Poulten Selfe & Lee Ltd
VCM Viscometer Control Module – for measurement and cleaning
User Manual Gen 3 Pre-release
Poulten Selfe & Lee Ltd
RPV-3_VCM_V0.9
Russell House, Burnham-on-Crouch, Essex, CM08TE. UK www.psl-rheotek.com
Viscometer Control module – USER MANUAL
Contents Safety ...................................................................................................................................................... 3 Lifting .................................................................................................................................................. 5 Voltage ................................................................................................................................................ 5 Solvents ............................................................................................................................................... 5 Replacement Parts .............................................................................................................................. 5 Introduction ............................................................................................................................................ 6 Description .......................................................................................................................................... 6 Viscometer Control Module - Single ................................................................................................... 7 Viscometer Control Module - dual...................................................................................................... 8 Unpacking ........................................................................................................................................... 9 Technical Specifications ........................................................................................................................ 10 Viscometer Control Module.............................................................................................................. 10 Periphery items ................................................................................................................................. 11 Solvents ............................................................................................................................................. 12 Installation ............................................................................................................................................ 13 Location of the Viscometer Control Module .................................................................................... 15 Rear Connections .............................................................................................................................. 16 Front of the module .......................................................................................................................... 17 Side of the module (LHS and RHS) – PTFE valves.............................................................................. 18 Waste Connections ....................................................................................................................... 19 Internal layout – PTFE – 2 solvents - Left hand side ......................................................................... 20 Internal layout – PTFE – 2 solvents – right hand side ....................................................................... 21 Communication connections ............................................................................................................ 22 Measuring Head Connections ........................................................................................................... 23 Connect the power cable .................................................................................................................. 24 VCM Operation ..................................................................................................................................... 25 Start up.............................................................................................................................................. 25 Check list on Start Up ........................................................................................................................ 26 Maintenance ......................................................................................................................................... 27 Breather Clean .................................................................................................................................. 28 Moving the Instrument ..................................................................................................................... 29 Shipping the Instrument ................................................................................................................... 30 Trouble Shooting................................................................................................................................... 31 Poor cleaning or drying ..................................................................................................................... 31 POULTEN SELFE & LEE LTD
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Viscometer Control module – USER MANUAL Replacement Spare Parts ...................................................................................................................... 33 Viscometer Control Module – valves, pumps and fittings ................................................................ 33 Electronics ......................................................................................................................................... 34 Recommended Accessories .................................................................................................................. 35 EVS-MH-100 Measuring Head........................................................................................................... 35 Shelf Assembly .................................................................................................................................. 36 EVS-TCB Temperature Controlled Bath ............................................................................................ 37
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Viscometer Control module – USER MANUAL
Safety The instrument is intended to be used in a laboratory by trained technical personnel. For safe and correct use, both operating and service personnel should follow the instructions contained in the USER MANUAL when installing, cleaning, and maintaining the instrument. The following safety precautions must be observed during all phases of operation, maintenance, service, and repair of the instrument. Failure to comply with these precautions, or with specific warnings elsewhere in the USER MANUAL violates safety standards of design, manufacture, and intended use of the instrument. Poulten Selfe & Lee Ltd assumes no liability for the customer’s failure to comply with these requirements,
Risk Assessment This manual provides guidance on the safe installation and operation of the Viscometer Control Module, however, the user should carry out their own full Risk Assessment.
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Viscometer Control module – USER MANUAL The following electronic and hazard symbols may appear on the instrument:
The following notices may appear in this manual:
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Viscometer Control module – USER MANUAL
Lifting Using the hand holds on either side of the instrument, it can be lifted by one person. Refer to the Technical Specification for the weight of the instrument. Always lift the instrument using the handholds provided. Ensure that the 4 thumbscrews securing the top cover are in place and are tight. The instrument should be unpacked carefully, removing any loose packing materials before lifting.
Voltage Access to the left- and right-hand side panels is necessary. The instrument must be detached from all voltage sources before maintenance, service, repair, or exchange of parts. For normal operation, the instrument is to be grounded through the AC line cable. Failure to do so can result in potential shock hazard resulting in serious personal injury. Use only fuses with the rated current and of the specified type as specified in this manual. And with the grounded AC line cable provided.
