MALCOM Hand-Held Digital Viscometer Model PM-2 Series

Transcription

1 0 MALCOM Hand-Held Digital Viscometer Model PM-2 Series ISTRUCTIO MAUAL MALCOMTECH ITERATIOAL IDUSTRIAL BLVD. HAWARD, CA USA TEL. (510) FAX. (510) WEB.

2 FORWARD 1 Thank you for purchasing this Malcom PM-2 series viscometer. This lightweight hand-held unit will enable you to make quick, on-the-spot measurements with relative ease. Like all Malcom viscometers, the PM-2 series employs the patented spiral pump sensor for accurate and repeatable measurements. Please read this instruction manual carefully in order to take full advantage of this unit. OTE: Please read and understand the following conditions 1. Specifications and features are subject to change without notice. 2. Please retain the carrying case and shipping box used for when this unit will be transported. Since this unit is a precision instrument, it can be damaged if it is transported in an inadequate container. In such circumstances, repairs will be charged even if the nature of the damage is covered by the warranty. 3. ever disassemble the unit. If the unit is disassembled or if it appears to have been disassembled before, you will not be entitled to warranty repairs. All such repairs will be charged for. 4. Do not attempt to lubricate the unit in any way. Only special oils can be used in the construction of the viscometer. Use of other lubricants may damage the viscometer or hinder it's operation. Repairs necessary to rectify these situations are not covered by the warranty. 5. Should you find that the operation of the PM-2 has become substandard, or that there is a problem with it's use, please contact Malcom Instruments immediately. Do not attempt to repair the unit yourself, for doing so would void it's warranty.

3 TABLE OF COTETS 2 Packing List... 4 I. OVERVIEW A. Introduction... 5 B. Features... 5 C. Specifications... 5 D. omenclature... 6 E. Functions... 7 II. USAGE A. Preparation... 8 B. Operation... 8 C. Change of Speed, Temporary... 9 D. Change of Speed, Default... 9 E. Guidelines F. Removing and Installing the Inner Spiral and Outer Cylinder G. Cleaning III. MAITEACE AD REPAIR A. Storage B. Calibration Zero Adjustment with Gain Adjustment Gain Adjustment C. Felt Replacement D. Battery Replacement E. Repair and Warranty F. Spare Parts and Options IV. APPEDIX A. Flow charts Operation Flow chart Change of Speed, Default Flow chart Zero Adjustment with Gain Adjustment Flow chart Gain Adjustment Flow chart B. Speed vs. Viscosity Measurement Windows C. Silicone Calibration Fluid D. Temperature Compensation E. Troubleshooting F. Checking Sensor G. Dimensions... 29

4 PACKIG LIST 3 Upon opening your PM-2 series viscometer, you will find the following items. Some items may be tucked behind the foam of the case lid. Should any of them be missing, please contact your Malcom dealer as soon as possible. 1. PM-2 Main Unit Inner Spiral Outer Cylinder Rest Stand Plastic Spatula Cleaning Brush Felt Packing AC Adapter Hard Case PM-2 Manual Warranty Malcom Instruments Industrial Blvd. Hayward, CA Phone: (510) Fax: (510) malcomint@aol.com

