ViscoSite Viscometer - Galvanic Applied Sciences€¦ · ViscoSite Viscometer. OPERATION MANUAL ....

ViscoSite Viscometer

OPERATION MANUAL P/N:

Oct 2017

Galvanic Applied Sciences, Inc. 41 Wellman Street Lowell, MA 01851 USA Phone: (978) 848-2701 Toll Free: 1-866-252-8470 E-mail: [email protected] World Wide Web: http://www.galvanic.com

http://www.galvanic.com/

NOTICES This system is covered by a limited warranty. A copy of the warranty is included with this manual. The operator is required to perform routine maintenance as described herein on a periodic basis to keep the warranty in effect. All information in this manual is subject to change without notice and does not represent a commitment on the part of Galvanic Applied Sciences, Inc. No part of this manual may be reproduced or transmitted in any form or by any means without the written permission of Galvanic Applied Sciences, Inc. Note: Changes or modifications not expressly approved by Galvanic Applied Sciences, Inc. could void the user's authority to operate the equipment. © Copyright 2016, Galvanic Applied Sciences, Inc. All rights reserved. Printed in Canada

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Table of Contents

SECTION 1 VISCOSITE VISCOMETER ............................................................................................... 12

1.1 OVERVIEW .......................................................................................................................... 12 1.2 PRINCIPLE OF OPERATION ................................................................................................... 12 1.3 FEATURES OF THE ANALYZER .............................................................................................. 13 1.4 SYSTEM OPERATING CONTROL ............................................................................................ 13 1.5 CONTENTS OF THIS MANUAL ................................................................................................ 13

SECTION 2 ANALYZER COMPONENTS .............................................................................................. 15

2.1 OVERVIEW .......................................................................................................................... 15 2.2 VISCOSITY TRANSDUCER ..................................................................................................... 15

2.2.1 VL500 Viscosity Transducer ................................................................................ 16 2.2.2 VL800 Viscosity Transducer ................................................................................ 17

2.3 SENSOR CABLE ................................................................................................................... 17 2.4 INTRINSICALLY SAFE (IS) BARRIER ....................................................................................... 17 2.5 VISCOSITE VISCOSITY TRANSMITTER .................................................................................... 18

2.5.1 Enclosure ............................................................................................................. 19 2.5.2 Swing Panel ......................................................................................................... 19 2.5.3 Motherboard ......................................................................................................... 20 2.5.4 Power Supply ....................................................................................................... 20

SECTION 3 INSTALLATION ............................................................................................................... 21

3.1 RECEIVING THE SYSTEM ...................................................................................................... 21 3.2 UNPACKING ......................................................................................................................... 21 3.3 INSTALLATION REQUIREMENTS ............................................................................................. 22

3.3.1 Electrical Requirements ....................................................................................... 22 3.3.2 Location of the Viscosity Transducer ................................................................... 22

3.3.2.1 Sample temperature considerations ............................................................. 22 3.3.2.2 Vibration Considerations ............................................................................... 22 3.3.2.3 Flow Considerations ..................................................................................... 23 3.3.2.4 Other Transducer Installation Location Considerations ................................ 24

3.3.3 Location of the ViscoSite Transmitter .................................................................. 24 3.3.4 Space Requirements............................................................................................ 25 3.3.5 Hazardous Area Classification Information .......................................................... 25

3.4 TRANSDUCER INSTALLATION ................................................................................................ 25 3.4.1 Flange Mount Installation ..................................................................................... 26 3.4.2 Sanitary Mount Installation ................................................................................... 26 3.4.3 Threaded Transducer Mount ............................................................................... 27

3.5 TRANSMITTER INSTALLATION ................................................................................................ 27 3.6 SENSOR CABLE INSTALLATION ............................................................................................. 27

3.6.1 Transmitter connections – no IS Barrier .............................................................. 28 3.6.2 Transmitter Connections – IS Barrier ................................................................... 28

3.7 TRANSDUCER COIL COOLING LINES (OPTIONAL) ................................................................... 29 3.7.1 Air Cooling ............................................................................................................ 30 3.7.2 Water Cooling ...................................................................................................... 31

3.8 COMMUNICATIONS CONNECTIONS ........................................................................................ 31 3.8.1 Analog Outputs .................................................................................................... 32 3.8.2 Analog Input ......................................................................................................... 33 3.8.3 Digital Outputs ...................................................................................................... 33 3.8.4 Serial Communications ........................................................................................ 33 3.8.5 USB Port .............................................................................................................. 34 3.8.6 Ethernet Port ........................................................................................................ 34

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SECTION 4 KEYPAD OPERATION ..................................................................................................... 35

4.1 INTRODUCTION .................................................................................................................... 35 4.2 LCD SCREEN ...................................................................................................................... 35 4.3 KEYPAD AND STATUS LEDS ................................................................................................. 35

4.3.1 Keypad ................................................................................................................. 36 4.3.2 Status LEDs ......................................................................................................... 37

4.4 DISPLAY SETUP MENU ......................................................................................................... 37 4.4.1 Main Display menu............................................................................................... 38 4.4.2 Alarms Display menu ........................................................................................... 39 4.4.3 Display Units menu .............................................................................................. 39

4.5 OUTPUT CONFIGURATION MENU .......................................................................................... 40 4.5.1 Analog Output Configuration ................................................................................ 40 4.5.2 Relay Configuration.............................................................................................. 41

4.6 OPTION SETUP MENU .......................................................................................................... 42 4.6.1 Network Setup ...................................................................................................... 43 4.6.2 COM Setup .......................................................................................................... 44

SECTION 5 SOFTWARE OPERATION................................................................................................. 45

5.1 GUI HOME PAGE ................................................................................................................. 45 5.2 TOOLBAR ............................................................................................................................ 46 5.3 GUI ACCESS LEVELS ........................................................................................................... 46

5.3.1 Operator ............................................................................................................... 47 5.3.2 Technician ............................................................................................................ 47 5.3.3 Factory ................................................................................................................. 47 5.3.4 Changing a Password .......................................................................................... 47

5.4 CONNECT TO VISCOMETER .................................................................................................. 48 5.5 DISPLAY SETUP PAGE .......................................................................................................... 49

5.5.1 Main Display ......................................................................................................... 49 5.5.2 Display Units ........................................................................................................ 50 5.5.3 Alarms Display ..................................................................................................... 51

5.6 OUTPUT CONFIGURATION PAGE ........................................................................................... 52 5.6.1 Analog Outputs .................................................................................................... 53 5.6.2 Relay Outputs ...................................................................................................... 53

5.7 OPTIONS SETUP PAGE ......................................................................................................... 55 5.7.1 Density Options .................................................................................................... 55

5.7.1.1 Automatic Density ......................................................................................... 55 5.7.1.2 Manual Density ............................................................................................. 56

5.7.2 Temperature Compensation ................................................................................ 56 5.7.3 Miscellaneous Options ......................................................................................... 57

SECTION 6 OPERATION OF THE VISCOSITE VISCOMETER ................................................................. 58

6.1 INTRODUCTION .................................................................................................................... 58 6.2 EDITING A CONFIGURATION .................................................................................................. 58

6.2.1 Parameters in tables ............................................................................................ 58 6.2.1.1 Numerical Parameters .................................................................................. 58 6.2.1.2 Non-Numerical Parameters .......................................................................... 59

6.2.2 Other Parameters ................................................................................................. 59 6.2.2.1 Radio Buttons ............................................................................................... 59 6.2.2.2 Check Boxes ................................................................................................. 60 6.2.2.3 Data Entry Fields .......................................................................................... 60

6.2.3 Uploading Changes to the Viscometer ................................................................ 60 6.3 EDITING THE VISCOSITE TRANSMITTER DISPLAY .................................................................... 61 6.4 EDITING THE OUTPUT CONFIGURATION ................................................................................. 62 6.5 EDITING THE OPTIONS ......................................................................................................... 62

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6.6 CALIBRATION AND VALIDATION ............................................................................................. 63 6.7 OTHER OPERATIONAL CONSIDERATIONS ............................................................................... 63

SECTION 7 MAINTENANCE .............................................................................................................. 65

7.1 MAINTENANCE GUIDELINES .................................................................................................. 65 7.2 CLEANING THE TRANSDUCER PROBE .................................................................................... 65 7.3 VERIFYING TRANSDUCER CALIBRATION ................................................................................ 66

SECTION 8 TROUBLESHOOTING THE VISCOSITE VISCOMETER .......................................................... 69

8.1 SENSOR CABLE CONTINUITY TEST ....................................................................................... 69 8.2 COMMONLY OBSERVED PROBLEMS ...................................................................................... 69 8.3 CONTACT GALVANIC APPLIED SCIENCES INC. ....................................................................... 71

SECTION 9 VISCOSITE VISCOMETER SCHEMATIC DIAGRAMS ............................................................ 72

SECTION 10 TECHNICAL SPECIFICATIONS .......................................................................................... 76

10.1 PERFORMANCE SPECIFICATIONS .......................................................................................... 76 10.2 COMMUNICATIONS / INTERFACE ............................................................................................ 76 10.3 INSTRUMENT SPECIFICATIONS .............................................................................................. 76

SECTION 11 SPARE PARTS ............................................................................................................... 77

APPENDIX 1: MODBUS REGISTERS .................................................................................................... 78

A1.1 DATA TYPES......................................................................................................................... 79

APPENDIX 2: CALIBRATION AND VALIDATION OF TRANSDUCER ............................................................ 81

A2.1 CALIBRATION TAB ................................................................................................................. 82 A2.1.1 Calibration Procedure ............................................................................................ 83

A2.2 VALIDATION TAB ................................................................................................................... 85 A2.3 TEMPERATURE TAB .............................................................................................................. 85 A2.4 DOME TEMPERATURE TAB .................................................................................................... 86

Figures and Tables: FIGURE 1.1: TORSION RESONANCE VISCOMETRY ............................................................................... 12 FIGURE 2.1 SCHEMATIC DIAGRAM OF VISCOMETER ............................................................................ 15 TABLE 2.1 VISCOSITY TRANSDUCER PROBE TIP TYPES ...................................................................... 16 FIGURE 2.2 VL500 VISCOSITY TRANSDUCER ..................................................................................... 16 FIGURE 2.3 VL800 VISCOSITY TRANSDUCER ..................................................................................... 17 FIGURE 2.2 INTRINSICALLY SAFE BARRIER ......................................................................................... 18 FIGURE 2.3 VISCOSITE VISCOSITY TRANSMITTER ............................................................................... 18 FIGURE 2.4 SWING PANEL FRONT (L) AND REAR ® ............................................................................. 19 FIGURE 2.5 VISCOSITE MOTHERBOARD ............................................................................................. 20 FIGURE 3.1 TRANSDUCER PACKING. CARDBOARD BOX (LEFT); WOODEN CRATE (RIGHT) ...................... 21 FIGURE 3.2 HANDLING THE VISCOSITE VISCOSITY TRANSDUCER ......................................................... 22 FIGURE 3.3 VIBRATION TOLERANCE GRAPH ....................................................................................... 22 FIGURE 3.4 INSTALLATION ON BYPASS LINE ....................................................................................... 23 FIGURE 3.5 NOT RECOMMENDED AND PREFERRED TRANSDUCER MOUNTING ..................................... 24 FIGURE 3.6 VISCOSITY TRANSDUCER PROBE GUARD .......................................................................... 24 FIGURE 3.7 VISCOSITE TRANSMITTER DIMENSIONS ........................................................................... 25 FIGURE 3.8 TRANSDUCER ORIENTATION FLANGE MARKING ................................................................ 26 FIGURE 3.9 CONNECTING CABLE TO TRANSDUCER ............................................................................. 27 TABLE 3.1 TRANSMITTER MOTHERBOARD SENSOR CABLE CONNECTIONS ........................................... 28 FIGURE 3.10 INTRINSICALLY SAFE BARRIER CONNECTION FOR VL500 SENSOR CABLE ....................... 29 FIGURE 3.11 INTRINSICALLY SAFE BARRIER CONNECTIONS FOR VL800 SENSOR CABLE ..................... 29 FIGURE 3.12 LOCATION OF AIR COOLING CONNECTIONS ON TRANSDUCER ........................................... 30

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FIGURE 3.13 INSTALLATION OF AIR COOLING FOR TRANSDUCER ......................................................... 30 FIGURE 3.14 INSTALLATION OF WATER COOLING FOR TRANSDUCER .................................................... 31 FIGURE 3.15 TRANSMITTER COMMUNICATIONS CONNECTIONS (NO IS BARRIER) ................................. 32 TABLE 3.2 ANALOG OUTPUT WIRING FOR TRANSMITTER .................................................................... 32 TABLE 3.3 ANALOG INPUT WIRING FROM DENSITY TRANSDUCER ........................................................ 33 TABLE 3.4 RELAY WIRING FOR TRANSMITTER .................................................................................... 33 TABLE 3.5 SERIAL PORT WIRING ....................................................................................................... 33 FIGURE 4.1 DEFAULT SCREEN CONFIGURATION ................................................................................. 35 FIGURE 4.2 VISCOSITE TRANSMITTER KEYPAD AND STATUS LEDS ..................................................... 36 TABLE 4.1 KEYPAD KEY FUNCTIONS .................................................................................................. 37 TABLE 4.2 FRONT PANEL STATUS LEDS ........................................................................................... 37 FIGURE 4.3 DISPLAY SETUP MENU SCREEN ....................................................................................... 37 FIGURE 4.4 DISPLAY SETUP MENU – LINE SETUP .............................................................................. 38 TABLE 4.3 EDITABLE PARAMETERS FOR EACH LINE OF THE DISPLAY .................................................. 38 FIGURE 4.5 ALARMS DISPLAY MENU .................................................................................................. 39 FIGURE 4.6 DISPLAY UNITS MENU ..................................................................................................... 39 TABLE 4.4 SELECTABLE UNITS FOR EACH MEASUREMENT PARAMETER ............................................... 40 FIGURE 4.7 OUTPUT CONFIGURATION MENU ..................................................................................... 40 FIGURE 4.8 ANALOG OUTPUT CONFIGURATION .................................................................................. 41 TABLE 4.5 ANALOG OUTPUT CONFIGURATION .................................................................................... 41 FIGURE 4.9 RELAY CONFIGURATION .................................................................................................. 42 TABLE 4.6 RELAY CONFIGURATION ................................................................................................... 42 FIGURE 4.10 OPTION SETUP MENU ................................................................................................... 43 TABLE 4.7 OPTIONS SETUP MENU EDITABLE PARAMETERS ................................................................. 43 FIGURE 4.11 NETWORK SETUP SUBMENU .......................................................................................... 44 FIGURE 4.12 COM SETUP SUBMENU ................................................................................................. 44 FIGURE 5.1 GUI SOFTWARE HOME PAGE .......................................................................................... 45 FIGURE 5.2 TOOLBAR ....................................................................................................................... 46 FIGURE 5.3 ENTER PASSWORD PROMPT ............................................................................................ 46 FIGURE 5.4 INVALID PASSWORD MESSAGE ......................................................................................... 47 FIGURE 5.5 FACTORY ACCESS LEVEL TOOLBAR ................................................................................. 47 FIGURE 5.6 CHANGE PASSWORD PROMPT ......................................................................................... 48 FIGURE 5.7 SELECT PORT PROMPT ................................................................................................... 48 FIGURE 5.8 GUI TOOLBAR SHOWING CONNECTION INDICATOR ........................................................... 48 FIGURE 5.9 DISPLAY SETUP PAGE .................................................................................................... 49 FIGURE 5.10 MAIN DISPLAY SETUP ................................................................................................... 49 TABLE 5.1 POSSIBLE DISPLAY OUTPUT PARAMETERS ........................................................................ 50 FIGURE 5.11 DISPLAY UNITS SETUP .................................................................................................. 50 FIGURE 5.12 VISCOSITY UNIT SELECTION MESSAGE ........................................................................... 51 FIGURE 5.13 ALARMS DISPLAY CONFIGURATION ................................................................................ 51 FIGURE 5.14 OUTPUT CONFIGURATION PAGE .................................................................................... 52 FIGURE 5.15 ANALOG OUTPUTS CONFIGURATION .............................................................................. 53 FIGURE 5.16 INVALID CELL CONTENTS ERROR MESSAGE ................................................................... 53 FIGURE 5.17 RELAY OUTPUTS CONFIGURATION ................................................................................. 54 FIGURE 5.18 OPTIONS SETUP PAGE .................................................................................................. 55 FIGURE 5.19 DENSITY OPTIONS ........................................................................................................ 55 FIGURE 5.20 TEMPERATURE COMPENSATION .................................................................................... 56 FIGURE 5.21 MISCELLANEOUS OPTIONS ............................................................................................ 57 FIGURE 6.1 CELL HIGHLIGHTED FOR EDITING...................................................................................... 58 FIGURE 6.2 EDITING A NON-NUMERICAL PARAMETER .......................................................................... 59 FIGURE 6.3 RADIO BUTTON OPTIONS ................................................................................................ 59 FIGURE 6.4 PARAMETER WITH CHECK BOX ........................................................................................ 60 FIGURE 6.5 UNSAVED CHANGES PROMPT .......................................................................................... 60 FIGURE 6.6 DISPLAY SETUP PAGE .................................................................................................... 61 FIGURE 6.7 OUTPUT CONFIGURATION ............................................................................................... 62 FIGURE 6.8 OPTIONS SETUP ............................................................................................................. 63

