DAEHO FLOW INSTRUMENTS CO., LTD.

INSTRUCTION MANUAL
PNEUMATIC VERSION

Process Viscometer

VISCOSUM
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TECHNICAL MANUAL : V150 2

DAEHO FLOW INSTRUIIENTS

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OAEHO FLOW INSTRUMENTS CO., LTD.

#1610-6, SONGJUNG-DONG, KANGSEO-GU, BUSAN, KOREA
TEL: 82-51-831-3720, 3730
FAX: 82-51-831-3750

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DAEHO FLOW INSTRUMENTS

1.0 INTRODUCTION
1.1 GENERAL
3

1.2 TO RECORD IMPORTANT SERIAL NUMBERS

1.3 SYSTEM CONFIGURATION
TABLE OF CONTENTS

6.0 OPERATING INSTRUCTIONS

6.1 VISCOSUM SENSOR / DPT ASSEMBLY
6.2 VISCOSITY CONTROL STATION
6.3 AIRFILTER-REGULATOR
--

1.4 MODEL NO. IDENTIFICATION 6.4 ALARM PRESSURE SWITCH

2.0 FUNCTION DESCRIPTION 7.0 MAINTENANCE

2.1 SYSTEM OPERATION 7.1 GENERAL
2.2 VISCO. SENSOR / DPT 7.2 "A" MAINTENANCE CHECKS
2.3 SYSTEM COMPONENT 7.3 "B" MAINTENANCE CHECKS
7.4 "C" MAINTENANCE CHECKS
3.0 TECHNICAL SPECIFICATIONS 7.5 MAINTENANCE OF DPT
3.1 VISCOSUM SENSOR 7.6 MOTOR WITH GEAR BOX
3.2 PNEUMATIC DPT 7.7 CONTROL STATION
3.3 STARTER BOX 7.8 CONTROL VALVE
3.4 VISCOSITY CONTROL STATION 7.9 AIRFILTER-REGULATOR
3.5 CONTROL VALVE 7.10 VISCOSITY RECORDER
3.6 AIRFILTER-REGULATOR 7.1 1 ANALOG VISCOSITY INDICATOR
3.7 VISCOSITY RECORDER 7.12 ALARM PRESSURE SWITCH
3.8 ANALOG VISCOSITY INDICATOR
3.9 ALARM PRESSURE SWITCH 8.0 TROUBLE SHOOTING
8.1 VISCOSITY SIGNAL TOO LOW
4.0 INSTALLATION INSTRUCTIONS 8.2 VISCOSITY SIGNAL TOO HIGH
4.1 SENSOR WITH FACTORY INSTALLED DPT 8.3 VISCOSITY SIGNAL REMAINS AT
4.2 DPT SEPARATE FROM SENSOR MAXIMUM VALUE
4.3 STARTER BOX OR MOTOR SWITCH 8.4 NO VISCOSITY SIGNAL
4.4 PNEUMATIC CONNECTIONS - DPT 8.5 CONTROL STATION
4.5 ELECTRICAL CONNECTIONS 8.6 CONTROL VALVE
- SENSOR ELECTRIC MOTOR 8.7 AIRFILTER-REGULATOR
4.6 ELECTRICAL CONNECTIONS - STARTER BOX 8.8 ANALOG VISCOSITY INDICATOR
4.7 CONTROL STATION
4.8 CONTROL VALVE 9.0 PARTS LIST
4.9 AIRFILTER-REGULATOR 9.1 VISCOSUM SENSOR
4.10 INSTALLATION OF RECORDER 9.2 PNEUMATIC DPT
4.1 1 ANALOG VISCOSITY INDICATOR 9.3 VISCOSITY CONTROL STATION
4.12 ALARM PRESSURE SWITCH 9.4 STEAM CONTROL VALVE WITH HANDWHEEL
9.5 AIRFILTER-REGULATOR
5.0 DIMENSION DRAWING
5.1 VISCOSUM SENSOR / DPT ASSEMBLY 10.0 MANUFACTURER'S WARRANTY
5.2 SEPARATE VISCOSUM SENSOR AND DPT 10.1 MANUFACTURER'S WARRANTY
5.3 STARTER BOX
5.4 VISCOSITY CONTROL STATION
5.5 CONTROL VALVE
5.6 AIRFILTER-REGULATOR
5.7 VISCOSITY RECORDER
5.8 ANALOG VISCOSITY INDICATOR
5.9 ALARM SWITCH

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1.0 INTRODUCTION 4
DAEHO FLOW INSTRUMENTS

1.1 GENERAL

This manual contains instructions for installation, operation and maintenance

of the control components supplied with a DAEHO Viscosum Series V15
Pneumatic Viscosity Control System. This bulletin contains the instructions for installation,
operation and maintenance for Viscosum Series 15
Sensor / Pneumatic Differential Pressure Transmltter Assembly and components.

1.2 TO RECORD IMPORTANT SERIAL NUMBERS

Before installing a Viscosum system it is advisable to record type and

serial numbers of the system's components.

Always quote the serial number, as printed on the "-" tagplate of the
Viscosum Sensor, when contacting the factory or local sales representative.

ONLY TO BE USED TOGETHER WITH

TYPE 7 1
SERIAL NO. 7 1 c O N ~ R O U E R ~

Fig. I, Location of type and serial numbers on Viscosum Sensor.

Record nameplate data of other system components here :

Component Name Nameplate data

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DAEHO FLOW INSTRUMENTS
1.0 INTRODUCTION
6

1.4 MODEL NUMBER IDENTIFICATION

The typenumber stamped on the "-" tagplate on the Viscosum housing identifies
the instruments as follows.

ORDER CODE KEY

(VISCOSUM SENSOR WITH DIFFERENTIAL PRESSURE TRANSMITTER)

CODE 1 D E S C R I P T I O N ASSEMBLY MODEL NO.

El PNEUMATIC DIP TRANSMllTER

ELECTRIC DIP TRANSMllTER
1
2

1 7
8
CONNECTION SIZE AND FLANGE RATING
DN50 JIS 10K
DN50 JIS 16K
DN65 JIS 10K
DN65 JIS 16K
2" ANSI 150 #
2 x 112" ANSI 150#
3
4
5
6
7
8

r=i%Fl MEASURING RANGE

ELECTRIC MOTOR
1
2

220VAC/240VAC, 1PH 1
220VAC/380VACl 3PH
240VAC/415VAC, 3PH 2
250VAC/440VAC, 3PH
llOVAC, 1PH 3
11OVDC

1
2
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3

ASSEMBLY MODEL NO. V15

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DAEHO FLOW INSTRUMENTS
2.0 FUNCTION DESCRIPTION

2.2 SENSOR WITH DIFFERENTIAL PRESSURE TRANSMllTER

a. SENSOR
The Viscosum sensor consists of a housing in which is mounted a capillary tube assembly as the measuring
element, together with a gear pump. An electric motor with reduction gear drives the pump in such a way
that the volume of oil flowing through the capillary tubes is constant. As the flow through the capillaries is
8

also laminar, the pressure differential across the capillaries is directly proportional to the viscosity of the
fuel oil.

The capillary tube assembly consists of a fluon plastic metal measuring capillary in a resilient stainless steel
housing and damping capillary to compensate for under pressure waves in the fuel lines. The use of a metal
capillary reduces the possibility of clogging by cold heavy fuel oil.
A thermometer indicates the actual fuel temperature.

Two pressure taps are provided to connect the differential pressure devel'oped across the capillaries to the
differential pressure transmitter (DPT). A mechanical coupling between the electric motor and the gear pump
provides a leak free power transmission and prevents overload of the electric motor.

==-.==--=----
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=:y---

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DAEHO FLOW INSTRUMENTS

d. STARTFR BOX
2.0 FUNCTION DESCRIPTION

The starter box is used for on-off control of the Viscosum Sensor Motor.
The starter box is equipped with a thermal relay for protection of sensor motor.
10

2.3 SYSTEM COMPONENT

a. VISCOSITY CONTROL STATION

The viscosity control station receives a 0.2-1 bar control signal, representing the actual fuel viscosity,
from the differential pressure transmitter (DPT) and compares this signal with the desired (setpoint) viscosity
value. Any deviation between the actual viscosity and the desired viscosity results in a corrective air signal
to the steam or thermal oil control valve, t o bring the measured value to setpoint value.

b. CONTROL VALVE

The control valve regulates the flow of steam or thermal liquid to the fuel heater. Standard valve action is
air-to-close, to ensure heating medium still being suplied to the heater in the event of a control signal
failure, while maintaining the possibility of controlling the valve by means of the manual override
(when this option has been ordered).

C. AIRFILTER-REGULATOR

Provides regulated air supply to the differential pressure transmitter, the control station and the (option)
analog viscosity indicator.

