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Instrument

Maintenance and

Troubleshooting

Daily

Weekly

Monthly or Long Term

Maintenance

Remove the orifice and clean thoroughly with brush and drill bit. Clean your
indexer barrel with cotton patch when hot. Piston should spin easily when
placed into a clean barrel.

Give good cleaning with brass brush. Use oven cleaner to clean the piston rod
assembly and orifice.

Depending on your company policy, a calibration or calibration check may be
needed on a monthly, quarterly or yearly basis. It is a good idea to create a
repetitive maintenance schedule for your instrument. We cannot do this for you,
however we can suggest what to do:

Clean, Clean, Clean

Clean the dust and dirt out of the electronics module with clean air every six
months to one year, more often in dirty environments.
Remove the orifice and clean thoroughly.
Clean your barrel.
Use oven cleaner to clean the piston rod assembly and orifice.
Clean dust from optical flag sensor.

Check mechanical tolerances

Is your piston tip in spec? diameter = 0.3730 +/- .0003
length = 0.2500 +/- .0050
Does assembled piston rod weigh 100 grams?
Does your GO/NO GO gage work properly on the orifice?
Orifice length O.K.? length = 0.3150 +/- .0010
Operating temperature within spec? +/- 0.2 degree Celsius
Weights still weigh correctly?
Sample scale calibrated?
Digital Encoder calibration OK?

Series 4000 Melt Indexer Operation Manual

Instrument Maintenance and Troubleshooting

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Summary of Contents for 4001

Page 1: ...Polymer Test Systems LMI 4000 Series Melt Indexer Manual Version 4 1 38 Forge Parkway Franklin MA 02038 Phone 1 508 541 9400 Fax 1 508 541 6206 Manual Part Number M0704 www dynisco com Original Language Version ...

Page 2: ...est Systems without prior notice Dynisco Polymer Test Systems is not responsible for errors or omissions that may be contained herein or for incidental or consequential damages in connection with the furnishing or use of this information The information contained in this manual is the property of Dynisco Polymer Test Systems unless otherwise stated Comments or suggestions for possible improvement ...

Page 3: ...3 4 Model 4004 4 Method B Encoder Option 4 Pneumatic Lift 5 Mini Lift 5 Intrinsic Viscosity Option 5 Getting Started 6 Unpacking the Indexer 6 Bench Requirements and Placement 6 Level the Melt Indexer 6 Pneumatic lift setup 7 Installing the Digital Encoder 7 RTD Connection 9 Power Cord 9 Printer Connection 9 Computer Connection 9 Options 9 Safety 10 Use gloves it s HOT 10 Electrical Hazard 10 Cali...

Page 4: ... 16 Selecting TEST in the SYS Mode 17 TEST RTD Display 17 TEST Digital Encoder 17 TEST Printer 17 TEST Display Brightness 17 The SETUP mode 17 Introduction 17 REJECTION 17 AVERAGE 17 MFR MVR 17 B FLAG 17 VISCOSITY 17 PRINTER 17 FORM FEED 17 COMM PORT 18 MINI LIFT 18 PNEU LIFT 18 LOCKOUT 18 DATE and TIME 18 MACHINE ID 18 LANGUAGE 18 ORIFICE DIA 18 ORIFICE LEN 18 Programming 18 Introduction 18 Creat...

Page 5: ...d A B 27 Programming Method A B 27 Introduction 28 Machine Setup 28 The Actual Run 29 How to do it Step by Step 29 Instrument Prep 29 Loading the Barrel 29 Inserting the Timing Flag 30 Making the Cut 31 Cleaning Up 31 Your data 31 Method B Run 32 General Description 32 Calculations Method B 32 Programming Method B 33 Method B Flags Setup 33 Choosing a Timing Flag 34 The Actual Run 35 How to do it ...

Page 6: ...roduction 49 The Digital Encoder Use and Calibration 50 Introduction 50 Method B Encoder Option 50 Encoder Advantages 50 Why use it 51 Digital Encoder Installation 51 Programming for use with the Digital Encoder 52 Method B Setup 52 Enable the Digital Encoder 52 Auto Flag ON OFF 52 Flag Calculation MANUAL or AUTO 53 AUTO flag selected 53 So you picked MANUAL 53 Encoder Homing and Maintenance 53 Di...