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FIGURE 6.9 VISCOSITE TRANSMITTER INDICATOR LEDS ..................................................................... 64 FIGURE 7.1 REMOVING THE TRANSDUCER .......................................................................................... 65 FIGURE 7.2 HANDLING THE VISCOSITE VISCOSITY TRANSDUCER ......................................................... 66 FIGURE 7.3 BENT TRANSDUCER PROBE ............................................................................................ 66 FIGURE 7.4 VISCOSITY STANDARD LABEL .......................................................................................... 67 FIGURE 7.5 MOUNTING TRANSDUCER FOR VALIDATION ...................................................................... 67 FIGURE 7.6 MOUNTING LARGE TRANSDUCER FOR VALIDATION ............................................................ 68 TABLE 8.1 SENSOR CABLE CONTINUITY TEST .................................................................................... 69 TABLE 8.2 COMMONLY OBSERVED PROBLEMS ................................................................................... 70 FIGURE 9.1 SENSOR CABLE CONNECTIONS (NO IS BARRIER) ............................................................. 72 FIGURE 9.2 SENSOR CABLE CONNECTIONS (IS BARRIER) .................................................................. 72 FIGURE 9.3 TRANSDUCER CONNECTIONS .......................................................................................... 73 FIGURE 9.4 IS BARRIER AND TRANSDUCER WIRING ........................................................................... 73 FIGURE 9.5 TRANSMITTER INTERIOR LAYOUT (NO IS BARRIERS) ........................................................ 74 FIGURE 9.6 TRANSMITTER INTERIOR LAYOUT (6 IS BARRIERS, NO DOME TEMPERATURE RTD)............ 74 FIGURE 9.7 TRANSMITTER INTERIOR LAYOUT (7 IS BARRIERS) ........................................................... 75 FIGURE A1.1: ENGINEERING PAGE OF GUI SOFTWARE ...................................................................... 78 FIGURE A1.2 – DATA FILTERING........................................................................................................ 79 TABLE A1.1 DATA TYPES IN MODBUS LIST ........................................................................................ 80 FIGURE A1.3 INVALID REGISTER VALUE MESSAGE ............................................................................. 80 FIGURE A2.1 CALIBRATION PAGE ...................................................................................................... 81 FIGURE A2.2 CALIBRATION TAB ........................................................................................................ 82 FIGURE A2.3 MOUNTING SMALL TRANSDUCER FOR CALIBRATION ........................................................ 83 FIGURE A2.4 MOUNTING LARGE TRANSDUCER FOR CALIBRATION ........................................................ 83 FIGURE A2.5 CALIBRATION STANDARD LEVEL .................................................................................... 84 FIGURE A2.6 VALIDATION TAB .......................................................................................................... 85 FIGURE A2.7 TEMPERATURE TAB ...................................................................................................... 85 FIGURE A2.8 DOME TEMPERATURE TAB ............................................................................................ 86

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Safety Symbols used in Manual

The Danger symbol indicates a hazardous situation that, if not avoided will result in death or serious injury.

The Warning symbol indicates a hazardous situation that, if not avoided could result in death or serious injury.

The Caution symbol with the safety alert symbol indicates a hazardous situation that, if not avoided could result in minor or moderate injury.

The Notice symbol is used to highlight information that will optimize the use and reliability of the system.

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Important Safety Guidelines for the ViscoSite Viscometer

Please read the following warnings and cautions carefully before using the ViscoSite Viscometer

This equipment must be used as specified by the manufacturer or overall safety will be impaired.

Access to this equipment should be limited to authorized, trained personnel ONLY.

Observe all warning labels on the analyzer enclosures. The analog outputs and alarm relay contacts may be powered by a source separate from the one (s) used to power the analyzer system. Disconnecting the main power source may not remove power from the analog output signals Any safety recommendations or comments contained herein are suggested guidelines only. Galvanic Applied Sciences Inc. bears no responsibility and assumes no liability for the use and/or implementation of these suggested procedures. This system, when operating in its normal mode, and/or when it is being serviced, maintained, installed and commissioned contains items which may be hazardous to humans if handled or operated incorrectly or negligently. These items include, but are not limited to; The ViscoSite Viscometer transmitter can be configured to be safely operated in a Class 1, Div 2, Groups B, C. D area or General Purpose area.

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Manufacturer’s Warranty Statement Galvanic Applied Sciences Inc. (“Seller”) warrants that its products will be free from defects in materials and workmanship under normal use and service in general process conditions for 12 months from the date of Product start-up or 18 months from the date of shipping from Seller’s production facility, whichever comes first (the “Warranty Period”). Products purchased by Seller from a third party for resale to Buyer ("Resale Products") shall carry only the warranty extended by the original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. Buyer must give Seller notice of any warranty claim prior to the end of the Warranty Period. Seller shall not be responsible for any defects (including latent defects) which are reported to Seller after the end of the Warranty Period. THIS WARRANTY AND ITS REMEDIES ARE IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS EXPRESSED OR IMPLIED, ORAL OR WRITTEN, EITHER IN FACT OR BY OPERATION OF LAW, STATUTORY OR OTHERWISE, INCLUDING BUT NOT LIMITED TO, WARRANTIES OR CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHICH SELLER SPECIFICALLY DISCLAIMS. Seller’s obligation under this warranty shall not arise until Buyer notifies Seller of the defect. Seller’s sole responsibility and Buyer’s sole and exclusive remedy under this warranty is, at Seller’s option, to replace or repair any defective component part of the product upon receipt of the Product at Seller’s production facility, transportation charges prepaid or accept the return of the defective Product and refund the purchase price paid by Buyer for that Product. If requested by Buyer, Seller will use its best efforts to perform warranty services at Buyer’s facility, as soon as reasonably practicable after notification by the Buyer of a possible defect provided that Buyer agrees to pay for travel time, mileage from the Seller’s facility or travel costs to the airport / train station closest to Buyer’s facility plus all other travel fees, hotel expenses and subsistence. Except in the case of an authorized distributor or seller, authorized in writing by Seller to extend this warranty to the distributor’s customers, the warranty herein applies only to the original purchaser from Seller (“Buyer”) and may not be assigned, sold, or otherwise transferred to a third party. No warranty is made with respect to used, reconstructed, refurbished, or previously owned Products, which will be so marked on the sales order and will be sold “As Is”. Limitations These warranties do not cover:

• Consumable items such as lamps.

• Analyzer components which may be damaged by exposure to contamination or fouling from the process fluid due to a process upset, improper sample extraction techniques or improper sample preparation, fluid pressures in excess of the analyzer’s maximum rated pressure or fluid temperatures in excess of the analyzer’s maximum rated temperature. These include but are not limited to sample filters, pressure regulators, transfer tubing, sample cells, optical components, pumps, measuring electrodes, switching solenoids, pressure sensors or any other sample wetted components.

• Loss, damage, or defects resulting from transportation to Buyer’s facility, improper or inadequate maintenance by Buyer, software or interfaces supplied by Buyer, operation outside the environmental specifications for the instrument, use by unauthorized or untrained personnel or improper site maintenance or preparation.

• Products that have been altered or repaired by individuals other than Seller personnel or its duly authorized representatives, unless the alteration or repair has been performed by an authorized factory trained service technician in accordance with written procedures supplied by Seller.

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• Products that have been subject to misuse, neglect, accident, or improper installation.

• The sole and exclusive warranty applicable to software and firmware products provided by Seller for use with a processor internal or external to the Product will be as follows: Seller warrants that such software and firmware will conform to Seller’s program manuals or other publicly available documentation made available by Seller current at the time of shipment to Buyer when properly installed on that processor, provided however that Seller does not warrant the operation of the processor or software or firmware will be uninterrupted or error-free.

The warranty herein applies only to Products within the agreed country of original end destination. Products transferred outside the country of original end destination, either by the Seller at the direction of the Buyer or by Buyer’s actions subsequent to delivery, may be subject to additional charges prior to warranty repair or replacement of such Products based on the actual location of such Products and Seller’s warranty and/or service surcharges for such location(s). Repaired Products Repaired products are warranted for 90 days with the above exceptions. Limitation of Remedy and Liability IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY INDIRECT, CONSEQUENTIAL, INCIDENTAL, SPECIAL OR PUNITIVE DAMAGES, OR FOR ANY LOSS OF USE OR PRODUCTION, OR ANY LOSS OF DATA, PROFITS OR REVENUES, OR ANY CLAIMS RAISED BY CUSTOMERS OF BUYER OR ANY ENVIRONMENTAL DAMAGE OR ANY FINES IMPOSED ON BUYER BY ANY GOVERNMENTAL OR REGULATORY AUTHORITIES, WHETHER SUCH DAMAGES ARE DIRECT OR INDIRECT, AND REGARDLESS OF THE FORM OF ACTION (WHETHER FOR BREACH OF CONTRACT OR WARRANTY OR IN TORT OR STRICT LIABILITY) AND WHETHER ADVISED OF THE POSSIBILITY OF SUCH DAMAGES OR NOT.

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Section 1 ViscoSite Viscometer 1.1 Overview

The ViscoSite Viscometer transmitter, when connected to either a VL500 or VL800 viscosity transducer, is designed to measure the viscosity in any type of liquid sample stream, over a broad range of temperatures, ranging from very low viscosity all the way to very high viscosity. The ViscoSite is also capable of both temperature and density compensation in the viscosity measurement.

1.2 Principle of Operation The ViscoSite viscosity sensor operates on the principle of torsion resonance oscillation viscometry, as per Figure 1.1.

Figure 1.1: Torsion Resonance Viscometry

Electromagnetic coils are used to drive a crossarm connected to a drive shaft with a torsional oscillation at a constant amplitude. Changes in viscosity affect the amount of electrical power needed to maintain this constant amplitude, so by measuring these changes in electrical power it is then possible to determine the viscosity of the fluid being measured. In addition, by changing the surface area of the oscillating body, it is possible to measure a very broad range of viscosity, from 0.1 to 1 000 000 cP x g/cm3.

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1.3 Features of the Analyzer

The ViscoSite Viscometer provides the following capabilities: • Broad dynamic range of viscosity measurement • Automatic zeroing function • Automatic vibration compensation • Several communications options – Ethernet, USB, RS232C/RS485, including Modbus RTU

support • Analog inputs for density, probe tip temperature, and probe dome temperature measurement • User programmable analog outputs (3) and relay outputs (2) • On-board LCD for analyzer current status and measurement results display • On-board membrane keypad with status LEDs for analyzer control and status information

display • Separate transducer and transmitter to allow for remote installation of transmitter in non-

hazardous area (maximum distance 300 metres) • Optional transducer cooling and choice of probe materials for harsh process environments

1.4 System Operating Control The ViscoSite Viscometer’s transmitter is controlled by a dedicated data acquisition system which provides supervisory control, performs all calculations and provides the user interface. The transmitter includes an onboard computer system which provides full screen display of the various parameters, including density, viscosity, and temperature, as selected by the user, as well as alarms and other status measurements. A key pad is provided on the front panel of the transmitter for user interface with the analyzer. Operation of the system with the keypad is described in Section 4. As an alternative, a PC based graphical user interface (GUI) can be used to enter information on a remote basis (Section 5).

1.5 Contents of this Manual

This manual contains the following information: • Section 1: ViscoSite Viscometer presents introductory information about the system and the mode

of operation. • Section 2: Analyzer Components describes the design of the major components of the system. • Section 3: Installation describes unpacking the analyzer, installing it in the facility and interfacing with

other devices. • Section 4: Keypad Operation describes how the user enters data and views system parameters using

the hand held controller module and on board display panel • Section 5: Software Operation presents a detailed discussion of the various aspects of the application

program on the personal computer. • Section 6: Operating the System describes how to use the GUI software to edit the ViscoSite

Viscometer configuration and set it up for sample analysis and data output. • Section 7: Maintenance includes a discussion of activities which should be performed on a routine

basis to optimize operation • Section 8: Troubleshooting includes information that may be useful in diagnosing and / or solving

problems with the VisoTech Viscometer

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• Section 9: ViscoSite Schematic Diagrams includes diagrams to assist the operator in interfacing auxiliary components such as a density transducer and a control computer to the transmitter.

• Section 10: Technical Specifications presents the specifications for the analyzer. • Section 11: Spare Parts lists a number of items which may be required to maintain operation of the

analyzer. • Appendix 1: Modbus Registers describes the Modbus output configuration for the ViscoSite

Viscometer to aid in the set up of Modbus output to a control computer. • Appendix 2: Calibration and Validation describes the process for calibrating and validating the

ViscoSite Viscometer’s viscosity transducer and associated temperature RTDs.

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Section 2 Analyzer Components

2.1 Overview

The ViscoSite Viscometer is a modular system consisting of either a VL500 or VL800 viscosity transducer and a ViscoSite transmitter connected via a signal cable, designed to monitor the viscosity of a liquid sample stream using the method described in section 1.2. If the sensor is to be mounted in a hazardous area, an intrinsically safe barrier is installed between the sensor and transmitter. An overview of the system is shown in figure 2.1.

Figure 2.1 Schematic diagram of Viscometer

The system consists of the following components: • Viscosity Transducer (Section 2.2) • Sensor Cable (Section 2.3) • IS Barrier (Section 2.4) • Viscosity transmitter (Section 2.5)

2.2 Viscosity Transducer

The ViscoSite Viscometer can use one of two viscosity transducers, depending on the customer requirements. The two available viscosity transducers are the VL500 and the VL800. There are a total of four probe tips to chose from, depending on the sample fluid viscosity, as outlined in table 2.1.