OPTION

d. VISCOSITY RECORDER

For registration of the viscosity of the fuel oil a recorder can be ordered as optional extra, The input of the

recorder i s the 0.2-1.0 bar control signal from the differential pressure transmitter.

e. ANALOG VISCOSITY INDICATOR

The viscosity indicator i s used to provide viscosity indication at a point remote from the point of actual
viscosity measurement, e.g. in the control room or on the bridge. The instrument can be supplied with
adjustable low and high viscosity alarm contacts which can be connected to the ship's alarm system.

f. ALARM PRESSURE SWITCH

The non-indicating pressure switch is pneumatically connected to the viscosity control signal from the
differential pressure transmitter and has two microswitches to signalise a low or high viscosity alarm via
the ship's alarm system.

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DAEHO FLOW INSTRUMENTS

3.1 VlSCOSUM SENSOR

3.0 TECHNICAL SPECIFICATIONS

Viscosity measuring range : see Model Number Identification code

Flange connections : DN 50mm ( 2 )
Flange rating : see Model Number ldentlfication code
Materials
Body : ductile cast iron
Capillary ass'y : fluonplastlc coated metal
Gear pump : stainless steel
Temperature : fuel oil max. 180C (380.F)
ambient max. 60C (140.F)
Maximum fuel flow rate : 35 m3/h
Output differential pressure : approx. 0-0.5 bar (depends on motor frequency)
Connections to DPT : 10 mm pipe couplings
Response time : 1 minute
Accuracy : better than +I- 2% (see note below)
Thermometer scale : 0 - 20072 (0-392'F)
Net weight sensor / DPT : 32 kilos

Electric motor
Supply voltage : see Model Number lndentlfication code
Insulation class : VDE 0530 class F. Tropical insulation
Protection class : IP 55, ex-proof motor IP 54
Power consumption : 0.63 A

Conduit connector : PG13.5, suitable for 10-1 2.5 mm cabie dia.

3.2 PNEUMATIC DIFFERENTIAL PRESSURE TRANSMCrrER

Temperature influence : < 0.05% per C

Max. static pressure : 10 MPa (100 bar ; 1,500 psi)
Single sided pressure overload protection : 10 MPa (100 bar ; 1,500 psi)
Manifold block : 2 isolating valves, 1 equalising valve
Process connections : 2 pipe couplings for 10 mm O.D. steel piping
Output signal : 0.2 - 1.0 bar (3-15 psi)
Supply air pressure : 1.4 bar (20 psi)
Air consumption : 14.5 Nllmin
Pneumatic connections : 114" NPTF
Ambient temp. limits : -40 tp 120C (-40 to 248°F)
Materials
Body : Cadmium plated carbon steel
Diaphragm : Stainless steel 316Tl (W. Nr. 1.4571)
Manifold housing : Cadmium plated carbon steel
Filling liquid : Glycerin
Net weight, incl. valve manifold : 14 kilos

3.3 STARTER BOX

Protection class : IP 65
Cable glands : 2 x PG13.5, for 10 - 12.5 mm O.D. cable dia.
Operating voltage : same as viscosum sensor motor

Starter box only

Motor protection : thermal relay
Switching current

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 3.0 TECHNICAL SPEClFlCATlONS 12
DAEHO FLOW INSTRUMENTS I

1 3.4 VISCOSITY CONTROL STATION

Model no. : VC 30
Air signal : 140 kPa (1.4 bar ; 20 psi)
Input signal : 20 - 100 kPa (0.2 - 1.0 bar ; 3 - 15 psi) from
differential pressure transmitter
Output signal - -
: 20 100 kPa (0.2 - 1.0 bar ; 3 15 psi) to control valve
Pneumatic connections : 1.4" NPT female
Control mode : P+I (proportional + reset) ; reverse (standard) or direct acting ;
manual or automatic operation.
Proportional band : 5 - 200% (factory adjusted to 35 %)
Reset time : 0.05 - 15 minutes (factory adjusted to 5 minutes)
Viscosity scales :0 - 22 mPa.s / 0 - 25 cSt , 0 - 44 mPa.s / 0 - 50 cst
Control accuracy : 1 % F.S.
Static air consumption : 0.13 NM~/H
Pneumatic relay : Non-bleed type
Materials
Measuring element : Ni-Span C bellows
Encasing : Die-cast alumimium
Protection class : IP 54, weatherproof, tropically resistant
Mounting : Wall or flush panel
Mounting hardware : Mounting brackets and 4 rubber vibration
dampeners supplied with instrument.
Max. static working pressure : 100 kPa (1 bar ; 15 psi)
Overrange protection : 100 kPa (1 bar ; 15 psi)
Ambient temperature limits : -20 to 80C
Weight : 4 kilos

I 3.5 CONTROL VALVE

Model no. : VL 20
Type : Signal seated giobe valve
Connection size : DN 25 (I"), DN 40 (1-112") , DN 50 (2")
Flanges : DIN PN 10 / 16 / 25 / 40,
ANSI Class 150 RF, 300 RF,
JIS 10K, 16K, 20K

Materials
Body : Cast carbon steel ASTM A216, gr. WCB
Trim : AlSl 316
Packing : Steam valve : Teflon V-rings
Thermal liquid valve : stainless steel bellows seal
Actuator yoke : Cast iron
Actuator diaphragm : Neoprene with fabric insert
Cv value : DN 25 : 3.6 , 5.4, 13 ;
DN 40 : 13 , 23.5 , 32 ;
DN 50 : 21 , 35 , 50

Actuator
TYpe : Spring & diaphragm
Action : Air-to-close (std.) or air-to-open
Control signal -
: 0.2 - 1.0 bar ( 3 - 15 psi ; 20 100 kPa)
Air connection : 114" NPT female
Manual operation : Handwheel optional, supplied when ordered.
Weinht. excl. handwheel
Steam valve : DN 2 5 : 18 k g , DN 4 0 : 22 k g , DN 50 : 26 kg
Thermal oil valve : DN 25 : 22 k g , DN 40 : 26 k g , DN 50 : 30 kg
Weight of handwheel : 4.5 kg
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DAEHO FLOW INSTRUMENTS
13

3.6 VISCOSITY CONTROL STATION

Model no.
Type
3.0 TECHNICAL SPECIFICATIONS

: VF 70
: Reducing-relief type automatic regulator
Maximum supply pressure : 2,000 kPa (20 bar ; 300 psi)
Regulated output pressure :0 - 250 kPa (0 - 2.5 bar ; 0 -35 psi)
Air output capacity : Max. 34 Nm3lh
Connections : 114" NPT
Materials
Housing : Die-cast aluminium
Valve plug : Stainless steel
Range spring : Cadmium plated carbon steel
Diaphragm : Nylon reinforced Buna-N
Filter element : Sintered stainless steel
Filter mesh width : 0.005 mm
Ambient temperature range : -50 to 65t:
Accessories supplied : Wall mounting bracket
Output pressure gauge
Weight : 0.58 kilos

3.7 VISCOSITY RECORDER

Model no. : VI 41
Type : Pneumatic 1-pen strip-chart recorder
Mounting : Wall or panel mounting
Measuring element : Triple bourdon tube
Input air signal : 20 - 100 kPa (0.2 - 1.0 bar ; 3 - 15 psi)
Air connectlon : 114" BSP female pipe connection tube damping screw
Materials
Measuring element : Phosphor bronze
Encasing : Steel
Protection class : Watertight acc. IP55
Recording paper
Drive :7 - day spring wound clock
Reading units : Same as control station. Refer to para 3.1
Paper width : 120 mm
Recording speed : 20 mmlh
Recording capacity : 30 days
Accessorles supplied : 6 fibre-tipped felt pens
12 chart rolls for 1 year operation
Weight : 11.5 kilos

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DAEHO FLOW INSTRUMENTS

3.8 ANALOG VISCOSITY INDICATOR

Model no.
TYpe
Mounting
3.0 TECHNICAL SPECIFICATIONS

: VI 40
: Edge scale manometer
: Flush panel mounting
14

Measuring element : Bourdon tube

Input air signal : 20 - 100 kPa (0.2 - 1.0 bar ; 3 - 15 psi)
Overrange protection : Up to 150 kPa (1.5 bar ; 23 psi)
Air connection : 114" NPT female
Reading units : Same as control station. Refer to para 3.1
Accuracy class : 1 % F.S.
Materials
Measuring element : CuSn
Housing : Steel
Protection class : IP 45
Alarm device
Contact type : 2 normally open normally closed change-over switches
Contact rating : DC24V+1.5%, 2W18V
Electric connection : Cable gland Pg 9
Weight : 1.2 kilos

3.9 ALARM PRESSURE SWITCH

Model no. : VA 60
TYpe : Non-indicating pressure switch
Mounting : Wall or front panel mounting
Switch type : Two SPDT diaphragm pressure switches
lnput air signal : 20 - 100 kPa (0.2 - -
1.0 bar ; 3 15 psi)
Max. input pressure : 400 kPa (4 bar ; 60 psi)
Air connection : 114" NPT female
Cable gland : Pg 13.5, tor 10 - 12.5 mm cable diameter
Contact rating -
: 125 250 VAC/lOA ; 480 VACl3A ; 6 - 28 VDCl0.5A
Factory switch settings : Low 4 psi, high 7 psi, Also see para 2.5
Materials
Diaphragm -
: Stainless steel 17 7 PH
Housing -
: Die cast aluminium
Protection class : IP 54 (NEMA 4)
Welght : 0.95 kilos

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DAEHO FLOW INSTRUMENTS
i5 4.0 INSTALLATION INSTRUCTIONS

4.1 SENSOR WITH FACTORY INSTALLED DIFFERENTIAL PRESSURE TRANSMllTER

1. The sensor1DPT assembly must be installed as shown in figure 5, in a position where it will be
free from excessive vibrations, moisture and large fluctuations of temperature. Also refer to section
2.1 of this manual. Mounting to the main engine or other machinery is not recommended.
Avoid bending strains on the sensor housing by using adequate fuel piping support.

