TT100 Manual

BROOKFIELD MODEL TT100
IN-LINE VISCOMETER
Installation, Operation, and Maintenance Instructions
Manual No. M/97-520-A899
S P E C I A LI S T S I N T H E
MEASUREMENT AND
CONTROL OF VISCOSITY
BROOKFIELD ENGINEERING LABORATORIES, INC.
11 COMMERCE BOULEVARD, MIDDLEBORO, MA 02346 USA
TEL 508-946-6200 or 800-628-8139 (USA excluding MA)

FAX 508-946-6262 INTERNET http://www.brookfieldengineering.com
The information in this document is believed to be accurate and reliable. However,
Brookfield Engineering Laboratories, Incorporated, cannot accept any financial or other
responsibilities that may result from the use of this information. No warranties are granted or
extended by this document.
Brookfield Engineering Laboratories, Incorporated reserves the right to change any or all
information contained herein without prior written notice. Revisions may be issued at the time of
such changes and/or deletions.
Any duplication of this manual or any of its parts without expressed written permission from
Brookfield Engineering Laboratories, Incorporated is strictly prohibited.
Any correspondence regarding this document should be forwarded to:
Brookfield Engineering Laboratories, Incorporated

Process Viscometer Division
11 Commerce Boulevard
Middleboro, Massachusetts 02346
U.S.A.
Telephone: (508) 946-6200
FAX: (508) 946-6262
Internet: http://www.brookfieldengineering.com
The following Brookfield Engineering Laboratories, Incorporated trademarks and service marks
may appear in this document:
All other trademarks or registered trademarks are the property of their respective holders.
Copyright© 1999 Brookfield Engineering Laboratories, Incorporated Printed in U.S.A.

TT-100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
Table of Contents
Section 1 - In-Line Viscometer Description

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Correlation with Other Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Required Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Current Draw - Starting & Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Torque Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Sensing Endcap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Stop Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Inlet/Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Drive Endcap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Bleed Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Measuring Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Measuring Annulus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Sensing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Torsion Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Heat Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Torque Sensor Electronics Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Motor Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Double Mechanical Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Elliptical Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Perforated Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Serrated Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Flushing Endcap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
P/N M/97-520 vi
In-Line Viscometer Description
Table of Contents (continued)
Section 2 - Installation
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Calculating Minimum Straight Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Flushing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Section 3 - Calibration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fine Zero Milliampere Calibration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Preliminary Torque Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Single Range Viscometer Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Dual Range Viscometer Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Coarse Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Fine Zero Voltage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Section 4 - Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Mechanical Seal Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Normal Operation Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Section 5 - Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Clean-In-Place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Disassembly and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the Sensing Endcap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning the Drive Endcap Assembly and Measuring Chamber . . . . . . . . . . . 5-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Elliptical Baffle Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
vii P/N M/97-520

Section 6 - Service
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Sensing Endcap Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Microsyn Field Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Torque Sensor Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . 6-9
Torsion Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Sensing Endcap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Drive Endcap Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Motor and Gearbox Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Oriental Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Oriental Motor Gearbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Groschopp Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Groschopp Motor Gearbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Drive Endcap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Double Mechanical Seal Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . 6-28
Section 7 - Troubleshooting
Appendix A - Customer Support
Appendix B - Drawings
Appendix C - Viscosity Range Change

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Changing Range or Shear Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Speed of Rotation Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Stator Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Torsion Element Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Electronic Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
P/N M/97-520 viii

Appendix D - Agency Approvals
Appendix E - Warranty Information
Glossary
Index
Figures
Figure 1-1: Typical TT100 In-Line Viscometer with Oriental Motor . . . . . . . . 1-3
Figure 1-2: Typical TT100 In-Line Viscometer with Groschopp Motor . . . . . 1-4
Figure 1-3: TT100 In-Line Viscometer Product Stream Flow . . . . . . . . . . . . . 1-5
Figure 1-4: In-Line Viscometer Correlation with Other Measurement
Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-5: Typical Model TT100 In-Line Viscometer Component
Identification (NEMA 4 Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Figure 2-1: Typical In-Line Viscometer Installation . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-2:NEMA 4 - 115 or 230 VAC 50/60 Hz Installation . . . . . . . . . . . . . 2-5
Figure 2-3:NEMA 7 - Explosion Proof 115 VAC 50/60 Hz Installation . . . . . 2-6
Figure 2-4:CENELEC - 115 or 230 VAC 50/60 Hz Installation . . . . . . . . . . . . 2-7
Figure 3-1: Typical Installation Calibration Flowchart . . . . . . . . . . . . . . . . . . . 3-3

Figure 3-2: Typical Calibration after Viscometer Disassembly and Cleaning . 3-4
Figure 3-3:Typical Calibration after Component Replacement . . . . . . . . . . . . 3-5
Figure 3-4:Torque Sensor Electronics Board Adjustment Component
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-5: Applying Torque to the Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-6: Calibration Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-7: Calibration Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-8: Microsyn Field Coil Assembly Rotation . . . . . . . . . . . . . . . . . . . 3-19
Figure 3-9: Stator Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
ix P/N M/97-520
Figure 5-1: Typical Viscometer Disassembly for Cleaning . . . . . . . . . . . . . . . 5-4

Figure 5-2: Typical Stator Removal and Torsion Element Wire Cleaning . . . . 5-6
Figure 5-3: Stator Installation and Stop Post Centering . . . . . . . . . . . . . . . . . . 5-7
Figure 6-1: Sensing Endcap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Figure 6-2: Sensing Endcap Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6-3: Microsyn Field Coil Pin Identification . . . . . . . . . . . . . . . . . . . . . . 6-6
Figure 6-4: Removing the Armature Clamping Nut . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6-6: Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Figure 6-7: Torsion Element and Endcap Alignment . . . . . . . . . . . . . . . . . . . 6-14
Figure 6-8: Stator Installation and Stop Post Centering . . . . . . . . . . . . . . . . . 6-15
Figure 6-9: Motor Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Figure 6-10: Motor and Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Figure 6-11: Drive Endcap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Figure 6-12: Drive Endcap Disassembly (with Single Mechanical Seal) . . . . 6-22
Figure 6-13: Groschopp Motor and Gearbox Disassembly . . . . . . . . . . . . . . . 6-27
Figure 6-14: Drive Endcap Disassembly (with Double Mechanical Seal) . . . 6-31
Figure B-1:NEMA 4 Oriental Motor Wiring Diagram . . . . . . . . . . . . . . . . . . . B-1

Figure B-2:Groschopp Motor Wiring Diagram (Factory Mutual Housing) . . . B-2
Figure B-3:Torque Sensor Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Figure B-4:230 VAC Wiring Diagram for IP 55 Groschopp Motor . . . . . . . . . B-4
Figure B-5:CENELEC 115 VAC Groschopp Motor Wiring Diagram . . . . . . . B-5
Figure B-6:CENELEC 230 VAC Groschopp Motor Wiring Diagram . . . . . . . B-6
Figure B-7:TT100 In-Line Viscometer (NEMA 4 with Oriental Motor) . . . . . B-7
Figure B-8:TT100 Viscometer for Hazardous Areas (NEMA 7) . . . . . . . . . . . B-8
Figure B-9:TT100 Viscometer for Hazardous Areas (CENELEC) . . . . . . . . . . B-9
Figure B-10:TT100 In-Line Viscometer Double Mechanical
Seal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
P/N M/97-520 x
Tables
Table 1-1:Model TT100 In-Line Viscometer Specifications . . . . . . . . . . . . . . 1-7

Table 1-2:Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table 3-1:Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Table 6-1:Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Table 7-1:Process Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Table 7-2:Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Table 7-3:Calibration Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Table 7-4:Correlation/Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Table C-1:Shear Rates and Factors for 2.440 ID Rotor . . . . . . . . . . . . . . . . . . . C-4

Table C-2:Shear Rates and Factors for 1.450 ID Rotor . . . . . . . . . . . . . . . . . . . C-4
Table D-1:Agency Approvals - TT100 In-Line Process Viscometer . . . . . . . . D-1
xi P/N M/97-520
TT100 In-Line Viscometer Installation, Operation, Maintenance and Service Instructions
Section 1 - In-Line Viscometer Description
Introduction
The Brookfield Model TT100 In-Line Viscometer is a highly sensitive
versatile instrument that measures process fluid viscosity in a fully flooded
product stream under pressure or vacuum. Brookfield In-Line Viscometers
are unaffected by changes in pressure, laminar flow, or density.
The TT100 In-Line Viscometer generates a 4 - 20 milliampere (mA) or

0 - 10 Volts DC (VDC) signal proportional to process fluid viscosity. The
signal is stable, can be transmitted over long distances with minimal loss,
and is not affected by noise. Adjustable electronic damping maintains
signal quality under severe process conditions.
The TT100 In-Line Viscometer, shown in Figures 1-1 and 1-2, can be used
in a variety of industrial applications where the viscosity of chemical,
coating, fuel oil, and many other process fluids must be controlled or
monitored.
Features and Benefits

The TT100 In-Line Viscometer incorporates the following features:
• Easy start-up, operation, and cleaning
• Instantaneous response
• Optional selectable dual viscosity range
• Continuous linear output signal (4 - 20 mA) or (0 - 10 VDC)
• Coaxial cylinder measurement geometry for viscosity values at

defined shear rates
• Optional temperature compensation
The TT100 In-Line Viscometer provides the following benefits:
• Highly sensitive measuring system unaffected by changes in

pressure, laminar flow, or density.
P/N M/97-520 1-1

• Can be cleaned-in-place thereby minimizing downtime.
• Eliminates manual procedure for lab viscosity analysis. Provides

early detection of anomalous processing.
• Accurate and proven control - optimizes product consistency and

quality.
• Provides a permanent record for quality control when used with a

recorder or integrated computer system.
• Due to the unique design of the torsion element, pressure does not
affect its response.
• Operates continuously and instantly responds to changes in

viscosity.
• Minimal pressure drop.
• Linear output signal is proportional to viscosity and compatible

with most industrial process control equipment.
• Installs directly in-line or in a by-pass line.
• Optional features and accessories are available to enhance In-Line

Viscometer performance.
1-2 P/N M/97-520

Figure 1-1: Typical TT100 In-Line Viscometer with Oriental Motor
P/N M/97-520 1-3

CENELEC
NEMA 7
Figure 1-2: Typical TT100 In-Line Viscometer with Groschopp Motor
1-4 P/N M/97-520

Theory of Operation
The product stream flows through the inlet into the TT100 In-Line
Viscometer measuring chamber, as shown in Figure 1-3, where it pushes
against a cylinder or rotor driven by a drive motor. The rotation of the rotor
causes a gentle pumping action forcing the product to flow into the
measuring annulus between the rotor and the stator. The viscous drag of the
product on the stator is resisted by a torsion element which transmits an
angular deflection signal to a rotary transformer drive transducer. This
signal is processed through solid state torque sensor electronics in a remote
enclosure to produce a linear 4 - 20 mA signal proportional to the
viscometer’s viscosity range.
Measuring range and shear rate can be varied by changing rotational speed
(via gearbox or by speed control) or by changing the rotor and/or stator as
specified in Table D-1. Refer to Appendix D for more information on
changing geometrical components.
OUTLET
ROTOR
STATOR PRODUCT DRIVE ENDCAP

STREAM
OUTPUT SIGNAL
TO ENCLOSURE DRIVE MOTOR
MEASURING CHAMBER GEARBOX

TORSION ELEMENT
PRODUCT
MEASURING ANNULUS STREAM
INLET
Figure 1-3: TT100 In-Line Viscometer Product Stream Flow
P/N M/97-520 1-5

Correlation with Other Measurements

Typically, there is a difference between laboratory and process viscosity
measurements. Laboratory measurements, for a given fluid, are usually
higher than process measurements.
Viscosity measurements are unique among common types of fluid

measurement in that, for most fluids, numerical values that are generated
are dependent upon flow conditions in the fluid being measured (shear rate
or velocity gradient). Other factors such as temperature change,
turbulence, and pressure among the most prominent, also affect the
readings.
Frequently it may become necessary to correlate readings provided by

your on-line viscometer to those factors that influence viscosity obtained
by other methods. The correlation consists of holding the viscosity
dependent factors constant, as mentioned above, and plotting the on-line
viscosity value against the other reading as shown in Figure 1-4. A
successful empirical correlation will assure the process operator that an on-
line reading can be matched to a viscosity value derived by the other
method. The correlation of these readings may be instrumental in
educating process operators how the process stream relates to bench-top
derived viscosity measurements.
Many factors beyond those noted above, which are more difficult to control
in an on-line situation than in a laboratory environment, can potentially
affect your correlation. Refer to Appendix A and contact Brookfield
Engineering Laboratories, Inc. for assistance in generating an empirical
correlation.
LAB/QC VISCOMETER READING (cP)
AT STANDARD TEMPERATURE
N
ATIO
RE L
COR
ACCEPTABLE LIMIT
ACCEPTABLE LIMIT
ONLINE VISCOMETER READING (cP)

AT PROCESS TEMPERATURE
Figure 1-4: In-Line Viscometer Correlation with Other Measurement Techniques
1-6 P/N M/97-520

Specifications
The TT100 In-Line Viscometer is available in standard or optional
configurations as listed in Table 1-1.
Table 1-1: Model TT100 In-Line Viscometer Specifications
Parameter Standard Configuration Optional Configuration*
Viscosity Range 10 - 500,000 cP 10 - 500,000 cP

(See Note 1)
Shear Rate Range 10 - 1000 sec-1 0.02 - 12,000 sec-1
Temperature Range -40º - 300º F -40º - 500º F
(See Note 2)
Pressure Range 0 - 200 psi Vacuum to 500 psi
(See Note 3)
Reproducibility ± 0.5% of span ± 0.5% of span
Signal Output 4 - 20 mA 0 - 20 mA, 0 - 10 VDC
Power Requirements 115VAC 50/60Hz 230VAC 50/60 Hz
100 Watts 100 Watts
Chamber 300 Series S/S 316 S/S wetted parts
1 inch NPT (Female) construction
inlet and outlet 1, 1 1/2, or 2 inch threaded or
flanged, 4 inch flanged
Motor Single-speed synchronous Multiple-speed with speed

control
Dimensions 5 x 5 x 17 inches 5 x 5 x 17 inches
(127 x 127 x 431.8 mm) (127 x 127 x 431.8 mm)
Construction NEMA 4 Refer to Appendix D
Water tight and dust tight
Weight 50 lbs. (23 kg) 50 lbs. (23 kg)
* Optional Configurations offer dual range capability, custom mounting and/or special viscosity ranges and shear
rates.
NOTE 1: Range is calibrated with a 0 cP lower limit. The upper limit can be any value between 10 - 500,000 cP.
NOTE 2: Under certain conditions, temperatures as high as 700º F may be accommodated.
NOTE 3: Under certain conditions, pressures as high as 1000 psi may be accommodated.
P/N M/97-520 1-7

Required Utilities
The TT100 In-Line Viscometer requires the utility connections listed in
Table 1-2 to operate.
Table 1-2: Utility Requirements
Parameter Value
Supply Voltage 115/230 VAC

Line Frequency 50 or 60 Hz
(See Note 1)
Power 100 Watts
Flushing Requirements 3 - 10 gpm
(See Note 2) 30 - 40 psig
1/8 inch pipe thread endcap connection
Barrier Fluid Pressure 20 psi above maximum process flow pressure
(See Note 3)
NOTE 1: Variations in line frequency will affect instrument span and accuracy.
NOTE 2: If viscometer is equipped with flushing option.
NOTE 3: If viscometer is equipped with double mechanical seals.
Current Draw - Starting & Running

The normal running power requirement for TT100 In-Line Viscometer is
100 watts. However, the instantaneous starting current requirement for the
TT100 drive motor can be at least five times greater.
Brookfield Engineering Laboratories, Inc. recommends that any inverter,

transformer, or similar device that is used with the Model TT100 should be
rated at 750 volt-amperes or greater.
1-8 P/N M/97-520

Cleaning
To ensure proper viscometer operation, it is important to properly clean or
flush the viscometer at regularly scheduled intervals. Solids can build up
on the opposing cylinder surfaces and interfere with the angular movement
of the stator and torsion element and their movement in relation to the stop
posts which protrude through the stator. Additionally, solids can build up at
the mechanical seal which may affect its ability to maintain leak-free
operation.
The user must establish cleaning procedures and cleaning fluids.