Page 7: ...Vendors 64 Conversion Factors 65 Troubleshooting 65 Flow Rates are Changing 65 Temperature is Unstable 66 Mercury Separation in Thermometer 66 Reuniting Mercury Thermometers 66 Pneumatic Lift Troubleshooting 67 Pneumatic Lift maintenance 67 Questions and Answers 69 Typical Problems 69 Typical Questions 70 Glossary of Terms 73 Digital Flag Digital Encoder 73 Firmware 73 Flow rate 73 Flow Rate Ratio...

Page 8: ...Setting Up USB Communications 74 Set Up with Daisy Software 74 Set Up with MI Works Software 77 Index 81 Series 4000 Melt Indexer Operation Manual Contents vi ...

Page 9: ...8 by Dynisco and is now a wholly owned subsidiary of Dynisco Inc Dynisco an ISO 9002 qualified supplier is the world s largest manufacturer of pressure transducers and is located in Franklin MA How to Use this Manual This manual describes the setup procedure and basic operation of the Dynisco Polymer Test Systems Series 4000 class indexers With the accompanying MIWORKS or Daisy software manual if ...

Page 10: ...your questions as quickly as possible have the following items ready before you call Machine name and model number Machine serial number on back panel Current version of firmware Power up unit to see Computer system make and model Current version of software if applicable Call Dynisco Polymer Test directly at 508 541 9400 and ask for technical support Should you wish to comment or query in writing...

Page 11: ...g technique cleaning cutting weighing etc With moisture sensitive polymers dryness can also play a major role and time can be a factor with thermally unstable polymers so procedures must be identical Dynisco Polymer Test Systems has found that charging a consistent mass of material into the barrel 0 1 grams is the most critical factor in getting precise data ASTM Melt Index Tests Two basic methods...

Page 12: ...plete test programs set ups can be stored The Digital Encoder option replaces the optical flag and sensor with highly accurate digital flags and sensors You can perform experiments using from one digital flag up to fifteen digital flags The Dynisco Polymer Test Encoder for Method B tests employs a 1016 count optical encoder coupled to high accuracy gears to measure the piston travel The optical en...

Page 13: ...he weight safely This is a small Pneumatic Lift assembly that supports the piston rod itself It is useful for high flow materials and can be used in conjunction with a melt plug This is a firmware upgrade to the computer housed in the Series 4003 and 4004 melt indexers only It enables a calculation of IV values based on the correlation between melt index and the wet chemistry technique for determi...

Page 14: ...ght if purchased the melt indexer printer computer Test shake the melt indexer for stability The bench top should also be able to withstand hot dies and tools being dropped on them Carpet protection is necessary near the indexer since a hot die dropped on the carpet will quickly burn spots in it Adequate ventilation will also be required to remove potentially harmful fumes from samples being teste...

Page 15: ...th of tubing supplied to the main solenoid valve 6 Push the tubing into the brass fitting and pull it to seal Attach shop air supply 60 psi to the other end of the tubing Be sure to incorporate a water trap in the air line d 8 is the low voltage solenoid switch which controls the UP and DOWN functions via signals from the Indexer The main solenoid valve 6 directs air pressure to the appropriate cy...

Page 16: ...head Note for Pneumatic Lift Users With the encoder arm in the down position lower the pneumatic lift Move the arm up and down to check for clearance with the pneumatic lift bucket Clearance may be increased a small amount by rotating the encoder housing before tightening the screws If no clearance exists and the arm hits the pneumatic lift bucket contact Dynisco Polymer Test before proceeding Tig...

Page 17: ... to the power source Connect the printer if you have one to the melt indexer A cable is provided with two distinctly different ends one connects to the printer and the other to the melt indexer The connections are on the back sides of both machines Be sure the printer is OFF when connecting the indexer The data processing system 4004 models only consists of a PC and the MIWORKS software package If...

Page 18: ...e outlet used to power the indexer is properly grounded Calibration Thermometers use Mercury To calibrate the temperature on the indexer a thermometer containing about 8 grams of mercury is used Every lab with mercury thermometers or equipment containing mercury must be prepared for breakage Note that mercury exposed to air evaporates at room temperature producing an invisible tasteless odorless a...