Solvents Observe safe laboratory practices when handling solvents. If working with hazardous solvents or flammable liquids, ensure that there is proper ventilation and that adequate protection such as safety glasses, gloves and protective clothing are used. If dangerous liquids are used, precautions should be taken to limit potential hazards from leaks and/or spillages or fumes through the use of a fume hood or other local extraction. If there is the potential of explosive gases being developed, a fume hood or other means should be used to safely manage that risk.
Replacement Parts Ensure to use only replacement parts as specified in this USER MANUAL. Do not repair the instrument or change parts not listed in this USER Manual. Contact Poulten Selfe & Lee Ltd, PSL Rheotek USA, or local agent for any part not listed.
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Viscometer Control module – USER MANUAL
Introduction Description
The RPV Viscometer Control Module has been designed to control the flow time measurement and cleaning of 1 or 2 automated viscometer positions.
Features - the Viscometer Control Module comprises of a stainless-steel outer case with an easily removal top lid Configurations – various configurations are available to support 1 or 2 measuring positions with 2 or 3 cleaning solvents or nitrogen purge. Power – the Viscometer Control Module uses a 24VDC, 150W, 6.25A power supply. Interfaces - the Viscometer Control Module is interfaced to the following: -
PC Control System Measuring Heads for meniscus detection Solvent containers Waste containers Vacuum source Optional sample delivery system
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Viscometer Control Module - Single A single Viscometer Control Module is designed to be configured with one or two measuring heads as follows:
PC Other periphery modules e.g. sample preparation
Configured with Windows & internal control cards RPV Software
Viscometer Control Module
MH 1
PIAB or Vacuum Pump
MH 2
Viscometer Bath
Solvent container Waste container MH 1
Measuring Head – to accommodate glass viscometer container
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Viscometer Control module – USER MANUAL
Viscometer Control Module - dual Dual Viscometer Control Modules are designed to be configured with four measuring heads as follows:
PC
Viscometer Control Module 2
Viscometer Control Module 1
Configured with Windows & internal control cards RPV Software
MH 1
MH 2
MH 3
MH 4
PIAB or Vacuum Pump
Viscometer Bath Solvent container Waste container MH 1
Measuring Head – to accommodate glass viscometer container
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Viscometer Control module – USER MANUAL
Unpacking The Viscometer Control Module will be supplied fully assembled. Keep the original packing in case the control module has to be returned. Standard equipment After unpacking the control module, you should have the following: Standard equipment: • •
Viscometer Control Module 24VDC power supply
Cables: Depending upon the instrument platform the following cables will be included: • Communication cable to PC • RS232 USB cable • Optional accessories: • •
Solvent containers and lines Waste containers and lines
The following documents are included: •
User Manual
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Technical Specifications Viscometer Control Module Changes or modifications made to the RPV (Gen 3) VCM Viscometer Control module not expressly
NOTICENOTICE agreed by Poulten Selfe & Lee Ltd may void the warranty
Viscometer Control Module – 1 or 2 positions with 2 solvent/3 solvent cleaning (or Nitrogen purge) Model Dimensions (W x D x H) Weight
VCM-1P-* 375 x 285 x 175mm
VCM-2P-* 375 x 285 x 175mm
20 kg
25 kg
100 to 240V 50/60Hz
100 to 240V 50/60Hz
24 V 6.25A 150W
24 V 6.25A 150W
1
2
2 or optionally 3
2 or optionally 3
Nitrogen purge
Option
Option
Valve material
PEEK or PTFE (T models)
PEEK or PTFE (T models)
Communication
RS232
RS232
Power Requirements for external bench top supply: Input: Voltage range Frequency range Output (to VCM): Voltage rating Current range Power Consumption (max) No. of measuring positions No. of Solvent connections
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Periphery items For information only, refer to specific manuals for full operating and safety instructions. Part PC Controller
Dimensions
375 x 285 x 175mm (W x D X H)
Weight
15 kg
Power*
100 to 240V, 50/60Hz, 650W, 5A
PC Monitor
Dimensions Weight Power*
500 x 200 x 300mm (W x D X H) 3kg 100 to 240V, 50/60Hz, 120W, 0.5A
Diaphragm vacuum pump
Dimensions
243 x 211 x 198mm (W x D X H) 9.6 x 8.3 x 7.7 in 23 kg 10.2 lbs 230V, 50Hz, 400W, 1.8A 110V, 60Hz, 400W, 3.4A
Weight Power*
PIAB Pump
Dimensions Weight Power Air in
195 x 66 x 120 mm (W x D X H) 1kg n/a 87 PSI (max)
* this can vary with model
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Viscometer Control module – USER MANUAL
Solvents In the case of solvents carefully read the SDS and carry out an appropriate risk assessment. Wear the appropriate PPE.
