Dynisco LMI 4000 Series User manual

Dynisco Polymer Test Systems
LMI 4000
Series
Melt
Indexer
Manual
Version 4.1
38 Forge Parkway
Franklin, MA 02038
Phone [phone]
Fax [phone]
Manual Part Number: M0704 www.dynisco.com
Original Language Version

Notice
This manual contains descriptions, drawings and specifications for a Dynisco Polymer Test
Systems Product. Equipment or products made prior to or subsequent to the publication
date of this manual may have parts, features, options or configurations that are not covered
in this manual. Specifications contained herein are subject to change by Dynisco Polymer
Test 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 to the manual are appreciated and may
be sent to the following location:
38 Forge Parkway
Franklin, MA 02038
Phone [phone]
Fax [phone]
www.dynisco.com

Contents
Introduction 1
About DYNISCO POLYMER TEST SYSTEMS Inc. ...................................................................................1
How to Use this Manual..................................................................................................................................1
Typographic Conventions...............................................................................................................................2
How to Contact Dynisco Polymer Test Systems Inc.......................................................................................2
Model Descriptions.........................................................................................................................................2
On Overview of MI.........................................................................................................................................3
ASTM Melt Index Tests..................................................................................................................................3
Method A..........................................................................................................................................3
Method A/B ......................................................................................................................................3
Method B ..........................................................................................................................................3
Series 4000 Product Offerings:.......................................................................................................................3
Introduction.......................................................................................................................................3
Model 4001.......................................................................................................................................4
Model 4002.......................................................................................................................................4
Model 4003.......................................................................................................................................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
Calibration Thermometers use Mercury........................................................................................................10
Pinch Points...................................................................................................................................................11
Fumes from Materials ...................................................................................................................................11
Pre-Run Check List.......................................................................................................................................11
Series 4000 Melt Indexer Operation Manual Contents  i

Series 4000: A Guided Tour 12
Four Options from the main menu screen.....................................................................................................12
Overview.........................................................................................................................................12
Setup ...............................................................................................................................................12
Edit..................................................................................................................................................12
Run..................................................................................................................................................12
System.............................................................................................................................................12
Navigating the Keypad..................................................................................................................................13
Introduction.....................................................................................................................................13
The Keypad.....................................................................................................................................13
Keypad Definitions.........................................................................................................................14
Configuring the Instrument 15
Intro: The SYS (SYSTEM) Mode.................................................................................................................15
Selecting CALIB (Calibration) in the SYS Mode.........................................................................................16
CALIB:Digital Flag Home..............................................................................................................16
CALIB:RTD Electronics.................................................................................................................16
CALIB:RTD Sensor........................................................................................................................16
CALIB:Optical Flag........................................................................................................................16
CALIB:Intrinsic Viscosity Offset...................................................................................................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
Create (New)...................................................................................................................................18
Recall (Old).....................................................................................................................................18
Save Program..................................................................................................................................18
While EDITING .............................................................................................................................18
Method A Run Parameters..............................................................................................................19
Method A/B Run Parameters..........................................................................................................19
Method B Run Parameters..............................................................................................................19
RATIO (Flow Ratio) Run parameters..............................................................................................20
Series 4000 Melt Indexer Operation Manual Contents
 ii

Run a Program...............................................................................................................................................20
Method "A" Run 21
General Description ........................................................................................................................21
Calculations: Method A..................................................................................................................21
Power-Up........................................................................................................................................21
Introduction.....................................................................................................................................21
Programming a Method A.............................................................................................................................21
Machine Setup ................................................................................................................................22
Loading the Sample.......................................................................................................................................23
Loading the Barrel ..........................................................................................................................23
Bubbles ...........................................................................................................................................23
RUN................................................................................................................................................23
Making the Cut ...............................................................................................................................24
Weigh the Sample...........................................................................................................................24
Cleaning Up....................................................................................................................................25
User Tips:......................................................................................................................................................25
User Tip #1 .....................................................................................................................................25
User Tip #2 .....................................................................................................................................25
Always leave the barrel clean. ........................................................................................................26
Cleaning Up a really Big Mess .......................................................................................................26
Method "A/B" Run 27
General Description ........................................................................................................................27
Calculations : Method 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: Step by Step..............................................................................................................35
Instrument Prep...............................................................................................................................35
Loading the Barrel ..........................................................................................................................35
Timing Flag and Starting the Run...................................................................................................36
Cleaning Up....................................................................................................................................37
“Flow Ratio” Runs 39
Flow Rate Ratio test and the Pneumatic Lift Option.....................................................................................39
Series 4000 Melt Indexer Operation Manual Contents
 iii