Page 19: ...keys only when the areas above and below the weight are clear Fumes from Materials Plan for the unexpected when it comes to materials giving off hazardous vapors Many polymers PVC PVF etc are well known for giving off hazardous fumes at elevated temperatures An exhaust system that removes fumes from both the die exit and near the top of the barrel is strongly recommended Consideration should also ...

Page 20: ...and units for particular parameters Melt Index experiments particularly method A tests rely on the instrument to reach the proper temperature and in method B and A B tests collect information on the travel of the plunger The user is first expected to input the appropriate parameters for the experiment and subsequent calculations in the EDIT routine After this is accomplished the user may RUN the p...

Page 21: ... controls 10 The Keypad 11 ESC PROG SYS SHIFT ABC 7 DEF 8 GHI 9 1 2 3 4 ID SETUP JKL MNO 4 5 PQR 6 6 CLEAR BACkSP kg STU VWX 1 2 YZ 3 9 8 0 ENTER 12 ESC ESCAPE Backs out one level from any mode Quits a test totally PROG PROGRAM Browse and select a preprogrammed program SYS SYSTEM Enter self calibration modes or hardware diagnostic modes for testing unit SHIFT Toggle between numerical and alpha num...

Page 22: ...ions Page for more detailed operations of tests SHIFT The shift key is used when inputting numeric and alphanumeric characters in the sample operator or program identification screens Pressing SHIFT then the appropriate numeric alpha key enters the alpha input mode This mode provides a selection of alpha characters above the SMART KEYS that correspond to the numeric alpha key pressed When in the a...

Page 23: ...ISPLAY Your instrument uses a 4 line vacuum fluorescent display VFD to display information Brightness can be adjusted in the SYSTEM TEST mode SMART KEYS Dynisco Polymer Test provided three keypads below the VFD to allow for quick navigation of the machine interface The functions of these keys change depending on the mode of operation Each SMART KEY is clearly and concisely labeled to assist you in...

Page 24: ...is calibrated at Dynisco Polymer Test prior to shipment There should be no need to re calibrate the RTD sensor Please reference the section entitled Instrument Calibration for further details on actual calibrations The instrument allows for the adjustment of the Optical Flag sensitivity This determines how sensitive the Optical Flag LED Receiver is in either of two states blocked or open Sensitivi...

Page 25: ...fter entry is complete press the ESC key to save modified information After pressing SETUP scroll through the list of settings using the UP or DOWN SMART KEYS Select the EDIT SMART KEY to change the parameter accordingly Please reference Configuring the Instrument Section for a detailed description of each parameter Note the order the items appear can vary 1 5 OFF Exclude data points that are more...

Page 26: ...s X XXX Store standard orifice radius 8 000 mm Used in calculations Scroll through this menu and make appropriate changes Press ESC twice and any changes that have been made will be implemented Programming This section is intended for a quick reference of method parameters Please refer to the appropriate sections in the manual for more specific information about a particular method Before a measur...

Page 27: ...haracters Name of program up to 14 characters long METHOD A B A B or RATIO SELECT and ENTER Method A B SET POINT Temp Celsius Dependent on the material ASTM requirements Enter or Select value using browse key MELT TIME Time Seconds ASTM D1238 equilibration time for most materials Enter or Select value using browse key CUT TIME Time Seconds This is the sample collection time the length of time an e...

Page 28: ...ts Enter or Select value using browse key MELT DENSITY X XXX g cm Numeric value calculated from A B Run MELT TIME Time Seconds ASTM D1238 equilibration time for most materials Enter or Select value using browse key FLG LENGTH Length mm Flag length in millimeters for Optical Eye Instruments Dependent on Melt Flow Rate Digital Encoder equipped instruments will be asked further questions Reference Di...

Page 29: ...mass in grams of material collected over time T in seconds The MFR value has units of g 10 min grams 10 minutes Power Up The instrument is turned on by throwing the switch located on the rear right top corner of the instrument as one faces the instrument Toggle the switch to the right and the unit will power up The large friendly VFD display will power up and display system information as follows ...

Page 30: ...re on the numeric keypad and press enter or use the ENTER SELECT and SCROLL SMART Key keys to choose a typical value Press SELECT ENTER to accept the value and move to the MELT TIME MELT TIME The user may enter a melt time from the numeric keypad and press enter or use the Enter Select and Scroll SMART Key keys to choose a typical value Press SELECT ENTER to accept the value and move to the NO OF ...

