Dynisco LMI 4000, 4003, 4004, 4002, 4001 Series Manual
Dynisco Polymer Test Systems
LMI 4000
Series
Melt
Indexer
Manual
Version 4.1
Manual Part Number: M0704 www.dynisco.com
Original Language Version
38 Forge Parkway
Franklin, MA 02038
Phone +1 508 541 9400
Fax +1 508 541 6206
Notice
This manual contains descriptions, drawings and specifications for a Dynisco Polymer Test
Systems Product. Equipment or products made prior to or subsequent to the publication
date of this manual may have parts, features, options or configurations that are not covered
in this manual. Specifications contained herein are subject to change by Dynisco Polymer
Test Systems without prior notice. Dynisco Polymer Test Systems is not responsible for
errors or omissions that may be contained herein or for incidental or consequential damages
in connection with the furnishing or use of this information. The information contained in
this manual is the property of Dynisco Polymer Test Systems, unless otherwise stated.
Comments or suggestions for possible improvement to the manual are appreciated and may
be sent to the following location:
38 Forge Parkway
Franklin, MA 02038
Phone +1 508 541 9400
Fax +1 508 541 6206
www.dynisco.com
Contents
Introduction 1
Getting Started 6
Safety 10
Series 4000 Melt Indexer Operation Manual Contents i
About DYNISCO POLYMER TEST SYSTEMS Inc. ................................................................................... 1
How to Use this Manual.................................................................................................................................. 1
Typographic Conventions ............................................................................................................................... 2
How to Contact Dynisco Polymer Test Systems Inc....................................................................................... 2
Model Descriptions ......................................................................................................................................... 2
On Overview of MI ......................................................................................................................................... 3
ASTM Melt Index Tests.................................................................................................................................. 3
Method A .......................................................................................................................................... 3
Method A/B ...................................................................................................................................... 3
Method B .......................................................................................................................................... 3
Series 4000 Product Offerings: ....................................................................................................................... 3
Introduction....................................................................................................................................... 3
Model 4001 ....................................................................................................................................... 4
Model 4002 ....................................................................................................................................... 4
Model 4003 ....................................................................................................................................... 4
Model 4004 ....................................................................................................................................... 4
Method B Encoder Option ................................................................................................................ 4
Pneumatic Lift................................................................................................................................... 5
Mini-Lift ........................................................................................................................................... 5
Intrinsic Viscosity Option ................................................................................................................. 5
Unpacking the Indexer .................................................................................................................................... 6
Bench Requirements and Placement ................................................................................................. 6
Level the Melt Indexer ...................................................................................................................... 6
Pneumatic lift setup........................................................................................................................... 7
Installing the Digital Encoder ........................................................................................................... 7
RTD Connection ............................................................................................................................... 9
Power Cord ....................................................................................................................................... 9
Printer Connection ............................................................................................................................ 9
Computer Connection ....................................................................................................................... 9
Options:............................................................................................................................................. 9
Use gloves, it's HOT! .................................................................................................................................... 10
Electrical Hazard ........................................................................................................................................... 10
Calibration Thermometers use Mercury........................................................................................................ 10
Pinch Points................................................................................................................................................... 11
Fumes from Materials ................................................................................................................................... 11
Pre-Run Check List ....................................................................................................................................... 11
Series 4000: A Guided Tour 12
Four Options from the main menu screen. .................................................................................................... 12
Overview......................................................................................................................................... 12
Setup ............................................................................................................................................... 12
Edit.................................................................................................................................................. 12
Run.................................................................................................................................................. 12
System............................................................................................................................................. 12
Navigating the Keypad.................................................................................................................................. 13
Introduction..................................................................................................................................... 13
The Keypad ..................................................................................................................................... 13
Keypad Definitions ......................................................................................................................... 14
Configuring the Instrument 15
Series 4000 Melt Indexer Operation Manual Contents ii
Intro: The SYS (SYSTEM) Mode................................................................................................................. 15
Selecting CALIB (Calibration) in the SYS Mode ......................................................................................... 16
CALIB:Digital Flag Home.............................................................................................................. 16
CALIB:RTD Electronics................................................................................................................. 16
CALIB:RTD Sensor........................................................................................................................ 16
CALIB:Optical Flag........................................................................................................................ 16
CALIB:Intrinsic Viscosity Offset ................................................................................................... 16
Selecting TEST in the SYS Mode ................................................................................................................. 17
TEST:RTD Display ........................................................................................................................ 17
TEST:Digital Encoder .................................................................................................................... 17
TEST:Printer ................................................................................................................................... 17
TEST:Display Brightness ............................................................................................................... 17
The SETUP mode ......................................................................................................................................... 17
Introduction..................................................................................................................................... 17
REJECTION ................................................................................................................................... 17
AVERAGE ..................................................................................................................................... 17
MFR / MVR .................................................................................................................................... 17
B FLAG .......................................................................................................................................... 17
VISCOSITY.................................................................................................................................... 17
PRINTER ........................................................................................................................................ 17
FORM FEED .................................................................................................................................. 17
COMM PORT................................................................................................................................. 18
MINI LIFT ...................................................................................................................................... 18
PNEU LIFT..................................................................................................................................... 18
LOCKOUT ..................................................................................................................................... 18
DATE and TIME ............................................................................................................................ 18
MACHINE ID................................................................................................................................. 18
LANGUAGE .................................................................................................................................. 18
ORIFICE DIA ................................................................................................................................. 18
ORIFICE LEN ................................................................................................................................ 18
Programming ................................................................................................................................................. 18
Introduction..................................................................................................................................... 18
Create (New) ................................................................................................................................... 18
Recall (Old)..................................................................................................................................... 18
Save Program .................................................................................................................................. 18
While EDITING ............................................................................................................................. 18
Method A Run Parameters .............................................................................................................. 19
Method A/B Run Parameters .......................................................................................................... 19
Method B Run Parameters .............................................................................................................. 19
RATIO (Flow Ratio) Run parameters .............................................................................................. 20
Run a Program............................................................................................................................................... 20
Method "A" Run 21
Programming a Method A ............................................................................................................................. 21
Loading the Sample....................................................................................................................................... 23
User Tips: ...................................................................................................................................................... 25
General Description ........................................................................................................................ 21
Calculations: Method A .................................................................................................................. 21
Power-Up ........................................................................................................................................ 21
Introduction..................................................................................................................................... 21
Machine Setup ................................................................................................................................ 22
Loading the Barrel .......................................................................................................................... 23
Bubbles ........................................................................................................................................... 23
RUN ................................................................................................................................................ 23
Making the Cut ............................................................................................................................... 24
Weigh the Sample ........................................................................................................................... 24
Cleaning Up .................................................................................................................................... 25
User Tip #1 ..................................................................................................................................... 25
User Tip #2 ..................................................................................................................................... 25