What is it?.......................................................................................................................................39
Why do it?.......................................................................................................................................39
Flow Rate Ratio - How to Do It......................................................................................................39
“Intrinsic Viscosity” Runs with PET 41
Calculating PET I.V. from the Melt Indexer.................................................................................................41
What is it?.......................................................................................................................................41
Why do it?.......................................................................................................................................42
How to do it ....................................................................................................................................42
Charge Weight 44
The Amount of Sample.................................................................................................................................44
A-Standard Operating Procedure 46
Introduction:....................................................................................................................................46
Instrument Preparation....................................................................................................................46
Conducting the Test........................................................................................................................47
Clean Up .........................................................................................................................................47
Your data.........................................................................................................................................47
Out of Control Action List 48
Actions............................................................................................................................................48
Generic Run Check List..................................................................................................................48
Model 4004 and Computer Control 49
Introduction...................................................................................................................................................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
Digital Flag Home...........................................................................................................................53
Testing and Maintenance................................................................................................................53
Complete Digital Encoder Calibration............................................................................................54
Referenced Spec D1238-95 ............................................................................................................54
Pneumatic Lift Options 59
Pneumatic Lift...............................................................................................................................................59
Introduction.....................................................................................................................................59
Activation and Operation................................................................................................................59
Series 4000 Melt Indexer Operation Manual Contents
 iv

Mini-Lift........................................................................................................................................................59
Introduction.....................................................................................................................................59
Activation and Operation................................................................................................................59
Instrument Calibration 60
RTD Electronics............................................................................................................................................60
RTD Sensor...................................................................................................................................................60
Calibration Steps:............................................................................................................................60
SINGLE..........................................................................................................................................60
DOUBLE........................................................................................................................................61
Optical Flag...................................................................................................................................................61
Calibration Steps:............................................................................................................................61
Digital Encoder Calibration ..........................................................................................................................62
Calibration:Digital Flag Home........................................................................................................62
Intrinsic Viscosity .........................................................................................................................................62
Offset ..............................................................................................................................................62
Instrument Maintenance and Troubleshooting 63
Maintenance..................................................................................................................................................63
Daily................................................................................................................................................63
Weekly............................................................................................................................................63
Monthly or Long Term ...................................................................................................................63
Barrel Diameter...............................................................................................................................64
Support 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............................................................................................73
Intrinsic Viscosity.........................................................................................73
Melt Flow Indexer ........................................................................................73
Method A......................................................................................................73
Method A/B..................................................................................................73
Method B......................................................................................................73
MVI ..............................................................................................................73
Optical Flag or Optical Eye Sensor ..............................................................73
Pneumatic Lift ..............................................................................................73
RTD..............................................................................................................73
Timing Flag ..................................................................................................73
Series 4000 Melt Indexer Operation Manual Contents
 v

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

Introduction
About Dynisco Polymer Test
Dynisco Polymer Test is a manufacturer of laboratory test equipment supplying
capillary rheometers, melt indexers, a variety of impact testers, coefficient of
friction testers, contact angle testers, film tensile testers and other small test
devices. Through its innovative work with electronics and mechanical design,
Dynisco Polymer Test Systems has carved a niche in the market place by
providing the highest performance per cost ratio in the business.
The company was founded in the late '60's in Honey Brook P.A., and is built on
two principles: quality workmanship and outstanding service. Dynisco Polymer
Test Systems' mission has grown to meeting the physical testing needs of the
plastics, food, and rubber industries by providing high quality equipment and
services at low cost. The company was purchased in 1988 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 software was purchased) it provides
the complete description of resources at your command. It is not necessary to
read this manual in its entirety. However, even experienced rheologists and
technicians can benefit from the SAFETY tips and cleaning suggestions learned
over many years of operating these instruments in our applications laboratory.
The Getting Started Chapter explains the details of setting up the instrument and
preparing it for use. Please take a few minutes to review the safety precautions
that should be taken when operating Dynisco Polymer Test Systems Melt Index
equipment.
Series 4000 Melt Indexer Operation Manual Introduction
 1

