Ametek 7550 Operating Manual

Model 7550

High Temperature

High Pressure Viscometer

Operating Manual

Rev J – August 2019

P/N: 7550-1050

S/N _____________

2001 N. Indianwood Ave.

Broken Arrow, Oklahoma 74012 U.S.A.

Tel: [phone] Fax: [phone]

E-mail: [e-mail]

Web: www.chandlereng.com

Copyright © 2016, by Chandler Engineering Company, LLC
P.O. Box 470710, Tulsa, Oklahoma 74147
All rights reserved. Reproduction or use of contents in any manner is prohibited without express permission from AMETEK Chandler Engineering Company,
LLC. While every precaution has been taken in the preparation of this manual, the publisher assumes no responsibility for errors or omissions. Neither is any
liability assumed for damages resulting from the use of the information contained herein.

This publication contains the following trademarks and/or registered trademarks: AMETEK, CHANDLER ENGINEERING. These trademarks or registered
trademarks and stylized logos are all owned by AMETEK, Inc. All other company, product and service names and logos are trademarks or service marks of their
respective owners.

TABLE OF CONTENTS T-1

Table of Contents

General Information ....................................................................... P-1

Purpose and Use............................................................................................................................ P-1

Description of Instrument ............................................................................................................. P-1

Features and Benefits .................................................................................................................... P-2

Specifications ................................................................................................................................ P-3

Safety Requirements ..................................................................................................................... P-5

Symbols Used on Equipment ........................................................................................................ P-6

Where to find help ........................................................................................................................ P-7

Section 1 – Installation ................................................................... 1-1

Unpacking the Instrument .............................................................................................................. 1-1

Utilities Required ........................................................................................................................... 1-1

Equipment Required ...................................................................................................................... 1-1

Setup Instructions .......................................................................................................................... 1-2

Software Setup ............................................................................................................................... 1-2

Software Installation ...................................................................................................................... 1-3

Minimum PC Requirements ....................................................................................................... 1-3

Installation Procedure ................................................................................................................. 1-3

Serial Hub USB Driver Installation Procedure ........................................................................... 1-4

Section 2 – Operating Instructions .................................................. 2-1

Front Panel Controls ...................................................................................................................... 2-1

Power .......................................................................................................................................... 2-1

Pump ........................................................................................................................................... 2-1

Vessel .......................................................................................................................................... 2-1

Heater .......................................................................................................................................... 2-2

Pressure Gauge............................................................................................................................ 2-2

Pressure Release Valve ............................................................................................................... 2-2

Temperature and Pressure Controllers ........................................................................................ 2-2

Operational Guidelines .................................................................................................................. 2-2

Sample Volume ................................................................................................................................ 2-3

Vessel Disassembly .......................................................................................................................... 2-3

Vessel Assembly .............................................................................................................................. 2-8

Preparing to Pressurize and Heat the Sample ................................................................................... 2-12

Starting a Test ................................................................................................................................ 2-12

Test Preparation ....................................................................................................................... 2-12

Automated Instrument Operation ........................................................................................... 2-14

Software Operation Notes ................................................................................................................ 2-16

Schedule Entry Tab .................................................................................................................. 2-16

Preferences ............................................................................................................................... 2-23

Rheological Models ......................................................................................................................... 2-25

Ending a Test ................................................................................................................................. 2-26

Instrument Calibration ..................................................................................................................... 2-27

Calibration Overview ............................................................................................................... 2-27

T-2 TABLE OF CONTENTS

System Linearity ....................................................................................................................... 2-28

Slope ......................................................................................................................................... 2-28

Intercept .................................................................................................................................... 2-28

Hysteresis .................................................................................................................................. 2-28

Standard Deviation .................................................................................................................. 2-29

Maximum Hysteresis................................................................................................................ 2-29

Typical Hysteresis Curve ......................................................................................................... 2-29

Calibration Procedure.............................................................................................................. 2-29

Calibration Summary ............................................................................................................... 2-30

Section 3 - Maintenance and Servicing .......................................... 3-1

Tools Required ............................................................................................................................... 3-1

Cleaning and Service Tips ............................................................................................................. 3-1

Controller Calibration and Configuration Procedure ..................................................................... 3-1

High Pressure Diaphragm Valve ................................................................................................... 3-4

Rupture Disk .................................................................................................................................. 3-5

High Pressure Transducer .............................................................................................................. 3-5