Always leave the barrel clean. ........................................................................................................ 26
Cleaning Up a really Big Mess ....................................................................................................... 26
Method "A/B" Run 27
Programming Method A/B ............................................................................................................................ 27
The Actual Run ............................................................................................................................................. 29
General Description ........................................................................................................................ 27
Calculations : Method A/B ............................................................................................................. 27
Introduction..................................................................................................................................... 28
Machine Setup ................................................................................................................................ 28
How to do it: Step by Step .............................................................................................................. 29
Instrument Prep ............................................................................................................................... 29
Loading the Barrel .......................................................................................................................... 29
Inserting the Timing Flag................................................................................................................ 30
Making the Cut ............................................................................................................................... 31
Cleaning Up .................................................................................................................................... 31
Your data......................................................................................................................................... 31
Method "B" Run 32
Programming Method B ................................................................................................................................ 33
The Actual Run ............................................................................................................................................. 35
General Description ........................................................................................................................ 32
Calculations: Method B .................................................................................................................. 32
Method B Flags Setup..................................................................................................................... 33
Choosing a Timing Flag.................................................................................................................. 34
How to do it: Step by Step .............................................................................................................. 35
Instrument Prep ............................................................................................................................... 35
Loading the Barrel .......................................................................................................................... 35
Timing Flag and Starting the Run ................................................................................................... 36
Cleaning Up .................................................................................................................................... 37
“Flow Ratio” Runs 39
Series 4000 Melt Indexer Operation Manual Contents iii
Flow Rate Ratio test and the Pneumatic Lift Option..................................................................................... 39
What is it? ....................................................................................................................................... 39
Why do it?....................................................................................................................................... 39
Flow Rate Ratio - How to Do It ...................................................................................................... 39
“Intrinsic Viscosity” Runs with PET 41
Calculating PET I.V. from the Melt Indexer ................................................................................................. 41
What is it? ....................................................................................................................................... 41
Why do it?....................................................................................................................................... 42
How to do it .................................................................................................................................... 42
Charge Weight 44
The Amount of Sample ................................................................................................................................. 44
A-Standard Operating Procedure 46
Introduction:.................................................................................................................................... 46
Instrument Preparation .................................................................................................................... 46
Conducting the Test ........................................................................................................................ 47
Clean Up ......................................................................................................................................... 47
Your data......................................................................................................................................... 47
Out of Control Action List 48
Actions ............................................................................................................................................ 48
Generic Run Check List .................................................................................................................. 48
Model 4004 and Computer Control 49
Introduction ................................................................................................................................................... 49
The Digital Encoder: Use and Calibration 50
Programming for use with the Digital Encoder............................................................................................. 52
Encoder Homing and Maintenance ............................................................................................................... 53
Introduction..................................................................................................................................... 50
Method B Encoder Option .............................................................................................................. 50
Encoder Advantages ....................................................................................................................... 50
Why use it? ..................................................................................................................................... 51
Digital Encoder Installation ............................................................................................................ 51
Method B: Setup ............................................................................................................................. 52
Enable the Digital Encoder ............................................................................................................. 52
Auto Flag ON/OFF ......................................................................................................................... 52
Flag Calculation MANUAL or AUTO? ......................................................................................... 53
AUTO flag selected ........................................................................................................................ 53
So you picked MANUAL ............................................................................................................... 53
Digital Flag Home........................................................................................................................... 53
Testing and Maintenance ................................................................................................................ 53
Complete Digital Encoder Calibration ............................................................................................ 54
Referenced Spec D1238-95 ............................................................................................................ 54
Pneumatic Lift Options 59
Series 4000 Melt Indexer Operation Manual Contents iv
Pneumatic Lift ............................................................................................................................................... 59
Introduction..................................................................................................................................... 59
Activation and Operation ................................................................................................................ 59
Mini-Lift........................................................................................................................................................ 59
Introduction..................................................................................................................................... 59
Activation and Operation ................................................................................................................ 59
Instrument Calibration 60
RTD Electronics ............................................................................................................................................ 60
RTD Sensor ................................................................................................................................................... 60
Calibration Steps: ............................................................................................................................ 60
SINGLE .......................................................................................................................................... 60
DOUBLE ........................................................................................................................................ 61
Optical Flag ................................................................................................................................................... 61
Calibration Steps: ............................................................................................................................ 61
Digital Encoder Calibration .......................................................................................................................... 62
Calibration:Digital Flag Home........................................................................................................ 62
Intrinsic Viscosity ......................................................................................................................................... 62
Offset .............................................................................................................................................. 62
Instrument Maintenance and Troubleshooting 63
Maintenance .................................................................................................................................................. 63
Daily................................................................................................................................................ 63
Weekly ............................................................................................................................................ 63
Monthly or Long Term ................................................................................................................... 63
Barrel Diameter............................................................................................................................... 64
Support Vendors ............................................................................................................................. 64
Conversion Factors ......................................................................................................................... 65
Troubleshooting ............................................................................................................................................ 65
Flow Rates are Changing ................................................................................................................ 65
Temperature is Unstable ................................................................................................................. 66
Mercury Separation in Thermometer .............................................................................................. 66
Reuniting Mercury Thermometers .................................................................................................. 66
Pneumatic Lift Troubleshooting ..................................................................................................... 67
Pneumatic Lift maintenance............................................................................................................ 67
Questions and Answers 69
Typical Problems ............................................................................................................................ 69
Typical Questions ........................................................................................................................... 70
Glossary of Terms 73
Series 4000 Melt Indexer Operation Manual Contents v
Digital Flag, Digital Encoder........................................................................ 73
Firmware....................................................................................................... 73
Flow rate ....................................................................................................... 73
Flow Rate Ratio ............................................................................................ 73
Intrinsic Viscosity ......................................................................................... 73
Melt Flow Indexer ........................................................................................ 73
Method A ...................................................................................................... 73
Method A/B .................................................................................................. 73
Method B ...................................................................................................... 73
MVI .............................................................................................................. 73
Optical Flag or Optical Eye Sensor .............................................................. 73
Pneumatic Lift .............................................................................................. 73
RTD .............................................................................................................. 73
Timing Flag .................................................................................................. 73
Setting-Up USB Communications 74
Set-Up with Daisy Software ........................................................................ 74
Set-Up with MI Works Software.................................................................. 77
Index 81
Series 4000 Melt Indexer Operation Manual Contents vi
Introduction
About Dynisco Polymer Test
Dynisco Polymer Test is a manufacturer of laboratory test equipment supplying
capillary rheometers, melt indexers, a variety of impact testers, coefficient of
friction testers, contact angle testers, film tensile testers and other small test
devices. Through its innovative work with electronics and mechanical design,
Dynisco Polymer Test Systems has carved a niche in the market place by
providing the highest performance per cost ratio in the business.
