RPV-1 Gen3 User Manual Issue1 30 November 2021
Contents 1
System Photos............................................................................................................................. 2
2
Power On .................................................................................................................................... 3
3
Using the RPV-1 Gen 3 ................................................................................................................ 5 3.1
How to Measure a Sample .................................................................................................. 5
3.2
Results ................................................................................................................................. 9
3.2.1
Results Database ......................................................................................................... 9
3.2.2
How to Enter a Manually Measured Solvent Result ................................................. 10
3.2.3
How to create a Control Sample ............................................................................... 11
3.2.4
Results Factoring ....................................................................................................... 13
3.2.5
Results Extract........................................................................................................... 14
3.2.6
Print Results .............................................................................................................. 14
3.2.7
Access Results Over a Network ................................................................................. 14
3.3
Daily Maintenance ............................................................................................................ 15
3.3.1
Solvent and Waste Management ............................................................................. 15
3.3.2
Cleaning..................................................................................................................... 15
4
How to Remove a Viscometer .................................................................................................. 16
5
Error Messages and Trouble Shooting ...................................................................................... 17 5.1
VOID RUN .......................................................................................................................... 17
5.1.1
The draw up time is exceeded .................................................................................. 17
5.1.2
The released sample time out was exceeded ........................................................... 17
5.2
FALSE TRIGGER .................................................................................................................. 17
5.3
OTHER PROBLEMS ............................................................................................................ 18
5.3.1
“SOFTWARE ALWAYS STARTS UP WITH LAB DETAILS SCREEN”................................ 18
5.3.2
SAMPLE IS PUSHED UP THE AIR ARM AT THE SAME TIME AS THE CAPILLARY ARM 18
5.3.3
SAMPLE IS LEFT IN THE VISCOMETER AFTER CLEANING ........................................... 18
5.3.4
THE RESULTS ARE WRONG! ...................................................................................... 18
5.4
CHECKS BEFORE CALLING PSL FOR ASSISTANCE ............................................................... 18
Note: The end user must carry out their own risk assessment prior to using this equipment.
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1
System Photos
The photo shows: -
RPV-1 Gen3 Control Module Bath with TCB 7 MkII temperature controller External Chiller 2 x vacuum gauge, diaphragm vacuum pump (Note: (1) your system may have PIAB venturi type vacuum source). 2 x waste bottles and 3 x solvent bottles. (Note: (2) your system may have only 2 x solvent bottles) 2 x viscometer tube/measuring head/filling station (Note: (1) your system may have only 1 x viscometer tube/measuring head/filling station).
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2
Power On
Ensure waste bottles are empty and solvent bottles are full, apply pressure to PIAB/turn on vacuum pump. Step 1 - Power on PC. For information, 5V is supplied via the 78way cable to the RPV-1 Gen3 module.
Step 2 - Power on/off RPV-1 Gen2 using switch on top right hand side The power ON/OFF button activates the 24V DC. Green light on front comes on.
Step 3 - Power on TCB7 MK II bath Power on by pressing red button, display will show OFF.
Then Press OK, temperature will be displayed
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Step 4 - Power on chiller (Note: your chiller may differ), set to 5 degrees below bath set point
Step 5 - Open software using shortcut
Click in shortcut available on the Desktop. RPV-1 software will start initialisation; Click OK to proceed.
Software will open (Note: picture shows four head system, your system may differ.)
To shut down the system, follow the Power on procedure in reverse order (close software first).
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3 3.1
Using the RPV-1 Gen 3 How to Measure a Sample
1. Press the START button
2. Select the sample type 3. Enter the following: - USERNAME - SAMPLE NAME
If you are running a “SOLUTION” or “CONTROL” sample, then highlight the “solvent” flow time (t0) you wish to use and enter the concentration in box. Add each unique sample details in the description box.
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4. Load the sample by following the steps
B A
-
Unscrew filling station cap and pour SAMPLE into viscometer Pour in enough sample so that the volume is between the two lines A and B. Screw the cap ensuring the correct cap was placed in the filling station position. [IMPORTANT: MAKE SURE THE CAP IS REPLACED TIGHTLY – BE SURE NOT TO CROSSTHREAD THE CAP. IF THE CAP IS NOT REPLACED “AIRTIGHT” THEN THE RPV-1 MAY NOT WORK PROPERLY.]
5. Press START TEST to begin testing the sample. To STOP the test press RESET The RPV-1 STATUS will now go through the following stages: - Thermal Equilibrium time. - Resting time - Drawing sample - Timing Draw Up - Overfilling - Stabilising - Holding - Released Sample - Timing
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These stages will be repeated until the number of flow times selected and measured consecutively agree within the criteria found in the HEAD Settings.
On the picture shown, the average of two consecutive timings will be taken automatically (up to a maximum of 5 flow times attempts), provided the maximum deviation criteria on the Settings screen is met. The Settings screen is accessed by pressing the Settings button for each individual position on the Viscometer screen. (For viscometer screen, although in the photo the settings is not available because this option is always unavailable during cleaning or measurement). IMPORTANT: The settings are specific to each measuring head positions, always check each one of them. IMPORTANT: It is the customer responsibility to ensure that the settings and pass/fail criteria for the measurement are in accordance with your standard test method or SOP.