2. Install the sensor1DPT assembly between fuel oil heater and fuel injection pump, as close as possible
to the outlet of the fuel heater.
Ensure that pipe length between heater and sensor is not more than 4 metres.

3. Include isolation valves and a bypass valve in the fuel piping, to permit normal engine operation
If the sensor must be taken out the line for servicing.

4. To enable removal of the electric motor with its gearbox for servicing approximately 20 Cms
clearance should be left to the side of the sensor.

5. The sensing lines between sensor

and DPT must be heated when
fuel of 500 mPa.s (2,200 sR1) or
thicker is measured.
Use 6 mm O.D. isolated steam
tracing or 20 Watt/metre
resistance wiring. VISCOSUM SENSOR WITH
D/P TRANSMITTER ASSEMBLY

* NOT SUPPLIED BY "DAEHO"

Fig. 5, installation diagram Viscosum Sensor/DPT Ass 'y

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 4.0 INSTALLATION INSTRUCTIONS
DAEHO FLOW INSTRUMENTS I

4.2 INSTALLATION OF DPT SEPARATE FROM SENSOR

CAUTION :
The DPT is filled with glycerine to prevent fuel oil entering the instrument. To prevent loss of filling liquid
do NOT open valves on DPT manifold until viscosity control system will be taken into operation.

1. If the differential pressure transmitter is not factory installed to the sensor,

the distance between sensor and DPT must not exceed 1.5 metres.

2. Install DPT (Fig.6) to bulkhead or other suitable support, using mounting bracket supplied. The process
lines between sensor and DPT must slope downwards. Therefore process connections at manifold
of DPT must be at least 10 cm below "+" and "-" output connections of sensor.

3. Connect "+" connection at sensor to "+" connection at DPT valve manifold and connect "-" connection
at sensor to "-" connection at DPT valve manifold, using 10 mm O.D. steel piping.
NOTE : + and - signs are marked on the sensor and in the sides of the DPT housing.

4.3 INSTALLATION OF STARTER BOX OR MOTOR SWITCH

1. install starter box or motor switch at a convenient place in the engine room or control room.

4.4 PNEUMATIC CONNECTIONS - DIFFERENTIAL PRESSURE TRANSMllTER

1. Connect 1.4" bar (20 psi) regulated air supply to 114" NPT "IN" port of DPT.

2. Connect 114" NPT "OUT port of DPT to "process" connection of viscosity control station.
This output port must also be connected to the viscosity recorder, remote viscosity indicator andlor
alarm pressure switch, if these options have been supplied.

CAUTION : Remove shipping stops from process and air connections before making connections.

'IN' 1I4'NPTF aIr supply. Connccl 10

'OUT' connoellon of rlrllltarmoulalor

M~nlloldvalve block Illlad with

glycerin. Do NOT open volvms 'OUT' I14"NPTF 0.2-1.0 bar
bcfom procoss connocllono (3-15 pal) control slgnrl.
hove been made. Connoct from 'PROCESS'
\ conntctlon of control stallon.

Connect to '-" connecllon ol Connact to '6' connccllon of

Vl8cosum tensor, uslno 102 lmm Vl8co8um sonsor, uslnp 10 r: lrnm
(318-0.0.) sloet plplng. (318'0.0.) stool piplng.

These tonntCt10n¶ must be In horizontal.

or varllcal UPIVAKDS POblliofl. IdEVER Install
Ihe lransrnlllor wilh downword connecllons.

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DAEHo FLOW lNsTRuuEws 19
4.9 INSTALLATION OF AIRFILTER-REGULATOR
4.0 INSTALLATION INSTRUCTIONS

1. Install filter-regulator in upright position to wall or bulkhead, using the mounting bracket supplied.
Leave sufficient clearance below instrument to remove bowl for servicing.

2. Make pneumatic connections, using 6 x l m m or 318" O.D. copper tubing, or 114" O.D. copper pipe,
as follows :

a. Connect 114" NPTF "IN" port of regulator to compressed air supply with maximum air pressure
of 2,000 kPa (20 bar ; 300 psi).

b. Connect 114" NPTF "OUT" port of regulator to "IN" port of differential pressure transmitter
and to "SUPPLY" port of control station.

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

Output pressure gauge I

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I
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114" NPT famale "IN"

\
Supply air "Out", 1 / 4 " rip1 female
from compressor
max. 20 bar ( 3 0 0 ~ ~ 1 )

Connect to
'SUPPLY' connection of control slat~on
'IN' connectton of dlfferent~alpressure
lransrnlller

Fig. 11, Airfilter-regulator

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 4.0 INSTALLATION INSTRUCTIONS 20

4.10 INSTALLATION OF RECORDER

1. Install recorder vertically to wall or in a panel, where it will be free as possible from vibration,
moisture and large fluctuations of temperature. Four (4) mounting holes 06.5mm are provided
in the panel mounting flange.

2. Connect the 114" EST fitting on top of the recorder with the 114" NPT "OUT" connection of the
differential pressure transmitter, using 6 x l m m or 318" O.D. copper tubing, or 114" brass pipe.

NOTE : The screw in the fitting on top of the recorder is a damping screw, to reduce excessive pulsations
which can cause poor record.

Fig. 12, Viscosity recorder

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DAEHO FLOW INSTRUMENTS

4.12 INSTALLATION OF ALARM PRESSURE SWITCH

4.0 INSTALLATION INSTRUCTIONS 22

1. Install the pressure switch in any convenient place, which is accessible and where it is free from moisture,
large fluctuations of temperature, vibration or shock. Mount the switch to a wall or bulkhead using two (2)
M4 bolts or screws. The mounting bracket may be rotated in 90' increments to suit the mounting position.

2. Connect the 114" NPT pressure port to the 114" NPT "OUT" connection of the differential pressure
transmitter, using G x l m m or 114" tubing or piping.

3. Make electrical connections, through the Pg 13.5 conduit connector, to the ship's alarm system,
-
using cable with 10 12.5mm O.D. See connection diagram of Fig, 17.

NOTE : Switches are factory preset to the values mentioned in section 2.5. If required low and high alarm
can be individually turned by screwdrive adjustment after removing lid on top of the instrument.

112" NPS condu~tconnector

for s~gnalwlrlng to

/
s h ~ p ' spannel

For electr~caiconnect~on
see f ~ g16

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3

install
sw~tchw ~ t h
(2) M4 screws.
\ 114" female NPT pressure port,
conner to couput s~gnall ~ n e
from Dif ferental Pressure
transm itter

Fig. 16, Pneumatic and electrical connections of pressure switch

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DAEHO FLOW INSTRUMENTS
5.0 DIMENSION DRAWING
26
5.3 STARTER BOX
(DIMENSION : mm)

i
c.

Fig, 20, Dimensions of starter box.

5.4 VISCOSITY CONTROL STATION (DIMENSION : mm)

NOTE

1.PNEUMATIC CONNECTION : 114 NPT.F

2. E : AIR SUPPLY (1.4 BAR)
3. V : OUTPUT (0.2 - 1.0 BAR) TO CONTROL VALVE
4. P : PROCESS (0.2 - 1.0 BAR) FROM TRANSMllTER
AIR PIPE SIZE WILL BE RECOMMENDED
AS 6 @ BITE BRASS NIPPLE

Fig. 21, Dimensions of control station

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DAEHO FLOW INSTRUMENTS I
5.5 CONTROL VALVE
PNEUMATIC 2-WAY STEAM CONTROL VALVE (DIMENSION : mm)

HANDWHEEL OPTIONAL
7

TmONs
1/4 NPT

ACTION : AIR TO CLOSE INLET CONNECTION I

AIR TO OPEN INLET CONNECTION I1

Fig. 22, Pneumatic steam control valve, Series VL 20

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DAEHO FLOW INSTRUMENTS

PNEUMATIC 2-WAY THERMAL LIQUID CONTROL VALVE

5.0 DIMENSION DRAWING

(DIMENSION : mm)
28

HANDWHEEL OPTIONAL
/I

ACTION : AIR TO CLOSE INLET CONNECTION I

AIR TO OPEN INLET CONNECTION I1

Fig. 23, Pneumatic thermal liquid control valve, Series VL 20

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 6.0 OPERATION INSTRUCTIONS
DAEHO FLOW INSTRUMENTS

6.1 VISCOSUM SENSOR / DIP TRANSMIlTER ASSEMBLY

6.1.1 INITIAL START-UP

This chapter describes general procedures for initial start-up of a Viscosum system.
Initial start-up of the system should always be done with diesel oil.