The company was founded in the late '60's in Honey Brook P.A., and is built on
two principles: quality workmanship and outstanding service. Dynisco Polymer
Test Systems' mission has grown to meeting the physical testing needs of the
plastics, food, and rubber industries by providing high quality equipment and
services at low cost. The company was purchased in 1988 by Dynisco, and is
now a wholly owned subsidiary of Dynisco Inc. Dynisco, an ISO 9002 qualified
supplier, is the world’s largest manufacturer of pressure transducers and is
located in Franklin, MA.
How to Use this Manual
This manual describes the setup procedure and basic operation of the Dynisco
Polymer Test Systems Series 4000 class indexers. With the accompanying
MIWORKS or Daisy software manual (if software was purchased) it provides
the complete description of resources at your command. It is not necessary to
read this manual in its entirety. However, even experienced rheologists and
technicians can benefit from the SAFETY tips and cleaning suggestions learned
over many years of operating these instruments in our applications laboratory.
The Getting Started Chapter explains the details of setting up the instrument and
preparing it for use. Please take a few minutes to review the safety precautions
that should be taken when operating Dynisco Polymer Test Systems Melt Index
Series 4000 Melt Indexer Operation Manual Introduction 1
equipment.
Typographic Conventions
Italics: Rheological items that have defining equations presented in the manual
are shown in italics. If you come across an italicized item that is unclear you
can be sure it has a mathematical definition previously defined in the manual.
Bold Italics: These are parameters that are set from the front panel on the
indexer (i.e. Melt Time, Mtd A Time etc.). These parameters are entered into
the indexer's control programs via the indexer key pad.
BOLD ALL CAPITALS: This indicates an actual key found on the indexer
key pad. Example: Press the RESET button to return to main screen. Underlined
Items: Underlined items' head paragraphs or sections that pertain to the
particular item or model underlined. If you do not have or are not interested in
the underlined item skip the section that follows it. Underlining is also used
to emphasize safety issues.
How to Contact Dynisco Polymer
Test Inc.
Before calling Dynisco Polymer Test be sure you have gone through the
"Answers to common questions" section of the manual. To help us handle your
questions as quickly as possible, have the following items ready before you call:
Machine name and model number
Machine serial number (on back panel)
Current version of firmware (Power up unit to see)
Computer system make and model
Current version of software (if applicable)
Call Dynisco Polymer Test directly at (508) 541-9400 and ask for technical
support. Should you wish to comment or query in writing, address to:
Dynisco Polymer Test Inc. : Customer Service
38 Forge Parkway
Franklin, MA 02038
You can also reach us through the internet at: www.Dynisco.com.
Model Descriptions
The DYNISCO POLYMER TEST SYSTEMS Series 4000 Melt Flow Indexer
incorporates the latest in micro-electronic technology. It is designed to make
melt flow rate testing faster, more accurate and flexible, and generate more
rheological information. The heart of the system is a 32 bit microprocessor
developed by DYNISCO POLYMER TEST SYSTEMS. It controls
temperature, responds to keyboard commands and implements testing programs.
Series 4000 Melt Indexer Operation Manual Introduction 2
System capabilities:
Communications with computers
Direct output to printer
Stores test conditions in program memory
Shows instantaneous flow rate read-out
Battery backed-up date & test conditions
Download to MS-DOS compatible systems
Methods A, B, or A/B conversion and flow rate ratio
Automated purge or weight lowering
Control temperature within 0.1C.
Automatic check of RTD sensor probe and over temperature alarm.
On Overview of MI
A flow rate test is a measure of a polymer's mass flow rate (grams extruded in
10 minutes) using a particular orifice under specified conditions of temperature
and load. Machines that determine flow rate are generally called Melt Indexers.
Test methods by ISO, DIN, ASTM and others specify heat chamber and piston
tip diameter such that the shear stress on the polymer is the same in all machines
for a given load. In addition, material specification guidelines (by ISO, DIN,
ASTM, GM etc) may exist which give further constraints on how a particular
type of material may be run.
The tests we are interested in performing are those described by ASTM D1238
and ISO 1133. This manual in no way supersedes either of these documents.
The precision and accuracy of the test has been determined by ASTM method
D1238 and can be found at the end of this manual. Contributing to both
precision and accuracy are operator variances such as; packing technique,
cleaning, cutting, weighing etc. With moisture sensitive polymers, dryness can
also play a major role, and time can be a factor with thermally unstable
polymers, so procedures must be identical. Dynisco Polymer Test Systems has
found that charging a consistent mass of material into the barrel (0.1 grams) is
the most critical factor in getting precise data.
ASTM Melt Index Tests
Two basic methods have been developed for running flow rate tests under D1238, Methods A and B. Method A is simply the collection of extrudate over
time, while Method B is the measurement of time for the flow of a fixed volume
Method A
Method A/B
Method B
Series 4000 Melt Indexer Operation Manual Introduction 3
Introduction
of polymer.
Method A -- the test is completely manual and is sometimes called the "cut-nweigh" method.
Method A/B -- this employs the electronic eye or digital encoder. In order to
run a method B test, an A/B run MUST be run first to determine the polymer's
melt density
Method B can be conducted only after an A/B experiment is conducted. This is
a "no-cuts" test that is the most convenient for busy laboratories.
Series 4000 Product Offerings:
The Series 4000 of melt indexers are actually 2 pieces of equipment in one.
First, the instrument houses the hardware needed to conduct the measurement
itself -- the heaters, temperature sensors, die/orifice assembly, and so on.
