ducts in line with the supplied connection plan. Ensure that the flange plate is sufficiently stable even with the holes.

  • Page 96: Supplying With Instrument Air

    Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning 6.6.2 Supplying with instrument air  Ensure that the instrument air is in line with the specification (see page 45).  Open the system-side shut-off valve in the instrument air supply line.
  • Page 97 Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning Hot operating materials WARNING Danger of burns due to hot operating materials! Operating materials can reach high temperatures during op- eration and cause burns upon contact.  Avoidance measures see chapter 2 Safety.

  • Page 98: Rinsing The Coolant Supply Line

    Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning 6.6.4 Rinsing the coolant supply line Some specific analyzer versions require coolant. Cooling can be performed  By the chiller option.  From outside by adding coolant. If cooling is provided from the outside, the coolant supply lines require rinsing.
  • Page 99 Viscosity Process Analyzer VISC-4 Installation and preparation for commissioning  Procedure Open the system-side stop valve in the coolant supply line.  Check whether the screw connection is sealed tightly. The coolant flows through the components. NOTICE In particular the use of a coolant with a low temperature can cause condensation to form.

  • Page 100: Commissioning

    Viscosity Process Analyzer VISC-4 Commissioning Commissioning NOTICE BARTEC BENKE recommends that commissioning is per- formed by employees of the manufacturer and having oper- ating and maintenance personnel trained by the manufacturer. Make sure that all preparatory work for commissioning has been performed.
  • Page 101 Viscosity Process Analyzer VISC-4 Commissioning Hazardous materials WARNING Danger of injury from toxic substances! Swallowing, inhaling or contact with skin or eyes can lead to serious, permanent health damage or death.  Avoidance measures see chapter 2 “Safety”. Hot operating materials...

  • Page 102: Commissioning Visc-4 Ht Or Hv

    Viscosity Process Analyzer VISC-4 Commissioning Commissioning VISC-4 Ht or Hv Highly viscous materials are examined with the variants Ht and Hv at temperatures above 60 °C. With these variants the analyzer must be switched on electrically before it can be supplied with product.

  • Page 103: Supplying The Analyzer With Product

    Viscosity Process Analyzer VISC-4 Commissioning 7.2.2 Supplying the analyzer with product NOTICE The analyzer can be fitted with an optional sample condition- ing system (section 4.5.5 “Sample conditioning system (op- tional)” on page 63). As standard it is fitted with a 3/2-way valve to switch between supplying product and supplying with purge gas or rinsing medium.

  • Page 104: Commissioning Visc-4 Lt, Lv, Mt, And Mv

    Viscosity Process Analyzer VISC-4 Commissioning Commissioning VISC-4 Lt, Lv, Mt, and Mv With the variants Lt, Lv, Mt, and Mv, petrochemical substances are examined at temperatures below 60 °C. With these variants, the analyzer can be supplied with product without the voltage supply being switched on.

  • Page 105: Switching On The Power Supply

    Viscosity Process Analyzer VISC-4 Commissioning 7.3.2 Switching on the power supply  Preparation Check all safety equipment. For more information, see the Maintenance chapter.  Check that all electrical terminals have a tight fit.  Check that the mains supply was executed in line with the electrical documentation.

  • Page 106: Bleeding The Differential Pressure Transmitter

    Viscosity Process Analyzer VISC-4 Commissioning Bleeding the differential pressure transmitter Before the first measurement, the pipes to the differential pressure transmitter must be rinsed so that accumulated air can be removed. Automatic bleeding If the analyzer is equipped with an automatic bleeding unit, you can bleed the differential pressure transmitter only with the PACS software.

  • Page 107: Monitoring And Operation

    Viscosity Process Analyzer VISC-4 Commissioning Monitoring and operation  Monitoring After 2 hours of operation, check all connections for leaks and perform a general visual inspection (see Maintenance chapter). Supplying with product:  Check the settings of the pressure regulator.
  • Page 108 Viscosity Process Analyzer VISC-4 Commissioning 98 / 158 04/2016...

  • Page 109: Operation

    Viscosity Process Analyzer VISC-4 Operation Operation This chapter provides a brief overview of how to operate the analyzer. The safety instructions for switching the analyzer on and off and for operating it must be observed. Safety Personnel The analyzer may only be operated by specialists for potentially explosive atmospheres.