Typographic Conventions
Italics: Rheological items that have defining equations presented in the manual
are shown in italics. If you come across an italicized item that is unclear you
can be sure it has a mathematical definition previously defined in the manual.
Bold Italics: These are parameters that are set from the front panel on the
indexer (i.e. Melt Time, Mtd A Time etc.). These parameters are entered into
the indexer's control programs via the indexer key pad.
BOLD ALL CAPITALS: This indicates an actual key found on the indexer
key pad. Example: Press the RESET button to return to main screen. Underlined
Items: Underlined items' head paragraphs or sections that pertain to the
particular item or model underlined. If you do not have or are not interested in
the underlined item skip the section that follows it. Underlining is also used
to emphasize safety issues.
How to Contact Dynisco Polymer
Test Inc.
Before calling Dynisco Polymer Test be sure you have gone through the
"Answers to common questions" section of the manual. To help us handle 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 [phone] and ask for technical
support. Should you wish to comment or query in writing, address to:
Dynisco Polymer Test Inc. : Customer Service
38 Forge Parkway
Franklin, MA 02038
You can also reach us through the internet at: www.Dynisco.com.
Model Descriptions
The DYNISCO POLYMER TEST SYSTEMS Series 4000 Melt Flow Indexer
incorporates the latest in micro-electronic technology. It is designed to make
melt flow rate testing faster, more accurate and flexible, and generate more
rheological information. The heart of the system is a 32 bit microprocessor
developed by DYNISCO POLYMER TEST SYSTEMS. It controls
temperature, responds to keyboard commands and implements testing programs.
System capabilities:
 Communications with computers
 Direct output to printer
 Stores test conditions in program memory
 Shows instantaneous flow rate read-out
 Battery backed-up date & test conditions
Series 4000 Melt Indexer Operation Manual Introduction  2

 Download to MS-DOS compatible systems
 Methods A, B, or A/B conversion and flow rate ratio
 Automated purge or weight lowering
 Control temperature within 0.1C.
 Automatic check of RTD sensor probe and over temperature alarm.
On Overview of MI
A flow rate test is a measure of a polymer's mass flow rate (grams extruded in
10 minutes) using a particular orifice under specified conditions of temperature
and load. Machines that determine flow rate are generally called Melt Indexers.
Test methods by ISO, DIN, ASTM and others specify heat chamber and piston
tip diameter such that the shear stress on the polymer is the same in all machines
for a given load. In addition, material specification guidelines (by ISO, DIN,
ASTM, GM etc) may exist which give further constraints on how a particular
type of material may be run.
The tests we are interested in performing are those described by ASTM D1238
and ISO 1133. This manual in no way supersedes either of these documents.
The precision and accuracy of the test has been determined by ASTM method
D1238 and can be found at the end of this manual. Contributing to both
precision and accuracy are operator variances such as; packing 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 have been developed for running flow rate tests under D-
1238, Methods A and B. Method A is simply the collection of extrudate over
time, while Method B is the measurement of time for the flow of a fixed volume
of polymer.
Method A
Method A/B
Method B
Introduction
Method A -- the test is completely manual and is sometimes called the "cut-n-
weigh" method.
Method A/B -- this employs the electronic eye or digital encoder. In order to
run a method B test, an A/B run MUST be run first to determine the polymer's
melt density
Method B can be conducted only after an A/B experiment is conducted. This is
a "no-cuts" test that is the most convenient for busy laboratories.
Series 4000 Product Offerings:
The Series 4000 of melt indexers are actually 2 pieces of equipment in one.
First, the instrument houses the hardware needed to conduct the measurement
itself -- the heaters, temperature sensors, die/orifice assembly, and so on.
Series 4000 Melt Indexer Operation Manual Introduction  3