Second, the instrument has a 32 bit micro-processor incorporated into its base
to control the aforementioned hardware, but also to make calculations of the
Melt Index, Viscosity, and in some cases (Model 4003, 4004) calculate
rheological data about the sample as well.
Method B Encoder Option
Model 4001
Model 4002
Model 4003
Model 4004
Series 4000 Melt Indexer Operation Manual Introduction 4
This is the entry level machine. It will conduct method A tests only and cannot
be upgraded to higher models. The 4001 has a 5 program memory.
This model performs Method A, Method B and flow rate ratio testing.
Temperature and flow rate are displayed on the instrument front panel. It has a
20 program memory. The unit can be upgraded to higher models.
This model contains additional program capacity and can retain up to 60 test
programs. In addition, it communicates with printers and can provide a series of
more advanced technical information such as shear rate, shear stress and
viscosity. Statistics on flow rate and viscosity can be averaged over replicated
tests.
The 4004 is the most sophisticated of the Dynisco Polymer Test's models ever
available. It has all of the capabilities of the 4001, 4002 and 4003, and will
communicate with other computers, and can be multiplexed (8 machines to one
PC). With the addition of the encoder option, 10 complete test programs (set
ups) can be stored.
The Digital Encoder option replaces the optical flag and sensor with highly
accurate digital flags and sensors. You can perform experiments using from one
digital flag up to fifteen digital flags. The Dynisco Polymer Test Encoder for
Method B tests employs a 1016 count optical encoder, coupled to high accuracy
gears, to measure the piston travel. The optical encoder has dual outputs,
enabling the signal to be processed in quadrature, yielding a resolution of 0.015
mm. The linear distance of the piston is transferred to rotary displacement via a
precisely calibrated arm. The tip of this arm employs a hardened & ground tip
for extra long life. Accuracy over the ASTM measurement range of 0.25" and
1.00" is +/-0.4%. The optical encoder, while being very accurate, also enables
the test length signal to be processed and varied digitally. Thus, any test length
up to 1"(ASTM) or 30 mm (ISO) may be selected. Up to 15 MFR results per
barrel filling can be obtained. The unit is securely fastened to the rear of the Melt
Indexer, and the arm latches down to facilitate cleaning of the unit after the test is
completed.
Encoder Advantages
Completely Automatic Flag Length Selection on Single MFR Tests
Up to 15 MFR readings per Barrel Filling
Any test length ("Flag") up to 30 mm
User Defined test length & test spacing for single or multiple tests
Automatic Test Length & Test Spacing for multiple tests
Pneumatic Lift
Intrinsic Viscosity Option
Mini-Lift
The pneumatic lift accessory is a key piece of hardware if the flow ratio test
needs to be conducted. The Flow Ratio test provides users with insight into a
material’s thinning ability. This test involves obtaining two flow rates at two
different stress levels, of generally a 10:1 ratio. First, the lower mass weight is
added to the piston. Next the higher mass weight is added to the piston. The
high mass weight can be 21 Kilograms. The pneumatic lift automatically raises
and lowers the weight safely.
This is a small Pneumatic Lift assembly that supports the piston rod itself. It is
useful for high-flow materials and can be used in conjunction with a melt plug.
This is a firmware upgrade to the computer housed in the Series 4003 and 4004
melt indexers only. It enables a calculation of IV values, based on the correlation
between melt-index and the "wet-chemistry" technique for determining the
Intrinsic Viscosity of a polymer. The IV is used to determine the molecular
weight of a poly mer. This is described in greater detail in the Dynisco Polymer
Test applications brief, "Correlating Melt Rheology of PET to Solution Intrinsic
Viscosity" by J. Reilly and P. Limbach.
Series 4000 Melt Indexer Operation Manual Introduction 5
Bench Requirements and Placement
Level the Melt Indexer
Series 4000 Melt Indexer Operation Manual Getting Started 6
Getting Started
Unpacking the Indexer
The DYNISCO POLYMER TEST'S Melt Flow Indexer comes in a heavy duty,
double-walled cardboard container. First, open the main box and remove the
instrument. Several boxes will also arrive by UPS; check that all boxes are
received. They are coded 1 of 5 or 3 of 5, indicating the total number is five. It
is recommended that the shipping carton be saved a few days until you are
certain the machine works as expected.
Typical laboratory benches are too high for efficient use of the indexers.
Cleaning can be difficult and requires awkward hand positions and forces that
could lead to carpal tunnel syndrome or back discomfort. We strongly suggest a
bench height of 29 inches (desk top height) for an average height operator.
Place the front of the indexer flush with the edge of the table. This will prevent
the operator from having to bend forward excessively when cleaning the barrel
and allow easier access to the back of the machine. As a minimum, the lab
bench should easily be able to support the indexer and operator (total approx.
300 lbs.). DYNISCO POLYMER TEST recommends placing from left to
right, if purchased, the melt indexer; printer; computer. Test shake the melt
indexer for stability. The bench top should also be able to withstand hot dies
and tools being dropped on them. Carpet protection is necessary near the
indexer since a hot die dropped on the carpet will quickly burn spots in it.
Adequate ventilation will also be required to remove potentially harmful fumes
from samples being tested. Consult the Material Safety Data Sheets (MSDS) on
the products to be tested and your material supplier to assess the magnitude of
your ventilation needs. You may wish to consider these ventilation needs when
positioning the instrument in the laboratory.
Most of the machine comes pre-assembled to your door, however, cer tain parts
are prone to breakage if they were placed in their normal operating position
during shipping. These items will need to be installed before safe operation of
the machine is possible. Other issues important to getting accurate data must
also be addressed before valid testing can begin.
Using the small round bubble level, supplied, level the melt indexer. Place the
level on top of the COLD barrel and using the adjustable screw feet, bring the
machine into level. Tighten the locking nuts to keep the feet in level position
Test shake the melt indexer for stability. Some companies bolt the machines
directly to their benches. Be sure to remove the level before turning on the
machine. The level will be damaged if it gets hot.
Pneumatic lift setup
*** Be sure to enable the following features in the SETUP Mode ***
(Please refer to drawing below)
a.) Find the safety spike
shipped in the down position. Remove the spike from the post and mount it into
the aluminum weight bucket
bottom of the weight bucket. Tighten set screw
b.) Loosen the guide block set screws
the guide post
block. Tighten the guide block set screws
c.) Connect a length of tubing (supplied) to the main solenoid valve
Push the tubing into the brass fitting and pull it to seal. Attach shop air supply
(60 psi) to the other end of the tubing. Be sure to incorporate a water trap in the
air line.
