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ViscoIndicator

Dynisco ViscoIndicator Installation & Service Manual

P/N: 975389 | Rev: current | ECO: xxxxx
From lab to production,
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ViscoIndicator
Rheological sensing for the masses
Assembly, Installation
& Service Manual
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P/N: 975389 | Rev: current | ECO: xxxxx
From lab to production,
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P/N: 975389 | Rev: current | ECO: xxxxx
From lab to production,
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Contents
1 General ............................................................................................................................................................. 5
1.1 Important information about the use of this manual ............................................................ 5
2 Safety ................................................................................................................................................................ 6
2.1 Safety summary .................................................................................................................................... 6
2.2 Obligation of the operator to exercise due care ...................................................................... 7
2.3 Obligation of the personnel to exercise due care .................................................................... 8
3 Transportation, handling, storage ..................................................................................................... 10
3.1 System Description .......................................................................................................................... 10
3.2 Transportation .................................................................................................................................. 10
3.3 Inspection upon receipt ................................................................................................................. 10
3.4 Storage conditions............................................................................................................................ 10
3.5 What's in the boxes .......................................................................................................................... 11
4 Assembly ...................................................................................................................................................... 14
4.1 Assemble IRCU-STAND (optional) ............................................................................................. 14
4.2 Mount RCU to the stand ................................................................................................................. 21
4.3 Attach the RSU (Head) to the stand ........................................................................................... 23
4.4 Attach the HMI to the stand .......................................................................................................... 29
4.5 Install Vortex coolers into RSU & RCU (option).................................................................... 30
4.6 Attach Vortex cooler regulators and tubing (option) ......................................................... 31
4.7 Attach ViscoIndicator Cable Bundle: electrical cables between RSU, HMI to RCU . 31
4.8 Attach RCU power cable to RCU .................................................................................................. 31
5 Installation .................................................................................................................................................. 33
5.1 Process Connection Tie-in ............................................................................................................. 33
5.2 Connect VI system assy to Process Connection .................................................................... 35
5.3 Install PIV heater and RTD ............................................................................................................ 37
5.4 Connect cables between process connection and RSU ...................................................... 39
5.5 Connect airlines to Vortex regulators (option) ..................................................................... 39
5.6 Insulate supply tube, ext. tube assy ends, dump valve and PIV ...................................... 39
5.7 Connect RCU cable to main line power .................................................................................... 39
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6 Mechanical/pneumatic parts - Operation ....................................................................................... 40
6.1 Vortex cooler ...................................................................................................................................... 40
6.2 IRCU-STAND casters ........................................................................................................................ 40
6.3 Dump valve ......................................................................................................................................... 41
6.4 Process Isolation Valve (PIV) ....................................................................................................... 43
6.5 Rheological Sensing Unit (RSU) Extrudate Stream ............................................................. 43
7 HMI Operation (Obtaining rheological measurements from the ViscoIndicator) .......... 44
8 Preventative Maintenance .................................................................................................................... 45
8.1 Check RSU enclosure for plastic leaks ...................................................................................... 45
9 Service ........................................................................................................................................................... 46
9.1 Changing RSU burst plug ............................................................................................................... 46
9.2 Changing Pressure Transmitter .................................................................................................. 46
9.3 Changing capillary ............................................................................................................................ 46
9.4 Detaching VI main system from process connection .......................................................... 47
9.5 Preparing VI system for shipment ............................................................................................. 47
10 Support/Contact Dynisco ...................................................................................................................... 48
10.1 Recommended replacement parts / list and drawings of replacement parts ...... 48
11 Customer service ...................................................................................................................................... 49
12 Warranty ...................................................................................................................................................... 50
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P/N: 975389 | Rev: current | ECO: xxxxx
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1 General
1.1 Important information about the use of this manual
This manual covers the Assembly, Installation and Service of the ViscoIndicator. The operation of the ViscoIndicator is covered in a separate manual (Dynisco p/n 974175).
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P/N: 975389 | Rev: current | ECO: xxxxx
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2 Safety
All safety instructions must be heeded and observed. Non-observance of safety instructions may cause damage to life and health of persons, environmental damage and/or extensive damage to property.
Observing the safety instructions included in the operating instructions will help to avoid dangers, to operate the installation profitably and to secure the full use of the product.