  • Page 110: Switching On

    Viscosity Process Analyzer VISC-4 Operation Switching on Preparation Make sure that:  All safety equipment is installed and fully functional (see section 10.7 “Checking the safety equipment” on page 126).  Pressure and flow rates in the supply lines for the instrument air are set correctly.

  • Page 111: Switching Off

    Viscosity Process Analyzer VISC-4 Operation NOTICE For more detailed information on operating, controlling and configuring the analyzer and on the analyzing process, please refer to the PACS software manual. Switching off NOTICE For detailed information on operating the analyzer with the touchscreen and pen, please refer to the PACS software manual.
  • Page 112 Viscosity Process Analyzer VISC-4 Operation  Close any system-side valves of the coolant supply and return line (not required with the chiller option).  If available, close the system-side valves for the supply of the instrument air and auxiliary media.

  • Page 113: Conduct In The Event Of Danger

    Viscosity Process Analyzer VISC-4 Operation Conduct in the event of danger  Depending on the type of fault, have it rectified by the manufacturer or rectify it yourself. Read more on this in Chapter 9 “Faults” on page 105. WARNING...
  • Page 114 Viscosity Process Analyzer VISC-4 Operation 104 / 158 04/2016...

  • Page 115: Faults

    Viscosity Process Analyzer VISC-4 Faults Faults The following chapter describes the possible causes of faults and the work re- quired to rectify them.  If faults occur frequently, the maintenance intervals must be shortened according to the actual load. ...
  • Page 116 Viscosity Process Analyzer VISC-4 Faults Securing against being switched on DANGER again Danger of death due to unauthorized restarting! During work in danger areas, there is the danger that the power supply can be switched on without authorisation. This poses a life-threatening hazard for the persons in the danger area.

  • Page 117: Fault Analysis

    Viscosity Process Analyzer VISC-4 Faults Hazardous materials WARNING Danger of injury from toxic substances! Swallowing, inhaling or contact with skin or eyes can lead to serious, permanent health damage or death.  Avoidance measures see chapter 2 “Safety”. Hot operating materials...
  • Page 118 Incorrect or defective replacement parts can result in dam- ages, faults or total failures as well as impairments to safety. FOR THIS REASON:  Only use replacement parts from BARTEC BENKE.  See chapter 2.1 “Intended use”. 108 / 158...
  • Page 119 Viscosity Process Analyzer VISC-4 Faults Error Possible cause Troubleshooting No ready signal / measuring Device is switched off The voltage supply of Check the power supply and restore it result for a long time / will not start the device has been interrupted (e.g.
  • Page 120 Viscosity Process Analyzer VISC-4 Faults Error Possible cause Troubleshooting Measurement value outputs Sudden change in product properties Validate device shows an unusual or implausi- (see PACS software manual) ble value / measuring result Fault in product conditioning (dirt, water, or gas...
  • Page 121 Viscosity Process Analyzer VISC-4 Faults Error Possible cause Troubleshooting Insufficient or no cooling or Installation error Peltier elements mounted as described heating power of the Peltier in section (see page 129). element of the tempering sys- Fuse or ground fault circuit breaker of the volt-...

  • Page 122: Starting Up After Rectifying A Fault

    Viscosity Process Analyzer VISC-4 Faults Error Possible cause Troubleshooting Leaks in fluid system compo- For components through which cooling Dry the components with a cloth and nents medium flows: condensation water can give observe whether there is actually a leak...

  • Page 123: Maintenance

    Work on the electrical systems may only be performed by electricians. NOTICE BARTEC BENKE recommends that operating and mainte- nance staff be trained by the manufacturer. Personal protective equipment Wear the basic protective equipment in line with chapter 2 “Safety” and the following additional protective equipment: ...
  • Page 124 Incorrect or defective replacement parts can result in dam- ages, faults or total failures as well as impairments to safety. FOR THIS REASON:  Only use replacement parts from BARTEC BENKE.  See chapter 2.1 “Intended use”. Liquids and gases under...
  • Page 125 Viscosity Process Analyzer VISC-4 Maintenance Hot operating materials WARNING Danger of burns due to hot operating materials! Operating materials can reach high temperatures during op- eration and cause burns upon contact.  Avoidance measures see chapter 2 “Safety”. Hot surfaces...