(2)
up until the bottom snap ring touches the bottom of the guide
(1)
taped to the guide post
(3)
as shown. The spike should be flush with the
(5)
with a 3/32” hex wrench and slide
(5)
.
(2)
. The guide post is
(4)
with a 1/8” hex wrench.
(6)
.
d.)
(8)
is the low voltage solenoid switch which controls the UP and DOWN
functions via signals from the Indexer. The main solenoid valve
pressure to the appropriate cylinder for UP and DOWN movement. Switch
Installing the Digital Encoder
Series 4000 Melt Indexer Operation Manual Getting Started 7
is an extra safety “lock” feature that will lock the lift in place if closed.
The following parts should be in the encoder upgrade kit or included with the
encoder based melt indexer: (if ordered)
Two 1.25" long #8-32 Socket Head Cap Screws (SHCS)
Two 5/8" long #8-32 Socket Head Cap Screws
Two 5/8" long #8-32 Reduced Head Socket Cap Screws
Six #8 Lock Washers & Four #8 Washers
One Encoder Housing
One Long Plate, Plate #1
(6)
directs air
(7)
One Small Plate, Plate #2
Installation Steps (See Figure 1);
1. Using two 5/8 " Reduced Head Socket Cap Screws & two #8 Lock Washers,
attach plates #1 & #2 to plate #3 (plate #3 is already attached to the MI).
Tighten the screws.
Two Reduced Head
#8-32 x 5/8" Long
Socket Cap Screws &
Two Lock Washers
Plate #2
Figure #1
Plate #3 (Already Mounted to MI)
Two #8-32 x 1.25" SHCS
Two Washers & Lock Washers
Encoder Housing
Phone Jack Cable
Plate #1
Two #8-32 x 5/8" SHCS
Two Washers & Lock Wash
2. Attach the Encoder Housing to the long plate (plate #1) using two 1.25" long
SHCS, two 5/8" long SHCS, 4 washers & 4 lock washers (washers first then
lock washers, i.e. lock washers under screw head).
Note for Pneumatic Lift Users: With the encoder arm in the down position,
lower the pneumatic lift. Move the arm up and down to check for clearance
with the pneumatic lift bucket. Clearance may be increased a small amount by
rotating the encoder housing before tightening the screws. If no clearance
exists and the arm hits the pneumatic lift bucket, contact Dynisco Polymer Test
before proceeding.
Tighten the screws
3. Plug the phone jack cable into the encoder housing.
4. Move the encoder arm into the down position.
5. Turn the power on.
6. Enable the Encoder by pressing the SETUP key. Browse the options until
you reach B FLAG and press EDIT. Press —› Quick Key so that ENCODR is
over the SELECT Quick Key. SELECT ENCODER and press ENTER to
accept. Press ESC to back out to the main menu.
Series 4000 Melt Indexer Operation Manual Getting Started 8
7. Press the SYS key and select TEST. Browse the menu and select Digital
Encoder Test. The display shows current position and should change when the
arm is moved. Press QUIT ending the procedure. ESC out to main menu.
8. See section entitled for detailed instructions on the variety of uses and
RTD Connection
Printer Connection
Computer Connection
Power Cord
Series 4000 Melt Indexer Operation Manual Getting Started 9
Options:
programming available with the encoder option.
The RTD, or thermocouple, is buried inside the instrument's barrel. The RTD
and associated temperature control electronics are calibrated against NIST
traceable temperature probes at Dynisco Polymer Test Systems. To achieve
accuracy required by ASTM D1238 the RTD and electronics control should be
kept together. Changing a RTD requires a complete temperature re-calibration.
Please consult the factory when required to replace the RTD.
Connect the power cord to the melt indexer. There may be a number of standard
power cords supplied; the heaviest is used for the melt indexer. The factory
suggests using a noise filtering outlet strip to connect the instrument and
associated components to the power source.
Connect the printer (if you have one) to the melt indexer. A cable is provided
with two distinctly different ends; one connects to the printer and the other to
the melt indexer. The connections are on the back sides of both machines. Be
sure the printer is OFF when connecting the indexer.
The data processing system (4004 models only) consists of a PC and the
MIWORKS software package . If your melt indexer is so configured, you will
find the proper cable included with the equipment. The cable will connect to
COM 1 on the computer side and to the smaller connector on the back of the
indexer. Set COMM PORT to PC under the SYSTEM key on the indexer.
Refer to the MIWORKS software manual for more details.
If system purchased after February, 2012, the system will only have a USB
connection. Please see “Setting-Up USB Connections” section of this manual.
The Series 4000 melt indexer has various options to make conducting specific
measurements easier, or make running multiple samples faster and more
convenient. As previously described, the Melt Indexer maybe shipped with a
Digital Encoder, a Pneumatic Lift System or a Mini-Lift system. The
installation of these options is described in the appropriate Appendix of this
manual.
Safety
Use gloves, it's HOT!
To prevent burns, gloves and a long sleeve shirt (or lab coat) are essential. Dies
and piston rods are extremely hot and are designed to quickly transfer heat to
the sample being tested. Unfortunately this means they will transfer heat very
quickly to you as well. Even brief contact with a hot item can cause a burn. The
indexer barrel housing can also get fairly hot, however, at barrel temperatures
lower than 350 C these will not cause burns if touched for a brief period.
Consider where dies may fall. If they are dropped on Nylon carpeting or similar
materials they can quickly form holes. Protective mats may be needed.
DYNISCO POLYMER TEST recommends keeping a hot piston rod in the
chamber; this precludes someone picking it up inadvertently. Be sure to hold
the piston by the top insulator.
Electrical Hazard
Your Dynisco Polymer Test indexer contains high voltage inside the steel
housing. DO NOT remove the housing unless you are instructed to do so by a
DYNISCO POLYMER TEST representative or are experienced with high
voltage devices. Be sure the outlet used to power the indexer is properly
grounded.
