Polymer Melt Indexer (Extrusion Plastometer) PDF

MP600 Extrusion Plastometer
(Melt Indexer)
SYSTEM INSTALLATION AND OPERATION MANUAL.

Part # 02001560
Revision 5b
Date: 15 October 2010
This document contains confidential and proprietary information of Tinius Olsen

Testing Machine Company. In consideration of the receipt of this document, the
recipient agrees not to reproduce, copy, use or transmit this document and/or the
information therein contained, in whole or in part, or to permit such action by
others, for any purpose, except with prior written permission of Tinius Olsen
Testing Machine Company. All rights reserved.
______________________________________________________________________
TINIUS OLSEN TESTING MACHINE COMPANY

1065 Easton Road
P.O. Box 1009
Horsham, Pennsylvania 19044-8009 USA
TINIUS OLSEN
Operation Manual # 02001560 Rev. 5b. Testing Machine Company
MP600 Extrusion Plastometer
Table of Contents
Factory Certificate, Declaration of Conformity, Caution Pages & Warranty
Section 1 Introduction
Section 2 Model MP600 Digital Controller/Timer
Section 3 Standard Operating Tools
Section 4 Options and Accessories
Section 5 Setup and Installation
Section 6 Optional PPDT-600 Installation
Section 7 OPTIONAL Motorized Weight Support and Lowering/Raising Device
(MWLD-600) and Swing-Away Attachment
Section 8 Installation of OPTIONAL OKIDATA Model 320-Dot Matrix Printer &
Printer Cable
Section 9 Initial Start-Up
Section 10 Configuration Mode
Section 11 Test Parameters Set-Up Mode
Section 12 Testing Polymer According to ASTM D 1238 Procedure A (Manual Cut-Off)
12.1 Introduction
12.2 Configuring the MP600 Controller for Procedure A Testing
12.3 Test Procedure
Section 13 Testing Polymer According to ASTM D 1238 Procedure B (Automatically
Timed Flow Rate) when the Melt Density is known.
13.1 Introduction
13.2 Configuring the MP600 Controller for Procedure B Testing
13.3 Test Procedure
Section 14 Testing Polymer According to ASTM D 1238 Procedure B (Automatically
Timed Flow Rate) When the Melt Density is Unknown (Procedure for
Calculating the Melt Density of a Polymer)
14.1 Introduction
14.3 Test Procedure
Section 15 Flow Rate Ratio Package
15.1 Introduction
15.2 Flow Rate Ratio Components
15.3 Installation of Components for Three-Load Test
15.4 Test Procedure for a Typical Three-Load FRR Test
15.5 Test Procedure for a Typical Two-Load FRR Test
Version 5b - 15 October 2010

Table of Contents Continued
Section 16 Cleaning Instructions

Section 17 Preventative Maintenance
17.1 Cleanliness
17.2 PPDT-600 Arm Length Adjustment
17.3 Motorized Weight Lowering Device (MWLD-600)
17.4 Miscellaneous
Section 18 Calibration/Verification
18.1 Calibration/Verification Procedure for PPDT-600
18.2 Temperature Verification/Calibration
18.2.1 Suggested Equipment
Section 19 Temperature Control Configuration Mode
**Revised PIDS for MP 600 Controllers on page 19-5.
Section 20 Communications
20.1 Overview - Serial Port Connection
20.2 Connecting a Dot-Matrix Serial Printer to the MP600
20.3 Connecting a single MP600 to a Computer running EP600-Single
Software (EIA-232 protocol)
20.4 Connecting Multiple MP600 Melt Indexers to the USB Port on a
computer using EP600-Multiple Software Package (EI-232 protocol)
20.5 Connecting MP600 Melt Indexers to an existing computer system
running MFW-2 Multiple Machine Software (EI-485/422 protocol)
20.6 MP600 Communication Parameters
20.7 MP600 Communication Commands
Section 21 Troubleshooting
21.1 System Warnings
21.2 System Errors
21.3 Electrical Checks
21.4 MP600 Error 20
Section 22 Recommended Spare Parts List
Section 23 Shipping Instructions
Appendix A Typical Assembly Drawings with Part List & Wiring Diagrams
Additional Accessories & Instructions Provided:
Version 5b - 15 October 2010

TINIUS OLSEN TESTING MACHINE COMPANY
FACTORY CERTIFICATE
This is to certify that the Tinius Olsen MP600 Extrusion Plastometer (Melt Indexer) and
Accessories are checked prior to shipment and found to conform to the applicable portions
of ASTM D 1238 and ISO 1133 Test Methods (when used with the appropriate options).
The verification devices are traceable to the National Institute of Standards and
Technology and are listed below.
The optional thermometers are manufactured and calibrated to standards traceable to
the International System of Units (SI) through NIST.
The orifices are checked with orifice gauges manufactured and calibrated with
Calibration Standards traceable to the International System of Units (SI) through
NIST.
Piston feet, rods and collars are checked using devices verified with Gage Blocks
traceable to the International System of Units (SI) through NIST.
The weights are calibrated with Weights traceable to the International System of Units
(SI) through NIST.
Note: The instrument, and especially components subject to wear during normal use,
should be inspected periodically to insure continued conformance to ASTM D 1238
and ISO 1133.
CAUTIONS
CAUTION: Read the instruction manual thoroughly before attempting to use this
equipment.
CAUTION: This instrument has been designed to determine the melt flow index
property and other thermal processing properties of polymers. It is not intended for
any other use. Any attempt to use this instrument in any fashion other than its
intended use may damage the machine and/or harm the operator.
CAUTION: Do not use a sharp object to press any of the keys on the Model
MP600 Controller, as this will puncture the membrane cover.
CAUTION: The tools used on the machine may get hot during use.
CAUTION: Thermometers contain mercury! When a thermometer is being used,

extreme care should be taken not to heat the thermometer bulb too quickly or to
exceed the temperature range of the thermometer, as the internal pressure will
cause it to break.
CAUTION: Always check to make sure that the Set Temperature does not
exceed the range of the glass reference thermometer if one is being used.
CAUTION: This machine is designed for indoor use only. It shall be used in a
controlled environment (temperature range 5oC to 40oC, maximum R.H. of 80%
o
at 31 C). Maximum operating altitude is 3,200 meters. The area that it is
located shall be free from vibrations.
CAUTION: Prior to shipment, the cylinder of the machine is coated with oil to
prevent rust from forming. When the machine is first turned on, it is normal for
the machine to smoke as the cylinder comes to temperature and the oil residue
burns off. To reduce the amount of smoke that forms, clean the cylinder
thoroughly before turning the machine on. Be sure that a ventilation system is
operating at this time.
CAUTION: In some instances an exhaust system may be used to remove the

excess heat and/or odors released during a test. These instructions do not
address all of the safety concerns related to ventilation of fumes produced during
normal testing operations.
CAUTION: The machine is heavy and care must be used when lifting the
machine from the box or moving the machine. Always lift the machine by the
base plate. Never pick the machine up by the Motorized Weight Lowering
Device (MWLD-600) or by the furnace assembly.
Note that Cautions are continued on the next page.

CAUTION: Over adjusting the leveling foot can run the stud (Item 28) out of the
foot or out of the base of the machine, which would require the removal of the
base pan to correct.
CAUTION: Possible pinch points associated with the weight-lowering device

exist. One is between the lift cap and the lifter top at the bottom most position of
the platform and the second exists between the weight lowering platform and the
piston rod.
CAUTION: The surfaces of the furnace assembly can be extremely hot when the
machine is in operation!
CAUTION: Protective gloves should be worn when operating the machine with a
plastic that has a high flow rate.
WARRANTY
The Tinius Olsen Testing Machine Company guarantees its products to be free from
defects in material and workmanship under normal use and service for which they were
intended, and under condition of proper maintenance for one year from date of receipt
of equipment.
CALIBRATION
Tinius Olsen certifies that this instrument meets all dimensional, temperature control
and performance specifications of ASTM D 1238. That specification recommends
verification of calibration at least once a year. Contact Tinius Olsens Field Service
Department at (215) 675-7100 or contact your local Sales & Service Representative to
schedule an appointment.
1 Section 1 Introduction
1.1 Basic Unit
The Tinius Olsen Extrusion Plastometer with microprocessor-based Model MP600

Controller/Timer is used for measuring the flow rates of thermoplastics. The unit is
a dead-weight piston Plastometer with which the extrusion rate of thermoplastic
materials through an orifice of specified dimensions is determined under
prescribed conditions of temperature and pressure in accordance with ASTM
Standard Test Method D 1238. With minor procedural modifications, the MP600
can also meet ISO 1133, BS 2782, DIN 53735, JIS K7210 and other similar
standards.
The standard MP600 can be used for testing in accordance with other ASTM
methods; including D 2581, D 3364, D 4203, D 4507 and D 4550 (a special orifice
is required for D 3364). Other methods, such as D 2116, D 3159, D 3275 and D
3307, require the optional corrosion resistant cylinder, orifice and piston foot.
The basic Plastometer (Melt Indexer), as described, may be used for Procedure
A - Manual Operation. With the addition of optional accessories, Procedure B -
Automatically Timed Flow Rate Measurement may be performed. The purchaser
can easily upgrade the basic model.
CAUTION: This instrument has been designed to determine the melt flow index
property and other thermal processing properties of polymers. It is not intended for
any other use. Any attempt to use this instrument in any fashion other than its
intended use may damage the machine and/or harm the operator.
1.2 Single Unit Construction
Sturdy modular design includes housing for temperature and timing controls,
rugged uprights for supporting the hardened steel test cylinder, which is heated
by a precision dual zone, controlled band heater, is insulated and jacketed in an
aluminum housing. A tool rack is provided for convenient access to frequently
used operating tools. The unit is semi-portable and contains provisions for
leveling the cylinder.
1.3 Precision Temperature Sensors
Two platinum RTD Probes sense the cylinder temperature, sending signals to
the MP600 Controller, which regulates the temperature of the upper and lower
portions of the cylinder to within 0.1C. The te mperature of the lower portion of
the cylinder is displayed as the Actual Temperature (AT).
1.4 Precision Dual Zone Band Heater
300 Watts (nominal) -- contains a special concentric heating element, which is

form-fitted and designed to uniformly maintain the required temperature. The
heater and furnace assembly is rated for use up to 450C.
1-1
Version 5b 15 October 2010
1.5 Machine Dimensions:
(Standard Unit) 51 cm (20 inches) wide by 38 cm (15 inches) deep and 58 cm

(24 inches) in height.
(Motorized Unit) 51 cm (20 inches) wide by 38 cm (15 inches) deep and 95 cm
(38 inches) in height.
Net Weight:
The (Standard Unit) approximately 18 kilograms (40 pounds), not including any
weights or options.
The (Motorized Unit) approximately 32 kilograms (70 pounds), not including any
weights or options.
1.6 Electrical Requirements:
The basic Model MP600 Extrusion Plastometer is arranged for 115 Volts 10%
or 220 Volts 10%, 50/60 Hz, Single Phase. Check machine label for actual
electrical requirements.
115 Volt Units

Input Power ...................................................................................................... 500 W
Voltage ............................................................................................ 115 VAC +/- 10%
Current ................................................................................................................. 4.5A
Frequency ..................................................................................................... 50/60HZ
Phase ................................................................................................................ Single
Line Fuse ..................................................................................... 5A 250V MDL/3AG
220 Volt Units
Input Power ...................................................................................................... 500 W
Voltage .............................................................................................. 220 VAC +/10%
Current ................................................................................................................. 4.5A
Frequency ..................................................................................................... 50/60HZ
Phase ................................................................................................................ Single
Line Fuse ..................................................................................... 5A, 250V GDC/213
Note: The line filter used in the Power Entry Module typically has a leakage current of
0.25 mA to ground at 115 VAC, and 0.5 mA at 220 VAC. This current leakage
may cause a Ground Fault Interrupt (GFI) receptacle to trip, therefore a GFI is
not recommended.
1-2
2 Section 2 - Model MP600 Digital Controller/Timer
2.1 Introduction
The MP600 microprocessor-based Controller/Timer is fully interactive with the

operator. It features a membrane keyboard; high visibility vacuum fluorescent
display; serial communications port; test parameter storage with power-up in last
used parameters; calibration information stored in battery-backed-up RAM;
indicating LEDs; operating controls and other related features.
2.1.1 Two-Zone Temperature Control
The temperature controller features two-zone proportional, integral, and

derivative (PID) control, assuring spatial temperature variations of less than
0.25C along the test area of the cylinder. Temper atures up to 450C are
controlled and displayed to 0.1C; utilizing two platinum RTDs embedded in
the cylinder wall. The controller also has built-in temperature sensor failure. If
an RTD opens or shorts out (or temperature control becomes erratic), power to
the heater is interrupted and an error message is displayed.
2.1.2 Calibration Offsets
The Calibration Offsets are a correction factor for the small difference in
temperature between the Actual Temperature (AT) displayed on the MP600
Controller and a NIST (National Institute of Standards and Technology) traceable
temperature measuring device placed in the test area of the cylinder. In other
words, the Calibration Offset value entered adjusts the displayed temperature
to agree with the temperature standard in the cylinder.
Because of the wide range of temperatures that the MP600 Controller may be
used, it may be necessary to enter Calibration Offsets for each test temperature
(Set Temperature).
The actual cylinder temperature was determined at the factory using a NIST
traceable RTD probe placed 10 mm above the upper face of the standard 8 mm
(0.315) long orifice. The digital electronic temperature display is also NIST
traceable. This procedure is described in the current version of ASTM D 1238.
For new machines shipped with optional thermometers, a MP600

Configuration/Calibration Settings Worksheet will be provided showing the Actual
Cylinder Temperature, the Machine Displayed temperature, the Calibration
Offset setting, and the Thermometer Reading (while inserted in the cylinder),
along with the serial number of each thermometer ordered with the machine. By
using the appropriate thermometer, the actual cylinder temperature can be
indirectly monitored by comparing the actual thermometer reading with the
thermometer reading and display temperature when the machine was calibrated.
For new machines shipped without thermometers, an MP600
Configuration/Calibration Settings Worksheet will be provided for 190, 250C
and 300C. There will not be any reference thermom eter reading.
2-1
2.1.3 Multiple Data Determinations (Captures)
The MP600 gives the operator the ability to make up to 10 individual flow rate
(melt index) determinations within a single sample charge when performing a
test to ASTM Procedure B. While this feature is not required by ASTM D 1238, it
can be useful for checking the consistency of results and in improving accuracy
by isolating sources of error such as air bubbles and allowing the operator to
eliminate obviously flawed data. The multiple capture feature may be used with
any material, but it is most often used with materials that have flow rates greater
than 10 g/10 minutes. A typical example of the test parameters used for a multi-
capture test has been preprogrammed in Program #3 (see Table 11-2).
2.1.4 Built-in Timer
Timing functions up to 999 seconds are available for preheat timing, cut-off
intervals, operating an automatic weight support and lowering device, as well as
other optional features. Piston displacement timing is displayed in 0.01 second
increments up to 1000 seconds and in 0.1 second increments from 1000 to 3600
seconds. An audible alarm can be activated which will prompt the operator to
perform functions such as applying the load, cutting off the extrudate, etc.
2.1.5 Membrane Keyboard
The membrane keyboard allows the operator to communicate with the

microprocessor in response to interactive prompts, which appear on the high-
visibility vacuum fluorescent display. Up to 25 sets of testing parameters can be
stored for recall or the necessary values can be entered at test time. The
Parameters can be set up for conducting flow rate tests under both Procedure A
(Manual Cut-off Procedure) and Procedure B (Automatic Timed Procedure).
2.1.5.1 Display
Four-line vacuum-florescent display for displaying software
prompts and tests results.
2.1.5.2 Numeric Key Pad

Used for entering required numerical test data and for activating
specific functions and features as required.
2.1.5.3 Up (^) Key (numeric key 9)

When pressed, energizes the Motorized Weight Lowering/Lifting
Device (MWLD-600) to move upward.
2.1.5.4 Down (v) Key (numeric key 3)

When pressed, energizes the Motorized Weight Lowering/Lifting
Device (MWLD-600) to move downward.
2-2
2.1.5.5 Top (^^) Key (numeric key 7)
Energizes the Motorized Weight Lowering/Lifting Device (MWLD-
600) to move upward until its upper limit is reached or the STOP
key is pressed.
2.1.5.6 Bottom (vv) Key (numeric key 1)

Energizes the Motorized Weight Lowering/Lifting Device (MWLD-
600) to move downward until its lower limit is reached or the
STOP key is pressed.
2.1.5.7 Stop Key (numeric key 4)

When pressed, stops the movement of the Motorized Weight
Lowering/Lifting Device (MWLD-600)
2.1.5.8 CLEAR
This is used to delete erroneous data entries.
2.1.5.9 EXIT
This is used to leave the current screen when prompted.
2.1.5.10 START
This is used to start tests.
2.1.5.11 ENTER
Used to confirm and store data entry.
2.1.5.12 Heater LED Indicators

Flashing indicators designates top & bottom heater operation.
2.1.5.13 Capture LED Indicator

When this indicator is lit, the PPDT-600 Automatic Timing
Switch is in operation.
2.1.5.14 Power On/Off Switch