Pivot Bearing and Pivot ................................................................................................................. 3-7

Heating / Cooling Jacket ................................................................................................................ 3-7

Pressure Vessel .............................................................................................................................. 3-8

O-rings and Backup Rings .......................................................................................................... 3-8

Sample Cup .................................................................................................................................... 3-9

Thermowell ................................................................................................................................. 3-9

Magnetic Drive .............................................................................................................................. 3-9

Inner Magnetic Rotor .................................................................................................................. 3-9

Outer Magnetic Drive Rotor ..................................................................................................... 3-10

Encoder Assembly ....................................................................................................................... 3-10

Supply Containers ........................................................................................................................ 3-12

Internal Regulator Pressures ........................................................................................................ 3-13

Motor Drive Belt and Stepper Motor ........................................................................................... 3-14

Pump and High Pressure Valves .................................................................................................. 3-15

Instrument Voltage Selection....................................................................................................... 3-16

Instrument Circuit Breakers ......................................................................................................... 3-17

Instrument Solenoid Valves ......................................................................................................... 3-17

Section 4 - Troubleshooting Guide ................................................. 4-1

Rheology Equations ....................................................................................................................... 4-2

Section 5 – Replacement Parts List ................................................ 5-1

Section 6 – Drawings and Schematics ............................................ 6-1

General Information

Figure 1 - Model 7550 HPHT Viscometer

PREFACE P-1

Purpose and Use

The Model 7550 high pressure high temperature (HPHT) couette viscometer is designed for
determining the rheology of well completion fluids under varying conditions in accordance
with applicable API and ISO standards.

Description of Instrument

The shear stress created between a stationary bob and rotating rotor is measured using a
precision torsion spring and high-resolution encoder. Known sample shear rates are created
between the bob and rotor using defined bob/rotor geometry and a stepper motor sub-system
providing rotational speeds ranging from 0 – 600 rpm. Suspended solids in the sample are
circulated during a test using a helical screw on the outside diameter of the rotor.

The sample viscosity is determined as the ratio of shear stress (dyne/cm2) to shear rate (sec-1)
resulting in dyne-sec/cm2, otherwise expressed as Poise.

These measurements are made at sample conditions ranging from 0 - 30000 psi (207 MPa),
and 32°F - 500°F (0°C - 260°C). A chiller is a separate option.

The system is controlled using a program that provides data acquisition, multi-axis data
display options and automatic instrument operation and calibration features.

P-2 PREFACE

Features and Benefits

The major features of the Model 7550 HPHT Viscometer are listed below:

 Viscometer meets applicable API and ISO requirements
 Bench-top instrument
 Data acquisition and control system
 Automatic control of sample temperature and pressure using PID controllers
 High pressure (30000 psi, 207 MPa), high temperature (500°F, 260°C) sample testing
 Mixing of sample during test using helical screw on outside diameter of rotor
 Automatic control of instrument, including data collection, shear rate scheduling, power-

law model coefficients (n’ and K’), display and calibration

 Automatic 10 second and 10 minute gel strength measurements
 Sample wetted parts made from stainless steel and other corrosion resistant high strength

materials

 Stepper motor and magnetic drive used to generate shear rates, providing high accuracy

and stability

 High resolution measurement of shear stress
 Safety systems designed into the instrument and software (over-pressure, over-

temperature)

 Microsoft Excel compatible data output

Specifications

Instrument Utilities:

 Main Power: 208-240 VAC, 50/60Hz, 10A maximum
 Instrument Air or N2: 150 psi, 1034 kPa ±10% (filtered and dry)
 Coolant: Water

Sample Environment:

 Maximum Pressure: 30000 psi, 207 MPa
 Maximum Temperature: 500˚F, 260˚C
 Minimum Temperature: 32˚F, 0˚C

Sample Rheology:

 Minimum Shear Stress: 2.0 dyne/cm2
 Maximum Shear Stress (approximate, varies with spring assembly):

 Shear Stress Resolution: ±0.02% of F.S. (encoder resolution 2:10000)
 Motor Speed Range: 0.001– 600 RPM
 Shear Rate Range: .0017 – 1022 sec-1, corresponding to 1 – 600 RPM (B1/R1)
 Sample Gel Strength: Peak value at 3 RPM

PREFACE P-3

 F4: 6000 dyne/cm2
 F2: 3000 dyne/cm2 (Standard)
 F1: 1500 dyne/cm2

Couette Geometry:

 Bob Radius (Ri): 1.7245 cm (B1) – other bobs are available, contact Chandler Engineering
 Rotor Radius (R0): 1.8415 cm (R1)
 Bob Length (L): 3.805 cm (B1)
 Sample mixing via helical screw on OD of rotor with circulation ports in rotor and bob. A

rotor without the helical mixing option is available.