IS B

arrie

r

Viscosity Transducer (Pipe or Tank-mounted)

Visc

osity

Tr

ansm

itter

Sensor cable (max length 300m)

Viscosity Transmitter Enclosure

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Probe tip type Picture Viscosity Range Sensor Availability

Rod type

100 to 1 000 000 cP x g/cm3

VL800 only

Sphere Type

10 to 100 000 cP x g/cm3

VL500 or VL800

Cylinder Type (MV)

1.0 to 10 000 cP x g/cm3

VL500 or VL800

Cylinder Type (LV)

0.1 to 1000 cP x g/cm3

VL500 or VL800

Table 2.1 Viscosity Transducer Probe Tip Types

2.2.1 VL500 Viscosity Transducer

The VL500 is shown in Figure 2.2.

Figure 2.2 VL500 Viscosity Transducer

The VL500 is capable of withstanding temperatures between 0°C and 120°C, and is available with cylindrical (shown) or spherical probe tips. It is capable of measuring viscosity over a three-decade range.

The VL500 viscosity transducer is made of NEMA 4-rated 316 Stainless Steel.

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2.2.2 VL800 Viscosity Transducer

The VL800 is shown in Figure 2.3.

Figure 2.3 VL800 Viscosity Transducer

The VL800 is capable of handling sample temperatures between -40°C and 300°C, although temperatures above 200°C require optional air cooling (refer to section 3.7.1). Sample temperatures between 300°C and 450°C can be handled with optional water cooling of the transducer (refer to section 3.7.2). It is available with rod, cylindrical, or spherical (shown) probe tips, and can measure viscosity over a five-decade range. The VL800 transducer is typically made of NEMA 4 rated stainless steel, though other material options are available depending on customer requirements. Please contact Galvanic Applied Sciences Inc. for more information.

2.3 Sensor Cable

The sensor cable is a 3/8” diameter cable that carries power to the viscosity and temperature sensors in the viscosity transducer and signals from these sensors back to the transmitter. The maximum length of this cable is 300 metres. A military spec NEMA-4X MS3102E (Shell size 20) connector OR a ½” NPT cable gland is used to connect the sensor cable to the top of the transducer dome.

Significant changes to the cable length during operation (for example, if the location of the transmitter relative to the sensor needs to be changed) will have a major effect on analyzer readings. Please contact Galvanic Applied Sciences prior to making any changes to the sensor cable length.

2.4 Intrinsically Safe (IS) Barrier If the ViscoSite Viscometer’s viscosity transducer is to be installed in a classified (hazardous) area (Class 1 Division 1), an IS barrier must be connected between the Viscoliner transducer and the transmitter, regardless of where the transmitter is located. The transmitter cannot be installed in Class 1 Division 1 hazardous area. The intrinsically safe barrier is installed in the transmitter enclosure. The IS barrier is shown in figure 2.2

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Figure 2.2 Intrinsically Safe Barrier

The purpose of the IS barrier is to limit the amount of power transferred from the safe area into the hazardous area, such that the power entering the hazardous area is insufficient to cause an explosion by either spark or thermic effects.

Analyzer calibration is carried out with the IS barrier installed. If the intrinsically safe barrier needs to be replaced for any reason, the whole system will require recalibration. Refer to Appendix 2 for the calibration procedure for the viscosity transducer and associated temperature RTDs.

2.5 ViscoSite viscosity transmitter The ViscoSite viscosity transmitter consists of a fibreglass enclosure into which is installed the transmitter motherboard, the transmitter display and keypad on an internal swing panel, the intrinsically safe barrier (if present), and the power supply for the transmitter and transducer. The ViscoSite viscosity transmitter is shown in figure 2.3.

Figure 2.3 ViscoSite viscosity transmitter

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On the bottom of the transmitter are located Ethernet and USB connection ports for connecting the transmitter to a computer either locally (USB) or remotely (Ethernet), as well as glands to allow the connection of power supply and signal cables to the transmitter.

2.5.1 Enclosure The standard transmitter enclosure is a NEMA-4X certified enclosure. It is suitable for installation in Class 1 Division 2 hazardous areas or General Purpose (non-hazardous) areas. ATEX and IECEx certifications are forthcoming. The enclosure has a transparent front panel to allow the operator to observe the analysis results without opening the enclosure. Other enclosure types are available upon request – please contact Galvanic Applied Sciences for more information.

2.5.2 Swing Panel The ViscoSite viscosity transmitter enclosure contains the analyzer display and keypad mounted on a swing panel, as shown in Figure 2.4.

Figure 2.4 Swing Panel front (L) and rear ®

The display is a 4-line x 20 column LCD display that, by default, indicates the calculated viscosity, the transducer probe tip temperature, the transducer dome temperature, and the resonance frequency of the probe. The keypad, below the LCD display, allows the operator to control the operation of the viscosity transmitter and change the transmitter’s operating parameters. At the top of the keypad is a line of four status LEDs which indicate the current status of the viscosity transmitter. The operation of the viscosity transmitter via the keypad is covered in Section 4 of this manual.

If the ViscoSite viscosity transmitter is installed in a Class 1 Division 2 hazardous area, the area MUST be declassified prior to opening the enclosure to operate the keypad. On the reverse side of the swing panel are installed the LCD display’s control electronics board, a ribbon cable connecting to the keypad (grey), and a ribbon cable that connects the display control board to the transmitter’s motherboard (multi-coloured). On the LCD control electronics board there is a potentiometer that can be used to adjust the brightness of the LCD screen (Refer to Figure 2.4).

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2.5.3 Motherboard The ViscoSite viscosity transmitter’s motherboard is located behind the swing panel. If an intrinsically safe barrier is used, it is also installed in this area. The motherboard of the ViscoSite viscosity transmitter is shown in Figure 2.5.

Figure 2.5 ViscoSite motherboard

The ViscoSite motherboard is responsible for all data processing, signal inputs and outputs, and communications. It has two relay (digital) outputs for alarm and status outputs, three analog outputs for analysis output to a control system, an analog input for signal input from an external density sensor, as well as Ethernet, RS232/RS485, and USB communications ports. The transmitter display and keypad, as well as the viscosity transducer, all receive electrical power from the transmitter motherboard.

2.5.4 Power Supply The ViscoSite Viscometer requires either 24VDC or 90-240VAC, 50-60Hz. If AC power is used, an AC-DC power supply is located underneath the transmitter motherboard. An EMI/RF filter is placed in line with the power supply in order to prevent any electrical noise from interfering with the signal from the viscosity transducer.

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Section 3 Installation 3.1 Receiving the System

When the system arrives, inspect the packaging for external signs of damage. If there is any obvious physical damage, contact the shipping agent and Galvanic Applied Sciences to report the damage and request that the carrier's agent be present when the unit is unpacked. It is recommended that you retain the shipping container so that it may be used for future shipment of the unit, if necessary.

3.2 Unpacking

To unpack the system: • Open the shipping container and remove all packing material and boxes. Visually inspect the

system and accessories packages to ensure that no major damage has occurred. If damage has occurred, contact the shipping company and Galvanic Applied Sciences. Place the small packages aside in a safe, secure storage area as they are not needed at this stage of the system installation.

• If any damage is visible do not proceed with the system installation. Do not attempt to facilitate repairs yourself as this will negate and/or invalidate any possible insurance claim or equipment warranty.

Keep the original packing, particularly for the transducer. If for any reason the transducer needs to be shipped back to the factory, it should be shipped back in the original packaging.

Viscosity transducers may be shipped in cardboard or wooden crates, depending on their size. These two types of packing are shown in Figure 3.1.

Figure 3.1 Transducer Packing. Cardboard box (left); wooden crate (right)

DO NOT under any circumstances lift the viscosity transducer by the probe end or allow the transducer to rest on the probe end. This may cause irreparable damage to the viscosity transducer! Lift using the flange or transducer dome end only! Refer to Figure 3.2.

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Figure 3.2 Handling the ViscoSite viscosity transducer

3.3 Installation Requirements

3.3.1 Electrical Requirements

The ViscoSite Viscometer can be powered by 90-240VAC 50/60Hz or 10-32VDC sources. The power requirement is 10W.

3.3.2 Location of the Viscosity Transducer 3.3.2.1 Sample temperature considerations The suitable sample fluid temperature ranges for each model of viscosity transducer are given in sections 2.2.1 and 2.2.2.

3.3.2.2 Vibration Considerations

While the ViscoSite Viscometer can compensate for some line vibration, it is still ideal reduce the vibration at the install point as much as possible. Figure 3.3 shows the vibration tolerance for both the VL500 and the VL800 viscosity transducers.

Figure 3.3 Vibration Tolerance Graph

Probe Oscillation Frequency 400-700Hz

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The installation location should be checked with a vibration analyzer that can determine the deflection and frequency of the pipe vibration. These measurements must be made under normal operating flow conditions, with all normally operating equipment running at the time of the measurement to ensure that the vibration measurement realistically reflects standard process conditions. In order to reduce vibration, the following points should be observed:

• Do not install in a free, unsupported pipe • Provide valves to control flow rate, as a lower flow rate results in less pipe vibration • Mount the transducer to the suction side of a pump • Install rigid floor supports for pipes • Ensure that pumps are balanced and shocks are properly installed • Install transducer either upstream or as far away downstream as possible from

mechanical noise sources such as pumps, motors, agitators, and moving machinery.

• Load pipe with a mass to dampen the vibration • Double clamp sections of pipe that show flexing • Install intermediate supports in long run pipes • Secure vertical pipes to major beams.

If vibration cannot be minimized to acceptable levels according to Figure 3.1, the transducer must be isolated from the sources of shock by installing a bypass line as shown in Figure 3.4.

Figure 3.4 Installation on Bypass Line

If a bypass line is installed, rigid supports should be included for the transducer. Flex hoses or expansion joints should aid in reducing vibration in the bypass line.

3.3.2.3 Flow Considerations

While the transducer can be installed horizontally, vertically, or at any angle, it is very important that the probe points into the sample flow, in order to minimize stagnant flow and trapped air. The sensor must be immersed in representative material. If the flow rate of the sample fluid is high, and/or the viscosity of the sample fluid is high, to prevent damage to the probe the transducer should NOT be installed perpendicular to the direction of flow, but rather parallel as indicated in Figure 3.4. Figure 3.5 shows not recommended and preferred mounting for the viscosity transducer.

Viscosity transducer on bypass line

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Figure 3.5 Not Recommended and Preferred Transducer Mounting

3.3.2.4 Other Transducer Installation Location Considerations

• It is preferable to mount in reactors and their outlet pipes • The viscosity transducer should be installed away from pumps and equipment

that generates magnetic fields. • If the sample fluid is very high temperature, air (sample temperature 200-300°C)

or water (>300°C) is required for transducer cooling, so ensure that there is cooling fluid available near the mounting location. The air must be clean and dry.

• The sample fluid should ideally not contain large solids, as these could damage the transducer probe. If it does, an optional probe guard should be installed on the transducer probe, as shown in Figure 3.6.

Figure 3.6 Viscosity transducer probe guard

3.3.3 Location of the ViscoSite Transmitter

The ViscoSite transmitter is designed to be operated at ambient temperatures from 0°C to 50°C. The transmitter should be mounted in a location where it is not exposed to direct sunshine or rainfall. It should also be installed in a location where the vibration is not excessive. Further, it should be located no more than 300 metres from the viscosity transducer install point (less if the signal cable cannot travel in a straight line from the transducer to the transmitter).

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3.3.4 Space Requirements

The dimensions of the ViscoSite transmitter are given in Figure 3.7.

Figure 3.7 ViscoSite Transmitter Dimensions

Be sure to leave space below the transmitter to allow for the connection of signal wires, power wires, and communication wires to the transmitter, and space to the left of the transmitter to allow the enclosure door to open fully.

3.3.5 Hazardous Area Classification Information Transmitter: Class 1, Division 2 Groups B, C, D ATEX / IECEx EEx G3 nC IIC T4 (Future) Transducer Class 1 Division 1 Groups B, C, D ATEX 1G EEX ia IIB T3 (VL800 only)

3.4 Transducer Installation

Once a suitable location has been chosen for the installation of the transducer (refer to section 3.3.2), it should be installed. The viscosity transducer may have a flange mount, a sanitary mount, or a threaded mount depending on the specific customer requirements.

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3.4.1 Flange Mount Installation

Install a flange gasket between the transducer and the pipe or vessel flange. Lift the transducer by the flange or the dome (DO NOT LIFT BY THE PROBE!) and install the transducer on the pipe or vessel flange. Always tighten the flange mounting bolts in a staggered, cross-wise fashion to ensure evenly spread non-changing stress on the flange face surface. Bolts should be well lubricated and should be torqued to 50% of bolt yield stress for appropriately well-lubricated bolts. If the transducer has been removed for cleaning, when re-installing the transducer, be sure to re-install it with the same orientation as it had prior to removal. There is a ^ marking on the transducer flange that can be used as a reference point, as shown in figure 3.8.

Figure 3.8 Transducer Orientation Flange Marking

By ensuring the transducer is always installed with the same orientation, this should lead to a consistent coupling effect and minimize Zero adjustment occurrences.

If the transducer must be installed near magnetic field generating equipment (such as pumps), rotating this marking by 90° may eliminate magnetic interference.

3.4.2 Sanitary Mount Installation

If the system must be disassembled for cleaning, or meet FDA sanitary code clean-in-place requirements, the viscosity transducer will be equipped with a sanitary mount. As sanitary piping is generally not well supported, the pipe surrounding the transducer mount must be secured in a stable manner; several pipe supports on the incoming and outgoing piping rigidly attaching it to a nearby floor, wall, or I beam are generally needed. If the process pipe cannot be suitably secured, an optional Sanitary Sample Cell can be used to ensure a stable, stress free mounting.

For sanitary clamps, follow the clamp manufacturer’s guidelines for minimum torque. A clamp which is not secured properly may lead to unstable measurement.

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3.4.3 Threaded Transducer Mount

For high temperature, high pressure sample applications, and in situations where stagnant regions in the flow cannot be tolerated, a threaded transducer mount is used. The threaded transducer mount eliminates the stagnant region of flow in a standard flange mount by flush mounting the probe into the flow. Prior to installing the transducer, the threads should be coated with Dow Corning Molykote ® P37 or equivalent anti-seize paste.

Care must be taken during installation to eliminate thread galling during installation and removal. Use the included wrench to install the transducer. Use of other methods to install the transducer (pipe wrenches, etc) will invalidate the instrument warranty.

Do not install the transducer more than five turns into the mating connector. Take care during installation and removal of the transducer to avoid damaging the threads. DO NOT OVERTIGHTEN.

3.5 Transmitter Installation The transmitter should be installed in a suitable location. It should be installed out of direct sunlight and in a location where the ambient temperature range does not exceed 0-60°C. If the ambient temperature range expected at the installation site falls outside this range, the transmitter should be installed in a temperature-controlled enclosure or shelter. Connections for power and signals (relay and analog output) must be available.

3.6 Sensor Cable Installation The sensor cable should be run through conduit from the transmitter to the transducer. No rigid connection should be made to the transducer, so the sensor cable must exit the rigid conduit and travel through flexible metal conduit (e.g. Sealtite NDA ½” type, minimum length 2’) before connecting to the transducer. The cable connector on the transducer should be sprayed with contact cleaner/moisture repellant before connecting the cable. Securely fasten the cable to the transducer using the screw fitting on the cable. Figure 3.9 shows a schematic of the transducer cable installation.

Figure 3.9 Connecting cable to transducer

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If the provided cable is too long, DO NOT attempt to cut it. Cutting the cable will affect the calibration of the analyzer, and will give results that are not accurate. Simply neatly wrap up the excess cable length. It is best to determine the installation points for the transducer and transmitter prior to ordering the system so that a correct length of cable can be specified at the time of ordering.

