Dynisco ViscoIndicator Installation & Service Manual Download Page 5

Page: 5 / 50

P/N: 975389

Rev: current

ECO: xxxxx

www.dynisco.com

From lab to production,

providing a window into the process

-5-

General

1.1

Important information about the use of this manual

This manual covers the Assembly, Installation and Service of the ViscoIndicator. The

operation of the ViscoIndicator is covered in a separate manual (Dynisco p/n 974175).

Summary of Contents for ViscoIndicator

Page 1: ...P N 975389 Rev current ECO xxxxx www dynisco com From lab to production providing a window into the process 1 Rheological sensing for the masses Assembly Installation Service Manual ViscoIndicator ...

Page 2: ...P N 975389 Rev current ECO xxxxx www dynisco com From lab to production providing a window into the process 2 ...

Page 3: ...ssemble IRCU STAND optional 14 4 2 Mount RCU to the stand 21 4 3 Attach the RSU Head to the stand 23 4 4 Attach the HMI to the stand 29 4 5 Install Vortex coolers into RSU RCU option 30 4 6 Attach Vortex cooler regulators and tubing option 31 4 7 Attach ViscoIndicator Cable Bundle electrical cables between RSU HMI to RCU 31 4 8 Attach RCU power cable to RCU 31 5 Installation 33 5 1 Process Connect...

Page 4: ...43 7 HMI Operation Obtaining rheological measurements from the ViscoIndicator 44 8 Preventative Maintenance 45 8 1 Check RSU enclosure for plastic leaks 45 9 Service 46 9 1 Changing RSU burst plug 46 9 2 Changing Pressure Transmitter 46 9 3 Changing capillary 46 9 4 Detaching VI main system from process connection 47 9 5 Preparing VI system for shipment 47 10 Support Contact Dynisco 48 10 1 Recomm...

Page 5: ...on providing a window into the process 5 1 General 1 1 Important information about the use of this manual This manual covers the Assembly Installation and Service of the ViscoIndicator The operation of the ViscoIndicator is covered in a separate manual Dynisco p n 974175 ...

Page 6: ...ground a circuit before touching it When making electrical connections the services of a qualified electrician must be employed Contact with live electrical circuits can cause serious personal injury or death Be sure no circuits are energized during installation connection or removal of any electrical cables or lines Examine the cabling and housings regularly for damage Machines with damaged wirin...

Page 7: ...must therefore be taken roll the unit slowly The castors on the base of the stand must be examined regularly for damage and secure fit damaged castors are to be replaced immediately 2 2 Obligation of the operator to exercise due care The Dynisco component conforms to the state of the art technology and ensures a maximum of safety In practical operation this safety can however be achieved only if a...

Page 8: ...l have to be made available as a supplement to the operating instructions 2 3 Obligation of the personnel to exercise due care The ViscoIndicator melt rheometer may only be operated by persons trained instructed and authorized to do so These persons must know the operating instructions and act accordingly The respective competences of the staff must be clearly determined The following work describ...

Page 9: ...itched off the Dynisco component In addition to the operating instructions the service instructions within the meaning of the industrial safety legislation and the ordinance for the use of work materials will be observed In case of malfunctions the operator or the supervisors will be informed The necessary personal protective equipment for the operating maintenance and service personnel will be us...

Page 10: ...on the floor Sudden stops can cause the machine to tip over 3 3 Inspection upon receipt Check the delivery for completeness and signs of shipping damage Any shipping damages must be sent to the shipping carrier and Dynisco in writing Immediately submit any claims in writing to the following address For Americas and APAC For EMEA Dynisco Dynisco Europe GmbH 38 Forge Parkway Pfaffenstrasse 21 Frankl...

Page 11: ...osity directly on the extruder The ViscoIndicator consists of the following A sample tube that transfers polymer from the process to the ViscoIndicator for measurement The Process Isolation Valve PIV allows the flow of polymer to the ViscoIndicator to be shut off allows purging and allows a pressure transducer measurement on the process line A Rheological Sensing Unit RSU that measures the propert...

Page 12: ...ameters and provides measured and computed material properties It provides rheological data similar to a Laboratory Capillary Rheometer or MFI readings similar to a Melt Flow Indexer HMI Because of the system options available please refer to the purchase order for the particular configuration and accessories However the following items are part of the standard ViscoIndicator ViscoIndicator Cable ...