Solvents for use with Peek or PTFE valves Specified Solvent Peek ✓ Orthochlorophenol (OCP) ✓ Phenol TCE Dichloroacetic acid (DCA) ✓ Formic acid (90%) Sulphuric acid (96%) ✓ m-Cresol ✓ Cyclohexanone ✓ Cupriethylene Diamine Solution (CED) ✓ Decahydronaphalene (Decalin) ✓ Xylene ✓ Acetone ✓ Methanol
NOTICE
PTFE ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Changes to the specified solvents not expressly agreed by Poulten Selfe & Lee Ltd may void the warranty
Cleaning Solvent The cleaning solvent is typically the dissolving solvent. The VCM can be configured with 1 or 2 cleaning solvents. Drying solvent The drying solvent is typically acetone. Other solvents can be used e.g. methanol or Xylene (typically for higher temperature applications).
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Viscometer Control module – USER MANUAL
Installation
Installation should be carried out by a trained factory engineer, authorised agent or via seeking technical support via video link from the factory
NOTICE
The Viscometer Control Module is located on top of the bath module, or on an optional shelf
Filling station
PC communication from the lefthand side of the VCM
Measuring Head
Temperature Controlled bath
•
Ensure all packing material has been removed.
•
Locate the Viscometer Control Module on top of the bath or for multiple modules using the optional shelf (see below).
•
Ensure the location is free from vibration
Ensure sufficient ventilation space is provided at the rear of the bath as well as on the right-hand side. Inadequate ventilation will cause damage to the bath.
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Viscometer Control module – USER MANUAL
Installation steps: •
Locate the bath on a bench, ensure it is level and that there is sufficient space for ventilation behind and to the right-hand side of the bath
500mm
620mm
PC Monitor
VCM
PC
660mm
BATH
Keyboard
•
Locate the Viscometer Control Module (VCM) on the space provided on top of the bath module or on the optional shelf
•
For multiple Control modules use the optional shelf:
900mm width is required for 2 x VCM’s
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Location of the Viscometer Control Module From above
660 mm
900 mm width From Rear
Ensure that there is a minimum of 100mm clearance behind the Viscometer Control Module and Bath module
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Rear Connections
24V DC power jack Breathers
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Front of the module
Measuring Head DIN sockets LED for flow time measurement
Sensitivity adjustment for measuring heads
Pressure Control (for sample push up)
ON/OFF LED
Pneumatic tube connections to filling stations
FILL arm CAP arm AIR arm
Each position has 6 valves (for 2 solvent configurations) or 7 valves (for 3 solvent/N2 configurations). AIR and CAP valves are two-way valves and are NORMALLY CLOSED. This means that the valves are in the OFF position and there can be no flow, until the valves are energised. All other valves are three-way valves and consist of a COMMON port, NORMALLY OPEN (NO) port and a NORMALLY CLOSED (NC) port
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Viscometer Control module – USER MANUAL
Side of the module (LHS and RHS) – PTFE valves
Ports in lower section signify PTFE valves
Solvent 1
Solvent 2
Solvent 3 or Breather Breather Waste 1 and optionally 2
Attach Solvent 1..3 tubes to the ports on either side of the instrument as shown.