1. Close block valve (D & E, Fig. 28) and open equalizing valve (F, Fig. 28) on manifold of differential
pressure transmitter (DPT)

2. Open block valves and bypass valve (K, L & M, Fig. 29) around Viscosum sensor.

3. Close block valves and bypass valve (A, B & C, Fig. 291 around control valve..

4. Allow diesel oil t o enter fuel system.

5. Start booster pumps and after approximately 15 minutes close bypass valve i n fuel line (L, Fig. 29).

6. Start electric motor of Viscosum sensor.

7. Unscrew plpe coupling i n sensing line to DPT on "-" side (see arrow In Fig. 28), to vent piping.
Walt until no more air bubbles come out wlth the diesll oll, Retighten coupling.

8. Open block valves of DPT manlfold (D & E, Flg. 28).

9. Turn on supply alr to DPT and viscosity control station :

a. Slowly open compressed air supply t o air filter-regulator.
b. Adjust output of air filter-regulator to 1.4bar (20 psi).

10. Observe vlscoslty reading of viscosity controller. If reading is not zero, re-adjust zero point of DPT,
i n accordance wlth section 7.7 and 7.8 of thls manual.
Close equalizing valve (F, Fig.28) on manlfold of differential pressure transmitter (DPT).

11. Check that control parameters of viscosity controller are at their desired valves.
Refer t o technical manual of controller supplied with the instrumentl.

12. Switch viscosity controller to MANUAL mode and check operation of steam valve,
as, described i n technical manual supplied with viscosity controller.

13. Make sure that steam control valve is fully closed.

14. Switch viscosity controller to AUTOMATIC mode and adjust setpoint to a valve approximately
1 mPa.s higher than actual viscosity of diesel oil.

(Continued)

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DAEHO FLOW INSTRUMENTS
6.0 OPERATING INSTRUCTIONS

Ooen here
32

Fig. 28, Block valves and equalizing valve on manlfold

VISCOSUM SENSOR WITH

D/P TFUNSYI'ITER ASSEMBLY

THERMAL OIL

* NOT SUPPLIED BY "DAEHO"

Fig. 29, Valves in bypass lines of sensor and control valve

-31 -
 dkdm
- .
33 6.0 OPERATING INSTRUCTIONS
DAEHO FLOW INSTRUMENTS

6.1 -1 INITIAL START-UP (continued)

15. Open block valves in steam line (B & C, Fig. 29).

16. Allow heavy fuel oil to enter fuel system. Viscosity controller will take up control of viscosity
as soon as actual fuel viscosity exceeds setpoint valve.

17. Gradually increase setpoint of viscosity sontroller to desired final value.

When the setpoint is at desire value and viscosity control has stabilized, the initial start-up procedures
are completed.

6.1.2 ROUTINE START-UP WITH DIESEL OIL AND CHANGE-OVER TO HEAVY FUEL

1. Check that bypass valve of DPT manifold (F, Fig. 28) is open.

2. Switch on booster pumps and allow diesel oil to enter fuel system.

3. Close bypass valve of DPT manifold (F, Fig. 28) and check that block valves of manifold
(D & E, Fig. 28) are open.

4.Switch on electric motor of Viscosum sensor.

5. If viscosity reading on display of viscosity control station exceeds maximum limit of viscosity range,
switch off electric motor Viscosum sensor.
Switch viscosity controller to MANUAL and open steam control valve using regulator adjusting knob
on control station refer to Technical Manual supplied with control station, to add more heat to the fuel.
Then switch Viscosum electric motor on again and check whether viscosity reading is within
maximum operating limit.

6. Decrease controller setpoint to a value just above the measured actual fuel viscosity.

7. Allow heavy fuel oil to enter fuel system.

The viscosity controller will take up control of viscosity as soon as the measured viscosity
will exceed setpoint value.

8. Gradually increase setpoint of controller to desired final valve.

9. Turn the system as described in the relevant chapter in the technical manual supplied
with the viscosity controller

When viscosity control has stabilized at the desired setpoint value, the start-up is comoplete.

-32-
 6.0 OPERATING INSTRUCTIONS 34
DAEHO FLOW INSTRUMENTS I
6.1 -3 ROUTINE START-UP ON HEAVY FUEL OIL

1. Check that bypass valve of DPT manifold (F, Flg. 28) is open.

2. Switch on booster pumps and allow HFO to enter system.

3. Close bypass valve of DPT manifold (F,Flg. 28) and check that block valves of DPT manifold
(D & E, Flg. 28) are open.

4. Switch vischsity controller to MANUAL.

5. Using regulator adjusting knob on viscosity controller, preheat fuel by opening steam control valve
to approximately 50 percent.

6. After approximately 20 minutes switch on electric motor of Viscosum sensor. Observe viscosity reading
by black pointer of viscosity controller. When reading is approaching maximum valve (see note below),
switch off electric motor of Viscosum sensor and increase valve opening by 10 percent.

NOTE :
"Maximum value" means maximum value of the Viscosum's viscosity range : 25 or 50 mPa.s.
This range i s coded in the type number on the "-" tagplate of the Viscosum sensor with cross-reference
to the identification code in section 1.2 of this manual.

7. Wait approximately 10 minutes and then repeat step 6.

8. If viscosity reads lower than maximum value of viscosity range, switch controller to AUTO.
The setpoint of the controller will be the same as the measured value at the moment of switching
over to automatic mode.

9. Every 5 minutes decrease setpoint by 5 mPa.s, until the desired viscosity value is reached.

6.1 -4 TUNING CONTROL PARAMETERS TO PROCESS

When the fuel system is completely filled with HFO and the control station is in the automatic mode,
the behaviour of the system has to be checked and adjusted. This is best done by observing the actual
viscosity reading directly after a substantial change in the fuel consumption of the main engine.

When the process is hunting (the viscosity is oscillating around setpoint value), increase the proportional
band and/or increase the reset time at the viscosity control station, until the process behaves properly.

Proper viscosity control is characterised by a fast return of the measured actual viscosity value
(indicated by the black pointer) to setpoint value, with only one or two oscillations around the setpoint.

If the actual viscosity value returns very slowly to the setpoint value, decrease the proportional band
and/or decrease the reset time, until the process behaves properly.

If despite continued adjustment, the process can not be brought into good control, refer to the trouble
shooting procedures in section 8 of this manual.
 m-
-.
DAEHO FLOW INSTRUMENTS
6.0 OPERATING INSTRUCTIONS

6.1.5 SHUT-DOWN WITH CHANGE-OVER FROM HEAW FUEL OIL TO DIESEL OIL

1. Switch fuel supply to diesel oil.

The viscosity controller will now try maintain viscosity at setpoint value. This action will result in a
decreasing fuel temperature. At a certain moment there is so much dlesel oll In the system that the
controller is no longer able to maintain the viscosity at the desired value. The viscosity Indication
will now gradually decrease to the viscosity of the diesel oll.

2. When the fuel system is completely filled wlth diesel oil, switch off electric motor of Viscosum sensor.

3. Open bypass valve of OPT manifold (F, Fig. 28).

This completes the shut-down procedures.

6.1 -6 SHUT-DOWN ON HEAVY FUEL OIL

1. Switch viscosity controller to MANUAL.

2. Close steam valve completely, uslng regulator adjusting knob on vlscoslty controller.

3. Switch off electric motor of Viscosum sensor.

4. Open bypass valve in DPT manlfold (F, Fig. 28).

This completes the shut-down procedures.

6.1.7 OPERATION IN CASE OF FAILURE OF VISCOSUM SENSOR

When the viscosum sensor or the differential pressure transmitter is malfunctioning, there is no viscosity
signal available to the viscosity controller. Hence no vlscoslty control is possible.

To enable operation of the fuel system on HFO the heatlng must then be manually controlled.

The measuring value on which to control is the temperature of the oil.

This temperature can be read on toe thermometer of the Viscosum sensor,
or on an other temperature sensor in the fuel system, as close as possible to the engine.

As "setpoint" temperature a value must be chosen identical to the temperature

during normal operation on HFO.
It is therefore important that this normal working temperature of the HFO is regularly recorded.

Refer to chapter 8 for trouble shooting and possible corrective actions which can be performed to
re-instate the normal functioning of the Viscosum sensor or the differential pressure transmitter.

-34-
6.2 VISCOSITY CONTROL STATION

CONTROLLER / Fig. 30
1) P. band adjustment knob
2) Set point indicator
3) Set point knob
4) Integral Action knob
5) AIM Selector
6) Regulator knob

Fig. 30, P + I controller

6.2.1 OPERATING PRINCIPLE (P+l CONTROLLER)

If the control unit has an automatic/manual selector, set the selector t o the "AUTOMATIC" operating position.