Calibration Thermometers use
Mercury
To calibrate the temperature on the indexer, a thermometer containing about 8
grams of mercury is used. Every lab with mercury thermometers or equipment
containing mercury must be prepared for breakage. Note that mercury exposed
to air "evaporates" at room temperature, producing an invisible, tasteless,
odorless and dangerous vapor. Thermometers have been used for decades in
laboratory equipment and when used properly provide an accurate and effective
means of calibration. Keep the thermometer in a safe place where it will not be
crushed or otherwise broken. When using the thermometer be careful not to
drop or bend the glass. Place a hot thermometer onto cotton patches to cool .
Never put a hot thermometer in contact with cold metal or cold solvent because
the thermal shock can crack or shatter the glass. Mercury is extremely toxic and
should be handled accordingly.
A material safety data sheet (MSDS) for mercury (Hg) can be found in the
appendix. Observe local, state and federal hazardous waste disposal laws when
disposing of any broken thermometers. If packaged in a sealed plastic container
Series 4000 Melt Indexer Operation Manual Safety 10
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.
Pinch Points
Do not place weights in precarious positions where they can be bumped and fall
to the floor. For large weights (over 10 kg) the pneumatic lift system is
recommended. In using a pneumatic lift system for weights up to 21,600 gram,
the safety pin (spike) that goes through the weights must be used. When the
machine is in operation the lift system moves the weight downward quickly
creating an area where anything lying beneath could be crushed. Press the UP
and DN keys only when the areas above and below the weight are clear.
Fumes from Materials
Plan for the unexpected when it comes to materials giving off hazardous vapors.
Many polymers (PVC, PVF etc.) are well known for giving off hazardous fumes
at elevated temperatures. An exhaust system that removes fumes from both the
die exit and near the top of the barrel is strongly recommended. Consideration
should also be given to additives that may degrade or decompose at elevated test
temperatures.
Pre-Run Check List
The following points should be addressed before running the instrument for the
first time:
120V power outlet properly grounded? (230 V Europe/Asia)
Indexer level and on a sturdy bench?
Protective oil wiped out of barrel?
Exhaust hood or snorkel working?
Arm protection, long sleeves or lab coat
Operator using high temp gloves?
Series 4000 Melt Indexer Operation Manual Safety 11
Operator using safety glasses?
Series 4000:
A Guided Tour
Overview
Setup
Edit
Series 4000 Melt Indexer Operation Manual Series 4000: 12
Run
System
Four Options from the main menu
screen.
The Series 4000 Melt Indexer has been designed for ease of use. The VFD
display prompts the user for input necessary to program, configure and run the
instrument. From the main menu screen, the user has the choice of four
instrument routines. The user may:
Configure the Instrument (by pressing the SETUP Key)
Edit a Program (by pressing the EDIT Smartkey)
Run a Program (by Pressing the RUN Smartkey)
Enter Calibration and Test Routines (by pressing the SYS key)
It is important that the instrument first be properly configured. This involves
pressing the SETUP key and checking instrument options and units for
particular parameters
Melt Index experiments (particularly method A tests) rely on the instrument to
reach the proper temperature and (in method B and A/B tests) collect
information on the travel of the plunger. The user is first expected to input the
appropriate parameters for the experiment and subsequent calculations in the
EDIT routine. After this is accomplished, the user may RUN the program.
The melt index unit relies on the operator to properly program the unit, load the
sample, start the experiment, wait the appropriate length of time, and (in method
A tests) collect the sample to weigh. All tests require that the instrument be
properly cleaned between runs
Many calibrations can be performed in the SYS, CALIBRATE mode. Although
the unit is not expected to change calibration values over years, it is always wise
to check the previous values. Maintenance should typically be performed on our
instruments every 6 months. Your lab procedures may be different.
Each of these instrument routines is covered in greater detail in the following
sections. Before the user attempts to work with the instrument, it is important to
become familiar with the keyboard itself and the keystrokes necessary to
perform particular functions.
Navigating the Keypad
Introduction
Series 4000 Melt Indexer Operation Manual Series 4000: 13
The Keypad
The keypad provides all of the means necessary for programming the Dynisco
Polymer Test Melt Indexer (Unless it is connected to a PC.) Other functions that
can be performed on the keypad include calibration, instrument tests, parameter
setups and pneumatic lift controls.
10
11
12
ESC (ESCAPE) - Backs out
one level from any mode. Quits a
test totally
PROG (PROGRAM) - Browse
and select a preprogrammed program
SYS (SYSTEM) - Enter self
calibration modes or hardware
diagnostic modes for testing unit.
SHIFT - Toggle between
numerical and alpha-numerical input
ID (IDENTIFICATION) -
Enter operator and sample
identifications
SETUP - Change system
parameters
LIFT UP/DOWN - Raise and
lower pneumatic lift(s) if equipped
CLEAR - Clears present value
in editing modes
ESC PROG SY S
1 2 3 4
ID SETUP
6
CLEAR BACkSP
98
Destructive backspace
Allows for numerical and alpha
numerical character input.
display
used for browsing, selecting and
entering values and parameters
SHIFT ABC 7 DEF 8 GHI 9
JKL MNO4 5 PQR 6
kg STU VWX1 2 YZ 3
*-# 0 .
ENTER
7
BACKSP (BACKSPACE) -
NUMERAL/ALPHA INPUT -
DISPLAY - 4 X 20 instrument
SMART KEYS - Main Keys
Keypad Definitions
ESC (ESCAPE)
The ESC key can be used in any screen. During an EDIT function, ESC backs
out one level. During a sample run, ESC aborts the test.
PROG (PROGRAM)
Pressing the PROG key lets the user browse through a list of preprogrammed
test parameters. From this mode the user can browse through a list of programs
by using the UP or DOWN SMART KEY button and then select the desired
program by pressing the ACTIVE SMART KEY button.
SYS (SYSTEM)
In this mode the user can choose to calibrate, test or quit by selecting the
appropriate CALIB, TEST or QUIT SMART KEY, respectively.
*** Depending on what instrument model you have, prompts may vary ***
CALIB- Select either Digital Flag, RTD Electronics, RTD Sensor, Optical
Flag or IV Offset calibrations by toggling prompt with UP or DOWN QUICK
KEYS and using SELECT to start the calibrations. Please reference
Configuring the Instrument sections (Page ) or Appendix # for more
detailed operations of calibrations.
TEST- Select either RTD Display, Digital Encoder, Printer or Display
Brightness tests by toggling prompts with the UP or DOWN SMART KEYS
and using SELECT to start the test. Please reference Configuring the
Series 4000 Melt Indexer Operation Manual Series 4000: 14
Instrument sections (Page ) for more detailed operations of tests.
