Dynisco LMFI 5000 User manual

Manual Part No. M0726(2)
LMFI 5000 Series
Melt Indexer
User’s Guide
Original English Version

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SUPPORT CONTACT INFORMATION
Dynisco Polymer Test can be contacted for questions and support at:
By Phone and Fax:
Phone [phone]
Fax [phone]
To help us handle your questions as quickly as possible, have the following items ready before
you call:
1. Instrument name and model number (on back panel)
2. Instrument serial number (on back panel)
3. Current version of instrument firmware (Power up unit to see, version shown on “About”
screen under “Maintenance Tab”)
4. Computer system make and model (if applicable)
5. Current version of LaVA Suite software (if applicable)
By Internet:
For Technical and Service Support: http://www.dynisco.com/polytest-services
For all Other Inquiries: http://www.dynisco.com/
By Mail/Post:
38 Forge Parkway
Franklin, MA 02038
Copyright © Dynisco 2012

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All Rights Reserved
DISCLAIMER OF WARRANTY AND LIABILITY
The information provided herein is believed to be true and correct but no warranty is given as to its
completeness, accuracy or fitness for use for any particular purpose. Dynisco shall not be liable
for any loss or damage arising from the failure to achieve a particular result by the application of
any route, method or process that is recommended herein. Dynisco reserves the right to change
any information, route, method, or process which is discussed or provided herein without notice.
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.
Dynisco represents that to the best of its knowledge neither the products, equipment and systems
supplied by it nor their use for the purpose for which they were supplied nor the use of the
information or recommendation provided herein will infringe a valid patent right of any third party,
but no warranty, express or implied, is given in this respect.
Document History
Document
Number
Date
Comments
M0726 (0)
December 2012
Original edition; initial release
M0726 (1)
May 2103
Updated, Product Launch Release
M0726 (2)
Feb 2014
Updated for Versions 1.9 and 2.0
Internal Firmware, Improved Wording

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TABLE OF CONTENTS
SAFETY INSTRUCTIONS..................................................................................................................... 6
Warnings, Danger and Informational Symbols......................................................................... 6
Safety summary............................................................................................................................. 7
Use Gloves, it's very HOT!........................................................................................................... 7
Electrical Hazard........................................................................................................................... 8
Calibration Thermometers Using Mercury................................................................................. 8
Pinch Points................................................................................................................................... 9
Fumes From Materials.................................................................................................................. 9
INTRODUCTION .................................................................................................................................. 11
SPECIFICATIONS................................................................................................................................ 12
INSTRUMENT MAINTENANCE RECOMMENDATIONS.............................................................. 13
Equipment Setup .................................................................................................................................. 14
Unpacking the Indexer................................................................................................................ 14
Bench Requirements and Placement ...................................................................................... 14
Level the Melt Indexer................................................................................................................ 15
Instrument Overview ............................................................................................................................ 16
Front View.................................................................................................................................... 16
Rear View..................................................................................................................................... 16
Spares/Consumable Items ........................................................................................................ 17
Instrument Operation/Log-In............................................................................................................... 18
Instrument Operation/Icons................................................................................................................. 19
Instrument Operation/Menus............................................................................................................... 20
Instrument Operation/Buttons............................................................................................................. 21
Instrument Operation/Miscellaneous Touch Areas.......................................................................... 24
Instrument Operation/Panel Overview............................................................................................... 24
Test Calculations .................................................................................................................................. 25
Calculations: Method A .............................................................................................................. 25
Calculations for the Method A test are:.................................................................................... 25
Calculations: Method A/B........................................................................................................... 25
Calculations: Method B .............................................................................................................. 26
Calculating PET Intrinsic Viscosity (I.V.) from the Melt Indexer........................................... 27

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The Amount of Sample............................................................................................................... 28
Create/Edit Test Conditions................................................................................................................ 29
System Configuration........................................................................................................................... 31
Selecting Multi-select Data.................................................................................................................. 31
Entering Numeric Data......................................................................................................................... 33
Setting Up a Test.................................................................................................................................. 34
Loading and Packing Material into the Barrel................................................................................... 35
Running a Test...................................................................................................................................... 36
Cleaning Up........................................................................................................................................... 37
TROUBLESHOOTING......................................................................................................................... 38
Actions.......................................................................................................................................... 38
Generic Run Check List............................................................................................................. 38
Prior to loading Sample:............................................................................................................. 38
Long term items:.......................................................................................................................... 39
Support Vendors ......................................................................................................................... 39