In the ON position for normal operation. The OFF position
removes power to the MP 600 Controller and accessories.
2-3
Figure 2-1 MP600 Controller
2-4
2.1.6 Prompt Driven Operation
The selected program prompts the operator to enter the necessary information
when starting a test, alerts the operator to perform tasks that may be necessary
during the test, prompts for any information that might be necessary after the
test, and then calculates and displays test results.
2.1.7 Test Set-Up and Storage
The MP600 Controller can store up to 25 different sets of test parameters,

allowing operators to configure the MP600 Controller for the types of materials
that are tested in the laboratory.
2.1.8 Test Results
For Procedure A type tests, the Flow Rate (Melt Index) is calculated and
displayed for each manual cut-off. When Procedure B type tests are performed
using the optional PPDT-600 Automatic Timing Switch, the Flow Rate (Melt
Index), apparent Shear Stress, Shear Rate and Viscosity, and Volumetric Flow
Rate can be selected for calculation and display. A subroutine for calculating the
Melt Density of the polymer at Test Temperature is also provided.
2.1.9 Communications Port
The test information and results can be sent directly to an optional dot-matrix
serial printer or the machine can be interfaced to a computer utilizing the serial
Communications Port (EIA-232/485 protocol) provided as standard. Up to ten
machines can be interfaced to a single computer.
2-5
B
2-6
3 Section 3 Operating Tools & Accessories
3.1 The following tools are included with each MP600 as standard equipment:
Refer to Figure 3-1 for an illustration. See Section 16 for cleaning instructions.
IMPORTANT: All these tools are made of materials that are softer than the cylinder.
This is to prevent any scoring or damage to the walls of the cylinder. If the cotton
cleaning patches cannot effectively clean the cylinder walls, an optional 0.406
diameter soft brass brush (available from Tinius Olsen) can be used to help clean the
cylinder.
One (1) ASTM Piston Assembly (Items 1A, 1B & 1C, Figure 3-1) - consisting of a
removable stainless steel piston foot (P/N: 02001086); piston guide collar
(P/N: 02001088); and a piston rod (P/N: 02001085). The piston rod and
foot weighs 100 grams (not including the guide collar). It is considered
the first 100 grams of all test loads. Piston feet made from other materials
can also be supplied. An optional combination ASTM/ISO Piston Rod
(P/N: 02001439), an ISO (only) Piston Rod (P/N: 02001665) & a piston
foot to ISO tolerances (P/N: 02001440) are also available.
One (1) Charging Tool (P/N: 02001582), is used to compress the test material
down into the cylinder (cylinder bore), and helps to remove some of the
entrapped air when charging material. Provided with a replaceable tip
(P/N: 02001071).
Two (2) ASTM D 1238 Orifice (die), D2 tool steel (P/N: 02001030). Note that
Carbide orifices are also available (P/N: 02001031). Contact factory for
other orifice dimensions & materials
One (1) Level (P/N: 02001271) - consisting of a base (P/N: 02001226) and a circular
level (P/N: 02001227), is used to check the Cylinder Alignment (Level) of
the cylinder. This level is made to fit over the end of the Piston Rod
Assembly, with the piston and orifice in the cylinder.
One (1) Stainless Steel Funnel, (P/N: 02001091) - is used to help introduce a
sample of material into the cylinder.
One (1) Orifice Remover, (P/N: 02001073) - is used from the bottom of the
furnace to push the orifice up and out of the cylinder.
One (1) Cylinder Cleaning Tool, (P/N: 02001527) is used to clean the cylinder
after each test with the cotton cleaning patches.
One (1) Cutoff Tool, (P/N: 02001090) this U-shaped tool is used to cut-off the
extruded sample at the bottom of the orifice.
One (1) Orifice Drill, (P/N: 02001075) this soft drill bit is used to clean material out
of the inside diameter of the orifice.
CAUTION: The tools used on the machine may get hot during use.
3-1
Figure 3-1 Extrusion Plastometer Tools
1. Piston Rod Assembly 6. Funnel

A. Piston Rod 7. Cutoff Tool
B. Guide Collar 8. Charging Tool
C. Piston Foot 9. Orifice Remover
2. Cylinder Cleaning Tool 10. Thermometer (Optional)
3. Orifice Drill 11A. Thermometer Support (Optional)
4. Orifice 11B. Thermometer Plug (Optional)
5. Level Assembly
A. Level
B. Base
3-2
4 Section 4 Available Options & Accessories
4.1 Weights
Table 4-1 shows the weights that can be supplied for the standard test conditions
in ASTM D 1238. The Piston Rod and Piston Foot (less the collar) weigh 100
grams. All the weights are marked in grams. Tinius Olsen certifies that the
weights are accurate to within +/- 0.5% of the stamped weight.
EXAMPLE: To apply a Test Load of 2.16 kilograms you would use the 2,060 gram
weight, adding in 100 grams for the piston rod assembly (less the collar).
Table 4-1 Weight Loading for Typical Melt Flow Rate Tests
ASTM D 1238
TEST LOAD USE WEIGHT(S) PISTON
TEST CONDITION = +
(GRAMS) (GRAMS) WEIGHT
(Reference Only)
A, D & K 325 = 225 (P/N 02001019) + 100
B, C, E, L, R, T, V & W 2,160 = 2,060 (P/N 02001023) + 100
H&O 1,200 = 1,100 (P/N 02001022) + 100
I 3,800 = 3,700 (P/N 02001025) + 100
2,400 (P/N 02001024) +
J&U 12,500 = + 100
10,000 (P/N 02001029) .
G, P, S & X 5,000 = 4,900 (P/N 02001026) + 100
6,600 (P/N 02001027) +
F 21,600 = 4,900 (P/N 02001026) + + 100
10,000 (P/N 02001029) .
M 1,050 = 950 (P/N 02001021) + 100
N 10,000 = 9,900 (P/N 02001028) + 100
Q 1,000 = 900 (P/N 02001020) + 100
4.2 Glass Reference Thermometers
Caution: Thermometers contain mercury! Extreme care must be taken not to

heat the thermometer bulb too quickly or to exceed the temperature range of the
thermometer, as the internal pressure will cause the thermometer to break!
4.2.1 Extrusion Plastometer thermometers may be used as a reference for

indirectly monitoring the approximate temperature level in the test cylinder 10
mm above the orifice. These thermometers have a 4C range ( 2C about the
stipulated temperature) and are graduated in 0.2C divisions. Note: Use of a
reference thermometer in the cylinder of the MP600 Extrusion Plastometer
requires a Thermometer Support and Plug (P/N 02001530).
4-1
Periodic checks (using the thermometer, thermometer support and plug) can be
made to indirectly verify that the cylinder temperature is at the correct temperature.
NOTE: This procedure should not be substituted for annual calibration/verification
of the entire instrument.
To reduce the potential of breaking the reference thermometer, it is recommended

the thermometer be safely stored once the correct operating temperature has
been verified.
4.2.2 Mercury Separation
Extrusion Plastometer thermometers have expansion chambers (see Figure 4-2).

The mercury in thermometers with contraction chambers tends to separate more
readily than straight capillary thermometers. There is no known method to
ensure that the mercury in a thermometer will not separate when the
thermometer is subjected to shock. This can occur either in transit or by
improper storage and handling.
Before using any thermometer it should be examined very carefully for mercury
separation in the main mercury column, expansion chamber, contraction
chamber and bulb (mercury separation in the bulb will usually show as small
bubbles). All the mercury must be united. A check at the ice point will
immediately tell if there is mercury separation.
In a small Dewar flask or thermos bottle, mix powdered dry ice with methanol or
ths
acetone. Holding the thermometer vertically, immerse about 3/4 of the lower
section of the bulb into the mixture. DO NOT immerse the capillary or funnel
section above the bulb into the mixture. The main portion of the mercury will
retreat into the bulb and the separated portion should follow. When all the
mercury, including the separated portion, has retreated into the bulb, remove the
thermometer from the dry ice mixture (see Figure 4-3). The mercury should go
together. Stand the thermometer in a vertical position to allow the mercury to
rise into the capillary of its own accord.
Caution: Do not touch the bulb of the thermometer with your hands or it may
affect the reading.
Occasionally, the separated portion may cling to the walls of the funnel portion of
the bulb. If the mercury is not completely united, repeat the process, but this
time, gently tap (do not bounce) the thermometer bulb vertically on a desk pad
(see Figure 4-4) after removing it from the flask.
4-2
Figure 4-2 Typical 230C Extrusion Plastometer th ermometer
4-3
Figure 4-3 Figure 4-4 Figure 4-5
If there is a large amount of gas trapped between the separated portion of and
the main portion of the mercury, immerse the bulb until the separated mercury is
in the widest part of the contraction chamber, and then gently tap the bulb on a
pad (see Figure 4-5). This should drop the mercury separation to the lower part
of the chamber, allowing most of the gas to escape above the separation.
Repeat the immersion process to completely reunite the mercury.
Figure 4-6 Figure 4-7
If gas bubbles are observed in the bulb of the thermometer (see Figure 4-6),
immerse the bulb of the thermometer in the mixture until all the mercury has
entered the bulb. Remove the thermometer bulb from the mixture and gently tap
the bulb of the thermometer against a rubber pad hand while holding the
thermometer horizontal with the bulb slightly elevated (see Figure 4-7). Rotate
the thermometer while continuing to tap, allowing a large gas bubble to form and
to roll around the inner bulb wall and gather all the small bubbles as it rolls.
When all the small bubbles have been gathered, gently tap the bulb against the
pad to force the gas bubble to the top of the bulb. Allow the thermometer to
warm up on its own accord.
Always store any unused thermometers in a vertical position.
Caution: In case of thermometer breakage while in the melt indexer, contact

your Hazardous Materials Coordinator prior to attempting the removal.
4-4
4.2.3 Thermometers Available from Tinius Olsen
P/N: 02001005 120C P/N: 02001012 235C

P/N: 02001006 125C P/N: 02001013 250C
P/N: 02001007 150C P/N: 02001014 265C
P/N: 02001008 175C P/N: 02001015 275C
P/N: 02001009 190C P/N: 02001016 297C
P/N: 02001010 200C P/N: 02001017 300C
P/N: 02001011 230C P/N: 02001066 310C
P/N: 02001018 372C
Notes:
1. For a Model MP600, a Thermometer Support & Plug, P/N 02001530, is
required when using reference thermometers.
2. Contact factory for thermometers other than those listed (to 400C max.)
3. Thermometers have a graduated range of 2C in 0 .2C increments (up
to 339C) and in 0.5C increments (from 340C to 40 0C).
4.3 PPDT-600 Automatic Timing Switch (P/N 02001505)
The PPDT-600 is required when conducting Procedure B - Automatically Timed

Flow Rate Measurement tests in accordance with Procedure B of ASTM D 1238,
ISO 1133, DIN 53735, JIS K7210 and other similar methods. The PPDT-600
utilizes a precision optical encoder to monitor piston position and operate the timer
in the MP600 Controller/Timer. The Starting Positions and Piston Travel
Distances for up to ten time vs. distance captures can be preprogrammed into
the MP600 Controller/ Timer.
4.4 Automatic Timing Switch Calibrator (P/N 02001531)
Used for verifying and calibrating the actual piston travel distances measured by
the PPDT-600. It can also be used to verify and/or calibrate older style
Mechanical and Programmable Actuating Switches and Programmable Piston
Displacement Transducers used on older Model UE, MP987, MP993 and MP993a
Extrusion Plastometers. However, the instructions in this Manual cover only the
verification/calibration of the PPDT-600 on a melt indexer equipped with a MP600
Controller/Timer. Contact the factory for instructions for verification/calibration
when using other types of controllers and actuating switch types.
The Calibrator consists of a 0 to 2 barrel-type micrometer head with 0.001

divisions and a mounting bracket. The mounting bracket permits checking the
switch while it is mounted on the machine. The standard calibrator is shipped fully
assembled. A wooden storage box is also included.
NOTE: Digital version available. Contact factory for details.
4-5
4.5 MWLD-600 Motorized Weight Support, Lowering and Lifting Device with Swing
Away Weight Support Platform (P/N 02001504)
This accessory includes an integrated encoder that permits display and control of the
height of the weight support platform. It can be operated manually by keys on the
keyboard. When performing Procedure B tests, it can be programmed to
automatically move to a selected height at the start of a test and then lower fully to
reapply the load after a selected pre-heat period (Release Time).
This option is required for automatic operation and is also recommended

whenever high loads are being used in a manual testing mode. Weights are
contained on the weight support platform that swings-away automatically when in
its raised position for easy cylinder cleaning.
4.6 Go/No-Go Gauge
The Go/No-Go gauge is used to check the inner diameter of the standard ASTM D
1238 orifice (die) for compliance to the test method requirements.
P/N: 02001134: Go/No-Go Gauge, Half-Die, CERTIFIED

P/N: 02001133: Go/No-Go Gauge, ASTM D 1238/ISO1133 orifice - CERTIFIED
P/N: 02001034: Go/No-Go Gauge, standard ASTM D 1238/ISO1133 orifice
4.7 OKIDATA Model 320-I Dot-Matrix Printer (P/N 02001429 for 110 V or P/N
02001454 for 220 V)
This includes a serial interface card and the MI-Printer AME Cable (see below) for
connecting to the communications port on the MP600 Controller.
4.8 MI-Printer AME Cable (P/N 90002871)
A 25 pin Male to 25 pin Male, 10 long cable, for connecting an optional Dot-Matrix
Serial Printer to the communications port on the MP600 Controller. Order this
option if printer is being supplied by the end user.
4.9 Flow Rate Ratio Attachment Package (P/N 02001418)
Use of this option requires that the MP600 Extrusion Plastometer is also equipped
with the PPDT-600 Automatic Timing Switch and the MWLD-600 Motorized Weight
Support and Lowering Device. This package consists of:
a) Load change (lift) pins and extended safety uprights and split collars for weight
containment.
b) Weight change height setting adjuster for setting up typical programs.
c) Weight set consisting of 2060 g (P/N 02001023), 7840 g (P/N 02001250) and
11,600 g (P/N 02001251) for applying loads of 2.16, 10 and 21.6 kg. (Other
load combinations can be supplied - consult factory.)
4-6
Using the above components, flow rates can be determined under up to three
different loads using the following automated sequence. After charging the test
material and lowering the weights over the top of the piston rod, the operator starts
the Preheat period. At the end of the Preheat period, the MWLD-600 lowers and
applies the selected total load. The time for the first selected piston travel is
measured and stored. As the test progresses, the load on the piston is reduced
automatically and, after a selected distance to allow for equilibration of flow, the time
for the selected second piston distance is measured and stored, and a similar
sequence can be selected to obtain a measurement under a third load. At the end
of the test the flow rates and other selected data are calculated by the
microprocessor for readout on the display.
4.10 EP600 Data Acquisition & Machine Control Software
EP600 Software Packages are available for connecting a single Melt Indexer or up
to ten Melt Indexers to a computer. Consult the factory or your local representative
for complete details.
P/N 02001561 Software - EP600-Single Machine Package

P/N 02001562 Software - EP600- Multiple Machine Package
4.11 Orifice (Die) Options
P/N: 02001030 Orifice, D2 tool steel (ASTM D 1238, ISO 1133)-Standard

P/N: 02001268 Orifice, Carbide 0.0413 ID x 0.157 L (Half Die)
P/N: 02001033 Orifice, Carbide (PVC, ASTM D3364)
P/N: 02001032 Orifice, Stainless Steel (PVC, ASTM D3364)
P/N: 02001031 Orifice, Carbide (ASTM D 1238, ISO 1133)
4.12 Piston Foot Options
P/N: 02001086 Piston Foot, stainless steel (standard foot)

P/N: 02001440 Piston Foot, stainless steel (to ISO tolerances)
P/N: 02001441 Piston Foot, D2 tool steel hardened 50-55
P/N: 02001113 Piston Foot, corrosion resistant alloy (for use with corrosion
resistant alloy cylinder)
4.13 Miscellaneous
P/N: 02001439 Piston Rod Combo both ASTM & ISO Scribed Lines
P/N: 02001665 Piston Rod ISO Scribed Lines only
P/N: 02001455 Orifice Plug for High Flow resins
P/N: 02001071 Charging Tool Tips
4-7
B
4-8
5 Section 5 Set-Up and Installation
NOTE: Instructions in this Section cover basic machine setup. For instruction on
installing and operating optional accessories supplied with the unit, please refer to the
appropriate Section of this manual.
CAUTION: This machine is designed for indoor use only. It shall be used in a

controlled environment (temperature range 5 C to 40 C (40 to 100 F), maximum
R.H. of 80% at 31C). Maximum operating altitude i s 3,200 meters (10,000 feet).
CAUTION: In some instances an exhaust system may be used to remove the

excess heat and/or odors released during a test. These instructions do not
address all of the safety concerns related to ventilation of fumes produced during
normal testing operations.
5.1 Unpacking the Machine
5.1.1 Locate the packing list and carefully uncrate and remove all packing
material from around the machine. Carefully remove the machine from the crate.
Check all parts and accessories against the packing list.
CAUTION: The machine is heavy and care must be used when lifting the
machine from the box or moving the machine. Always lift the machine by the
base plate. Never pick the machine up by the Motorized Weight Lowering
Device (MWLD-600) or by the furnace assembly.
5.2 Locating the Machine
5.2.1 Place the machine on a sturdy, level surface. The area that it is located
shall be free from vibrations. Place the tools on the rack on the right hand side
of the machine.
5.2.2 The basic machine is shipped fully assembled. There is some assembly
required for optional accessories.
5.3 Leveling the Machine
5.3.1 Insert the orifice in the cylinder, and then insert the piston assembly.
5.3.2 Place the precision level over the top of the piston. The piston rod must
be straight and the base of the level seated cleanly on the shoulder of the piston.
5-1
5.3.3 Level the machine using the 4 screw adjustment feet on the corners of the
base plate. Verify that the machine is level by rotating the level only and
then the piston assembly only. At all level positions, no more than half of
the bubble will be outside the circle.
To level the machine, loosen the lock nut (Item 39) up off the adjusting nut
on the foot, adjust the leveling foot (Item 27) using the lower adjust nut.
Note that the feet only have a limited amount of adjustment and the table
surface should be fairly level to begin with. Tighten the lock nuts back
down on the adjusting nuts with a wrench after leveling. The lock nut
should be tightened down against the hex nut on the foot, not the bottom
of the MP600.
CAUTION: Over adjusting the leveling foot can run the stud (Item 28) out of the
foot or out of the base of the machine, which would require the removal of the
base pan to correct. Locktite is applied to the top of the stud at assembly.
5.3.4 Remove the precision level from the piston and store it in a safe place.
5-2
6 Section 6 - OPTIONAL Programmable Piston Displacement
Transducer (PPDT-600)
6.1 Installing PPDT-600 ordered with the MP600
6.1.1 Tools Required:

3/16 inch hex key (supplied); small slotted screwdriver (not supplied)
6.1.2 Remove the shrink-wrap that secures the PPDT-600 during transit. Be
careful not to bend the PPDT-600 arm.
6.1.3 Mount the switch mounting bracket to the furnace as shown in Drawing 5-
6-549 (located in Appendix A at the rear of this manual). Secure the bracket
using the two 1/4-20 screws provided. Ensure washers are installed between
mounting bracket and furnace top.
NOTE: The PPDT-600 arm and the encoder in the PPDT-600 are very sensitive and
can easily be damaged by misuse or abuse. When moving the arm by hand, never
exceed the upper or lower stops. Never allow the arm to fly up from the down
position. The arm must be gently guided back to the upper position using a finger.
6.1.4 Plug the PPDT-600 into appropriate port at the rear of the MP600
controller cabinet and tighten screws with a small slotted screwdriver. Be sure
cable clamps are tight.
6.2 Field Installation, Setup and Configuration of the PPDT-600 for encoder type
ENCI (for units that were not originally purchased with the MP600)
6.2.1 Tools Required:

3/16 inch hex key (supplied); small slotted screwdriver (not supplied)
6.2.2 Mount the switch mounting bracket to the furnace as shown in Drawing 5-
6-549 (located in Appendix A at the rear of this manual). Secure the bracket
using the two 1/4-20 screws provided. Ensure washers are installed between
mounting bracket and furnace top.
NOTE: The PPDT-600 arm and the encoder in the PPDT-600 are very sensitive and
can easily be damaged by misuse or abuse. When moving the arm by hand, never
exceed the upper or lower stops. Never allow the arm to fly up from the down
position. The arm must be gently guided back to the upper position using a finger.
6.2.3 Plug the PPDT-600 into appropriate port at the rear of the MP600
controller cabinet and tighten screws with a small slotted screwdriver. Be sure
the cable clamps are tight.
6-1
6.2.4 Turn on the MP600 and go through the initial dialog. Rotate the PPDT-
600 clockwise into the Test position.
6.2.5 From the Main screen (shows Actual Temperature, Set Point
Temperature, Program Number, and Procedure), select #4 Options. Under the
Options Menu, select #4 Calibration.
6.2.6 Enter the Calibration access code: 8 3 5 and press ENTER.
6.2.7 Under Calibration, select #2 PPDT. Under PPDT, select #1 Full

Calibration. Select the PPDT type as #1 ENC.
6.2.8 The MP600 will then prompt the operator to lower the PPDT arm all the
way, hold it, and press ENTER. This defines the bottom position.
6.2.9 The MP600 will then prompt the operator to set the horizontal position.
Use a straight edge and place it along the PPDT arm so that it is perfectly
horizontal and press ENTER.
6.1.10 The next screen prompts the user to MOVE PPDT ARM TO DETECT
INDEX. Gently lower and raise the arm of the PPDT to momentarily activate the
Capture LED.
6.2.11 The next screen shows you a live reading of the PPDT position (Piston
Height) and the current Arm Length and Offset. Pressing ENTER toggles
between allowing you to change the Arm Length and change the Offset. With
each entry or movement of the PPDT arm, the Piston Height is recalculated and
updated.
6.2.12 Enter the Calibrated Arm Length value found on the tag attached to the
PPDT-600.
6.2.13 The Offset is used to change the PPDT position (Piston Height) relative
to the top of the orifice. You may change this to trim it in if needed (see below).
6.2.14 Place a single orifice in the barrel, put the piston rod down the barrel,
and put a weight on the piston rod. Position the PPDT arm under the weight.
The Piston Height should read nearly zero. If not, adjust the Offset accordingly.
NOTE: The easiest way to determine the correct Offset is to set the Offset to 0.
Then read the Piston Height with the PPDT arm at the zero piston position (see
above). Multiply the reading by 1 and enter this as the new Offset. BE
CAREFUL to change only the Offset, not the Arm Length.
6-2
6.2.15 Press EXIT to exit out of the Calibration mode and return to the Main
screen.
NOTE: You can check the PPDT (Piston Height) by entering the Test mode
(Procedure B) and proceeding to a screen that shows the Piston Height. Check
the zero piston position using the procedure described above (#13). The Piston
Height will probably never read exactly 0, because of minor deviations in the
initialization procedure, contact surfaces, etc., but it should be within several
hundredths of an inch (about 1 mm).
Changes to the PPDT Offset will not affect the calibration. However, you do
want to set the Offset value so that the displayed Piston Height generally
corresponds to the actual piston position.
NOTE: Some MP600 Extrusion Plastometers that are purchased with the optional
PPDT-600 Automatic Timing Switch may have been configured for the Encoder
Type ENC. If your machine has been configured in this manner, the following
prompt will be shown on the display EVERY time that the MP600 is powered-up.
FULLY LOWER PPDT ARM
HOLD DOWN ARM AND

PRESS ENTER TO INIT
When this prompt is displayed:
1. The user must rotate the PPDT-600 Switch clockwise on its bracket so that the
tip of the arm is pointing toward the center of the barrel (the Test Position).
2. The user should then gently push down on the switch arm until it stops. DO
NOT FORCE THE ARM ANY FURTHER. Then while holding the arm down in
this position, press the [ENTER] key on the MP600.
3. Then gently allow the switch arm to return to its UP position.
Note: The above steps are required to provide the MP600 with a position
reference and to initialize the PPDT-600 Automatic Timing Switch.
6-3
B
6-4
7 Section 7 - OPTIONAL Motorized Weight Support and
Lowering/Raising Device (MWLD-600) with Swing-Away Feature
7.1 Preparation for use of Factory Installed MWLD-600
7.1.1 Install the weight retaining rods (Refer to Drawing 5-6-543 located in
Appendix A at the rear of this manual) provided with the MWLD-600. The rods
are used to safely contain the weight(s). When using 3 diameter or smaller
weights, three (3) rods are threaded into the inner tapped holes of the weight
platform in a triangular pattern.
7.1.2 For larger diameter weights, all four of the rods should be installed using
the outer, square pattern.
CAUTION: Possible pinch points associated with the weight-lowering device

exist. One is between the lift cap and the lifter top at the bottom most position of
the platform and the second exists between the weight lowering platform and the
piston rod.
CAUTION: Do not allow the MWLD-600 to lower when there is any obstruction
between the top of the furnace and the bottom of the weight platform that would
prevent the full lowering of the MWLD-600. Should the MWLD-600 lowering be
initiated inadvertently when an obstruction is present, immediately press the
STOP key located on the keypad of the MP600 Controller/Timer.
7.2 Manual Operation
7.2.1 Disable the automatic operation of the MWLD-600 by changing the test
parameters if necessary (see Section 11.3.19).
7.2.2 Use the [UP] and [DOWN] keys on the MP600 Controller to raise or lower
the MWLD-600 weight platform. NOTE: The [UP] and [DOWN] keys will not
operate when a numeric entry is expected by the MP600 Controller.
7.2.3 Use the [TOP] key to raise the MWLD-600 weight platform to the upper
most Swing-Away position. Use the [BOTTOM] key to lower the MWLD-600
weight platform to the bottom most position. If running a Method B test and the
weight platform is above the Wt Sup Ht, the [BOTTOM] key will lower the
weight platform to the Wt Sup Ht. Use the [STOP] key at anytime to stop the
MWLD-600 weight platform.
7.3 Automatic Operation
7.3.1 Enable the automatic operation of the MWLD-600 by changing the test
parameters if necessary (see Section 11.3.19).
7-1
7.3.2 When the [START] key is used to initiate a test, the MWLD-600 weight
platform will automatically lower to the weight support height (See Wt Sup Ht in
Section 11.3.20). After the Release Time has counted down to zero, the MP600
Controller/Timer will automatically lower the MWLD-600 weight platform down to
the lowest position.
While the MWLD-600 weight platform is in motion, the [STOP] key will stop the
weight platform.
7.3.3 The [UP], [DOWN], [TOP] or [BOTTOM] keys can be used at any time to
raise or lower the MWLD-600 weight platform, except when the MP600
Controller display is requesting a numeric input.
7.4 Field Installation of MWLD
7.4.1 Tools required: 3/32, 5/32, and 3/16 hex key, 5/8 & 11/16 wrench, flat
head screwdriver, Phillips screwdriver, (optional 1 5/16 wrench).
7.4.2 Refer to Appendix A for assembly drawings and wiring diagram.
7.4.3 Unplug the MP600 from the power source. Allow the Furnace to cool
down before proceeding.
7.4.4 Remove the PPDT-600, if installed. Remove all tools from the Tool Rack.
7.4.5 Remove the cover plate (Cover MWLD Opening - Item 27 from drawing
5-6-557), located behind the furnace assembly from the base plate (item 24).
The cover may be discarded, but save the screws and washers (items 40 & 71).
7.4.6 Lower the MWLD-600 Assembly into the Base Plate opening. Guide the
wires towards the controller. Hand start the four mounting screws from step 3.
Move the MWLD-600 until alignment between Furnace Top Plate (item 16 on
drawing 5-6-530) and MWLD-600 Lifter Top (item 6 on drawing 5-6-543) is a
uniform .001 to .005 inch gap. Once aligned, tighten the two #10-32 x 2.5 inch
long screws (item 58 on 5-6-543) and then the four screws and washers from
step 7.4.5.
Caution: If not properly align serious damage to the MWLD-600 can occur.
7.4.6.1 For angular adjustments,
7.4.6.1.1 Remove Pan Cover, (see step 7.4.7 below).
7.4.6.1.2 Loosen Furnace Leg-Screw (item 10 on 5-6-530). In

the normal upright operation position, align the Furnace Top Plate
with the MWLD-600 Lifter Top.
7-2
7.4.6.1.3 If still not aligned, loosen (maximum 1 turn) three 1/4-
20 screws (item 34 on 5-6-530). Do not remove these screws.
Again align Furnace Top Plate with the MWLD-600. Tighten
these three screws; see 5-6-530 for torque setting.
7.4.6.1.4 Tighten both Furnace Leg-Screws and recheck

alignment.
7.4.6.2 For height adjustments:
7.4.6.2.1 Remove the five #4-40 screws holding the Motor

Cover (items 48 and 9 on 5-6-543).
7.4.6.2.2 Remove the four #8-32 screws holding the Top Cover
(items 61 and 2).
7.4.6.2.3 Remove the four 1/4-20 screws holding the MWLD-

600 to the Base Plate and slide the MWLD-600 back.
7.4.6.2.4 Remove the back #10-32 screw (item 55 on 5-6-557)

mounting the Tool Rack (item 38). Loosen the front Tool Rack
mounting screw. Rotate the Tool Rack out of the way.
7.4.6.2.5 Carefully flex open the Motor Cover with one hand
while the other hand holding the Top Cover edges, lift up and out
the Top Cover. This will expose the motor controller and fuse.
7.4.6.2.6 Remove the Weight Platform (item 7 on 5-6-543) by

taking out the two 5/16-18 screws and washers (items 62, 67, &
71). Lift the Motor Cover up and off.
7.4.6.2.7 Loosen the two #10-32 screws (item 55 on 5-6-543)

on the back holding the Lifter Top (item 6).
7.4.6.2.8 Remove the two #10-32 (item 56) though Screw

Support channel (item 5). Screw threads must be cleaned (both
the screw and hole) before assembly.
7.4.6.2.9 Slide the Lifter Top to vertically match the Furnace

Top Plate mounting holes. Tighten the two screws (item 55) on
the back.
7.4.6.2.10 Start the two #10-32 mounting screws (item 58) into
the furnace to verify alignment. With cleaned screw (item 56) and
hole, add a serviceable thread locker (Loctite #222) to the screw
and tighten (do not over tighten).
7-3
7.4.6.2.11 Remove the two #10-32 mounting screws (item 58)
and reassemble. Slide the Motor Cover back down around the
motor. Slip on Top Cover. Replace the four Top Cover screws
and five Motor Cover screws. Replace the MWLD-600 mounting
screws (four into the Base Plate and two into the Furnace
assembly).
7.4.6.2.12 Replace the back Tool Rack mounting screw and

tighten the front screw. Replace the Weight Platform with screws
and washers from step 7.4.6.2.6 above.
7.4.7 Flip the MP600 onto the backside, resting on the Base Plate and MWLD-
600 Top Cover (item 2 on 5-6-543). Take care not to damage the MWLD-600
Motor Cover (item 9 on 5-6-543). Remove the four leveling feet and lock nuts
(items 57 & 58 on 5-6-557). Remove the Pan Cover (item 26 on 5-6-557) with
the four screws and washers (items 41 & 65). Lift off the Pan Cover and set
aside.
7.4.8 Put the MWLD-600 wire ends into the controller Cabinet (Item 25 on 5-6-
557). Mount the supplied cable clamps with screws as shown on drawing 5-6-
556, keep all cables free from MWLD-600 belt and pulleys (items 16, 26 & 27 on
5-6-543).
7.4.9 Put the Pan Cover into the Base Plate groove and mount with screws &
washers. Install Leveling Feet and lock nuts. Upright the MP600 back onto the
Leveling Feet.
7.4.10 Remove the four screws (item 44 on 5-6-557) holding the Controller
(item 42). Carefully pull the upper half of the Controller and rotate the Controller
upside down onto the Base Plate.
7.4.11 See drawing 8-12-1366 for MWLD-600 wiring to the Controller. The
wires maybe trimmed to suit.
7.4.12 Replace the Controller and screws from step 7.4.10.
7.4.13 Plug in the MP600. Turn on the MP600. Configure the MWLD-600 for
proper operation with the MWLD-600 according to Section 7.2. The Set Point
should be at room temperature.
7.4.14 After verifying proper MWLD-600 operation, level the machine per
Section 5.3 of this manual.
7-4
7.4.15 With the Weight Platform (item 7 on 5-6-543) in the BOTTOM position,
insert an orifice and the piston assembly into the furnace. Add the lightest 6 inch
diameter weight onto the piston rod. If necessary, loosen the two 5/16 screws
(items 62 on 5-6-543) and adjust the Weight Platform to have the weight seated
flat on the Weight Platform. Tighten adjustment screws. Run the weight
platform up and down a few times to check weight alignment is smooth on/off
piston rod assembly.
7.4.16 Install the Weight Retaining Rods (item 1 on 5-6-543) per Section 7.1 of
this manual.
7.5 Configuring the MP600 after Field Installation of MWLD-600
7.5.1 Verify the proper MWLD Motor Controller voltage setting. (For 220 V use
the inside pin settings, 110 V use the outside pin settings.)
7.5.2 Verify all of the other jumpers for proper settings.
Jumper Set To
115 or 230
J1A & J1B
(See Step 1)
J2 1.7A
J3 A90
J4 10V
J5 SPD
J6 RTS
7.5.3 Verify MWLD Motor Controller pot settings.
7.5.4 Turn the power on.