3.6.1 Transmitter connections – no IS Barrier The sensor cable should enter the transmitter enclosure through one of the cable glands on the bottom of the transmitter. If the transmitter is not equipped with an IS Barrier (refer to section 2.4), the sensor cable is wired directly to the transmitter motherboard terminal blocks J10 (transducer temperature RTDs) and J9 (viscosity sensor). The sensor cable wires are labeled with numbers and colour-coded. Connections are shown in table 3.1.

Terminal Block

Terminal Number

Wire Number

Wire Colour Function

J11

1 1 Green Sensor 2 2 Black Sensor 3 3 Orange Sensor 4 4 Red Sensor 5 5 White Sensor

J10

1 6 Red/Black Probe RTD 2 7 White/Black Probe RTD 3 8 Green/Black Probe RTD 4 9 Black/Red Transducer Block RTD

(VL800 only) 5 10 Black/White Transducer Block RTD

(VL800 only) 6 11 Black/Green Transducer Block RTD

(VL800 only)

Table 3.1 Transmitter Motherboard Sensor Cable Connections

3.6.2 Transmitter Connections – IS Barrier If the transmitter is equipped with an IS Barrier (refer to section 2.4), the connections between the motherboard terminal blocks J9 and J10 and the non-intrinsically safe side of the IS barrier are made at the factory. The sensor cable is connected to the intrinsically safe side according to Figure 3.10 (VL500 transducer) or Figure 3.11 (VL800 transducer).

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Figure 3.10 Intrinsically Safe Barrier Connection for VL500 Sensor Cable

Figure 3.11 Intrinsically Safe Barrier Connections for VL800 Sensor Cable

3.7 Transducer Coil Cooling Lines (Optional) The electromagnetic coils in the VL800 transducer are rated for continuous operation between -40°C and 232°C. Natural cooling of the transducer permits use in applications where the process temperature is slightly above the maximum coil temperature rating, though the transducer dome temperature should never be allowed to exceed 230°C.

DO NOT use water to spray down the transducer dome of a transducer whose dome temperature is reading above 230°C. This can cause thermal shock to the transducer coils and could lead to permanent, irreparable damage to the transducer.

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3.7.1 Air Cooling If the process temperature is between 250°C and 300°C, air cooling is required to keep the coil temperatures below 230°C. There are cooling channels for air circulation provided inside the transducer dome. Generally, air pressure of around 5psi is sufficient to keep the coil temperatures at a suitable level. Supply air is connected to the cooling channel via 1/8” NPT brass fittings (shipped separately; cooling connections are shipped with plugs installed to prevent exposure to rain, moisture, or ambient air) which must first be installed. Use Teflon tape on the fitting threads. The location of the fittings is shown at position “B” in the drawing in Figure 3.12.

Figure 3.12 Location of air cooling connections on transducer

The supplied cooling air must be dry, moisture free, and enter and exit through flexible tubing or hoses. No stress should be applied to the transducer from these hoses. A typical instillation is shown in Figure 3.13.

Figure 3.13 Installation of Air Cooling for Transducer

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The transducer electromagnetic coils are not hermitically sealed from the cooling channel, and therefore to prevent damage to the coils the cooling gas (air or inert gas such as nitrogen) must be clean and dry. The air cooling channel must not be exposed to ambient air, moisture, or rain.

3.7.2 Water Cooling

If the process temperature exceeds 300°C, water cooling channels are provided for water circulation to ensure that the magnetic coils in the transducer block remain below 230°C, regardless of the process temperature. Low pressure water is generally sufficient. Supply water is connected to the cooling channel via 1/8” NPT brass fittings (shipped separately; cooling connections are shipped with plugs installed to prevent exposure to rain, moisture, or dirt) which must first be installed. Use Teflon tape on the fitting threads. Several ports are provided for location convenience, though only two ports are required. The chosen ports should be located opposite each other. The supplied cooling water must enter and exit through flexible tubing or hoses. No stress should be applied to the transducer from these hoses. A typical instillation is shown in Figure 3.14.

Figure 3.14 Installation of water cooling for transducer

Air cooling and water cooling ports are similar (1/8” NPT fittings). DO NOT apply water to air cooling ports!

3.8 Communications Connections The ViscoSite transmitter is equipped with 3 analog outputs, 1 analog input, 2 digital relay outputs, 1 RS232c/485 serial output, 1 USB Type-B connection port, and one Ethernet connection port. If no IS barrier is present, the USB and Ethernet connection ports are on the bottom side of the enclosure and can be accessed even while the area is classified, while all other connections are made at the analyzer motherboard and can only be accessed while the area is known to be safe. The communications connection ports and glands on the bottom of the transmitter can be seen in figure 3.15.

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Figure 3.15 Transmitter Communications Connections (no IS Barrier)

The Ethernet port is visible at the top left in Figure 3.15, the USB Type-B port is directly in the centre of image, and the remaining ports are cable glands to connect power, transducer, and communications cables to the transmitter. If an IS barrier is present in the transmitter enclosure, the orientation of the motherboard is changed such that the Ethernet cable passes through a cable gland on the right hand side of the enclosure and connects directly to the Ethernet port on the motherboard. The communication cables should pass through the glands on the right hand side of the bottom of the transmitter. The Ethernet, USB, and RS232/485 communications ports all use the Modbus RTU protocol with Master-Slave communication, with a 100ms delay between messages as needed.

3.8.1 Analog Outputs There are three isolated analog output channels on the ViscoSite transmitter motherboard, found at terminal blocks J6, J7, and J8. These analog output channels are self-powered three-wire analog outputs, and can be configured in the ViscoSite GUI (refer to Section 5) to ouput 0-20mA, 4-20mA, 0-10VDC, or 2-10VDC. The parameters output on each channel can also be selected in the ViscoSite GUI. Install the required analog output cables to the transmitter according to Table 3.2.

Terminal Block

Analog Output Channel

Pin Number

Function

J6

1

1 Current Out (+) 2 Current Out (-) 3 Voltage Out (0-10VDC or 2-10VDC) 4 Ground

J7

2


J8

3


Table 3.2 Analog Output Wiring for Transmitter

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3.8.2 Analog Input

The ViscoSite transmitter motherboard has one isolated analog input channel used for the input of a 4-20mA signal from an external density transducer. This density transducer signal is connected at terminal block J9. The wiring of the signal cable from the density transducer should be connected according to Table 3.3.

Pin Number Function 1 Density 4-20mA (-) 2 Density 4-20mA (+)

Table 3.3 Analog Input Wiring from Density Transducer If no density transducer is present, nothing should be connected to this terminal block. In addition, a static density should be entered into the GUI according to the typical density of the sample stream (refer to Section 5).

3.8.3 Digital Outputs

The ViscoSite transmitter motherboard has two digital (relay) outputs whose functions can be configured in the ViscoSite GUI (refer to Section 5). These relays can be used to output status and alarm information. The relay connections are found on the transmitter motherboard terminal block J5. Install the wires to the required relays according to the information in table 3.4.

Pin Number Function 1 Relay 1: Common 2 Relay 1: Normally Closed (NC) 3 Relay 1: Normally Open (NO) 4 Relay 2: Common 5 Relay 2: NC 6 Relay 2: NO

Table 3.4 Relay Wiring for Transmitter

3.8.4 Serial Communications The ViscoSite transmitter motherboard has one combined RS232/485 serial communications port, motherboard terminal block J12, to which analyzer data is always sent. The RS232/485 port is output only, and cannot be used for remotely changing analyzer parameters via the GUI. The RS232/485 port is typically used for Modbus communication. Signal cables for serial communication should be installed according to the information in table 3.5. The serial port type is configured via the transmitter’s keypad (refer to section 4.6.2).

Pin Number Function 1 RS232c Transmit / RS485 (+) 2 RS485 (-) 3 RS232c Receive 4 Ground

Table 3.5 Serial Port Wiring

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3.8.5 USB Port

The external USB Type-A port is used for a direct local connection between the ViscoSite transmitter and a local computer. When a USB Type-A to Type-A cable (included with the system) is connected between the transmitter and the local computer, the GUI software (refer to Section 5) can be used to make local configuration changes.

When a USB connection to a local computer AND an Ethernet connection to a remote computer are both present, commands from the remote computer will be locked out until the USB connection is broken. However, there is no lockout between the USB channel and the transmitter’s keypad (refer to Section 4) as these are both considered to be local, so parameter changes can be made via USB or Keypad while a USB connection is present.

To connect to either the USB or the Ethernet port, a virtual COM port is required.

3.8.6 Ethernet Port

The external Ethernet port is used to establish a connection between a remote computer and the ViscoSite transmitter. An Ethernet connection cannot be established by simply connecting an Ethernet cable from the Ethernet port on the transmitter to the Ethernet port on a local computer – the Ethernet port on the transmitter must be connected to a local area network (LAN). The network settings, including the IP address, for the transmitter are configured via the keypad (refer to section 4.6.1). This IP address can then be used to connect to the transmitter from a remote computer via the GUI software (refer to Section 5) or for Modbus communication (refer to Appendix 1).

When a USB connection to a local computer AND an Ethernet connection to a remote computer are both present, commands from the remote computer will be locked out until the USB connection is broken. Further, commands sent to the Ethernet port will be locked out until no button has been pressed on the transmitter keypad for at least 3 minutes.

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Section 4 Keypad Operation

4.1 Introduction

The front panel of the ViscoSite transmitter includes a series of LEDs and an LCD screen which provides information about the status of the viscometer system. In addition, below the screen is a membrane keypad which can be used to view/edit a variety of viscometer settings and analytical results. The ViscoSite transmitter can also be configured using a personal computer running the ViscoSite GUI software, as discussed in Section 5. The overall operation of the ViscoSite viscometer system is controlled by the parameters that are stored in the motherboard memory. These parameters can be changed either via the keypad or the GUI software.

4.2 LCD Screen

At the top of the swing panel is an LCD screen that is used to display the viscometer’s current measurement results and, in conjunction with the keypad, to locally modify and display a variety of operating parameters. The default screen configuration is shown in Figure 4.1.

Figure 4.1 Default Screen Configuration

By default, the screen outputs four measurement results – the calculated viscosity, the transducer probe temperature, the transducer dome (coil) temperature, and the vibrational frequency of the probe. The displayed parameters, as well as their measurement units, can be configured via either the keypad or via the GUI software. The display can also be configured to alternate between a primary and a secondary display parameter for each line. In the case of an alarm situation, the display can be configured to output alarm status information using the GUI software.

4.3 Keypad and Status LEDs

Below the LCD display is a membrane keypad that can be used to enter data, make changes to the viscometer’s operating parameters, and display status information.

The keypad is located inside the ViscoSite transmitter’s enclosure, and as such may ONLY be accessed if the area is known to be safe. DO NOT open the transmitter UNLESS the area has been de-classified and is known to be non-hazardous.

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The keypad and the status LEDs are shown in Figure 4.2.

Figure 4.2 ViscoSite Transmitter Keypad and Status LEDs

4.3.1 Keypad

The numerical keys and the decimal point key are used for data entry. The functions of the other buttons on the keypad are given in Table 4.1.

Button Label Function

ESC Exit out of a menu OR exit out of an editable parameter without saving changes.

Display Setup Accesses the Display Setup menu, allowing user to configure the parameters displayed on the transmitter’s LCD screen. Refer to section 4.4.

Output Config Accesses the Output Configuration menu, allowing user to configure the three on-board analog outputs and the two on-board digital (Relay) outputs. Refer to section 4.5.

Option Setup Accesses the Option Setup menu, allowing the user to configure other parameters that affect the operation of the viscometer. Refer to section 4.6.

BACK SPACE Removes one character in a data entry field with each press

↑ (Up Arrow) On main screen, toggles between primary and secondary display parameters. In menus, moves up one line in the menu. In an editable parameter with multiple choices, cycles through available options.

↓ (Down Arrow) On main screen, toggles between primary and secondary display parameters. In menus, moves down one line in the menu. In an editable parameter with multiple choices, cycles through available options.

ENTER Selects an option within a menu. Saves a data point just entered. A second enter press after saving returns to the previous screen.

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Table 4.1 Keypad Key Functions

4.3.2 Status LEDs Above the keypad is a row of four LEDs that are used to provide at-a-glance status information about the operation of the viscometer. The LEDs’ functions are given in Table 4.2

Label Colour Function

FAULT Red ON – Error Detected BLINK – Information being saved to transmitter OFF – No Errors

COMM Green BLINK – Indicates communication in progress (Transmit or Receive) on any communication port OFF – No communication

TUNED Green ON – Probe oscillation is tuned to the correct frequency OFF – Probe oscillation not tuned

POWER Green ON – Power is available OFF – No Power available

Table 4.2 Front Panel Status LEDs

4.4 Display Setup Menu The Display Setup menu, accessed by pressing the “Display Setup” button on the front panel keypad, allows the user to configure the parameters displayed on the transmitter’s LCD display, both in terms of which parameters are displayed and also in terms of which units they are displayed in. From the default screen (Figure 4.1), when the “Display Setup” button is pressed, the menu screen shown in Figure 4.3 is shown.

Figure 4.3 Display Setup Menu screen

The currently selected parameter has a cursor under its first letter (note the circled M in Figure 4.3 has a line under it). While within a menu, the following commands can be used:

• ENTER – opens the currently selected menu • ESC – returns to the main screen of the display. After returning to the main screen, the red

‘FAULT’ LED will illuminate for a few moments indicating that the analyzer is writing any changes to memory.

• Up / Down keys – move cursor from one selection to the next.

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4.4.1 Main Display menu

When ENTER is pressed when ‘Main Display’ is selected, the Main Display menu shown in figure 4.4 will open.

Figure 4.4 Display Setup Menu – Line Setup

Once again, the currently selected parameter is indicated by a cursor under the first letter of the line. It can be changed by pushing the up or down keys, allowing the user to select among the parameters shown in Table 4.3 to modify for each line of the default display. Pressing ENTER will allow the user to modify the value for a given parameter. The cursor will then move to the end of the selected line, indicating that the parameter can be edited. The L followed by a number from 1 to 4 indicates which line of the display is being modified.

Parameter Meaning Selectable Values

‘Pri’ - Primarily Displayed

Parameter displayed on the selected line by

default

None (Nothing displayed on this line) Density

Viscosity Temp Probe (transducer probe temperature) Temp Dome (transducer dome temperature) Temp Elec (Transmitter internal temperature)

Freq (oscillation frequency of probe) Temp Cp Vis (Temperature compensated

viscosity)

‘Sec’ - Secondarily Displayed

Parameter displayed on the given line by pressing the up or

down arrow key from the default screen

Table 4.3 Editable Parameters for Each Line of the Display

The selectable values can be scrolled through by pressing the Up or Down arrow keys. Press ENTER to choose the desired value, and press ENTER again to save the selection to the transmitter’s memory. The cursor will then return to the beginning of the line, allowing the user to then select a new parameter for editing. Pressing ESC while the cursor is at the end of the line will allow the user to exit the currently selected parameter without editing it. Pressing ESC from within the Main Display menu when not currently editing a parameter will return to the Display Setup menu. The display can also be configured via the GUI – refer to section 5.5.1.

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4.4.2 Alarms Display menu When ENTER is pressed when ‘Alarms Display’ is selected, the screen shown in figure 4.5 is shown.