  • Page 126: Maintenance Plan

    Viscosity Process Analyzer VISC-4 Maintenance 10.2 Maintenance plan The maintenance plan provides an overview of the most important mainte- nance work. The sections below describe the maintenance work in detail. If increased wear is detected at regular inspections, shorten the required maintenance intervals according to the actual degree of observed wear.
  • Page 127 Viscosity Process Analyzer VISC-4 Maintenance  Do not clean the touchscreen window with aggressive solvents or scour- ing agents and do not clean with instrument air or steam cleaners. The touchscreen is a part of the control box and therefore fulfils a protective function and must not be damaged.

  • Page 128: Rinsing And Emptying Product-Carrying Components

    Viscosity Process Analyzer VISC-4 Maintenance 10.4 Rinsing and emptying product-carrying components NOTICE Rinsing and emptying product-carrying components is a pre- requisite for many maintenance tasks. Special note is made of this in the individual sections on maintenance work. In the following sections, products which are capable of flowing at room tem- perature are referred to as low or normally viscous products.
  • Page 129 Viscosity Process Analyzer VISC-4 Maintenance For devices with sample treatment:  Close valve 15 (see Figure 4.6 on page 63). NOTICE Only the analyzer and not the sample treatment is rinsed and emptied. The sample treatment remains filled with product.

  • Page 130: Highly Viscous Products (Special Case Of The Variants Ht Or Hv)

    Viscosity Process Analyzer VISC-4 Maintenance  Turn the flow controller to maximum (see page 67). The product is pressed out of the analyzer and also out of the pressure differential transmitter and its supply lines.  Force the product residues out of the analyzer with the purge gas.
  • Page 131 Viscosity Process Analyzer VISC-4 Maintenance Liquids and gases under pressure WARNING Danger of injuries due to rinsing medium with high vapor pressure! When feeding in rinsing medium with a high vapor pressure in components which have not yet cooled down, the pressure rises considerably.
  • Page 132 Viscosity Process Analyzer VISC-4 Maintenance WARNING Danger of suffocation when inert gas is in use! If inert gas is used to rinse the analyzer, there is a danger of suffocation if the concentration of the gas in the air becomes too high as a result of leaks or unsealed connections.
  • Page 133 Viscosity Process Analyzer VISC-4 Maintenance  Open the system-side valve for the supply of purge gas slowly.  Set the pressure of the purge gas on the pressure regulator for the prod- uct in the measuring unit enclosure. The target value can be found on the plate of the pressure gauge.

  • Page 134: Cleaning Of Product-Carrying Components (Highly Viscous Products)

    Viscosity Process Analyzer VISC-4 Maintenance 10.5 Cleaning of product-carrying components (highly viscous products) Products are designated as highly viscous if they are no longer capable of flowing at room temperature. Highly viscous products are analyzed exclusively with the variants Ht and Hv.
  • Page 135 Viscosity Process Analyzer VISC-4 Maintenance NOTICE CAUTION! Changing the pressures and the flows have an ef- fect on the current measurement. 04/2016 125 / 158...

  • Page 136: Checking The Safety Equipment

    Viscosity Process Analyzer VISC-4 Maintenance 10.7 Checking the safety equipment Procedure The external safety signs can be checked while the device is in operation. Signs and positioning of warning signs and stickers on the analyzer see page 32. To check all other safety equipment, in particular items in the control box: ...

  • Page 137: Checking The Pressure Monitor

    Viscosity Process Analyzer VISC-4 Maintenance Inspection table Safety equipment Target condition Warning signs Present, clearly legible Stickers Present, clearly legible Key switch Position On Explosion protection  Control box No damage to housing or add- on structures  No open drill holes ...

  • Page 138: Bleeding The Differential Pressure Transmitter

    Viscosity Process Analyzer VISC-4 Maintenance  Preparation End all the PACS process software. For more information, see the PACS software manual.  Shut down the control computer.  Procedure Open the control box. The pressure monitor cuts off all currents to electrical consumers.