1- Connect the unit to an air suppl!, 31 1.4 bar and temporarily open the bleed valve of the reducer filter
until any condensate has been completely discharged.
2- Make certain that there are no air leaks i n the connection to the control valve.
3- Use the knob (3) t o position the red indicator (2) to the desired value.
4- Use the ring (1) to adjust the proportional band to a width of 20% making certain that the action of
the instrument (direct or reverse) is type of operation requied.
 -
& $@
DAEHO FLOW INSTRUMENTS

6.2.1 (continued)
37 6.0 OPERATING INSTRUCTIONS

5- Turn the integral knob (4) to bring the automatic selector to the value of 0.5 repetitions a minute
(for the P+I control).
6- If the pneumatic valve Is equipped wlth a bypass, make certain that the valve is actually closed
and the downstream cutoff valve Is fully open.
7- If the control setting tends to fluctuate, with continuous oscillations of the black Indicator with respent
to the red Indicator, gradually increase the wldth of the proportlonal band In steps beyond the value of 20%
initially specified. If increaslng the width of the proportlonal band dose not reduce the fluctuation, turn the
integral control knob (4) to reduce the number of repetltions per mlnute (e.g. 0.2 repetltions/minute).
Do not go below values of 0.15 repetltions/minute.
8- If the fluctuation disappear, slowly and gradually reduce the wldth of the proportional band until there
is a slight fluctuation, and then lncrease the width of the band as necessary until stablllty i s restored;
If necessary, turn the Integral action knob (4) to gradually Increase the number of repetltions/minute above
0.5 repetltlons/mlnute to use the maximum acceptable automatic adjustment speed I n the system, as long
as it dose not cause fluctuations.
9- To make certain that you have selected appropriate values, both for wldth of the proportional band
and for the automatic adjustment velocity, artificially initiate a disruption by rapidly moving the red
Indicator about 5mm from the setpolnt. If oscillation occurs, slightly wlden the proportional band,
repeating the operation until stablllty is restored. The best control Is obtained wlth the narrowest
proportlonal band whlch is compatible with the stability of the process at the various loads.(see Fig. 30)

6.2.2 DIRECTION OF CONTROL ACTION

The actlon of the pneumatic control elements can be changed from dlrect action (output signal increase as
the variable increase) to reverse action (output signal increase as the variable decreases) or vice-versa,
simply by moving the selector ring to the desired type of operatlon.
However, the viscosity mode should be reverse mode.

6.2.3 AUTOMATIC/MANUAL SELECTOR

The Automatic/Manual selection panel Is used when the operator wishes to override the automatic control
system and to operate the system manually, when control operations are difficult or when problems are
encountered. The control panel consists of a two-position switch (Automatic and Manual), a control knob
and a pressure gauge which indicates the value of the signal output from the panel.
Before operating the control unit equipped with an Automatic/Manual selector switch, make certain
that the proportional band and the manual adjustment have already been set described above.

1- Set the selector to the manual operation position "Mu.

2- Turn the control knob on the panel to completely close the pneumatic control valve.
3- Completely open the cutoff valves upstream and downstream of the control valve; the bypass valve
must be closed.
4- Use the control knob on the panel to gradually open the pneumatic valve until the black indicator
coincides with the red indicator.
5- Set the selector to the automatic operation position "A".

Naturally, the automatic/manual selector panel can also be used to switch back and forth between automatic
and manual operation.
To switch between automatic and manual operation, bring the pneumatic signal output from the control
panel to the same pressure as the control signal (read on the output pressure gauge of the instrument)
and move the selector from the position "A" to the position "M".
-36-
 6.0 OPERATING INSTRUCTIONS
DAEHO FLOW INSTRUMENTS I
6.3 AIRFILTER - REGULATOR
This pressure-reducing regulator (Fig. 31) 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, premitting 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 than escapes to atmosphere through the relief opening i n 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 loading drain valve is used for periodic draining of the liquid which collects In the bowl.

A RANGE ADJUST SCREW

y
- DRAIN VALVE

Flg. 31, Sectional vlew of aliltee~mgulator

 *-
DAEHO FLOW INSTRUMENTS
.. 6.0 OPERATING INSTRUCTIONS

6.4 ALARM PRESSURE SWITCH

The non-indicating pressure switch is pneumatically connected to the measuring signal from
the differential pressure transmitter.
This control air signal acts on a diaphragm which, in turn, actuates either of two microswitches
when predetermined high or low viscosity values are reached.

Switch points are factory set as follows :

Low alarm point setting 4 psl (0.27 bar), corresponding with a viscosity of 8.75 mPa.s (35 sR1) for indicator
with a maximum scale reading of 50 mPa.8 (220 sR1).
or :
35 mPa.s (100 sR1)for indicator with a maximum scaie reading of 100 mPa.s (440 sR1).

High alarm point setting 7 psi (1.47 bar), corresponding with a viscosity of 17.5 mPa.s (80 sR1) for indicator
with a maximum scale reading of 50 mPa.s (220 sR1)

or :
38 mPa.s (160 sR1) for Indicator with a maximum scale reading of 100 mPa.s (440 sR1).

Circuit 1. low contact

Circuit 2. h ~ g hcontact

Fig. 32, Alarm pressure switch

-38-
 -
&&@
DAEHO FLOW INSTRUMENTS

7.1 GENERAL
7.0 MAINTENANCE

Under normal conditions the viscosum requires a minimum of maintenance. "Normal" means :
a. A clean operating environment,
b. Viscosum system components installed i n accordance with the installation instructions given.
40

c. Operation of the viscosity control system in accordance with this manual and other related publications
issued by DAEHO.
d. Uninterrupted electric power supply at the specified normal values.

7.2 "An MAINTENANCE CHECKS (DAILY AND PERIODIC)

, TIME INTERVAL MAINTENANCE CHECK AND/OR ACTION

Monthly - Perform zero check of DPT.

- Observe operation of control valve.
- Replace chart roll of recorder.
Daily - Checking packing box of control valve for leaks.
- Observe pressure gauge of airfilter-regulator to check that instrument
air supply is 1.4 bar (20psi)
- Wind-up clock work of recorder.
- Check writing pen of recorder.

Annualy - Clean control station.

7.3 "B" MAINTENANCE CHECK (BI-ANNUAL FIELD CHECK BY OFFICIAL DAEHO INSTRUMENTS
SERVICE ENGINEER OR QUALIFIED PERSON)

DPT : Range and zero adjustment.

Total system : Running test to determine.
Control station - inspection of key parts.
- Performance test.
Control valve - Performance test and adjustments.

7.4 "C" MAINTENANCE CHECKS (EVERY 4 TO 6 YEARS)

"C" maintenance checks include :

- Relevant "A" and "B" maintenance operations ;

- Complete inspection and clearing of all system instruments supplied ;
- Replacement of worn and defective parts ;
- Re-calibration of Viscosum sensor and differential pressure transmitter at the factory ;
- Re-installation of overhauled instruments ;
- Performance test runs to determine if the system may be operated for another service period.

-39-
 7.0 MAINTENANCE
DAEHO FLOW INSTRUMENTS

7.5 MAINTENANCE OF DPT

The nozzle assembly and the dynamic restriction of the differential pressure transmitter must be cleaned
once a year. An accumulation of dirt at the flapper may cause a zero shift and a clogged dynamic
restriction will cause an output signal that is not related to the actual differential pressure developed
in the Viscosum sensor.

1. Remove cover of DPT and note the calibration values Inside the DPT cover
(see Fig. 33, for a typical example).

2. If the operating span of the DPT needs to be adjusted, this can be done by turning the range ring
(Fig. 34).

BUSAN-KOREA
T.82-51-831-3720
F.82-51-831-3750
O DAEHO FLOW INSTRUMENTS CO.,LTD 0
SER.NO.JI
0 DpT
VT 20 MAT'L 7 1

Fig. 33, Typicai exampie of calibration data inside cover of DPT.

Range rlng

--
- - Zero adjust screw

Fig. 34, Location of range and zero adjust points of DPT.

-40-
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DAEHO FLOW INSTRUMENTS

7.5 (continued)

1. UNSCREW NOZZLE NUT

DO NOT LET SOLDERED NUT
ON OPPOSITE SIDE OF
7-0 MAINTENANCE

CLEAN NOZZLE WITH 0.6 mm(0.03Q) DIA WIRE

COMPRESSED AIR OR SUITABLE SOLVENT.
WIPE TOP OF HAPPER CLEAN.
NOZZLE ASSEMBLY
CASI'ING TURN.

2. EASE NOZZLE OUT OF CASING.

3. UJOSEN CLAMP SCREW AND BEFORE REPLACING APPLY

ROTATE S- CLAMP. A THIN FILM OF VASELINE
WITHDRAW NOZZLE O-RING OR SIMILAR LUBRICANT TO
CONNECTION WITH TWISTING O-RING. REPLACE NOZZLE
MOTION. W NOT BEND TUBING. ASSEMBLY IN REVERSE ORDER
CHECK ZERO ADJUSTMENT

CONNECnON FEEDBACK O-RING CONNECTION

Fig. 35, To clean noule assembly of DPT,

CLEAN BY INSERTING A 0.17 mm(O.OOT) DIA WIRE

THROUGH ORIFICE.