Pressure Vessel:

 Removable sample plug assembly with support stand
 Sample/Oil separation zone
 High pressure magnetic drive for rotor
 High strength, corrosion resistant superalloy construction
 High pressure pressure ports (F250C), knurled nuts and wrench flats
 Elastomer with metal backup seals
 Material heat traceability, hydrostatically tested to 1.5x rated pressure (45000 psi, 310 MPa)

Test Fluids:

 Well completion fluids containing hematite, barite, calcium carbonate

P-4 PREFACE

Torque Measurement System:

 External cooled torque sensor, magnetically coupled to bob shaft

Motor System:

 Stepper motor subsystem

Temperature Control:

 Programmable PID Controller
 Resistance heaters with contactor and redundant over-temperature protection
 Temperature steady-state control stability: ±2˚F, ±1˚C
 J-type thermocouple located on centerline of bob and within cast heater

Pressure Control (Pump and Valve):

 Programmable PID Controller
 Air/Liquid Pump
 Diaphragm operated high pressure valve and flow restriction
 Pressure control stability: ±500 psi at F.S.
 Pressure transducer
 High pressure rupture disk (31000 psi, 214 MPa)
 Pressurizing fluid: heat transfer fluid

Control System:

 Microsoft Windows based program providing the following:

o Temperature and Pressure control time-based profiles with data collection inhibits

during temperature and pressure stabilization periods

o Motor RPM (shear rate) time or temperature based profiles providing standard speeds

(600, 300, 200, 100, 6, 3) or other user-defined speeds

o Saved user defined test profiles
o Configurable multiple axis plots of all variables (T, P, Shear Rate, Shear Stress,

Viscosity, Dial Reading, etc.)

o Automatic calibration using Newtonian oil and multiple shear rates
o Serial interface to instrument temperature, pressure, motor controllers
o Data export in CSV format, compatible with Microsoft Excel
o Configurable alarms for maximum shear stress, temperature, pressure
o Pause, Resume, Jump feature for profile steps
o Schedule “wizard” to simplify new schedule creation

Environmental Conditions:

 Pollution degree 2
 Altitude 2000 m
 Humidity 50 to 80%
 Indoor use only
 Temperature 5°C to 40°C (41°F to 104°F)
 The mains supply voltage fluctuations are not to exceed ±10% of the nominal supply voltage

PREFACE P-5

Safety Requirements

READ BEFORE ATTEMPTING OPERATION OF THE INSTRUMENT

The Chandler Engineering Model 7550 HPHT Viscometer is designed with
operator safety in mind. Any instrument that is capable of high temperatures and
pressures should always be operated with CAUTION.

NOTE: If this is equipment is not used in a manner consistent with

manufacturer’s specifications, the protection provided by the equipment
may be impaired.

WARNING: Read before attempting operation of instrument. This instrument is

capable of extremely high temperatures and pressures and must always
be operated with CAUTION. The instrument is designed for operator
safety. To ensure that safety it is essential to follow the instructions
outlined below.

WARNING: During a test, the top panel around the test cell can become hot and

cause injury.

WARNING: Remove oil from surfaces prior to conducting tests at high temperatures

to avoid the possibility of creating fumes. The instrument should be
mounted under a vent hood, or equivalent ventilation, if sample
temperatures will be above 400°F, 204°C for extended time periods.

WARNING: The instrument is calibrated with known viscosity silicone oils, do not

expose these oils to temperature above ambient to avoid thermal
decomposition of the silicone oil that may form dangerous fumes.

NOTE: The instrument must be mounted under a vent hood, or equivalent ventilation, if

sample temperatures will be above 400°F, 204°C for extended time periods.

To further ensure safety:

 Provide adequate training of all personnel that will operate the instrument.
 Locate the instrument in a low traffic, well-ventilated area.
 This is a bench top device; place the instrument on a suitable level and stable surface.

Allow a minimum of 5-inches (127mm) unobstructed clearance around the instrument
to provide adequate ventilation.