  • Page 139: Replace The Peltier Elements

    Viscosity Process Analyzer VISC-4 Maintenance 10.10 Replace the Peltier elements Personal protective equipment Wear the basic protective equipment in line with section 2 Safety and the fol- lowing additional protective equipment:  Safety goggles  Safety gloves (hazardous substances) ...
  • Page 140 Viscosity Process Analyzer VISC-4 Maintenance  Loosen the screw pipe connections of the tempering system (1 to 3), starting below on the control box. Carefully move the heat insulation on the pipelines so that the screw pipe connections can be accessed.
  • Page 141 Viscosity Process Analyzer VISC-4 Maintenance  Loosen the three fastening nuts (1 to 3) on the outside of the control box. Figure 10.4: Fastening nuts on the outside of the control box  Loosen the fastening nuts in the measuring unit enclosure (1).
  • Page 142 Viscosity Process Analyzer VISC-4 Maintenance  Unscrew the five screws (1).  Lift off the top aluminum plate (2) and fold it to the side. (The panel sticks due to the old thermally conductive paste).  Note the location of the Peltier elements.
  • Page 143 Viscosity Process Analyzer VISC-4 Maintenance  Installing the tempering system Insert the tempering system into the control housing.  Put on the seals.  Tighten the fastening nuts (1) in the measuring unit enclosure. Figure 10.8: Fastening nuts in the measuring unit enclosure ...

  • Page 144: Turning Out The Swing Arm With The Measuring Unit

    Viscosity Process Analyzer VISC-4 Maintenance  Remove the blank plugs from the connections of the tempering system.  Turn the swing arm back. Lock it in place (see page 145). Figure 10.11: Screw pipe connection of the tem- pering system in the measuring unit enclosure ...
  • Page 145 Viscosity Process Analyzer VISC-4 Maintenance  Exit the PACS software.  Shut down the PC.  Interrupt the product stream using the shut-off valve.  Disconnect the analyzer from the power supply and secure it against be- ing switched on again.

  • Page 146: Replacing The Mass Flow Meter

    Viscosity Process Analyzer VISC-4 Maintenance  Loosen the screw pipe connection (1) of the product supply line. The base of the measuring unit enclosure is covered with an insulating mat.  Take out the insulating mat. ATTENTION! If a heater is installed, there is a risk of burns from hot surfaces.

  • Page 147: Installing A Mass Flow Meter

    Viscosity Process Analyzer VISC-4 Maintenance 10.12.2 Installing a mass flow meter  Position the new mass flow meter.  Attach the mass flow meter with the two two-part plastic holders (3 and 7) to the studs. Tighten the four screws by hand.

  • Page 148: Replacing The Capillary Unit

    Viscosity Process Analyzer VISC-4 Maintenance 10.13 Replacing the capillary unit Required special tools and auxiliary Size 14 spanner, very short and flat equipment 10.13.1 Removing the insulation container  Turn and swing the measuring unit out of the measuring unit enclosure using the swing arm see chapter 10.11 “Turning out the swing arm with...
  • Page 149 Viscosity Process Analyzer VISC-4 Maintenance  Remove the ground (1) of the insulated container. Figure 10.21: Grounding the insulated container Figure 10.22: Dismantling the holding panel of the insulated container  Unscrew the two fastening bolts (1 and 2) (4 mm Allen key) and remove them.
  • Page 150 Viscosity Process Analyzer VISC-4 Maintenance  Loosen the large cable bushing to the control box in the bottom part of the housing (7). NOTICE: Ensure that the ferrite cores (8) are not lost!  Open the control box. The cable to the Pt 1000 temperature sensors on the capillary is connected to the transmitter HiRES ADC.
  • Page 151 Viscosity Process Analyzer VISC-4 Maintenance A Pt 1000 temperature sensor (1) is mounted on the container heater. It can be connected to the capillary unit with the connection cable. Figure 10.25: Temperature sensor of the insulat- ed container  Make sure that the capillary unit is disconnected from the temperature sensor.
  • Page 152 Viscosity Process Analyzer VISC-4 Maintenance NOTICE You can use a thin tool (e.g. an Allen key) to push the box nuts through the drill holes up to the line ends.  Tighten the screw pipe connections 1 to 4. NOTICE: For reasons of space, for the box nut (1) you need a shortened jaw wrench with a width across flats of 14 mm.
  • Page 153 Viscosity Process Analyzer VISC-4 Maintenance Figure 10.30: Mounting the holding panel of the insulated container  When the lid (9) is firmly seated on the holding plate, tighten the two fas- tening bolts (1 and 2) with a 4 mm Allen key.
  • Page 154 Viscosity Process Analyzer VISC-4 Maintenance  Attach the ground (1) of the insulated container. The capillary unit is installed and all cables connected. Figure 10.31: Grounding the insulated container  Installing the insulated container Make sure that the O-ring on the lid is positioned at the intersection to the holding panel.