B E W R E REPLACING APPLY A THIN FILM O F

UNSCREW RESTRICTOR T U B E FROM CASTING. VASELINE OR SIMILAR LUBRICANT TO O-RING.

Fig. 36, To clean dynamic restriction of DPT.

CAUTION :
A l w a y s c l o s e b l o c k v a l v e (Fig.28) w h e n DPT i s removed f r o m s e r v i c e ,
o r l o s s o f g l y c e r i n s e a l i n g liquid will o c c u r .

-41 -
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*
DAEHO FLOW INSTRUMENTS

7.8 MAINTENANCE OF CONTROL VALVE

7.8.1 GENERAL
7.0 MAINTENANCE

The steam or thermal oil valve requires a minimum of maintenance.

44

A few drops of oll should be placed on all bearing points periodically.

Check all mounting bolts and the air connection to see that there is no leakage.

MONTHLY SERVICING

7.8.2 CHECK VALVE PACKING

1. Check that valve stem packing is not leaking.

If leakage is observed, tighten packing box flange nuts evenly until leakage stops.
CAUTION : Excessive tightening will bind valve stem and prevent sensitive response.

7.8.3 CHECK OPERATION OF CONTROL VALVE

This should be done when the viscosity control system is out of operation, or interference with
viscosity control will occur.

1. Turn on air to control station.

I
2. Switch control station to MANUAL.
The output air signal to the control valve can now be regulated by hand.

3. Using regulator knob (6, Fig. 30) adjust output pressure to 0.2 bar. The output can be read from the
output gauge of the control station.
When the valve action is air-to-close, valve should now be fully closed.
When the valve action is air-to-open, valve should be fully open.

4. Using regulator knob adjust output pressure to 1 bar.

When the valve action is air-to-close, valve should now be fully closed.
When the valve action is air-to-open, valve should be fully open.

5. Lubricate all bearing points and stem of handwheel (if supplied).

6. While valve is opening or closing, check that valve stem moves smoothly.
If valve stem does not move smo~thlycheck alignment of packing box.

-43-
---
7.0 MAINTENANCE
- .
DAEHO FLOW INSTRUMENTS

7.9 MAINTENANCE OF AIRFILTER-REGULATOR

ATTENZIONE: BEFORE PERFORMING THE PERIODICAL MAINTENANCE MAKE SURE THAT THE AIR
FILTER REGULATOR IS CLOSED.

To clean the air fllter regulator loosen the screws (A) and (B) and remove the filter cartridge (C).
To clean the filter use a solvent such as gasollne and blow compressed alr In the cartrldge.
The life of the dlaphragm (D) loosen the screw (El and completely release the spring (F).
Loosen the screws (G) and remove the bonnet (HI.

Fig. 38, Analysis view of aidiiterreguiator

-44-
 -
@
&
DAEHO FLOW INSTRUMENTS

7.10 MAINTENANCE OF VISCOSITY RECORDER

DAILY SERVICING
7.0 MAINTENANCE

1. Wind-up clockwork.
2. Check writing pen. Replace if necessary.
3. Check chart roll speed. Adjust If necessary.

MONTHLY SERVICING

7.10.1 TO REPLACE CHART ROLL

1. Pull pen arm (1, Fig, 39) into longitudinal direction and turn to the right.
The pen is now free from the chart table.
2. Fold back left-hand and right-hand chart guides (4).
3. Push left-hand and right-hand lower catches (7) downwards and pull out chart carrier (8).
Remove used chart roll from lower carrier (8).
4. Push left-hand and right-hand upper catches (3) downwards. The chart table can now be turned forward,
as Fig. 40, shows.
5. Remove end of used chart roll and install a new roll in upper chart carrier (9).
Snap chart table back in its operation position.
6. Insert beginning of new chart roll under clip of lower chart carrier (8).
Replace carrier in Its holder.
7. Tighten roll by turning tension knob (2) and adjust chart position to local time.
8. Fold down chart guides (4) and place pen (10) on chart.

1. PEN ARM

2. TENSION KNOB
3. UPPER CATCH -
3. UPPER CATCH

4. CHART GUIDE
4. CHART GUIDE
DIRECnON OF CHART MOVEMENT

5. ON-OFF LEVER

8 . WIND-UP SHUT

7. LOWER CATCH 7. lDWER CATCH

8. lDWER CHART CARRIER

Fig. 39, Recorder parts

-45-
 7.0 MAINTENANCE
DAEHO FLOW INSTRUMEWS I
7.10.2 TO REPLACE WRITING PEN

1. Pull pen out of tip of pen arm.

2. Install new pen by just sliding in.
3. Remove pen protecting cap.

7.10.3 TO ADJUST CHART SPEED

1. Pull pen arm (1, Fig. 39) in longitudinal direction and turn it to the right.
2. Push left-hand and rlght-hand upper catches (3) downwards and turn chart table forward (as Fig. 40 shows)
3. Adjust chart speed by sliding "arrow" towards "+" or "-" posltion as required.
4. Re-install chart table and pen arm.

3 - 15 p ~ RECEIVER
l

Fig. 40, Tilted chart table for installation of new chart roll or adjustment of chart speed.

7.11 MAINTENANCE OF ANALOG VISCOSITY INDICATOR

MONTHLY SERVICING

1.When performing monthly zero check of differential pressure transmitter, check that reading of analog
viscosity indicator is indencial to indication of control station.
Excessive deviation indicates air piping or instrument failure.

2. Check that alarm switch points (If alarm option is supplied) are at their desired levels.

7.12 MAINTENANCE OF ALARM PRESSURE SWITCH

The non-indicating alarm pressure switch requires no maintenance.

 *-
DAEHO FLOW INSTRUMENTS

8.1 VISCOSITY SIGNAL TOO LOW

POSSIBLE CAUSE
8.0 TROUBLE SHOOTING

Sensing line betweem Viscosum sensor and DPT

CORRECTIVE ACTION
Tighten coupling or repair leak.

leaks at high pressure ("+"I side.

Vent sensing lines as described in section 6.1.1-7.
Air entrapped in sensing lines between Viscosum
sensor and DPT.
Adjust zero point as described in section 7.7

Wrong zero seting of DPT.

Compare sln of DPT with sln given on "+" plate of
Viscosum sensor.
DPT dose not match Viscosum sensor. Contact DAEHO lnstruments if these numbers are
different.

Internal leakages in the Viscosum sensor Replace damaged parts of contact DAEHO instruments
or nearest service representative for repair. I
(damaged O-ring or gear pump).

8.2 VISCOSITY SIGNAL TOO HIGH

I
i
-, j
POSSIBLE CAUSE CORRECTIVE ACTION 1j
Sensing line between Viscosum sensor and DPT Tighten Or repair leak- :i
' i
leaks at low ("-"I pressure side.
Adjust zero point as described in section 7.7 . I
i
1
Wrong zero setting o f DPT.
Compare sln of DPT with sln given on "+" plate of
Viscosum sensor.
DPT dose not match Viscosum sensor. Contact DAEHO lnstruments if these numbers are
different.

Measuring capillary in Viscosum sensor fouled. Clean measuring capillary as described in section 9.3.

8.3 VISCOSITY SIGNAL REMAINS AT MAXIMUM VALUE

POSSIBLE CAUSE CORRECTIVE ACTION

Start the system up in sccordance with the

Fuel too cold during start-up procedures in section 6.1 andlor heat sensing lines
between sensor and DPT as described in section
4.1.1.5.

Fuel too cold during normal system operation, Increase output signal of viscosity controller to
due t o insufficient heating. control valve, i n accordance with instructions in the
technical manual of these components.

DPT malfunctioning. Contact DAEHO Instruments or nearest service

representative for repair or replacement of DAEHO.

-47-
 -
&
&
DAEHO FLOW INSTRUMENTS

8.4 VISCOSITY SIGNAL

4 8.0 TROUBLE SHOOTING

POSSIBLE CAUSE CORRECTIVE ACTION

Electric motor of Viscosum sensor not running.

Check mains suppiy. Has motor correct voltage ?
Is motor switch 'on' ?

3-phase electric motor of Viscosum sensor rotates

Reverse both outer leads at terminal strip of motor.
in wrong direction.

Sensing iine(s) between Viscosum sensor and

DPT leaking. Tighten coudling(s) or repair leaks.

Air entrapped in sensing lines after system or

Vent sensing lines as described in section 6.1.7.
instrument rebuild.

Equalising valve (F, Fig. 28) on DPT is open and/or

Ensure that equaiising valve is ciosed and block
block valves (D 81 E, Fig. 28) are ciosed.
valves are open.

Low supply pressure to DPT.

Adjust suppiy pressure to 1.4 bar (20 psig) and/or
check pneumatic suppiy piping for leaks.

Dynamic restrication of DPT clogged.