Page 13: ...P N 975389 Rev current ECO xxxxx www dynisco com From lab to production providing a window into the process 13 Optional Items Vortex cooler Stand ...

Page 14: ...d per the instructions below If this stand was not purchased skip to section 3 2 NOTE Item numbers refer the numbers on drawing IRCU STAND included at the end of this section unless noted 4 1 1 Assemble Base Loosen the four connector set screws on the cross brace extrusion item 13 QTY 1 On each end of item 13 slide one caster extrusion item 2 QTY 2 onto the T nuts The two T nuts on each end of ite...

Page 15: ...4 1 2 Assemble Mast Loosen the two connector set screws on the rectangular mast item 3 QTY 1 Loosen the two connector set screws on the square mast item 1 QTY 1 Slide the two masts together using the T nuts on each mast Tighten all four connector set screws on the masts Insert two M5 T nuts item 17 into upper end of item 3 Attach endcap to lower end of item 3 ...

Page 16: ...d of item 1 into two slots of item 13 orienting the mast assy as shown Position item 1 approximately in the center of item 13 Tighten the four connector set screws on the lower end of item 1 CAUTION The positioning of the mast to the base described above may not provide the most stable configuration when an RSU is later mounted to the stand Repositioning the mast relative to the base may provide a...

Page 17: ...ut connectors Tighten two connector set screws of item 12 Slide the RSU support onto item 3 Tighten the two connector set screws of item 11 for the desired height of the ViscoIndicator RSU Loosen the connection between items 11 and 12 and move item 12 to make both ends of item 12 flush to items 11 and 3 Tighten all four connector set screws of item 12 CAUTION The higher the RSU support on the mast...

Page 18: ... farthest slot from the RSU support position the connector set screws facing the RSU support red circle position the two lower arms 2in from item 13 position the two upper arms approximately 17in from the lower arms the top arms will be moved to a final position later Install one M5 T nut item 17 into each item 6 in the slot opposite the connector set screw slot yellow circles CAUTION Raising the ...

Page 19: ...s of item 2 Place a washer item 9 QTY 4 over each threaded caster shaft onto item 2 Thread a nut item 10 QTY 4 onto each threaded caster shaft and tighten until caster is secure 4 1 7 Install Endcaps Press cover endcaps into extrusion ends item 5 QTY 1 install on top end of item 1 item 8 QTY 4 install on exposed ends of item 6 item 4 QTY 9 install on all remaining exposed ends ...

Page 20: ...P N 975389 Rev current ECO xxxxx www dynisco com From lab to production providing a window into the process 20 ...

Page 21: ...ncluded at the end of the previous section unless noted NOTE Dynisco P N 1016335 consists of two parts a lower and upper bracket 4 2 1 Attach lower brackets to the stand Center and attach one lower bracket part of Dynisco P N 1016335 to the upper cabinet support arms using two M5 x 12mm long button head cap screws Dynisco P N 550186 Put the two screws through the holes nearest the ends of the brac...

Page 22: ... 20 lbs It is recommended that two physically capable people lift the RCU carefully to install it on the stand in a controlled fashion Center and attach the bottom of the RCU to the lowest bracket of the stand by centering the RCU on the mast then bringing the RCU down until the lower bracket seats red circle The RCU is not fully attached Hold the RCU up against the mast until the next step is com...

Page 23: ... in this section refer to item numbers on drawing IRSU MOUNT included at the end of this section unless noted 4 3 1 Remove the IRSU MOUNT from the RSU CAUTION The following step requires two people CAUTION The RSU PIV IRSU MOUNT weighs approx 40 lbs Only physically capable personnel should lift this assembly Remove the RSU PIV IRSU MOUNT assembly from the shipping box and carefully rest it on a su...

Page 24: ...P N 975389 Rev current ECO xxxxx www dynisco com From lab to production providing a window into the process 24 Place the RSU PIV assy on a stable surface ...

Page 25: ...er slots of item 11 of drawing IRCU STAND yellow circle Position the IRSU MOUNT on top of the inserted M8 T nuts so the thru holes in item 6 are as close as possible to the mast red circle Slide two M8 bolts item 7 QTY 2 thru the two holes in item 6 and into the two M8 T nuts and begin to tighten Slide the IRSU MOUNT on the RSU support to the desired position and then fully tighten the two M8 bolt...