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Viscometer Control module – USER MANUAL
Waste Connections With internal vacuum pumps:
Connect the waste bottle as follows: -
Vacuum IN Waste OUT
With external PIAB or vacuum pump:
To mains power supply
PIAB
To compressed air supply (85psi max)
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Viscometer Control module – USER MANUAL
Internal layout – PTFE – 2 solvents - Left hand side Configuration – 2 solvents and external vacuum source
To FILL arm
To CAP arm
To AIR arm
Pump Adjuster Solvent Bottle
Normally Open (NO)
Waste Bottle VAC valve – connects vacuum or atmospheric pressure to the viscometer
Normally Closed (NC)
Common
NC – joined to VACUUM PUMP or PIAB via waste trap NO – to breather (see instructions on “Breather Clean” Comm – to T-piece which connects AIR and CAP 2-way valves
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Viscometer Control module – USER MANUAL
Internal layout – PTFE – 2 solvents – right hand side Configuration – 2 solvents and external vacuum source
VPH valve – Viscometer Pump – to turn on air from the pump to the filling arm NC
NO
Waste 2
Common
NC – connects to MINI PUMP pressure side NO – connects to breather Comm – connects to Solvent 2 or Solvent 3
Waste lines from both LH and RH positions can exit the same side for convenience.
Pump Adjuster
To CAP arm
To AIR arm
To FILL arm
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Viscometer Control module – USER MANUAL
Communication connections
For RPV-1 Gen. 3 systems, connect the 78-way cable to the rear of the VCM (to the PC)
Connect the RS232 communication cable to the port on the left-hand side (to the PC)
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Viscometer Control module – USER MANUAL
Measuring Head Connections
Connect the measuring heads to MH1 and MH2
Summary instructions for measuring head, filling station and vacuum connections
Insert the required glass viscometer tube into each measuring head and place in the viscometer bath, Attach a filling station to each measuring head – the filling station consists of three parts – a base, funnel and screw cap. Push the base on, so that it forms a seal with the glass viscometer tubes. Connect the AIR and CAP tubes to the base. The filling tube is connected to the cap. Attach the vacuum gauge to the waste container cap. If an external vacuum source is being used - attach the vacuum pump inlet to the waste container cap. Attach a tube to the vacuum source outlet. This tube should run to a fume cupboard. Solvent may condense in this tube, so we recommend the use of a trap to contain any liquid.
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Viscometer Control module – USER MANUAL
Connect the power cable The final installation step is to power up the module.
The power switch is located on the left-hand side panel.
The power ON/OFF button activates the 24V DC. Green light on front comes on
24VDC power in
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Viscometer Control module – USER MANUAL
VCM Operation Start up To start the Viscometer Control Module: 1. The module is connected to a power source 2. The module is connected to the PC 3. Turn on the ON/OFF switch located on the LHS of the module
On power up: •
The LED on light will be Green
Validation on Start Up The Viscometer Control Module can be validated via the RPV software using the Engineer Screen.
Switching valves on and off individually can produce dangerous results.
Each valve can be clicked on or off to check that it is working. Clicking a single valve on/off should not create a dangerous situation as long as ALL other valves/pumps are turned OFF.
When you energise a valve you should be able to hear it click. This will indicate that the valve is working and is not blocked. A full description of the valve and pump operations are set out in the RPV user/software manual.
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Viscometer Control module – USER MANUAL
Check list on Start Up
Wear PPE, including safety glass and gloves when connecting solvents to the control module
Step 1
Check Viscometer Control Module is connected to the PC using the communication cable
2
RS232 cable is also connected to the PC
3
24VDC power supply is plugged in at rear
4
Solvent 1 “cleaning” solvent is plugged in.
5 6
Solvent 2 “drying” solvent is plugged in (or optional second cleaning solvent) Solvent 3 is plugged in if applicable
7
Waste line is connected
8
Waste vessel is empty
9
Vacuum is connected
10
Vacuum gauges are reading a vacuum level below 0.8 bar
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Yes/No (tick)
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Viscometer Control module – USER MANUAL
Maintenance
To obtain optimum performance and maximum life from the Viscometer Control Module, the following maintenance should be observed: Daily
Check solvent and waste levels
6 monthly
Check all external tubing connections – replace as necessary Check the performance of the mini pumps – hold spares to replace as necessary
Annually
Check all tubing connections – internal Check vacuum pump performance – service diaphragm type external pump
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Viscometer Control module – USER MANUAL
Breather Clean To unblock the RPV if sample gets into the breather
The blocked breather tube is shown on the diagram above. If the breather becomes slightly or totally blocked with sample, it will affect the viscosity measurements. Find the external port labelled: VAC BREATHER – there is one for each measuring position. To unblock: Step 1 – carry out a user activated clean to ensure that the viscometer is empty. Step 2 – attach the vacuum supply (from the waste position). Step 3 – Using Engineer mode – select Breather Clean – or manually energise: AIR valve followed by the S1 valve for 2 seconds – watch to ensure solvent goes through the viscometer and out via the breather tube. Repeat several times. Step 4 - Repeat step 3 using S2.