Clean-In-Place (CIP) is strongly recommended as the cleaning procedure
of choice. In addition to CIP, the user may choose the flushing option in
order to direct cleaning fluid to the internal components to enhance the
cleaning process. The third choice for cleaning is to manually clean the
internal components. This is not a recommended practice due to the
damage that can be caused on the torsion element when exposed to this
manual cleaning.
The clean-in-place procedure can be accomplished with high flow rate

cleaning fluid or steam.
NOTE: The cleaning fluid must be compatible with the seal. Steam
Temperature should not be higher than the temperature rating of the
viscometer.
In some instances, the instrument installation can be plumbed with 2 three-
way valves with the cleaning fluid introduced and drained through the side
ports of these valves.
The flushing option, available in the TT100, is offered in either or both

endcaps. When in use, the cleaning fluid is introduced towards the internal
components through directional spray nozzles. This cleaning procedure
should be accomplished with the measuring chamber void of any process
fluid and the cleaning fluid at a pressure of approximately 30-40 psi and a
flow rate of 3-10 gpm.
Refer to Section 5 - Maintenance for clean-in-place or flushing

procedures.
P/N M/97-520 1-9

Component Identification
The following paragraphs provide a brief description of each component
within the TT100 In-Line Viscometer. Refer to Figure 1-5 for the
component location within the viscometer.
Torque Sensor Assembly

The Torque Sensor Assembly contains the torsion element, armature, and
field coil. These components generate an electrical signal proportional to
the viscous drag of the process fluid which is sent to the torque sensor
electronics enclosure for signal processing.
Sensing Endcap
The Sensing Endcap contains the torque sensor assembly and all related
components.
Stator
The Stator, which is mounted on the torsion element, applies torque
generated by viscous drag to the torsion element. The dimensions of the
stator, in conjunction with the rotor, are critical to the accuracy of the
viscometer. Many different stator sizes are available which provide
different viscometer measurement ranges.
Stop Posts
The stop posts limit stator/torsion element movement to prevent torsion
element damage.
Inlet/Outlet
The Inlet and Outlet are provided with an appropriate connection type and
allows process fluid to enter or exit the viscometer. Either connection may
be used to allow process fluid to enter or exit the viscometer.
Rotor
The Rotor is a hollow cylinder which constantly rotates around the stator,
driven by the motor. The rotation of the rotor moves process fluid in the
measuring annulus which results in viscous drag on the stator. Rotors are
available that contain additional surface holes to allow a faster turnover of
process fluid in the measuring annulus. Different rotor sizes are also
available.
1-10 P/N M/97-520

Drive Endcap
The Drive Endcap supports the rotor, mechanical seal, drive shaft, bearings
and bearing housing, motor, and all related mechanical components.
Motor Cable
The Motor Cable supplies electrical power to the motor from the motor
control enclosure, or directly from a power source.
Gearbox
The Gearbox reduces rotational speed and allows the drive shaft to rotate
slower than the motor. The rotational speed of the drive shaft is determined
by Brookfield Engineering Laboratories, Inc. based upon customer
viscosity range requirements.
Drive Motor
The Drive Motor is an electric motor which provides a constant rotational
speed to the gear box, drive coupling, and viscometer drive shaft. The
drive motor is usually a single-speed synchronous motor but is also
available in a controlled variable speed induction motor for custom
applications.
Drive Coupling
The Drive Coupling connects the viscometer drive shaft to the
gear box. The drive coupling contains a rubber cushion (or bronze cushion
for high temperature applications) to isolate the viscometer from motor
vibration.
Bleed Screw
The Bleed Screw is used to vent air from the viscometer which may be
trapped within the measuring chamber.
Measuring Chamber
The Measuring Chamber is the area in which process fluid viscosity is
measured. Process fluid may flow through it in either direction.
Measuring Annulus
The Measuring Annulus is the space between the stator and rotor. Process
fluid is continuously sheared within the measuring annulus which creates
viscous drag on the stator.
P/N M/97-520 1-11

Sensing Cable
CAUTION
Changing the length of the sensing cable will affect viscometer calibration.
Refer to Appendix A and contact Brookfield Engineering Laboratories for
more information.
The Sensing Cable carries the electrical signal that is proportional to the
viscous drag of the process fluid. The signal is sent to the torque sensor
electronics enclosure for processing. The Sensing Cable also carries an
excitation current from the torque sensor electronics enclosure to the
torque sensor assembly.
Torsion Element
The Torsion Element, which is part of the torque sensor assembly, senses
the torque from the viscous drag on the stator. The twist or deflection of the
torsion element is proportional to the torque applied to it.
Heat Baffle
The Heat Baffle, which is sometimes referred to as an insulator, dissipates
heat from the viscometer that has been transferred from the process fluid.
The transfer of heat to the baffle protects the field coil from high
temperatures.
Torque Sensor Electronics Enclosure

The Torque Sensor Electronics Enclosure contains a circuit board which
processes the signal from the torque sensor assembly and generates a linear
electrical signal (4 - 20 mA) proportional to the viscosity of the process
fluid in the measuring annulus. The circuit board also provides an
excitation current to the field coil.
The 4 - 20 mA signal can be:
• Observed on a readout display
• Transmitted to a personal computer for process monitoring and

control
• Recorded for process control records
1-12 P/N M/97-520

Motor Control Enclosure

The Motor Control Enclosure accepts 115/230 VAC and supplies
appropriate power to the drive motor. The enclosure also contains the
motor ON/OFF power switch and optional motor speed controller for
variable speed motor applications.
OUTLET
STATOR
ROTOR GEARBOX
DRIVE ENDCAP
SENSING ENDCAP
TORQUE SENSOR PRODUCT
ASSEMBLY STREAM
HEAT BAFFLE DRIVE MOTOR
DRIVE COUPLING
TORSION ELEMENT
PRODUCT BLEED SCREW
STREAM
MEASURING ANNULUS
MEASURING CHAMBER
STOP POST
INLET
SENSING CABLE MOTOR CABLE
TORQUE SENSOR MOTOR

OUTPUT SIGNAL 4 - 20 mA ELECTRONICS CONTROL ON/OFF SWITCH
ENCLOSURE ENCLOSURE
115/230 VAC 115/230 VAC
50/60 HZ 50/60 HZ
Figure 1-5: Typical Model TT100 In-Line Viscometer Component Identification

(NEMA 4 Shown)
P/N M/97-520 1-13

Options
The following optional equipment is available to enhance the operation of
the TT100 In-Line Viscometer when installed within certain product
stream applications. Refer to Appendix A and contact Brookfield
Engineering Laboratories, Inc. for more information on these options and
accessories.
Double Mechanical Seal

A double mechanical seal can be installed in the following the service
conditions which are too severe for the standard (single) mechanical seal:
• Vacuum
• Abrasive Slurries
• Toxic Fluids
• Fluids which harden when exposed to air and/or elevated

temperatures
Elliptical Baffle
The Elliptical Baffle can be installed when measuring highly viscous or
low flow product streams to direct sufficient flow through the annulus.
Perforated Rotor
The Perforated Rotor can be installed to increase product turnover within
the measuring annulus.
Serrated Stator
The Serrated Stator can be installed to ensure shearing by overcoming
slippage between the stator and the fluid being measured. The serrated
stator is useful with certain product streams such as slurries.
Flushing Endcap
The Flushing Endcap design facilitates cleaning the measuring annulus and
torsion element. Compatible solvent can be introduced under pressure
when cleaning while the In-Line Viscometer is on-line and empty of
process fluid.
1-14 P/N M/97-520

Accessories
The following accessories are available to display, control, and record data
from the TT100 In-Line Viscometer.
• Analog Display
• Digital Display
• Controller
• Recorder
• Temperature Indication
• Temperature Compensation
P/N M/97-520 1-15

1-16 P/N M/97-520

Section 2 - Installation
Unpacking and Inspection

NOTE: Upon receipt, inspect the shipping carton and viscometer
components for shipping damage. Report any damage to the shipping
company immediately.
The shipping carton should contain the following components:
• TT100 In-Line Viscometer
• Torque Sensor Enclosure and Cable
• Motor Controller Enclosure and Cable
• Instruction Manual
• Calibration Bars and Tools
• Optional Equipment
NOTE: Make sure the calibration bars are kept in a safe place and
accessible for use during calibration.
Installation Requirements
NOTE: Refer to the TT100 In-Line Viscometer Specification sheet to
determine the configuration of the viscometer.
The TT100 In-Line Viscometer must be installed in a manner that will
optimize its performance. The installation requirements are:
• Provide a continuous product stream to the viscometer with a

minimum time lag between changes in process and their effects on
the viscometer. This stream must be representative of other process
fluid.
• Install the viscometer so that it is always full of fluid without air

pockets or voids. Upflow line mounting is recommended as shown
in Figure 2-1. Avoid pipe configurations which allow air or solids
to collect in the viscometer. The viscometer can only measure the
viscosity of fluids contained in the measuring annulus.
P/N M/97-520 2-1

Installation
• Provide a continuous product stream flow rate of 0.5 to 20 GPM

that produces a pressure drop of less than 25 psi.
NOTE: The estimated resistance to flow of a 1, 1.5, or 2 inch TT100 is

equivalent to that of an average 3 inch globe valve.
• Provide a straight pipe leading into the viscometer that is at least
ten times the pipe diameter in length.
• Know the product stream’s rheology and how it responds to other

factors occurring in the process such as temperature, pH, pressure,
etc. Control or monitoring of the product stream’s temperature may
be required.
• Power: Single phase, 115 or 230 VAC 50 or 60 Hz
• For NEMA 7 applications, the customer must provide a 600 VAC,

18 Gauge, two conductor with ground viscometer power cable
between the Motor Control Enclosure and the viscometer motor
which must conform to local electrical codes.
• Flushing connection: 1/8 inch-27 NPT thread in either endcap

5 - 10 GPM of flushing fluid at 40 - 90 psig.
• If equipped, double mechanical seals require clear barrier fluid

under pressure at 20 psi above maximum process pressure
connected to a 1/8 inch standard pipe thread connection in the drive
endcap. No flow is required, but venting of air from the seal is
required to avoid premature seal wear.
• If the viscometer is to be cleaned in place, isolation valves, flow

boosters, or other auxiliary items may be required.
2-2 P/N M/97-520

Calculating Minimum Straight Pipe Length

NOTE: The TT100 In-Line Viscometer does not require special supports or
special pipe alignment. The housing is symmetrical with respect to the
flow direction.
Refer to Figure 2-1 and the following procedure to install the viscometer.
1. Calculate the minimum straight pipe length leading to the

viscometer as follows:
Pipe Diameter x 10 = minimum straight pipe length
2. Select an installation location that will provide clearances of 14

inches from the sensing endcap, and 16 inches from the chamber
side as shown in Figure 2-1.
3. Using standard plumbing practices for the appropriate viscometer
flange type, install the viscometer in the preferred position as
shown in Figure 2-1.
4. If equipped, install the flushing fluid supply using the appropriate
valves.
5. If equipped, install the double mechanical seal barrier fluid supply
using appropriate valves as follows:
a. Connect the barrier fluid to the lower valve.
b. Vent the barrier fluid from the upper valve.
NOTE: The viscometer may be equipped with an optional pressure sensing
switch which is mounted on the double mechanical seal housing. If the
appropriate barrier fluid pressure is not sensed, the motor will not operate.
Installation
NOTE: Refer to the TT100 In-Line Viscometer Specification sheet to
determine the configuration of the viscometer.
1. Depending upon your configuration, refer to the appropriate
installation diagram as shown in Figures 2-2 through 2-4 to
install the viscometer.
P/N M/97-520 2-3

Installation
ALTERNATE
INSTALLATION
TORQUE SENSOR
ELECTRONICS
ENCLOSURE
115 or 230 VAC

50 or 60 HZ
14 INCH MINIMUM
CLEARANCE
16 INCH MINIMUM PREFERRED

CLEARANCE INSTALLATION
PIPE DIAMETER X 10 = MINIMUM STRAIGHT PIPE LENGTH

MOTOR
CONTROL
ENCLOSURE
MAIN
115 or 230 VAC LINE
50 or 60 HZ
BYPASS FLOW
0.5 - 20 GPM
NOTE: When installing the viscometer in the alternate position, rotate the viscometer on
the pipe axis to minimize pockets where air or solids may collect.
NOTE: For all viscometers, position the drive endcap bleed screw in the UP position to
assist in the venting of gases.
Figure 2-1: Typical In-Line Viscometer Installation
2-4 P/N M/97-520

TORQUE SENSOR
ELECTRONICS
ENCLOSURE
POWER CABLE
CUSTOMER SUPPLIED 4 - 20 mA OUTPUT SIGNAL CABLE
SENSING CABLE
MOTOR POWER CABLE
MOTOR
CONTROL
ENCLOSURE
POWER CABLE
NOTE: REFER TO DRAWING NUMBER CA1-001 (115 VAC) OR CA1-047 (230 VAC) IN
APPENDIX B FOR ELECTRICAL CONNECTIONS.
Figure 2-2:NEMA 4 - 115 or 230 VAC 50/60 Hz Installation
P/N M/97-520 2-5

Installation
TORQUE SENSOR
NON-HAZARDOUS AREA ELECTRONICS
ENCLOSURE
POWER CABLE
CUSTOMER SUPPLIED CONDUIT

HAZARDOUS (CLASSIFIED) AREA
CUSTOMER
SUPPLIED
MOTOR MOTOR POWER
CONTROL CABLE
ENCLOSURE
NON-HAZARDOUS AREA
POWER CABLE
NOTE: REFER TO DRAWING NUMBER CA1-035 IN APPENDIX B FOR ELECTRICAL CONNECTIONS.
NOTE: ALL CONNECTIONS SHALL BE TERMINATED ACCORDING TO FACTORY MUTUAL NEMA 7

SPECIFICATIONS.
Figure 2-3:NEMA 7 - Explosion Proof 115 VAC 50/60 Hz Installation
2-6 P/N M/97-520

NON-HAZARDOUS AREA TORQUE SENSOR

ELECTRONICS
SENSING CABLE
ENCLOSURE
POWER CABLE

CUSTOMER SUPPLIED MOTOR POWER CABLE
HAZARDOUS (CLASSIFIED) AREA
MOTOR CONTROL
ENCLOSURE
NON-HAZARDOUS AREA
POWER CABLE
NOTE: REFER TO DRAWING NUMBER CA1-024 (115 VAC) OR CA1-025 (230 VAC) IN APPENDIX B
FOR ELECTRICAL CONNECTIONS.
NOTE: ALL CONNECTIONS WITHIN HAZARDOUS AREA SHALL BE TERMINATED

ACCORDING TO CENELEC SPECIFICATIONS.
Figure 2-4:CENELEC - 115 or 230 VAC 50/60 Hz Installation
P/N M/97-520 2-7