Page 31: ...wo thirds of the beaker into the barrel using the brown fill funnel The loading should be done in two increments the first consisting of approximately 60 of the material Tamp down the material with the packing tool using approximately 20 pounds of force The packing tool can be inserted through the fill funnel If bridging clogging up of the material occurs in the fill funnel slide the fill funnel o...

Page 32: ...ad e g 2160 to 21 600 g Increase the test temperature e g 190 to 230 C Change to a non standard die typically larger diameter Making the Cut Weigh the Sample When the lower scribe mark on the plunger reaches the top of the guide bushing simultaneously cut the extrudate and press RUN Use the cutting knife in a wiping like action up against the bottom of the die After pressing RUN a countdown timer ...

Page 33: ... in the grooves of the drill bit and repeat until the drill passes easily through the die Scrape the die with the cutting knife if needed to clean the top and bottom faces For materials that crystallize quickly you can clean the die by first running a drill bit up into the die while it is hot and in the indexer This will make it much easier to get the cleaning drill bit in when the die is removed ...

Page 34: ...ard to clean Polystyrene EVA and elastomers etc solvents may be required Never use flammable solvents on a HOT barrel In general however DYNISCO POLYMER TEST does not recommend using solvents for health safety and environmental reasons Oven cleaner Easy Off sprayed onto a cold plunger and left overnight will do an excellent job of cleaning degraded material off of the shaft the outside of the die ...

Page 35: ...ected over the time TA in seconds MFR has units of g 10 min grams 10 minutes is called the apparent melt density and is defined by equating the methods the Method B flow rate must equal Method A This apparent melt density definition forces the two test methods to agree DYNISCO POLYMER TEST recommends taking an average of apparent melt densities from at least five separate A B tests on representati...

Page 36: ...espectively METHOD Press the SMART Key browse until the 3rd line of the display has the A B over the SELECT SMART Key Press the SELECT SMART Key to select the method A B test The second line should now read METHOD A B Press SELECT ENTER to accept the value and move to the SET POINT SETPOINT The user may enter a temperature on the numeric keypad and press enter or use the ENTER SELECT and SCROLL SM...

Page 37: ...t wait until the specified temperature has been achieved to continue with the experiment When the instrument has latched in continue with sample testing The Actual Run How to do it Step by Step Instrument Prep Loading the Barrel Note that the standard Dynisco Polymer Test In house test procedure section in this manual is an abbreviated version of what follows Press EDIT and verify all entered prog...

Page 38: ...gital encoder module Inserting the Timing Flag Insert the plastic flag down into the slot on the top right side of the indexer then slide the flag onto the plunger arm through the flag hole Make sure that the flag does not touch the sides of the flag slot Twist the plunger as needed to get it to line up with the flag slot and slide the flag on the arm until it is in a vertical position Immediately...

Page 39: ...mer appears on the left of the front display As it counts down it will give a warning beep when 10 seconds remain Exactly when it reaches zero and beeps cut the extrudate up against the bottom of the die as before Weigh the sample and enter the weight in grams using the touch panel then press YES You may have to wait for the flag to traverse the photo eye for slow flowing materials A precision bal...

Page 40: ... A and B start in the same place Flags may be 1 8 1 4 1 2 or 1 Multiple flags are discussed in later Recently Method B has become the more common test because it is simpler to run and more precise for routine analysis In addition the encoder system makes it possible to get as many as 15 results from one run Flow rate for method B is computed as follows MVR MFR R L 2 600 T Where R radius piston cm ...

Page 41: ...een prompting the user to input the number of the program that will be created or edited 2 Enter a number and ENTER on the numeric keypad Now you are editing a new program of number You can press the EDIT SMART Key to edit the existing program and select a B Method test 3 After pressing EDIT SMART Key enter run parameters by pressing EDIT again The instrument is now in the VIEW Program mode starti...

Page 42: ...ROGRAM ID Enter the program ID and press ENTER when finished Numeric and alphanumeric values may be input See Navigating the Keypad for more information on alphanumeric input To SAVE the program Press ESC twice to back out to the SAVE Program mode and select SAVE to save the program under the OLD program name Change the program name in the EDIT mode 4 Choosing the Program Press the PROGRAM button ...