Step 5 - allow air to be sucked through for 10 minutes to ensure the breather path is completely dry. Step 6 – visibly inspect the breather tube to make sure it is clear of sample or solvent – all liquid must be removed Step 7 – disconnect the vacuum from the breather and re-connect to the waste port Step 8 – carry out a final normal clean of the viscometer – using a user activated clean
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Viscometer Control module – USER MANUAL
Moving the Instrument
Before moving the Viscometer Control Module, follow these steps: Step 1: Carry out a user activated clean and dry of the system Step 2: Carefully remove the solvent lines from the solvent bottles and place in a clean beaker Step 3: Carry out a second clean and dry – this time not sucking any new solvent into the system – this is designed to purge the system Step 4: Turn off the vacuum (if external) Step 5: Turn off the Viscometer Control Module and remove the power lead Step 6: Dis-connect the waste lines Step 7: Disconnect the solvent lines Step 8: Disconnect any other communication cables Step 9: Ensure that the thumbscrews holding the top lid on are secure and tight Step 10: Lift the module using the two hand holds on either side
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Viscometer Control module – USER MANUAL
Shipping the Instrument
Before shipping the Viscometer Control Module, follow these steps: Step 1: Carry out a user activated clean and dry of the system Step 2: Carefully remove the solvent lines from the solvent bottles and place in a clean beaker Step 3: Carry out a second clean and dry – this time not sucking any new solvent into the system – this is designed to purge the system Step 4: Turn off the vacuum (if external) Step 5: Turn off the Viscometer Control Module and remove the power lead Step 6: Dis-connect the waste lines Step 7: Disconnect the solvent lines Step 8: Disconnect any other communication cables Step 9: Ensure that the thumbscrews holding the top lid on are secure and tight Step 10: Lift the module using the two hand holds on either side Step 11: Use the original packaging or a strong shipping crate Step 12: Ensure plenty of foam or packaging material is in the bottom of the case Step 13: Place the instrument carefully into the packing case Step 14: Pack with plenty of foam on the sides and top
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Trouble Shooting Poor cleaning or drying 1. First of all, after cleaning (or during) does solvent 1 and/or solvent 2 fall back in its tubing towards the bottle? 2. If no OK go to3, if yes, then there is a leak at either: a. Where tubing goes into the Viscometer Control Module b. At connections SOL1 or SOL2.
3. Check for a vacuum leak. a. If vacuum is at zero and you turn the pump on, do both gauges increase in vacuum at the same rate? (also see 5.) b. When the vacuum reaches its maximum value, do both gauges give the same reading? c. If no to a) and/or b), then you have a leak. The system is idle (no valves activated), so the leak is somewhere between: i. The back of the V1 valve and the connection to the vacuum pump manifold. ii. (It could be a simple thing, like the waste bottle lid is not tight enough)! iii. However, you may need to check tightness of fittings and tubing flanges: 1. On the vacuum valve port 2. All three fittings on bottle lid (to RPV, to vacuum pump, to gauge) 3. Fitting on vacuum pump manifold.
4. If the gauges increased at the same rate and to same maximum (at least -0.6) then: a. The leak is on other side of vacuum valve, so i. Open vacuum valve – does vacuum on gauge decrease? ii. If no, OK (go to x.) iii. If yes, then leak may be at fitting to front of vacuum valve iv. Or on one or more of the three fittings to the round T piece. v. Or at back of C or A valve. vi. Troubleshoot by disconnecting V valve at round T piece. vii. Put your finger over the fitting - does vacuum go back to maximum?