Installation
Flushing Connections
NOTE: The flushing connections and lines, which may be connected to one
or both endcaps, are application specific.
1. Remove the flushing connection plug from each endcap.
2. Install the flushing line connector in the respective endcap.
3. Connect the flushing lines to the connectors on each endcap.
4. Proceed with Section 3 -Calibration.
2-8 P/N M/97-520

Section 3 - Calibration
Introduction
The TT100 In-Line Viscometer is custom calibrated at the factory and
shipped ready for service. Brookfield Engineering Laboratories, Inc.
recommends that certain calibration procedures be performed after any of
the following events have occurred:
• Installation
• Disassembly and Cleaning
• Component Replacement
The flowcharts in Figures 3-1, 3-2, and 3-3 describe the appropriate
calibration procedures that should be performed after installation,
disassembly and cleaning, and component replacement.
CAUTION
The length of the sensing cable should not be changed. Contact Brookfield
Engineering Laboratories, Inc. for more information.
CAUTION
The viscometer must be empty of process fluid, clean, and free of obstruc-
tions before it can be calibrated. Refer to Section 5 - Maintenance and
perform the appropriate cleaning procedure for the process fluid applica-
tion.
P/N M/97-520 3-1

Calibration
Tools Required
The tools listed in Table 3-1 are required for calibrating the TT100 In-Line
Viscometer.
Table 3-1: Tools Required
Tool Quantity
Digital Volt Meter 1

#18 - 24 AWG Insulated Wires - 6 inches long 2
Medium Straight Blade Screwdriver 1
Small Straight Blade Screwdriver 1
5mm Hex Wrench 1
Calibration Bars 1 or 2*
* Dual range viscometers may be supplied with two calibration bars.
3-2 P/N M/97-520

START
Install
Viscometer
(Refer to Section 2)
Perform Fine
Zero Milliampere
Calibration Test
(Refer to Page 3-6) Perform Fine Zero
Voltage Calibration
(Refer to Page 3-21)
Did the Fine Zero FAIL Perform Coarse Zero

Calibration Test Calibration
Pass or Fail? (Refer to Page 3-18)
PASS
Operate
Viscometer
END
Figure 3-1: Typical Installation Calibration Flowchart
P/N M/97-520 3-3

Calibration
START
Perform Disassembly and

Cleaning Procedures
Perform Preliminary
Torque Sensor Test
(Refer to Page 3-8)
Perform Single or Dual

Range Viscometer Span
Calibration
(Refer to Page 3-10 or 3-14)
Operate
Viscometer
END
NOTE: This flowchart assumes that the Microsyn housing cover has not been removed
during the cleaning process.
Figure 3-2: Typical Calibration after Viscometer Disassembly and Cleaning
3-4 P/N M/97-520

START
Perform Component
Replacement Procedure(s)
Perform Preliminary
Torque Sensor Test
(Refer to Page 3-8)
Were armature and

Microsyn field coil YES
disturbed during
component replacement?
Perform Coarse Zero

Calibration
NO (Refer to Page 3-18)
Perform Fine Zero Voltage

Calibration
(Refer to Page 3-21)
Perform Single or Dual

Range Viscometer
Span Calibration
(Refer to Page 3-10 or 3-14)
Operate
Viscometer
END
Figure 3-3:Typical Calibration after Component Replacement
P/N M/97-520 3-5

Calibration
Fine Zero Milliampere Calibration Test

The Fine Zero Milliampere Calibration Test should be performed after the
viscometer has been installed and before process fluid has been introduced
into the viscometer. This procedure ensures that the zero position of both
the Microsyn field coil assembly and the torque sensor electronics are
matched.
CAUTION
The internal components of the viscometer must be empty of process fluid,

clean, and free of obstructions before it can be calibrated. Refer to Section
5 - Maintenance and perform the appropriate cleaning procedure for the
process fluid application.
NOTE: Refer to Figure 3-4 for torque sensor circuit board component
locations.
1. Turn power OFF to the motor controls and torque sensor
electronics enclosure.
2. Open the cover to the torque sensor electronics enclosure.
3. Disconnect milliampere output cable from J1 Pins 1 and 2 on the
torque sensor electronics circuit board.
4. Perform the following steps to allow Digital Volt Meter (DVM)
connections to the torque sensor printed circuit board:
a. Cut two lengths of #18 - 24 AWG wire 6 inches long.
b. Strip approximately 1/8 inch of insulation off each end.
c. Connect the first wire to J1-Pin 1.
d. Connect the second wire to J1-Pin 2.
5. Set the Digital Volt Meter (DVM) to the 0 - 20.00 mA scale.
6. Connect the DVM positive lead to the wire installed on J1-Pin 1.
7. Connect the DVM negative lead to the wire installed on J1-Pin 2.
8. Turn power ON to the torque sensor electronics enclosure.
9. Adjust R18 (or the Remote Zero potentiometer if so equipped) until
the DVM indicates 4.00 mA.
NOTE: If 4.00 mA cannot be achieved, perform the Coarse Zero
Calibration procedure.
10. Turn power OFF to the torque sensor electronics enclosure.
3-6 P/N M/97-520

11. Remove the DVM connections and wires from J1 on the circuit
board.
12. Reconnect the milliampere output cable to J1 Pins 1 and 2 on the
13. Install the enclosure cover.
15. Refer to Section 4 - Operation.
R36
R17
R18
SHIELD 12
PRIMARY - (RED) 11
PRIMARY + (GREEN) 10
GROUND - (PURPLE) 9
SECONDARY - (BLUE) 8
SECONDARY + (YELLOW) 7
6
-V 5
+V 4
3
-mA 2
4 3 2 1
+mA 1
R19 J1
+
R20 J2 J3
R31 1 2 3 4 1 2 3
SIGNAL COMMON GROUND
LOW RANGE
R51 L1
HIGH RANGE L2
GROUND R56
Figure 3-4:Torque Sensor Electronics Board Adjustment Component Locations
P/N M/97-520 3-7

Calibration
Preliminary Torque Sensor Test

Perform the following checks to make sure the torque sensor is not
damaged before calibrating the viscometer.
1. Remove the sensing endcap from the viscometer as follows:
CAUTION

Handle the sensing endcap assembly with care when removing it from the
measuring chamber. Damage to the torsion element may result by
contacting the stator with the rotor.
a. Remove seven of the eight screws that secure the sensing

endcap to the measuring chamber.
b. While holding the sensing endcap in position, remove the
last screw and carefully remove the sensing endcap from the
measuring chamber.
c. Carefully place the sensing endcap flange in a vise to hold it
secure and parallel to the work surface as shown in Figure
3-5.
2. Visually inspect the torsion element to make sure the wires are
straight and square. Gently straighten any minor deviations.
3. Check for the absence of friction within the torque sensor assembly
by performing the following steps:
c. Remove the cover from the torque sensor electronics enclo-
sure.
d. Connect the first wire to J1-Pin 1 torque sensor printed cir-
cuit board.
e. Connect the second wire to J1-Pin 2 torque sensor printed
circuit board.
f. Set the Digital Volt Meter (DVM) to the 0 - 20.00 mA scale.
3-8 P/N M/97-520

g. Connect the DVM positive lead to the wire installed on

J1-Pin 1.
h. Connect the DVM negative lead to the wire installed on
J1-Pin 2.
i. Turn power ON to the torque sensor electronics enclosure.
j. Gently apply torque to the stator, as shown in Figure 3-5,
and observe the DVM display for a rapid, smooth response
to the torque applied to a maximum of + 20.00 mA.
Figure 3-5: Applying Torque to the Stator
k. Release the stator and note the final (zero) position DVM
reading.
l. Repeat steps j and k to apply torque in the opposite direc-
tion.
m. Repeat steps j - l several times. If the zero position DVM
readings from one direction of torque are not within
± 0.05 mA and from opposite directions within ± 0.1 mA,
then the viscometer will not be able to be calibrated. Refer
to Appendix A and call Brookfield Engineering Laborato-
ries, Inc. for assistance.
n. Proceed with Single or Dual Range Viscometer Calibration.
P/N M/97-520 3-9

Calibration
Single Range Viscometer Span Calibration

In this procedure, a calibration bar will be used to simulate torque the
torsion element will encounter during single range measurement of your
specific process fluid. Span calibration allows the torque sensor
electronics to be adjusted for the specific range gain in milliamperes from
the no torque or (zero point) set at 4.00 mA through 20.00 mA with the
calibration bar applied.
CAUTION

NOTE: This procedure must be performed before process fluid is

introduced into the viscometer.
NOTE: The value of the calibration bar is determined by viscosity range,
torque range, and the geometry of the cylinders and should not be
considered to represent full scale.
NOTE: Refer to the range information within the Viscosity & Calibration
Data on the Viscometer Specification Sheet, that came with your
viscometer, for the appropriate single range calibration information to be
used for this calibration procedure.
NOTE: Refer to Figure 3-4 for torque sensor circuit board component
locations.
electronics enclosure and remove the cover.
CAUTION

3-10 P/N M/97-520


measuring chamber.
NOTE: Both the torsion element axis and the calibration bar axis must be
within 8º of horizontal for calibration within the limits of the instrument.
3. Carefully place the sensing endcap flange in a vise to hold it secure
and parallel to the work surface as shown in Figure 3-6.
4. Make sure the torsion element is clean. Refer to Section 5 -
Maintenance for more information.
5. Disconnect milliampere output cable from J1 Pins 1 and 2 on the
c. Connect one wire to J1-Pin 1.
7. Depending upon your viscometer’s range (refer to viscometer
specification sheet), verify that the range jumper wire between
J2-Pin 1 and J2-Pin 3 (HIGH range) or J2-Pin 1 and J2-Pin 2
(LOW range).
9. Set the digital volt meter (DVM) to the 0 - 20.00 mA scale.
10. Connect the DVM positive lead to the wire on J1-Pin 1.
11. Connect the DVM negative lead to the wire on J1-Pin 2.
12. Observe the DVM reading. Adjust R18 for 4.00 mA.
NOTE: If you cannot obtain 4.00 mA by adjusting R18, set R18 to mid
point (approximately 7.5 turns) and then perform the Fine Zero Voltage
Calibration procedure.
NOTE: To ensure proper span calibration, make sure the calibration bar is
installed as shown in Figure 3-6.
P/N M/97-520 3-11

Calibration
CAUTION
Do not apply extra torque beyond that which is provided by the calibration
bar. Damage to the torsion element may result.
13. Install the calibration bar, that came with your viscometer, on the
stator mounting screws, parallel to the work surface, and in the
direction to which torque will be applied, as shown in Figure 3-6.
SENSING ENDCAP ASSEMBLY
CALIBRATION BAR
UE
RQ
TO
NOTE: The viscometer may actually be calibrated to sense torque in either direction. The viscometer
motor can be wired to rotate in either direction. Calibration and the direction of rotation must be
matched. The standard calibration method is shown in Figure 3-6.
Figure 3-6: Calibration Bar Installation
14. Adjust R20 for the single LOW range or R51 for the single HIGH
range mA value shown on the Viscometer Specification Sheet.
15. Remove the calibration bar. The DVM should indicate
4.00 ± .02 mA.
NOTE: If steps 13 and 14 cannot be achieved, refer to Appendix A and
call Brookfield Engineering Laboratories, Inc. for assistance.
16. Repeat steps 12 - 14 to ensure calibration repeatability.
18. Remove the DVM wire connections from the torque sensor
electronics circuit board.
3-12 P/N M/97-520

19. Reconnect the milliampere cable to J1 Pins 1 and 2 on the torque

sensor electronics circuit board and install the enclosure cover.
CAUTION
Handle the sensing endcap assembly with care when installing it into the
20. Remove the sensing endcap from the vise and carefully install it
into the viscometer.
21. Install the sensing endcap mounting bolts and tighten them in a
rotational pattern.
CAUTION
Do not run the motor without fluid in the viscometer. Damage to the
mechanical seals may result.
P/N M/97-520 3-13

Calibration
Dual Range Viscometer Span Calibration

In this procedure, calibration bars will be used to simulate a torque the
torsion element will encounter during dual (high and low range)
measurement of your specific process fluid. Span calibration allows the
torque sensor electronics to be adjusted with the calibration bar applied for
the specific range gain in milliamperes from the no torque (zero point) set
at 4.00 mA through 20.00 mA.
CAUTION

NOTE: Refer to the high and low range information within the Viscosity &
Calibration Data on the Viscometer Specification Sheet, that came with
your viscometer, for the appropriate range calibration information to be
used for this calibration procedure. Only one calibration bar may be
supplied with dual range units if the same bar is used to calibrate both
ranges.
electronics enclosure and remove the cover.
CAUTION
measuring chamber to prevent damage to the torsion element.

measuring chamber.
3. Place the sensing endcap flange in a vise to hold it secure and
parallel to the work surface as shown in Figure 3-7.
4. Make sure the torsion element is clean. Refer to Section 5 -
Maintenance for more information.
3-14 P/N M/97-520


c. Connect one wire to J1-Pin 1.
6. Connect a range jumper wire between J2-Pin 1 and J2-Pin 3
(HIGH range).
NOTE: To ensure proper span calibration, make sure the calibration bar
installed as shown in Figure 3-7.
8. Set the digital volt meter (DVM) to the 0 - 20.00 mA scale.
11. Observe the DVM reading. Adjust R18 for 4.00 mA.
12. Move the range jumper wire between J2-Pin 1 and J2-Pin 2
(LOW range).
13. Observe the DVM reading. It should indicate 4.00 mA.
14. Move the range jumper wire between J2-Pin 1 and J2-Pin 3
(HIGH range).
NOTE: If 4.00 ± .02 mA is not displayed on the DVM after switching the
range jumpers, then perform the Fine Zero Voltage Calibration procedure.
CAUTION
Do not apply extra torque beyond that which is provided by the calibration
bar. Damage to the torsion element will result.
15. Install the heaviest of the two calibration bars that came with your
viscometer, on the stator mounting screws, parallel to the work
surface, and in the direction to which torque will be applied, as
NOTE: Some dual range viscometers may be supplied with one calibration
bar. If so, only one calibration bar will be shown on the viscometer
specification sheet.
P/N M/97-520 3-15

Calibration
SENSING END CAP ASSEMBLY
CALIBRATION BAR
UE
RQ
TO
NOTE: Torque may be applied in the opposite direction for some viscometer models.
Figure 3-7: Calibration Bar Installation
16. Adjust R51 for the HIGH range mA value shown on the Viscometer
Specification Sheet.
NOTE: If 4.00 ± .02 mA cannot be achieved in step 16, refer to Appendix
A and call Brookfield Engineering Laboratories, Inc. for assistance.
4.00 ± .02 mA.
18. Remove the range jumper wire from J2-Pin 3 and connect it to
J2-Pin 2 (LOW range).
19. Observe the DVM reading.
NOTE: If 4.00 ± .05 mA is not displayed on the DVM after switching the
range jumpers, then perform the Fine Zero Voltage Calibration procedure.
20. Install the lightest of the two calibration bars, that came with your
viscometer, on the stator mounting screws, parallel to the work
surface as shown in Figure 3-7.
21. Adjust R20 for the mA LOW range value shown on the Viscometer
Specification Sheet.
NOTE: If 4.00 ± .02 mA cannot be achieved, refer to Appendix A and call
Brookfield Engineering Laboratories, Inc. for assistance.
4.00 ± .02 mA
23. Repeat steps 11 - 22 to ensure calibration repeatability.
3-16 P/N M/97-520


25. Remove the DVM wire connections from the torque sensor
electronics circuit board.
26. Reconnect the milliampere cable to J1 Pins 1 and 2 on the torque
sensor electronics circuit board and install the enclosure cover.
27. Remove the sensing endcap from the vise and careful install it into
the viscometer.
28. Install the sensing endcap mounting bolts and tighten them in a
rotational pattern.
CAUTION
Do not run the motor without fluid in the viscometer. Damage to the
mechanical shaft seals may result.
P/N M/97-520 3-17

Calibration
Coarse Zero Calibration
CAUTION
If the sensing endcap has been disassembled, then Coarse Zero

Calibration must be checked before fine zero voltage calibration can
occur. Failure to check the coarse zero calibration may cause problems
with fine zero voltage calibration. If the sensing endcap has not been disas-
sembled, then fine zero voltage calibration can be performed without
checking the coarse zero calibration.