Page 43: ...lag The experimental run time would be halved The Actual Run How to do it Step by Step Instrument Prep Loading the Barrel The standard Dynisco Polymer Test In house test procedure section in this manual is an abbreviated version of what follows Press EDIT and verify all entered program data values are correct Make sure all equipment has been properly cleaned Insert piston rod and let the system co...

Page 44: ...urements without digital encoder module Timing Flag and Starting the Run Insert the plastic flag down into the slot on the top right side of the indexer Next slide the plastic flag onto the plunger arm flag post through the flag hole The flag should not touch the sides of the slot Twist the plunger as needed to get it to line up with the flag slot and slide the flag on the arm until it is in a ver...

Page 45: ...rials are harder to clean that others Repeat the process until used patches come out clean When the system is clean put the die and plunger back into the barrel This allows the plunger and die to heat up before the next test With materials that are thermally stable less than 5 viscosity change over 1 2 hour we recommend only cleaning the barrel between runs of the exact same material For materials...

Page 46: ...begin the next test Loading material will cause a small temperature change even if temperature set point was locked in The melt time 360 seconds will allow ample time to get the temperature to set point before the first data point is collected Always leave the machine clean If it is going to sit at room temperature for an extended period of time you may wish to coat the barrel with a light machine...

Page 47: ...ift option from DYNISCO POLYMER TEST Inc The weights involved are quite heavy and dangerous for an operator to be routinely lifting The pneumatic lift automatically and safely lifts the weights as needed Assess shear thinning behavior of material Correlation to MWD You must have a Flow Ratio capable instrument Note Flow Ratio can only be run in one pass in Method B In a Flow Ratio test when the me...

Page 48: ...e lift must be manually told to lower the weight via the keypad 4 After the AUTO LOWER prompt AUTO RAISE appears If set to YES the lift system will raise the weight after the run is complete If set to NO the lift must be manually told to raise the weight via the keypad 5 Proceed with run normally Series 4000 Melt Indexer Operation Manual Flow Ratio Runs 40 ...

Page 49: ...scosity or MFI measurement is another empirical non absolute like I V way to assess molecular weight Melt Viscosity and Intrinsic Viscosity are related in such a way that IV can be directly calculated from Melt Index values This is described in greater detail in the applications brief Correlating Melt Rheology of PET to Solution Intrinsic Viscosity by J Reilly and P Limbach available from DYNISCO ...

Page 50: ... at a temperature of 285 ºC This option if purchased Models 4003 4004 only enables only at 285 ºC 1 Clean the orifice piston rod and barrel thoroughly This is very important Put piston rod back into barrel until temperature has locked 2 Enable IV calculations under the Setup on the indexer Note that a typical Pet test temperature is to 285 ºC 3 Set the following parameters accordingly in EDIT mode...

Page 51: ...a repeatable MFI and record the value 6 Perform a run using parameters in step 3 7 After the run an Intrinsic Viscosity will be displayed and printed After each run Clean Barrel Clean Die remove first Series 4000 Melt Indexer Operation Manual Intrinsic Viscosity Runs with PET 43 ...

Page 52: ...ted if an approximate melt flow rate and melt density for the material are known by using the following formula Charge Mass 3 6 0 6 MFR Where the charge mass is in grams is the melt density in g cc and MFR is the melt flow rate in the typical units of g 10 min This equation will tend to slightly overestimate the charge needed For a Polypropylene with an expected MFR of 3 5 at 230 C getting the mel...

Page 53: ... 4 4 0 2 2 8 3 7 4 4 0 5 3 0 3 9 4 6 1 3 3 4 2 4 9 2 3 9 4 8 5 5 3 4 5 5 4 6 1 4 5 1 6 0 6 7 5 5 7 6 6 7 3 6 6 3 7 2 7 9 7 6 9 7 8 8 5 8 Plug 8 4 9 1 9 Plug 9 0 9 7 10 Plug 9 6 10 3 11 Plug Plug 10 9 12 Plug Plug 11 5 13 Plug Plug Plug Series 4000 Melt Indexer Operation Manual Charge Weight 45 ...

Page 54: ...ave been obtained using this method NOTE the A B method should always be used for operator training Only the A B method assesses cutting and flag methodology together Use 2060 weight The Test Procedure for Indexer SQC runs Instrument Preparation Use the standard die D 0 0825 L 0 315 Use the 1 4 flag Set MTD A Time to 180 sec All calibrations completed All machine oils removed from barrel and machi...

Page 55: ... of extrudate collected over the cut time then press END then YES to print to the mini printer or Okidata 320 Push down on weight hard to purge remaining material out Always use two patches must have enough frictional forces against barrel to clean Eight or more strokes completely up and down the barrel Toss patches repeat Or use the power cleaning tool and make two cleaning passes with fresh patc...

Page 56: ...el Prior to loading Sample Is material properly prepared dried mixed check for contaminates Machine on for 20 minutes Correct Die in machine Correct program being run Hand tools in position for run packing funnel and tool cleaning drill bit etc Encoder Arm in place Long term items in order of importance Are die diameters within spec passed G0 No Go gage ASTM ISO DIN Temperature calibration OK Pist...

Page 57: ...Features include Direct programming of the instrument via personal computer Point click interface for program setup and data analysis Comprehensive data base type features Graphical display of program Talk to your Dynisco sales person for more information USA 508 541 9400 Series 4000 Melt Indexer Operation Manual Model 4004 and Computer Control 49 ...

Page 58: ...n quadrature yielding a resolution of 0 015 mm The linear distance of the piston is transferred to rotary displacement via a precisely calibrated arm The tip of this arm employs a hardened ground tip for extra long life Accuracy over the ASTM measurement range of 0 25 and 1 00 is 0 4 The optical encoder while being very accurate also enables the test length signal to be processed varied digitally ...

Page 59: ...Head Cap Screws Two 5 8 long 8 32 Reduced Head Socket Cap Screws Six 8 Lock Washers Four 8 Washers One Encoder Housing One Long Plate Plate 1 One Small Plate Plate 2 Installation Steps See Figure 1 1 Using two 5 8 Reduced Head Socket Cap Screws two 8 Lock Washers attach plates 1 2 to plate 3 plate 3 is already attached to the MI Tighten the screws Encoder Housing Two Reduced Head 8 32 x 5 8 Long S...

Page 60: ...ange when the arm is moved Press QUIT to end procedure ESC out to main menu 8 See section entitled for detailed instructions on the variety of uses and programming available with the encoder option Programming for use with the Digital Encoder Method B Setup Enable the Digital Encoder Auto Flag ON OFF This procedure assumes you are already set up to perform a Method B test as explained in the secti...

Page 61: ...ter start position for flag 1 press NEXT for flag 2 and so on The instrument will suggest positions for you but you don t have to accept them EXIT when finished editing Dynisco Polymer Test recommends 1mm minimum flag spaces Encoder Homing and Maintenance Calibration Digital Flag Home The Digital Encoder is calibrated at Dynisco Polymer Test prior to shipment Because the arm is locked into place c...

Page 62: ...fers from our standard Galaxy Series melt indexer Complete Digital Encoder Calibration Referenced Spec D1238 95 The Digital Encoder is calibrated at Dynisco prior to shipment Because the arm is locked into place calibration is rarely required If calibration needs to be checked due to suspected encoder damage then the following steps should be followed if an Encoder Calibrator is available If an en...

Page 63: ...reading in step 2 and multiply the result by 25 4 example 25 45 Go to Table 1 and determine if calibration is required The specified limits are 0 4 ASTM D1238 95 and 0 10mm for DIN 53735 If calibration is required go to step 4 otherwise stop Note Repeating this measurement before proceeding with the calibration procedure is recommended 4 If calibration is required then the right hand cover on the ...

Page 64: ...rmine the appropriate degrees of movement Repeat this process until the arm is calibrated Once the arm is calibrated secure the arm in place by re tightening the second arm set screw see Figure 1 Apply removable thread locker Loctite type 290 or equivalent Reinstall the cover and tighten all hardware ADJUSTMENT SCREW TURN CW TO EXTEND ARM TURN CCW TO RETRACT ARM SECOND SET SCREW LOCKS ARM IN PLACE...

Page 65: ... 49 25 5 25 51 25 52 25 53 25 54 25 55 Number of Degrees of Rotation Required To Bring Arm Into Calibration degrees_turn n 261 243 226 208 191 174 156 139 122 104 87 69 52 35 17 0 17 35 52 69 87 104 122 139 156 174 191 208 226 243 261 Positive turn cw screw rotation push arm out to make longer Negative turn ccw screw rotation pull arm in to make shorter Series 4000 Melt Indexer Operation Manual Th...

Page 66: ...Figure 3 Series 4000 Melt Indexer Operation Manual The Digital Encoder Use and Calibration 58 ...

Page 67: ...e keypad There are also references to lift operation in the EDIT and SETUP modes Some notable settings are described Auto Purge At end of test last flag or cut drop weight to purge material Auto Raise If enabled this option requests that the lift system raise the weight after the experiment has ended Auto Raise time If Auto Raise enabled wait this long to raise the weight See following graph Mini ...

Page 68: ...thermometers or equivalent to perform this calibration 1 Press SYS Key and CAL Smart key to enter calibration mode Select RTD Sensor in the Calibrate Select mode 2 The instrument prompts you to select a SINGLE or DOUBLE procedure Each procedure requires a thermometer or two rated at the desired calibration temperature SINGLE uses one temperature reference to perform a calibration accurate to one t...

Page 69: ...mometer s temperature readings Select SAVE to use the new temperature offset and gain values or manually enter an offset correction factor and gain value Optical Flag The instrument allows for the adjustment of the Optical Flag sensitivity The sensitivity determines how sensitive the Optical Flag LED Receiver is to being in either two states blocked or open Sensitivity directly affects the measure...

Page 70: ...enu and select Digital Flag Home The instrument prompts you to place the encoder arm in the home position This is the up most position that the flag arm can go into 2 Place the encoder arm in the up most position and press RESET to set the encoder count to 105 00 mm at the top home position Press QUIT to end procedure ESC out to main menu The encoder should now be set to the proper encoder setting...

Page 71: ... however we can suggest what to do Clean Clean Clean Clean the dust and dirt out of the electronics module with clean air every six months to one year more often in dirty environments Remove the orifice and clean thoroughly Clean your barrel Use oven cleaner to clean the piston rod assembly and orifice Clean dust from optical flag sensor Check mechanical tolerances Is your piston tip in spec diame...

Page 72: ...urnham St South Windsor CT 06074 203 528 6526 Ask for Class X pins ISO specs are 0 0002 of nominal ASTM specs D3835 are 0 0003 of nominal 2 Cleaning Patches Skyline Center Inc P O BOX 3064 Clinton IA 52732 319 243 4065 800 747 4065 Extension 4065 FAX 319 243 9901 3 Bore Gages Inspex Corp 664 Bussee Hwy Park Ridge IL 60068 708 825 2200 Fax 825 0825 Order Diameter Probe 029 Probe N 6 Needle 0 0001 d...

Page 73: ...57E 03 Atm STD Pa 1 01325E 05 Atm 1 kgf cm2 Pa 9 80665E 4 bar Pa 1 0E 5 dyne cm2 Pa 0 10 ksi kip in2 Pa 6 894757E 6 Troubleshooting Flow Rates are Changing Cleanliness of the barrel and components is a critical factor in the behavior of materials The barrel of the unit should be cleaned as well as possible All components associated with the instrument Piston tip and Orifice should be cleaned of al...

Page 74: ... from the units cooling fan Air must flow freely to properly cool the unit Before using any thermometer it should be examined very carefully for mercury separation in the main mercury column expansion chamber contraction chamber and bulb Mercury separation in the bulb will usually show as small bubbles All the mercury must be united If a thermometer does not read zero at the ice point mercury sepa...

Page 75: ...nnect one lead of the DC voltmeter to chassis ground and the other lead to either solenoid connectors Enter the solenoid cycle in the SYS TEST mode Measure the DC voltage to each connection Voltages should be a constant 4 to 5 volts or greater on one connector and should switch from 4 to 5 volts UP to less than 1 volt DOWN on the other connector If these conditions are not met call Dynisco Polymer...

Page 76: ...GUIDE ROD FIGURE C Series 4000 Melt Indexer Operation Manual Instrument Maintenance and Troubleshooting 68 ...