Second, the instrument has a 32 bit micro-processor incorporated into its base
to control the aforementioned hardware, but also to make calculations of the
Melt Index, Viscosity, and in some cases (Model 4003, 4004) calculate
rheological data about the sample as well.
Model 4001
Model 4002
Model 4003
Model 4004
Method B Encoder Option
This is the entry level machine. It will conduct method A tests only and cannot
be upgraded to higher models. The 4001 has a 5 program memory.
This model performs Method A, Method B and flow rate ratio testing.
Temperature and flow rate are displayed on the instrument front panel. It has a
20 program memory. The unit can be upgraded to higher models.
This model contains additional program capacity and can retain up to 60 test
programs. In addition, it communicates with printers and can provide a series of
more advanced technical information such as shear rate, shear stress and
viscosity. Statistics on flow rate and viscosity can be averaged over replicated
tests.
The 4004 is the most sophisticated of the Dynisco Polymer Test's models ever
available. It has all of the capabilities of the 4001, 4002 and 4003, and will
communicate with other computers, and can be multiplexed (8 machines to one
PC). With the addition of the encoder option, 10 complete 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 encoder has dual outputs,
enabling the signal to be processed in 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 and varied digitally. Thus, any test length
up to 1"(ASTM) or 30 mm (ISO) may be selected. Up to 15 MFR results per
barrel filling can be obtained. The unit is securely fastened to the rear of the Melt
Indexer, and the arm latches down to facilitate cleaning of the unit after the test is
completed.
Encoder Advantages
 Completely Automatic Flag Length Selection on Single MFR Tests
 Up to 15 MFR readings per Barrel Filling
 Any test length ("Flag") up to 30 mm
 User Defined test length & test spacing for single or multiple tests
 Automatic Test Length & Test Spacing for multiple tests
Series 4000 Melt Indexer Operation Manual Introduction
 4

Pneumatic Lift
Mini-Lift
Intrinsic Viscosity Option
The pneumatic lift accessory is a key piece of hardware if the flow ratio test
needs to be conducted. The Flow Ratio test provides users with insight into a
material’s thinning ability. This test involves obtaining two flow rates at two
different stress levels, of generally a 10:1 ratio. First, the lower mass weight is
added to the piston. Next the higher mass weight is added to the piston. The
high mass weight can be 21 Kilograms. The pneumatic lift automatically raises
and lowers the 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 determining the
Intrinsic Viscosity of a polymer. The IV is used to determine the molecular
weight of a polymer. This is described in greater detail in the Dynisco Polymer
Test applications brief, "Correlating Melt Rheology of PET to Solution Intrinsic
Viscosity" by J. Reilly and P. Limbach.
Series 4000 Melt Indexer Operation Manual Introduction
 5

Getting Started
Unpacking the Indexer
The DYNISCO POLYMER TEST'S Melt Flow Indexer comes in a heavy duty,
double-walled cardboard container. First, open the main box and remove the
instrument. Several boxes will also arrive by UPS; check that all boxes are
received. They are coded 1 of 5 or 3 of 5, indicating the total number is five. It
is recommended that the shipping carton be saved a few days until you are
certain the machine works as expected.
Bench Requirements and Placement
Level the Melt Indexer
Typical laboratory benches are too high for efficient use of the indexers.
Cleaning can be difficult and requires awkward hand positions and forces that
could lead to carpal tunnel syndrome or back discomfort. We strongly suggest a
bench height of 29 inches (desk top height) for an average height operator.
Place the front of the indexer flush with the edge of the table. This will prevent
the operator from having to bend forward excessively when cleaning the barrel
and allow easier access to the back of the machine. As a minimum, the lab
bench should easily be able to support the indexer and operator (total approx.
300 lbs.). DYNISCO POLYMER TEST recommends placing from left to
right, 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 tested. Consult the Material Safety Data Sheets (MSDS) on
the products to be tested and your material supplier to assess the magnitude of
your ventilation needs. You may wish to consider these ventilation needs when
positioning the instrument in the laboratory.
Most of the machine comes pre-assembled to your door, however, certain parts
are prone to breakage if they were placed in their normal operating position
during shipping. These items will need to be installed before safe operation of
the machine is possible. Other issues important to getting accurate data must
also be addressed before valid testing can begin.
Using the small round bubble level, supplied, level the melt indexer. Place the
level on top of the COLD barrel and using the adjustable screw feet, bring the
machine into level. Tighten the locking nuts to keep the feet in level position
Test shake the melt indexer for stability. Some companies bolt the machines
Series 4000 Melt Indexer Operation Manual Getting Started
 6