7.5.5 When prompted, press the 9 (UP) key and hold to raise weight support.
After the weight support has moved up about 1/2 inch, let go of the (UP)
key and the weight support should stop. Press the 9 (UP) key and hold
until weight support stops, must stop before weight support swings away.
If the weight support does not move, check the encoder connections
(Error Code 10) and/or turn the DB Pot counterclockwise.
7.5.6 At the SET POINT Screen and CAL OFFSET Screens, press 0 and
ENTER. This will keep the furnace at room temperature.
7.5.7 At the main IDLE Screen, press 4 (OPTION) key to enter the options.
7-5
7.5.8 At the OPTION Screen, press 4 (CALIBRATE) key.
7.5.9 Enter the access code, press 8 3 5 and ENTER.
7.5.10 At the SELECT CAL FUNCTION Screen, press 1 (WT SUPPORT).
7.5.11 At the WEIGHT SUPPORT Screen, press 2 (DC) and ENTER.
7.5.12 At the DC MOTOR CALIBRATION Screen, press 2 (CONFIG WT
SUPPORT). Verify the following values (change as required) and press
ENTER to continue:
a. ENC RES = 46080
b. DC MOTOR OFFSET = 0%
c. DC MOTOR FS FAST = 100% (up)
d. DC MOTOR FS SLOW = 40%
e. DC MOTOR FS FAST = -100% (down)
f. DC MOTOR FS SLOW = -40%
g. DC MOTOR PROP BAND = 1
h. TOTAL TRAVEL = 9.070 (inch, or 230.38 mm)
i. OVER TRAVEL = .800 (inch, or 20.32 mm)
j. UNDER TRAVEL = .150 (inch, or 3.8 mm)
7.5.13 Back at the DC MOTOR CALIBRATION Screen, press EXIT several

times.
7.5.14 Press the 3 (DOWN) key and hold. Weight support should move down,
slowly at first then speed up. Once the weight support is near the bottom,
release the 3 (DOWN) key and the weight support should stop. Continue
to jog down (pressing & releasing the down key) weight support until it
stops, should have about 1/8 inch gap between the Lifter Top and Lift
Cap.
7.5.15 With the weight support down, turn off the MP600 and turn it back on.
Following the directions on the screen, then press and hold the 9 (UP) key
to raise the platform until it stops.
7.5.16 At the SET POINT Screen and CAL OFFSET Screens, press 0 and
ENTER. This will keep the furnace at room temperature.
7.5.17 At the main IDLE Screen, press 1 (TEST) key to enable the weight
lowering device.
7.5.18 Press the 9 (UP) key and jog the weight support as far as it will swing
around. The weight support must stop at about 90 and not go any
farther. Verify that the cam is not bottomed out on the cam tube slot. If it
is, lower the OVER TRAVEL parameter in Step 7.5.12.
7.5.19 At the main IDLE Screen, press 4 (OPTION) key to enter the options.
7.5.20 At the OPTION Screen, press 4 (CALIBRATE) key.
7.5.21 Enter the access code, press 8 3 5 and ENTER.
7.5.22 At the SELECT CAL FUNCTION Screen, press 4 (DIAG).
7-6
7.5.23 Press ENTER 11 times to cycle though the diagnostic screens, to get to
the CYCLE WS MOTOR Screen.
7.5.24 Press START to cycle the Weight Platform up and down.
7.5.25 Verify smooth weight support movement. Adjust the Motor Controller Pots
(from step 2) if required. If varying speed (up or down) adjust IR pot CW.
If the red LED (near the pots) is on or blinking (start-up blink OK) turn RCL
pot CW.
7.5.26 Press 4 (STOP) at any time to stop the Weight Platform. When stopped
and on the CYCLE WS SUPPORT Screen, all the Weight Support keys
are functional: 1 (BOTTOM), 3 (DOWN), 7 (TOP), and 9 (UP).
7.5.27 When finished running the Weight Support, press 4 (STOP) and then 1
(BOTTOM). Once the Weight Support stops at the bottom position turn
power OFF.
7.5.28 In final inspection do the following:
a. Check the parameters set in Step 7.5.12.
b. Check the OVER TRAVEL. Turn the machine off and then back on
with the weight platform in the down position. Following the directions
on the screen, then press and hold the 9 (UP) key to raise the platform
until it stops. Initialize the machine and press the 7 (TOP) key to raise
the weight support as far as it will swing around. The weight support
must stop at about 90 and not go any farther.
c. If equipped with a PPDT Switch, match the weight support position
with the switch position by adjusting the UNDER TRAVEL parameter in
Step 7.5.12.
7-7
B
7-8
8 Section 8 - Installation of OPTIONAL OKIDATA Model 320-Dot
Matrix Printer & Printer Cable
8.1 Connect one end of the MI-Printer cable (P/N 90002871) to the serial port at the
rear of the machine and connect the other end to the serial port on the printer.
8.2 Configure the MP600 as covered in Section 10.4.
8.3 Configure the printer with the appropriate communications parameters. The
MP600 uses 1200 baud, Odd parity, 7 data bits, 1 stop bit. An example of the
serial configuration for an OKIDATA MICROLINE 320 (with serial port option) is as
follows:
Parity Odd
Serial Data 7 or 8 Bits 7
Protocol Ready/Busy
Diagnostic Test No
Busy Line SSD-
Baud Rate 1200 BPS (or as selected in the MP600)
DSR Signal Valid
DTR Signal Ready on Power UP
Busy Time 200 ms
8-1
B
8-2
9 Section 9 Initial Start-Up
CAUTION: Prior to shipment, the cylinder of the machine is coated with oil to
prevent rust from forming. When the machine is first turned on, it is normal for
the machine to smoke as the cylinder comes to temperature and the oil residue
burns off. To reduce the amount of smoke that forms, clean the cylinder
thoroughly before turning the machine on. Be sure that a ventilation system is
operating at this time.
9.1 Powering Up the MP600
9.1.1 The MP600 is now ready for operation. Check nameplate to verify the
correct voltage is being used. Connect the MP 600 to a suitable power supply
(500 WATT MINIMUM) and turn both Power Switches (front & rear) ON.
9.1.2 When the MP600 is first turned on, the controller will display the
EPROM program version, the date and the time. If an MWLD-600 is attached
and not raised, the display may prompt the operator to raise the weight support
by pressing the 9 key. Press and hold the 9 key until the platform stops.
Pressing the ENTER key will skip this step; however, the MWLD-600 will not
function until this step has been completed.
9.2 Setting the Temperature
NOTE: The Set Temperature and Calibration Offset prompts will appear at
this point if the At Program Initiate option was selected in the Test Parameters
Set-Up Mode (see Section 11).
9.2.1 The MP600 will now display the following screen:

SET POINT PI C
ENTER NEW SET POINT
PRESS ENTER TO CONT
Program a fixed temperature between 0 and 450C and press [ENTER].
TEST TIP: If the operator is unfamiliar with melt index testing procedures and
machine operations, it might be beneficial to turn off the heaters at this point.
Enter a temperature near or below the ambient temperature (or enter 0) and
then press the [ENTER] key until you return to the idle screen. A 0 setting
should also be entered when the Calibration Offset screens are displayed (see
Section 9.3).
9-1
9.3 Entering the Calibration Offset
9.3.1 The MP600 will then prompt the operator to enter the Calibration Offset
for top and bottom. Enter the offset values that correspond to the desired test
temperature. The Calibration Offset values are found on the MP600
Configuration/Calibration Settings Worksheet that was supplied with the machine
or that was supplied by the Calibration Engineer at the last calibration/verification
service. Refer to Section 2.1.2 of these instructions for more information on the
Calibration Offset value.
9.3.2 The MP600 Controller will now display the Idle screen that resembles the
following:
Actual Temperature AT 23.8 SP 190.0 C Set Temperature

Program Number. PN 04 PROC A Test Type
1=TEST 2=VIEW
3=SELECT 4=OPTIONS
At this point, the machine is ready to accept programming for the testing.
CAUTION Once the idle screen is displayed, the cylinder will start to heat up
to the Set Point.
9.4 Final Preparation
9.4.1 Thoroughly clean the inside of the cylinder and orifice (see Section 16
for Cleaning Instructions), then drop the orifice into the cylinder. The orifice
should fall freely to the bottom of the cylinder with an audible click. If not,
remove the orifice and visually inspect the orifice and cylinder for any defects or
obstructions. Clean the cylinder and orifice again if necessary. It is imperative
that the cylinder has a mirror finish and that no residue remains on the outside or
the inside diameter of the orifice.
9.4.2 Without using any material, and with the orifice already at the bottom,
insert the Piston Rod Assembly into the cylinder.
9-2
10 Section 10 - Configuration Mode
10.1 The Configuration Mode provides for the basic setup and configuration of the
MP600 Controller. This mode is accessed by pressing the [4] key (OPTIONS) from
the IDLE Screen to advance to the OPTIONS Menu:
1=RUN TEST
2=EDIT PROGRAM
3=CONFIGURE
4=CALIBRATE
From the OPTIONS Menu; press the [3] key for CONFIGURE. At the ENTER
ACCESS CODE screen, press the [8], then the [3] and then the [4] key followed
by [ENTER] to access the CONFIGURE Menu:
1=GENERAL
2=TEMP CONTROL
3=SERIAL PORT
PRESS EXIT TO EXIT
10.2 Pressing the [1] key from the CONFIGURE Menu accesses the GENERAL
Configuration Mode. The following screens can now be configured. (Note that
pressing [ENTER] accepts the existing entry and advances to the next screen.
Pressing [EXIT] returns the user to the CONFIGURE Menu.)
10.2.1 "Alarm" - Enter a "0" to turn off the alarm that sounds at the end of the
Release Time (Preheat Time). Enter a "1" to activate the alarm.
10.2.2 "Display Inten." - Enter a number between 1 and 4. The higher the
number the brighter the display but the shorter its expected life. A setting of 3
usually works well in most cases.
10.2.3 "Position" - Enter a "1" to work in inches, enter a "2" to work in

millimeters.
10.2.4 Date - If incorrect, enter the current date in mm-dd-yyyy format.
10.2.5 Time - If incorrect, enter the current time in hh:mm format. (Use the [-]
key to enter the colon.)
10.2.6 Language Select from the available languages shown on the screen.
10.2.7 Print Parameters If the machine is connected to a printer and

PRINTER has been selected on the Serial Port Configuration screen, pressing
the [1] key when on this screen will produce a printout of the Configuration.
10-1
10.3 Pressing the [2] key from the Configure Menu accesses the TEMP CONTROL
Configuration Menu.
1=GENERAL
2=VIEW
3=SET PID PARAMS
PRESS EXIT TO EXIT
10.3.1 Pressing the [1] key from the TEMP CONTROL Configuration Menu
accesses the GENERAL TEMP CONTROL Configuration Mode. The following
screens can now be configured. (Note that pressing [ENTER] accepts the existing
entry and advances to the next screen. Press [EXIT] to return to the TEMP
CONTROL Configuration Menu.)
10.3.1.1 Voltage - The Extrusion Plastometer is set up at the factory

for operation from either 115 or 230 VAC main power. This screen must
be set to agree with this main power requirement. Press the [1] key if
the machine is arranged for operation from 115 VAC. Press the [2] key if
arranged for operation from 230 VAC.
10.3.1.2 "High Temp" - This temperature limit control should be set for a
temperature of approximately 5 degrees C above the highest test
temperature normally used, but no higher than 455C . When this
temperature is reached, the MP600 Controller will remove power from the
heaters and display ERROR 16.
10.3.2 Press the [2] key from the TEMP CONTROL Configuration Menu to access
the VIEW PID/TEMP Screens. This provides access to screens for viewing the set
point, temperature of top and bottom control zones, and the proportional, integral
and derivative terms for the top and bottom zones. These screens are used
primarily for diagnostic purposes. Press [ENTER] to scroll through the VIEW
PID/TEMP Screens. Press [EXIT] to return to the TEMP CONTROL Configuration
Menu.
SET POINT xxx.x C
ACTUAL TOP yyy.y C
ACTUAL BOT zzz.z C
PRESS ENTER TO CONT
Where xxx.x is the current setpoint, yyy.y is the actual top zone temperature and
zzz.z is the actual bottom zone temperature. The [ENTER] Key will move the
display to CFGv2. The [EXIT] Key will return the user to the TEMP CONTROL
Configuration Menu.
10-2
PROP TERM uuuuu
INT TERM vvvvv CFGv2
DER TERM wwwww
ATT= aaa.a C
PROP TERM xxxxx

INT TERM yyyyy CFGv3
DER TERM zzzzz
ATB= bbb.b C
CFGv2 and CFGv3 show the current PID term values and the actual temperature
for the Top and Bottom zones, respectively. The [ENTER] Key will advance from
CFGv2 to CFGv3 and then to the TEMP CONTROL Configuration Menu. Press
[EXIT] key at any time to return to the TEMP CONTROL Configuration Menu.
10.3.3 Pressing the [3] key from the TEMP CONTROL Configuration Menu
accesses the SET PID PARAMS Configuration Mode. Screens that show the
present PROP BAND, RESET, ILM, RATE BAND, and RATE for both the top and
bottom control zones can be viewed and new values entered. (Note that pressing
[ENTER] accepts the existing entry and advances to the next screen. Pressing
[EXIT] returns the user to the TEMP CONTROL Configuration Menu). Refer to
Section 19 for additional information.
CAUTION: Machines are shipped with factory settings already entered in the
above SET PID PARAMS Configuration Mode. DO NOT CHANGE ANY OF
THESE SETTINGS WITHOUT A GOOD UNDERSTANDING OF THE EFFECT
THE CHANGE WILL HAVE ON THE TEMPERATURE CONTROL CAPABILITY
OF THE MP600.
10.4 Pressing the [3] key from the CONFIGURE Menu accesses the SERIAL PORT
Configuration Mode. The following screens can now be configured. (Note that
pressing [ENTER] accepts the existing entry and advances to the next screen.
Pressing [EXIT] returns the user to the CONFIGURE Menu.)
10.4.1 "Ser Port" - Enter a "1" to have the MP600 work with a Dot-Matrix Serial
Printer and print test reports. Enter a "2" to use the MP600 with a computer
program. If 2 (Computer) is selected, refer directly to 10.4.3. If 1 (Printer) was
selected, the following screen appears:
10.4.2 Baud Rate = - Select a baud rate compatible with the printer. Press
[ENTER] to return to the CONFIGURE Menu.
10-3
10.4.3 Interface - Enter a 1 (RS232) if using a computer and software with a
single MP600 connected to the serial port of the computer or if using Tinius
Olsens EP600 Software Package with the MP600 connected to either the serial or
USB port of the computer. Enter 2 (RS485) if the MP600 is being connected to a
COM 422 card installed in the computer. Press [ENTER] to return to the
CONFIGURE Menu.
10.4.4 "Device Address" - If using the RS485 Interface, enter a number

between 0 and 9. When connecting more than one Extrusion Plastometer to a
single computer using Tinius Olsen software, each Plastometer must have a
different address. NOTE: This screen will only appear when the RS485 Interface
is being used.
10.4.5 Baud Rate - Select the baud rate specified for the software. If using
Tinius Olsens EP600 Software Package with the MP600 connected to either the
serial or USB port of the computer, enter 19200. If the MP600 is being connected
to a COM 422 card installed in the computer, enter 1200.
10-4
11 Section 11 - Test Parameters Programming Mode
11.1 General Information
11.1.1 Test parameters are bits of information that the microprocessor must
know in order to perform a melt index test, i.e. test temperature, weight loading,
etc. Test parameters vary with the material being tested. Twenty-five (25) test
programs may be configured, and stored in the microprocessor for later use.
11.1.2 When this machine was originally shipped, the first four programs were
set up at the factory as examples. These are shown in Table 11-2. Do not
change these programs until you fully understand the operation of the
MP600 Controller.
11.1.3 Access to the features described below is from the Idle Screen, similar
to the following.

1=TEST 2=VIEW
3=SELECT 4=OPTIONS
11.1.4 The test parameters in a program may be viewed, but not changed, by
pressing the [2] key and following the instructions on the display.
11.1.5 Select a program by pressing the [3] key, entering a number between 1
and 25 and following the instructions on the display. The selected Program
Number should now appear on the left side of the second line of the Idle Screen.
(Note: When using a computer and Tinius Olsen software to operate the
machine, avoid using Program 25 for operating the machine without use of the
computer since the computer downloads to Program 25 and would therefore
overwrite any manually programmed information.)
11.1.6 To modify (Edit) the selected program, press the [4] key for OPTIONS
and then the [2] key for EDIT. At the ENTER ACCESS CODE screen press
the [8], then the [5] and then the [2] key followed by [ENTER]. Select EDIT
PROGRAM by pressing the [1] key. A series of parameter screens will be
displayed and, in most cases, a default value will be displayed.
11.1.7 The first screen will determine the PROCEDURE, i.e., a Procedure A
(Manual cutoff and weigh) or Procedure B (Automatically timed) Test. The
PROCEDURE can be changed by pressing the appropriate numeric key or,
press [ENTER] to accept the existing default.
11.1.8 Many of the remaining parameter screens will be dependent upon the
type of test selected. The default value can be accepted by pressing [ENTER] or
the existing default can be changed and then press [ENTER] to advance to the
next screen. Press [CLEAR] if an entry error is made.
11-1
11.1.9 Most of the parameter screens can be answered with a numeric value,
or by pressing the [-] key to enter NU, i.e., NOT USED, or by pressing the
[START] key to enter TT or PI, i.e., Ask at Test Time or Ask at Program
Initiation. Changes are stored automatically. Pressing the [EXIT] key will exit the
Programming Mode without having to respond to all screens.
11.1.10 When finished, the MP600 will return to the EDIT/SELECT screen and
additional programs can be selected for editing. Pressing [EXIT] returns the user
to the Idle Screen.
11.2 Test Parameters Programming - ASTM D 1238 Procedure A Testing
The following screens are shown when programming a Type A Test (manual
cutoff and weighing of the extruded sample).
11.2.1 Type Test Enter a 1 for a Type A Test.
11.2.2 Sample ID This is used only for identification purposes on a printed

test report. Enter either a fixed number, press the [-] key to not use the Sample
ID, or press the [START] key to be prompted for the Sample ID at test time.
11.2.3 Run Number This is used for identification purposes only on a

printed test report. Enter either a number, press the [-] key to not use the Run
Number, or press the [START] key to be prompted for the Run Number at test
time. The Run Number is automatically incremented during a group of tests and
is reset when a new group of tests is started.
11.2.4 Set Point Enter a fixed temperature between 0 and 450 C or press
the [START] key. If the [START] key is pressed, the Set Point entry will be
prompted each time the program is selected.
11.2.5 Cal Offset-Top This Calibration Offset is used to adjust the

temperature readout and control point to agree with the temperature reference
standard used to measure the cylinder temperature at 75 mm above the orifice.
Enter the value provided with each new machine (or the value from reverification
by a certified technician). If desired, press the [START] key to have this question
asked at program initiation. The program will also set the Cal Offset Bottom to
PI and skip the next screen.
11.2.6 Cal Offset-Bottom This Calibration Offset is used to adjust the

standard used to calibrate the cylinder temperature at 10 mm above the orifice.
by a certified technician.) If desired, press the [START] key to have this question
asked at program initiation. This screen will not show if the Cal Offset Top is set
to PI.
11-2
11.2.7 Load Enter the test load in kilograms to have Load and Shear Stress
printed on the Test Report. The [START] key may be pressed to permit entry of
the load at test time or the [-] key may be pressed to enter NU and not have the
Load and Shear Stress values reported.
11.2.8 Orifice Dia The nominal orifice diameter for ASTM D 1238 is 2.095
mm (0.0825 in.). Enter the numeric value of the orifice diameter to have Shear
Stress calculated. Press the [-] key for NU (Not Used) or press the [START]
key to permit entry of the orifice diameter at test time.
11.2.9 Orifice Lgth The nominal orifice length for ASTM D 1238 is 8.00
mm (0.315 in.). Enter the numeric value of the orifice length to have Shear
Stress calculated. Press the [-] key for NU (Not Used) or press the [START]
key to permit entry of the orifice length at test time.
11.2.10 Cutoff Time The manual Cutoff Interval time is entered in seconds.
During the test, the timer beeps, resets, and begins recounting this time. The
beeps are used to signal the user when to make the cut-offs. A numerical
value between 1 and 999 may be entered. Press the [START] key to enter the
cutoff time at test time.
11.2.11 Preheat Time (for preheat timing) A fixed value from 1 to 999
seconds may be entered, the [START] key may be pressed to permit entry of the
preheat time at test time or the [-] key may be pressed to enter NU (Not Used)
for the preheat time.
When the preheat time is reached in a Type A Test, the alarm will sound, the
elapsed timer (ET) will continue to display the total test time and the [START]
key is pressed to start the Cutoff Interval Timer (CI).
Note that the optional MWLD-600 will not be lowered automatically during a Type
A Test, the operator must manually position it.
11.3. Test Parameters Programming ASTM D 1238 Procedure B Testing
The following screens are shown when programming a Type B Test