Clean dynamic restriction as described in Fig 24.

Pneumatic piping between DPT and viscosity control Repair leak.

station leaking.

-48-
 -
*
DAEHO FLOW INSTRUMENTS

8.5 CONTROL STATION

LOW OUTPUT PROBLEMS

8.0 TROUBLE SHOOTING

Check for leakage in the nozzle line connections at the nozzle and at the relay. If satisfactory, remove flexible
tubing from relay and close hole with finger, If pressure increases the problem is in the nozzle assembly.
50

Remove nozzle assembly and clean or replace as necessary. If pressure does not increase, the problem is
in the relay. Contact the factory or nearest DAsH service agent.

HIGH OUTPUT PROBLEMS

Move flapper away from nozzle. If output decreases, check friction in shaft, linkage and overtravel spring.
If output does not decrease, remove nozzle's flexible tubing at relay. If output decreases, the problem is
does not decrease when the nozzle line at the relay is open, the problem is i n the relay.
Check the push-button orifice (refer to Fig. 25)

OUTPUT HUNTING PROBLEMS

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 with a screwdriver
Increasing the proportional band effects a slower, but more stable control.

If widening the band does no help, the feedback may be inoperative (clogged tube or 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 t o look for erratic behaviour
of the process or other system components.

8.6 CONTROL VALVE

The control valve for steam or thermal liquid must sized correctly. 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, it is probably oversize. For valve
sizing formula, refer to Technical Manual 728 or product Bulletin 764 "control Valves for Viscosum Systems".

Erratic valve action can occur from sticking of the stem due to corrosion or misalignment of the packing box.
Also refer to MAINTENANCE, para 7.8.

8.7 AIRFILTER-REGULATOR

Excessive air leakage through the bleed hole and failing regulated pressure signal usually indicates
a ruptured regulator diaphragm. replace airfilter-regulator if defective.

8.8 ANALOG VISCOSITY INDICATOR

If the difficulties are in the indicator, check the internal mechanism for corrosion, loose pointer,
links or movement.

-49-
 51
9.0 PARTS LIST
DAEHO FLOW INSTRUMENTS

9.1 VISCOSUM SENSOR

Fig, 41. Exploded view of Viscosum Sensor

ITEM ITEM
Q'TY PART NAME PART NO. Q'TY PART NAME PART NO.
NO. NO.
1. 1 HOUSING 150100
21.b 1 MOTOR 440 VAC 30 150310
2. 1 BRASS PACKING 150110
22. 4 S.H. SCREW + WASHER 150320
3. 1 THERMO NETER 150120
23. 1 NUT 150330
4. 4 SOCKET HEAD CAPSCREW 150130
24. 1 MECHANICAL SEAL 150340
5. 4 S.H. SCREW + WASHER 150140
25. 1 DRIVE SHAFT 150350
6. 1 SIGNAL STUD 150150
26. 1 RING 150360
7.+ 4 "0"-RING 150160
27. 1 DISTANCE TUBE 150370
8.
9.
1
1
SIGNAL STUD
MAIN FLANGE
150170
150180
28.* 2 BALL BEARING 150380
29. 4 SPACER TUBE 150390
10.t 1 PACKING HOUSE SIDE 150190
30. 4 150400
11.* 1 PACKING HOLDER SIDE 150200
31. 1
S.H. SCREW + WASHER
PLATE, GEAR PUMP 150410
12. 1 ADAPTER 150210
32. 1 PUMP 150420
13. 1 S.H. SCREW + WASHER 150220
33.* 2 PUMP PACKING 150430
14. 1 LOCK PIN 150230
34. 1 PLATE, GEAR PUMP 150440
15. 1 PACKING HOLDER 150240
35. 2 DEAlRATlON PLUG JOINT 150450
16. 4 S.H. SCREW + WASHER 150250
36. 2 SIGNAL PIPE 150460
17. 1 COUPLING FOR PUMP 150260
37.a 1 CAPILLARY(0-25CST) 150470
18. 1 COUPLING CASE 150270
37.b 1 CAPILLARY(0-SOCST) 150480
19. 1 COUPLING FOR MOTOR 150280
38. 6 S.H. SCREW + WASHEWNUT 150490
20. 1 LOCK SCREW 150290
39. 1 PACKING CAPILLARY 150500
21.a 1 MOTOR 220 VAC 10 150300

* : 2 YEARS RECOMMENDED SPARE PARTS.

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 9.0 PARTS LIST
DAEHO FLOW INSTRUMENTS I
9.2 ELECTRIC MOTOR BOX

Fig, 42. Exploded view of Electric Motor Box

-
ITEM. NO. -
Q'TY PART NAME PART NO. MATERIAL
1 1 Fan Cover M63001 Steel
2 4 Tapping Screws M63002 Steel
3 1 Fan Clamp M63003 Steel
4 1 Cooling Fan M63004 Syntheic
5 1 Electromagnet M63005 Aluminum
6 1 Brake Disc M63006 Steel
7 1 Circlip M63007 Steel
8 1 Hub M63008 steel
9 1 Shield M63009 Aluminum
10 2 Key M63010 Steel
11 2 Bearing M63011 Steel
12 1 Rotor With Shaft M63012 Steel
13 1 Spacer Ring M63013 Steel
14 1 Shim M63014 Steel
15 1 Frame M63015 Aluminum
16 1 Front Shield M63016 Aluminum
17 1 Oil Sealring M63017 Rubber
18 4 Rods And Nut M63018 Steel
19 1 Seal M63019
20 2 Cable Inlet M63020 Plastic
21 1 Terminal Box M63021 Aluminum
22 4 Screws M63022 Steel
23 1 Seal M63023
24 1 Tereminal Box Cover M63024 Aluminum
25 4 Screws M63025 Steel
26 1 Condenser (Only for 220VAC) M63027

-51 -
 1
9.0 PARTS LIST 54
DAEHO FLOW INSTRUMENTS

9.3 PNEUMATIC DIFFERENTIAL PRESSURE TRANSMITTER

ERELA Y ASSEMBL Y
SECTIONAL VIEW

Fig, 44. Exploded view of pneumatic DPT

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&
-
DAEHO FLOW INSTRUMENTS

9.3 (Continued)

ITEM. NO. Q'TY

55

PART NAME
9.0 PARTS LIST

PART NO. MATERIAL

- 1 D.P.T. Complete Assembly W O
1 2 Vent Screw T21001
2 2 Vent Plug T20001
3 4 Nut, Body Mtg. T13402
4 TI7003 Carbon Steel, Cadl
Body, low pressure side -mium plated
* 5 Diaphragm Seallng rlng T20101 Teflon
ANSI-316 filled wlth
6 1 Diaphragm Assembly
Sillcone oil
7 4 Bolt, Valve Manlfold Mtg. T14402
8 5 Plug, Drain TI4603
* 9 1 Gasket, Cover T20102
NPT

10 2 Screw, Cover Support plate T I 3106

11 1 Plate, Cover Support T123002
* 12 1 "0"-Rlng, Force Bar T20103

13 Bolt, Body Mtg. T12701

14 Body, High Pressure Slde T18020
15 2 Fllter, Gauze T14502
* 16 2 Gasket, Valve Manlfold T20104 Teflon
Flange, Valve Manlfold T22003
17
18 4 Bolt, Flange Mtg. T14204
21 1 Bracket, Wall Mtg. TO4190
23 T13007
Screw, Flexure
24 T I 3304
Plaln Washer

25 Feedback Assembly, ConSlSting of Items 26-31 and 57-62 TI4008

26 Zero Adjust Screw l74001
27 Nut, Bellows T61002
28 1 Zero Flexure l75003
29 1 Bracket, Zero sprlng l70004
30 1 Feedback Bellows T59005
* 31 3 "OW-Rlng(1 each for Dynamlc Restrlctlon,
Nozzle & Feedback Assy) T20105 Vlton

32 2 Screw, Flapper T l 0101

33 1 Flapper T51002
34 1 Scale Plate T12903
35 2 Flexure T36004 Spring Steel
36 1 Plate, Flexure Mtg. T41005
37 Mounting Screw T49006

38 1 Bracket T42001
39 1 Nut, Flapper Adjust Screw T44002
40 1 Adjusting Screw, Flapper T43003
41 1 Nozzle Retaining Nut T47004
42 1 Cover Assembly, conslstlng of Cover,
(4) Mtg. Screws, Gasket T94005 Die-cast Aluminium
43 1 Gasket, Cover T95006
44 1 Mounting Plate, Range Bar T40007
45 1 Flexure Group T39008
46 1 Screw T54001
47 1 Nozzle Assembly T45002
48 2 Washer T35003
49 1 Force Bar Assembly, consisting of items 50-55 T28004
50 1 Force Bar, Upper Section ~34005 ANSI-31 6
51 1 Separation Diaphragm T33006 Elgiloy

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 9.0 PARTS LIST
DAEHO FLOW INSTRUMENTS I
9.3 (Continued)

I
ITEM. NO. Q'TY I PART NAME I PART NO. MATERIAL
1 Force Bar, Lower Section T32001
1 Plain Washer T31002
1 Spring Washer T30003
1 Nut T29004
1 Bracket T25148
1 Range Bar T55005

1 Ring Nut, Zero Set Screw T68001

1 Ring Nut, Static Pressure Adjustment T63001
1 Threaded Piece T54002
1 Zero Set Spring T66003 Ni-Span
1 Retaining Bracket T69004

1 Relay Assembly, consisting of Items 64-72, T I 5001

a n d one "0"-Ring of Item 31
1 Dynamic Restriction Plug T20106
1 "0"-Ring T20112
1 Retaining Clamp l76007
1 Screw T49008
2 Filter, Gauze T20107
-
-
1 Relay, containing: l7800l
1 a. Relay Body
1 b. Spring, laminated
1 c. Ball Valve
1 d. Exhaust Valve Plug T20108
1 e. Diaphragm T20109 Beryllium Copper
1 f. Gasket, Cover T20110
1 a. Relay Cover
2 h. Screw and Washer, cover to Body
1 i. Screw, Spring Mtg.