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SAFETY INSTRUCTIONS
All safety instructions must be understood and observed. Non-observance of safety instructions
may cause damage to life and health of persons, environmental damage and/or extensive
damage to property.
Observing the safety instructions included in the operating instructions will help to avoid dangers,
to operate the product profitably and to secure the full use of the product.
Warnings, Danger and Informational Symbols
General safety instructions concerning the activities are given at the beginning of the relevant
chapter. Special safety instructions concerning the individual steps of action will be given together
with the corresponding step of action.
The following pictographs are used in the present operating instructions
Danger
This symbol indicates that death, serious bodily
injuries or considerable damage to property will
occur if the corresponding safety measures are not
observed!
Warning
This symbol indicates that death, serious bodily
injuries or considerable damage to property may
occur if the corresponding safety measures are not
observed!
Caution
This symbol indicates that minor bodily injuries or
minor damage to property may occur if the
corresponding safety measures are not observed!
This symbol indicates that special danger to the life
and health of persons is present due to electric
potential!
This symbol indicates that special danger to the life
and health of persons is present due to hot surfaces!
This symbol indicates that sufficient personal
protective equipment must be worn when working
with the LMFI. The type of personal protective
equipment will be defined in detail!
This symbol signalises user hints and other special
information, which may be useful. This symbol does
not signalise safety instructions!
Please also note that a safety symbol may never substitute the text of a safety instruction -
therefore, the text of a safety instruction must always be read completely!

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Safety summary
The following are recommended safety precautions unrelated to any specific procedures in this
manual and therefore do not appear elsewhere. Personnel must understand and apply them as
appropriate during all phases of operation and maintenance. IN ALL CASES, BE PRUDENT.
Keep away from live circuits
Do not replace components or make adjustments inside
equipment with power turned on. To avoid injuries, always
remove power source and discharge and 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.
Wear protective clothing
Wear protective clothing (gloves, apron, goggles, etc.)
approved for the materials and tools being used.
Provide adequate ventilation
Warning
Provide ventilation to remove heat and noxious odors and to
prevent the accumulation of asphyxiates such as nitrogen gas.
Avoid hot surfaces
Keep hands away from hot surfaces and materials. Contact
with hot surfaces or materials can cause blistering and third
degree burns. Wear approved, clean, thermally insulated
gloves when handling these components. Should injury occur;
immerse injured area in cold water and get immediate medical
attention.
Use gloves, it's very 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
any barrel temperature, these should not cause burns if touched for a very brief period except

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very near the barrel top and bottom. 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 hot piston rod and hot die in the
chamber/barrel; this precludes someone picking it up inadvertently. Be sure to hold the piston
by the top insulator.
Electrical Hazard
Your Dynisco Lab Melt Flow Indexer contains high voltage inside the housing. DO NOT remove
the housing or any part of its outer covers; there are no user serviceable parts inside. Service
should only be done by a qualified DYNISCO Service Technician. Be sure the outlet used to
power the indexer is properly grounded.
Calibration Thermometers may use Mercury
To calibrate the temperature on the indexer, a thermometer containing about 8 grams of mercury
may be 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 on the Internet. 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:
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.

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Pinch Points
Do not place weights in precarious positions where they can be bumped and fall to the floor. For
large test weights (over 10 kg) the pneumatic lift system is recommended. The lift system
has a mechanical capture rod which will not allow the weights to “fall” out of the machine. When
the machine is in operation the lift system moves the weight downward somewhat quickly
creating an area where anything lying beneath could be crushed. The lift system has a safety
door that, when installed correctly and not tampered with, will prevent the lift from moving when
open. There are redundant internal firmware and mechanical hardware safeties in place in the lift
system.
Fumes from Materials
Please plan for unexpected issues to arise. 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.

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Obligation of the operator to exercise due care
The LMFI was designed and constructed taking into consideration a hazard analysis having
carefully adhering to the harmonised safety standards as well as further technical specifications.
Thus, the LMFI 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 all necessary measures are
taken. The obligation of the plant operator to exercise due care includes planning these measures
and supervising their execution.
Especially, the operator has to ensure that
•The LMFI will be used only in accordance with the intended purpose.
•The LMFI will be operated in a flawless, functionally efficient condition and that, in particular,
the functional efficiency of the safety devices will be checked at regular intervals.
•No modifications will be made to the component except by a Dynisco service person.
•The necessary personal protective equipment for the operation, maintenance, and service will
be available and used by any personnel performing these functions.
•The operating instructions are always available completely and fully legible at the installation
location of the LMFI. It must be guaranteed that all persons who work with the LMFI can
consult the operating instructions at any time.
•Only sufficiently qualified and authorized personnel will operate, maintain, and repair the LMFI.
•All safety and warning labels, attached to the LMFI, must not be removed and must remain
fully legible.
•Additional instructions, in accordance with facility, local, state and federal industrial safety
regulations and their corresponding, related ordinances for the use of work materials, will have
to be made available as a supplement to the operating instructions.

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INTRODUCTION
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 performed are those described by ASTM D1238 and ISO 1133-1, 1133-2. This manual
in no way supersedes either of these documents. The precision and accuracy of the test has been
determined by ASTM method D1238. 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.
Several methods have been developed for running flow rate tests under D1238, with Methods A
(mass of material over time) and B (volume of material over time) being the basic of all methods.
Method A is simply the collection of extrudate over time, while Methods B, C and D are the
measurement of time for the flow of a fixed volume of polymer. All but Method A require an
encoder to measure distance traveled to detemine volume of material extruded during the test.
Method A
Method A -- the test is completely manual and is sometimes called
the "cut-and-weigh" method. Measurement in g/10min.
Method A/B
Method A/B -- this employs a digital encoder. In order to run a
method B test, an A/B test MUST be run first to determine the
polymer's melt density. This test takes both A-type and B-type
results to determine melt density. Measurement in g/cc.
Method B
Method B can be conducted only if material melt density is known as
is determined by an A/B type test. This is a "no-cuts" test that is the
most convenient for busy laboratories. Measurement in cc/10min.
Method C
Method C can be conducted only if material melt density is known as
is determined by an A/B type test. This is also known as the “half
die” method. A half-length die is used and is generally used for
testing high flow rate polymers. This is a "no-cuts" test that is the
most convenient for busy laboratories. Measurement in cc/10min.
Method D
Method D can be conducted only if material melt density is known as
is determined by an A/B type test. This is also known as a FRR
(Flow Rate Ratio) test. It uses two weights with the same charge
of material to determine the materials FRR. The FRR is the ratio of
the average flow rate of the material under higher load to the
average flow rate of the material under lower load. This is a "no-
cuts" test that is the most convenient for busy laboratories.
Measurement is unit-less ratio.

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SPECIFICATIONS
UTILITIES:
Electrical Requirements: 100-120 VAC / 220-230 VAC, 6A/4A-Peak at Power-up,
5A/2.5A, 500VA-normal operational power, 50 Hz / 60 Hz
PNEUMATICS:
Lift Option (PSI/Bar): MIN: 60/4.2 MAX: 80/5.5
Packer Option (PSI/Bar): MIN: 20/1.4 MAX: 50/3.5
DIMENSIONS:
Base model
With Lift System (no weights
installed)
Height (in/cm)
20/51
51/132
Width (in/cm)
13/33
13/33
Depth (in/cm)
25/64
25/64
Weight (lb/kg)
47/21.4
100/45.5
Instrument with weight system could have up to 70lbs/31.6Kg weights installed (shipped
uninstalled with unit)
OTHER:
Complies with ISO ASTM D1238 and ISO 1133-1, ISO 1133-2.

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INSTRUMENT MAINTENANCE RECOMMENDATIONS
Daily: Remove the orifice and clean thoroughly with brush and precision drill bit. Clean your
indexer barrel with cotton patches when hot. Piston should spin easily when placed into a
clean barrel.
Weekly: Give good cleaning with brass brush. Use oven cleaner to clean the piston rod
exposed metal and orifice.
Monthly or Long Term: Depending on your company policy, a calibration or calibration check
may be needed on a monthly, quarterly or yearly basis. It is a recommended that a repetitive
maintenance schedule be created for your instrument.
Clean unit: Clean the dust and dirt out of the electronics module with clean air every six
months to one year, more often in dirty environments. Perform this with power removed from
the system. Remove the orifice and clean thoroughly. Clean your barrel. Use oven cleaner to
clean the piston rod assembly and orifice.
Check Mechanical Tolerances: All dimensions and tolerances per ASTM D1238 and ISO
1133-1. Piston tip diameter = 0.3730”/9.474mm +/-0.0003”/0.0076mm; piston tip length =
0.2500”/6.35mm +/- 0.0050”/0.127mm. Assembled piston rod weighs 100 grams. GO/NO-GO
gage works properly on the orifice. Orifice length = 0.3150”/8mm +/- 0.0010”/0.0254mm.
Weights still weigh correctly. Digital Encoder calibration. Gages can be purchased from
Dynisco Polymer Test.
Barrel Diameter: Once the barrel is extremely clean, all dimensional measurements are to be
made at room temperature it can be checked using a bore gage. Gage can be purchased from
Dynisco Polymer Test. At the time of manufacture, the barrel center bore measures
0.3760”/9.55mm +/- 0.0002”/0.00508mm.All dimensions and tolerances per ASTM D1238
and ISO 1133-1.
Pneumatic Lift maintenance: The guide rod and the pneumatic cylinder rod can be
lubricated. Dynisco Polymer Test suggests that WD-40 or machining oil be used as a lubricant.
You can also spray a small amount of WD-40 into the air manifold through the manifold’s air
intake to lubricate all internal parts.
Ask for help: Call Dynisco Polymer Test directly at [phone] or visit
http://www.dynisco.com/polytest-services and ask for technical support. To help us handle your
questions as quickly as possible, have the following items ready before you call:
1. Instrument name and model number (on back panel)
2. Instrument serial number (on back panel)
3. Current version of instrument firmware (Power up unit to see, version shown on
“About” screen under “Maintenance Tab”)
4. Computer system make and model (if applicable)
5. Current version of LaVA Suite software (if applicable)

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Equipment Setup
Unpacking the Indexer
The Lab Melt Flow Indexer comes in a heavy duty, wood container. First, remove the
container’s lid—a bit tool should be within the crate packing documents on the outside of the
container that can be inserted into an electric type drill to remove the lid and bracing screws.
Several boxes may be packed inside along with the instrument; remove them and check that all
boxes are received. For example, they are coded 1 of 5 or 3 of 5, indicating the total number is
five.
For non-weight lift model instruments, the instrument is braced into the box with test weights and
possibly accessories under the instrument in a foam pattern. Remove the instrument’s bracing.
Minding that a base unit weights 45lbs/21.4Kg, either lift the unit out from the top of the
container with two people or carefully lay the container on its side and slide the instrument out of
the container.
For weight lift models, the instrument is braced into the box with test weights and accessories in
separate, internal boxes removed from above step. Noting which side is the bottom of the
instrument and leaving the cross bracing in place, stand crate upward with the bottom of the
instrument downward. Remove the cross bracing and slide the instrument carefully out of the
container onto the floor or a lift. Use a minimum of 3 personnel for this operation for lifting and
stabilizing the instrument as it is being moved. Note the shipping weight of the instrument with
lift is 100lbs/45.45Kg.
It is recommended that the shipping container be saved a few days until you are certain the
machine is functioning as expected.
Bench Requirements and Placement
Typical laboratory benches are too high for efficient use of the indexers. Cleaning and
material packing 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 front
edge of the table. This will prevent the operator from having to bend forward excessively when
cleaning and packing 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.
300lbs/136.36Kg).
DYNISCO POLYMER TEST recommends placing from left to right, if using these options, the melt
indexer; sample scale and computer. Shake test the melt indexer for stability. The bench top
should also be able to withstand hot dies and tools being dropped on them. If carpet is present on
the floor near the LMFI, carpet protection is necessary since a hot die, hot material or hot piston
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 will want 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
obtaining accurate data must also be addressed before valid testing can begin.