(Automatically Timed Test). The PPDT-600 Automatic Timing Switch is required
to perform this test type.
11.3.1 Type Test Enter a 2 for a Type B Test.
11.3.2 Sample ID This is used only for identification purposes on a printed

test report. Enter either a fixed number, press the [-] key to not use the Sample
ID, or press the [START] key to be prompted for the Sample ID at test time.
11-3
11.3.3 Run Number This is used for identification purposes only on a
printed test report. Enter either a number, press the [-] key to not use the Run
Number, or press the [START] key to be prompted for the Run Number at test
time. The Run Number is automatically incremented during a group of tests and
is reset when a new group of tests is started.
11.3.4 Set Point Enter either a fixed temperature between 0 and 450 C or
press the [START] key. If the [START] key is pressed, the Set Point entry will be
prompted each time the program is selected.
11.3.5 Cal Offset-Top This Calibration Offset is used to adjust the
standard used to measure the cylinder temperature at 75 mm above the orifice.
by a certified technician). If desired, press the [START] key to have this question
asked at program initiation. The program will also set the Cal Offset Bottom to
PI and skip the next screen.
11.3.6 Cal Offset-Bottom This Calibration Offset is used to adjust the
standard used to calibrate the cylinder temperature at 10 mm above the orifice.
Enter the value provided with each new machine (or the value from reverification by
a certified technician.) If desired, press the [START] key to have this question asked
program initiation. This screen will not show if the Cal Offset Top is set to PI.
11.3.7 Load Enter the test load in kilograms to have Load and Shear
Stress or Viscosity printed on a test report. The [START] key may be pressed to
permit entry of the load at test time or the [-] key may be pressed to enter NU
and not have the Load and Shear Stress values reported.
11.3.8 Orifice Dia The nominal orifice diameter for ASTM D 1238 is 2.095
mm (0.0825 in.). Enter the numeric value of the orifice diameter to have Shear
Stress, Shear Rate and Viscosity calculated. Press the [-] key for NU (Not
Used) or press the [START] key to permit entry of the orifice diameter at test time.
11.3.9 Orifice Lgth The nominal orifice length for ASTM D 1238 is 8.00
mm (0.315 in.). Enter the numeric value of the orifice length to have Shear
Stress, Shear Rate and Viscosity calculated. Press the [-] key for NU (Not
Used) or press the [START] key to permit entry of the orifice length at test time.
11.3.10 Density The melt density is required to obtain the Flow Rate in a
Type B test. It is not required to obtain the Volume Rate, Shear Stress, Shear
Rate or Viscosity.
Press the [1] key when entering a fixed melt density value, the [2] key to have the
melt density calculated from a cut-off made during the first timed capture of a test,
the [START] key to permit selection at test time, or the [-] key for NU (Not Used).
11-4
11.3.11 Melt Den - This screen appears if a 1 (fixed value) or START (at test
time) was entered above for Density. If a fixed melt density is used, enter the
numeric value in grams per cubic centimeter, or press the [START] key to permit the
melt density to be entered at test time. The melt density is required to calculate Flow
Rate in a Type B test and normally has to be calculated. Do not use the room
temperature density normally stated in the material specifications which is higher.
11.3.12 FR Constant Enter the constant 426 (mean of the areas of the piston
and cylinder X 600) found in the Procedure B Flow Rate Calculation Section of ASTM
D 1238. (Or check other applicable Test Method for the proper constant if not using
ASTM D 1238. For example ISO 1133 uses 427.)
11.3.13 Auto Piston Travel Select Method This screen is shown only when
Entered is selected on the above Density screen. If Yes is selected the MP600
will follow the criteria in ASTM D 1238 and automatically select a piston travel of 6.35
mm (0.25 in.) when the Flow Rate is equal to or less than 10 grams per 10 minutes,
or a piston travel of 25.4 mm (1.00 in.) if the Flow Rate is less than 10 grams per 10
minutes. If No is selected, the next four screens will appear. If the [START] key is
pressed, these selections can be made at test time.
The next four screens will appear ONLY if the Auto Piston Travel Select
Method is set to No.
11.3.14 No of Captures The MP600 can make up to 10 captures (test
measurements) during a test. Enter the desired number of captures or press [START]
to permit selection at test time. At least one capture must be used to obtain a result.
11.3.15 Piston Travel Cap 1 Enter the desired piston travel distance for this
capture or press [START] to permit its entry at test time.
11.3.16 Start Capture 1 Enter the desired starting height, i.e., distance above
the top of the orifice, for Piston Travel Cap 1. 46 mm (1.811 in.) is appropriate when
testing in accordance with ASTM D 1238.
Note: If more than one capture has been selected above in the No of Captures screen,
Piston Travel and Start Capture screens will appear for each capture. The MP600 will
automatically set all Piston Travels equal to the Piston Travel Cap 1 distance, but these
values can be overwritten by use of the numerical keys. Also, the Starting Heights are
automatically set back-to-back based on the Piston Travel Cap 1 distance, but can also
be overwritten. The starting height of a subsequent capture must be programmed
not to occur prior to the finishing height of the previous capture.
11.3.17 Display Press the [1] key to have the Flow Rate or the [2] key to have
the Volume Rate displayed on the Test Screen at the end of each capture. The [-] key
will disable this function and the [START] key will permit selecting the desired result for
display at test time.
11-5
11.3.18 Release Time (for preheat timing) When the release time is
reached in a Type B test, the alarm will sound (if activated) and the MWLD-600
(if available and activated) will lower its weight support platform fully. A fixed
value from 1 to 999 seconds may be entered. Press the [START] key to permit
the time entry at test time or the [-] key to enter NU. If NU is entered and the
Auto Weight Lower screen is set to Yes, the weight support platform will
automatically lower to the bottom when a test is started.
The following screens appear ONLY when the machine is equipped with
the optional MWLD-600 Motorized Weight Support and Lowering Device.
11.3.19 Auto Weight Lower Press the [0] key to disable or the [1] key to
enable the MWLD-600 automatic lowering feature, or press the [START] key to
permit selection at test time. If disabled, the operator must manually lower the
weight support platform using the keys on the keypad. If enabled, when starting
a test the optional MWLD-600 will automatically lower the weight support
platform to the height entered on the following Wt Sup Ht screen. At the end of
the Release Time, the weight support will then be lowered automatically to the
bottom of its stroke.
11.3.20 Wt Sup Ht Enter the desired height that the weight support
platform of the MWLD-600 should run to at the start of a test, or press the
[START] key to permit the height entry to be made at test time. (Also, refer to
11.3.19.) Note: If an initial automatic lowering is not desired, set the above
height entry to 228.6 mm (9.00 in.). The 228.6 mm entry is a nominal setting
and your machine may be different depending on the under travel setting.
Displayed Orifice Orifice Melt Piston Start

Load
Results Diameter Length Density Travel Point
Melt Density * * *
Shear Stress * * * * *
Capture Time * *
Shear Rate * * *
Viscosity * * * * *
Flow Rate * * *
Volume Rate * *
Table 11-1 - lists the available test results in the left column and what items must
be selected in the program to obtain that result. For example to obtain the Flow
Rate result the program must have the Melt Density, Piston Travel(s), Start
Point(s) and Constant entered.
* - Indicates a value that must be entered to obtain this result. (Or press the [-]
key for NU and this result will not be calculated.)
11-6
PROGRAM # 1 PROGRAM # 2 PROGRAM # 3 PROGRAM # 4
Procedure Procedure Procedure Procedure
B B B A
Sample ID Sample ID Sample ID Sample ID
NU NU NU NU
Run Number Run Number Run Number Run Number
NU NU NU NU
Set Point Set Point Set Point Set Point
PI PI PI PI
Cal Offset - TOP Cal Offset - TOP Cal Offset - TOP Cal Offset - TOP
PI PI PI PI
Cal Offset - BOTTOM Cal Offset - BOTTOM Cal Offset - BOTTOM Cal Offset - BOTTOM
PI PI PI PI
Load Load Load Load
TT TT TT TT
Orif Dia Orif Dia Orif Dia Orif Dia
2.096 mm (0.0825 in.) 2.096 mm (0.0825 in.) 2.096 mm (0.0825 in.) 2.096 mm (0.0825 in.)
Orif Lgth Orif Lgth Orif Lgth Orif Lgth
8.001 mm (0.315 in.) 8.001 mm (0.315 in.) 8.001 mm (0.315 in.) 8.001 mm (0.315 in.)
Density Density Density Cutoff Time
Entered Calc Entered TT
Melt Den Melt Den Preheat Time
TT TT 420 s
FR Constant FR Constant FR Constant
426.0 426.0 426.0
Auto Piston Travel Auto Piston Travel
Select Method No Select Method No
No of Captures No of Captures No of Captures
1 1 4
Piston Travel Cap 1 Piston Travel Cap 1 Piston Travel Cap 1
TT TT 6.35 mm (0.250 in.)
Start Capture 1 Start Capture 1 Start Capture 1
46.00 mm (1.811 in.) 46.00 mm (1.811 in.) 46.00 mm (1.811 in.)
Display Display Piston Travel Cap 2
Flow Rate Flow Rate 6.35 mm (0.250 in.)
Release Time Release Time Start Capture 2
TT TT 39.65 mm (1.561 in.)
Auto Wt Lower Auto Wt Lower Piston Travel Cap 3
Yes Yes 6.35 mm (0.250 in.)
Wt Sup Ht Wt Sup Ht Start Capture 3
228.6 mm (9.00 in.) 228.6 mm (9.00 in.) 33.30 mm (1.311 in.)
Piston Travel Cap 4
6.35 mm (0.250 in.)
Start Capture 4
26.95 mm (1.061 in.)
Display
Flow Rate
Release Time
TT
Auto Wt Lower
Yes
Wt Sup Ht
228.6 mm
Table 11-2 Factory Programmed MP600 Test Parameter Screens

(Note: Programs No. 5 through 25 are factory programmed the same as Program No. 4.)
11-7
PROGRAM # PROGRAM # PROGRAM # PROGRAM #
A A A A
Cal Offset - Top Cal Offset - Top Cal Offset - Top Cal Offset - Top
Cal Offset - Bottom Cal Offset - Bottom Cal Offset - Bottom Cal Offset - Bottom
Load Load Load Load
Cutoff Time Cutoff Time Cutoff Time Cutoff Time
Preheat Time Preheat Time Preheat Time Preheat Time

A A A A
Cal Offset - Top Cal Offset - Top Cal Offset - Top Cal Offset - Top
Cal Offset - Bottom Cal Offset - Bottom Cal Offset - Bottom Cal Offset - Bottom
Load Load Load Load
Cutoff Time Cutoff Time Cutoff Time Cutoff Time
Preheat Time Preheat Time Preheat Time Preheat Time
Table 11-3 For User Developed Programs for Procedure A Tests
This blank page can be copied and used to write in the specific programs for ASTM D
1238 Procedure A - Manual Cutoff Test Procedure that are set up after receiving the
unit. Keep them in your records or with the machine for future reference.
11-8
B B B B
Cal Offset-Top Cal Offset-Top Cal Offset-Top Cal Offset-Top
Cal Offset-Bottom Cal Offset-Bottom Cal Offset-Bottom Cal Offset-Bottom
Load Load Load Load
Density Density Density Density
Melt Den Melt Den Melt Den Melt Den
FR Constant FR Constant FR Constant FR Constant
Auto Piston Travel Auto Piston Travel Auto Piston Travel Auto Piston Travel
Select Method- Select Method- Select Method- Select Method-
Yes/No Yes/No Yes/No Yes/No
No of Captures No of Captures No of Captures No of Captures
Piston Travel Cap 1 Piston Travel Cap 1 Piston Travel Cap 1 Piston Travel Cap 1
Start Capture 1 Start Capture 1 Start Capture 1 Start Capture 1
Piston Travel Cap 5-10 Piston Travel Cap 5-10 Piston Travel Cap 5-10 Piston Travel Cap 5-10
Start Capture 5-10 Start Capture 5-10 Start Capture 5-10 Start Capture 5-10
Display Display Display Display
Release Time Release Time Release Time Release Time
Auto Wt Lower Auto Wt Lower Auto Wt Lower Auto Wt Lower

Yes/No Yes/No Yes/No Yes/No
Wt Sup Ht Wt Sup Ht Wt Sup Ht Wt Sup Ht
Table 11-4 For User Developed Programs for Procedure B Tests
This blank page can be copied and used to write in the specific Programs for ASTM D
1238 Procedure B - Automatic Timed Test Procedure that are set up after receiving the
unit. Keep them in your records or with the machine for future reference.
11-9
B
11-10
12 Section 12 - Testing Polymers According to ASTM D 1238
Procedure A (Manual Cut-Off Operation)
NOTE: The instructions in this Section are based on ASTM D 1238. This test
method should be thoroughly studied by all operators prior to using the MP600.
Copies of the standard are available from ASTM, 100 Barr Harbor Drive, West
Conshohocken, PA 19428-2959 USA Telephone: (610) 832-9721.
12.1 Introduction
12.1.1 Each MP600 is shipped from the factory with the first four programs
already configured with example Test Parameters (see Table 11-2). Program 4 is
set up for a Procedure A test. The instructions in this Section will follow the
factory settings in Program 4. Any changes the operator makes in the program
may affect the way the controller prompts the operator.
12.1.2 To perform tests to ASTM D 1238 Procedure A, only the basic machine
is required, along with the appropriate weight(s) for the polymer to be tested, and
the optional thermometer, if desired. If the machine is equipped with a PPDT-
600 Automatic Timing Switch, simply rotate the switch in a counter-clockwise
direction until it is out of the way. The optional Motorized Weight Lowering
Device (MWLD-600) may be used if desired. However, the weight platform will
have to raised and lowered manually by use of the keys. A laboratory scale, (not
supplied by Tinius Olsen), having a resolution of 0.001 grams is also required.
12.2 Configuring the MP600 Controller for Procedure A Testing
12.2.1 When the unit is powered up, the MP600 will prompt the user to ENTER
NEW SET POINT. Use the numeric keys to enter the desired test temperature
and press the [ENTER] key.
NOTE: If the machine is equipped with the optional MWLD-600 Motorized

Weight Lowering Device, the MP600 may first prompt the user to RAISE WT
SUPPORT. In this case, press the [9] (UP) key until the MWLD-600 weight
platform stops and displays the above prompt.
12.2.2 The MP600 will then prompt the user to enter the TOP OFFSET. Enter
the TOP calibration offset for the above entered test temperature. Refer to the
MP600 Configuration/Calibration Settings Worksheet that was supplied by the
factory (or at the last calibration/verification). Press the [ENTER] key.
12.2.3 The display will prompt the user to enter the BOTTOM OFFSET. Enter
the BOTTOM calibration offset for the above entered test temperature. Refer to
the MP600 Configuration/Calibration Settings Worksheet that was supplied by
the factory (or at last calibration/verification). Press the [ENTER] key.
12-1
12.2.4 After the temperature prompts have been answered, the Idle Screen,
similar to the one shown below, will be displayed. The MP600 Controller will
then begin to ramp the temperature up to the Set Temperature (SP). The
Program Number is shown on the left side of the second line of the Idle Screen.
If the Program Number is not set to 4; press the [3] key to select a new program.
Then press the [4] key and the [ENTER] key and follow the prompts to access
the Idle Screen for Program 4 (PN).
1=TEST 2=VIEW
3=SELECT 4=OPTIONS
CAUTION: The surfaces of the furnace assembly can be extremely hot when
the machine is in operation!
12.2.5 Once the machine has stabilized at the set temperature (+/- 0.2C),
remove the orifice (if present) and thoroughly clean the inside of the cylinder and
orifice (see Section 16 for Cleaning Instructions).
12.2.6 Insert the orifice into the cylinder. The orifice should fall freely to the
bottom of the cylinder with an audible click. If not, remove the orifice and visually
inspect the orifice and cylinder for any defects or obstructions. Clean the
cylinder and orifice again if necessary and insert the orifice into the cylinder. It is
imperative that the cylinder has a mirror finish and that no residue remains on
the outside or the inside diameter of the orifice.
12.2.7 Check that the piston rod assembly is clean and that the guide collar
slides freely along the piston rod. Clean as needed and insert the piston into the
cylinder. Allow the machine to stabilize at the set temperature.
12.2.8 To start the Procedure A type test, press the [1] Test key. The Test
Mode Screen, similar to the one shown below, will be displayed. Note that the
piston and orifice must be at temperature and in place prior to starting the test.
DO NOT start a test with a room temperature piston and orifice.