 Post signs where the instrument is being operated to warn non-operating personnel

that high pressure, high temperature equipment is in use.

 Read and understand instructions before attempting instrument operation.
 Observe caution notes.
 Observe and follow the warning labels on the instrument.
 Never exceed the instrument maximum temperature and pressure ratings.
 Always disconnect main power to the instrument before attempting any service or

repair.

 Turn OFF the heater at completion of each test.
 Remove oil on heated surfaces that may pose a hazard prior to starting a test that will

exceed 400°F, 204°C.

 Although the pressure vessel was designed using suitable materials and techniques,

due to the extreme pressure rating, it is imperative to monitor the condition of the

P-6 PREFACE

Symbol

Meaning

bef

ore servicing.

 Note that AMETEK Chandler Engineering recommends periodic re-inspection and

 A fire extinguisher, type 8 BC, should be located within 50 feet (15

 Have the safety officer at your location or laboratory review the safety aspects of the

Before attempting to operate the instrument, the operator must read and
understand this manual.

vessel and related components with a focus on safety. Any damage to the vessel or
related high pressure components must be brought to the attention of Chandler
Engineering.

testing of the pressure vessel assembly to maintain the rated temperature and pressure
ratings. Without re-inspection and testing, the pressure rating of the vessel assembly
must be de-rated as a function of age, usage and condition in accordance with
established vessel de-rating schedules at Chandler Engineering. Chandler
Engineering supports the design and offers periodic vessel testing services and
component replacement if/when required.

meters) of the instrument.

instrument and installation and approve the operational and installation procedures.

Symbols Used on Equipment

Protective Conductor
Terminal

Caution, risk of electric
shock. Equipment may be
powered by multiple
sources. Disconnect
(Lock-out) all services

Caution, hot surface. Do
NOT touch. Allow to cool
before servicing.

On (Power)

Off (Power)

PREFACE P-7

Where to find help

In the event of problems, the local sales representatives will be able to help or the
personnel at Chandler Engineering can be contacted.

 Telephone: [phone]
 FAX: [phone]
 E-mail: [e-mail]
 Website: www.chandlereng.com

P-8 PREFACE

This page is intentionally left blank.

Section 1 – Installation

Unpacking the Instrument

Remove the instrument from the packing crate carefully. The unit comes fully equipped with
all the necessary components and any spare parts that were ordered with the unit. Make sure
that no parts or tools are lost when discarding the packing materials. Place the instrument on
a firm table, close to the coolant and air sources and required electrical outlet.

After the instrument is removed from the shipping crate, the equipment and spare parts
should be checked against the packing list to ensure that all parts have been received and
none are damaged.

NOTE: File an insurance claim with your freight carrier if damage has occurred

during shipping. Verify all parts shown on the enclosed packing list have
been received. If items are missing, immediately notify Chandler
Engineering.

SECTION 1 – INSTALLATION 1-1

Utilities Required

 Main Power to Instrument: 208-240 VAC, 50/60 Hz, 10A maximum.
 A suitable uninterruptible power supply is recommended to prevent data loss during a

power failure.

 Coolant: Clean water
 Optional Chiller subsystem
 Drain: Suitable for steam

 Air or Nitrogen: Filtered, dry; 75-150 psi, 517-1034 kPa.

NOTE: To achieve 30000 psi, 207 MPa using the internal pump, a supply of at

least 130 psi, 900 kPa Air or Nitrogen is required.

Equipment Required

 Set of English open-end wrenches
 Set of English size hex wrenches (supplied with instrument)
 Solvent based parts cleaning equipment
 Mounted bench vise

1- 2 SECTION 1 - INSTALLATION

Warning:

Verify that the proper input voltage is applied

Setup Instructions

READ BEFORE ATTEMPTING OPERATION OF INSTRUMENT

1. Locate the instrument near power, air, water, and drain connections.

2. Level the instrument by adjusting the legs under the instrument. A bubble level is

provided on the top panel of the instrument. Place the bubble on the top of the vessel
when leveling the instrument. This approach ensures that the bob shaft is vertical.

3. This instrument requires 208-240VAC.

before connecting power (220 VAC).
Damage can occur if the wrong line voltage is applied, verify

that the proper input voltage is applied. To prevent shock
hazard, connect the instrument to an electrical outlet using a
three-prong socket to provide positive ground.

4. Connect power to the instrument using the power cord supplied with the instrument. All

power and grounding must be consistent with local wiring codes.