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The required viscosity is then calculated and displayed automatically at the end of the test
You can go back and see the flow times by pressing the ‘Return’ button
You can go back and see the Results again by pressing the ‘Re-show results’ button
NOTE: The process can be stopped at any time by pressing Viscometer Stop button towards the top right-hand corner of the screen.
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3.2
Results
3.2.1
Results Database
1. When a flow time is measured it is stored in a database. The database can be accessed by entering the Results Menu.
2. Press RESULTS > MEASUREMENT RESULTS. 3. See Figure above. 4. At the top of the Measurement Results you will find all possible database fields to view. 5. You can choose which columns you display by “ticking” the required fields. 6. You can change the order of the columns using the arrows, < and >. 7. You can change the width of the fields by changing the number associated with each field. This is the number of characters displayed. 8. Each test carried out is allocated a unique Test Number. The latest Test Number is normally at the top of the database. 9. This database only shows completed results – so if the test was not completed the then results will not be shown. For incomplete tests and interim flow times you should use All Measurement Results Database.
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3.2.2 How to Enter a Manually Measured Solvent Result This function is particularly useful if solvent results were measured manually or by other means other than RPV-1. 1. On the main Menu Go to Results, Results Calculator to open Calculator Tool.
2. Select Solvent (Sample Type). 3. Select Viscosities (Enter Data as). 4. Enter all other items as required, including the viscosity result measured in your manual tube. 5. Select Use Density if you are working in dynamic viscosity units, mPa.s. Otherwise, leave blank to work in kinematic viscosity units (mm2/s). 6. Select calculate. 7. Select Save to save the solvent result in measurement results. 8. This solvent result will be used by future measurements for RV calculations.
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3.2.3 How to create a Control Sample 1. On the main menu, Go to tools > lab setup > control sample maintenance > enter password. 2. Control Sample Maintenance screen is shown on the picture. 3. Fill in the fields like shown, using relevant values for the customer. The values on the picture are just for explanation purposes. 4. Make sure the customer relevant parameter is selected on the Control values. 5. Click Add/Update. 6. Click OK.
7. Next time you prepare a sample in the Prepare screen, you will be able to select Control as a Sample type on the Sample details section.
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8. Control option will also be available when you select Sample in each Viscometer window before you load the sample.
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3.2.4 Results Factoring 1. On the main Menu go to Tools > Lab Set Up > Maintain Default Information. 2. Default Information Maintenance screen will open (See picture). 3. Select Results Factoring. 4. Enter a calculation name and a formula name. 5. Select the Result to be factored (RV, IV or DP). 6. Enter a name for the factor e.g., this may correspond to a sample name. The formula is shown in the format y=mx +c. So, for a simple multiplier, enter the multiplier in the first factor box and zero in the second (y=mx), select add. If the formula is a linear relationship, then add a value for c in the second factor box on the right.
7. 8. 9. 10.
Calculations may be highlighted and deleted. Choose result types to be displayed to the right. When a formula is added or deleted , Press “OK” and then reboot the software. Factorisation will only be available if the Calculation name given is selected on the Lab details screen and press OK. Software will reboot automaticaly.
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11. The formula will be available to choose from the drop-down box on the Prepare screen.
12. The Calculation Name, Formula Name and Formula Value will now be available to select and view in Measurement Results
3.2.5 Results Extract In the Measurements results screen, select Extract All (or Extract defined) as shown to the right.
A Save As window will appear. Give the file a name of your choice and save as a .csv file in a location of your choice.
3.2.6 Print Results If a printer has been installed on the PC according to the manufacturer instructions and selected as default printer, then results may be printed using the print button as shown above.
3.2.7 Access Results Over a Network If a live copy of the RPV-1 folder has been set up at a network location (please refer to Installation Manual) then the copy software can be opened in the same way as described in this manual. Results can be viewed, extracted, and printed in the same way.
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3.3
Daily Maintenance
3.3.1 Solvent and Waste Management 1. Fill the solvent containers – you will receive a reminder to do this from time to time when the systems reach the Warning number of cleaning cycles completed. 2. Once the containers are full enter your name and press the appropriate Reset button.
3. Empty the waste container and reset the waste. DO NOT LET WASTE BOTTLES OVERFLOW. 4. Check the vacuum level make sure it is normal. 5. To review the history of daily maintenance, go to the Results menu and choose Solvent and Waste Management Log. This allows you to make sure that the daily maintenance is being carried out. Note: Please ensure solvents bottles do not run out of solvent. Also, be very careful not filling the solvent bottles with the correct solvents. If any of these happen, viscometers and valves can get blocked and the measurement cycles will be impaired.