5 I. OVERVIEW 4 A. Introduction The concept of viscosity as a process variable in the use of pastes and inks has become a significant quality control criterion. Traditionally, measurements of simple, viscous liquids could be done with a T-bar spindle type viscometer. However unlike ewtonian or ideal liquids, the viscosity of on- ewtonian liquids change when subjected to changing or prolonged shearing. Pseudoplasticthixotropic liquids, such as pastes and inks, have a viscosity drop when they are subjected to increasing shear rate or extended shear time. Often, this drop is irreversible. Bearing this in mind, the comparison and standardization of viscosity as a control variable cannot be done if the viscometer employed does not resolve these characteristics. Because of the spiral pump design of the Malcom PM-2 series of hand held viscometers, the shear time is a function of the shear rate and both are a constant for a given rotational speed. By recording the viscosity of a pseudoplastic-thixotropic fluid at several speeds for known durations, it is possible to calculate the rheological characteristics of that fluid. B. Features Compact cordless hand-held design makes in-the-field measurements convenient. Continuous measurement of ewtonian and on-ewtonian fluids with constant shear rate and shear time. High contrast LCD digital display makes measured viscosity values easy to read. Three models for three ranges of viscosity measurement are available. Re-calibration is user possible. Temperature measurement of sample with optional probe. C. Specifications Item Specification Model umber PM-2A PM-2B PM-2C Measurement Range Pa s Pa s mpa s Speeds Available Shear Rate Example for 10 RPM 0.6 x RPM sec ¹ 6 sec ¹ 10, 20, 30, 40, 50, 60 RPM 1.2 x RPM sec ¹ 12 sec ¹ 4.8 x RPM sec ¹ 48 sec ¹ Measurement Accuracy ± 10% of indicated value ± 5% of indicated value Speed Accuracy ± 5% at 10 RPM ± 5% at 10 RPM Repeatability ± 3% Power Supply Internal icd battery pack or 115 VAC Adapter Weight 640g 740g All specifications are subject to change without notice

6 D. OMECLATURE DIAGRAM 1 5

7 E. FUCTIOS 6 1. Digital Display The viscosity, speed, and temperature values are displayed on this LCD display. 2. POWER Button Push this button to turn the PM-2 on. Press it again to turn off the PM HOLD Button When you wish to change the rotational speed, press this button. For every press, the speed will increase by 10 RPM, in the following manner: DO OT PRESS THIS BUTTO WHILE POWERIG O THE PM-2! 4. SET Button If you have the optional temperature probe, press this button to display the temperature. ou may need to hold this button for 10 seconds to get a stable reading. DO OT PRESS THIS BUTTO WHILE POWERIG O THE PM-2! 5. Grip Use this to properly hold the PM Inner Spiral This is the heart of the PM-2, it enables the viscometer to make continuous measurement of the fluid without thixotropically affecting the fluid. 7. Outer Cylinder The outer cylinder causes the fluid being measured to be brought in and sheared against the inner spiral. The result is a torque on the inner spiral and the pumping action of the sensor. 8. Outlet When the PM-2 is measuring a fluid properly, the fluid will continuously exit from the outlet. 9. AC Adapter Receptacle To recharge the icd batteries in the PM-2, use the AC adapter. Should you require the PM-2 to be operated over many continuous hours, then use the AC adapter as a power supply. 10. Battery Box The icd battery pack is stored inside of here. See section III D. Battery Replacement.

8 II. USAGE 7 A. Preparation 1. Turn on the unit by pushing the POWER button. If the word "BATT" appears on the digital display, then turn off the PM-2 and recharge the batteries for at least 3 hours. 2. Make sure the inner spiral and outer cylinder are clean and the sample is at the proper temperature. 3. Carefully install the inner spiral and the outer cylinder. See section II F. Removing and Installing the Inner Spiral and Outer Cylinder. DO OT TORQUE EITHER OF THEM DURIG ISTALLATIO! B. Operation 1. Grip the PM-2 in a secure manner. Carefully insert the tip of the outer cylinder into the sample fluid. The depth of insertion should be no greater than the lower lip of the outlet. For the PM-2A, this is approximately 10 mm, for the PM-2B, 15 mm and for the PM-2C about 25 mm. (see Diagram 4) PM-2A PM-2B PM-2C 2. Turn on the POWER button and the speed will be displayed for 3 seconds. 3. ow measurement begins. If the word "OVER" is seen on the digital display, then the torque on the outer cylinder is too great for the motor. If this happens, you need to reduce the rotational speed. See section II C. Change of Speed, Temporary. 4. Obtaining a stable accurate reading of viscosity will require several minutes. However with the PM-2A, 90% of the final value can be read seconds after the fluid has passed out of the outlet. The PM-2B and the PM-2C will require about seconds to obtain a reading 90% of the final value. 5. If you have the temperature option, press the SET button to display the temperature of the fluid. 6. After use, press the POWER button a second time to turn the power off. 7. Clean up the viscometer (see section II G. Cleaning ).