5. The power plug may need to be changed if the local receptacle is incompatible with the

plug supplied with the instrument.

6. Connect the Air (or N2), Coolant, and Vent connections to the instrument. The coolant

outlet connection must be rated for high temperature steam.

7. The Vent port is connected to the rupture disk discharge. If the rupture disk fails,

potentially hot fluid will discharge from this port. Route the discharge from this port to a
safe location.

8. An additional Exhaust port is used to discharge low pressure air during valve switching.

Discharge from this port may include oil mist. Route the discharge from this port to a
safe location.

Software Setup

1. Leave computer off until instructed to turn it on. This will ensure proper installation of

drivers later in the process.

2. Install the USB serial port hub by connecting the USB cable from the hub to the PC, and

connecting the two (2) supplied Serial Communication Cables from the hub to the
Viscometer:

 Connect USB hub serial port S1 or Port 1to DATA serial port (the top serial

connection provides serial communication to the System I/O and temperature
controller.)

 Connect USB hub serial port S2 or Port 2 to MOTOR serial port (the bottom serial

connection provides serial communication to the motor controller.)

3. Connect the power cable.

SECTION 1 – INSTALLATION 1-3

Software Installation

The Model 7550 viscometer is operated remotely via PC serial interface, using the
Rheo7500 software.

If the Model 7550 viscometer is ordered with a computer, the software will be
pre-installed on the computer, and it is only necessary to click the Rheo7500 icon
on the desktop to start the software.

Alternatively, the software can be installed on a user’s computer following the
procedure.

Minimum PC Requirements

 Microsoft Windows XP or Windows 7 Operating System
 1 GB RAM
 2 RS232 Ports (via USB HUB or direct connection)
 1024 X 768 Display Resolution or higher
 CD-ROM/DVD Drive (for software installation, data backup)

Installation Procedure

1. Turn on the computer.

2. Insert the Rheo7500 CD into the CD drive of the computer. Run the Setup.exe file from

the root folder on the CD (double-click it).

3. The “Preparing to Install” window will appear. Read the information and Click “Next”

to continue.

4. The “Install Shield Wizard” window will appear. Read the information and Click “Next”

to continue.

5. The “License Agreement” window will appear. Read the information, click “I accept” if

you accept the terms of the agreement, and wish to continue installation. Click “Next” to
continue.

6. The “Customer Information” window will appear. Fill in your Username and Company

Name. Click “Next” to continue.

7. The “Ready to Install” window will appear. Verify the information and Click “Install” to

continue or “Back” to make a change.

8. The “Installing Rheo7500” window will appear showing installation progress.

9. When installation is complete, the screen below will appear. Click “Finish” to exit the

installer.

10. Proceed to the Driver installation procedure.

1- 4 SECTION 1 - INSTALLATION

Serial Hub USB Driver Installation Procedure

1. Install the driver for the Rocketport or Edgeport serial hub on the CD

2. Follow the on-screen instructions to install the device driver.

3. Right-Click on “My Computer” and select “Properties.”

4. Select the “Hardware” tab and “Device Manager” to determine the COM port

assignments. They will be needed during software configuration.

5. Click on the Rheo7500 icon to start the software.

6. From the manager screen, click “File” then “Open Instrument” and select the instrument

(usually SNxxx.ini) - "xxx" = instrument serial number

7. In the instrument window, select the “Setup” tab.

8. Select “Communication Settings,” “7550 Serial Ports,” “I/O, Pressure & Temperature

Control”. Assign the COM port that is used with the pressure and temperature control

9. Select “Communication Settings,” “7550 Serial Ports,” “B Motor Controller”. Assign the

COM port that is used with the motor control.

10. Verify that values on the temperature and pressure controllers are indicated on the main

screen user interface.

11. Verify that the motor may be controlled in manual mode.

12. The instrument is now ready to calibrate.

The instrument is tested and calibrated at the factory before
shipment, but it is recommended that it be re-calibrated before its
first use.

SECTION 2 – OPERATING INSTRUCTIONS 2-1

Section 2 – Operating Instructions

Front Panel Controls

Figure 2 - Front Panel Controls

Power

Controls the main power to the instrument.