Page 26: ...ss 26 CAUTION Increasing the distance between the IRSU MOUNT and the mast increases the stand instability 4 3 3 Attach the RSU to the IRSU MOUNT Place the RSU onto the IRSU MOUNT and line up the RSU cover screw holes with the holes in item 1 red circles Continue to support the RSU so it will not fall over ...

Page 27: ...t ECO xxxxx www dynisco com From lab to production providing a window into the process 27 Reinsert the four pcs of item 4 into the holes in item 1 and tighten the 4 screws into the capture nuts in the RSU to secure the RSU ...

Page 28: ...P N 975389 Rev current ECO xxxxx www dynisco com From lab to production providing a window into the process 28 ...

Page 29: ...TAND in section 4 1 4 4 1 Insert M5 T Nuts Position four M5 T Nuts item 17 into 2 slots towards the top end of item 3 yellow circles 4 4 2 Place HMI on top of square post and open HMI box Place the HMI on top of the square post item 1 against item 3 Open the HMI box by unscrewing the 4 screws in the cover panel being careful to hold the box and cover panel in place USE CAUTION FRAGILE The cover pa...

Page 30: ...tightening the four M5 screws Close the HMI box by putting the cover panel back on and screw the 4 original cover screws back in be careful to not pinch any wiring when closing the cover 4 5 Install Vortex coolers into RSU RCU option 4 5 1 Installing RSU Vortex cooler Install small 90degree pressure fitting into Vortex cooler port using teflon tape Remove plastic plug from RSU 90 degree cooler por...

Page 31: ...lator body using teflon tape on the fitting threads Mount regulator in convenient location such as on the stand mast Install air lines between each regulator output port and the Vortex cooler inlet port 4 7 Attach ViscoIndicator Cable Bundle electrical cables between RSU HMI to RCU Remove box receptacle covers if installed Three cables go between the RSU and the RCU and one cable goes between the ...

Page 32: ...e RCU cabinet and clamp in place for strain relief Connect the ground wire to terminal 2 of terminal block 5 TB5 Connect the line wire to terminal 2 of the ON OFF switch S1 Connect the neutral wire to terminal 4 of the ON OFF switch S1 Verify all connections are secure and tight Verify all breakers are turned to the on position Close and lock cabinet prior to turning on the system ...

Page 33: ... process connection requires working in close proximity to hot extruder surfaces Use appropriate heat protection clothing gloves as needed to prevent injury 5 1 1 Extruder at operating temperature but no pressure The process connection must be installed when the extruder is at operating temperature with the extruder screw not rotating no extruder pressure 5 1 2 Remove port plug pressure transducer...

Page 34: ...thread Reinstall the collar onto the tube end by hand fully threading the collar onto the tube 1 to 2 full threads of the tubing must be exposed for proper installation Repeat this process for the other end of the extension tube Install the extension tube into the pressure port so the end of the tube with protruding cables is farthest away from the port Install extension tube into supply tube by t...

Page 35: ...n this section refer to item numbers on drawing PIV I HALF20 included at the end of this section unless noted 5 2 1 Adjust RSU height angle to match process connection height angle CAUTION The following step requires two people CAUTION The RSU IRSU MOUNT weighs approx 40 lbs Only physically capable personnel should lift support this assembly Position the VI system up to the process connection and ...

Page 36: ...em to process connection Install a 1 7 diameter o ring item 8 into the PIV if not already installed Apply anti seize to the o ring if it will not stay in the o ring groove Connect the process connection to the RSU by mating the PIV to the flowblock the PIV has two offset alignment pins that key into the flowblock surface red circles Apply anti seize to four SHCS 3 8 16 x 1 5 lg Dynisco p n F714 an...

Page 37: ...e to the heater cartridge item 12 and secure in heater block thru hole using small set screw item 13 Position heater length in middle of heater block thru hole Install PIV spring loaded RTD item 7 in the bayonet fitting o Insert the PIV RTD into the bayonet fitting aligning the slot in the PIV RTD fitting with the tab in the bayonet fitting o Continue pressing down on the RTD into the bayonet fitt...

Page 38: ...P N 975389 Rev current ECO xxxxx www dynisco com From lab to production providing a window into the process 38 ...