Figure 4.5 Alarms Display menu

This screen allows the user to select the line of the screen on which an alarm is displayed, as well as the method used for alarm presentation on the transmitter display. Selecting any of the parameters marked ‘LINE X’, where X is a number from 1 to 4 representing the four lines of the transmitter display, will allow the user to choose which line to display an alarm on. The ‘Method’ parameter allows the user to choose the display behaviour for a given alarm. There are three choices – Steady, Blinking, or Alternating:

• Steady – The chosen alarm parameter will stay displayed on the given line until the alarm is cleared

• Blinking - The chosen alarm parameter will blink on the given line until the alarm is cleared

• Alternating – The chosen alarm parameter will alternate with the chosen display parameter for the given line.

Please note that the actual alarm parameter and the alarm limits cannot be set from the keypad – they must be set in the GUI. Refer to section 5.5.3. Pressing ESC from the Alarms Display menu when not currently editing a parameter will return to the main Display Setup menu.

4.4.3 Display Units menu When ENTER is pressed when ‘Display Units’ is selected, the screen shown in Figure 4.6 is shown.

Figure 4.6 Display Units menu

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This screen allows the user to select the measurement units used for each type of parameter. Pressing ENTER on a selected parameter will allow the user to edit the measurement unit for that parameter by using the Up and Down keys. The choices allowed for each type of parameter’s measurement units are shown in Table 4.4.

Parameter Selectable Units Viscosity cP x g/cm3 (centipoise multiplied by

density) mPas (millipascals multiplied by seconds)

cP (centipoise) cSt (centistoke)

Density g/cm3 Temperature °C

°F Distance Meters

Feet

Table 4.4 Selectable Units for each Measurement Parameter

The measurement units can also be set in the GUI software – refer to section 5.5.2. Pressing ESC when inside the Display Units menu, as long as the user is not currently editing a parameter, will return to the main Display Setup menu.

4.5 Output Configuration Menu

The Output Configuration menu, accessed by pushing the Output Config button, allows the user to configure the three analog outputs and two digital (relay) outputs on the transmitter motherboard. From the default screen (Figure 4.1), when the Output Config button is pushed, the menu shown in Figure 4.7 is displayed. Navigation within the menu can be accomplished by pressing the Up/Down arrow keys.

Figure 4.7 Output Configuration Menu

4.5.1 Analog Output Configuration

The channel (Analog #1, #2, or #3) that the user wishes to configure can be changed by pressing the Up or Down arrow keys. Once the desired channel has been selected, press ENTER to enter the setup screen for that Analog output, as shown in Figure 4.8.

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Figure 4.8 Analog Output Configuration

Figure 4.8 shows the four parameters that can be edited for each of the three analog outputs. Parameters can be edited by selecting the parameter for editing with the Up/Down arrow keys, then pressing ENTER. Press ESC to exit editing a parameter without saving. The editing can be accomplished by either using the Up/Down keys or by using the numerical keypad. Once editing is complete, press ENTER to save changes. These parameters are explained in Table 4.5. Parameter Meaning Selectable Values

MODE Type of signal output by the analog output

Current 4-20 (mA) Voltage 0-10 (VDC) Current 0-20 (mA)

Voltage 2-10 (VDC)

MEASURE Parameter output

on the given analog output

None (nothing output on this channel) Density

Viscosity Temp Probe (transducer probe temperature) Temp Dome (transducer dome temperature)

Temp Elec (transmitter enclosure temperature)

Min

Numerical value that corresponds to the minimum value on the signal scale (current or voltage)

Value can be entered using the keypad. Press ENTER to accept the input value.

Max

Numerical value that corresponds to the maximum value on the signal scale (current or voltage)


Table 4.5 Analog Output Configuration The analog outputs can also be configured in the GUI software – refer to section 5.6.1. Pressing ESC when inside the Analog Output configuration menu, as long as the user is not currently editing a parameter, will return to the main Output Configuration menu.

4.5.2 Relay Configuration The channel (Relay #1 or #2) that the user wishes to configure can be changed by pressing the Up or Down arrow keys. Once the desired channel has been selected, press ENTER to enter the setup screen for that relay, as shown in Figure 4.9.

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Figure 4.9 Relay Configuration

Figure 4.9 shows the three parameters that can be edited for each of the three analog outputs. Parameters can be edited by selecting the parameter for editing with the Up/Down arrow keys, then pressing ENTER. Press ESC to exit editing a parameter without saving. The editing can be accomplished by either using the Up/Down keys or by using the numerical keypad. Once editing is complete, press ENTER to save changes. These parameters are explained in Table 4.6. Parameter Meaning Selectable Values

MEASURE Parameter alarm

output on the given relay

None (nothing output on this channel) Density

Viscosity Temp Probe (transducer probe temperature) Temp Dome (transducer dome temperature)

Temp Elec (transmitter enclosure temperature)

Min

Low alarm value – any value below this threshold will trigger the relay


Max

High alarm value – any value above this threshold will trigger the relay


Table 4.6 Relay Configuration

The relays can also be configured in the GUI software – refer to section 5.6.2. The GUI software configuration also allows the user to configure the relay behaviour on alarm. Pressing ESC when inside the Relay configuration menu, as long as the user is not currently editing a parameter, will return to the main Output Configuration menu.

4.6 Option Setup Menu

The Option Setup menu, accessed by pressing the Option Setup key, allows the user to configure some optional parameters that affect the operation of the viscometer. When the Option Setup key is pressed, the menu shown in Figure 4.10 is presented.

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Figure 4.10 Option Setup Menu

The parameters that can be edited in the Option Setup menu are shown in Table 4.7. Moving from one parameter to the next is accomplished by using the Up/Down arrow keys. Press the ENTER key to select a parameter for editing.

Parameter Options Explanation

Density

Auto The density used by the system is a live 4-20mA signal from an attached density transducer.

Manual

The density used by the system is a value entered manually into the GUI software (refer to section 5.7.1). IF NO DENSITY TRANSDUCER IS PRESENT, THIS OPTION MUST BE SELECTED.

Nom Temp

The normal temperature of the sample stream. This is used for temperature compensated viscosity. Enter in a value using the keypad. More information must be entered into the GUI for this to work correctly. Refer to section 5.7.2.

Time Avg Enabled

The calculated viscosity is an average of a user selected time window’s worth of viscosity data. The width of the time window is set in the GUI software (refer to section 5.7.3) or in this menu.

Disabled The calculated viscosity is a live value with no averaging applied.

Avg Time Width of the time window used for averaging of the viscosity reading.

Table 4.7 Options Setup Menu editable parameters When a parameter is selected for editing by pressing the ENTER key, the editing can be accomplished by either pressing the Up/Down keys to toggle between possible options, or by using the keypad to edit numerical values. When editing is complete, press ENTER to save the edited value to the transmitter. Press ESC to leave a parameter without saving. At the bottom of the Option Setup menu are two sub-menus: Network Setup and COM setup.

4.6.1 Network Setup

The Network Setup submenu, used for configuring the ViscoSite transmitter for communication across a Local Area Network (LAN) is shown in Figure 4.11.

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Figure 4.11 Network Setup submenu

In order for the LAN setup to work correctly, the ViscoSite transmitter must be connected to a wired LAN via the transmitter’s Ethernet port. There are three options that must be configured for Ethernet communication to work correctly.

• IP – the IP address of the transmitter • GW – the IP address of the network gateway • Subnet – the subnet mask for the network

These values should be set in consultation with the IT department at the user’s facility. Incorrectly setting these values will result in the transmitter being unable to communicate across the network. Use the keypad, including the decimal point key (“.”) in order to enter the values for these three parameters. Press ENTER to save the edited parameter. Press the ESC key to leave a parameter without saving. Press ESC when not editing a parameter to exit back to the main Option Setup menu.

4.6.2 COM Setup The COM Setup submenu, used for configuring the serial port on the ViscoSite transmitter’s motherboard, is shown in figure 4.12.

Figure 4.12 COM Setup submenu

In this menu, the serial port can be configured as either RS485 or as RS232. This setting can be toggled by pressing ENTER, then using the Up/Down arrow keys to toggle between the two choices. Press ENTER to save the desired value to the transmitter. Press ESC to leave the editing without saving changes. The choice of RS485 or RS232 will depend on the facility’s specific needs. Cycle power from transmitter to finish configuring changes. Pressing ESC while not editing this parameter will return to the main Option Setup menu.

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Section 5 Software Operation The GUI (Graphical User Interface) software can be configured to connect to the ViscoSite viscometer either on a local PC via USB or a remote PC via Ethernet or serial (RS232c/485).

5.1 GUI Home Page

This discussion assumes that the ViscoSite transmitter has been connected to a personal computer, either locally or remotely. The hardware connections between the transmitter and a computer are discussed in Sections 3.8.4, 3.8.5, and 3.8.6. The GUI is a Microsoft Windows®-based application program which allows the operator to set a broad range of operating parameters for the ViscoSite viscometer, including instrument calibration and validation. When the program is first opened, the window shown in Figure 5.1 is presented.

Figure 5.1 GUI Software Home Page

The home page has three main buttons, described below.

• Connect / Disconnect – Pressing this button will open the Connection dialog box, allowing the user to choose which viscometer to connect to. Refer to section 5.4 for more details about connecting the GUI to a viscometer. If the GUI is currently connected to a viscometer, this button will be labeled “Disconnect” and pressing it will break the connection between the PC and the analyzer.

• Enter Password – pressing this button will open the Enter Password dialog box, allowing the user to enter into a higher access level for the GUI. The various access levels and passwords are discussed in Section 5.3.

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• Change Password – pressing this button will open the Change Password dialog box, allowing the user to change the passwords protecting the higher access levels for the GUI. The various access levels and passwords are discussed in section 5.3.

5.2 Toolbar

At the bottom of every page of the GUI is located the toolbar. The toolbar is shown in Figure 5.2.

Figure 5.2 Toolbar

The toolbar is used for navigation between the various pages of the GUI. In certain access levels it has more buttons than are shown in figure 5.2. The buttons in the toolbar are as follows.

• Home Page – returns to the home page of the GUI (section 5.1) • Display Setup - goes to the display setup page of the GUI, allowing the user to configure the

transmitter’s LCD display. See section 5.5. • Output Config – goes to the Output Configuration page of the GUI, allowing the user to

configure the transmitter’s analog and digital (relay) outputs. See section 5.6. • Option Setup – goes to the Option Setup page of the GUI, allowing the user to change a

variety of parameters that affect the operation of the viscometer. See section 5.7. • Exit - causes the GUI to close.

5.3 GUI Access Levels

The ViscoSite GUI has three access levels – read-only, update, and factory. Each of these access levels has different access permissions within the GUI, and the latter two are password-protected. In order to enter the password, the user must first go to the Home Page and then press the “Enter Password” button. Pressing this button brings up the prompt shown in Figure 5.3.

Figure 5.3 Enter Password prompt

The user can then enter the password for the desired access level and then click “OK”. If the entered password is incorrect, the prompt displays the message shown in Figure 5.4.

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Figure 5.4 Invalid Password message

5.3.1 Operator When the GUI is connected to the transmitter at the operator access level, the operator is able to look at the configurations on each page of the GUI, but is unable to make any changes to these configurations. No password is required for this access level.

5.3.2 Technician

When the GUI is connected to the transmitter at the technician access level, the operator is able to look at and make changes to the configuration in the three setup pages shown in the toolbar in Figure 5.2. See Section 6 for information on making changes to the system using the GUI. The default password for this access level is the transmitter serial number.

5.3.3 Factory

When the GUI is connected to the transmitter at the factory access level, the operator is able to look at and make changes to the configuration in the three setup pages shown in the toolbar in Figure 5.2. In addition, when the correct factory password is entered, the toolbar changes to the one shown in Figure 5.5. The factory access level should only be given to those who are trained in the operation of this ViscoSite viscometer.

Figure 5.5 Factory Access Level Toolbar

The two additional pages listed on the factory access level toolbar – Calibration and Engineering – are described in Sections 5.8 and 5.9 respectively.

5.3.4 Changing a Password

It is a good idea to change the access passwords for the password-protected access levels to prevent unauthorized access. In order to change passwords, from the Home Page press the ‘Change Password’ button. If the button is greyed out as in Figure 5.1, first enter in one of the elevated access level passwords and the ‘Change Password’ button will then become active. Pressing this button will bring up the prompt shown in figure 5.6.

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Figure 5.6 Change Password prompt

The original password for the password being changed must be first entered into the ‘Original Password’ box, and then the new password must be entered twice. If the password in the ‘Retype Password’ box doesn’t match the one in the ‘Password’ box, the password will not be changed. Putting a check in the ‘Clear Password’ box will clear the password for this access level and allow editing access without password entry. Press OK to complete the process of changing the password. In order to re-enter a password after the password has been cleared, press the ‘Change Password’ button again. The same prompt as in Figure 5.6 will again appear, but the ‘Original Password’ box will be greyed out. Enter the new password into the two text fields in the ‘New Password’ section, again ensuring that the passwords typed into the ‘Password’ and ‘Retype Password’ fields are the same.

5.4 Connect to Viscometer

Once the ViscoSite transmitter has been connected to a computer, either locally via USB or remotely via Ethernet or serial connection, and the GUI has been opened, it is possible to connect the GUI to the transmitter. From the Home Page, pressing the “Connect” button will bring up the “Select Port” prompt shown in Figure 5.7.

Figure 5.7 Select Port prompt

This prompt will show all of the COM ports that are available to connect to. Click on the desired COM port and press “OK”. The GUI will then connect to the ViscoSite transmitter on the chosen COM port. Depending on the type of communication port being used (USB, Ethernet, or Serial) connection may take some time. Pressing the “Loopback” button in the Select Port prompt will allow the user to access the other windows of the GUI without connecting the PC to a ViscoSite transmitter. When a connection has been established, a small icon will appear in the bottom left corner of the GUI window that indicates that the GUI is connected to a ViscoSite transmitter – refer to Figure 5.8.

Figure 5.8 GUI Toolbar showing Connection indicator

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Hovering the mouse pointer over this connection indicator will show a label that indicates the COM port that the GUI is connected to, also as seen in Figure 5.8.

5.5 Display Setup page

From anywhere in the GUI, pressing the “Display Setup” button on the toolbar will bring up the Display setup page. The Display Setup page is shown in Figure 5.9

Figure 5.9 Display Setup Page

The Display Setup page is divided into three regions – Main Display, Display Units, and Alarms Display.

5.5.1 Main Display

The Main Display section of the Display setup page is used to set up the transmitter’s local LCD display. It is very similar to the configuration menu accessed by pressing the transmitter keypad’s “Display Setup” button (refer to Section 4.4). The main Display section is shown in Figure 5.10.

Figure 5.10 Main Display setup

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The main display section consists of a table with three columns. The first column, titled “Line” indicates the line of the display being configured (1 to 4). The numbers in the cells of this column cannot be edited. The second column, “Primary Display”, indicates the parameters that are being output on each line of the LCD display as the primary display values. The default values for this column are shown in Figure 5.10. The third column, “Secondary Display”, indicates the parameters that are being output to each Line as the secondary display values. By default, there are no parameters configured to output as secondary display values. The parameter output as a primary and secondary display value for each line can be edited by clicking twice on the cell to be edited. When the desired cell is clicked on the first time, a downward triangle will appear at the right edge of the cell. When the cell is clicked on again a drop-down menu like the one shown in Figure 5.10 opens, giving a list of possible output parameters. Simply click on the desired parameter to select it. The possible output parameters are explained in Table 5.1.

Parameter Explanation Blank Nothing output on this line if this option is selected

Viscosity Current calculated viscosity Temp Probe Temperature measured by the transducer probe RTD Temp Dome Temperature measured by the transducer dome RTD Temp Elec Temperature measured inside the transmitter enclosure Frequency Current oscillation frequency of probe

Temp Comp Visc Measured viscosity compensated for sample temperature

Table 5.1 Possible Display Output Parameters

Note that the secondary display parameter output style (refer to Table 4.3) cannot be configured from the GUI – it must be configured from the transmitter’s keypad.