Pump

ON: Provides manual control of the internal pump
OFF: Disables the internal pump

AUTO: Controller provides pressure control of the pump

Vessel

FILL: Fills the pressure vessel with pressurizing fluid from the right-front supply

bottle

OFF: Vents the low pressure air or nitrogen to the supply vessel

DRAIN: Drains the pressurizing fluid from the pressure vessel once the pressure release

valve is open.

2-2 SECTION 2 – OPERATING INSTRUCTIONS

Heater

ON: Enables the heater
OFF: Disables the heater

Pressure Gauge

The instrument is equipped with a 30000 psi, 207 MPa pressure gauge in addition to the
internal pressure transducer.

Pressure Release Valve

The pressure release valve must be closed for pressure to build inside the vessel. When
opened, pressure is released from the vessel and the fluid drains to the rear bottle located
at the right-rear of the instrument.

Temperature and Pressure Controllers

The instrument is equipped with two controllers that are interfaced to the computer based
software. Each controller may be enabled / disabled by pressing the EZ1 button.

Operational Guidelines

 Thoroughly clean vessel components and threads after each test.
 Replace top cap and plug o-rings at the first sign of wear. These o-rings must be

discarded after each test that exceeds 450°F. Use the FFKM o-rings when the sample
temperature will exceed 450°F. Below this temperature the FKM o-rings may be
used.

 Routinely inspect the pivot bearing and pivot, replacing if the instrument sensitivity

has diminished.

 Routinely inspect the bushing that is located below the rotor, replacing as needed.
 Routinely inspect the o-rings (2) that are used on the sample cup baffle, replacing as

necessary. Note that neglecting these o-rings will result in contamination of the
sample, pressurizing oil and incorrect results.

 Assemble the plug assembly without sample. Verify that bob and spring assemblies

move freely, and the top pivot is supported by the top clip. Verify that the top pivot
does not extend beyond the top clip.

 Mount the plug assembly in the vessel.
 Mount the top seal ring and o-ring (FFKM or FKM) and screw the top cap into place.
 Attach the high-pressure interconnection tube.
 Mount the encoder and attach cable and cooling air tube.
 Zero the encoder electronics.
 Open the pressure release valve.
 Operate the motor at 50 rpm, use the syringe adapter and luer-tip syringe to slowly fill

the sample cup with 110 mL of sample.

 In cases where the sample viscosity is excessive, zero the encoder, remove the plug

assembly and fill the sample cup with 80 mL of sample. Replace the plug assembly
and encoder, noting that the encoder reading may indicate a positive deflection due to
the gel strength of the sample.

 Use the syringe adapter and luer-tip syringe to slowly fill the sample cup with 30 mL

of sample.

 Remove the syringe adapter and install the high-pressure plug.

Sample Volume

The sample is pressurized with an inert mineral oil. To eliminate frictional effects, seals
are not used to separate the sample from the mineral oil. The oil/sample interface exists
within the plug above the sample volume. During use, provided the interface remains
within the plug, mixing of the oil and sample does not occur.

During a test over a range of temperatures and pressures it is important to be aware of
sample PVT characteristics. In other words, the sample volume varies with pressure and
temperature.

The volume of the sample cup below the plug is 100 mL. The 7500 Viscometer is
designed with adequate volume in the plug needed for changes in sample volume during
a test.

At no time during a test can the mineral oil exceed the 100 mL sample volume since this
will cause incorrect measurement results.

SECTION 2 – OPERATING INSTRUCTIONS 2-3

A sample fill volume of 105 - 110 mL is satisfactory in most cases. Other cases
involving sample volumes that change more than 10% as a function of temperature and
pressure (increasing or decreasing) during a test may require adjustment of the starting
sample volume.

The sample volume up to the level of the front fill port may be determined using the
syringe adapter and syringe. With the plug assembly mounted on the stand, fill the plug
assembly with water using a 60mL syringe. The sample volume is determined when it is
apparent that the water level is level with the fill port.

Figure 3 – Sample Injection

Vessel Disassembly

1. Remove the encoder assembly, disconnecting the cable and air-cooling tube.

2. Disconnect the high-pressure tube between the top cap of the vessel and the top panel

of the instrument. The nuts on each end of the tube require a 5/8-inch open-end
wrench.

2-4 SECTION 2 – OPERATING INSTRUCTIONS

3. Unscrew the top plug assembly from the vessel. The plug is loosened by turning

counterclockwise.