1
1 Relay Gasket T20111
2 Screw, long, Relay to Relay Block T89001
Relay Block T93002
Screw T I 3203
Screw, Relay Block Mtg. T I 4704
Screw, Bracket Mtg. T I 3505

Manifold Valve Block T20101

Valve Stem T20202
Nipple T20303
Spacer T20404
3 Hexagonal unt T20505
3 Handle T20606
3 Plain Washer T20707
3 Retaining Nut T20808
2 Male Elbow TO6213 114" NPT - 0 10mn
4 Hex. Hd. Screw, Mounting Bracket T I 62911 7/16" - 20 UNF X

314" Lg.

* Contained in Spare Parts Kit, for 2 year operation.

** Contained in Spare Parts Kit, for 5 year operation.
 -
&&@
DAEHO FLOW INSTRUMENTS
9.0 PARTS LIST

9.5 PNEUMATIC STEAM CONTROL VALVE WITH HANDWHEEL, MODEL : VL20

58

A
A

B
B

FLOW DIRECTION

Fig, 46. Pneumatic steam control valve with handwheel, model : VL20

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 -
$&
DAEHO FLOW INSTRUMENTS

9.5 (Continued)

Fig, 46.
-

59 9.0 PARTS LIST

ITEM NO. Q'TY PART NAME PART NO. MATERIAL

1 1 Yoke L20100 Cast iron

2 2 Screw for range plate L20101 Stainless stee
3 1 Range plate L20102 Stainless steel
4 4 Screw, hex, head L20103 Steel
5 4 Washer, serrated lock L20104 Steel
6 Ir 1 Packing L20105 Sentlnal
7.a 1 Stem, (welded to plug, item 32)DN25 CV3.6 L20106 Stainless steel
7.b 1 Stem, (welded to plug, item 32)DN25 CV5.4 L20107 Stainless steel
7.c 1 Stem, (welded to plug, Item 321DN25 CV13 L20108 Stainless steel
7.d 1 Stem, (welded to plug, item 321DN40 CV13 L20109 Stainless steel
7.e 1 Stem, (welded to plug, item 32)DN40 CV23.5 L20110 Stainless steel
8 1 Valve body L20111 Steel

19 1 Coupllng L20112 Stalnless steel

20 1 lndlcator L20113 Stainless steel
21 2 Nut, hex. L20114 Stainless steel
22 1 Gland L20115 Stainless steel
23 Ir set(5) Packlng rlng L20116 PTFE
24 1 Bushlng L20117 Stainless steel
25 1 Sprlng L20118 Stainless steel
26 1 Bonnet, standard L20119 Steel
27 1 Guide bushlng L20120 Stalnless steel

30.a 1 Valve seat (DN25 CV3.6) L20121 Stainless steel

30.b 1 Valve seat (DN25 CV5.4) L20122 Stainless steel
30.c 1 Valve seat (DN25 CV13) L20123 Stainless steel
30.d 1 Valve seat (DN40 CV13) L20124 Stainless steel
30.e 1 Valve seat (DN40 CV23.5) L20125 Stainless steel
31A 1 Screw L20126 Steel
32 1 Plug, (weldlng to stem, Item 7) L20127 Stainless steel
34A 1 Screw L20128 Steel
35NB 1 Cover, upper L20129 Steel
36A 1 Spacer L20130 Steel
37 1 Screw, hex. hd. 81 washer, serr. L20131 Steel
38A 1 Screw, handwheel L20132 Stainless steel
39 1 Spacer, fiat L20133 Steel
40NB 1 Handwheel with nut L20134 Steel
41A/B 1 Handwheel L20135 Steel
428 1 Bushing L20136 Bronze
438 1 Stem, handwheel L20137 Stainless steel
448 1 Pin, elastic L20138 Steel
45A 1 0-rlng L20139 Nitrile rubber
46 1 Plate, handwheel L20140 Steel

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@
&
DAEHO FLOW INSTRUMENTS

9.5 (Continued)

Fig, 46.
9.0 PARTS LIST 60

ITEM NO. Q'TY PART NAME PART NO. MATERIAL

47 12 Bolt & nut, hex. head L20141 Steel
48 1 Diaphragm L20142 Neoprene with fabric insert
49 1 Plate, diaphragm L20143 Steel
50 1 Spring L20144 Steel
51 1 Ring, spring guide L20145 Aluminium allou
52 1 Cover, lower L20146 Steel
53 1 Seal ring L20147 H9 Gaco elastomer
54 1 Locking ring, threaded L20148 Steel
55 1 Bushing L20149 Steel
56 1 Nut L20150 Stainless steel
57 1 Stem L20151 Steel
58B 1 Spacer L20152 Steel
598 1 Flat spacer L20153 Steel

Ir Included in recommended spare parts kits.

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 -
$&
DAEHO FLOW INSTRUMENTS
10.1 MANUFACTURER'S WARRANTY
10.0 MANUFACTURE'S WARRANTY
1. The supplier warrants against defects in work-
manship or materials as well as for the corrent
operation of the goods suppiied by him, if and
insofar this operation would be insufficient as a
consequence of these defects.
2. This guarantee implies that the Supplier shaii
remedy these defects, or take back, in full or in
part, the goods supplied and replace the
defective parts by a new delivery, exciusiveiy at
the discretion of the Supplier. To this effect, the
Purchaser shaii return to Suppiier the goods
andlor parts involved, without being entitied to
charge any of the costs arising from the return
to the Supplier. Repair under guarantee in the
Suppiier's factories is at no charge. Goods are
returned free of charge to nearest shipping port.
3. if the guarantee work cannot be carried out in
Supplier's factories, Purchaser shail aiiow the
Supplier to perform this work, or have it
performed elsewhere, without being entitled to
charge any of the cost arising thereform to the
Supplier. if necessary, Purchaser shall in time put
at Supplier's disposal ail necessary auxiliary
labourers, auxiliary tools and equipment, aids
and appiiances (fuels, oils, water, electricity,
compressed air, etc.), at the correct place
without charging any of the cost arising
therefrom to the Supplier. Any cost arislng
nonfuifiiment, or late fulfilment of any of the
above provisions shaii be for Purchaser's account.
The costs arising from making the goods available
for repair, as weii as the repair hours,
the travelling hours, travel and lodging expenses,
shall at ail time be for Purchaser's account.
4. if, in fulfiiment of the obligations under guarantee
Supplier repiaces any parts, the parts replaced
shail become the property of the Supplier.
5. The goods suppiied are guaranteed during a
period of 12 months. The guarantee period sets
in at the moment the goods suppiied are put
into use, provided this point of time is not later
than 6 months after the date of deiivery of the
goods.
-61
6. The supplier reserves the right to have
62
guarantee work carried out by third parties.
7. Supplier's guarantee shall not apply if the
defects are the consequence of injudicious
putting into operation, of injudicious use,
incorporating instailation or storage by the
Purchaser or the Owner, nor if after consuit-
ation with the Purchaser used materials or
special materials are furnished by the Supplier,
the application of which he is not familiar with.
8. Supplier's guarantee shall also not apply, if a
product or parts is ordered without giving
written infirmation concerning the application.
9. No guarantee shall be granted by the Supplier
for damages to goods suppiied arising within
the terms referred to under section 5 of this
present article, If these damages are the
consequence of corrosion caused by:
a. iiquids, the material execution agreed upon
with the Purchaser is not resistant against
and the use which by the Purchaser or
the Owner was not known to the Supplier at
the time of acceptance of the order.
b. liquids, the harmful action of which on the
material execution agreed upon with the
Purchaser was not known to the Supplier at
the time of acceptance of the order, and of
which It would not be demanded in reason
that the Supplier would have been able to
know.
10. Suppiier's liability under this guarantee shaii
cease to exist, if during the guarantee period
the Purchaser or the Owner of the goods
furnished by the Supplier carries out repairs
and/or modifications to the goods suppiied on
his own initiative, or has them carried out
without Supplier's knowledge and his express
consent.
-