CI TT s
PRESS ENTER TO CONT
12.2.9 Press [ENTER]. The MP600 will then prompt the user to enter LOAD.
Use the numeric keys to enter the total test load in kilograms and press [ENTER].
12.2.10 The MP600 will then prompt the user to enter the CUTOFF TIME. Use
the numeric keys to enter the appropriate Cutoff Time Interval in seconds. (Refer
to Table 2 of ASTM D 1238 for the appropriate Time Interval that is based on the
Flow Rate of the material under test.) DO NOT PRESS [ENTER] AT THIS TIME.
12-2
12.3 Test Procedure
12.3.1 Remove the preheated piston and place it in the tool rack. Verify that the
orifice is at the bottom of the cylinder.
12.3.2 Press [ENTER]. The display will prompt the user to LOAD SAMPLE
while indicating the elapsed time, ET.
12.3.3 Charge the cylinder with the material that is to be tested. Refer to ASTM
D 1238, Table 1 (Table 2 in earlier versions) for suggestions on the amount of
polymer to use for a test. To charge the cylinder, insert the funnel into the
cylinder, and then slowly pour the material into the funnel. Do not dump it in all
at once as it will melt and stick to the funnel. The brass orifice remover may be
used to guide the material into the cylinder. This should be done within a
reasonable time (refer to test method).
CAUTION: The funnel, when placed in the cylinder, can become extremely hot
when the machine is at operating temperature! The time that the funnel is
allowed to sit in the cylinder should be kept to a minimum.
12.3.4 After charging the cylinder, reinsert the piston and place the appropriate
weight on the piston. If the machine is equipped with the optional Motorized
Weight Support and Lowering Device, use the [DOWN] (3) key to lower the unit
and apply the weight to the piston. NOTE: The ASTM D 1238 Method allows one
minute to charge the cylinder, insert the piston, and start the preheat time of test.
TEST TIP: When testing materials with high melt flow rates (> 10 g/10
minutes), the weight platform of the optional MWLD-600 can be used to prevent
excessive polymer from being purged from the cylinder prior to the end of the
preheating period. To use this feature, lower the weight platform so that the top
surface of the platform is approximately 25 mm (1 inch) above the 46 mm (1.81
inch) start position of the test measurement. (This can be accomplished above
in 12.3.4 by using the [3] (DOWN) key to obtain a reading of approximately 71
mm (2.81) on the WT SUP HT display. The weight platform will now catch the
weight as it falls and support it, temporarily reducing the load on the material in
the cylinder. When the Elapsed Time reaches the 420 seconds preheat
requirement, lower the weight platform all the way and allow the test to continue.
Materials with extremely high melt flows may require the orifice to be plugged in
addition to supporting the weight. Use the optional Tinius Olsen High Melt Flow
Orifice Plug (TO P/N 02001455).
12.3.5 Press [ENTER] and the Test Screen, similar to the one shown below, will
be displayed. The Elapsed Time (ET) display will reset to zero and begin to
count up, in seconds. Material will begin to extrude through the orifice.
Cut-Off Interval. CI 30 ET 0 s Elapsed Time
START= CUTOFF TIMING
EXIT=WEIGHT ENTRY
12-3
12.3.6 When the Elapsed Timer reaches the Release Time (Preheat Time)
that was entered in the Set-up Parameters, an alarm will sound for about 5
seconds. At that time, the first (lower) scribe line on the piston rod should be
close to entering the guide collar. ASTM D 1238 requires a preheat time of 7 +/-
0.5 minutes (420 +/- 30 seconds). If the scribe line has not entered the guide
collar during the preheating period, the amount of material charged should be
reduced. Alternatively, the material in the cylinder can be manually purged
during the first 300 seconds of the preheating period.
12.3.7 Using the cutoff tool, cut off the material that has extruded from the
orifice, while at the same time pressing the [START] key to activate the Cutoff
Interval Timer (CI). (All cut-offs must be made directly at the bottom of the
orifice.) The timer will then begin counting down. When the Cutoff Interval
Timer reaches zero, the alarm will beep. The cut-off should be made at the time
of the beep. The timer will automatically reset and begin counting for the next
cut-off should additional cutoffs be required. To reset the timer during the middle
of a test, press the [START] key. When the cut-off(s) have been completed,
press the [EXIT] key.
12.3.8 The operator will then be prompted to enter the weight of the first cut-off.
Weigh this cut-off to the nearest milligram (0.001 grams). Enter its weight, in
grams, using the numeric keys and press the [ENTER] key. The display will
show the FLOW RATE in grams per 10 minutes. Press the [ENTER] key and
continue entering cutoff weights to obtain FLOW RATE values for additional cut-
offs that were made. Enter 0 for a cutoff weight when you are finished, and the
average FLOW RATE and the number (n=) of cut-offs will be displayed.
12.3.9 Allow the remaining material to purge from the cylinder and then, if the
machine is equipped with the optional MWLD-600, press the [7] (TOP) key to raise
the weight support platform.
12.3.10 Thoroughly clean the piston, cylinder and orifice as described in Section
16. IT IS IMPERATIVE THAT THE MACHINE IS CLEANED AFTER EACH TEST.
If no more tests are needed, remove the piston and orifice from the furnace before
turning the MP600 off to prevent them from being welded in place as any material
left in the barrel hardens.
12.3.11 To prepare for another test, press the [EXIT] key. The display will
Prompt, Another Test? 1=SAME PARAMETERS, 2=NEW PARAMETERS,
PRESS EXIT to EXIT. If the [1] key is pressed, the CUTOFF TIME screen will
be displayed and the previous time entry can be accepted by pressing [ENTER]
or the time entry can be changed by use of the numeric keys. If the [2] key is
pressed, all At Test Time screens will be displayed and can be changed by use
of the numeric keys or accepted by pressing [ENTER]. After all At Test Time
(TT) screens have been reviewed or changed, pressing [ENTER] returns the
user to the LOAD SAMPLE screen in preparation for the next test. Pressing
[EXIT] returns the user to the Idle Screen.
12-4
Procedure B (Automatically Timed Flow Rate) when the Melt
Density is known.
Copies of the standard are available from ASTM at 100 Barr Harbor Drive, West
Conshohocken, PA 19428-2959, USA Telephone: (610) 832-9721.
13.1 Introduction
13.1.1 The MP600 must be equipped with the PPDT-600 Automatic Timing
Switch in order to perform a test according to ASTM D 1238, Procedure B. The
test also requires the appropriate weight(s) for the polymer to be tested. The
optional Motorized Weight Lowering Device (MWLD-600) may be used if desired.
13.1.2 Each MP600 is shipped from the factory with the first four programs
already configured with example Test Parameters (see Table 11-2). Programs 1,
2 & 3 are set up as examples of a Procedure B test. Instructions in this Section
will follow the factory settings in Program Number 1. Any changes the operator
makes in the program may affect the way the controller prompts the operator.
13.1.3 If the optional MWLD-600 is being used, it is good practice to manually
lower the weight onto the piston prior to testing in order to check the alignment of
the piston with respect to the hole in the weight. After checking the alignment,
raise the weight platform to its upper position.
13.2.1 When the unit is powered up, the MP600 will prompt the user to
ENTER NEW SET POINT. Use the numeric keys to enter the desired test
temperature and press the [ENTER] key.
factory (or at the last calibration/verification). Press the [ENTER] key.
13.2.3 The display will then prompt the user to enter the BOTTOM OFFSET.
Enter the BOTTOM calibration offset for the above entered test temperature.
Refer to the MP600 Configuration/Calibration Settings Worksheet that was
supplied by the factory (or at last calibration/verification). Press the [ENTER] key.
13-1
If the Program Number is not set to 1; press the [3] key to Select a new
program. Then press the [1] key and the [ENTER] key and follow the prompts to
access the Idle Screen for Program 1 (PN).

Program Number. PN 01 PROC B Test Type
1=TEST 2=VIEW
3=SELECT 4=OPTIONS
13.2.5 Once the machine has stabilized at the set temperature (+/- 0.2oC),
orifice. (See Section 16 for Cleaning Instructions)
13.2.8 To start the Procedure B type test, press the [1] Test key. The Test
Mode Screen, similar to the one shown below, will be displayed.

Release Time RT TT s
PRESS ENTER TO CONT
Use the numeric keys to enter the total test load in kilograms and press
[ENTER].
13-2
13.2.10 The MP600 will then prompt the user to enter the MELT DEN (Melt
Density). Use the numeric keys to enter the Melt Density of the resin in grams
per cubic centimeter and press [ENTER].
13.2.11 The MP600 will then prompt the user to enter the Piston Travel Cap
(Capture) 1. ASTM D 1238 requires a piston travel of 6.35 mm (0.25 inch) for
materials with expected flow rates of up to 10 grams/10 minutes and 25.4 mm
(1.0 inch) for higher flow rate materials. Use the numeric keys to enter the
appropriate piston travel and press [ENTER].
TEST TIP: The above Step for selecting the appropriate piston travel distance
can be eliminated by modifying Program 1 or setting up another Program with
AUTO PISTON TRAVEL SELECT METHOD = YES (Refer to Section 11). If
this method is used, the MP600 will automatically select the correct piston travel
based on a real-time calculation of the Flow Rate at the end of the first 6.35 mm
(0.25) capture of piston travel. If = or < 10 the test measurement will then
terminate automatically. If >10 the test measurement will continue for the entire
25.4 mm (1).
13.2.12 The MP600 will then prompt the user to enter START CAPTURE 1,
i.e., the starting distance above the top of the orifice, for CAP (Capture) 1. For
ASTM D 1238, an acceptable starting position is 46 mm (1.811). This is the
default value. Press [ENTER] to accept this value.
13.2.13 The MP600 will then prompt the user to enter the Release Time. The
release time is actually the preheat time. Currently, ASTM D 1238 requires a
preheat time of 7 +/- 0.5 minutes (420 +/- 30 seconds). However, refer to the
appropriate ASTM material specification to determine the recommended preheat
time for the material that is to be tested. Enter 420 seconds or other appropriate
time. DO NOT PRESS [ENTER] AT THIS TIME.
13.3 Test Procedure
13.3.1 Remove the piston and place it in the tool rack. Verify that the orifice is
at the bottom of the cylinder.
while indicating ET the elapsed time.
D 1238, Table 1 (Table 2 in earlier versions), for suggestions on the amount of
at once as it will melt and stick to the funnel. The brass orifice remover (P/N:
02001073) may be used to guide the material into the cylinder.
13-3
13.3.4 After charging the cylinder, tamp the material down with the charging
tool (P/N 02001582) in order to remove some of the trapped air. (Depending on
the amount of material to be charged, you may have to tamp the material down
more than once to load it all into the cylinder). Reinsert the piston, rotate the
PPDT-600 clockwise so that the end of the arm is close to the piston rod, and
place the appropriate weight on the piston (either manually or, if using the
optional MWLD-600, hold the [3] (DOWN) key depressed). NOTE: The ASTM D
1238 Method allows 1 minute to charge the cylinder, insert the piston rod and
start the preheat time of the test.
TEST TIP: When testing materials with high melt flow rates (> 10g/10 minutes),
the weight platform of the optional MWLD-600 can be used to prevent excessive
polymer from being purged from the cylinder prior to the end of the preheating
period. To use this feature, lower the weight platform so that the top surface of
the platform is approximately 25 mm (1 inch) above the 46 mm (1.81 inch) start
position of the test measurement. This can be accomplished above in 13.3.4 by
using the [3] (DOWN) key to obtain a reading of approximately 71 mm (2.81) on
the WT SUP HT display. The weight platform will now catch the weight as it
falls and support it, temporarily reducing the load on the material in the cylinder.
When the Release Time reaches 420 seconds (or other time entered above in
13.2.13), the weight platform will lower fully and allow the test to continue. Note
that to achieve the total preheat time of 420 +/- 30seconds, it may be necessary
to reduce the Release Time. The total time from start of test to the start of test
measurement can be observed by watching the elapsed time ET display.
Orifice Plug (P/N 02001455).
13.3.5 Press [START] and the Test Screen, similar to the one shown below, will
count up, in seconds. Material will begin to extrude through the orifice. The test
can be aborted at any time by pressing the [EXIT] key.
Capture Time. C1 0.00 ET 0 s Elapsed Time
Flow Rate F RATE 0.000 g/10
PISTON HT 87.02 MM
CAUTION: If the optional MWLD-600 is being used in the automatic mode, and
the Weight Support has been programmed to run to a height less than its
maximum height, the weight platform will automatically begin to lower the
weight(s) when the [START] key is pressed. Keep hands clear!
13.3.6 When the elapsed time (ET) reaches the Release Time (Preheat Time)
that was entered in 13.2.13, an alarm will sound (if enabled) for about 5 seconds.
The first (lower) scribe line on the ASTM piston rod should now be close to
entering the guide collar.
13-4
CAUTION: If the optional MWLD-600 is being used, and the Auto Wt Lower
screen has been set to Yes, the MWLD-600 will automatically begin to lower
the weight(s) at the end of the preheating period (Release Time), provided that it
has not already been lowered all the way at the start of the test. Keep hands
clear!
Note: ASTM D 1238 requires the test measurement to be started at 46+/-2

mm (1.81+/- 0.079 inches) above the top of the orifice and 7+/-0.5 minutes
(420+/-30 seconds) after starting the release (preheat) time. If the preheat time
criteria is not met, the amount of material charged and/or the release time used
should changed accordingly.
13.3.7 When the weight drives the arm of the PPDT-600 to the Start Capture
1 Height, a momentary alarm will sound and the Capture light on the MP600
will illuminate. The MP600 will automatically start recording the time it takes for
the piston to travel the programmed Piston Travel CAP 1 distance entered in
13.2.11.
NOTE: There is no need to cut off the extrudate during a typical Procedure B test
when the Melt Density value has been entered.
13.3.8 When the arm of the PPDT-600 reaches the end of the capture
distance, the alarm will beep twice and the Capture light will turn off.
13.3.9 At the end of the measured piston travel, the F RATE will be shown on
the third line of the display (and all results will printed if a printer is connected). If
a printer is not being used, all results can be viewed by pressing the [ENTER]
key.
machine is equipped with the optional MWLD-600, press the [7] (TOP) key to
raise the weight support platform.
13.3.11 Rotate the PPDT-600 counter-clockwise so that its arm is toward the
rear of the furnace. This will prevent damage to the arm during cleaning
operations.
13.3.12 Clean the piston, cylinder and orifice thoroughly as described in Section
16. IT IS IMPERATIVE THAT THE MACHINE IS CLEANED AFTER EACH
TEST. If no more tests are needed, remove the piston and orifice from the
furnace before turning the MP600 off to prevent them from being welded in place
as any material left in the barrel hardens.
13-5
prompt, Another Test? 1=SAME PARAMETERS, 2=NEW PARAMETERS,
PRESS EXIT to EXIT. If the [1] key is pressed, the Melt Density screen will be
displayed. The previous entry can be accepted by pressing [ENTER] or the
entry can be changed by use of the numeric keys. If the [2] key is pressed, all
At Test Time screens will be displayed and can be changed by use of the
numeric keys or accepted by pressing [ENTER]. After all At Test Time (TT)
screens have been reviewed or changed, pressing [ENTER] returns the user to
the LOAD SAMPLE screen in preparation for the next test. Press [EXIT] to
return to the Idle Screen.
13-6
Procedure B (Automatically Timed Flow Rate) when the Melt
Density is Unknown (Procedure for Calculating the Melt Density of
a Polymer)
Copies of the standard are available from ASTM, 100 Barr Harbor Drive, West
Conshohocken, PA 19428-2959 USA Telephone: (610) 832-9721.
14.1 Introduction
14.1.1 The MP600 must be equipped with the PPDT-600 Automatic Timing Switch
in order to determine the melt density. The test also requires the appropriate
weight(s) for the polymer to be tested. The optional Motorized Weight Lowering
Device (MWLD-600) may be used if desired. A laboratory scale, (not supplied by
Tinius Olsen), having a resolution of 0.001 grams is also required.
14.1.2 Each MP600 is shipped from the factory with the first four programs already
configured with example Test Parameters (see Table 11-2). Programs 1, 2 & 3
are set up as examples of a Procedure B test. Instructions in this Section will
follow the factory settings in Program Number 2. Any changes the operator makes
in the program may affect the way the controller prompts the operator
14.1.3 If the optional MWLD-600 is being used, it is good practice to manually

lower the weight onto the piston prior to testing in order to check the alignment of
the piston with respect to the hole in the weight. After checking the alignment,
raise the weight platform to its upper position.
14.2.1 When the unit is powered up, the MP600 will prompt the user to ENTER
NEW SET POINT. Use the numeric keys to enter the desired test temperature
and press the [ENTER] key.

factory (or at the last calibration/verification). Press the [ENTER] key once to
accept the entry and again to advance to the next screen.
14-1
14.2.3 The display will then prompt the user to enter the BOTTOM OFFSET.
Enter the BOTTOM calibration offset for the above entered test temperature.
Refer to the MP600 Configuration/Calibration Settings Worksheet that was
supplied by the factory (or at last calibration/verification). Press the [ENTER]
key.
If the Program Number is not set to 2; press the [3] key to Select a new
program. Then press the [2] key and the [ENTER] key and follow the prompts to
access the Idle Screen for Program 2 (PN).