4. Once the plug assembly is removed, place the assembly in the plug support bracket.

Figure 4 - Plug Assembly in Stand

5. Remove the top cap, rotating counterclockwise. Remove the top o-ring and metal

backup ring. You may use the Seal Extractor tool 7500-2292, when necessary.
Replace the o-ring after each high temperature test.

Plug Assembly

Plug Support
Bracket

HP O-ring and
HP Backup Ring

SECTION 2 – OPERATING INSTRUCTIONS 2-5

Tool

Figure 5 - Removal/Installation of Top Seals

Seal Extractor

6. Secure pivot by hand or remove before inverting the sample cup. Unscrew and

remove the sample cup, rotating clockwise. Secure the pivot by hand or remove
before inverting the sample cup (see Figure 10). While supporting the rotor assembly
inside the sample cup, empty the sample from the cup into a suitable disposal
container.

Sample cup

Figure 6 – Removal/Installation of Sample Cup

7. Invert the sample cup and remove the internal rotor and magnet assembly.

8. Note that the rotor support bearing may become unseated and may be retained by the

rotor magnet.

9. Use tool 7500-2204 to retain the bob shaft and unscrew the bob by hand, rotating

clockwise. Note that the tool engages the groove in the baffle.

10. Secure the tungsten carbide insert. It can easily drop out if the bob is inverted (see

2-6 SECTION 2 – OPERATING INSTRUCTIONS

Head Screw

Section 3 – Maintenance and Servicing).

Figure 7 - Bob Removal Tool Installed

11. Remove the hex socket head screw from the shaft clip. Remove the spring module

assembly from the plug.

Hex Socket

Clip, Shaft

Figure 8 - Removal/Installation of Spring Module

12. Invert the plug and remove the hex socket head screws (4) and remove the baffle and

o-ring located between the baffle and plug and sample cup threads. Discard and
replace the baffle o-rings (2) as needed to ensure separation between the pressurizing
oil and sample.

13. Remove the high-pressure seal o-ring and metal backup ring. Discard and replace the

o-rings after each high temperature test.

14. Remove the high-pressure gland and plug from the front of plug assembly using a

5/8-inch open end wrench.

15. Carefully and thoroughly clean all parts using a solvent tank in preparation for re-

assembly. Rinse all parts with water. Dry all parts thoroughly.

Bob Shaft
Tool

Top Pivot
Spring Module
Assembly

Baffle
O-ring

SECTION 2 – OPERATING INSTRUCTIONS 2-7

Sample cup
O-ring

HP Backup
ring

HP O-ring

Figure 9 – Removal/Installation of Baffle and Seals

2-8 SECTION 2 – OPERATING INSTRUCTIONS

Vessel Assembly

1. Use tool 7600-1160 to seat the support bearing in the rotor. Retain the bearing in

place inside the rotor by applying a small amount of grease prior to assembly.
Alternately, place the bearing on the thermowell; it will rest inside the rotor when the
rotor assembly is inserted into the sample cup.

2. Install the bushing in the bottom of the rotor assembly. Verify that it is not

excessively worn.

Bearing Extraction Tool

Figure 10 - Rotor Bearing and Outer Race Installation

3. Insert the rotor and magnet assembly into the sample cup. Verify that the rotor

bearing rests on the top of the thermowell and the pivot extends through the bearing.
Verify that the rotor rotates freely.

SECTION 2 – OPERATING INSTRUCTIONS 2-9

P

ivot

Figure 11 - Sample Cup with Rotor Installed, Ready to Fill with Sample

4. Install the baffle o-ring between the baffle and plug and at the root of the sample cup

threads. Mount the baffle. Tighten the hex socket screws (4).

5. Position the plug assembly upright in the support bracket.

6. Assemble the spring module, adjusting the spring and magnet assembly to ensure that

the dowel pin is positioned properly (see Section 3 – Maintenance and Servicing).

7. Insert the spring module assembly into the top of the plug.

8. Mount the shaft clip and hex socket head screw.

Top Pivot
Spring Module

Figure 62 - Installation of Spring Module

2-10 SECTION 2 – OPERATING INSTRUCTIONS

Figure 13 - Installation of Spring Module

9. Mount the bob assembly to the bob shaft. Gently tighten the bob on the shaft, using

the bob tool.

NOTE: Excessive tightening may bend the bob shaft.

10. Apply a small amount of anti-seize compound to the threads on the sample cup.

11. While empty, screw the sample cup onto the baffle. Verify that the center magnet

assembly elevates slightly as the sample cup is screwed into place.