5.5.2 Display Units The Display Units section of the Display Setup page is used to configure the measurement units used for the variety of measurements made by the ViscoSite viscometer. The Display Units section is shown in Figure 5.11.

Figure 5.11 Display Units setup

The measurement parameters each have user-selectable measurement units. The only measurement units that cannot be changed are the units for density, which can only be in grams per cubic centimetre (g/cm3). The units that can be chosen for the other measurement parameters are shown below.

• Viscosity: cP x g/cm3 (default), cP, mPa∙s, cSt

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• Temperature: °C, °F • Distance: metres, feet

The units can be selected by clicking twice on the cell to be edited and selecting the desired unit from the drop-down menu. Note that if a viscosity unit other than the default of centipoise multiplied by grams per cubic centimetre is chosen, the message shown in Figure 5.12 is shown.

Figure 5.12 Viscosity unit selection message

The Density Options referred to in this message are set up in the Options Setup page. Please refer to section 5.7 for more information on how to configure the Density Options. This is because the default viscosity calculation also takes density into account – in order to calculate the viscosity in any other units, a density value, either manually entered or from a density transducer, is required.

5.5.3 Alarms Display

The Alarms Display section of the Display Setup page allows the user to configure the alarms that are displayed on the ViscoSite transmitter’s LCD screen. The Alarms Display section is shown in Figure 5.13.

Figure 5.13 Alarms Display configuration

This section allows the user to configure the following settings. The Line and Display Method can be selected by clicking twice on the cell to be edited and selecting the desired choice from the drop-down menu. Numerical values can be edited by clicking on the cell to be edited, entering in the desired value, and then pressing enter.

• Line - allows the user to choose which line of the LCD screen the given alarm is presented on. Options are 1-4.

• Display Method – there are several optional display methods, as shown below. o Steady – when the alarm is triggered, it remains constantly on the

selected line of the display

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o Blinking – the selected line of the display will blink with the alarm message when the alarm is triggered

o Alternating – the selected line of the display will alternate between the alarm message and the line configuration from section 5.5.1 when the alarm is triggered.

o Blank (no words) – the alarm will not be output on the selected line. • Lower Limit - if the value of the given parameter drops below the value entered

in this column, the alarm will be triggered. This is the low alarm limit. • Upper Limit – if the value of the given parameter rises above the value entered

in this column, the alarm will be triggered. This is the high alarm limit.

The ‘Alarm Source’ column cannot be edited – it shows all the possible parameters than can be configured to have an on-screen alarm displayed. The ‘Units’ column values also cannot be edited. The values in this column depend on the values chosen in the ‘Display Units’ section (refer to section 5.5.2).

5.6 Output Configuration page

From anywhere in the GUI software, pressing the ‘Output Config’ button on the toolbar will bring up the Output Configuration page. The Output Configuration Page is shown in Figure 5.14.

Figure 5.14 Output Configuration page

The Output Configuration page is divided into two sections – Analog Outputs and Relay Outputs.

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5.6.1 Analog Outputs The Analog Outputs section allows the user to configure each of the three analog outputs on the ViscoSite transmitter’s motherboard. The Analog Outputs section is shown in Figure 5.15.

Figure 5.15 Analog Outputs configuration

The analog outputs configuration section shows the three available analog output channels. To make changes to a specific cell, click on it twice and select the desired value from the drop-down menu that appears by clicking on it. Numerical cells can be changed by clicking on the cell and typing in the desired value, and then pressing enter. The values that can be edited are as follows:

• Output Type – allows the user to choose how the signal is output on the analog output. The possible choices are Current 4-20mA, Voltage 0-10VDC, Current 0-20mA, and Voltage 2-10VDC.

• Measurement – allows the user to choose what parameter is output on the given analog output channel. The choices in this column are the same as those listed in Table 5.1.

• Min – allows the user to configure what value for the chosen parameter will be set to the 0/4mA or 0/2VDC signal, depending on the type of output chosen.

• Max – allows the user to configure what value for the chosen parameter will be set to the 20mA/10VDC signal, depending on the type of output chosen.

The value in the Max column must be larger than the value in the Min column, otherwise the cell border will turn red, indicating that the cell contents are invalid. Hovering over the triangle in the upper right hand corner will bring up an error message like the one in Figure 5.16 explaining why the cell contents are invalid.

Figure 5.16 Invalid Cell Contents Error Message

The channel column cannot be edited. The values in the units column depend on the measurement units chosen in the units section of the Display Setup page (refer to section 5.5.2) and also cannot be edited here.

5.6.2 Relay Outputs

The Relay Outputs section allows the user to configure the two relays on the ViscoSite transmitter motherboard to be associated with alarm values for two chosen parameters. The Relay Outputs section is shown in Figure 5.17.

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Figure 5.17 Relay Outputs configuration

The analog outputs configuration section shows the two available relay output channels. To make changes to a specific cell, click on it twice and select the desired value from the drop-down menu that appears by clicking on it. Numerical cells can be changed by clicking on the cell and typing in the desired value, and then pressing enter. The values that can be edited are as follows:

• Measurement - allows the user to choose which measurement parameter is associated with the given relay. The possible choices are the same as those given in table 5.1, except that Density is not a possible choice.

• Active Condition – allows the user to configure the relay behaviour. The two options are as follows:

o Open on Alarm - in this case, when an alarm is triggered the relay will open so that a circuit connecting Normally Closed (NC) and Common will be completed.

o Close on Alarm – in this case, when an alarm is triggered the relay will close so that a circuit connecting Normally Open (NO) and common will be completed.

• Lower Limit - allows the user to set the low limit value for the given parameter that will trigger the relay. If the value of the chosen parameter drops below this value, the relay will be triggered.

• Upper Limit – allows the user to set the high limit value for the given parameter that will trigger the relay. If the value of the chosen parameter rises above this value, the relay will be triggered.

As with the analog output ‘Min’ and ‘Max’ columns, the value for each relay’s upper limit must be larger than the value for the lower limit otherwise an error like the one shown in Figure 5.16 will be seen. The Relay column cannot be edited. The values in the Units column depend on the chosen parameter and on the units chosen in the Display Units section of the Display Setup page (refer to section 5.5.2) and cannot be edited here.

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5.7 Options Setup page

From anywhere in the GUI software, pressing the ‘Option Setup’ button on the toolbar will bring up the Options Setup page. The Options Setup Page is shown in Figure 5.18.

Figure 5.18 Options Setup page

The Options Setup page is divided into three sections – Density Options, Temperature Compensation, and Miscellaneous Options.

5.7.1 Density Options

The Density Options section allows the user to configure how sample density is handled by the ViscoSite viscometer. The Density Options section is shown in Figure 5.19.

Figure 5.19 Density Options

To use any other viscosity measurement units other than cP x g/cm3, the ViscoSite Viscometer must have a valid density measurement input. The ViscoSite viscometer can handle sample density in one of two ways – automatic or manual.

5.7.1.1 Automatic Density

The ViscoSite Viscometer is able to take the signal from a connected density transducer and use this for the density required to calculate other viscosity in units of millipascal seconds (mPa∙s), centipoise (cS) or centistoke (cSt). In order to enable this function, the

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‘Auto Density Enabled’ radio button must be selected and the density transducer must be hooked up to the transmitter motherboard as described in section 3.8.2. The signal output type from the Density Transducer must be selected in the ‘Input Type’ box. The ViscoSite transmitter can accept signals in 0-20mA, 4-20mA, 0-10VDC, or 2-10VDC – be sure to select the correct type as per the density transducer’s configuration. Enter the density transducer’s correct output range in the Min and Max boxes.

If the density transducer is not configured correctly, or if the Auto Density is enabled when no density transducer is connected to the Viscometer, the calculated viscosity in units of mPa∙s, cP, or cSt WILL BE INVALID!

5.7.1.2 Manual Density

If no density transducer is present, density compensation for the calculation of viscosity in units of millipascal seconds (mPa∙s), centipoise (cS) or centistoke (cSt) can be accomplished by using a fixed density value based on a laboratory analysis of the sample fluid. The fixed density value should be entered into the Density box and the ‘Manual Density Enabled’ radio button should be selected.

If the fixed density value is entered incorrectly, the calculated viscosity in units of mPa∙s, cP, or cSt WILL BE INVALID! Manual Density should only be used if the density of the sample fluid is relatively constant – if large variations in the sample density are expected, Galvanic Applied Sciences Inc. strongly recommends the use of a density transducer for automatic density compensation.

5.7.2 Temperature Compensation

The Temperature Compensation section allows the user to enter in parameters that will allow the ViscoSite viscometer to compensate the viscosity reading for significant variations in sample temperature. Temperature compensation is carried out in accordance with ASTM Standard D341-09, Standard Practice for Viscosity-Temperature Charts for Liquid Petroleum Products.The Temperature Compensation section is shown in Figure 5.20.

Figure 5.20 Temperature Compensation

The value in the Nominal Temperature box is the normally expected sample temperature when the process is functioning normally. The value placed in the Low Temperature box is the lowest sample temperature that the Viscometer would be expected to see during operation, and the value placed in the viscosity box beside this low temperature box is the expected viscosity (as from a lab test, for example) of the sample fluid at this low temperature. In the same way, the value placed in the high temperature box should be the highest sample temperature that the viscometer would be expected to see, and the value

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placed in the viscosity box beside the high temperature box would be the expected viscosity of the sample fluid at this high temperature. The values in this section will be used to calculate the ‘Temp Comp Visc’ parameter that can be output on the viscometer’s LCD screen and analog outputs. If all the values in this section are zero, this disables the temperature compensation.

5.7.3 Miscellaneous Options

The Miscellaneous Options section allows the user to chose whether the displayed viscosity is a live value or a time average value. The Miscellaneous Options section is shown in figure 5.21.

Figure 5.21 Miscellaneous Options

If a checkmark is placed in the ‘Time Average Viscosity’ box, this will make the displayed viscosity, on the display screen and on all outputs, a time average value rather than a live value. The ‘Averaging Span’ box displays the width of the averaging window in seconds.

If the averaging span is set to a very large number, short term changes in viscosity will not be registered as they will likely be averaged out. Unless the sample stream viscosity is known to be relatively constant, if this averaging feature is used the averaging span should be set to a low number.

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Section 6 Operation of the ViscoSite Viscometer

6.1 Introduction

The overall operation of the ViscoSite viscometer is based on the information entered in the PC GUI software and downloaded to the analyzer. The collection of analytical parameters, settings, alarms, and related information regarding viscometer operation is called a “Configuration”. While the PC GUI Software cannot be used to observe the current status of the viscometer, it can be used to make changes to the overall configuration of the viscometer, provided that the user is in either ‘technician’ or ‘factory’ access level in the GUI (refer to section 5.3 for more information on access levels). The role of this section is to provide a short overview of the application program from an operation point of view. It assumes that the ViscoSite viscometer has been properly installed as described in section 3, with all input and output devices correctly interfaced. Each GUI software page’s role in the operation of the ViscoSite viscometer will be pointed out. A detailed discussion of each page is presented in Section 5. While the full configuration can only be edited through the PC GUI software, the transmitter keypad and its integrated status LEDs can be used to monitor and edit a large number of instrument parameters. The keypad and the status LEDs are discussed in Section 4.

6.2 Editing a Configuration

A configuration is generated as part of the manufacturing, QA, and final acceptance steps and is stored in the ViscoSite transmitter when the unit is shipped to the end user. When the GUI software is opened and the operator logs into the transmitter, the present configuration is then available for viewing to the operator. If the operator wishes to edit the active configuration in the transmitter, it is necessary to enter the password to enter either the technician or factory access level.

6.2.1 Parameters in tables

Many of the editable parameters in the viscometer configuration are found in tables. There are two types of parameters that can be edited in tables – numerical parameters and non-numerical parameters.

6.2.1.1 Numerical Parameters

Numerical parameters, which are all decimal integers, can be edited by clicking on the cell that contains the parameter to be edited. Once clicked on, the cell becomes highlighted, as shown in Figure 6.1

Figure 6.1 Cell highlighted for editing

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The new value can be typed into the cell. Once finished, pressing Enter will move down to the next editable cell in the table. If an invalid value, such as a letter, is placed into any cell containing a numerical parameter, the border of the cell will become red in colour, indicating that the entered value is invalid.

6.2.1.2 Non-Numerical Parameters

Some editable parameters only have a small number of valid values. In this case, a drop down menu is available from the cell that contains all of the valid values. An example of a drop-down menu in a table is shown in Figure 6.2.

Figure 6.2 Editing a non-numerical parameter

To open the drop down menu, simply click on the cell to be edited twice – the first time will present a small downward-facing triangle in the right edge of the cell, and the second time will open the drop-down menu. To choose a value, simply click on the desired value.

6.2.2 Other Parameters

There are some editable parameters that are not found in tables. These parameters include radio buttons, check boxes, and data entry fields.

6.2.2.1 Radio Buttons

Radio buttons are used to select between two available options. An example of radio buttons is shown in Figure 6.3.

Figure 6.3 Radio Button Options

When a radio button for a specific option is chosen, the parameters associated with that option will then become available for editing. The parameters for the other option will become greyed out and cannot be edited.

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6.2.2.2 Check Boxes

A check box is used to enable a specific option. An example of a check box is shown in Figure 6.4.

Figure 6.4 Parameter with Check Box

If there is a check mark in the check box, this indicates that the option is enabled. Parameters associated with the option enabled by the check box may be edited regardless of whether the option is enabled or not.

6.2.2.3 Data Entry Fields

Data entry fields are used to enter numerical data for a certain parameter. An example of a data entry field is seen in Figure 6.4. To edit these values, simply click on the data entry field to place a cursor into it, and then edit the value as desired. Invalid values are indicated by a red coloured border on the data entry field. Hovering over the triangle in the upper right hand corner of the cell with the mouse cursor will bring up an error message explaining why the cell contents are invalid. Refer to Figure 5.16.

6.2.3 Uploading Changes to the Viscometer

Once changes have been made to a certain page, it is necessary to upload them to the viscometer. When changes have been made, the connection indicator (refer to figure 5.8) will have a blue dot flashing on it. Clicking on the connection indicator will save any changes that have been made on the current page to the transmitter. Alternatively, simply press one of the buttons in the tool bar. Pressing any toolbar button after changes have been made on a given page will bring up the prompt shown in Figure 6.5.

Figure 6.5 Unsaved Changes prompt

There are three options – Save, Continue, or Cancel. • Save – pressing this button will cause all changes made on the current page to be

uploaded to the viscometer. • Continue – pressing this button will discard all changes made on the current page

and switch to the selected page. CHANGES LOST AS A RESULT OF PRESSING THIS BUTTON CANNOT BE RECOVERED!

• Cancel - press this button to remain on the current page of the GUI. Any changes made up to this point will not be lost, but they have not yet been uploaded to the viscometer.

If the GUI software is connected remotely, changes cannot be made remotely if a local PC is also connected to the transmitter via a USB connection. In order to make

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changes remotely, first disconnect any local PCs from the transmitter, and DO NOT make adjustments via the keypad.

6.3 Editing the ViscoSite transmitter display The transmitter’s LCD screen is used to present a series of analysis results. A maximum of eight different parameters, four at a time, can be output on the transmitter’s display screen. In addition, alarm status reports can also be configured to output on the transmitter’s LCD screen. The output parameters and their measurement units, as well as the alarms shown on the display, can be configured on the Display Setup page of the GUI software, shown in Figure 6.6.