9 C. Change of Speed, Temporary 8 If you wish to change the speed temporarily, do the following: 1. While the viscometer is running, press the HOLD button. 2. ou will hear a beep and the current speed is displayed. 3. Press the HOLD button again and the speed will increase by 10 RPM. For each consecutive press of the HOLD button, the speed will increase an additional 10 RPMs, until it reaches 60 RPM, where it rolls over to 10 RPM. 4. After 3 seconds of inactivity, the display will return to viscosity measurement. 5. If you wish to change the speed again, wait 3 seconds and repeat from step 1. IMPORTAT: The speed is reset when the power is shut off. If you wish to change the default or startup speed, refer to the following section. D. Change of Speed, Default If you wish to startup the PM-2 at a speed different than the normal default speed, do the following: 1. Press the POWER button on, the LCD will display the speed for three seconds and then begin viscosity measurement. 2. While the speed is displayed, press the HOLD button. ou will hear a beep and the speed will increase by 10 RPM. 3. For each consecutive press of the HOLD button, the speed will increase an additional 10 RPMs, until it reaches 60 RPM where it rolls over to 10 RPM. 4. After 3 seconds of inactivity, the display will continue to viscosity measurement. For an instant, "BATT" will flash. 5. If you wish to change the speed again, turn the power off and repeat from step 1. IMPORTAT: When the power is turned off, the new speed will be entered into memory and it will become the default speed. For a temporary speed change, refer to the previous section.

10 E. Guidelines 9 For correct, repeatable measurements, refer to these guidelines. 1. When a highly viscous suspension or paste is brought from storage and readied for measurement, it is necessary to thoroughly mix the sample, to bring it to an even consistency. However, care must be given that no air entrapment happens. These bubbles or voids can cause inaccurate measurement. Should it become evident that there is a void at the inlet of the sensor, gently oscillate the PM-2 in a slight clockwise motion. An alternative is to gently oscillate the sample in a slight counter-clockwise motion. Additionally, the plastic spatula can be used to push sample into the void. 2. Water and low viscosity oils are ewtonian, all other liquids are on-ewtonian. Of the non- ewtonian fluids, solder paste is pseudoplastic and thixotropic. This means that with increasing shear, the viscosity will lower, and with continued constant shearing, the viscosity will also decrease. Fluids such as solder paste will recover their lost viscosity, but only after a long duration without shear. With this in mind, it is suggested that if a rheological analysis of solder paste or any other thixotropic or pseudoplastic fluid is going to be conducted, the sample should be subjected to an increasing sequence of shear rates. If the trend were to be reversed, the sample might not fully restore before the next shear rate change, and hence would exhibit undesirable behavior. 3. It is important that the outer cylinder be inserted into the sample fluid to the proper depth. This is achieved when the liquid surface is at the lower lip of the outlet. If the sensor is inserted too far, an excessive load will be put upon both the inner spiral and the outer cylinder. If not deep enough, then the fluid will not be properly circulated through the sensor. This is evident with the PM-2B and PM-2C. Also, observe that the axis of the outer cylinder does not deviate more than 10ø from the vertical and that the outer cylinder does not make contact with anything other than the sample (see Diagram 4). 4. Viscosity is greatly influenced by temperature. Quite often, what is thought of as instability of viscosity is actually instability of temperature. With this in mind, the measurement environment should have a constant stable temperature and at the very least, the sample's temperature should be controlled. F. Removing and Installing the Inner Spiral and Outer Cylinder Great care must be taken when removing and installing the inner spiral, so that the sensor shaft is not over torqued. Doing so would cause the viscometer to lose accuracy and therefore require calibration. For these instructions, the sensor shaft is pointing towards you.