2. Remove the Microsyn housing cover as follows:
a. Using a wrench, loosen and remove the signal cable strain
relief nut. Slide the nut, ring, and insulator down the cable.
b. Remove the screws from the Microsyn housing cover.
c. Rotate and lift the housing cover off the assembly and slide
it down the cable.
4. Connect a range jumper wire between J2-Pin 1 and J2-Pin 3
(HIGH range).
5. Set R31 to its mid point position (approximately 7.5 turns).
8. Set the DVM to the 0 - 10 VDC scale.
9. Connect the DVM positive lead to the wire installed on J1-Pin 4.
3-18 P/N M/97-520

10. Connect the DVM negative lead to the wire installed on J1-Pin 2.
11. Loosen, but do not remove the Microsyn field coil assembly
mounting screws as shown in Figure 3-8.
12. Rotate the Microsyn field coil assembly, as shown in Figure 3-8,
until 0 ± .2 VDC is observed on the DVM. Tighten the mounting
screws.
Figure 3-8: Microsyn Field Coil Assembly Rotation
CAUTION

measuring chamber.
14. Carefully place the sensing endcap flange in a vise to hold it secure
and parallel to the work surface.
P/N M/97-520 3-19

Calibration
15. Rotate the stator as shown in Figure 3-9. The DVM should increase
in a positive direction. If the DVM reading does not increase in a
positive direction, loosen the Microsyn field coil mounting screws
and rotate the field coil to obtain the next possible 0 ± .2 VDC
position. Tighten the screws.
Figure 3-9: Stator Direction of Rotation
16. Rotate the stator once again as shown in Figure 3-9. The DVM
should increase in a positive direction.
17. Proceed with Fine Zero Voltage Calibration.
3-20 P/N M/97-520

Fine Zero Voltage Calibration
CAUTION

Fine Zero Voltage Calibration ensures that the zero voltage level has been
properly calibrated.
This procedure can be used to perform fine zero voltage adjustment once
the viscometer has been installed, or after a component requiring
calibration has been replaced.

5. Adjust R31 on the torque sensor printed circuit board to its mid-
point position (approximately 7.5 turns).
6. Connect the range jumper wire between J2-Pin 1 and J2-Pin 3
(HIGH range).
7. Set the digital volt meter (DVM) to the 0 - 10 VDC scale.
10. Adjust R31 until the DVM indicates 0 ±.005 VDC.
11. Remove the range jumper wire from J2-Pin 3 and connect it to
J2-Pin 2 (LOW range).
12. Verify the DVM indicates 0 ±.005 VDC. If not, adjust R31 to
0 ±.005 VDC.
P/N M/97-520 3-21

Calibration
13. Proceed with Single or Dual Range Viscometer Span

Calibration.
3-22 P/N M/97-520

Section 4 - Operation
Introduction
Once the TT100 In-Line Viscometer has been installed as described in
Section 2 - Installation and calibrated as described in Section 3 -
Calibration, the viscometer is ready to be used.
CAUTION
Do not proceed with the operation of the viscometer unless the calibration
has been verified as described in Fine Zero Milliampere Calibration Test
in Section 3 - Calibration.
Mechanical Seal Requirements

The TT100 In-Line Viscometer is provided with mechanical face seals
which prevents the leakage of process fluid into or from the measuring
chamber at the drive shaft entry point. The seals are designed for
continuous operation only if lubricated (wetted) by a film of clear fluid at
their point of face contact.
CAUTION
Do not operate the viscometer motor for more than five (5) revolutions
when the measuring chamber is empty. The mechanical seals may be
damaged.
Do not operate a TT100 In-Line Viscometer equipped with a double

mechanical seal unless the seal housing is supplied with an appropriate
pressurized fluid as described in Section 2 - Installation.
P/N M/97-520 4-1

Operation
Normal Operation Observations

The following conditions are considered to be normal while the TT100
In-Line Viscometer is operating:
• The drive motor will be hot to the touch.
• The TT100 In-Line Viscometer generates a continuous output

signal that is proportional to the apparent viscosity of the process
fluid being measured.
• Depending upon the viscosity, flow rate, and resultant mixing in the
measuring chamber, the viscometer will respond quickly to the
introduction of new process fluid.
• Since shear conditions, temperature, shear history may differ

between the viscometer and another measurement, it is not unusual
for numerical values to differ. Refer to Correlation with Other
Measurements in Section 1 - Introduction for more information.
• If solids are allowed to form on the internal surfaces of the

viscometer, they may alter span by changing the measuring annulus
dimensions. Solids may also limit the torsion element motion .
Refer to Cleaning In Place in Section 5 - Maintenance for more
information.
Interlocks
Viscometer interlocks are options that prevent the viscometer from being
damaged due to abnormal process fluid temperature or double mechanical
seal assembly pressure. The interlocks prevent the viscometer motor from
being activated when below the calibrated setpoint.
CAUTION
Do not disconnect an interlock from the viscometer. Viscometer damage

may result.
4-2 P/N M/97-520

Start-up
Once the TT100 In-Line Viscometer has been installed as described in
Section 2 - Installation and proper calibration has been verified as
described in Section 3 - Calibration, the viscometer can be energized.
CAUTION
Do not energize the TT100 In-Line Viscometer motor equipped with a

double mechanical seal housing unless the fluid pressure has been applied.
Damage to the double mechanical seal assembly may occur.
Do not operate the TT100 In-Line Viscometer motor for more than five (5)
revolutions when the measuring chamber is empty. The mechanical seals
may be damaged.
Do not operate the TT100 In-Line Viscometer motor if the process fluid
temperature or double mechanical seal assembly pressure is not within
normal operating specifications. Damage to the viscometer may result.
1. If the TT100 In-Line Viscometer is equipped with a double-seal

housing, apply the barrier fluid.
2. Add process fluid to the viscometer as follows:
a. Loosen, but do not remove the bleed screw.
b. Allow the process fluid to slowly flow into the viscometer
until the fluid flows out of the bleed screw opening.
c. Tighten the bleed screw.
3. Check the viscometer motor for proper operation by performing the
following steps:
a. Set the POWER switch on the Torque Sensor Electronics
Enclosure to the ON position.
b. Set the POWER switch on the Motor Control Enclosure to
the ON position.
c. Observe the display device. The torque sensor output signal
should increase in a positive direction.
P/N M/97-520 4-3

Operation
Shutdown
CAUTION
Do not allow the process fluid to dry or solidify. Damage to the TT100
In-Line Viscometer may result.
1. Shut the TT100 In-Line Viscometer OFF by performing the

following steps:
a. Set the POWER switch on the Torque Sensor Electronics
Enclosure to the OFF position.
b. Set the POWER switch on the Motor Control Enclosure to
the OFF position.
c. If equipped with a double mechanical seal assembly, release
the pressure on the pressurized seal fluid.
4-4 P/N M/97-520

Section 5 - Maintenance
Introduction
There are three different methods for cleaning the internal components of
the TT100 Process Viscometer. The Clean-in-Place method, which is
typically used, provides minimal downtime and effective cleansing of the
viscometer during process system cleaning. The Flushing method is used
when additional internal viscometer cleansing is required. The
Disassembly and Cleaning method is used when the process system is
seriously contaminated and the viscometer cannot otherwise be cleaned.
Clean-In-Place
NOTE: The solvent used for cleaning the viscometer is dependent upon the
process fluid being measured.
1. Refer to Section 4 - Operation and perform the Shutdown
procedure.
NOTE: It may be preferable to isolate the section of pipe in which the
viscometer is installed from the main process system.
2. Drain the process fluid from the system or isolated section of pipe
in which the viscometer is installed.
3. Fill the system, or isolated section of pipe in which the viscometer
is installed, with cleaning fluid.
4. If equipped with a double mechanical seal assembly, apply the
barrier pressurized fluid pressure.
NOTE: The time duration of step 5 varies by the amount of process fluid
build-up and its cleaning characteristics.
5. Set the POWER switch on the Motor Control Enclosure to the ON
position. Allow the viscometer motor to operate until the
viscometer is clean.
6. Set the POWER switch on the Motor Control Enclosure to the OFF
position.
7. Drain the cleaning fluid from the system or isolated section of pipe
in which the viscometer is installed
8. Refer to Section 4 - Operation and perform the Start-up procedure.
P/N M/97-520 5-1

Maintenance
Flushing
NOTE: This procedure assumes that flushing connections have been made
to the TT100 Viscometer as defined in Section 2 - Installation.
NOTE: The solvent used for cleaning the viscometer is dependent upon the
process fluid being measured.
1. Refer to Section 4 - Operation and perform the Shutdown
procedure.
NOTE: If possible, isolate the section of pipe in which the viscometer is
installed from the main process system.
2. Drain the process fluid from the system or isolated section of pipe
in which the viscometer is installed.
NOTE: The time duration of step 3 varies by the amount of process fluid
build-up.
3. With the system drain valve open, open the flushing fluid valve and
allow the fluid to flow through the viscometer and out through the
drain valve.
4. Close the flushing fluid valve.
5. Close the process fluid system drain.
6. Refer to Section 4 - Operation and perform the Start-up procedure.
5-2 P/N M/97-520

Disassembly and Cleaning

The following procedures will guide you through this process. The solvent
used for cleaning the viscometer is dependent upon the process fluid being
measured.
CAUTION
Always replace endcap O-rings when disassembling and cleaning the vis-
cometer. Refer to Appendix A and contact Brookfield Engineering Labo-
ratories, Inc. to order replacement O-rings.
CAUTION
Depending upon the application, the torsion element and other internal
components may be coated with Teflon. Make sure the solvent being used
does not harm Teflon. Do not scrape surfaces coated with Teflon.
Cleaning the Sensing Endcap Assembly
WARNING
Make sure power has been turned OFF at the motor and torque sensor
electronics enclosures before servicing the viscometer.
1. Shut power OFF to the motor and torque sensor electronics

enclosures.
CAUTION
2. Remove seven of the eight screws that secure the sensing endcap to
the measuring chamber as shown in Figure 5-1.
3. While holding the sensing endcap in position, remove the last screw
and carefully remove the sensing endcap from the measuring
chamber as shown in Figure 5-1.
P/N M/97-520 5-3

Maintenance
SENSING ENDCAP
ASSEMBLY
O-RING
STATOR
MEASURING CHAMBER
ROTOR
O-RING
DRIVE ENDCAP
ASSEMBLY
DRIVE SHAFT COUPLING
SPACERS
MOTOR BRACKET
ISOLATOR
MOTOR/GEARBOX
Figure 5-1: Typical Viscometer Disassembly for Cleaning
5-4 P/N M/97-520

4. Using an appropriate solvent, carefully clean any process fluid

build-up from the outside of the stator, between the stop posts and
the stator as shown in Figure 5-2, from the inside of the stator, and
from the flange. If required, remove the stator to clean the inside
diameter as follows:
CAUTION
If the torsion element is coated with Teflon (blue/green color), make sure
the solvent being used does not harm Teflon. Do not scrape surfaces
coated with Teflon. Do not touch the torsion element with a sharp object.
Clean only by using a stream of solvent or soft bristle brush
Do not apply torque to the torsion element while removing the stator
mounting screws. Damage to the torsion element may result.
a. Remove the mounting screws from the top of the stator as

b. Carefully remove the stator as shown in Figure 5-2.
CAUTION
Visually inspect the torsion element wires. They should be straight and
parallel to each other. If they are not, refer to Appendix A and contact
Brookfield Engineering Laboratories, Inc. for a replacement torsion
element.
c. Clean the inside and outside of the stator.
CAUTION
Be careful not to damage the torsion element wires if step d is performed.
d. If normal cleaning procedures are not successful, use

solvent and a soft bristle brush and carefully clean between
the torsion element wires as shown in Figure 5-2.
P/N M/97-520 5-5

Maintenance
STOP POST
TORSION ELEMENT WIRES
STATOR
STATOR MOUNTING
SCREWS
STOP POST
NOTE: There are many different versions of the sensing endcap. Your
viscometer may look different from the viscometer shown in Figure 5-2.
Figure 5-2: Typical Stator Removal and Torsion Element Wire Cleaning
5. Carefully install the stator and install the mounting screws but do
not tighten.
NOTE: The stop posts must be centered within the holes on the stator as
shown in Figure 5-3 to ensure free movement of the stator.
CAUTION
Do not apply torque to the torsion element while installing the stator
mounting screws. Damage to the torsion element may result.
6. With the stator mounting screws loose, rotate the stator so the stop
posts are aligned in the center of the holes in the stator as shown in
Figure 5-3. Tighten the stator mounting screws and check the
alignment of the stop posts.
5-6 P/N M/97-520

STOP
POSTS
MOUNTING
SCREWS
CORRECT INCORRECT
Figure 5-3: Stator Installation and Stop Post Centering
NOTE: If the stop posts will not align in the center of the stator holes,
remove the mounting screws and rotate the stator 180º. Install the screws
and repeat step 6. The stop posts may also be bent slightly to insure correct
alignment. Refer to Appendix A and contact Brookfield Engineering
Laboratories if the stop posts cannot be properly aligned.
7. Place the sensing endcap assembly in a safe place and proceed with
Cleaning the Drive Endcap Assembly and Measuring Chamber.
Cleaning the Drive Endcap Assembly and Measuring Chamber

In order to remove and clean the drive endcap, the drive motor, gearbox,
and mounting bracket must be removed from the measuring chamber.
They can be removed as one unit as shown in Figure 5-1.
CAUTION
Do not remove the drive endcap assembly as a unit unless the sensing end-
cap has been removed first.
1. Note the orientation of the drive motor bracket and measuring

chamber. The bracket should be reinstalled in the same position
during assembly.
P/N M/97-520 5-7

Maintenance
2. Remove the drive motor bracket mounting screws and spacers (if
applicable) from the measuring chamber as shown in Figure 5-1.
NOTE: Inspect the weep holes for signs of process fluid leakage. If
leakage has occurred, the mechanical seal and bearings should be
replaced. Refer to Section 6 - Service for more information.
3. Separate the drive shaft coupling between the measuring chamber
and the drive motor. Retain the isolator for later use.
4. Remove the drive endcap mounting screws and remove the drive
endcap from the measuring chamber as shown in Figure 5-1.
5. Using solvent, clean the inside of the measuring chamber and the
inlet and outlet tubes.
CAUTION
If the rotor is coated with Teflon (blue/green color), make sure the solvent
being used does not harm Teflon. Do not scrape surfaces coated with
Teflon.
6. Clean the inside and outside diameter of the rotor.