Figure 6.6 Display Setup Page

The choice of what parameters to output on the display screen, the units they are measured in, and the alarm outputs are all choices that the user can make based on the specific requirements of the installation facility. By default, the display is configured as shown in Figure 6.6. A full discussion of this page is given in section 5.5.

If viscosity measurements in units of centipoise (cP), centistoke (cSt) or millipascal seconds (mPa∙s) are required, a valid density value must be input into the ViscoSite transmitter, either via a density transducer or by a manually entered set density value.

Analytical results, as well as the configuration of the units and alarms will also be output to the transmitter’s Modbus registers. Refer to Appendix 1 for more information about the ViscoSite Viscometer’s Modbus outputs.

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6.4 Editing the Output Configuration

The transmitter can output a variety of signals on hardware analog and relay outputs. The configuration of these outputs can be edited on the Output Configuration page of the GUI software, shown in Figure 6.7.

Figure 6.7 Output Configuration

The analog outputs can be configured to output current (0-20mA or 4-20mA) or voltage (0-10VDC or 2-10VDC). The choice of current or voltage will depend on the receiving device and other facility requirments. It is advisable to choose the smallest appropriate scale for each analog output to ensure that the output value has the greatest possible resolution. The relay outputs can be associated with alarms from certain parameters, both high and low. The relays can be wired to an alarm signal (light or sound) in the control room. The choice of alarm measurement, relay behaviour, and relay alarm ranges will depend on facility requirements. A full discussion of this page is given in Section 5.6.

The alarm limits associated with the two relay outputs are unrelated to the alarms configured on the display page. Even with the same measurement parameter, the relay output alarm limits can be configured completely differently than the display output alarms.

6.5 Editing the Options

The Options page contains three parameters that also affect aspects of the ViscoSite Viscometer operation. The Options Setup page is shown in Figure 6.8.

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Figure 6.8 Options Setup

The choice of whether to use Automatic or Manual Density compensation will depend on facility-specific conditions. If auto density is used, please ensure that the range input into the Options page is the same as the range output by the density transducer. Please note that the ViscoSite Viscometer requires a valid density input in order to calculate viscosity in units other than cP x g/cm3. The use of temperature compensation is suggested if the sample stream is subject to wide swings in temperature. A full discussion of the Options Setup page is given in section 5.7.

6.6 Calibration and Validation

The ViscoSite Viscometer is calibrated at the factory and should not require re-calibration in the field. While calibration can be done in the field if absolutely necessary, it is a difficult process and one that Galvanic Applied Sciences Inc. recommends be only performed by factory-trained personnel. Details of the Calibration process are given in Appendix 2 of this manual. As part of a periodic maintenance operation, a user may wish to verify the function of the transducer and ensure that the calibration is still valid. This process is less involved than the calibration process, but still requires the removal of the transducer from the install location. The validation process is outlined in Section 7.3 and discussed in detail in Appendix 2.

6.7 Other operational considerations

The ViscoSite Viscometer is designed to be a “set it and forget it” type of measurement instrument. Once all desired parameters have been set for display, outputs, and options, very little further user interaction with the instrument should be required – it should continue to output valid viscosity and other data for long periods with little to no periodic maintenance necessary. However, occasional observation of the ViscoSite transmitter’s LCD screen and indicator LEDs will ensure that the instrument is operating correctly. The indicator LEDs are shown in Figure 6.9.

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Figure 6.9 ViscoSite transmitter indicator LEDs

Under normal circumstances, the Fault LED will be off, the COMM LED may blink occasionally, while the TUNED and POWER LEDs should be solid green. If this is the case, the instrument should require no further attention. The FAULT LED will occasionally illuminate when data is being written to the transmitter, but this will only be for a brief moment and then it will switch off. If the FAULT LED remains solid red for a long period of time, and/or the TUNED or POWER LEDs are also off at the same time, there is a serious issue with the instrument that requires immediate attention. Checking the LCD screen for any displayed alarm outputs is also important to ensure that the instrument is functioning normally. Alarm results are usually displayed on the bottom 2 lines of the screen, and if any alarms are observed, the instrument or the sample process may require immediate attention. See section 7 for details related to required periodic maintenance, and section 8 for details on troubleshooting the ViscoSite viscometer.

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Section 7 Maintenance The ViscoSite Viscometer is designed for maintenance-free operation. The transducer’s probe has no moving parts and is hermetically sealed from the process. However, there are some steps that should be taken on a periodic basis to ensure the continued long-term operation of the ViscoSite Viscometer.

7.1 Maintenance Guidelines

The following maintenance guidelines should be followed: • Check the seals on the transducer dome connection to ensure that no moisture or other

material has penetrated into the connection. Apply contact cleaner / moisture repellant to sensor cable connection to transducer every time check is performed.

• DO NOT under any circumstances hose down the transducer dome. This can lead to thermal shock damage to the transducer coils, requiring coil replacement and recalibration by Galvanic Applied Sciences Inc.

• Ensure that air provided for transducer air cooling is clean and dry. • Keep the transmitter in a dust-free area with an ambient temperature between 0°C and 50°C. • Respect the specifications! Do not operate the transmitter or transducer outside their specified

operating conditions (temperature, pressure, etc.) • In certain process environments, it may be necessary to periodically remove the transducer

from the process for cleaning (Section 7.2) • The transducer calibration should be checked at least once per year. (Section 7.3)

7.2 Cleaning the Transducer Probe

In order to clean the transducer probe, it must be removed from the process line or tank. A removed transducer is shown in Figure 7.1.

Figure 7.1 Removing the transducer

When removing the viscosity transducer for cleaning / maintenance, DO NOT under any circumstances lift the viscosity transducer by the probe end or allow the transducer to rest on the probe end. This may cause irreparable damage to the viscosity transducer! Lift using the flange or transducer dome end only! Refer to Figure 7.2.

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Figure 7.2 Handling the ViscoSite viscosity transducer

If the sample temperature is so low as to cause the transducer to freeze in contact with the mounting point, avoid twisting the transducer as this may cause damage to the probe. Use localized heat such as a flange heater to increase the transducer temperature until removal is possible. Ensure that the transducer dome temperature does not exceed 230°C while heating to prevent damage to the transducer coils. The probe end of the transducer should be cleaned thoroughly to remove any caked on material, taking care not to cause the probe to bend by putting too much lateral stress on the probe. A damaged probe is shown in Figure 7.3.

Figure 7.3 Bent Transducer Probe

The choice of cleaning materials to clean the probe will depend on the type of material on the probe. Chose an appropriate solvent and clean well.

7.3 Verifying Transducer Calibration

While the transducer is removed from the installation location, the validity of the transducer calibration should be verified. In order to verify the transducer calibration, a liquid of known viscosity is required. This liquid may be a Newtonian Viscosity Standard or an oil of known viscosity at a known temperature. Galvanic Applied Sciences Inc. recommends the use of Cannon Standards, available directly from Galvanic. Should the viscosity measurement range of the transducer be low, distilled water may be used, as it has a viscosity of about 0.9 cP at 25°C (and since the density of distilled water is 1 g/cm3, the viscosity may be reported by the ViscoSite viscometer as 0.9 cP x g/cm3).

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If the ViscoSite Viscometer is configured to report viscosity in cP x g/cm3, the reported viscosity of the standard must be multiplied by its density at the validation temperature in order to verify the calibration. The manufacturer of the viscosity standard provides both the viscosity and density for the calibration standard, as shown in Figure 7.4.

Figure 7.4 Viscosity Standard Label

In order to verify the calibration of the transducer, mount it securely on the stand originally provided with the transducer, as shown in Figure 7.5. If the transducer was originally shipped in a wooden crate, mount the transducer for validation as shown in figure 7.6.

Figure 7.5 Mounting Transducer for Validation

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Figure 7.6 Mounting large transducer for validation

Once the transducer has been mounted securely, raise the container containing the viscosity standard so that it immerses the sensor probe of the transducer. Allow the reading to stabilize, ensuring that the probe temperature is constant. Confirm that the viscosity reported by the ViscoSite Viscometer is the same as that given on the viscosity standard level at the validation temperature. You may need to convert viscosity units if the units reported by the ViscoSite Viscometer are not the same as those given on the viscosity standard label. If the calibration is correct, the transducer probe should be cleaned with an appropriate solvent and then can be reinstalled in the process line / tank. Remember to follow the guidelines given in Section 3.4 when reinstalling a transducer after maintenance. If the calibration is not correct, refer to section 8. A more thorough discussion of transducer calibration and validation is given in Appendix 2.

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Section 8 Troubleshooting the ViscoSite Viscometer While the ViscoSite Viscometer is designed to provide long term maintenance-free operation, occasionally it may be necessary to determine the source of a problem with the instrument. This section will highlight some commonly observed issues that may arise with the ViscoSite Viscometer and their possible solutions.

Oftentimes abnormal instrument readings are due to ‘abnormal’ changes in the process. To identify a process-related problem versus an electronics failure or damaged transducer, first turn off all nearby pumps and rotating machinery (ONLY if possible without damage to the equipment), allow reading to settle, and observe static condition response. If reading settles and is approximately correct, the abnormal reading is process-related. Note also that some materials do change viscosity under various process conditions. If possible, if a damaged transducer is suspected, empty the tank or vessel and check that the ViscoSite Viscometer gives a reading of 0 when the clean transducer is freely oscillating in air. If the reading does not return to zero, or becomes unstable and begins to drift, contact the service department of Galvanic Applied Sciences Inc.(refer to Section 8.3 for Contact Information). If necessary, pull the transducer from the process (section 7.2) and inspect the transducer for any signs of physical damage.

8.1 Sensor Cable Continuity Test

If transducer signal cable or coil damage is suspected, a continuity test of the wires should be carried out on the sensor cable using a multimeter set for measurement of electrical resistance (Ω). Table 8.1 shows the expected resistance across specific pins with and without the intrinsically safe barrier.

Terminal Block Pins Resistance (Ω) – No Barrier

Resistance (Ω) – With Barrier

J11 1 / 2 ~70 to 100 ~400 to 450 4 / 5 ~70 to 100 ~750 to 800

J10

1 / 2 ~ 110 ~160 1 / 3 ~ 110 ~160 2 / 3 <10 <50 4 / 5 ~110 ~160 4 / 6 ~110 ~160 5 / 6 <10 <50

Table 8.1 Sensor Cable Continuity Test

If the results of the continuity test do not match the results given in Table 8.1, contact the service department of Galvanic Applied Sciences Inc for assistance. Refer to Section 8.3 for contact information.

8.2 Commonly Observed Problems

While the ViscoSite Viscometer is likely to provide years of trouble-free operation, occasionally problems with analyzer operation will be observed. Table 8.2 shows a list of commonly observed problems and their potential solutions. If the solutions listed in the table are unable to resolve the problem, please contact the service department of Galvanic Applied Sciences Inc. (Section 8.3).

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Symptom Possible Causes / Solutions to try Transmitter screen not lit

1. Transmitter is not powered on. Check AC connection. 2. Ribbon cable connecting from display board (swing panel) to

motherboard is loose. 3. Thermal shutdown. Transmitter will only power up once the internal

temperature is below 70°C. Unchanging or erroneous display

1. If both temperature and viscosity readings are unchanging or very wrong:

a. Could be faulty connection between cable and transducer b. Check cable continuity (section 8.1) c. Transducer electronics may have failed

2. If only the viscosity reading is wrong, while temperature reading is accurate:

a. Probe may be damaged / bent b. Electromagnetic coils driving the probe oscillation may be

damaged / failed. Perform a continuity check. (section 8.1) Not reading zero in air 1. Material deposit on the transducer probe. Clean probe thoroughly

and try again. 2. Transducer not mounted securely. 3. Transducer probe may be damaged / bent 4. Electromagnetic coils driving the transducer probe oscillation may

have failed. Perform a continuity check. (Section 8.1) 5. Sensor cable is not connected correctly / is damaged. Perform a

continuity check (Section 8.1) Viscosity display reading not CORRECT

1. Material deposit on the transducer probe. Clean the probe thoroughly and try again.

2. Process temperature has changed from normal temperature. Try using temperature compensation (section 5.7.2)

3. If using viscosity units OTHER than cP x mg/m3, density input is not correct (section 5.7.1)

4. Transducer probe is damaged / bent 5. Calibration data has become corrupted. 6. Sensor cable is not connected properly.

Unstable viscosity reading (air or material)

1. Unstable mounting. Retighten bolts using stagger technique (Section 3.4.1)

2. Power cord is not properly grounded. 3. Improper grounding between transducer probe and electronics

(check for ground loop). 4. Check for loose screws on transducer. 5. Excessive pipe vibrations (Refer to Section 3.3.2.2) 6. Electromagnetic interference (Refer to Section 3.3.2.4, 3.4.1) 7. High material flow rate (turbulent flow)

Transducer Ringing / Excessive vibration can be detected by touching transducer

1. Transducer probe is bent / damaged 2. Sensor cable is not connected properly 3. Transducer electronics failure 4. Electromagnetic coils driving the transducer probe oscillation may

have failed. Perform a continuity check. (Section 8.1) Current / Voltage output of Analog output doesn’t proportionally correspond to display

1. Verify output span settings, including zero, span, and measurement units (refer to section 5.6.1)

2. Verify input settings on control computer match output settings on AO

Table 8.2 Commonly Observed Problems

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8.3 Contact Galvanic Applied Sciences Inc.

In the event that the information in this section cannot be used to successfully diagnose and resolve a problem with the ViscoSite Viscometer, or in the even of a major component failure, it is highly recommended that the user contact Galvanic Applied Sciences Inc.’s Service Department. The Service Department offers both phone/email technical support and on-site technical service if required. For Service and/or Assistance, contact: Galvanic Applied Sciences Inc. 41 Wellman Street Lowell, MA 01851 USA Phone: (978) 848-2701 OR Galvanic Applied Sciences Inc. 7000 Fisher Road SE Calgary, AB T2H 0W3 CANADA Phone: (403) 252-8470 Toll Free (CANADA/USA): 1-866-252-8470 E-mail: [email protected]

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Section 9 ViscoSite Viscometer Schematic Diagrams This section contains a series of diagrams that will allow the user to correctly install all necessary wiring for the ViscoSite Viscometer.

Figure 9.1 Sensor Cable Connections (No IS Barrier)

Figure 9.2 Sensor Cable Connections (IS Barrier)

Refer to Figure 9.4

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Figure 9.3 Transducer Connections

Figure 9.4 IS Barrier and Transducer Wiring

NOTE: RTD 2 (terminal 9,10,11 on transducer) is only found on VL800 transducers, not on VL500 transducers.