11 10 PM-2A 1. Hold the upper knurled end of the spindle. 2. Loosen the outer cylinder by turning it counter-clockwise and sliding it down over the inner spiral (see Diagram 5). 3. HOLD, BUT DO OT TORQUE the lowered knurled collar of the sensor shaft. 4. Grasp the knurling of the inner spiral and gently turn it CLOCKWISE. See Diagram Slide the inner spiral down off the sensor shaft. PM-2B, PM-2C 1. Hold the upper knurled end of the spindle. 2. Loosen the outer cylinder by turning it counter-clockwise (see Diagram 7). 3. Slide the outer cylinder down until it rests on the inner spiral. 4. HOLD, BUT DO OT TORQUE the knurled collar of the sensor shaft. 5. Grasp the knurling of the inner spiral and gently turn it CLOCKWISE. See Diagram Carefully slide both the inner spiral and the outer cylinder off of the sensor shaft together. Installation is the reverse of removal. Remember that the sensor shaft and inner spiral have lefthanded threads and EVER TORQUE THE SESOR SHAFT OR IER SPIRAL I A COUTER-CLOCKWISE DIRECTIO! G. Cleaning Clean the inner spiral, outer cylinder and sensor shaft immediately after every use. Failure to do so may cause the respective components to adhere together and become inseparable. Damage such as this is not covered by, and will void, the warranty. Directions are referenced with the sensor pointing towards you. 1. Use the plastic spatula to remove the majority of the sample off of the outside of the outer cylinder. 2. Remove the outer cylinder by turning it counter clockwise. Take care not to get sample into the gap between the sensor shaft and the spindle. Use the spatula to clean out the inside of the outer cylinder.

12 11

13 3. Use the spatula again to clean the flutes of the inner spiral. Turn the inner spiral clockwise to remove it from the sensor shaft. DO OT TUR IT COUTER-CLOCKWISE! Remove more of the sample by wiping the inner spiral and outer cylinder with a soft tissue, such as toilet paper. 5. Place the inner spiral and outer cylinder into a container with a mild solvent (see Diagram 9). Water, detergent, isopropyl alcohol or white gas are recommended thinners. Harsher solvents can dissolve epoxies used in the construction of viscometer components, rendering them inoperable. Use of these solvents, such as acetone, toluene or flux remover, will void the warranty. 6. Gloves and a toothbrush are suggested to facilitate cleaning. However, to simplify the cleaning process, an ultrasonic cleaner (Model AUC-201) is recommended (see Diagram 10). For convenience, these are available from your Malcom dealer. 7. Be sure to clean the inside of the inner spiral and the threading of the outer cylinder with the supplied brush. Wipe off the sensor shaft, the sensor shaft gap, and if equipped, the temperature probe, with a tissue moistened in solvent. AUC-201 Diagram 9 Diagram 10

14 13 III. MAITEACE AD REPAIR To maintain reliable and accurate operation of the PM-2, proper care, handling and storage are necessary. Additionally, periodic calibrations and inspections are needed to guarantee continued accuracy of measurement. While user calibration is sufficient for normal use, with time, the PM-2 will become out-of-specification and require servicing. In this case, contact your Malcom dealer or Malcom directly for assistance. Past experience has indicated that factory calibration is required on an annual basis and the icd batteries should be replaced every two years. A. Storage Before storing the PM-2 for extended periods: fully charge the icd batteries, make sure the POWER button is off, and secure the PM-2 and it accessories into the supplied hard case. The storage environment should be clean, cool, dry and dark. B. Calibration DO OT ATTEMPT A "DR RU" OF THE CALIBRATIO PROCEDURE! Doing so will require an actual calibration to be performed. Should you find that the calibration procedure is not giving satisfactory results, or that you do not wish to do the calibration yourself, please contact your dealer or Malcom. For proper calibration of the PM-2, you will need: 1. A temperature controlled water bath. 2. An accurate thermometer. 3. Malcom calibration fluid for the specific model of your PM A temperature compensation chart. 5. A calculator. 6. A stand to support: the calibration fluid in the water bath, the thermometer in the calibration fluid, and the PM-2 in the calibration fluid.