7. Make sure the rotor spins freely and the rotor is not asymmetrical.
NOTE: If the rotor does not spin freely, or is asymmetrical, refer to
Appendix A and contact Brookfield Engineering Laboratories for
assistance.
Reassembly
1. Install the O-ring and drive endcap on the measuring chamber
as shown in Figure 5-1 using the mounting screws. Tighten the
mounting screws in a rotational pattern.
2. Install the isolator on the drive shaft coupling shown in Figure 5-1.
3. Connect the drive motor shaft to the drive shaft coupling and rotate
the drive motor and bracket into the correct position.
4. Install the drive motor and bracket as shown in Figure 5-1 using the
mounting screws. Tighten the mounting screws in a rotational
pattern.
5. Turn power to the motor controller enclosure ON and allow the
motor to operate for a few revolutions to ensure the drive shaft
coupling is properly aligned.
5-8 P/N M/97-520

6. Turn power to the motor controller enclosure OFF.
CAUTION
Do not damage the torsion element when installing the drive endcap
assembly into the measuring chamber.
7. Refer to Section 3 - Calibration and perform the calibration

procedures shown in Figure 3-2.
Elliptical Baffle Precautions

NOTE: The following information only applies to viscometers that are
equipped with the optional elliptical baffle.
The optional elliptical baffle is installed on viscometers at the factory. The
baffle is held in position by a slight compression between endcaps and will
become loose as endcap mounting screws are removed. The baffle will be
withdrawn from the measuring chamber along with the drive endcap and
must be installed with the drive endcap.
CAUTION
The elliptical baffle must be oriented within the measuring chamber so that
it does not bisect the inlet/outlet pipe. Make sure the baffle is positioned
properly prior to final tightening of the endcap mounting screws during
reassembly.
P/N M/97-520 5-9

Maintenance
5-10 P/N M/97-520

Section 6 - Service
Introduction
The TT100 In-Line Viscometer is a highly-reliable and rugged unit that
requires little maintenance. Section 6 provides information on component
replacement.
CAUTION
Always replace endcap O-rings when disassembling and cleaning the vis-
cometer. Refer to Appendix A and contact Brookfield Engineering Labo-
ratories, Inc. to order replacement O-rings.
To order replacement parts, Refer to Appendix A and contact Brookfield

Engineering Laboratories, Inc. When ordering replacement assemblies,
make sure that all associated components (gaskets, O-rings, etc.) have been
ordered to ensure the new assemblies can be properly installed.
CAUTION

clean, and free of obstructions before it can be serviced. Refer to
Section 5 - Maintenance and perform the appropriate cleaning procedure
for the process fluid application.
P/N M/97-520 6-1

Service
Tools Required
Table 6-1 provides a list of tools that are required for viscometer service.
Refer to Appendix A and contact Brookfield Engineering Laboratories,
Inc. for price and availability of the special tools listed in Table 6-1.
Table 6-1: Tools Required
Tool Tool P/N
Armature Assembly Wrench TT100-1T

Insulator Centering Fixture TT100-101TY
Medium Straight Blade Screwdriver N/A
Standard Hex Wrench Set N/A
Metric Hex Wrench Set N/A
Large Adjustable Wrench N/A
Snap Ring Pliers N/A
Mallet N/A
Center Punch N/A
Motor Gearbox Lubricant N/A
(See Note)
NOTE: Use motor gearbox lubricant Mobil Lith AW #00

without EP Additives or equivalent.
6-2 P/N M/97-520

Sensing Endcap Service

This procedure provides instructions for disassembling the sensing
endcap, identifying and replacing damaged components, and assembling
the sensing endcap.
Disassembly
WARNING

enclosures.
CAUTION
4. Remove the stator mounting screws and remove the stator from the
sensing endcap assembly as shown in Figure 6-2.
5. Refer to Figure 6-2 and remove the Microsyn housing cover as
follows:
a. Using a wrench, loosen and remove the signal cable strain
relief nut. Slide the nut, ring, and insulator down the cable.
b. Remove the screws from the Microsyn housing cover.
c. Rotate and lift the housing cover off the assembly and slide
it down the cable.
6. Disconnect the wires from the Microsyn field coil and ground stud.
7. Remove the Microsyn field coil mounting screws and cable clamp
and remove the field coil from the sensing endcap assembly.
P/N M/97-520 6-3

Service
Figure 6-1: Sensing Endcap Removal
6-4 P/N M/97-520

NUT
RING
INSULATOR
SENSING CABLE MOUNTING
SCREW
TEFLON GASKET
MICROSYN (NEMA 4 ONLY)
HOUSING
COVER INSULATOR
(if so equipped)
COVER
SCREW TEFLON GASKET
(NEMA 4 ONLY)
READOUT WIRE
FIELD COIL O-RING

CONNECTORS
TORSION
MOUNTING ELEMENT
SCREW
ASSEMBLY
MICROSYN
FIELD COIL ENDCAP
ASSEMBLY
CABLE
CLAMP
O-RING
MICROSYN HOUSING
WITH JEWEL
O-RING STOP POSTS
ARMATURE
ASSEMBLY
STATOR
Figure 6-2: Sensing Endcap Disassembly
P/N M/97-520 6-5

Service
8. Refer to Figure 6-3 and perform an electrical test on the Microsyn

field coil as follows:
a. Set the DVM to measure resistance (Ω).
b. Connect the positive lead of the DVM to Pin 1.
c. Connect the negative lead of the DVM to Pin 2.
d. The DVM should indicate 2.0 ± 1 Ω.
e. Connect the positive lead of the DVM to Pin 3.
f. Connect the negative lead of the DVM to Pin 4.
g. The DVM should indicate 1500 ± 500 Ω.
h. If the measured values correspond with the specifications in
steps d and g, then proceed with step 9. If the measured
values do not correspond with the specifications in steps d
and g, then the Microsyn field coil must be replaced. Refer
to Microsyn Field Coil Replacement within this section.
PIN # 3 (BLUE WIRE)

PIN # 2 (RED WIRE)
PIN # 4 (YELLOW WIRE)
PIN # 1 (GREEN WIRE)

GROUND STUD
(PURPLE WIRE)
Figure 6-3: Microsyn Field Coil Pin Identification
9. Refer to Figure 6-4 and remove the armature assembly as follows:

a. Using the Brookfield Engineering Laboratories, Inc.
armature wrench P/N TT100-1T, hold the armature in place.
b. Using a 9/32 inch wrench, loosen the armature clamping
nut and remove the armature assembly.
6-6 P/N M/97-520

USE THE
TT100-1T WRENCH
TO HOLD THE
HEX HEAD SCREW
ARMATURE
USE THE
9/32 INCH WRENCH
TO LOOSEN AND
TIGHTEN THE
ARMATURE
CLAMPING NUT.
MICROSYN HOUSING
Figure 6-4: Removing the Armature Clamping Nut
10. Loosen and remove the three hex head cap screws, as shown in
Figure 6-4, which secure the Microsyn housing to the insulator.
CAUTION
Be careful not to break the sapphire jewel within the Microsyn housing
when performing step 11.
11. Carefully slide the Microsyn housing off the center wire of the
torsion element.
12. Clean and inspect the center wire as follows:
a. Using contact cleaner or other non-residue cleaner, gently
clean the length of the center wire.
b. Inspect the surface of the center wire that contacts the jewel.
If this area is scored, viscometer reproducibility problems
may occur. Refer to Appendix A and contact Brookfield
Engineering Laboratories, Inc. for a replacement torsion
element.
P/N M/97-520 6-7

Service
13. Clean and inspect the sapphire jewel as follows:

a. Using contact cleaner or other non-residue cleaner and a
toothpick, gently clean the sapphire jewel. Use compressed
air to ensure all particles have been removed from the
sapphire jewel.
b. Using a magnifying glass, inspect the sapphire jewel to
make sure it is not cracked or chipped. If the sapphire jewel
is damaged, refer to Appendix A and contact Brookfield
Engineering Laboratories, Inc. for a replacement Microsyn
housing assembly.
NOTE: If your viscometer does not have an insulator located under the
Microsyn housing, then proceed with step 16.
14. Loosen and remove the three hex head cap screws that hold the
insulator to the endcap.
15. Carefully remove the insulator with damaging the torsion element
center wire.
16. Rotate the torsion element flange and gently pull until the endcap
and the torsion element have been separated.
NOTE: NEMA 4 type sensing endcaps have two teflon gaskets on either
side of the insulator. Replace the gaskets if they are damaged. NEMA 7 or
CENELEC type sensing endcaps do not have teflon gaskets.
17. Carefully clean all disassembled parts with an appropriate solvent.
18. Proceed with Sensing Endcap Assembly.
Microsyn Field Coil Replacement
WARNING

enclosures.
2. Using a wrench, loosen and remove the signal cable strain relief nut
from the sensing endcap as shown in Figure 6-2. Slide the nut, ring,
and insulator down the cable.
3. Remove the Microsyn housing cover screws as shown in
Figure 6-2.
4. Rotate and lift the Microsyn housing cover off the assembly and
slide it down the cable as shown in Figure 6-2.
6-8 P/N M/97-520

5. Remove the wire connectors from the Microsyn field coil.

6. Remove the mounting screws, cable clamp, washers, and purple
ground wire from the Microsyn field coil, as shown in Figure 6-2,
and remove the Microsyn field coil from the sensing endcap.
7. Install the new Microsyn field coil.
8. Install the mounting screws, cable clamp, and washers. Do not
tighten the screws.
9. Refer to Figure 3-3 in Section 3 - Calibration.
Torque Sensor Printed Circuit Board Replacement
WARNING

enclosures.
2. Open the cover on the torque sensor electronics enclosure.
3. Disconnect the power cable and ground connections from J3 as
4. Disconnect the sensing cable connections from J1 as shown in
Figure 6-5.
5. Disconnect the display device from J1-T1 and T2.
6. Remove the printed circuit board mounting screws, as shown in
Figure 6-5, and remove the circuit board from the enclosure.
7. Install the new printed circuit board using the mounting screws.
P/N M/97-520 6-9

Service
MOUNTING SCREW HOLES
SHIELD 12
PRIMARY - (RED) 11
PRIMARY + (GREEN) 10
GROUND - (PURPLE) 9
SECONDARY - (BLUE) 8
SECONDARY + (YELLOW) 7
6
5
4
3
2
4 3 2 1
1
J1
+
J2 J3
1 2 3 4 1 2 3
GROUND
L1
L2
Figure 6-5:Torque Sensor Electronics Enclosure Signal and Power Connection Locations
8. Make the following electrical connections:

a. Connect the L1 power wire to J3-T1.
b. Connect the L2 power wire to J3-T2.
c. Connect a GROUND JUMPER wire between the cover
ground stud and J3-T3.
d. Connect the RED sensor wire to J1-T11.
e. Connect the GREEN sensor wire to J1-T10.
f. Connect the PURPLE sensor wire to J1-T9.
g. Connect the BLUE sensor wire to J1-T8.
h. Connect the YELLOW sensor wire to J1-T7.
i. Connect the GROUND power wire to the ground stud.
j. Connect the SHIELD wire to J1-T12.
k. Connect the wire connectors to the Microsyn field coil as
l. Connect the display device to J1-T1 and T2.
6-10 P/N M/97-520

m. Remove the range jumper from the old circuit board and
connect it to the same terminals on J2.
9. Refer to Figure 3-3 within Section 3 - Calibration.
Torsion Element Replacement
WARNING
electronics enclosures and the viscometer is empty and dry before ser-
vicing the viscometer.

enclosures.
the measuring chamber.
chamber.
4. Remove the two mounting screws from the top of the stator as
STOP POST
TORSION ELEMENT WIRES
STATOR
STATOR MOUNTING
SCREWS
STOP POST
NOTE: There are many different versions of the sensing endcap. Your viscometer may
look different from the viscometer shown.
Figure 6-6:Stator Removal
P/N M/97-520 6-11

Service
5. Carefully remove the stator.

6. Place the sensing endcap in a cylindrical device (vessel, can, etc.)
that will support the flange and allow the torsion element to be
suspended without contact.
7. Using a wrench, loosen and remove the signal cable strain relief.
Slide the nut, ring, and insulator down the cable.
8. Remove three screws from the Microsyn housing cover as shown in
Figure 6-2.
9. Rotate and lift the housing cover off the assembly and slide it down
the cable.
10. Remove the wires from the Microsyn field assembly.
11. Remove the two mounting screws, cable clamp, and washers from
the Microsyn field assembly.
CAUTION
Do not bend or damage the torsion element wire or sapphire jewel when
removing the Microsyn field coil.
12. Lift and remove the Microsyn field coil.

13. Using special wrench P/N TT100-1T, hold the assembly and loosen
the armature assembly nut with a 9/32 inch wrench and remove the
assembly from the center wire.
14. Remove the three Microsyn field coil mounting screws.
15. Carefully rotate the Microsyn field coil and lift it straight up and
remove it from the torsion element wire.
NOTE: When cleaning the sapphire jewel, use contact cleaner, or another
solvent that will not leave a residue on the sapphire jewel.
16. Using contact cleaner and toothpicks, clean the sapphire jewel
opening . Apply compressed air to the opening to ensure all
particles have been removed.
17. Inspect the sapphire jewel for cracks or chips. Refer to
Appendix A and call Brookfield Engineering Laboratories, Inc. if
jewel damage has been discovered.
18. Inspect the O-ring and replace it if it shows sign of wear or damage.
NOTE: NEMA 4 type sensing endcaps have two teflon gaskets on either
side of the insulator. NEMA 7 and CENELEC type sensing endcaps do not
have gaskets.
6-12 P/N M/97-520

19. Remove the Teflon gasket.

NOTE: Depending upon the application, the viscometer may contain none,
1, or 2 insulators.
CAUTION
Do not bend or damage the torsion element wire or when removing the
insulators.
20. Using a hex wrench, remove the insulator(s), gasket(s), and

mounting screws as required.
21. Using a mallet and a center punch, tap the torsion element flange to
remove the torsion element. Discard the torsion element.
22. Remove the shipping guards from the new torsion element.
23. Proceed with Sensing Endcap Assembly.
Sensing Endcap Assembly
CAUTION
Do not bend the torsion element center wire or otherwise damage the tor-
sion element when assembling the viscometer.
1. Insert the O-ring into the groove of the torsion element.