  • Page 155: Turning The Swing Arm Back And Fixing It In Place

    NOTICE: A spare O-ring is supplied along with the device. Additional O- rings can be obtained from BARTEC BENKE.  Position the swing arm so that the opposing parts of the screw pipe con- nections of the product supply line (1) and product return line (2) pro- trude into each other.

  • Page 156: Checking The Residual-Current Device (Rcd)

    Viscosity Process Analyzer VISC-4 Maintenance  Place the bridge (4) below the insulated container (2). Figure 10.36: Swing arm with measuring unit and insulated container  Fix the bridge (4) with the two hexagon head bolts (3). They are screwed into the bridge from below.

  • Page 157: Measures After The Rcd Has Triggered

     If the above mentioned causes are impossible or does the RCD malfunc- tions replace the RCD. A new RCD is available at BARTEC BENKE. If the RCD is damaged it may not be repaired. 04/2016 147 / 158...

  • Page 158: Replacing The Battery On The Industry Pc

    Unsuitable batteries can overheat and ignite explosive atmo- spheres in the event of a fault. FOR THIS REASON:  Only use replacement batteries from BARTEC BENKE. CAUTION Damage to the industry PC! Unsuitable batteries can damage the industry PC FOR THIS REASON: ...

  • Page 159: Measures After Maintenance

    Viscosity Process Analyzer VISC-4 Maintenance  Replace the batter of the industry PC.  Close the control box.  Switch the analyzer on. 10.17 Measures after maintenance After completion of the maintenance work and before switching on, carry out the following: ...
  • Page 160 Viscosity Process Analyzer VISC-4 Maintenance 150 / 158 04/2016...

  • Page 161: Dismantling

    Viscosity Process Analyzer VISC-4 Dismantling Dismantling At the end of its service life, the analyzer must be dismantled and disposed of in an environmentally friendly manner. 11.1 Safety  Personnel Dismantling is only to be performed by specialists for potentially explo- sive atmospheres.

  • Page 162: Preparing For Dismantling

    Viscosity Process Analyzer VISC-4 Dismantling 11.2 Preparing for dismantling  Clean the analyzer prior to disposal.  Empty product-conveying components and rinse them with inert gas.  Switch off the analyzer and ensure it cannot be restarted.  Unload the remaining residual energies.
  • Page 163 Viscosity Process Analyzer VISC-4 Dismantling Hazardous materials WARNING Danger of injury from toxic substances! Swallowing, inhaling or contact with skin or eyes can lead to serious, permanent health damage or death.  Avoidance measures see chapter 2 Safety.  Disconnecting pipe connections Check that the pressure has been fully released.
  • Page 164 Viscosity Process Analyzer VISC-4 Dismantling CAUTION Environmental damage due to incorrect disposal. Improper disposal damages the environment. FOR THIS REASON:  Have electric scrap, electronic components, lubricants and other auxiliary media disposed of only by autho- rised specialist companies. They are subject to the rules on special waste treatment.
  • Page 165 Viscosity Process Analyzer VISC-4 Index Index see Connecting ............65 Connections Analyzer ............47 Consumption ..........54 Brief description ............7 Contact partner ..........55 Measuring principle ............26 Control box ............100 ..............48 Operation Coolant ............53 Overview ............7 Customer service ............101...
  • Page 166 Viscosity Process Analyzer VISC-4 Index ............47 Mesh width ............... 47 Flow rate ............30, 83 Main switch ............113 Maintenance ..........116 Maintenance plan ..........50 General specifications ..........55 Measuring principle ........124 General visual inspection ..........97 Monitoring operation Ground see Potential matching ..............
  • Page 167 Viscosity Process Analyzer VISC-4 Index ...........29 ............47 Potential matching Filtering ........... 29, 62 ............ 47 Power supply box Inlet pressure ........22 ........... 47 Pressure-resistant enclosure Peltier cooling ............22 ........63 Pressurization Sample conditioning system ............101 Protective equipment Shutting down ...........90...
  • Page 168 Viscosity Process Analyzer VISC-4 Index types of protection ...... 22 Pressure-resistant enclosure (Ex d) ..........40 Unauthorized persons ..............55 Viscosity ............49 Voltage supply ............64 Vortex cooler ............... 33 Warnings 158 / 158 04/2016...

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