15 Viscometer Models and Recommended Calibration Fluids: 14 Model Silicon Oil Type PM-2A KF96H 100,000 PM-2B KF96H 10,000 PM-2C KF96H 1,000 Before calibration, the inner spiral and outer cylinder must be clean and installed on the PM-2. The calibration fluid should be supported in the water bath and at a stable temperature of 25.0øC. It may take several hours to achieve this. If this temperature is unobtainable, then use the temperature compensation chart and calculator to find the expected viscosity at the stable temperature. Turn on the power and see if the in-air viscosity value is actually 0. If it does not deviate from 0, then only a gain adjustment is necessary, otherwise adjust both zero and gain. Zero Adjustment with Gain Adjustment Zero adjustment is conducted with the sensor OT immersed in calibration fluid. 1. Turn on the power and verify the speed. It should be 10 RPM for the PM-2A and 40 RPM for the PM-2B and PM-2C. If it isn't, follow the instructions in "D Change of Speed, Default" to set it to the proper speed. 2. Turn the power off. 3. Press the HOLD button while turning the PM-2 on. Continue to hold the HOLD button for 10 seconds. This is the only instance that the HOLD button should be pressed while during power up. 4. The internal software version number will be displayed for 2 seconds. 5. The LCD should now show a value very close to 000. It may even be negative. Press the HOLD button to increase the displayed value, or the SET button to decrease the displayed value.

16 Gain Adjustment Gain adjustment may be made while the PM-2 is in the calibration liquid Turn on the power and verify the speed. It should be 10 RPM for the PM-2A and 40 RPM for the PM-2B and PM-2C. If it isn't, follow the instructions in "D Change of Speed, Default" to set it to the proper speed. 2. Turn the power off. 3. Press the SET button while turning the PM-2 on. Continue to hold the SET button for 10 seconds. This is the only instance that the SET button should be pressed while during power up. If you pressed the HOLD button instead of the SET button, then you will have to remove the PM- 2 from the calibration fluid, clean it, and start again from step 1 of the Zero Adjustment with Gain Adjustment. 4. ow a display of 00.0 will be seen on the LCD, with the left zero flashing. Use the HOLD button to increment this digit to the left most digit of the expected viscosity. Example: The expected viscosity is 95.3 Pa s, push the HOLD button repeatedly to obtain a Press the SET button to enter the nine, now the center zero will flash. Press and HOLD five times to increment to Press the SET button to enter the five and continue in this fashion for the When you press SET the third time, the entire display, 95.3, will flash. 8. Place the PM-2 into the calibration fluid at the correct depth, so that the liquid surface is at the lower lip of the outlet. (see Diagram 4) 9. Press the HOLD button. The outer cylinder will start to rotate and the LCD will alternately display the measured viscosity and the expected viscosity. 10. Allow the measured viscosity to rise and stabilize. This may take an hour or so. When the measured viscosity is stable regardless of it's value, press both the HOLD and SET buttons simultaneously. The viscosity will be measured again.

17 Most likely, the new measured viscosity will not be the same as the expected viscosity. If the difference between the two values is greater than 20 counts, then turn off the power. Leave the PM-2 in the calibration fluid. Turn the power back on while holding the SET button down. Continue to hold for 10 seconds. ow repeat from step 4. If you pressed the HOLD button instead of the SET button, then you will have to remove the PM-2 from the calibration fluid, clean it, and start again from step 1 of Zero Adjustment with Gain Adjustment. 12. If the difference is less than 20 counts, use the HOLD button to increase and the SET button to decrease the measured viscosity value to be the same as the expected viscosity. When the two values are the same, press the POWER button off. This will enter the calibrated value and ends calibration. To Summarize Power on with SET button. Continue to hold for 10 seconds.. HOLD to increment digit, SET to select digit of viscosity. PM-2 in calibration fluid. HOLD to start measurement. Wait for stability. HOLD and SET together to set viscosity. HOLD to increment, SET to decrement to expected viscosity. Power off, viscosity saved in memory, calibration finished.