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Viscometer Control module – USER MANUAL viii. If yes, reconnect, disconnect C valve at T piece and put your finger over fitting. ix. Carry on until point of leak is found. x. (We know that the sample can measure, so in this case a leak at the filling station or where the filling station connects to the Viscometer Control Module is not likely. Otherwise the sample would not measure, a leak on the C path would mean sample does not “hold”, a leak on the A path would mean sample would go up the air arm of the viscometer tube when drawing). xi. A leak at the filling station barrel, (where it fits into the viscometer filling arm) is possible. xii. Open vacuum valve and air valve. Do the same on viscometer 2 and compare gauge readings. xiii. If viscometer 1 reading is low, try a new barrel. xiv. If this still does not solve the problem…. xv. A leak or constriction at the AS1 valve may be the problem. When solvent is being drawn, do you see bubbles entering at the AS valve? xvi. Follow AS1 valve to H1S1 valve. Is there a leak here, do bubbles enter when cleaning? xvii. It is possible for H1S1 to become constricted and need changing. xviii. Maybe the problem is H1S2 valve (so not enough acetone?) xix. If the problem is drying; you will see the drying path goes through AS1, H1S1, H1S2, VPH1 to breather. xx. If you open Viscometer1 and Viscometer2 V and A valves, and Viscometer1 gauge drops away less then this would show a constriction on the path described above.
5. It is possible that Viscometer1 gauge is seen to increase quicker (and fall away slower when pump is turned off) than Viscometer2 gauge. a. This would indicate a constriction. b. Check all tubing (and change if required) from the vacuum valve to bottle, bottle to vacuum manifold. c. Check manifold for debris. d. Check down pipe in waste bottle, and other holes in underside of bottle.
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Replacement Spare Parts Viscometer Control Module – valves, pumps and fittings Part Ref RP164
Description 24VDC power supply
RA-1S-016
Internal vacuum pump
RPV289-REP
Mini pump (sample push up)
JV262
2 port Peek valve
JV263
3 port Peek valve
RPV001
Needle valve
RPV3-082
3.2mm UNF polypropylene nut, 20mm long
RPV081
3.1mm M8 polypropylene nut
RP00288
Push in connector, 3mm cross
RPV3-025
M4 thumbscrew
PTFE valves Part Ref RPV003-ASS
Description 3 port PTFE valve (small)
RPV004-ASS
2 port PTFE valve (small)
RPV032-ASS
2 port PTFE (large)
RPV033-ASS
3 port PTFE (large)
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Electronics Part Ref REP02000/ASS/*
Main bath RPV signal processing board – front control board
REP02200/ASS/*
RPV pneumatic control board
REP01600/ASS/*
RPV Main control board
REP01700/ASS/*
RPV timer pneumatic interface board
REP01710/ASS/*
RPV timer break out board
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Viscometer Control module – USER MANUAL
Recommended Accessories EVS-MH-100 Measuring Head
EVS-MH-100 Measuring head for standard applications – accommodates AKV Ubbelohde glass viscometer (not included)
EVS-MH-100/AC
Measuring head with PTFE top cover and PFA coated top plate - for corrosive applications – accommodates AKV Ubbelohde glass viscometer (not included)
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Viscometer Control module – USER MANUAL
Shelf Assembly
Shelf Assembly – to accommodate 2 x Viscometer Control Modules. Part Ref RPV3060
Description Shelf assembly for EVS-TCB type viscometer bath
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EVS-TCB Temperature Controlled Bath RPV-1, RPV-2, and RPV-3 viscometer systems – for dilute solution viscosity – PA, PET, rPET, PVC and other polymers
The EVS-TCB bath is one of the modules used in the configuration of the Gen. 3 RPV Polymer Viscometer System.
The EVS-TCB bath provides excellent temperature stability at set-point at set-points between 20 to 30°C commonly used for dilute solution viscosity. The bath is designed to accommodate a Viscometer Control Module on top – immediately behind the viscometer positions.
Part Ref EVS-TCB-3-C EVS-TCB-5-C EVS-TCB-3-RA
Description Suitable for use with RPV-1 and RPV-3 systems with 1 or 2 measuring positions Suitable for use with RPV-1 and RPV-3 systems with up to 4/5 measuring positions Suitable for use with RPV-2 system with 1 or 2 measuring positions
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