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Figure 9.5 Transmitter Interior Layout (No IS Barriers)

Figure 9.6 Transmitter Interior Layout (6 IS Barriers, no Dome Temperature RTD)

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Figure 9.7 Transmitter Interior Layout (7 IS Barriers)

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Section 10 Technical Specifications

10.1 Performance Specifications Range 0.1 – 1 000 000 cP x g/cm3 (depends on transducer model / probe

type, refer to section 2.2) Accuracy ±2% of reading Reproducibility ±1% of reading Repeatability ±0.25% of reading Response Time Real Time Analysis Analysis Frequency ~1Hz

10.2 Communications / Interface Outputs 3 – 0-10VDC/2-10VDC/0-20mA/4-20mA analog outputs (isolated,

scaled to range, user configurable) 2 – SPDT Alarm relays, 4A @30VDC/120VAC OR 2A @ 240VAC 1 – USB Port 1 – combined RS232c/RS485 isolated serial port 1 – Ethernet port Modbus communication available on all ports

Inputs 1 – 0-10VDC/2-10VDC/0-20mA/4-20mA analog input for density transducer (isolated, scaled to range, user configurable, no sourcing current) 2 – RTD Inputs (Transducer Dome and Probe temperature), factory configured

Operator Interface 4 line x 20 column LCD Screen (blue print on black) Front Panel membrane keypad (not intrinsically safe) 4 visual indicator LEDs for quick status Remote PC GUI Software program

10.3 Instrument Specifications

Size Transmitter: 301mm (H) x 335mm (W) x 172mm (D) (12” x 13” x 7”) VL500 Transducer: Depends on application VL 800 Transducer: Depends on application

Weight Transmitter: 5.5kg (12lb) VL 500 Transducer: Depends on application VL 800 Transducer: Depends on application

Power Consumption 10 W @ 24VDC or 90-265VAC Electrical CSA, C/US Certified Classifications Transmitter: Up to Class 1 Division 2 Groups ABCD T4

Transducer: Up to Class 1 Division 1 or ATEX Class 1 Zone 1 Ambient Temperature Transmitter: 0-60°C (32-140°F)

Transducer: Depends on model (refer to sections 2.2.1 and 2.2.2)

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Section 11 Spare Parts The following is a list of commonly used spare parts available from Galvanic Applied Sciences Inc. for the ViscoSite Viscometer.

Description Part Number Power Supply N700009 EMI/RF Filter K4905-2060-07 LCD Screen N700006

LCD Screen Display Driver Board N700007 Keypad N700005

Inner Swing Door N700004

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Appendix 1: Modbus Registers The Modbus register list for the ViscoSite Viscometer can be inspected in the Engineering Page of the GUI Software when logged in to the transmitter at the ‘Factory’ access level (refer to Section 5.3). Press the ‘Engineering’ button on the Factory Access level toolbar (Figure 5.8). The Engineering page of the GUI Software is shown in Figure A1.1.

Figure A1.1: Engineering Page of GUI Software

The Engineering Page consists of a table of several columns. The column headers are:

• Register Name – Indicates what data is output in that register • Index – Indicates the register number in extended register referencing. The initial digit of the

index number indicates the type of register, as follows: o 0 – Coil o 1 – Discrete Input o 3 – Input Register o 4 – Holding Register

The majority of the data in the ViscoSite Viscometer’s Modbus list is output in holding registers. • Value - Indicates the current value of the register. This column is the only column that can be

edited. • Data Type – Indicates the type of data (refer to Section A1.1 for more information on data types).

The amount of data shown on the Engineering page can be reduced by filtering the displayed data based on register name, index, or data type. In order to filter, click on the funnel icon ( ) on the right side of the column header. This will bring up the menu shown in Figure A1.2.

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Each column will have a slightly different filtering menu, but the general layout is the same. The menu shown in Figure A1.2 is for the data type column. At the top is a box that contains all of the values currently found in the column. Placing a checkmark in the box to the left of the name will select and filter based on that particular value. For example, in Figure A1.2, placing a checkmark in the ‘Date’ box will show all registers that have the ‘Date’ data type. Multiple values can be chosen for filtering. At the bottom the user can enter specific values to filter on based on Boolean logic. As this kind of filtering works best with numerical values, this filtering method is most useful for the Index column. Regardless of how the user chooses to filter, pressing the ‘Filter’ button will filter the list based on the chosen parameter(s), and pressing the ‘Clear Filter’ button will clear all previously chosen filter parameters.

Figure A1.2 – Data Filtering

A1.1 Data Types The Modbus list contains a number of different data types. The data types are explained in Table A1.1.

Data Type Explanation Allowed Values Analog Measurement Type of

measurement associated with relay alarm

0 – no value 1 – Density 2 – Viscosity 3 – Probe Temperature 4 – Dome Temperature 5 – Cabinet Temperature 6 – Oscillation Frequency 7 – Temperature Compensated Viscosity

Boolean A Boolean operator 0 – off 1 – on

cP x g/cm3 x 1000 Values associated with calibration

Any numerical value

Date Dates associated with calibration and

Any valid date

Density Units Choice of units to express density measurement

0 – g/cm3

Display Method Indicates how alarms are displayed on the analyzer LCD screen

0 – Steady 1 – Blinking 2 – Alternating 3 – Not used

Distance Units Choice of units to express length measurement

0 – metres 1 – feet

Double A 64-bit register than can express positive and negative decimal values

Any positive or negative decimal integer

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Electrical Interface Choice of analog output type

0 – 4-20mA 1 – 0-10VDC 2 – 0-20mA 3 – 2-10VDC

Integer A 32-bit register without a decimal point

Any positive or negative whole number integer

Measurements Choice of parameter to output on AO and LCD screen (primary and secondary)

0 – no parameter output 1 – Density 2 – Viscosity 3 – Probe Temperature 4 – Dome Temperature 5 – Cabinet Temperature 6 – Oscillation Frequency 7 – Temperature Compensated Viscosity

mg/cm3 Used for manual density entry

Any positive whole number value

Milliseconds Used for time average window for viscosity calculation

Any positive whole number value

Position 3 Fixed-Decimal Used for some numerical values

Any positive integer where the last three digits of the entered value are to the right of the decimal point (E.g. 6000 = 6.000, 50 = 050=0.050)

Relay Trigger Used to indicate relay behaviour on alarm

0 – De-energized (off on alarm) 1 – Energized (on on alarm)

Temperature Units Used to indicate the chosen temperature units

0 – Degrees Celsius 1 – Degrees Fahrenheit

Viscosity Units Used to indicate the chosen viscosity units

0 – cP x g/cm3 1 – mPa∙s 2 – cP 3 - cSt

Table A1.1 Data Types in Modbus List

When editing the value column in the Modbus list, the value in the value column must fit within the limits given in the Allowed Values column of Table A1.1. If it does not, the cell border will turn red to indicate that the entered value is invalid. Hovering the mouse cursor over the triangle in the upper right corner of the red-bordered cell will indicate the valid values that can be entered into the cell, as shown in Figure A1.3.

Figure A1.3 Invalid Register Value Message

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Appendix 2: Calibration and Validation of Transducer

The procedures outlined in this Appendix must ONLY be performed by qualified personnel using the appropriate calibration equipment and standards and under the advisement of the service department of Galvanic Applied Sciences Inc. Failure to use the appropriate equipment and standards will result in the transducer, and thus the ViscoSite Viscometer as a whole, being unable to operate correctly. In order to perform a transducer calibration, transducer validation, or temperature calibration, the operator must be logged into the GUI at the Factory access level (refer to section 5.3.3). Once in the Factory access level, pressing the Calibration button on the toolbar will bring up the Calibration page shown in Figure A2.1.

Figure A2.1 Calibration Page

At the top of the page are three data entry fields. They are:

• Serial Number – this number is user editable, and is the serial number of the transducer. • Resonant Frequency – this is the oscillation frequency, in Hertz, of the transducer probe in air • Resonant Phase – this is phase difference between the driver coils and detector coils of the

transducer, in Hertz, measured in air. Further, down the side of the page are a series of buttons. They are:

• Save to PC – pressing this button will save the currently displayed configuration to a file on the connected PC.

• Read from PC – pressing this button will populate the screen with data previously saved to the connected PC. It must be written to the transmitter like any other configuration change (refer to section 6.2.3).

• Freq.Sweep – pressing this button is done to determine the resonant frequency of a newly connected transducer. The transducer probe should be in air when this button is used. It should not be pressed unless the entire transducer is replaced.

• Alt.Folder - pressing this button will allow the user to select what folder the calibration data is saved to / read from.

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Below the three data fields at the top of the page are four tabs – Calibration, Validation, Temperature, and Dome Temperature. Each of these tabs accesses data for specific tasks.

A2.1 Calibration Tab

The calibration tab contains all of the calibration data for the transducer’s viscosity probe, as shown in Figure A2.2.

Figure A2.2 Calibration Tab

There are a total of 7 columns in the calibration tab, though not all of them are editable. The columns are as follows:

• Data Point – shows the data point number. This column cannot be edited. Depending on the transducer’s viscosity measurement range, there may be as few as 6 data points (small range) or as many as 16 data points (large range).

• Test Viscosity – shows the room temperature viscosity of the viscosity standard that was used to obtain this data point. This value is editable and should be read off the label of the chosen viscosity standard. Galvanic Applied Sciences Inc. recommends the use of Cannon Standards, available directly from Galvanic. Regardless of the desired output viscosity units, the values in this column should ALWAYS be in units of centipoise x density (cP x g/cm3).

• Lot Number – shows the lot number for the calibration standard used. This is for traceability to ensure that the calibration can be verified against records. When doing a new calibration, please keep note of the lot number for the calibration standard used.

• A/D Reading – shows the raw data output of the transducer for the given calibration data point. This number is generated by the transducer during the calibration process.

• Frequency – shows the oscillation frequency of the transducer probe in the given calibration standard

• Temp. – shows the temperature at which the calibration point data was obtained. This temperature is based on the temperature measured by the transducer’s probe.

• Action – allows user to either delete a calibration point (press ‘Delete’) or redo the calibration point (press ‘Start’).

Before pressing ‘Start’ it is essential that the transducer probe be immersed in the exact calibration standard given in the Test Viscosity and Lot # columns. If not, the obtained calibration will be wrong and the transducer will not give accurate viscosity readings. The calibration must be carried out according to the procedure given in A2.1.1.

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At the bottom of the calibration data table is the message ‘Click here to add new item’. Clicking on this message will add another row to the table, which the user then needs to fill in and carry out the calibration by pressing ‘Start’. Refer to section A2.1.1 for the complete calibration procedure.

A2.1.1 Calibration Procedure

Should the calibration of the transducer be found to be incorrect during a transducer validation (refer to section 7.3 and/or A2.2), a new calibration of the transducer can be carried out according to the procedure given in this section. Prior to carrying out this procedure, the transducer probe needs to be clean and dry, and securely mounted as per Figures A2.3 (small transducer) or A2.4 (large transducer).

Figure A2.3 Mounting small transducer for calibration

Figure A2.4 Mounting large transducer for calibration

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Unless the original calibration’s viscosity standards are still available and have not yet expired, the previous calibration should be deleted by pressing the delete button for each row. New calibration data points can then be added by clicking on the “Click here to add new item” message on the bottom of the calibration table. Be sure to have a sufficient number of calibration standards available. Galvanic Applied Sciences Inc. recommends the use of Cannon Standards, available directly from Galvanic. The available calibration standards should cover as much of the transducer’s measurement range as possible, and the more standards that are available, the more accurate the calibration will be. The calibration procedure is as follows: 1. Immerse the transducer probe in the calibration standard. Data should be entered into

the calibration table “Test Viscosity” and “Lot Number” columns as per the data on the calibration certificate on the standard. An example calibration certificate is shown in Figure A2.5.

Figure A2.5 Calibration Standard Level

The value entered into the “Test Viscosity” column is based on the data at 20°C (i.e. room temperature), and is the Dynamic Viscosity (shown here in mPa∙S; 1 mPa∙s = 1cP) multiplied by the density (shown here in g/mL, 1g/mL = 1g/cm3), giving a viscosity unit of cP x g/cm3. For example, based on the data in Figure A2.5, the data point to be entered would be:

𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑉𝑉𝑉𝑉𝑇𝑇𝑉𝑉𝑉𝑉𝑇𝑇𝑉𝑉𝑇𝑇𝑉𝑉 = 8.954𝑉𝑉𝑐𝑐 𝑥𝑥 0.8455 𝑔𝑔𝑉𝑉𝑐𝑐3 = 7.570607 𝑉𝑉𝑐𝑐 𝑥𝑥 𝑔𝑔/𝑉𝑉𝑐𝑐3

Also enter in the lot number from the calibration standard certificate for traceability purposes.

2. Ensure that the viscosity reading on the transmitter is stable, and then press the ‘Start’ button. The transmitter will then calibrate to the current calibration standard based on the measured temperature.

3. Remove the current calibration standard, clean the transducer probe with an appropriate solvent and dry it. Clean the container being used to hold the calibration standard before putting another standard into it.

4. Repeat steps 1-3 for all remaining calibration standards.

5. Save the calibration to the transmitter by pressing the Connection Indicator icon in the

bottom left. Save the new calibration to the computer by pressing “Save to PC”.

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A2.2 Validation Tab

The validation tab is used to validate the current calibration of the ViscoSite Viscometer’s transducer. The validation tab is shown in figure A2.6.

Figure A2.6 Validation Tab

The validation tab is very similar in layout to the calibration tab. The two columns that are new in the validation tab are:

• Viscosity – this column replaces the A/D Reading column from the calibration tab. The data in the viscosity column shows the ViscoSite viscometer’s calculated viscosity for the given calibration standard.

• % Accuracy - this column replaces the Frequency column from the calibration tab. The data in the % Accuracy column shows the percentage difference between the ViscoSite Viscometer’s calculated reading on the given calibration standard and the certificate value in the Validation Viscosity column. If the value in this column exceeds 2 x %, the given calibration data point will require calibration.

The procedure for validation is identical to the procedure for calibration given in section A2.1.1, except that the column titled ‘Test Viscosity’ in the Calibration tab is called ‘Validation Viscosity’ in the Validation tab.

A2.3 Temperature Tab

The Temperature tab is used for the calibration of the RTD in the transducer probe. The Temperature tab is shown in Figure A2.7.

Figure A2.7 Temperature Tab

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As the response of an RTD to temperature is basically linear, only a 2-point calibration is required. The columns in the data table are as follows:

• Data Point – shows the data point number for calibration • Temperature – shows the chosen temperature being calibrated. Any two temperatures can

be chosen, but the defaults are 0 and 100. Temperatures are given in °C. • Result – shows the transmitter signal received for the given temperature • Action – contains the ‘Start’ button used to start the data point calibration.

In order to carry out the temperature calibration, a temperature calibrator should be connected in place of wires 6, 7 and 8 of the sensor cable (1, 2, and 3 of J10 Terminal) at either the transmitter motherboard (no barrier, refer to section 3.6.1) or at the IS barrier (refer to section 3.6.2). The calibrator temperature should be set to the first temperature Data Point value. Confirm that the temperature given on the transmitter display is approximately the same as the calibrator output, and then press the ‘Start’ button to begin the calibration for this data point. Once “Result” number stabilizes, press “Stop” to complete the calibration for this point. Set the calibrator temperature to the second Data Point value, and repeat the process. When the process is complete, press the ‘Save to PC’ button to save the configuration to the computer, and click on the Connection Indicator in the bottom left corner of the screen to save the configuration to the transmitter. It is very unlikely that temperature calibration will be required in the field, and so the procedure given here should only be done after consultation with the Service Department of Galvanic Applied Sciences Inc.

Press small “Disc” save button after each calibration point.

A2.4 Dome Temperature Tab

The Dome Temperature tab is used for the calibration of the RTD in the transducer dome. The Dome Temperature tab is shown in Figure A2.8.

Figure A2.8 Dome Temperature tab

The calibration procedure for the Dome Temperature RTD is identical to that of the Probe Temperature RTD (Appendix 2.4) with the exception that the temperature calibrator needs to be connected in place of wires 9, 10 and 11 (4, 5 and 6 of J10 Terminal) from the sensor cable.

It is very unlikely that temperature calibration will be required in the field, and so the procedure given here should only be done after consultation with the Service Department of Galvanic Applied Sciences Inc.

Press small “Disc” save button after each calibration point.

Revision 1 87 10/09/2019

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