2. Insert the torsion element into the endcap and rotate the torsion
element so that the stator screws line up with the stop post correctly
as shown in Figure 6-7.
3. Place a teflon gasket on the torsion element flange.
4. Place the insulator on top of the teflon gasket and align the
mounting screw holes.
P/N M/97-520 6-13

Service
STATOR
Figure 6-7:Torsion Element and Endcap Alignment
5. Insert the mounting screws and using a hex wrench, rotate the
screws into position but do not tighten them.
6. Place the insulator centering fixture (P/N TT-100-101TY) into the
insulator.
7. Repeat steps 4 - 6 for each insulator.
8. Using a hex wrench, tighten the mounting screws and remove the
centering fixture.
9. Place an O-ring on the Microsyn housing.
10. Place a second teflon gasket on the insulator.
11. Carefully slide the torsion element center wire through the sapphire
jewel in the Microsyn field coil until it contacts the insulator.
12. Insert the mounting screws into the holes and tighten them using a
hex wrench.
NOTE: Do not tighten the armature clamping nut in step 13.
13. Install the armature clamping nut on the armature assembly.
14. Carefully slide the armature assembly down the torsion element
center wire until it touches the sapphire jewel.
CAUTION
The sapphire jewel may be damaged if the height of the armature assembly
is not set properly. Non-repeatability of signal will result.
6-14 P/N M/97-520

15. Set the height of the armature assembly as follows:

a. Place the armature wrench P/N TT100-1T, on the armature
hold the armature in place as shown in Figure 6-4.
b. Using a small ruler to measure, lift the armature assembly
1/16 of an inch.
c. Using a 9/32 inch wrench, tighten the armature clamping
nut.
16. Carefully install the stator and install the mounting screws but do
not tighten.
NOTE: The stop posts must be centered within the holes on the stator as
shown in Figure 6-8 to ensure proper calibration and operation of the
viscometer.
CORRECT INCORRECT
Figure 6-8: Stator Installation and Stop Post Centering
17. With the stator mounting screws loose, rotate the stator so the stop
posts are aligned in the center of the holes in the stator as shown in
Figure 6-8. Tighten the stator mounting screws and check the
alignment of the stop posts.
NOTE: If the stop posts will not align in the center of the stator holes,
remove the mounting screws and rotate the stator 180º. Install the screws
and repeat step 17. The stop posts may also be bent slightly to insure
correct alignment. Refer to Appendix A and contact Brookfield
Engineering Laboratories if the stop posts cannot be properly aligned.
18. Install the O-ring into the sensing endcap and turn the assembly
over.
P/N M/97-520 6-15

Service
19. Place the Microsyn field coil assembly on the Microsyn housing
and align the mounting screw holes.
20. Insert the mounting screws and washers and tighten the screws.
21. Refer to Figure 3-3 within Section 3 - Calibration.
Drive Endcap Service

The drive endcap should only require service if the gaskets or mechanical
seals need to be replaced, or if a bearing has seized.
Motor and Gearbox Test
WARNING

during assembly.
4. Turn power ON to the motor control enclosure.
5. Check the motor for unusual noises or vibration. Turn motor power
OFF. If there is an unusual noise or vibration, the motor, gearbox or
capacitor may be defective. Refer to step 6.
6. Refer to Figure 6-10 and check the motor and gearbox as follows:
a. Remove the screws that secure the motor to the gearbox.
b. Separate the motor and gearbox.
c. Turn power ON to the motor control enclosure.
d. Check the motor for unusual noises or vibrations. Turn
power OFF.
7. Proceed as follows:
a. If there are unusual noises or vibration, then the motor or
capacitor is defective. Refer to Appendix A and contact
Brookfield Engineering Laboratories for assistance.
6-16 P/N M/97-520

b. When the replacement motor arrives, refer to Motor

Replacement within this section.
c. When the replacement capacitor arrives, refer to Capacitor
Replacement within this section.
d. If there are no unusual noises or vibrations, then the gearbox
is defective. Refer to Appendix A and contact Brookfield
Engineering Laboratories for a replacement gearbox.
e. When the replacement gearbox arrives, refer to Gearbox
Replacement.
P/N M/97-520 6-17

Service
SENSING ENDCAP
ASSEMBLY
MEASURING CHAMBER
DRIVE ENDCAP
ASSEMBLY
WEEP HOLES
SPACERS
MOTOR BRACKET
ISOLATOR
MOTOR/GEARBOX
Figure 6-9: Motor Bracket Removal
6-18 P/N M/97-520

MOTOR BRACKET
GEARBOX
MOTOR
Figure 6-10: Motor and Gearbox Disassembly
Disassembly
CAUTION
The drive endcap should only be disassembled if process fluid is leaking

from the seals or weep holes.
Handle the drive endcap assembly with care when removing it from the
NOTE: Inspect the weep holes for signs of process fluid leakage. If
leakage has occurred, the mechanical seals should be replaced. Refer to
Mechanical Seal Replacement in this section for more information.
enclosures.
2. Remove seven of the eight screws that secure the drive endcap to
P/N M/97-520 6-19

Service
3. While holding the drive endcap in position, remove the last screw
and carefully remove the drive endcap from the measuring
4. Note the position of the drive endcap to the measuring chamber.
The drive endcap must be installed in the same position during
assembly.
CAUTION
If the rotor is coated with Teflon (blue/green color), make sure the solvent
being used does not harm Teflon. Do not scrape surfaces coated with
Teflon.
5. Place the rotor end of the drive endcap assembly on the work
surface.
6. Using a hex wrench, loosen the set screw and remove the drive
shaft coupling from the drive shaft as shown in Figure 6-12.
7. Remove the snap ring from the drive shaft.
8. Remove the bearing support mounting screws and remove it.
9. Inspect the bearings in the bearing support for damage. If the
bearings are seized or damaged, refer to Appendix A and contact
Brookfield Engineering Laboratories for replacement bearings.
Once the replacement bearings have been received, refer to
Bearing Replacement. If the bearings are not damaged, proceed
with step 11.
10. Remove the second snap ring and lift the seal support, seal seat, and
drive endcap from the shaft.
11. Loosen the set screws on the seal head and remove it from the shaft.
If the seal head face is scored, damaged, contains solids, or the
wedge ring or ring is damaged, refer to Appendix A and contact
Brookfield Engineering Laboratories for a replacement seal head.
12. Check the drive shaft for scoring or damage where the wedge ring
or O-ring is located. Refer to Appendix A and contact Brookfield
Engineering Laboratories for a replacement drive shaft.
13. Remove the seal seat and retaining ring from the drive endcap.
14. Inspect seal seat and O-ring for wear and replace if required.
6-20 P/N M/97-520

SENSING ENDCAP
ASSEMBLY
O-RING
MEASURING CHAMBER
O-RING
DRIVE ENDCAP
ASSEMBLY
Figure 6-11:Drive Endcap Removal
P/N M/97-520 6-21

Service
BEARING SUPPORT
MOUNTING SCREWS
SNAP RING
BEARING SUPPORT
SNAP RING
SEAL SUPPORT
SEAL SEAT AND O-RING
DRIVE ENDCAP
SEAL HEAD
DRIVE SHAFT
ROTOR
Figure 6-12:Drive Endcap Disassembly (with Single Mechanical Seal)
6-22 P/N M/97-520

Capacitor Replacement
WARNING
electronics enclosures before replacing the capacitor.
1. Turn power OFF to the Motor and torque sensor electronics

enclosure.
2. Remove the Motor Control enclosure cover.
3. Disconnect the capacitor connections and remove the capacitor.
4. Install the new capacitor and connect the leads.
5. Install the Motor Control enclosure cover.
6. Turn power ON to the Motor Enclosure.
Oriental Motor Replacement
WARNING
electronics enclosures before replacing the oriental motor.

enclosure.
2. Disconnect the power cable from the oriental motor.
3. Remove the defective motor and gearbox from the viscometer as
described in Drive Endcap Service.
4. Remove the gearbox mounting screws from the motor and separate
the gearbox and motor as shown in Figure 6-10.
5. Install the power cord according to Figure B-1.
6. Attach the existing gearbox to the replacement motor using the
previously removed mounting screws.
8. Check the motor for unusual noises or vibrations. Turn power OFF.
9. Proceed with Drive Endcap Assembly.
P/N M/97-520 6-23

Service
Oriental Motor Gearbox Replacement

1. Remove the motor and defective gearbox and associated brack-
ets from the viscometer as described in Drive Endcap Service.
2. Remove the gearbox mounting screws from the motor and separate
the gearbox and motor as shown in Figure 6-10.
3. Attach the replacement gearbox to the existing motor using the
previously removed mounting screws.
5. Check the gearbox for unusual noises or vibrations. Turn power
OFF.
Groschopp Motor Replacement
WARNING
electronics enclosures before replacing the oriental motor.

enclosure.
2. Disconnect the power cable from the oriental motor.
3. Remove the four hex bolts from the motor bracket and remove the
motor as shown in Figure 6-13.
4. Remove the three gearbox mounting screws and washers and
remove the gearbox.
CAUTION
Support the motor shaft and spline gear to prevent damaging these
components during step 3.
5. Using an awl and a mallet, remove the pin from the spline gear.
Remove the spline gear from the motor shaft.
6. Using an awl and a mallet, install the spline gear and pin on the
replacement motor.
7. Apply gearbox lube to the gearbox.
6-24 P/N M/97-520

8. Carefully install the gearbox on the replacement motor using the

previously removed mounting screws and washers.
NOTE: Do not tighten the screws.
9. Align the motor drive shaft coupling halves and install the motor on
the mounting bracket.
10. Install and tighten the motor mounting screws and washers.
11. With the gearbox mounting screws loose, adjust the position of the
gearbox until the motor drive shaft coupling halves are parallel to
each other. Tighten the gearbox mounting screws.
NOTE: If needed, refer to the viscometer specification sheet to determine
the appropriate drawing reference for step 12.
12. Install the power cable according to the appropriate Figure in
Appendix B.
OFF.
Groschopp Motor Gearbox Replacement

1. Remove the four hex bolts from the motor bracket and remove
the motor as shown in Figure 6-13.
2. Remove the three gearbox mounting screws and washers and
remove the gearbox.
3. Using a hex wrench, loosen the set screw and remove the drive
shaft coupling half from the gearbox shaft.
4. Install the drive shaft coupling half on the replacement gearbox
shaft and tighten the set screw.
5. Apply gearbox lube to the replacement gearbox.
6. Carefully install the replacement gearbox on the motor using the
previously removed mounting screws and washers.
NOTE: Do not tighten the screws.
7. Align the motor drive shaft coupling halves and install the motor on
the mounting bracket.
8. Install and tighten the motor mounting screws and washers.
P/N M/97-520 6-25

Service
9. With the gearbox mounting screws loose, adjust the position of the
gearbox until the motor drive shaft coupling halves are parallel to
each other. Tighten the gearbox mounting screws.
NOTE: If needed, refer to the viscometer specification sheet to determine
the appropriate drawing reference for step 10.
10. Install the power cable according to the appropriate Figure in
Appendix B.
OFF.
Bearing Replacement
This procedure provides instructions for installing new bearings in an
existing bearing support.
1. Remove the bearing support as described in Drive Endcap

Service procedure within this section.
2. Carefully remove the upper bearing from the bearing support.
3. Carefully remove the lower bearing from the bearing support.
4. Place the upper bearing into the mounting hole of the bearing
support.
5. Using your fingers, press the upper bearing into the bearing
support.
6. Place the lower bearing into the mounting hole of the bearing
support.
7. Using a your fingers, press the lower bearing into the bearing
support.
6-26 P/N M/97-520

GROSCHOPP MOTOR
HEX BOLTS
PIN
SPLINE GEAR
GEARBOX
MOTOR MOUNTING
BRACKETS
DRIVE SHAFT
COUPLINGS
TT100 VISCOMETER
Figure 6-13: Groschopp Motor and Gearbox Disassembly
P/N M/97-520 6-27

Service
Drive Endcap Assembly

1. Apply light oil to the wedge ring in the seal head or O-ring.
2. Compress the seal head assembly and slide the seal head onto the
shaft until it bottoms out. Tighten the four set screws.
3. Using O-ring lube, lube the O-ring on the seal seat and finger press
the seal seat back into the drive endcap.
4. Turn the drive endcap over and insert the seal support and align the
notches to the back side of the seal seat.
5. Make sure both sealing faces are clean then apply light oil to both
sealing faces.
6. Place the drive endcap on the shaft and slide it down the shaft until
the sealing faces meet.
7. Install the first snap ring into the groove on the shaft.
8. Place the bearing support on the shaft and slide it down until it
bottoms out on the drive endcap.
9. Install and tighten the four drive endcap mounting screws.
10. Compress the seal head and place the second snap ring into the
groove on the shaft.
11. Install the drive shaft coupling and tighten the set screw.
12. Install the isolator.
13. Rotate the shaft and make sure it spins smoothly. If the shaft does
not spin smoothly, check for proper snap ring location, improperly
located seal components, or defective bearings.
14. Carefully install the drive endcap assembly into the measuring
chamber.
15. Install and tighten the mounting screws.
16. Connect the motor drive shaft to the drive endcap assembly.
17. Install the drive motor bracket on the measuring chamber in the
original position.
18. Install the drive motor bracket mounting screws and tighten.
19. Install the sensing endcap assembly.
Double Mechanical Seal Assembly Replacement

1. Remove the barrier fluid connections from the viscometer.
during assembly.
6-28 P/N M/97-520

CAUTION
Do not damage the torsion element when removing the drive endcap.
5. Remove the drive endcap mounting screws and remove the drive
endcap from the measuring chamber.
6. Remove the rotor mounting screws and washers as shown in
Figure 6-14.
7. Remove the rotor as shown in Figure 6-14.
8. Remove the double mechanical seal assembly mounting screws
from the drive endcap as shown in Figure 6-14.
9. Separate the drive endcap from the double mechanical seal
assembly.
NOTE: Refer to Appendix A and contact Brookfield Engineering
Laboratories, Inc. to make arrangements to return the used double
mechanical seal assembly for repair.
10. Install a new O-ring on the replacement double mechanical seal
assembly.
11. Install the replacement double mechanical seal assembly into the
drive endcap.
CAUTION
Make sure the O-ring is in the correct position before tightening the
mechanical seal mounting screws.
12. Install and tighten the double mechanical seal mounting screws.
13. Install the rotor mounting screws and washers as shown in Figure
6-14.
14. Install the drive shaft coupling and isolator on the end of the drive
shaft.
15. Install the O-ring on the drive endcap assembly and carefully install
the drive endcap assembly into the measuring chamber.
P/N M/97-520 6-29

Service
16. Install and tighten the mounting screws.

17. Connect the motor drive shaft to the drive endcap.
18. Install the drive motor bracket on the measuring chamber in the
original position.
19. Install the drive motor bracket mounting screws and tighten.
20. Connect the barrier fluid connectors.
6-30 P/N M/97-520

DOUBLE MECHANICAL SEAL

MOUNTING SCREWS
DOUBLE MECHANICAL SEAL ASSEMBLY
O-RING
DRIVE SHAFT
DRIVE ENDCAP
O-RING
ROTOR
ROTOR MOUNTING SCREWS
Figure 6-14: Drive Endcap Disassembly (with Double Mechanical Seal)
P/N M/97-520 6-31

Service
6-32 P/N M/97-520

Section 7 - Troubleshooting
Introduction
The information in Section 7 will help you troubleshoot problems when
they occur. The problems presented in Table 7-1 are followed by possible
causes and corrective actions. The causes and corresponding actions are
listed in their order of probability of occurrence.
Technical Inquiries
Refer to Appendix A and call Brookfield Engineering Laboratories, Inc. if
you are in need of assistance.
Table 7-1: Process Fluid Leaks
Problem Possible Cause Corrective Action
Leak between chamber and Damaged O-ring Refer to Sensing Endcap

sensing endcap. Service in Section 6 and
replace the O-ring.
Leak between sensing end- Damaged O-ring Refer to Sensing Endcap
cap and torsion element. Service in Section 6 and
replace the O-ring.
Leak at Microsyn housing Damaged torsion element Refer to Sensing Endcap
Service in Section 6 and
replace the torsion element.
Leak from drive shaft seal/ Damaged mechanical seals Refer to Mechanical Seal
bearing housing of single Replacement in Section 6 and
mechanical seal replace the mechanical seals.
viscometer
Leak from drive shaft seal/ Damaged O-ring or double Refer to Double Mechanical
bearing housing of double seal housing Seal Assembly Replacement
seal mechanical seal in Section 6 and replace the
viscometer double seal assembly or O-ring.
P/N M/97-520 7-1

Troubleshooting
Table 7-2: Drive Motor

Motor noticeably Normal operation None
hot during operation
Motor will not operate, or Damaged motor or gearbox 1. Refer to Motor and
must be assisted to operate Gearbox Test in Section 6.
Damaged drive shaft bearings 2. Refer to Drive Endcap

or seal support seizure. Service in Section 6 and
check the bearings.
Process system pressure or 3. Repair process system as

temperature setpoint has required.
been reached.
Damaged pressure or temper- 4. Refer to Motor and

ature interlock. Gearbox Test in Section 6.
Motor wired incorrectly. 5. Refer to Motor Control