directly to their benches. Be sure to remove the level before turning on the
machine. The level will be damaged if it gets hot.
*** Be sure to enable the following features in the SETUP Mode ***
Pneumatic lift setup
(Please refer to drawing below)
a.) Find the safety spike (1) taped to the guide post (2) . The guide post is
shipped in the down position. Remove the spike from the post and mount it into
the aluminum weight bucket (3) as shown. The spike should be flush with the
bottom of the weight bucket. Tighten set screw (4) with a 1/8” hex wrench.
b.) Loosen the guide block set screws (5) with a 3/32” hex wrench and slide
the guide post (2) up until the bottom snap ring touches the bottom of the guide
block. Tighten the guide block set screws (5) .
c.) Connect a length 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 cylinder for UP and DOWN movement. Switch (7)
is an extra safety “lock” feature that will lock the lift in place if closed.
Installing the Digital Encoder
The following parts should be in the encoder upgrade kit or included with the
encoder based melt indexer: (if ordered)
 Two 1.25" long #8-32 Socket Head Cap Screws (SHCS)
 Two 5/8" long #8-32 Socket 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
Series 4000 Melt Indexer Operation Manual Getting Started
 7

 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
Socket Cap Screws &
Two Lock Washers
Phone Jack Cable
Plate #1
Plate #2
Two #8-32 x 5/8" SHCS
Two Washers & Lock Wash
Figure #1
Two #8-32 x 1.25" SHCS
Two Washers & Lock Washers
Plate #3 (Already Mounted to MI)
2. Attach the Encoder Housing to the long plate (plate #1) using two 1.25" long
SHCS, two 5/8" long SHCS, 4 washers & 4 lock washers (washers first then
lock washers, i.e. lock washers under screw 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.
Tighten the screws
3. Plug the phone jack cable into the encoder housing.
4. Move the encoder arm into the down position.
5. Turn the power on.
6. Enable the Encoder by pressing the SETUP key. Browse the options until
you reach B FLAG and press EDIT. Press —› Quick Key so that ENCODR is
over the SELECT Quick Key. SELECT ENCODER and press ENTER to
accept. Press ESCto back out to the main menu.
Series 4000 Melt Indexer Operation Manual Getting Started
 8

7. Press the SYS key and select TEST. Browse the menu and select Digital
Encoder Test. The display shows current position and should change when the
arm is moved. Press QUIT ending the 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.
RTD Connection
Power Cord
Printer Connection
Computer Connection
Options:
The RTD, or thermocouple, is buried inside the instrument's barrel. The RTD
and associated temperature control electronics are calibrated against NIST
traceable temperature probes at Dynisco Polymer Test Systems. To achieve
accuracy required by ASTM D1238 the RTD and electronics control should be
kept together. Changing a RTD requires a complete temperature re-calibration.
Please consult the factory when required to replace the RTD.
Connect the power cord to the melt indexer. There may be a number of standard
power cords supplied; the heaviest is used for the melt indexer. The factory
suggests using a noise filtering outlet strip to connect the instrument and
associated components 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 OFFwhen connecting the indexer.
The data processing system (4004 models only) consists of a PC and the
MIWORKS software package . If your melt indexer is so configured, you will
find the proper cable included with the equipment. The cable will connect to
COM 1 on the computer side and to the smaller connector on the back of the
indexer. Set COMM PORT to PC under the SYSTEM key on the indexer.
Refer to the MIWORKS software manual for more details.
If system purchased after February, 2012, the system will only have a USB
connection. Please see “Setting-Up USB Connections” section of this manual.
The Series 4000 melt indexer has various options to make conducting specific
measurements easier, or make running multiple samples faster and more
convenient. As previously described, the Melt Indexer maybe shipped with a
Digital Encoder, a Pneumatic Lift System or a Mini-Lift system. The
installation of these options is described in the appropriate Appendix of this
manual.
Series 4000 Melt Indexer Operation Manual Getting Started
 9