SHIFT
The shift key is used when inputting numeric and alphanumeric characters in the
sample, operator or program identification screens. Pressing SHIFT, then the
appropriate numeric/alpha key enters the alpha input mode. This mode provides a
selection of alpha characters above the SMART KEYS that correspond to the
numeric/alpha key pressed. When in the alpha mode it is not necessary to press
the SHIFT key to select alpha input every time. Just press the appropriate
numeric key to select different alpha characters. Press SHIFT to re-enter the
numeric input mode.
ID (IDENTIFICATION)
Define your operator and sample identifications for each program by pressing
the ID keypad. Toggle between operator and sample by pressing the right
SMART KEY . Press the ENTER SMART KEY to enter a new identification for
the desired parameter.
SETUP
Setup provides a series of system settings pertaining to your test. After pressing
SETUP, scroll through the list of settings using the UP or DOWN SMART
KEYS . Select the EDIT SMART KEY to change the parameter accordingly.
Please reference Configuring the Instrument Section for a detailed description
of each parameter
LIFT UP/DOWN
If your instrument is equipped with the Pneumatic lift option, these keys will
manually operate them.
CLEAR
The CLEAR key will clear any active value displayed in the EDIT PROGRAM
mode (EDIT SMART KEY then EDIT SMART KEY again) or any text entry.
The clear key will also clear the PROGRAM number in the VIEW PROGRAM
mode (EDIT SMART KEY) where a new program number can be entered.
BACKSP (BACKSPACE)
The BACKSP key performs a destructive backspace function in text editing
screens.
NUMERAL/ALPHA INPUT
Using combinations of the SHIFT key and the NUMERAL/ALPHA INPUT
keys, either numbers or letters can be entered in the SAMPLE, OPERATOR and
PROGRAM identification modes. Pressing SHIFT then the appropriate
numeric/alpha key enters the alpha input mode. This mode provides a selection of
alpha characters above the SMART KEYS that correspond to the numeric/alpha
key pressed. Press SHIFT to re-enter the numeric input mode.
A space can be entered by pressing the 3, YZ keypad.
DISPLAY
Your instrument uses a 4 line vacuum fluorescent display, VFD, to display
information. Brightness can be adjusted in the SYSTEM TEST mode.
SMART KEYS
Dynisco Polymer Test provided three keypads below the VFD, to allow for
quick navigation of the machine interface. The functions of these keys change
depending on the mode of operation. Each SMART KEY is clearly and
concisely labeled to assist you in programming your instrument.
Configuring the
Instrument
Series 4000 Melt Indexer Operation Manual Configuring the Instrument 15
Intro: The SYS (SYSTEM) Mode
Many functions can be performed on the instrument using its operator interface.
Hardware calibrations, tests and option configurations will be discussed in this
section.
The system mode lets the user perform calibrations or hardware tests. The
system mode is entered by pressing the SYS keypad. For complete information
on the keypad and its function's reference Navigating the Keypad Sections in
the manual. Once you have entered the CALIBRATE and TEST Select mode
you can select between calibrate and test.
Selecting CALIB (Calibration) in the
SYS Mode
CALIB:Digital Flag Home
CALIB:RTD Electronics
CALIB:RTD Sensor
CALIB:Optical Flag
CALIB:Intrinsic Viscosity Offset
Series 4000 Melt Indexer Operation Manual Configuring the Instrument 16
The Digital Encoder is calibrated at Dynisco Polymer Test prior to shipment.
Because the arm is locked into place, calibration is rarely required.
The instrument does allow you to reset the home position of the encoder.
If calibration needs to be checked due to suspected encoder damage, then
contact Dynisco Polymer Test for assistance and the necessary tool kit.
Please reference the section entitled “Instrument Calibration”
for further details on actual calibrations.
The RTD electronics are calibrated at Dynisco Polymer Test prior to shipment.
Please do not reconfigure this option.
Please reference the section entitled “Instrument Calibration”
for further details on actual calibrations.
Calibration of the RTD Sensors requires one or two thermometers or equivalent.
The RTD sensor is calibrated at Dynisco Polymer Test prior to shipment.
There should be no need to re calibrate the RTD sensor.
Please reference the section entitled “Instrument Calibration”
for further details on actual calibrations.
The instrument allows for the adjustment of the Optical Flag sensitivity. This
determines how sensitive the Optical Flag LED Receiver is in either of two
states, blocked or open. Sensitivity directly affects the measured length of the
tape flag.
The Optical Sensor is calibrated at Dynisco Polymer Test prior to shipment.
There should be no need to re-calibrate the Optical sensor. For this procedure
you must have the Flag Calibration Unit (Factory Part # D2044).
Please reference the section entitled “Instrument
Calibration” for further details on actual calibrations.
The IV offset is the difference between the computed IV and the experimentally
obtained IV. If option available, enter the difference here for correlation during
IV runs. See the I.V. section.
Please reference the section entitled “Instrument Calibration”
for further details on actual calibrations.
Selecting TEST in the SYS Mode
TEST:RTD Display
TEST:Digital Encoder
TEST:Printer
TEST:Display Brightness
Introduction
REJECTION
Series 4000 Melt Indexer Operation Manual Configuring the Instrument 17
AVERAGE
MFR / MVR
B FLAG
VISCOSI
TY
PRINTE
R
FORM FEED
Press SELECT to view actual temperature reading accurate to 1/100 of a degree
Celsius. Dynisco Polymer Test technical support may have you do this under
certain conditions. RTD Display Test may also come in handy when
equilibrating RTD’s and thermometers.
Displays the current digital encoder arm position. Readings for home position
should be 105.00 mm, +/- 1.5 mm.
Your model must support printer output to perform this test. A test pattern
output will be produced on the connected printer. Press STOP to end printer
output.
The operator can control the VFD brightness level. Select a percentage of
default brightness.
The SETUP mode
This software routine is used to set user preferences for data collection. This
routine also turns off instrument options such as the digital encoder or pneumatic
lift. Please scroll through the settings prior to commissioning the instrument and
make a note of the values particular to your instrument. If for some reason the
settings are changed or erased they can be easily re-entered from this menu. By
pressing the SETUP key the following series of inputs are requested of the user.