Enclosure Installation in
Section 2.
Motor runs in either direc- Damaged phase-shifting Refer to Capacitor Replace-
tion depending upon capacitor in motor. ment in Section 6 and replace
assistance the capacitor.
Motor rotation does not Torque sensor response not Refer to Figure 3-1 in
match torque response. properly calibrated. Section 3.
Motor wiring incorrect. Refer to Appendix B for

correct motor wiring informa-
tion.
7-2 P/N M/97-520

Table 7-3: Calibration Errors
No output, no change 1. No power to torque sensor 1. Make sure power is applied

in output when electronics and motor control to the torque sensor and
torqued, or no enclosures. motor enclosures.
response to calibra-
tion attempts. 2. Damaged torque sensor 2. Refer to Torque Sensor
electronics board. Printed Circuit Board
Replacement Section 6.
3. Damaged Microsyn field coil. 3. Refer to Microsyn Field

Coil Replacement in
Section 6.
4. Sensing endcap improperly 4. Refer to Figure 6-3 in

wired Section 6.
No change in output 1. Viscometer is not completely 1. Refer to Section 2 and make
when motor is ener- flooded with process fluid. sure viscometer is installed
gized or when fluid properly.
changes. No torque
response. 2. Motor is not operating. 2. Refer to Table 7-2.
3. Solids build-up within 3. Refer to Section 5 and clean

viscometer. the viscometer.
4. Open or shorted wiring to 4. Refer to Sensing Endcap

Microsyn field coil assembly. Service in Section 6.
5. Damaged Microsyn field coil 5. Refer to Microsyn Field

assembly. Coil Replacement in
Section 6.
6. Damaged torsion element. 6. Refer to Torsion Element

Replacement in Section 6.
P/N M/97-520 7-3

Troubleshooting
Table 7-3: Calibration Errors (Continued)
Reverse Torque 1. Coarse zero calibration 1. Refer to Coarse Zero

Response incorrect. Adjustment in Section 3.
2. Reverse motor rotation. 2. Refer to Table 7-2 in

Section 7.
3. Transducer wired incorrectly.
3. Refer to Figure 6-3 in
Section 6.
Partial torque 1. Coarse zero calibration incorrect. 1. Refer to Coarse Zero
Response Adjustment in Section 3.
2. Excessive load (above 600 ohms) 2. Reduce load.

on output.
3. Solids build-up within 3. Refer to Section 5 and clean

viscometer. the viscometer.
4. Incorrect/shorted Microsyn field 4. Refer to Sensing Endcap

coil wiring. Service in Section 6.
5. Excessive friction on readout 5. Refer to Sensing Endcap

wire at jewel. Service in Section 6.
6. Damaged torsion element. 6. Refer to Sensing Endcap

Service in Section 6.
7. Span calibration incorrect. 7. Refer to Single or Dual

Range Span Calibration
in Section 3.
8. Loose or misaligned armature 8. Refer to Sensing Endcap

assembly. Service in Section 6.
9. Optional elliptical baffle 9. Refer to the Elliptical

installed incorrectly. Baffle Precautions
in Section 5.
7-4 P/N M/97-520

Table 7-4: Correlation/Application
Viscometer ranging is too 1. Viscometer is empty, partially 1. Refer to Section 2 and

high. Reading is consis- empty, or contains trapped air. make sure viscometer is
tently less than 10% of installed properly.
scale.
2. No turnover of fluid in 2. Refer to Section 2 and
measurement zone or make sure viscometer is
viscometer. installed properly.
3. Improper calibration. 2. Refer to Figure 3-1 in

Section 3.
4. Wrong operating range selected 3. Refer to Appendix A

or viscometer is not calibrated and call customer
for dual range operation. support for assistance.
5. Fouling of torsion element and 4. Refer to Section 5 and

inner cylinder by solids. clean the viscometer.
Viscometer ranging is too 1. Possible torsion element 1. Refer to Sensing End
low. Reading is consistently damage. Cap Service in
greater than 90% of scale. Section 6.
2. Improper calibration. 2. Refer to Figure 3-1 in

Section 3.
3. Wrong operating range selected 3. Refer to Appendix A

or viscometer is not calibrated and call customer
for dual range operation. support for assistance.
P/N M/97-520 7-5

Troubleshooting
Table 7-4: Correlation/Application (Continued)

Viscometer reading continu- 1. Damaged torsion element. 1. Refer to Sensing End
ously over 100% of scale. Cap Service in
Section 6.
2. Solids in measuring chamber. 2. Refer to Disassembly

and Cleaning in
Section 5.
3. Incorrect wiring on Sensing end 3. Refer to Sensing End

cap. Cap Service in
Section 6.
Viscometer reading is differ- 1. Rheology of process fluid may 1. Refer to Correlation

ent from bench top viscome- produce these results. with other Measure
ter. ments in Section 1.
2. Temperature difference between 2. Ensure that both read-

process fluid on-line and ings are taken at the
fluid at bench top. same temperature or
refer to Correlation
with Other Measure
ments in Section 1.
7-6 P/N M/97-520

Introduction
Use the following information to Contact Brookfield Engineering
Laboratories, Inc. for technical assistance or service:
Brookfield Engineering Laboratories, Inc.

11 Commerce Boulevard
Middleboro, Massachusetts 02346 U.S.A.
TEL: 508-946-6200
800-628-8139 (USA only - excluding MA)
FAX: 508-946-6262
Please have the following information available when calling so that we

may assist you:
• Product Part Number
• Product Serial Number
• Product Application
• Specific Problem Area
• Hours of Operation
• Equipment Type
A-1
A-2
TITLE DOCUMENT NO.

CA1-001
WIRING DIAGRAM FOR NEMA 4 PAGE NO.
CREATED BY KFM 1 0F 1
APPROVED BY DAB ORIENTAL MOTOR REV. NO. DATE CHK. BY
DATE 11/12/91 1 11/3/92
OPTIONAL CIRCUIT BREAKER

SWITCH ASSEMBLY
BLACK LIVE
ON/OFF 115V/50HZ
SWITCH WHITE NEUTRAL OR
115V/60HZ
INPUT
GREEN EARTH GROUND
RED
BLACK
CAPACITOR 3 M.F.D.
WHITE
* REVERSE BLUE & YELLOW WIRES

FOR OPPOSITE ROTATION.
115V/60HZ ORIENTAL MOTOR WIRING

C.C.W. ROTATION VIEWING FROM SHAFT END
WHITE
*BLUE BLACK
RED
OPTIONAL
FENWAL
"SNAP DISC"
SWITCH
GREEN
Figure B-1:NEMA 4 Oriental Motor Wiring Diagram
P/N M/97-520 B-1

TITLE DOCUMENT NO.

CA1-035
MODEL TT100 & TT200 WIRING DIAGRAM
PAGE NO.
CREATED BY KFM FOR 115 VAC GROSCHOPP MOTOR 1 OF 1
APPROVED BY DJO FACTORY MUTUAL APPROVED (EXPLOSION PROOF) REV. NO. DATE CHK. BY
DATE 8/30/94 3 4/30/99

SWITCH ASSEMBLY
BLACK LIVE
ON/OFF
SWITCH WHITE NEUTRAL 115V/50/60HZ
INPUT
GREEN
EARTH GROUND
CAPACITOR (SEE TABLE)
NOTE: TO REVERSE MOTOR ROTATION, REVERSE THE LEADS

WHICH ATTACH TO THE BLACK & WHITE
LEADS FROM THE MOTOR.
NOTE 1
VOLT./FREQ. 115/50/60
R.P.M. 1500/1800 3000/3600

12 mfd. 20 mfd.
CAPACITOR
(TT-100-364) (TT-100-152)
MOTOR TT100-383 TT100-384
MOTOR
NOTE 1: VERIFY MOTOR WIRING CONFIGURATIONS

AS FOLLOWS.
BLACK TO BLUE = R
BLUE TO WHITE = R
BLACK TO WHITE = 2R
R R
Figure B-2:Groschopp Motor Wiring Diagram (Factory Mutual Housing)
B-2 P/N M/97-520

TITLE DOCUMENT NO.

CA1-042
ROTARY TRANSDUCER WIRING PAGE NO.
CREATED BY KFM 1 OF 1
APPROVED BY JRM TT100 REV. NO. DATE CHK. BY
DATE 1/7/95 2 5/9/96
RED BLUE
RED YELLOW
GREEN YELLOW
2.2 1.5K
RVTD FIELD GREEN BLUE
RVDT
3 2 1 4 3 2 1
1
2
3
4
TRANSDUCER ELECTRONICS SHIELD
5
REFERENCE DRAWINGS YELLOW SIGNAL
6
MODEL TT100 - DWG. #CA1-036 BLUE
7
MODEL TT200 - DWG. #CB1-009 8
RED
9
GREEN EXCITATION
10
5V @ 5 KHz
11 100 mA MAX.
12
Figure B-3:Torque Sensor Wiring Diagram
P/N M/97-520 B-3

TITLE DOCUMENT NO.

CA1-047
230V WIRING DIAGRAM FOR PAGE NO.
CREATED BY KFM 1 OF 1
APPROVED BY JRM IP 55 GROSCHOPP MOTOR REV. NO. DATE CHK. BY
DATE 9/9/96 1 12/18/97

SWITCH ASSEMBLY
BROWN LIVE
ON/OFF 230V/50HZ
SWITCH BLUE NEUTRAL OR
230V/60HZ
GREEN/YELLOW EARTH GROUND INPUT
6 M.F.D. - 3000 RPM

CAPACITOR
5 M.F.D. - 1500 RPM
NOTE: TO REVERSE ROTATION,

OPTIONAL TEMP. REVERSE RED & BLACK LEADS.
SWITCH (FENWAL
"SNAP DISC" TYPE) GROSHCOPP T.E.N.V. MOTOR IP 55 RATED
C.W. ROTATION VIEWING FROM TOP
GREEN
RED
WHITE
BLACK
U V W
NOTE:
THIS DRAWING SUPERCEDES DWG. #81-0106
Figure B-4:230 VAC Wiring Diagram for IP 55 Groschopp Motor
B-4 P/N M/97-520

Figure B-5:CENELEC 115 VAC Groschopp Motor Wiring Diagram
P/N M/97-520 B-5

TITLE DOCUMENT NO.
PAGE NO.
CREATED BY
APPROVED BY REV. NO. DATE CHK. BY

DATE
CONTACTOR K-M DILEM-10(230) OR EQUIVALENT

RELAY ZE-0.4 (1500 RPM)
RELAY ZE-0.6 (3000 RPM)-(TT100-436)
REF: CA1-043
BROWN LIVE
230/50
BLUE NEUTRAL
INPUT
GREEN/YELLOW
EARTH GROUND
CAPACITOR (PER MOTOR NAMEPLATE)
(1500 RPM TYPICALLY USES 3 MFD)

(3000 RPM TYPICALLY USES 5 MFD)
NOTE: TO REVERSE ROTATION,

REVERSE RED & BLACK LEADS.
GROSCHOPP MOTOR WIRING (INCREASED SAFETY TERMINAL HOUSING)

C.W. ROTATION VIEWING FROM TOP
BLACK
WHITE
2
3 RED
1
4
GREEN
Figure B-6:CENELEC 230 VAC Groschopp Motor Wiring Diagram
B-6 P/N M/97-520

TITLE DOCUMENT NO.
TT100 INLINE VISCOMETER CA3-067

PAGE NO.
CREATED BY KFM WITH 1" N.P.T. FEMALE INLET/OUTLET 1 0F 1
APPROVED BY AND ORIENTAL MOTOR (NEMA 4) REV. NO. DATE CHK. BY
DATE 8/19/94
4 7/8 6 1/4
4"
POWER IN
11 3/8
ORIENTAL MOTOR
(NEMA 4)
BLEED SCREW
1" N.P.T. THREAD

22 7/8 INLET & OUTLET
8 3/4
HEAT
BAFFLE
ELECTRONICS
5 9/64
SIGNAL OUT
NOTE:
INSTRUMENT RATINGS FOR PRESSURE, TEMPERATURE & VISCOSITY
REFER TO INSTRUMENT SPECIFICATION SHEET CA5-007
Figure B-7:TT100 In-Line Viscometer (NEMA 4 with Oriental Motor)
P/N M/97-520 B-7

TITLE DOCUMENT NO.
TT100 EXPLOSION-PROOF VISCOMETER (NEMA 7) CA3-074

PAGE NO.
CREATED BY KFM WITH 1 1/2" INLET/OUTLET, 300/600 LB. FLANGES 1 OF 1
APPROVED BY HWC REV. NO. DATE CHK. BY
AND GROSCHOPP EXPLOSION-PROOF MOTOR
DATE 1/2/96 1 2/24/99
11 29/32 1 7/32
POWER IN
8 27/32 1/2 N.P.T.
5 1/2
GROSCHOPP EXP.
PROOF MOTOR
SINGLE REDUCTION
WORMGEAR REDUCER
DRIVE
COUPLING
1 1/2", BEARING
300/600 LB. FLANGES SUPPORT
INLET & OUTLET
"A"
"B" INSULATOR (2)

(SEE TABLE)
MICROSYN
FIELD
COIL COVER
1/2" N.P.T. 7 1/4
# OF INSULATORS 14 1/2
DIM.
1 2
NOTE:
"A" 23 1/16 24 9/16
INSTRUMENT RATINGS FOR PRESSURE, TEMPERATURE & VISCOSITY
"B" 8 5/16 9 13/16
REFER TO INSTRUMENT SPECIFICATION SHEET CA5-007.
Figure B-8:TT100 Viscometer for Hazardous Areas (NEMA 7)
B-8 P/N M/97-520

TITLE DOCUMENT NO.

CA3-081
TT100 VISCOMETER WITH 1 1/2" 150 LB.INLET/OUTLET
PAGE NO.
CREATED BY KFM FLANGES, FOR HAZARDOUS AREA APPLICATIONS 1 OF 1
APPROVED BY JRM GROSCHOPP MOTOR REV. NO. DATE CHK. BY
DATE 10/6/97 1 3/17/99
11 1/32
8 13/16 1 7/32
GROSCHOPP MOTOR SINGLE REDUCTION

WORMGEAR REDUCER
BEARING
SUPPORT
DRIVE TT-100-102
COUPLING
1 1/2",150# FLANGE
INLET & OUTLET
3/4 CONDUIT
B
INSULATOR(1)
TT-100-101
7 1/4"
14 1/2"
#GECEAT-2 KILLARK EXP. PROOF
ENCLOSURE.(REF. DWG. TT-100-146Y)
ONE INSULATOR (AS SHOWN) TWO INSULATORS

INCREASED SAFETY EXPLOSION-PROOF INCREASED SAFETY EXPLOSION-PROOF
DIMENSION
MOTOR (SHOWN) MOTOR MOTOR (SHOWN) MOTOR
A 21 1/2 23 1/2 23" 25"
B 9" 9" 10 1/2 10 1/2
NOTES:
POWER LEADS TO CAPACITOR & SWITCH MOUNTED
IN SEPARATE ENCLOSURE IN NON-HAZARDOUS AREA.
(VOLTAGE & FREQUENCY PER SPEC. SHEET).
INSTRUMENT RATINGS FOR PRESSURE, TEMPERATURE & VISCOSITY:

REFER TO INSTRUMENT SPEC. SHEET.
Figure B-9:TT100 Viscometer for Hazardous Areas (CENELEC)
P/N M/97-520 B-9

Figure B-10:TT100 In-Line Viscometer Double Mechanical Seal Connections
B-10 P/N M/97-520

Introduction
The model TT100 viscometer operates under defined shear conditions.
As a single speed instrument, the viscometer measures viscosity at one
specific shear rate as determined by the speed of rotation and the internal
measuring geometry.
Depending on the application, the model TT100 viscometer can be

redesigned, with minimal effort, to change the measured viscosity range
and/or the shear conditions. With the design of this viscometer, the
viscosity range is inversely proportional to speed, and shear rate.
With the limited single-point viscosity measurement, on a bench-top

(laboratory) viscometer, little is known about the viscosity of the process
fluid while it flows under different conditions in the process stream.
Therefore, we normally provide some built-in flexibility in the measured
viscosity range and shear rate to allow changes to be made in instrument
ranging after initial shipment.
Changing Range or Shear Rate

Reasons for changing the existing viscosity range:
• Better accuracy; accuracy is defined as + 1% of full scale range.