1=TEST 2=VIEW
3=SELECT 4=OPTIONS
14.2.5 Once the machine has stabilized at the set temperature (+/- 0.2oC),
orifice. (See Section 16 for Cleaning Instructions)
cylinder and orifice again if necessary and insert the orifice into the cylinder. It
is imperative that the cylinder has a mirror finish and that no residue remains on

Release Time RT TT s
PRESS ENTER TO CONT
14-2
Use the numeric keys to enter the total test load in kilograms and press
[ENTER].
14.2.10 The MP600 will then prompt the user to enter the Piston Travel Cap
(Capture) 1. ASTM D 1238 requires a piston travel of 6.35 mm (0.25 inch) for
materials with expected flow rates of up to 10 grams/10 minutes and 25.4 mm
(1.0 inch) for higher flow rate materials. Use the numeric keys to enter the
appropriate piston travel and press [ENTER].
14.2.11 The MP600 will then prompt the user to enter START CAPTURE 1,
i.e., the starting distance above the top of the orifice, for CAP (Capture) 1. For
ASTM D 1238, an acceptable starting position is 46 mm (1.811). This is the
default value. Press [ENTER] to accept this value.
14.2.12 The MP600 will then prompt the user to enter the Release Time. The
release time is actually the preheat time. Currently, ASTM D 1238 requires a
preheat time of 7 +/- 0.5 minutes (420 +/- 30 seconds). However, refer to the
appropriate ASTM material specification to determine the recommended preheat
time for the material that is to be tested. Enter 420 seconds or other appropriate
time. DO NOT PRESS [ENTER] AT THIS TIME.
14.3 Test Procedure
14-3
14.3.4 After charging the cylinder, reinsert the piston, and then rotate the
PPDT-600 clockwise so that the end of the arm is close to the piston rod, and
place the appropriate weight on the piston (either manually or if using the
optional MWLD-600, hold the [3] (DOWN) key depressed). NOTE: The ASTM D
1238 Method allows 1 minute to charge the cylinder, insert the piston rod and
start the preheat time of the test.
TEST TIP: When testing materials with high melt flow rates (> 10 g/10
minutes), the weight platform of the optional MWLD-600 can be used to prevent
excessive polymer from being purged from the cylinder prior to the end of the
preheating period. To use this feature, lower the weight platform so that the top
surface of the platform is approximately 25 mm (1 inch) above the 46 mm (1.81
inch) start position of the test measurement. (This can be accomplished above
in 14.3.4 by using the [3] (DOWN) key to obtain a reading of approximately 71
mm (2.81) on the WT SUP HT display. The weight platform will now catch the
weight as it falls and support it, temporarily reducing the load on the material in
the cylinder. When the Release Time reaches 420 seconds (or other time
entered above in 14.2.12), the weight platform will lower fully and allow the test
to continue. Note that to achieve the total preheat time of 420+/-30seconds, it
may be necessary to reduce the Release Time. The total time from start of test
to the start of test measurement can be observed by watching the elapsed time
ET display.
Orifice Plug (TO P/N 02001455).
count up, in seconds. Material will begin to extrude through the orifice. The test
can be aborted at any time by pressing the [EXIT] key.

Release Time. RT 400 ET 0 s Elapsed Time
Weight Support Height WT SUP HT 71.0 mm
PISTON HT 76.45 mm
CAUTION: If the optional MWLD-600 is being used, and the Weight Support has
been programmed to run to a height less than its maximum height, the weight
platform will automatically begin to lower the weight(s) when the [START] key is
pressed. Keep hands clear!
14-4
14.3.6 When the elapsed time (ET) reaches the Release Time (Preheat Time)
that was entered in 14.2.12, an alarm will sound (if enabled) for about 5 seconds
and the Cut Off Prompt Screen, similar to the one shown below, will be
displayed. The first (lower) scribe line on the ASTM piston rod should now be
close to entering the guide collar.

Release Time. C1 0.00 ET 400 s Elapsed Time
PREPARE TO CUT OFF
PISTON HT 48.31 mm
CAUTION: If the optional MWLD-600 is being used, and the Auto Wt Lower
screen has been set to Yes, the MWLD-600 will automatically begin to lower the
weight(s) at the end of the preheating period (Release Time), provided that it has
not already been lowered all the way at the start of the test. Keep hands clear!
Note: ASTM D 1238 requires the test measurement to be started at 46+/-2
mm (1.81+/- 0.079 inches) above the top of the orifice and 7+/-0.5 minutes
(420+/-30 seconds) after starting the release (preheat) time. If the preheat time
criteria is not met, the amount of material charged and/or the release time used
should changed accordingly.
14.3.7 Observe the PISTON HT on the display. When the weight drives the
arm of the PPDT-600 to the Start Capture 1 Height, i.e., 46 mm (1.81), a
single beep will sound and the Capture light on the MP600 will illuminate.
Simultaneously with this single beep, use the Cut-Off Tool to cut off and discard
the material that has extruded through the orifice during the Preheat period.
The MP600 will automatically start recording the time it takes for the piston to
travel the programmed Piston Travel CAP 1 distance entered in 14.2.10.
14.3.8 When the arm of the PPDT-600 reaches the end of the capture
distance, the alarm will beep twice and the Capture light will turn off.
Simultaneously with this double beep, cut off the material that has extruded
through the orifice during the capture time.
TEST TIP: For best accuracy it is important that the cut-offs are made directly at
the bottom of the orifice and precisely at the sound of the single and double
beeps.
14.3.9 The display will now prompt the user to ENTER CUTOFF WT 1. Weigh
the material cut off in 14.3.8, use the numeric keys to enter its weight (in grams)
and press [ENTER].
14.3.10 The calculated FLOW RATE will be displayed (and all results will
printed if a printer is connected). If a printer is not being used, all results can be
viewed by repeatedly pressing the [ENTER] key. Record any data as required.
14-5
14.3.12 Rotate the PPDT-600 counter-clockwise so that its arm toward the rear
of the furnace. This will prevent damage to the arm during cleaning operations.
TEST. If no more tests are needed, remove the piston and orifice from the
14.3.14 Once the Melt Density is established for a particular polymer

formulation, this value should be recorded. (It is well to perform several tests to
obtain an average value.) Subsequent tests on this formulation can then be
made without the need to cut-off and weigh the extrudate. (Refer to Section 13.)
Keep in mind that any additive and/or variation in the formulation can affect the
melt density value.
PRESS EXIT to EXIT: If the [1] key is pressed, the user will be returned to the
LOAD SAMPLE screen. If the [2] key is pressed, all At Test Time screens will
be displayed and can be changed by use of the numeric keys or accepted by
pressing [ENTER]. After all At Test Time (TT) screens have been reviewed or
changed, pressing [ENTER] returns the user to the LOAD SAMPLE screen in
preparation for the next test. [EXIT] returns the user to the Idle Screen.
14-6
15 Section 15 - FLOW RATE RATIO PACKAGE
15.1 Introduction
15.1.1 The optional Flow Rate Ratio (FRR) Attachment is designed for use with
a Model MP600 Extrusion Plastometer that is equipped with a PPDT-600
Automatic Timing Switch and an MWLD-600 Motorized Weight Lowering Device.
15.1.2 The FRR Attachment allows flow rate determinations to be made using
two or three different test loads on one charge of material. Refer to Figure 15-1
for help with identifying components. Flow Rate Ratio determinations can be
made with or without a computer and Tinius Olsen software. However, the use
of the software makes setting up and collecting data much easier. Also, the
software will calculate the flow rate ratios; whereas, they must be calculated from
the basic flow rate data obtained from the MP600 when a computer and Tinius
Olsen software are not used.
15.1.3 The three test loads most commonly used for this test are 21.6, 10.0,
and 2.16 kilograms. (Weight sets can be provided for other load combinations.)
The weights will be set to change at the heights given in the example that
follows. Individual weights for the above test loads are 2,060, 7,840, and 11,600
grams. At the end of the preheat period, the MWLD-600 lowers the total weight
stack (21.6 kg) and, once the start point has been reached, the MP600 records
the flow rate for that particular load. When the upper weight reaches the Load
Change Collars, it is removed from the weight stack. The test continues with the
lower two weights (10 kg) applying the load. After the second flow rate is
determined, the middle weight will be removed from the weight stack by the
Load Change Pins. The third and last flow rate is made with only the lower
weight applying the test load. Flow rate values are calculated using ASTM D
1238, Procedure B methodology.
15.1.4 A two load test operates in a similar manner except that the upper, or
upper and middle weights are supported after the first flow rate determination
while the remaining weight(s) continue(s) downward for second flow rate
measurement.
15.2 Flow Rate Ratio Attachment Components
15.2.1 (3) Load Change Pins - used to remove (lift) the intermediate 5 inch
diameter weight. Each pin has two different length-adjusting screws with hex
nuts. The length-adjusting screws used are dependent on the height at which
the load change is to occur.
15.2.2 (4) Extended Weight-Retaining Rods - used for containing the weights.
They also hold the four split Load Change Collars used to remove the upper 6
diameter weight.
15-1
Figure 15-1 - Optional Flow Rate Ratio Package Setup for Three-Load Testing
Notes:
1. The Load Change Collars are used to remove the 6 diameter Weights.
2. The Load Change Pins are used to remove the 5 diameter Weights.
15-2
15.2.3 Height Adjuster - used during set-up to support the weight(s) at the
desired load change heights so that the height of the Load Change Pins and
Load Change Collars can be set.
15.2.4 Weights - includes (1) 2,060 gram weight (P/N: 02001023); (1) 7,840
gram weight (P/N: 02001250); and (1) 11,600 gram weight (P/N: 02001251).
(Other combinations are available)
15.3 Installation of Components for a Three-Load FFR Test
Note: To reduce the risk of burns, assemble the FRR components when the
machine is at ambient temperature.
15.3.1 Prior to installation, it must be decided at what piston heights the
changes of the test loads will occur. Normally, flow rate data is captured when
the piston foot is between 46 mm (1.81 in.) and 20.6 mm (0.81 in.) above the top
of the orifice. Also, it is recommended that at least 2.5 mm (0.1 in.) of piston
travel, or two minutes of time, be allowed between the load change and the start
of the next capture of flow rate data. This will usually allow sufficient time for the
polymer to adjust to the new pressure, so that the subsequent flow rate
measurement will be obtained under an equilibrated pressure.
15.3.2 A typical three-load FRR test starts by measuring the flow rate over a 10
mm (0.40 in.) of piston travel, starting when the piston is 46 mm (1.81 in.) above
the top of the orifice. The load is then changed when the piston foot is at 33.5
mm (1.31 in.) above the top of the orifice. The material is allowed a stress
equilibration period, and then the flow rate is measured over a 5 mm (0.20 in.) of
piston travel, starting when the piston foot is 32 mm (1.26 in.) above the top of
the orifice. The third load change occurs when the piston foot is 25.65 mm (1.01
in.) above the top of the orifice and the flow rate is measured over 2.5 mm (0.10
in.) of piston travel, starting when the piston is 23.1 mm (0.91 in.) above the
orifice.
Action Piston Foot Height Above Orifice

Start First 10 mm (0.4 in.) Capture 46 mm (1.81 in.)
End First Capture 36 mm (1.41 in.)
Change Weight 34.54 mm (1.36 in.)
Start Second 5 mm (0.2 in.) Capture 32 mm (1.26 in.)
End Second Capture 27 mm (1.06 in.)
Change Weight 25.65 mm (1.01 in.)
Start Third 2.5 mm (0.1 in.) Capture 23.1 mm (0.91 in.)
End Third Capture 20.6 mm (0.81 in.)
Table 15-1 Typical Three-Load Flow Rate Ratio Test Set-Up
15-3
15.3.3 Apply power to the MP600 and advance to the Idle Screen, similar to the
following. (If asked for SET POINT, enter 23.0 to maintain the machine at
room temperature during setup.)
AT 23.0 SP 23.0 C
PN 01 PROC B
1=TEST 2=VIEW
3=SELECT 4=OPTIONS
15.3.4 From the Idle Screen, press the [1] key for Test and then lower the
weight platform of the MWLD-600 Motorized Weight Lowering Device as far as it
will go by pressing the [1] (Bottom) key.
Note: Keys used to operate the MWLD-600 do not function when the MP600
display screen is asking for a numerical input.
5.3.5 Press the [EXIT] key to return to the Idle Screen. Press the [4] key for
Options. From the OPTIONS Menu, press the [4] key for CALIBRATE. At the
ENTER ACCESS CODE screen, press the [8], then the [3], and then the [5] key
followed by [ENTER] to access the SELECT CAL FUNCTION Menu. Now press
the [2] key for PPDT-600 and then the [2] key for Short Cal to advance to the
PPDT-600 Calibration screen, similar to the following:
PISTON HT 75.03 mm
ARM LGTH 152.40 mm
OFFSET 15.25 mm
EDIT ARM LGTH / EXIT
IMPORTANT: Do not attempt to raise or lower the MWLD-600 or press any of

the numeric keys while on the above screen. Doing so will overwrite the ARM
LGTH calibration value. Should overwriting inadvertently occur, press [CLEAR]
to restore the ARM LGTH.
15.3.6 Thread the three Load Change Pins into the three inner tapped holes
located on the MWLD-600 weight support platform. Thread a -20 socket head
cap screw (with hex nut) into the top of each Pin. The cap screw is used to
adjust the weight change point. There are two different screw lengths provided.
Usually the shorter screws are used.
15.3.7 Install the four Weight Retaining Rods and Load Change Collars in
place of the standard retaining rods.
15.3.8 Loosen the locking set screws on the Load Change Collars and lower
them so that they are resting on the weight platform.
15.3.9 Remove the piston foot and guide collar from the piston rod. Place the
Height Adjuster on the piston rod so that the long hex portion of the adjuster is
towards the top of the rod. See Figure 15-1. Reinstall the piston foot. Do not
put the guide collar back on the piston rod at this time.
15-4
15.3.10 Place the piston rod in the cylinder. The tip of the Height Adjuster
should fit into the cylinder.
15.3.11 Place the 2,060 and 7,840 gram weights over the Piston Rod
15.3.12 While holding the arm of the PPDT-600 down, rotate the PPDT-600
clockwise so that its arm is under the 2,060 gram weight. Adjust the height of the
weights and piston rod by rotating the long hex portion of the Height Setting
Adjuster until the PISTON HT display reads the desired lowest change weight
position. In this example, the lowest weight change occurs at 25.65 mm (1.01 in.).
15.3.13 Adjust the three 1/4-20 screws in the top of the three Load Change Pins
so that the tops of the screws are against the bottom of the 7,840 gram weight.
Use the longer screws, if necessary, to achieve the height required. Tighten the
hex nuts against the top of the Pins to lock the setting of these screws.
15.3.14 Using the Height Setting Adjuster as before, adjust the height so that the
PISTON HT display reads the position at which the upper weight change is to
occur. In this example the upper weight change is to occur at 34.54 mm (1.36
in.).
15.3.15 Place the 11,600 gram weight on top of the 7,840 gram weight. Slide
the Load Change Collars up and lock them in place so that they are touching the
bottom of the 11,600 gram weight.
15.3.16 Press the [EXIT] key repeatedly to return to the Idle Screen. From the
Idle Screen press the [1] key to advance to the Test Mode. Now raise the
weight support platform of the MWLD-600 by pressing the [7] (TOP) key.
Remove the piston rod from the cylinder. Remove the Height Adjust Assembly
from the piston and replace the piston guide on the piston rod assembly.
15.3.17 Press the [EXIT] key to return to the Idle Screen and program the
MP600 for the appropriate two or three load Type B test. Referring to Section11,
proceed as covered in Sections 11.1.5, 11.1.6 and 11.3. If using the examples
in Tables 15-1 and 15-2, note that the PISTON TRAVEL CAP 1 through 3 for
the three-load test would be 10, 5, and 2.5 mm (0.4, 0.2, and 0.1 in.), and the
START CAPTURES would be 46, 32, and 23.1 mm (1.81, 1.26, and 1.01 in.).
The proper response to the Load screen is NU. Refer to Table 15-2 for
examples of typical two and three-load testing programs for polyethylene.
NOTE: If the MP600 is operated from a PC using Tinius Olsens software, the
piston travel, capture distances, starting points, loads, etc., are programmed into
the test parameters of the software. Therefore, Section 15.3.17 can be ignored.
15-5
15.4 Typical Three-Load FRR Test
15.4.1 From the Idle Screen of the MP600, once the machine has stabilized at
o
the set temperature (+/- 0.2 C), remove the orifice (if present) and thoroughly
clean the inside of the cylinder and orifice. (See Section 16 for Cleaning
Instructions)
15.4.2 Reinsert the orifice into the cylinder. The orifice should fall freely to the
AT 190.0 SP 190.0 C
PN 10 PROC B
RT 390 s
PRESS ENTER TO CONT
15.4.8 After charging the cylinder, reinsert the piston rod, and then rotate the
PPDT-600 clockwise so that the end of the arm is close to the piston rod.
NOTE: The ASTM D 1238 Method allows 1 minute to charge the cylinder, insert
the piston rod and start the preheat time of the test.
15-6
be displayed. The Elapsed Time (ET) display will reset to zero and begin to count
up and the weight support platform of the MWLD-600 will be driven automatically
to the programmed WT SUP HT. Material will begin to extrude through the
orifice. The test can be aborted at any time by pressing the [EXIT] key.
AT 190.0 SP 190.0C
RT 390 ET 0 s
WT SUP HT 200.0 mm
PISTON HT 76.45 mm
15.4.10 When RT, the Release Time, reaches zero, the weight support platform
of the MWLD-600 will lower fully, applying the full 21.6 kg test load. When the
bottom of the piston foot is 46 mm (1.81 inches) above the top of the orifice, the
MP600 will emit a single beep and the first test measurement (C1) will begin. At
the end of the first measurement the MP600 will emit a second beep. The
upper weight will come to rest on the Load Change Collars after the second
beep, reducing the test load to 10 kg.
15.4.11 When the bottom of the piston foot is 32 mm (1.26 inches) above the top
of the orifice, the MP600 will again emit a single beep and the second test
measurement (C2) will begin. At the end of the second measurement, the will emit
a second beep. Shortly after this, the middle weight will come to rest on the
Load Change Lift Pins, reducing the test load to 2.16 kg.
15.4.12 When the bottom of the piston foot is 23.1 mm (0.91 inches) above the
top of the orifice, the MP600 will again emit a single beep, indicating that the third
test measurement (C3) is beginning. Completion of the third measurement will be
indicated by a double beep.
TEST TIP: Prior to actual testing, run several practice tests. Confirm that each
individual test measurement is completed prior to the point where the uppermost
weight (either the 11,600 gram or the 7,840 gram weight, depending on which
capture) reaches the Load Change Collars or the Load Change Pins. This can
be confirmed by observing if the beep, signifying the end of a test
measurement, occurs before the weight is supported on the collars or pins. Also,
observe that sufficient time has been allowed for stress equilibrium in the molten
polymer. Insufficient piston travel or time will result in low flow rate values. It
may be necessary to increase the distance between the weight change and the
start of the next capture.
15.4.13 At this point, a three-load test is completed. If the MP600 is not
connected to a printer or interfaced to a computer with Tinius Olsens software,
obtain the data by scrolling through the displays and recording the results by hand.
If the MP600 is interfaced to a printer, the raw test data will be automatically
printed at the end of the test. Either way, the FRR can be calculated by using one
of the following equations:
15-7
Flow Rate @ 21.6 kg Flow Rate @ 21.6 kg Flow Rate @ 10.0 kg
FFR = OR OR
Flow Rate @ 2.16 kg Flow Rate @ 10.0 kg Flow Rate @ 2.16 kg
15.4.15 Rotate the PPDT-600 counter-clockwise so that its arm toward the rear
of the furnace. This will prevent damage to the arm during cleaning operations.
TEST.
PRESS EXIT to EXIT.
15.5 Test Procedure for a Typical Two-Load FFR Test
15.5.1 Tests using only two of the three available loads can also be performed
once the components have been installed in accordance with Section 15.3.
15.5.2 For testing using loads of 21.6 and 2.16 kg, carefully scribe a thin
reference line on each of the four Weight Retaining Rods directly above the Load
Change Collars. Then loosen the Load Change Collars, lower them at least 12.5
mm (0.5 in) and retighten them at this lower position. Also, program the MP600,
as shown in Table 15-2, for a 21.6/2.16 kg Two-Load Test (or, if a computer is
being used, setup the appropriate parameters in the software).
NOTE: If the Load Change Pins were removed as covered in Section 15.5.3,
they must be replaced.
15.5.3 For testing using loads of 21.6 and 10 kg, it is only necessary to remove
the three Load Change Pins and program the MP600, as shown in Table 15-2,
for a 21.6/10.0 kg Two-load Test (or, if a computer is being used, setup the
appropriate parameters in the software).
NOTE: The Load Change Collars must be positioned as described in Section
15.3.15. If they have been moved as described in Section 15.5.2, they can be
repositioned using the scribe lines on the weight retaining rods as positioning
references.
15.5.4 For testing using loads of 10.0 and 2.16, it is only necessary to remove
the 11,600 gram weight and program the MP600, as shown in Table 15-2, for a
10.0/2.16 kg Two-load Test (or, if a computer is being used, setup the
appropriate parameters in the software).
15-8
15.5.5 Proceed with testing following Sections 15.4.1 through 15.4.17 (except
that only two measurements will be made and only one FRR can be calculated).
Table 15-2 - Typical Test Programs for Flow Rate Ratio Testing of Polyethylene
Two-Load Test Two-Load Test Three-Load Test
21.6/2.16 or 10/2.16 kg 21.6/10 kg 21.6/10/2.16 kg
Procedure Procedure Procedure