12. Verify that the pivot pin passes through the shaft clip as the sample cup is mounted.

NOTE: The pivot must not extend past the top of the clip to avoid interference

with the top cap. The limit stop dowel pin and magnets must not contact
the supporting housing or shaft clip while rotating.

13. The center pivot may be axially positioned to position the magnet support housing

assembly on the bob shaft. This may be accomplished by removing the spring
module and bob shaft and screwing or unscrewing the pivot using needle-nose pliers.

14. Verify that the magnet assembly and bob rotate freely against the spring torsion. An

oscillation must be observed when displacing the spring and releasing. If any binding
exists, disassemble, locate the problem and reassemble.

15. Position the top metal backup ring and o-ring.

16. If needed, add a small amount of pressurizing fluid to the top and bottom elastomeric

seals.

17. Insert the plug assembly into the pressure vessel. Tighten by turning clockwise.

Screw the plug until lightly shouldering then loosen until the high-pressure port faces
the front of the instrument.

18. Screw the top cap onto the plug. Screw the cap until lightly shouldering then loosen.

The top high-pressure port must face the right of the instrument, aligning with the
high-pressure interconnection tube.

19. Verify that the collars on the high-pressure interconnection tube are fully screwed

onto each end of the tube, noting that they have LH threads.

20. Connect the high-pressure interconnection tube between the top cap and the top panel

of the instrument. Tighten using a 5/8-inch wrench.

Adjustable pivot

- must not extend
past top of clip

Clip, Shaft

Needle Valve

Cooling Air Tube

SECTION 2 – OPERATING INSTRUCTIONS 2-11

21. Mount the encoder to the top of the vessel, aligning the encoder alignment pin with

the groove in the top cap.

22. Connect the encoder cable to the 9-pin connector on the encoder; tighten the retaining

screw(s).

23. Connect the cooling air tube to the encoder. The air flow may be adjusted using the

side mounted needle valve to cool the encoder during long duration high temperature
tests.

24. Using the software Tare button, zero the encoder.

HP Interconnection
Tube

Figure 74 – Encoder and High-Pressure Connections

25. Attach the 7600-1164 syringe adapter to the front high-pressure port on the plug.

Open the pressure release valve.

26. Using a syringe (C10480) inserted into the syringe adapter, slowly fill the plug and

cup assembly with 110mL of sample.

NOTE: The sample cup volume including the B1 bob, R1 rotor and related

27. Remove the 7600-1164 syringe adapter from the front high-pressure port on the plug.

28. Install the high pressure plug into the front high-pressure port on the plug assembly.

Tighten with a 5/8-inch open end wrench. Do not over-tighten the nut (recommended
torque: approx. 25 ft-lbf)

High Pressure Plug

components is 100mL, the total sample volume may need to be increased
based on the PVT characteristics of the sample.

Syringe Adapter

Figure 85 - Sample Injection

2-12 SECTION 2 – OPERATING INSTRUCTIONS

Preparing to Pressurize and Heat the Sample

1. Verify that the supply container (right - front) is at least 1/2-full of the pressurizing

fluid. Only use the fluid part number that is supplied with the instrument. Empty the
collection vessel (right - rear). The supply containers are hand tightened.

2. Once the vessel is closed and the high-pressure tube is connected, open the pressure

release valve, if needed. DO NOT ATTEMPT TO OPERATE THE PUMP UNLESS
THE HIGH-PRESSURE TUBE IS CONNECTED.

3. Turn the Vessel switch to Fill.

4. Operate the pump manually (pump switch ON) until oil is observed filling the rear oil

reservoir. Watch for any leaks as the vessel fills with mineral oil. If a leak is
discovered, turn the vessel and pump switches Off (center position) and correct the
leak.

5. Close the pressure release valve and place the Pump switch in the Auto position.

6. Turn the Heater switch to On.

7. Verify that the temperature and pressure controllers are ready for use. If the

controllers are in the OFF mode, press the EZ1 button once.

8. Mount the encoder on top of the plug assembly; connect the airline to the encoder.

Adjust the air flow to the encoder as needed for an elevated temperature test (>350°F,
177°C)

9. Close the cover over the encoder.

Pressure Release

Starting a Test

Test Preparation

1. Turn the instrument and computer ON. The software is started by clicking the Rheo 7500

icon, located on the desktop or the start menu. The Instrument Manager screen will
appear: