Dynisco ViscoIndicator User manual

P/N: 974175 | Rev: 092019 | ECO: 50719
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ViscoIndicator
Rheological Sensing for the Masses
Operations Manual

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TableofContents
1 Safety………………………………………………………………………………………….……….3
2How to use this manual....................................................................................................................6
3Contact Us.......................................................................................................................................6
4Abbreviations and System Description.............................................................................................7
5VI Start Guide .................................................................................................................................9
7Turning the ViscoIndicator ON/OFF..............................................................................................10
8Operating the VI using the HMI Software......................................................................................11
9PV Screen......................................................................................................................................12
10 Plot Screen.................................................................................................................................14
11 Machine State............................................................................................................................15
12 Recipes Screen...........................................................................................................................17
13 Alarms / Events .........................................................................................................................23
14 User Permissions .......................................................................................................................24
15 Help...........................................................................................................................................25
16 Settings screen...........................................................................................................................26
17 Machine Screen .........................................................................................................................27
18 Calibration Screens....................................................................................................................29
19 Pressure Screen (calibrating the Pressure transmitter).................................................................30
20 Temperature and Field Service Screens......................................................................................31
21 Rules Screen..............................................................................................................................31
22 Wi-Fi Screen..............................................................................................................................32
23 Overflow Protection Settings .....................................................................................................34
24 Rules screen (Configurable Machine Protection/Safety Settings)................................................36
25 Using Activation Energy with the ViscoIndicator.......................................................................41
26 ViscoIndicator calibration..........................................................................................................42
27 Laboratory Correlation of Results ..............................................................................................44
28 Troubleshooting.........................................................................................................................45
29 Warranty....................................................................................................................................47

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Safety
All safety instructionsmustbeheededandobserved.Non-observanceofsafetyinstructionsmay
causedamagetolifeandhealthofpersons,environmentaldamageand/orextensivedamageto
property.
Observingthesafetyinstructionsincludedintheoperatinginstructionswillhelptoavoiddangers,
tooperatetheinstallationprofitablyandtosecurethefulluseoftheproduct.
1.1 Safety summary
Thefollowingarerecommendedsafetyprecautionsunrelatedtoanyspecificproceduresinthis
manualandthereforedonotappearelsewhere.Personnelmustunderstandandapplythemas
appropriateduringallphasesofoperationandmaintenance.INALLCASES,BEPRUDENT.
Keep away from live circuits
Donotreplacecomponentsormakeadjustmentsinsideequipmentwithpowerturnedon.Toavoid
injuries,alwaysremovepoweranddischargeandgroundacircuitbeforetouchingit.Whenmaking
electricalconnections,theservicesofaqualifiedelectricianmustbeemployed.Contactwithlive
electricalcircuitscancauseseriouspersonalinjuryor 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 wiring or control
systems must be disconnected from the power line immediately and must not be operated again until they
have been repaired by qualified personnel.
Wear protective clothing
Wear protective clothing (gloves, apron, goggles, etc.) approved for the materials and tools being used.
Provide adequate ventilation
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.
Avoid tipping the stand
After assembling the stand, install the RCU on the stand before installing the RSU. Installing the RSU to
the stand before installing the RCU can make the stand unstable. Take care to follow this assembly order
unless the stand has been properly secured.

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The optional stand has flexible configuration capability. It is possible to configure it is such a way that it
is unstable. Take care not to use it this way unless it is properly secured.
Take care to avoid tipping the stand due to an impact (from something/somebody running into the stand),
or from a collision (a forklift or crane load, etc being driven into it), or while moving the stand. Do not
climb on or support yourself with this stand. Use signs or barriers as appropriate.
When moving the stand around on its castors, there is danger that it could suddenly stop sharply when it
rolls over uneven floor surfaces or other obstructions (screws, granules), and could tip. Appropriate
caution 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.
1.2 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 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 Dynisco component will be used only in accordance with the intended purpose.
The Dynisco component 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.
The necessary personal protective equipment for the operating, maintenance, and service personnel
will be available and used by them.
The operating instructions are always available completely and fully legibly at the installation
location of the Dynisco component. It must be guaranteed that all persons who have to work with
the Dynisco component can consult the operating instructions at any time.
Only sufficiently qualified and authorized personnel will operate, maintain, and repair the Dynisco
component.
Instructions concerning all relevant questions of industrial safety and environmental protection will
regularly be given to the personnel, and that these persons will know and understand the
operating instructions and, particularly, the safety instructions contained.
All safety and warning instructions, attached to the Dynisco component, will not be removed and will
remain fully legible.
The service instructions in accordance with the industrial safety legislation and the ordinance for the
use of work materials will have to be made available as a supplement to the operating
instructions.

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1.3 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 ViscoIndicator should only be operated by qualified persons.
Especially, the staff has to ensure that:
Inexperienced operating personnel should only work with the Dynisco component while directly
monitored by an experienced person.
All persons operating and maintaining the Dynisco component must read the operating instructions
and confirm by their signature that they understood the operating instructions.
Unauthorized persons do not stay in the working area of the Dynisco component.
The working area will be left only if all movable parts have come to a stop after having switched 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 used.

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2How to use this manual
Read this manual (Dynisco part number 974175) to understand how to operate the ViscoIndicator.
For information on assembly, installation & service of the ViscoIndicator, please see the Assembly,
Installation & Service manual (Dynisco part number 975389).
For further information as well as technical support, please contact Dynisco.
3Contact Us
Dynisco 38 Forge Parkway, Franklin, MA 02038
Toll Free +1 800-DYNISCO (800-396-4726)
Phone [phone], Fax [phone]
Dynisco Europe GmbH Pfaffenstrasse. 2174078 Heilbronn, Germany
Phone [phone], Fax [phone]
Dynisco China Bldg. 7A, No. 568, Longpan Rd., Malu, Jiading, 201801, China
Phone [phone], Fax [phone]
3.1 About Us
Dynisco has been a global leader providing innovative solutions for materials testing and extrusion-
control monitoring for the plastics industry for decades. Among our early pioneering achievements was
the first transducer to successfully measure melt pressure during the extrusion process.
Today, it is more vital than ever for us to offer our customers leading-edge technology, manufactured to
ISO 9000 quality standards, so they can achieve maximum manufacturing efficiency and productivity.

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4Abbreviations and System Description
Abbreviations
MFR - Melt Flow Rate
IV - Intrinsic Viscosity
VI - ViscoIndicator system
HMI - Human Machine Interface
RSU - Rheometer Sensing Unit
RCU - Rheometer Control Unit
PIV - Process Isolation Valve
System Description
The ViscoIndicator can provide continuous measurement of melt flow rate, apparent viscosity, or intrinsic
viscosity directly on an extruder.
Process Connection
Material is sampled through a connection port in the extruder and travels up through one (Aux1) or two
(Aux1 & Aux2) heated process connection tubes into the PIV and then into the RSU.
PIV
A heated valve positioned between the process connection and the RSU allows the process flow to be
isolated from the RSU if required.
RSU
Inside the RSU, a metering pump controls the rate of polymer flow through a heated flow block while
measurements are taken to determine rheological properties before the polymer passes thru a capillary and
exits to the plant floor/collection bin (material is not returned to the process stream).
RCU
The RCU is an electrical cabinet containing components that provides power and control to the RSU.
HMI
The HMI contains a small computer that is the user interface to the VI, providing control and display of
machine and recipe variables and rheological information.
STAND
The stand is an optional item that can be used to mechanically support the RSU, RCU, and HMI.

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General VI System Outline

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5VI Start Guide
Note: Details for each step below can be found in later sections of this manual.
1. Turn the VI on
2. Confirm or change Machine Values
Settings --> Machine
3. Confirm or change Rule Settings
Settings --> Rules
Settings --> Overflow Protection
4. Confirm or change Recipe Values
Recipes --> Edit
5. Run Recipe
Recipes --> Run
6. Turn on Heat and observe each temp zone is rising
PV --> Heat
7. Wait for system to come to recipe temperature set points, then wait 10 minutes
8. Calibrate Pressure Transmitter if zero value not within 1psi of zero
Calibration --> Pressure
9. If motor has not run for several days:
·create a speed mode recipe with 1/4 the motor speed you would normally run, and with rule 10
pressure set to 0 psi.
·run for 3-4 minutes, observing the pressure
·PV-->Motor
·if pressure builds up then shut off the motor and run the normal recipe
·if pressure doesn't build up, shut off motor and read troubleshooting section
10. If motor was run within the last few days:
·run standard recipe and observe motor speed and pressure
·PV-->Motor
·if pressure does not begin to build up in 3-4 minutes, shut off motor and follow step 9.
5.1 One time/infrequent steps
1. If you purchased a cloud account, register at iot.dynisco.com
2. Setup Manager Account pass code
3. Configure Wi-Fi
4. Confirm PIV is open (The PIV valve must be in the open position during VI operation)
5. changing rule settings
6. insulate process connection and PIV

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7Turning the ViscoIndicator ON/OFF
1. RCU Power Knob - turn the VI on by turning the large red knob on the RCU door 90deg clockwise
to the ON position.
2. Green Power light - should illuminate once the RCU power knob is turned to the ON. This light
indicates that the RCU is receiving power.
3. Yellow System Ready light - should illuminate shortly after the green power light. This light
indicates that the RCU is functioning correctly.
4. HMI display screen - should also turn on and begin booting up shortly after the RCU power knob is
turned ON. It may take several minutes for the HMI to fully power up and get to the PV software
screen (see following sections describing software function).
Turning the ViscoIndicator OFF
The ViscoIndicator can be turned off by turning the RCU Power Knob back to the OFF position.

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8Operating the VI using the HMI Software
The VI is controlled with software via a tablet-sized touch screen interface (HMI). How to operate the VI
software is described in the following sections.
The VI software functions are broken down into eight main software interface screens:
1. PV Screen - Shows measured and calculated variables, controls motor & heat, select plot display
variable
2. Plot display –Graphically displays selected variable
3. Machine state –Pictorial overview of machine set points and current values
4. Recipes –Material specific parameters for configuring tests
5. Alarms / Events –History of alarms and variable deviations
6. Permissions –Allows different levels of machine access depending on operator level
7. Help –VI Help information
8. Settings –Machine specific settings

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9PV Screen
The PV screen is the primary screen used to both view and control the state of the VI through measured
and calculated variables.
The sections of the screen are described as follows:
1. Motor button –turns the motor ON/OFF, and displays the motor state by button color and text:
·red - denotes motor is off
·yellow - denotes motor is running, but at a speed outside the limits in the recipe
·green - denotes motor is running, and at a speed within the limits in the recipe
·"wait" text - is displayed if a user attempts to restart the motor within 45 seconds of the motor
being last on. This is a safety feature to protect the motor from being turned on and off
rapidly, which could damage the motor. Once the text changes back to "motor" the motor
can be started again.
NOTE: The motor cannot be turned on/will stop running if the temperature of any temperature zone is
not with the temperature limits as defined in the recipe.
2. Heat button –turns heat ON/OFF for all temp zones and displays the heat state by button color:
·red - denotes heat is off
·yellow –denotes heat is on, but at least one temp zone is outside the limits in the recipe.
·green - denotes heat is on, and all temp zones are within the limits in the recipe

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3. Machine access level –Displays current access level of machine. There are three access levels:
·Operator - No login Required. No access to Machine State, Recipes, or Settings screens
·Manager -4 digit login code required - Access to all screens except the field service screen
under settings, and access to all functions except field service specific functions
·Field Service - 4 digit login code required - Used by Dynisco field service personnel only.
4. Current Recipe –Displays name of recipe that is currently running. A recipe consists of
material specific parameters that are followed (temperatures, motor speed, etc.) while running a
test. A different recipe can be selected and run from the recipe screen when changing to a
different material in the extruder.
5. WIFI connection status - Displays the current WIFI state of the HMI. If graduated bars are
displayed the HMI is connected to a WIFI network. If a circle with a slash is displayed the HMI
is not connected to a WIFI network. More details about the WIFI connection can be found under
the Settings screen.
6. Focus variable –The variable shown in large font in the upper left section of the screen. To
change the focus variable, select another variable by touching it in the bottom half of the screen.
The current focus variable is also displayed on the plot display screen.
7. Variable list toggle –Press either <<< or >>> to switch between two sets of variables on the
bottom half of the screen:
List 1
Melt Flow Index
Intrinsic Viscosity
Viscosity
Shear Stress
Shear Rate
List 2
Flow Block Temperature
PIV Temperature
Auxiliary 1 Temperature
Auxiliary 2 Temperature
Driving Pressure
Pump Speed
8. Tag Sample button - When this button is touched a “snapshot”is taken of the process conditions
and this data is sent to the cloud (often used for correlation with lab equipment).
9. Overflow protection button –When enabled, a countdown begins in the overflow protection
button location when the motor is turned ON. The timer will pause if the motor is turned OFF. If
the motor is again turned on, the timer will reset. If the timer reaches zero while the motor is
running the motor will turn off. The VI operator should periodically clear any extrudate building
up under the RSU and then touch the overflow protection button before the time reaches zero,
resetting the countdown. The countdown can be disabled under the Settings --> Rules screen by
turning rules 4 & 5 off, and it can also be disabled and the time limit changed under the Settings -
-> Overflow protection screen.

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10Plot Screen
The plot screen gives a graphical representation of the current focus variable on the PV screen.
X axis scale
By default, the graph shows data taken over the last minute. Touching the screen will change the time
duration from 60 seconds, to 60 minutes, to 60 hours, then back to 60 seconds.
Y axis scale
The lower and upper values displayed on the Y axis are fixed and are shown as red lines. They are equal
to the lower and upper limits in the current recipe for the plotted variable.

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11Machine State
This screen is a visual representation of the system with current values or set points of measured
parameters displayed. The variable set points can be seen without having to go to the recipe screen. The
current set points can also be changed from this screen.
1- Currently running recipe name
2- Current/Setpoint button - This button toggles the display between currently measured values
and current set points. A set point can be changed from either mode by touching the value to
bring up a numeric keypad.
NOTE: changing a set point through the Machine state screen does not modify the set point in the
saved recipe.
3- Current motor speed / speed set point
NOTE: motor speed set point only controls the motor speed in speed control mode
4- Current pressure / pressure set point
NOTE: pressure set point only controls the pressure in pressure control mode
5- PIV temperature / set point

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6- Auxiliary 1 temperature / set point (if Auxiliary 1 zone is enabled)
7- Auxiliary 2 temperature / set point (if Auxiliary 2 zone is enabled)
8- Flow block temperature / set point
9- Die characteristics (Length and Inner Diameter)
NOTE: The Length and inner diameter of the die can only be changed in the machine settings

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12Recipes Screen
Recipes are used to configure some of the settings required to measure the viscosity, MFR, etc. of a
particular material. The remainder of the settings required are configured from the Settings screen. Each
time a different recipe is run, different temperatures, test types and material parameters are loaded.
Recipe management
1- Recipe List –This area lists all available recipes. You may need to scroll down to see all recipes.
2- Currently Recipe –Displays the name of the recipe that is currently running. A recipe consists
of material specific parameters that are needed for control/display of the VI when running a test.
3- Selected Recipe - Touching a recipe in the recipe list selects that recipe (recipe will be
highlighted in blue). After selecting a recipe, press one of the buttons on the right side of the
screen (buttons 4 thru 7 described below) to perform that action.
4- Run Recipe button –Makes the selected recipe the current recipe ( updates the current
parameters of the VI)
5- New Recipe button- Makes a copy of the selected recipe. The new recipe name will have the
same name as the selected recipe except several random digits will be appended to the name.

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6- Edit Recipe button –Opens the selected recipe for editing.
7- Delete Recipe button –Deletes the selected recipe. There is a confirmation screen to verify the
user wants to delete the recipe.
NOTE: It is not allowed to delete the current recipe.
8- Export Recipes button –If a USB memory stick is attached to the HMI housing, pressing this
button will export all recipes to the memory stick.
9- Import Recipes button –Imports recipes from a memory stick into the ViscoIndicator’s
memory.

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12.1 Edit recipe screen
After selecting a recipe then pressing edit, the Edit recipe screen will appear. The edit recipe screen lists
all the recipe variables available for editing, along with their current values. A value can be changed by
touching the box containing the value (an editing keyboard will then pop up).
Notes for all low and high limit values
·Values on the PV screen will be displayed in red text if outside the limits
·The Graph screen Y axis limits equal the recipe limits
Notes for all low and high temp limit values
·Low temp limits must be below set points but at a high enough temperature so the polymer is molten
and flowing freely. Typically set to 5deg C below set point.
·Set high temp limits must be above set points but at a low enough temperature so the polymer will not
degrade significantly. Typically set to 5 deg C above set point.
·Rules 13 & 14 - If any temperature zone value is outside the limits, the motor will shut off/cannot be
turned on
Notes for all temperature set points
·typically set to the polymer temperature in the extruder near the VI process connection location
·Temperature set points control the temperature of the polymer during VI rheological measurements
and therefore can affect calculated IV/MFR values.

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Descriptions of each recipe variable
Recipe name –Name of recipe being edited. Try to enter a name that is descriptive of the test and
material being run. A suggested format is temperature set point - test mode - primary calculated
variable, for example: "285C - speed - IV"
Test mode –The VI can be run in two different modes, Speed and Pressure. Speed mode is used to
measure viscosity while pressure mode is used to measure melt flow rate.
·Speed mode - holds the motor speed constant and allows the pressure to vary
·Pressure mode - holds the pressure constant and allows the motor speed to vary
Melt density –Melt density of the material being sampled by the VI for rheological measurement. Used
in calculations of viscosity and melt flow rate.
MFI low limit –Lower acceptable limit of melt index.
MFI high limit - Highest acceptable limit of melt index.
Correlation factor –A multiplicative factor that can change the MFR value calculated by the VI. It can
be used to improve correlation between the ViscoIndicator and laboratory equipment.
·If the value = 1 the correlation factor has no effect
·In the form: VI_MFRcorrected = VI_MFRraw* Correlation factor
Reference temperature –Laboratory equipment polymer test temperature (typically ASTM standard
specified temperature)
·When the laboratory test temperature does not match the extruder temperature, activation energy
can be used to compensate for the difference (see activation energy below)
·Default value equal 190C for typical ASTM MFR test
Activation energy - Please see "Using Activation Energy with the ViscoIndicator" section later in this
guide for a description on how activation energy is used in to correct for differences in melt flow and
viscosity due to temperature differences between the ViscoIndicator and laboratory equipment.
·If the value = 0 activation energy has no effect
Flow block temperature set point –Temperature set point of the flow block (inside the RSU).
The flowblock is inside the RSU and is the location where the VI pressure, temperature, and motor
speed measurements are taken that are used to calculate viscosity/MFR.
Flow block temperature low limit - Lower acceptable limit of flow block temperature.
Flow block temperature high limit - Higher acceptable limit of flow block temperature.
PIV temperature set point –Temperature set point of the process isolation valve (PIV)
The PIV is located in-between the process connection and the RSU. It can be used to isolate the
process flow from the RSU. The PIV valve must be in the open position during VI operation.