Safety
Use gloves, it's HOT!
To prevent burns, gloves and a long sleeve shirt (or lab coat) are essential. Dies
and piston rods are extremely hot and are designed to quickly transfer heat to
the sample being tested. Unfortunately this means they will transfer heat very
quickly to you as well. Even brief contact with a hot item can cause a burn. The
indexer barrel housing can also get fairly hot, however, at barrel temperatures
lower than 350 C these will not cause burns if touched for a brief period.
Consider where dies may fall. If they are dropped on Nylon carpeting or similar
materials they can quickly form holes. Protective mats may be needed.
DYNISCO POLYMER TEST recommends keeping a hot piston rod in the
chamber; this precludes someone picking it up inadvertently. Be sure to hold
the piston by the top insulator.
Electrical Hazard
Your Dynisco Polymer Test indexer contains high voltage inside the steel
housing. DO NOT remove the housing unless you are instructed to do so by a
DYNISCO POLYMER TEST representative or are experienced with high
voltage devices. Be sure the 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 and dangerous vapor. Thermometers have been used for decades in
laboratory equipment and when used properly provide an accurate and effective
means of calibration. Keep the thermometer in a safe place where it will not be
crushed or otherwise broken. When using the thermometer be careful not to
drop or bend the glass. Place a hot thermometer onto cotton patches to cool .
Never put a hot thermometer in contact with cold metal or cold solvent because
the thermal shock can crack or shatter the glass. Mercury is extremely toxic and
should be handled accordingly.
A material safety data sheet (MSDS) for mercury (Hg) can be found in the
appendix. Observe local, state and federal hazardous waste disposal laws when
disposing of any broken thermometers. If packaged in a sealed plastic container
and labeled with the following symbol:
Series 4000 Melt Indexer Operation Manual Safety
 10

Broken thermometers and their spilled mercury can be sent back to the
manufacturer. UPS will accept these packages provided they are labeled and the
material is in a secure container. See Princo support vendor for address
information.
Pinch Points
Do not place weights in precarious positions where they can be bumped and fall
to the floor. For large weights (over 10 kg) the pneumatic lift system is
recommended. In using a pneumatic lift system for weights up to 21,600 gram,
the safety pin (spike) that goes through the weights must be used. When the
machine is in operation the lift system moves the weight downward quickly
creating an area where anything lying beneath could be crushed. Press the UP
and DN 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 be given to additives that may degrade or decompose at elevated test
temperatures.
Pre-Run Check List
The following points should be addressed before running the instrument for the
first time:
 120V power outlet properly grounded? (230 V Europe/Asia)
 Indexer level and on a sturdy bench?
 Protective oil wiped out of barrel?
 Exhaust hood or snorkel working?
 Arm protection, long sleeves or lab coat
 Operator using high temp gloves?
 Operator using safety glasses?
Series 4000 Melt Indexer Operation Manual Safety
 11

Series 4000:
A Guided Tour
Overview
Setup
Edit
Run
System
Four Options from the main menu
screen.
The Series 4000 Melt Indexer has been designed for ease of use. The VFD
display prompts the user for input necessary to program, configure and run the
instrument. From the main menu screen, the user has the choice of four
instrument routines. The user may:
 Configure the Instrument (by pressing the SETUP Key)
 Edit a Program (by pressing the EDIT Smartkey)
 Run a Program (by Pressing the RUN Smartkey)
 Enter Calibration and Test Routines (by pressing the SYS key)
It is important that the instrument first be properly configured. This involves
pressing the SETUP key and checking instrument options 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 program.
The melt index unit relies on the operator to properly program the unit, load the
sample, start the experiment, wait the appropriate length of time, and (in method
A tests) collect the sample to weigh. All tests require that the instrument be
properly cleaned between runs
Many calibrations can be performed in the SYS, CALIBRATE mode. Although
the unit is not expected to change calibration values over years, it is always wise
Series 4000 Melt Indexer Operation Manual Series 4000: 12