18 17 C. Felt Packing Replacement Past experience has shown that if the sensor was improperly handled, sample could collect into the gap at the knurled collar and the spindle. Doing so, the bearing at the gap would be damaged. To protect the bearing, a felt packing assembly has been utilized. For this procedure, the tip of the sensor is pointing towards you. Diagram Grasp the upper knurled end of the spindle. Turn the outer cylinder COUTER CLOCKWISE and remove it. 2. Hold the knurled collar of the sensor shaft and remove the inner spiral by turning it CLOCKWISE. Slide it over and off the sensor shaft. Diagram Gently turn the sensor shaft in a CLOCKWISE direction. The shaft will unscrew, then slowly remove it. (see Diagram 11) 4. Grasp the upper knurled end of the spindle and gently turn the lower knurled end COUTER- CLOCKWISE. Remove the fitting. (see Diagram 12) Diagram Use a pair of tweezers to remove the soiled felt packing inside the spindle. (see Diagram 13) 6. Check the condition of the plastic spacer. If it is soiled, carefully remove it. 7. Thoroughly wipe out the inside of the spindle with a cotton swab. Clean the plastic spacer too.

19 18 8. The replacement felt packing may be a little tight for the sensor shaft. If so, it should be stretched so that it can easily slide over the sensor shaft. Slightly stretch the felt packing by sliding it over the sensor shaft and oscillate the shaft inside the packing. (see Diagram 14) Be careful not to tear the felt. 8. To ease the replacement of the packing, slide the fitting over the shaft first, then the felt packing, and then the plastic spacer, (if it was removed). Insert the sensor shaft into the spindle. (see Diagram 15) 9. Grasp the upper knurling on the spindle and screw the fitting back into the spindle in a clockwise fashion. Tighten to a snug fit, DO OT TORQUE THE FITTIG! 10. Gently turn the sensor shaft counter-clockwise so that it screws into the spindle. DO OT TORQUE THE SESOR SHAFT!

20 19 D. Battery Replacement Battery pack replacement is typically needed every two years. Contact your dealer or Malcom for replacement parts. 1. Unscrew the two screws from the battery compartment cover and remove it. (see Diagram 3) 2. Disconnect the connector. Do not pull the connectors by the wires, they may break free. 3. Exchange the battery packs. 4. Re-connect the connectors, and replace the battery compartment cover. E. Repair and Warranty This Malcom PM-2 was manufactured using the finest quality components and assemblies. It was constructed with the greatest care, adjusted and calibrated with precision instrumentation. Should you find that the operation of the PM-2 has become sub-standard, or that there is a problem with its use, do not attempt to repair the unit yourself. Doing so would void its warranty. For repairs both in and out of warranty, return the unit to Malcom. Malcom warrants this equipment against defects in parts for six months and workmanship for three months from the date of purchase. Malcom will, at it's own discretion, repair or replace any defective parts which it, upon inspection, shall determine to be defective in materials and/or workmanship. This is provided that the unit is returned in safe proper packing, shipping prepaid, to the dealer or Malcom. The following will invalidate the warranty: disassembly, improper installation, abuse, misuse or mis-application, use beyond specifications, improper storage, damage caused from accidents, damage caused by improper packing. Malcom shall not be held responsible for damage caused from: natural and man-made disasters, pollution, improper operating environment, abnormal or incorrect voltages.

21 F. Spare Parts and Options 20 Spare Parts: Item Inner Spiral Outer Cylinder Type A Type B Type C Type A Type B Type C ote RIM-2A RIM-2B RIM-2C ROM-2A ROM-2B ROM-2C Sensor Shaft Packing Fitting Felt Packing Stainless Steel Stainless Steel Options: Item Support Stand Temperature Sensor Ultrasonic Cleaner Silicon Calibration Fluid: Type A, B Silicon Calibration Fluid: Type C ote Adjustable Height Platinum Resistor AUC-201 KF96H 100cc KF96H 300cc ote: the temperature sensor must be ordered at the same time as the PM-2

22 A. Flow Charts Operation Flow Chart 21 POWER Button On Speed Displayed Viscosity Measurement Was SET Button Pressed? Temperature Displayed (Option) Was HOLD Button Pressed? Sensor Stops Rotation Current Speed Displayed Was HOLD Button Pressed? Was Speed 60 RPM? Speed ow 10 RPM Speed Increases 10 RPM ew Speed Displayed Flow Chart: Change of Speed, Default POWER Button On Speed Displayed Was HOLD Button Pressed? Was Speed 60 RPM? Speed ow 10 RPM Speed Increases 10 RPM ew Speed Displayed Viscosity Measurement