3.3.2 Cleaning 1. The RPV-1 uses a carefully designed cleaning routine. The default cleaning times can be found on a per tube basis in Tube database (Tools > Tube database > Edit then press cleaning ). 2. By having the Automatically Clean box selected the viscometer will be cleaned automatically at the end of the test.
3. The viscometer can also be cleaned by pressing the clean button.
Note: The cleaning relies on vacuum. Any leakage in the vacuum system will prevent good cleaning. Bad cleaning will lead to bad results. Please check the vacuum level daily and maintain the vacuum pump regularly.
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4
How to Remove a Viscometer 1.1. Lift the Filling Station off the measuring head and place carefully on the top of the RPV-1 box – out of the way 1.2. Unscrew the 2 screws which hold the filling station base on the top of the measuring head. 1.3. Unscrew the fittings that are on top of the air and capillary arm. 1.3.1. If you have a 4mm Air/Vent tube connected to the viscometer – which is a push fit into the vent tube then disconnect this by carefully pulling it out 1.4. Remove the filling station base from the top of the measuring head. 1.5. Unplug the black cable which connects the measuring head to the RPV-1. 1.6. Remove the measuring head out of the bath and allow the oil to drain into the bath. 1.7. The viscometer is held in the measuring head with 2 springs, their positions are indicated by the horizontal black arrows 1.8. Hold the measuring head with one hand and the bottom of the viscometer with the other (where the white arrow is in the first picture) 1.9. Gently pull the bottom of the viscometer out of the measuring head - be careful to pull it straight, perpendicular to the measuring head 1.10. Only pull it so that the bottom is clear of the base plate of the measuring head and clear of the bottom spring. 1.11. Then start to pull the viscometer downwards as in diagram 2 – be careful not to catch the timing bulb as you pull downwards.
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5
Error Messages and Trouble Shooting
It is quite normal to occasionally get an error message such as VOID RUN or FALSE TRIGGER.
5.1
VOID RUN
There are two reasons why this error message appears
5.1.1 The draw up time is exceeded Long draw up times can also be caused by: • Wrong sample in wrong size tube (most common!!). • The viscometer is blocked. • The cap is not tight on the filling station. • The cap is on the wrong filling station. • The pump has broken. • The measuring head is broken. Adjust the pump to push up the liquid more quickly [or more slowly].
5.1.2 The released sample time out was exceeded Released Sample time out can be caused by: • Wrong sample in wrong size tube (most common!!) • The viscometer is blocked. • Bubbling of the sample during the draw up triggered the top sensor prematurely. Remedies: • Try running more sample in the viscometer at a slower speed so that the bubbling of the sample is reduced during draw up.
5.2
FALSE TRIGGER
This message appears when the meniscus drops below the top sensor before the RPV software is ready. This can be caused by: • Not enough sample pushed into overfill. • Bubbling of the sample during the draw up. • Wrong sample in wrong size tube • The capillary fitting is not secure • The capillary valve is not working Remedies: • Check fittings and valve on capillary side.
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5.3 OTHER PROBLEMS 5.3.1 “SOFTWARE ALWAYS STARTS UP WITH LAB DETAILS SCREEN” If this happens then the Tube.ini or Tube.dat files may be corrupted. This can happen if a character being entered is not valid. Typically, it could be the use of a decimal point “.” instead of a comma “,” etc. Try re-entering the data or restore a backup version.
5.3.2 SAMPLE IS PUSHED UP THE AIR ARM AT THE SAME TIME AS THE CAPILLARY ARM There is a leak in the air arm tube path; Check all fittings are leak tight. In particular, check filling station is connected properly and the air arm seal at the base of the filling station.
5.3.3 SAMPLE IS LEFT IN THE VISCOMETER AFTER CLEANING • • • • •
The cleaning solvents are low or empty. The vacuum pump diaphragm has broken and needs to be replaced. The waste container is full. There is a leak on one of the connecting tubes to the viscometer. The cap has not been replaced correctly on the filling station.
5.3.4 THE RESULTS ARE WRONG! • Have you confirmed the result with the wrong dry matter %? • Check the temperature of the viscometer bath. • Check the concentration calculations are correct. • Are you using the correct Blank (Solvent) flow time? • Are the settings in the Lab details screen correct? • Did you make a mistake in your calculations? • The viscometer tube details are wrong in the Tube Database. The wrong tube is selected from the Tube Database [press the Tube button and check the serial number against the tube in the viscometer bath]
5.4
CHECKS BEFORE CALLING PSL FOR ASSISTANCE (Email: technical-service@psl-rheotek.com) • • • • • • • • • • •
Is the RPV switched on? [switch at back – illuminated red and switch at power point] Has the RPV fuse blown? [check in the IEC socket at the rear of the RPV. It’s a 1A fuse for 230V and 2A for 110V] Is the PC switched on? Is the Vacuum pump switched on? [switch on pump and at power point] Are the solvent containers full of the correct solvents? Is the Waste container empty? Are all the solvent and waste container stoppers secure? Are the measuring heads connected to the RPV unit correctly? Are the software settings correct? Has someone used the instrument before you and changed something? Check the vacuum levels in each position.
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