Press the ENTER SMART Key to input the appropriate value. After entry is
complete, press the ESC key to save modified information.
After pressing SETUP, scroll through the list of settings using the UP or
DOWN SMART KEYS . Select the EDIT SMART KEY to change the parameter
accordingly. Please reference Configuring the Instrument Section for a
detailed description of each parameter. Note the order the items appear can vary.
[1..5, OFF] ] Exclude data points that are more than the operator entered
number of standard deviations from the mean. Exclude these points from all
statistical calculations. Points are not deleted but marked on the printouts with
asterisks. The rejection option is used for systems configured with a printer.
Data points are printed but not included in statistics.
[AUTO, OFF, ON] ON: average is computed for one or more data collection
runs. Generates statistics for printout. AUTO: compute the average of a single
data collection run without operator interaction at the end of the run.
[MFR or MVR] The operator can choose the calculated result. The choices are
Melt Flow Index or Melt Volume Index respectively.
[ENCODR or FLAG] Enable either the Digital Encoder or the Optical Flag
devices, respectively.
[POISE, PA-S, REYN] Select units of viscosity for displayed results.
[MINI, OFF, EPSON, IBM, LASER] Select output device. Mini printer, No
device, Epson compatible, HP Laser Jet compatible, respectively. (Only 4002
models will have the mini-printer option)
[OFF or ON] Perform a Form Feed (A page is sent out of the printer) after the
run data is printed.
COMM PORT
MINI LIFT
PNEU LIFT
LOCKOUT
DATE and TIME
MACHINE ID
LANGUAGE
ORIFICE DIA
ORIFICE LEN
Introduction
Create (New)
Recall (Old)
Save Program
While EDITING
[ PC, OFF, DIAG] Open up communications port for computer output, no
output or diagnostics mode, respectively.
[OFF or ON] Enable the mini lift to function during material runs when
installed.
[OFF or ON] Enable pneumatic lift to function during material runs, when
installed.
[OFF or ON] Enable password protection. When ON users can not edit test or
system parameters only run tests. The default password is 1234, if the
LOCKOUT is enabled this number must be put in to turn the LOCKOUT off.
The NUMBER item allows a new password number to be entered.
Set the appropriate date and time here. Follow prompts.
[##] Assign a unique machine number to the instrument. If using MIWORKS
be sure this is set to one if you have only a single machine or to the Porter box
port number for multiple machines. This allows you to tell what machine your
sample was run on when you have more than one machine.
[CUSTOM, ENGLISH, FRENCH, ITALIAN, SPANISH, GERMAN] Switch
between desired languages.
[XXX] Store standard orifice diameter, 2.096 mm. Used in calculations.
[X.XXX] Store standard orifice radius, 8.000 mm. Used in calculations Scroll
through this menu and make appropriate changes. Press ESC twice and any
changes that have been made will be implemented.
Programming
This section is intended for a quick reference of method parameters. Please refer
to the appropriate sections in the manual for more specific information about a
particular method.
Before a measurement can be made, the RUN PARAMETERS must be
entered. These parameters dictate how the experiment will be performed. Many
of these parameters are set by particular ASTM test procedures. The SERIES
4000 software has many of these values pre-loaded into memory.
Press the EDIT SMART Key to start the EDIT mode. Enter the new program
number into the upper left hand corner of the display and press ENTER.
Proceed to EDIT.
Press the PROG button and enter the program number in the upper left hand
corner of the display or BROWSE with the Smart Keys. Press ACTIVE to use
the selected program number.
From the EDIT mode, ESC out until prompted to SAVE PROGRAM. Select
SAVE to save. In order to receive the SAVE PROGRAM prompt, a value
must be changed while in the editing mode.
Browse the suggested values appearing on the 3rd line of the Edit Screen with
the
SMART Key (Browse Key). Select the desired value with the
Series 4000 Melt Indexer Operation Manual Configuring the Instrument 18
SELECT SMART Key. Accept the value with the ENTER SMART Key. The
user always has the option to enter values manually via the numeric keypad.
Below is a listing of the run parameters that are required for each test method.
Method A Run Parameters
METHOD = [A, B, A/B or RATIO] SELECT and ENTER Method A.
SET POINT = [Temp. Celsius] Dependent on the material, ASTM
requirements. Enter or Select value using browse key .
MELT TIME: [Time, Seconds] ASTM D1238 equilibration time for most
materials. Enter or Select value using browse key .
CUT TIME =[Time, Seconds] This is the sample collection time, the length of
time an extrudate sample is squeezed out. Enter or Select value using browse
key. Dependent on Flow Rate characteristics.
NO OF CUTS =[Number] Dependent on material - up to 5 cuts allowed
LOAD =[Weight, Grams]. Mass of weight plus piston assembly, ASTM
requirements
QC LIMITS [On or Off] Allows QC limiting of data to be used
QC Limits High [Number] Highest MFR limit saved
QC Limits Low [Number] Lowest MFR limit saved
PROGRAM ID [Characters] Name of program up to 14 characters long
METHOD = [A, B, A/B or RATIO] SELECT and ENTER Method A/B.
SET POINT = [Temp., Celsius] Dependent on the material, ASTM
Method A/B Run Parameters
requirements. Enter or Select value using browse key .
MELT TIME: [Time, Seconds] ASTM D1238 equilibration time for most
materials. Enter or Select value using browse key .
CUT TIME =[Time, Seconds] This is the sample collection time, the length of
time an extrudate sample is squeezed out. Enter or Select value using browse
key . Dependent on Flow Rate characteristics.
FLG LENGTH =[Length, millimeters] Flag length in millimeters. Dependent
on Melt Flow Rate. Digital Encoder equipped instruments will be asked further
questions. Reference Digital Encoder Section in manual.
LOAD =[Weight, Grams] Mass of weight plus piston assembly, ASTM
requirements
PROGRAM ID [Characters] Name of program up to 14 characters long
METHOD = [A, B, A/B or RATIO] SELECT and ENTER Method B.
Method B Run Parameters
SET POINT = [Temp. Celsius] Dependent on the material, ASTM
requirements. Enter or Select value using browse key.
MELT DENSITY =[X.XXX,g/cm³] Numeric value, calculated from A/B Run.
MELT TIME: [Time, Seconds] ASTM D1238 equilibration time for most
materials. Enter or Select value using browse key.
Series 4000 Melt Indexer Operation Manual Configuring the Instrument 19
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