23 Flow Chart: Zero Adjustment with Gain Adjustment 22 POWER Button On with HOLD Button Pressed Hold for 10 seconds Version Displayed Zero Display Was HOLD Button Pressed? Increase Zero Value Was SET Button Pressed? Decrease Zero Value HOLD and SET Buttons Pressed at same time? Zero Value Entered Proceed to Gain Adjustment * * * Flow Chart: Gain Adjustment POWER Button On with HOLD Button Pressed Hold for 10 seconds Version Displayed * * * Was Left Digit Set? Was Middle Digit Set? Was Right Digit Set? Setting Right Digit Setting Middle Digit Setting Left Digit Digit Digit to be Set is Flashing Was HOLD Button Pressed? Was SET Button Pressed? Continue Setting Increase Set Digit

24 Value ow Set 23 Set Value Flashing Sensor in Calibration Fluid Press HOLD Button Measured Viscosity Displayed Set Viscosity Displayed Is Measured Viscosity Stable? HOLD and SET Buttons pressed at same time Calibration Blue Entered Viscosity Value Displayed Was HOLD Button Pressed? Was SET Button Pressed? Inc rease Visc osity Value Decrease Viscosity Value Was POWER Button Pressed Off? PM-2 Calibrated Procedure Finished B. Speed vs. Viscosity Measurement Windows For these diagrams, the fluid is newtonian, The PM-2 is powered by the AC adapter and the shaded areas represent an accuracy of 15%. (see Diagrams 17, 18, & 19) PM -2A PM -2B PM -2C When using a PM-2A, measuring fluids with viscosities less than 100 Pa s at 10 RPM is not recommended. When using a PM-2B, measuring fluids with viscosities less than 5 Pa s at 20 RPM or less is not recommended. When using a PM-2C, measuring fluids with viscosities less than 200 mpa s at 40 RPM or less is not recommended.

25 24 C. Calibration Fluid Malcom Calibration Fluid is a silicone-based oil which is viscosity stable, chemically inert and relatively non-toxic. The fluid has an indefinite shelf life and service life is diminished only by chemical, particulate and moisture contamination. With this in mind, the fluid should be stored in a clean, cool, dry environment, with its lid securely tightened. Using gasoline, kerosene or mineral spirits can do rapid cleaning of parts, which have come in contact with the fluid. An alternate method is repeated cleanings with isopropyl alcohol and/or detergents. On the label of the calibration fluid are several values of importance. The viscosity is expressed in poise, (P), or Pascal seconds (Pa s), at 25.0 C when undergoing a shear rate of D reciprocal seconds, (sec ¹). By Malcolm s patented design, D is constant, but it is dependent upon the type of inner spiral and outer cylinder attached to the viscosity sensor and the speed, which the sensor rotates. For the PCU-200 series, an A Type, D is 6 at 10RPM. ou should not attempt to calibrate the viscometer at different rotational speeds, as this will yield incorrect measurements. D. Temperature Compensation When calibrating your viscometer, it is recommended that the silicone oil be at a constant temperature of 25.0 C. Since some Malcom viscometers do not have a thermostat, obtaining this temperature can be difficult. For that reason, a temperature compensation table was constructed. As an example, consider that the calibration fluid has a standard viscosity of 931 poise at 25.0 C under a shear rate of 6 reciprocal seconds. This is A Type. After waiting an hour for stabilization, the best temperature control you can obtain is 24.6 C, as seen on the viscometer digital display. Go to the left-most column of the table and proceed down to the 24. ow move to the right so that you are in the.6 column. ou should see This is the multiplier. At 25.0 C and standard conditions, the viscosity of the calibration fluid is 931 poise. However at 24.6 C, the viscosity is 931 x = poise. This should be rounded to the nearest poise. So, at 24.6 C, you should calibrate the viscometer to 938 poise. ºC