Page 77: ...1 degree C per second If it does usually a bad electrical connection or failing electrical component can be blamed Make sure the die and piston rod are in the unit when heating If you have any difficulty please call Dynisco Polymer Test Technical Support PROBLEM The VFD on the instrument displays a negative temperature SOLUTION The RTD is in a shorting condition Perform an RTD Display test If the ...

Page 78: ...end the power cleaning kit PN 8052 97K to help guarantee and promote a clean system Also make sure sample weight is consistent throughout tests PROBLEM What flag do I use SOLUTION Please refer to the section Choosing a Timing Flag in the manual PROBLEM How long should my cut time be for a Method A run SOLUTION Dynisco Polymer Test suggests that you collect about 1 gram of sample extrudate or more ...

Page 79: ...fore will not need any significant drying QUESTION Should I check the MFI on my finished product ANSWER Sure You want to know if what you made yesterday is the same as what you made today If it s the proper quality and did it change You also want to make sure that the performance of your process and end product are consistent day to day QUESTION What are the lowest MFI and highest MFI we can test ...

Page 80: ... storms can damage the instrument As with all accessories that are plugged into wall outlets a surge protector is a great idea QUESTION What spare parts should I keep ANSWER This depends on how mission critical your operation is You should have spare fuses and maybe a piston tip and die A spare parts list should be supplied with the quote Series 4000 Melt Indexer Operation Manual Questions and Ans...

Page 81: ...nual and is sometimes called the cut n weigh method This test measures the amount of material extruded over time and a volume extruded over a distance A means of measuring travel is employed In order to run a method B test an A B run MUST be run first to determine the polymer s melt density Measurement of the volume of material that extrudes over time Can be conducted only after an A B experiment ...

Page 82: ...y configuration file This can be done through the PC as follows Daisy Software Start Up Verify USB port assigned to LMI 1 Power up LMI with USB connected to PC 2 On PC go to Control Panel System Hardware Device Manager Ports Com and LPT 3 Note Comm port of ATEN USB to Serial Bridge 4 Go to PC and open with WordPad or NotePad C Device1 cfg Series 4000 Melt Indexer Operation Manual USB Setup 74 ...

Page 83: ...ort assignment noted from Device Manager in step 3 6 Save Device1 CFG if COM Port was changed To Verify Communications 7 Start LMI software by opening Daisy for Melt Indexer from desktop or through C Program Files Username alpha Password alpha Series 4000 Melt Indexer Operation Manual USB Setup 75 ...

Page 84: ...open If this first window does not open go to Daisy 8 50 Eclipse window the second below and press upper left button If the first window fails to open check communications to instrument Series 4000 Melt Indexer Operation Manual USB Setup 76 ...

Page 85: ...to the MI Works communications settings in step 8 If it is not COM1 or COM2 then you will need to change it to either COM1 or COM2 but COM2 would be preferred COM2 most likely will not conflict with a hardware 9 Pin serial port on the PC If the ATEN USB to Serial Bridge does not show in the Ports section or has errors a driver may need to be installed The driver for the PC s operating system can b...

Page 86: ...5 Right click on ATEN USB to Serial Bridge and select Properties 6 Select Port Settings Series 4000 Melt Indexer Operation Manual USB Setup 78 ...

Page 87: ...ttings select COM2 or COM1 then OK to Advanced Settings then OK to Communications Port Properties Then close Device Manager 8 Start MI Works and the following window should appear Series 4000 Melt Indexer Operation Manual USB Setup 79 ...

Page 88: ... following window should appear Select the COM port that was assigned the USB port in step 7 in the Select PC Port section of the window MI Works should now function with the LMI Series 4000 Melt Indexer Operation Manual USB Setup 80 ...

Page 89: ...ctrical Hazard 10 F Flag 35 Flow Rate Ratio 39 FORM FEED 18 Fumes from Materials 11 G gloves 9 Making the Cut 24 31 melt density 32 Mercury 10 mercury thermometers 10 Method B Encoder Option 4 50 Method B Flags Setup 33 Model Descriptions 2 moisture 3 Multi Weight 40 Multiple Method A 51 O on 21 out of control 48 Oven cleaner 26 P Pa sec 65 Poise 65 Power Cord 9 PRINTER 18 Prtinter Connection 9 PV...

Page 90: ...Series 4000 Melt Indexer Operation Manual Page 82 ...

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