2.1 Safety summary
The following are recommended safety precautions unrelated to any specific procedures in this manual and therefore do not appear elsewhere. Personnel must understand and apply them as appropriate during all phases of operation and maintenance. IN ALL CASES, BE PRUDENT.
Keep away from live circuits
Do not replace components or make adjustments inside equipment with power turned on. To avoid injuries, always remove power and discharge and ground a circuit before touching it. When making electrical connections, the services of a qualified electrician must be employed. Contact with live electrical circuits can cause serious personal injury or death. Be sure no circuits are energized during installation, connection or removal of any electrical cables or lines.
Examine the cabling and housings regularly for damage. Machines with damaged wiring or control systems must be disconnected from the power line immediately and must not be operated again until they have been repaired by qualified personnel.
Wear protective clothing
Wear protective clothing (gloves, apron, goggles, etc.) approved for the materials and tools being used.
Provide adequate ventilation
Provide ventilation to remove heat and noxious odors and to prevent the accumulation of asphyxiates such as nitrogen gas.
Avoid hot surfaces
Keep hands away from hot surfaces and materials. Contact with hot surfaces or materials can cause blistering and third degree burns. Wear approved, clean, thermally insulated gloves when handling these components. Should injury occur; immerse injured area in cold water and get immediate medical attention.
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Avoid tipping the stand
After assembling the stand, install the RCU on the stand before installing the RSU. Installing the RSU to the stand before installing the RCU can make the stand unstable. Take care to follow this assembly order unless the stand has been properly secured.
The optional stand has flexible configuration capability. It is possible to configure it is such a way that it is unstable. Take care not to use it this way unless it is properly secured.
Take care to avoid tipping the stand due to an impact (from something/somebody running into the stand), or from a collision (a forklift or crane load, etc being driven into it), or while moving the stand. Do not climb on or support yourself with this stand. Use signs or barriers as appropriate.
When moving the stand around on its castors, there is danger that it could suddenly stop sharply when it rolls over uneven floor surfaces or other obstructions (screws, granules), and could tip. Appropriate caution must therefore be taken - roll the unit slowly!
The castors on the base of the stand must be examined regularly for damage and secure fit, damaged castors are to be replaced immediately.
2.2 Obligation of the operator to exercise due care
The Dynisco component conforms to the state of the art technology and ensures a maximum of safety. In practical operation, this safety can, however, be achieved only if all necessary measures are taken. The obligation of the plant operator to exercise due care includes planning these measures and supervising their execution.
Especially, the operator has to ensure that:
• The Dynisco component will be used only in accordance with the intended purpose.
• The Dynisco component will be operated in a flawless, functionally efficient
condition and that, in particular, the functional efficiency of the safety devices will be checked at regular intervals.
• The necessary personal protective equipment for the operating, maintenance, and
service personnel will be available and used by them.
• The operating instructions are always available completely and fully legibly at the
installation location of the Dynisco component. It must be guaranteed that all persons who have to work with the Dynisco component can consult the operating instructions at any time.
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• Only sufficiently qualified and authorized personnel will operate, maintain, and
repair the Dynisco component.
• Instructions concerning all relevant questions of industrial safety and
environmental protection will regularly be given to the personnel, and that these persons will know and understand the operating instructions and, particularly, the safety instructions contained.
• All safety and warning instructions, attached to the Dynisco component, will not be
removed and will remain fully legible.
• The service instructions in accordance with the industrial safety legislation and the
ordinance for the use of work materials will have to be made available as a supplement to the operating instructions.
2.3 Obligation of the personnel to exercise due care
The ViscoIndicator melt rheometer may only be operated by persons trained, instructed and authorized to do so. These persons must know the operating instructions and act accordingly. The respective competences of the staff must be clearly determined.
The following work described in these instructions may be carried out by qualified persons only:
• Assembly
• Installation
• Operation
• Servicing
Especially, the staff has to ensure that:
• Inexperienced operating personnel should only work with the Dynisco component
while directly monitored by an experienced person.
• All persons operating and maintaining the Dynisco component must read the
operating instructions and confirm by their signature that they understood the operating instructions.
• Unauthorized persons do not stay in the working area of the Dynisco component.
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P/N: 975389 | Rev: current | ECO: xxxxx
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• The working area will be left only if all movable parts have come to a stop after
having switched off the Dynisco component.