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Level the Melt Indexer
Using a small round bubble level, 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 may choose to bolt the machines directly to their benches.
This can be done by removing the levelling feet and using their mounting holes to mount the
instrument to a bench or table. Use caution and remove power before doing so. Mounting this
way will entail removing some covers for internal access to the internal, main instrument plate.
Be sure to remove the level before turning on the machine. The level will be damaged if it gets hot.

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Instrument Overview
Front View
Figure 1: LMFI with lift, encoder and packer Figure2: LMFI base unit
Figure 1shows LMFI with the lift option; encoder option and packer option.
Figure 2 shows the LMFI base unit that has no options
Rear View
Figure 3: LMFI rear view Power connections
Power Switch
Power Cord
Packer
Encoder
Lift System

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Figure 4: LMFI side view USB connections
Figure 3 shows the rear connections of the LMFI. Figure 4 shows the side USB connections with
a PC cable connection to the USB, Type A connection. If using the LaVA Suite software, there is
one cable connection that must be made from the instrument to the computer: a USB cable. The
product sticker on the back of the LMFI will show the model, power requirements and the
instrument serial number.
Spares/Consumable Items
Item
Part No.
Qty (Each)
LMFI 5000 Operator’s Manual
M0726
1
Barrel (If wore, out of specification)
4051-25A
1
Piston Assembly (Tip, Piston, Weight Top)
7051-72
1
Piston Tip
0051-41
1
Die/Orifice (Standard 8mm Height)
0051-46
1
Die/Orifice (Half-Die 4mm Height Half
Diameter)
0051-46S
1
Insulator, Top Mica (Die Entry Point)
4051-20MA
1
Barrel Cleaning Patches
GP0104
1 bag (100ea)
Barrel Cleaning Patches
GP0103
1 bag (1000ea)
Die Go/No-Go Gauge
0051-55
1
Die Cleaning Drill
0051-39
1
Barrel Cleaning Brush
B0555
1
Barrel Cleaning Tool (Used with Patches)
0051-40
1
Die Removal Tool
0051-35
1
Funnel, Polymer Charging
0051-80
1
Polymer Packing Hand Tool
0051-36
1
Knife, Palette (For Cutting—Method A)
0051-53
1
USB Cable

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Instrument Operation/Log-In
When the system is powered-up, a log-in screen will appear. Below is a list of default user names
and password and levels of access. The system has 5 levels of default user types. Admin and
Maintenance user levels are defaulted with instruments at shipment. Users of Guest, Tester, and
Manager levels will have to be added by the Admin level user if desired.
User Groups
Default User
Password
Access Rights
GUEST
Viewing only. No programs, system
configuration (except volume and
screen brightness), or calibration can be
modified. Tests cannot be performed.
TESTER
Testing only. Cannot modify programs
that are stored in memory. Can run tests
and change test variables for the current
test in which the values are not saved
into memory. Can modify some of the
system configuration, but cannot run
calibration.
MANAGER
Program Editor. Same rights as “Tester”
plus modifying of programs that are
stored in memory.
ADMIN
ADMIN
ADMIN
System Admin. All rights as “Manager”
plus access to calibration tests.
MAINTENANCE
MAINTENANCE
Maintenance. All rights as “Admin”
plus access to special maintenance
information.
Logging-in at power-up can be turned off if not desired. Simply log-in at the Admin level.
Go to System Configuration’s second screen using the and then to get to the
screen. Then simply set User Login to “OFF” as shown here.

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Instrument Operation/Icons
Icons –An icon will be displayed when a device has been connected to either the master or
host USB connections.
Remote computer is connected
Error during initialization of the remote computer
Mass storage device is connected
Error during initialization of the mass storage
Printer is connected
Error during initialization of the printer
Scale is connected
Error during initialization of the scale

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Instrument Operation/Menus
Menu Buttons –Menu buttons are a specific type of button that does not have the same attributes
as a normal button. The menu button can be: not selected, selected, or disabled.
The button is only a touch area when in “not selected” mode.
Action
Not Selected
Selected
Disabled
Displays the Test Status Screen
Displays the Programs Screen
Displays the Test Setup Screen
Displays the System
Configuration Screen
Displays the Maintenance Screen