26 E. Troubleshooting 25 When experiencing difficulty with the operation of the PCU-200, consult this troubleshooting chart before contacting your Malcom dealer or Malcom for assistance. Situation Cause Solution Power switch is turned on, but no display is shown A constant value of or 1999 is displayed on LCD Values displayed do not change Values displayed fluctuate greatly Values displayed fluctuate mildly Air entrapment Temperature instability Changing speed Fuse has blown Internal circuit board damage Adjusting zero value Strain gage wire has broken Sample has glued bearing inside of spindle Internal circuit board damage Strain gage wire has broken Some object is caught between outer cylinder and inner spiral Sample has glued bearing inside of spindle Sensor shaft is bent There are large bubbles in the sample Sample size is too small There is a big difference between room and sample temperatures Shear rate is transient Replace fuse with 2A 250V type Contact your dealer or Malcom for repairs Press the adjust switch Contact your dealer of Malcom for repairs Contact your dealer of Malcom for repairs Contact your dealer of Malcom for repairs Contact your dealer of Malcom for repairs Remove outer cylinder and inner spiral, clean them and inspect for object Contact your dealer of Malcom for repairs Contact your dealer of Malcom for repairs Remove the bubbles with gentle stirring, or vacuum cleaner Obtain a larger sample Alter either or both temperatures to decrease difference Wait a few minutes for stability

27 26 Situation Cause Solution Large values are displayed, but no sample is being measured Measured value is different from expected Sample has glued bearing inside of spindle Sensor shaft or outer cylinder is bent, causing rubbing Zero adjustment is shifted Contact your dealer or Malcom repairs Contact your dealer or Malcom repairs Re-adjust the zero value Mis-calibrated by user Internal circuit board is damaged Re-perform the calibration or contact your dealer or Malcom for assistance Contact your dealer or Malcom repairs Paper LED illuminates Paper has torn or run out Check the paper and replace if necessary Printing of paper is too light to be easily read Paper is old Install new black printing thermal paper Printing on paper is blue, or pink Install new BLACK printing thermal paper Viscometer is a PCU-203 or PCU-205, but neither option A nor option B can be utilized Option B, LED flashes no computer control is possible Viscosity set switch is not a 0000 VAM-1 software was initiated too late An improper RS-232C cable is being used Set the viscosity set switch to Select option A or option B again with mix/start switch Exit the VAM-1 software and ready it for re-running. Turn the PCU-205 power off then back on. Run the VAM-1 software. Press the mix/start switch repeatedly until the option B, LED is illuminated Use only the cable supplied with your PCU-205. Contact your dealer or Malcom for replacements

28 F. Checking Sensor The sensor is the most sensitive and crucial part of the PCU-200. If you are experiencing difficulties not covered by the above chart, the following procedure will identify if the sensor is at fault. FOR THIS SEQUECE, THE DIRECTIOS ARE REFERECED WITH THE SESOR POITIG AWA FROM OU Remove the outer cylinder and inner spiral. 2. Position the PM-2 in an upright orientation. 3. Turn the power on. 4. The viscosity value should drop to zero within 1 minute. 5. Gently, turn the sensor shaft clockwise. It should rotate from 15 to 30 until major resistance is felt. 6. While turning, the viscosity displayed should increase. There is a time delay of 20 seconds for this to happen. 7. Release the sensor shaft. 8. The viscosity displayed will decrease. There is a time delay of 20 seconds for this to happen. 9. Within a few minutes, the viscosity should return to zero. 10. Gently, turn the sensor shaft counter-clockwise. 11. The viscosity displayed should stay at zero. 12. Release the sensor shaft. Should you observe results different from the procedure, there is possibly something wrong with the sensor. In this case, check with the troubleshooting chart again and if you still are unable to resolve the problem, contact your dealer or Malcom. MALCOM ISTRUMETS CORPORATIO IDUSTRIAL BOULEVARD HAWARD, CA USA TEL. (510) FAX. (510) malcomint@aol.com WEB.

29 G. Dimensions 28 Diagram 16 PM-2A PM-2B PM-2C