• In addition to the operating instructions, the service instructions within the
meaning of the industrial safety legislation and the ordinance for the use of work materials will be observed.
• In case of malfunctions, the operator or the supervisors will be informed.
• The necessary personal protective equipment for the operating, maintenance, and
service personnel will be used.
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3 Transportation, handling, storage
3.1 System Description
3.2 Transportation
The machine is usually placed on a palette or inside a card board box for shipping. The dimensions ensure that no damage can occur under normal shipping conditions. The ViscoIndicator is wrapped in plastic sheeting for transportation – for overseas transport the palette is covered in addition with a suitable wooden or a cardboard box.
Because of the low weight of the ViscoIndicator the machine can be removed manually from the palette or the card board box.
When moving the ViscoIndicator mounted in the optional stand on castors, watch out for unevenness and obstacles on the floor. Sudden stops can cause the machine to tip over!
3.3 Inspection upon receipt
Check the delivery for completeness and signs of shipping damage. Any shipping damages must be sent to the shipping carrier and Dynisco in writing.
Immediately submit any claims in writing to the following address:
For Americas and APAC: For EMEA:
Dynisco Dynisco Europe GmbH 38 Forge Parkway Pfaffenstrasse 21 Franklin, MA 02038, USA 74078 Heilbronn, Germany Fax: +1 508 541 6206 Fax: +49 (7131) 297 166
3.4 Storage conditions
When intermediate storage is required upon delivery, be sure to:
• choose a dry room with a moderate temperature (approx. 18° C)
• leave the ViscoIndicator in the plastic sheeting
• avoid storing the ViscoIndicator outside. If this is inevitable, be sure to:
- leave the ViscoIndicator in its original packaging
- provide an additional rain cover for the ViscoIndicator
- repair any defective paint work immediately
- position the ViscoIndicator on squared timber or a palette.
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Sample
Tube
PIV
RSU
As a rule, damages caused by inadequate storage will void any claims under the warranty
3.5 What's in the boxes
The ViscoIndicator provides continuous measurements of the melt flow rate, apparent viscosity, or intrinsic viscosity directly on the extruder.
The ViscoIndicator consists of the following:
A sample tube that transfers polymer from the process to the ViscoIndicator for measurement.
The Process Isolation Valve (PIV) allows the flow of polymer to the ViscoIndicator to be shut off, allows purging, and allows a pressure transducer measurement on the process line.
A Rheological Sensing Unit (RSU) that measures the properties of the resin. It can be mounted on extruders, reactors, or molten polymer transfer lines in various orientations.
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A Rheological Control Unit (RCU) that controls the measurement parameters of the RSU (temperature, pressure, flow rate), and communicates to an HMI.
RCU
The Human Machine Interface (HMI) remotely manages test parameters and provides measured and computed material properties. It provides rheological data similar to a Laboratory Capillary Rheometer or MFI readings similar to a Melt Flow Indexer.
HMI
Because of the system options available, please refer to the purchase order for the particular configuration and accessories. However, the following items are part of the standard ViscoIndicator:
ViscoIndicator Cable Bundle: These are the cables that connect the RCU to the RSU and HMI.
Additional Items:
Orifices Orifice removal tool
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Optional Items: Vortex cooler
Stand
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4 Assembly
4.1 Assemble IRCU-STAND (optional)
If the optional IRCU-STAND has been purchased, the locations for mounting the RSU, RCU, and HMI have been predetermined. Assemble the stand per the instructions below. If this stand was not purchased, skip to section 3.2.
NOTE: Item numbers refer the numbers on drawing IRCU-STAND (included at the end of this section), unless noted.
4.1.1 Assemble Base
• Loosen the four connector set screws on the cross brace extrusion (item 13 - QTY 1)
• On each end of item 13, slide one caster extrusion (item 2 - QTY 2) onto the T nuts
• The two T nuts on each end of item 13 slide into one slot of item 2.
• Center and position each item 2 perpendicular to item 13
•
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• Tighten all four connector set screws on item 13
4.1.2 Assemble Mast
• Loosen the two connector set screws on the rectangular mast (item 3 - QTY 1)
• Loosen the two connector set screws on the square mast (item 1 - QTY 1)
• Slide the two masts together using the T nuts on each mast
• Tighten all four connector set screws on the masts
• Insert two M5 T-nuts (item 17) into upper end of item 3
• Attach endcap to lower end of item 3
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