Accuracy improves with a finer viscosity range.
• Formulation change in the process.
• Over-ranging, requires broader viscosity range.
Reasons for changing the existing shear rate:
• Measure viscosity at a different part of the rheogram curve.
• Correlate/track with bench-top viscosity measurements in the

laboratory.
In order to change both the shear rate and viscosity measurement range, the
stationary cylinder (stator), and/or the gear box (speed of rotation) must be
replaced.
P/N M/97-520 C-1

Speed of Rotation Change

If only the speed of rotation is altered, the measured viscosity range
changes to the proportion of:
SPEED OF OLD VISCOSITY RANGE X OLD SPEED

ROTATION CHANGE =
NEW SPEED
1000 cP x 100 RPM

EXAMPLE: = 500 cP
200 RPM
By doubling the speed of rotation, the shear rate will double and the
measured viscosity range is decreased by a factor of two. If the old
measured shear rate was 67 sec-1 , the new shear rate will be 134 sec-1.
Each stator has a shear rate constant, that when multiplied by the speed of
rotation, yields the measured shear rate.
Rule of thumb; with all else equal, by increasing the speed of rotation
(rpm), the measured viscosity range is more refined but at a larger shear
rate. By decreasing the speed of rotation, the viscosity range broadens and
shear rate decreases.
Stator Change
By only changing the stator, the shear rate and viscosity range will change
by the ratio of factors for shear rate and geometry (ranging).
OLD SHEAR RATE X NEW SHEAR RATE FACTOR

NEW SHEAR RATE =
OLD SHEAR RATE FACTOR
OLD RANGE X NEW GEOMETRY FACTOR

NEW RANGE =
OLD GEOMETRY FACTOR
Rule of thumb; with all else equal, by changing to a stator which decreases
gap size, the viscosity range is more refined, but the shear rate increases.
By increasing the measurement zone gap, the viscosity range broadens, but
the shear rate decreases.
C-2 P/N M/97-520

Torsion Element Change
The third item which may be replaced, or have its response (calibration)
altered is the torsion element or viscosity sensing device. There are four
different torsion elements available, each capable of being calibrated over
relatively wide limits, depending upon the sensitivity required. By only
changing the torsion element, or its calibration, the viscosity range will
change without changing the shear rate.
NOTE: Torsion element replacement should be accomplished by the
factory or an experienced maintenance technician.
Electronic Change
The output signal can be altered by changing resistors on the torque sensor
electronics board in order to change calibration/and change viscosity
sensing ranges. Refer to Appendix A and contact Brookfield Engineering
Laboratories for more information.
A selectable high/low range provision exists within the electronics board

for greater accuracy. Factory calibration for both ranges is optional. If not
selected at the time of purchase, dual range calibration may be added.
Refer to Appendix A and contact Brookfield Engineering Laboratories for
more information.
Summary
Viscosity range can be accomplished with any of four methods, in usual
order of practicality; most to least:
a. Stator Replacement
b. Gearbox Replacement
c. Electronics Adjustment
d. Torsion Element Replacement
NOTE: Refer to Tables C-1 and C-2 for shear rate factors and geometry
factors for all rotor/stator combinations.
P/N M/97-520 C-3

Table C-1: Shear Rates and Factors for 2.440 ID Rotor
Shear Rate Geometry Geometry

Stators/RPM Factor Factor
SEC-1/RPM Uncoated Teflon Coated
TT100-4 2 1.101 1.02

TT100-4B 4 0.504 0.476
TT100-4C 1.161 2.804 1.91
TT100-4CZ 1.161 1.916 1.88
TT100-4D 0.67 4.13 3.817
TT100-4E 0.37 12.5 -
TT100-4F - 29.41 -
TT100-4G 1.42 1.353 1.333
TT100-4H 0.34 13.513 -
TT100-4VS1 0.891 2.445 2.347
TT100-4VS2 1.67 1.205 1.147
Serrated 1.00 1.962 1.60
Table C-2: Shear Rates and Factors for 1.450 ID Rotor
Shear Rate Geometry Geometry

Stators/RPM Factor Factor
SEC-1/RPM Uncoated Teflon Coated
TT100-4N 1.703 4.55 4.55

TT100-4F - 13.661 -
C-4 P/N M/97-520

Introduction
The following agencies have given the TT100 In-Line Process Viscometer
their approval for operation in the areas listed in Table D-1.
Table D-1: Agency Approvals - TT100 In-Line Process Viscometer
Viscometer Approval Approval Agency Protection Concept
TT100-XP Class 1, Division 1 and 2, Factory Mutual (FM) Hazardous area use:
Group C and D (NEMA 7) explosion proof.
TT100-XP Class 1, Division 1 and 2, Factory Mutual (FM) Hazardous area use:
with step- Group D (NEMA 7) explosion proof.
per motor
TT100-EX EEx d IIB T6 (CENELEC) Electrical Equipment Hazardous area use:
w/o motor Certification Service flame proof.
(EECS)
With EEx de IIC T4 Hazardous area use:

motor (CENELEC) flame proof and
increased safety
TT100 CE Radiated Emissions
all models
P/N M/97-520 D-1

D-2 P/N M/97-520

Guarantee
We hereby guarantee this Brookfield Viscometer to be free from defects in
workmanship and materials. If found to be defective in workmanship or
materials upon being returned, within one year from the date of purchase to
our factory, it will be repaired or replaced at the factory without charges.
Transportation charges shall be at the owner’s expense.
However, if upon being so returned and after inspection, we determine that

the instrument has been subjected to tampering, careless handling,
improper or faulty application or installation, the above guarantee shall not
be applicable and we shall have the right in any such case to make a charge
to cover the cost of repairs or servicing. Brookfield Engineering
Laboratories, Inc. assumes and shall have no liability for consequential
damages resulting from the use or misuse of the instrument.
The foregoing guarantee is in lieu of all other guarantees or warranties,

expressed or implied, and of all other obligations or liabilities, contractual
or otherwise, either to the original purchaser of said instrument or to any
other person whomsoever.
P/N M/97-520 E-1

E-2 P/N M/97-520

Glossary
Glossary
Control High and Low Limits

The measured values, expressed in engineering units, which cause control
output to change.
Centipoise/milli-pascal-seconds
Units of absolute viscosity. The viscosity of water at room temperature is 1
centipoise or 1 milli-pascal-second.
Correlation
A relationship, usually shown as a graph, between one measurement and
another. When correlating two viscosity measurements, it must be shown
that a particular value from one measurement always corresponds to a
particular value in the other. The conditions (method, temperature, amount
of rotations, etc.) should remain constant to obtain this correlation.
Cup Seconds
The amount of time required for a given fluid to flow completely from an
efflux cup through its chamber and accurately machined bottom orifice.
Dyne-centimeter/milli-Newton-meter
Units of torque that is measured as a force acting at a distance from a
reference point, such as the axis of rotation of an object.
Engineering Units
Units of viscosity as displayed on the readout panel of a viscometer. These
units may be in centipoise, or other units which relate to absolute viscosity,
such as cup seconds.
G-1
Glossary
Full Scale
The upper limit, in engineering units, of a viscometer. For Brookfield
Process Viscometers, this value must be calculated from the torque
capacity, rotational speed, and the spindle design of the instrument.
Laboratory Measurements
Viscosity measurements made off-line by a different instrument, usually
for purposes of quality control. Due to the unique nature of viscosity
measurement, the numerical value of this measurement may not agree with
that measured by Brookfield Process Viscometers.
Laminar Flow
Flow which occurs when layers of fluid move uniformly with respect to
one another, without mixing between elements.
Measuring Chamber
The container through which a fluid is caused to flow, in laminar flow
conditions, and where its viscosity is measured.
Repeatability
The ability of an instrument to measure the same value whenever identical
conditions of viscosity are presented to it. For Brookfield Process
Viscometers, deviation is expressed as a percentage of full scale.
Shear Rate
The speed at which layers of fluid move with respect to one another.
Also known as velocity gradient.
Shear Stress
The force per unit area required to move layers of fluid with respect to one
another.
G-2
Glossary
Spindle
The cylindrical object which is rotated in the fluid by the viscometer. Its
motion in the fluid causes a resistance called viscous drag which is
measured by the instrument as % torque. Its rotation causes fluid shearing
to occur.
Turbulent Flow
Flow which occurs when fluid moves randomly with respect to other
elements of fluid, with mixing between elements.
Viscous Drag
The resistance to rotation produced by an object such as a spindle when it
is rotated in a fluid.
Viscosity
A measure of the internal resistance within a fluid to resist flow.
Mathematically defined as shear stress divided by shear rate. Sometimes
called absolute viscosity.
4-20 mA Signal
The continuous electrical output produced by a viscometer which is
proportional to the % torque being measured and also proportional to the
scale. For Brookfield Process Viscometers, 4 mA = 0 cP, 12 mA = half of
full scale, and 20 mA = full scale, linear between 0cP and full scale.
% Torque
Brookfield Process Viscometers function as a rotating torque meter, whose
response is linear with respect to viscosity. A % torque measurement
displays the proportion of full scale which a measured fluid produces. This
factor is applied to full scale in order to give a measurement in engineering
units.
G-3
Glossary
G-4
Index
A
Abrasive Slurries 1-14
B
bench-top derived viscosity measurements 1-6
Benefits 1-1
Bleed Screw 1-11
build up 1-9
C
Calibration Bars 2-1, 3-2
CENELEC D-1
Cleaning 1-9
cleaning 1-1
Clean-In-Place (CIP) 1-9
Coaxial cylinder 1-1
correlate 1-6
Correlation with other Measurements 1-6, 7-6
D
damping 1-1
direction of rotation 3-12
double mechanical seal 1-14
double mechanical seal barrier fluid 2-3
Drive Coupling 1-11
Drive End Cap 1-11
Drive Motor 1-11
drive motor 4-2
Dual Range 3-14
dual viscosity range 1-1
E
Elliptical Baffle 1-14
empirical correlation 1-6
explosion proof D-1
P/N M/97-520 I-1

Index
F
Fluids which harden 1-14
flushing option 1-9
G
Gear Box 1-11
Groschopp Motor 1-4
H
Hazardous area D-1
Heat Baffle 1-12
hot 4-2
I
inverter 1-8
M
Measuring Annulus 1-11
Measuring Chamber 1-11
mechanical seal 1-9, 1-11
minimum time lag 2-1
Motor Cable 1-11
Motor Control Enclosure 1-13
Motor Gearbox Lubricant 6-2
N
NEMA 7 D-1
O
operation 1-1
optional equipment 1-14
Oriental Motor 1-3
P
pressurized 5-1
Product Stream Flow 1-5
pumping action 1-5
I-2 P/N M/97-520

R
Rotor 1-10
S
sapphire jewel 6-8
Sensing Cable 1-12
Sensing End Cap 1-10
shear rate 1-1
Solids 1-9
solids 4-2
Specifications 1-7
starting current requirement 1-8
start-up 1-1
Stator 1-10
Stop Post Centering 5-7
T
Teflon 5-5
temperature 1-6
Theory of Operation 1-5
torque sensor 3-8
Torque Sensor Assembly 1-10
Torque Sensor Electronics Enclosure 1-12
Torsion Element 1-12
torsion element 5-5
Toxic Fluids 1-14
U
Upflow line mounting 2-1
V
Vacuum 1-14
venting 2-2
Viscometer Specification Sheet 3-10
viscous drag 1-10
P/N M/97-520 I-3

Index
I-4 P/N M/97-520

TT100 Manual

Uploaded by

Copyright:

Available Formats

TT100 Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TT100 Manual

Uploaded by

Copyright:

Available Formats

BROOKFIELD MODEL TT100

Installation, Operation, and Maintenance Instructions

Manual No. M/97-520-A899

TEL 508-946-6200 or 800-628-8139 (USA excluding MA)

Any correspondence regarding this document should be forwarded to:

Brookfield Engineering Laboratories, Incorporated

Copyright© 1999 Brookfield Engineering Laboratories, Incorporated Printed in U.S.A.

Section 1 - In-Line Viscometer Description

Table of Contents (continued)

vii P/N M/97-520

Table of Contents (continued)

Appendix A - Customer Support

Appendix C - Viscosity Range Change

P/N M/97-520 viii

Table of Contents (continued)

Appendix D - Agency Approvals

Appendix E - Warranty Information

Figure 2-1: Typical In-Line Viscometer Installation . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 3-1: Typical Installation Calibration Flowchart . . . . . . . . . . . . . . . . . . . 3-3

Table of Contents (continued)

Figure 5-1: Typical Viscometer Disassembly for Cleaning . . . . . . . . . . . . . . . 5-4

Figure 6-1: Sensing Endcap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Figure B-1:NEMA 4 Oriental Motor Wiring Diagram . . . . . . . . . . . . . . . . . . . B-1

Table of Contents (continued)

Table 1-1:Model TT100 In-Line Viscometer Specifications . . . . . . . . . . . . . . 1-7

Table 3-1:Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Table 6-1:Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Table 7-1:Process Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Table C-1:Shear Rates and Factors for 2.440 ID Rotor . . . . . . . . . . . . . . . . . . . C-4

Table D-1:Agency Approvals - TT100 In-Line Process Viscometer . . . . . . . . D-1

Section 1 - In-Line Viscometer Description

The TT100 In-Line Viscometer generates a 4 - 20 milliampere (mA) or

Features and Benefits

• Easy start-up, operation, and cleaning

• Optional selectable dual viscosity range

• Continuous linear output signal (4 - 20 mA) or (0 - 10 VDC)

• Coaxial cylinder measurement geometry for viscosity values at

• Optional temperature compensation

The TT100 In-Line Viscometer provides the following benefits:

• Highly sensitive measuring system unaffected by changes in

P/N M/97-520 1-1

• Can be cleaned-in-place thereby minimizing downtime.

• Eliminates manual procedure for lab viscosity analysis. Provides

• Accurate and proven control - optimizes product consistency and

• Provides a permanent record for quality control when used with a

• Operates continuously and instantly responds to changes in

• Minimal pressure drop.

• Linear output signal is proportional to viscosity and compatible

• Installs directly in-line or in a by-pass line.

• Optional features and accessories are available to enhance In-Line

1-2 P/N M/97-520

Figure 1-1: Typical TT100 In-Line Viscometer with Oriental Motor

P/N M/97-520 1-3

Figure 1-2: Typical TT100 In-Line Viscometer with Groschopp Motor

1-4 P/N M/97-520

STATOR PRODUCT DRIVE ENDCAP

MEASURING CHAMBER GEARBOX

MEASURING ANNULUS STREAM

Figure 1-3: TT100 In-Line Viscometer Product Stream Flow

P/N M/97-520 1-5