Page 39: ...or inlets 5 6 Insulate supply tube ext tube assy ends dump valve and PIV It is recommended to wrap the supply tube dump valve and PIV in insulation as described below to improve ViscoIndicator temperature performance The exposed extension tube assy ends should also be wrapped in insulation High temperature insulation is required fiberglass pipe insulation recommended Flexible metal wire Buss wire ...

Page 40: ... a minimum pressure of 30psi from the Dynisco supplied pressure regulator filter Dynisco p n 9967 3759 Even when the ViscoIndicator isn t at temperature it is preferred to keep the Vortex coolers on with air flowing to maintain a positive pressure air flow inside the RSU and RCU enclosures to limit the accumulation of dust particulates in the enclosures 6 2 IRCU STAND casters After the connection ...

Page 41: ...bly degraded material before it can enter the RSU and possibly cause damage to the RSU The dump valve is integrated into the flange that connects the PIV to the ext tube assy or supply tube When not in use the valve spool should be kept in the closed position slot in the valve spool parallel with the floor and insulation in place around the dump valve spool and exit To operate the dump valve o wai...

Page 42: ...f being careful not to have your hand arm under the extrudate flow path o rotate the spool up to 90degrees until the plastic is flowing o once material is flowing the spool can be moved towards the closed position to reduce the amount of extrudate exiting the valve Return the spool to the closed position when completed with the material purge ...

Page 43: ...p valve see section 6 3 o wait until the RSU PIV and AUX zones reach operating temperature for at least 10 minutes before trying to operate the PIV o Engage the PIV spool with a 9 16 wrench and turn the spool 90 degrees counterclockwise to open the valve 6 5 Rheological Sensing Unit RSU Extrudate Stream Extrudate will collect under the RSU as it exits the RSU die through the bottom cover of the RS...

Page 44: ...CO xxxxx www dynisco com From lab to production providing a window into the process 44 7 HMI Operation Obtaining rheological measurements from the ViscoIndicator Please see the separate Dynisco Operation Manual for information ...

Page 45: ...U yellow circles This is the cover on the right hand side of the RSU if the RSU is between yourself and the extruder Caution RSU should be properly supported before removing 2 mounting screws holding head onto bracket Visually examine all the pressure port connections to the flow block flange pressure transducer burst plug and capillary plate If extrudate is seen retighten connections at leak poin...

Page 46: ...lly angle the PT and remove the PT from the enclosure Apply anti seize to the new PT threads and reverse previous steps and install PT to 25 ft lbs 42 ft lbs max 9 3 Changing capillary 9 3 1 Capillary Removal Confirm the ViscoIndicator is not at pressure and the PIV is closed Bring the flowblock to process temperature Thread the two brass rods together that are part of the capillary insertion remo...

Page 47: ...irm the ViscoIndicator is not at pressure and the PIV is closed Shut the VI system down and unplug the power from the RCU Perform the following steps while the VI is still at temperature o Remove any insulation wrapped around the PIV o Perform steps from section 5 3 in reverse order to remove the PIV RTD PIV bayonet fitting and PIV heater block with heater NOTE it is not necessary to remove the PI...

Page 48: ...acement parts list and drawings of replacement parts To maximize the service life of your ViscoIndicator use only original replacement parts from Dynisco Please indicate the machine number the construction year and the ordering number and position of the replacement parts in your order This allows us to send you the requested replacement parts faster Please contact For Americas and APAC For EMEA D...

Page 49: ...dled by our Customer Service department Please contact Dynisco Dynisco Europe GmbH 38 Forge Parkway Pfaffenstrasse 21 Franklin MA 02038 USA 74078 Heilbronn Germany Phone 1 508 541 9400 Phone 49 7131 297 0 Fax 1 508 541 6206 Fax 49 7131 297 166 E mail infoinst dynisco com Email dyniscoeurope dynisco com Please inform us immediately if you need the help of a service technician on site ...

Page 50: ...s described for each case As the guarantee period DYNISCO grants a 12 month guarantee from the date of delivery when the ViscoIndicator is used in single shift operation If it is used in multiple shift operation the duration of the guarantee is reduced to 6 months The guarantee covers assuming appropriate usage and excluding willful damage the primary design and error free manufacture of the produ...

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