B B B
Sample ID Sample ID Sample ID
NU* NU* NU*
Run Number Run Number Run Number
NU* NU* NU*
Set Point Set Point Set Point
190.0 190.0 190.0
Cal Offset Cal Offset Cal Offset
Per calibration data Per calibration data Per calibration data
Load Load Load
NU NU NU
Orif Dia Orif Dia Orif Dia
NU NU NU
Orif Lgth Orif Lgth Orif Lgth
NU NU NU
Density Density Density
Entered Entered Entered
Melt Den Melt Den Melt Den
0.7638 0.7638 0.7638
FR Constant FR Constant FR Constant
426.0 426.0 426.0
Auto Piston Travel Auto Piston Travel Auto Piston Travel
Select Method No Select Method No Select Method No
No of Captures No of Captures No of Captures
2 2 3
Piston Travel Cap 1 Piston Travel Cap 1 Piston Travel Cap 1
10 mm (0.4 in.) 10 mm (0.4 in.) 10 mm (0.4 in.)
46.0 mm (1.81 in.) 46.0 mm (1.81 in.) 46.0 mm (1.81 in.)
Piston Travel Cap 2 Piston Travel Cap 2 5mm Piston Travel Cap 2
2.5 mm (0.1 in.) (0.2 in.) 5mm (0.2 in.)
23.1 mm (0.91 in.) 32.0 mm (1.26 in.) 32.0 mm (1.26 in.)
Piston Travel Cap 3
2.5 mm (0.1 in.)
Start Capture 3
23.1 mm (0.91 in.)
Display Display Display
Flow Rate Flow Rate Flow Rate
Release Time Release Time Release Time
390 sec 390 sec 390 sec
Auto Wt Lower Auto Wt Lower Auto Wt Lower
Yes Yes Yes
Wt Sup Ht Wt Sup Ht Wt Sup Ht
71.4 mm 71.4 mm 71.4 mm
* - If the MP600 is connected to a dotmatrix serial printer, Sample ID and Run Number
screens can be set to TT during programming. This will permit numeric entries made at
test time to be printed out.
15-9
B
15-10
16 Section 16 Cleaning Instructions
16.1 It is absolutely imperative that the cylinder, orifice and piston are cleaned
thoroughly after EACH test.
16.2 After the test has been completed, allow the weight to remain on the piston until
all the excess material in the barrel has extruded through the orifice.
CAUTION: The piston rod assembly and the orifice become hot during use.
16.3 Remove the weight and the piston. If an MWLD-600 is being used, raise the
weight platform all the way up until the weight platform swings out of position. Wipe the
piston thoroughly using a cloth made from a natural fiber (cotton). The cloth must be
clean and free from oil or grease of any type as they may affect future test results.
Place the piston on the tool rack or on an insulated surface that will prevent it from
rolling.
16.4 Using the Orifice Removal Tool (P/N: 02001073) to remove the orifice by
pushing it up from the bottom of the cylinder. Clean the outside of the orifice with the
clean, natural fiber cloth. Clean the bore of the orifice with the soft orifice drill (P/N:
02001075). If necessary, the orifice bore can be brushed, using a 0.090 diameter
brass brush available from Tinius Olsen (P/N: 02001142). There should be no residue
on the orifice after cleaning.
16.5 Clean the cylinder by placing a cotton patch over the cylinder, then pushing the
patch through the cylinder using the Cylinder Cleaning Tool (P/N: 02001527) in a
manner similar to cleaning a gun barrel. Change the patch and repeat at least 3 times
or until there is no visual evidence of material remaining on the cylinder wall. If
necessary, the cylinder can be brushed, using a replaceable 0.406 diameter brass
brush tip (P/N: 02001143) and barrel brush handle (P/N: 02001144) available from
Tinius Olsen. 2-1/2 square Cotton patches (P/N 02001136) are available from Tinius
Olsen.
16.6 Drop the orifice in the cylinder. It should fall to the bottom easily and there
should be an audible click when it hits the bottom of the cylinder. If not, remove the
orifice and re-clean it and the cylinder.
16.7 Always replace the piston and orifice back into the furnace as soon as possible
so that they are up to temperature for the next test.
Note: If no more tests are needed, ALWAYS remove the piston and orifice from the
16-1
B
16-2
17 Section 17 Preventative Maintenance
17.1 Cleanliness
17.1.1 The most important factor in maintaining the accuracy of a melt index
machine is cleanliness. It is absolutely necessary that the cylinder, orifice and
piston be cleaned after each test. However, be aware that, despite the best
efforts, some material will build up on the components, causing them to appear
tarnished or discolored. Tinius Olsen does not recommend any other cleaning
practices besides those detailed in ASTM D 1238. Refer to Section 16.
17.1.2 At some point, it may become necessary to remove the insulator plate
and orifice support at the base of the furnace assembly. This will be necessary
to remove any build up of material at the base of the cylinder that has not been
removed by the normal cleaning process.
17.1.3 Some components of a melt indexer, including the cylinder, piston foot
and orifice, are considered to be consumable, meaning that normal wear will
cause them to go out of tolerance over time. Check the orifice bore frequently
using the Go/No-Go gauge. Inspect the piston foot for nicks or scratches, or for
signs of wear on the edges. Check the cylinder visually for nicks and or
scratches. Any obviously damaged components shall be discarded and
replaced.
17.2 PPDT-600 Arm Length Adjustment
17.2.1 Because any physical adjustments to the PPDT-600 require a complete

disassembly of the PPDT-600, it is recommended that the user does not attempt
to physically change the length of the arm of the PPDT-600. The PPDT-600 is a
precision instrument and should be treated with care. It has been designed so
that it resists damage from everyday use, even if the MWLD-600 Weight
Lowering device is lowered onto it when it is not rotated into the proper position.
If the arm is accidentally bent, it should be bent back into the approximate
original shape and recalibrated. A brief discussion of this procedure follows, a
more thorough one can be found in Section 18.1.
17.2.2 Changing the physical length of the PPDT-600 arm requires removing
the rotating assembly from the encoder shaft. This could cause the encoder to
loose the reference pulse and fail to calibrate at startup. There is no easy way
for the user to find this reference pulse and so it is recommended that no user
attempt to alter the physical length be made. If it becomes necessary to adjust
the arm length of the PPDT-600, the unit must be returned to the factory for
adjustment.
Warning: If you have a PPDT-600, be sure to initialize it before entering the

Calibration mode. Otherwise, the PPDT-600 calibration may be lost.
17-1
17.2.3 The arm on the PPDT-600 is designed so that the tip extends 5 9/16
from the counterweight giving a theoretical length from the center of rotation of 6
inches. This length was set at the factory and should NOT be adjusted in the
field.
17.3 Motorized Weight Lowering Device (MWLD-600)
17.3.1 For lubrication of the Motorized Weight Lowering Device refer to

Assembly Drawing No. 5-6-543 in Appendix A of these instructions. This should
be done approximately once a year or every 1,000 hours of use.
17.3.2 To lubricate the Acme screw & nut, lower the MWLD-600 weight
platform to its bottom position. Remove all weights from the weight platform.
Take off the weight platform (Item 7) by removing the two 5/16-18 x 1 BHCS
(Item 62) and washers (Items 67 & 71). Using an extreme pressure grease NLGI
consistency #2, add grease through grease fitting (Item 34).
17.3.3 To reassemble weight platform with mounting hardware, insert an orifice

and piston assembly into the furnace. Add the lightest 6-inch diameter weight
available on the piston rod. Align the weight platform with the 6-inch diameter
weight. Run the weight platform up and down a few times to check alignment
and evenly distribute the grease.
17.4 Miscellaneous
17.4.1 Heater Condition
17.4.1.1 With the power disconnected, remove the four screws and
carefully pull the MP600 controller out of the console to expose the main
terminal strip on the rear of the MP600 controller.
17.4.1.2 Check the resistance of the heater bands using an ohmmeter.

The resistance between Terminals 5 and 14 (Wires T and C) should be 71
to 79 ohms. The resistance between Terminals 6 and 14 (Terminals B
and C) should be 76 to 84 ohms. The resistance between Terminals 5
and 6 (Wires T and B) should be 147 to 163 ohms. The resistance
between any of the wires to the case of the heater or machine ground
should be above 10 Megohms.
17-2
18 Section 18 Calibration/Verification
NOTE: ASTM D 1238 recommends that the melt indexer should be thoroughly
inspected and verified for compliance to the specification at least annually. Follow
the guidelines as detailed in the current version of ASTM D 1238, or contact Tinius
Olsen Field Service to arrange to have the machine verified by Tinius Olsen
personnel. Tinius Olsens Field Service Department is accredited by A2LA for the
calibration/verification of melt flow indexers and maintains NIST traceable calibration
equipment and can issue the calibration/verification certificates that are required by
many quality programs. Contact the Tinius Olsen Field Service Department for more
information.
18.1 Calibration/Verification Procedure for PPDT-600
18.1.1 Introduction
18.1.1.1 Accurate calibration and verification of the measuring

capabilities of the PPDT-600 can be accomplished using the optional
PPDT Calibrator (Part Number 02001531). The calibrator consists of a 0
-2" barrel type micrometer head and a mounting bracket. The micrometer
has a resolution of 0.001 inch.
18.1.1.2 The instructions in this section only cover the calibration of the
PPDT-600 when used with the MP600 Controller. Please contact the
factory for information on calibrating other types of actuating switches and
controllers.
18.1.1.3 Before proceeding, read and comprehend the information on

the PPDT-600 theory of operation found in Section 18.1.2. Only then
should you proceed with the PPDT-600 Verification/Calibration.
18.1.2 Theory of Operation
This section will describe how the calibration parameters affect the
operation of the PPDT.
The distance of the piston above the zero position is calculated using the
angle from the horizontal reference, the PPDT-600 Offset and the PPDT-
600 Arm Length (which are set in the Calibration Menu) using the
equation in Section 18.1.2.1.
18-1
Index Pulse
(ENCI)
Arm
Length
Angle
Horizontal Reference Position
PPDT Offset
Zero
Position
18.1.2.1 Normal Operation
There are three options for PPDT type that are programmed in the
Calibration Mode: type 0 (none), type 1 (encoder without index pulse) and
type 2 (encoder with index pulse). Select type 2 for the PPDT-600.
The PPDT-600 is mechanically and electrically structured so that the

index pulse will trigger just as the arm starts to move down from its upper-
most (resting) position. The relationship between the index pulse and the
horizontal position are established during the calibration process. By
detecting the index pulse and knowing the horizontal position (defined
under calibration), the controller knows the position of the tip (height of
piston) at any time.
The angle, relative to horizontal (0 degrees), is as follows.
PPDT Angle Calculation
Where counts is the number of encoder counts.
The distance of the piston above the orifice is calculated as follows.
Piston Position Calculation Position = Offset + (ArmLength * sin (Angle))
Where the Offset and ArmLength are defined in the Calibration Mode and
Angle is defined in the equation above. The Arm Length multiplied by the
sine of the angle (relative to the horizontal) gives the linear position
(relative to the horizontal). The Offset is added in to give the height above
the top of the orifice (Piston Height).
18-2
Figure 18-1 Calibration of the PPDT-600 Automatic Timing Switch
NOTE: IT IS MOST IMPORTANT THAT THE CALIBRATOR CLAMPING SCREW IS

TIGHTENED FIRMLY SO THAT THERE IS NO CHANCE OF IT SHIFTING
DURING THE SWITCH VERIFICATION AND CALIBRATION PROCEDURES.
18-3
18.1.3 Mounting the Calibrator to the Extrusion Plastometer
18.1.3.1 Enter a Set Temperature of 0oC and allow the furnace to cool
down to room temperature. Do not insert or use the Calibrator when the
furnace is hot. A hot furnace can cause the Calibrator to expand and
introduce errors.
18.1.3.2 Remove the piston and orifice from the cylinder. If the MP600 is
equipped with an optional Motorized Weight Lowering Device, the weight
support platform must be raised and rotated out of the way.
18.1.3.3 Before mounting the Calibrator, make certain that all the parts
of the Calibrator are firmly tightened.
18.1.3.4 Insert the stem of the calibrator down the cylinder and place the
washers and nut on the bottom (threaded) portion. Tighten the nut and
ensure that the apparatus is seated properly and is perfectly vertical. The
calibrator must be kept square with respect to the PPDT-600.
18.1.4 Verification/Calibration Procedure
18.1.4.1 Follow the prompts on the display until the Idle screen is
displayed. The MP600 will show the Actual Temperature (AT) and Set
Point Temperature (SP) on the top line. The next line will display the
Program Number (PN) and Test Procedure (A or B). The bottom two lines
are your menu options.
18.1.4.2 Make sure the Set Point Temperature (SP) is below room
temperature and that the heaters are off (heater LEDs should be off). If
the heaters are on they must be turned off. If the Program prompts you to
enter the Set Point Temperature, enter 0 deg C. If the Set Point
Temperature is set in the Program, select Options (4) and choose Edit (2).
Enter the pass code (8 5 2 ENTER). Choose Edit Program (1) and use
the ENTER key to move through the screens until you get to the screen
for Set Point Temperature. Change this to Program Initiate (PI) by
pressing START. Then Press ENTER. Press EXIT until the Idle Screen
is displayed, and then Select (3) Program Number or simply power down
and power back up.
18.1.4.3 While the Idle screen is displayed, move the PPDT-600 (ENCI
encoder) arm through its entire travel. This will allow the PPDT-600 to find
its Index pulse.
18.1.4.4 Pivot the PPDT-600 into position so that the tip of the switch
arm is directly below and centered with the anvil on the end of the
micrometer screw.
18-4
18.1.4.5 Enter the Calibration Mode by selecting Options (4) from the
Idle screen. Then select Calibration (4) and enter the pass code (8 3 5
ENTER). Choose PPDT (2), and then select SHORT calibration to verify
your readings. IMPORTANT: Be certain the PPDT-600 has been
initialized properly BEFORE selecting the SHORT Calibration. If not,
you will lose your calibration, the displayed Piston Height will not
make sense and you will need to do a FULL Calibration.
18.1.4.6 Use a straight edge and/or a square and adjust the micrometer
so that it makes the tip of the PPDT-600 arm perfectly horizontal with the
center of rotation of the arm. Record your micrometer reading.
NOTE: Always operate the calibrator downward when taking readings.
18.1.4.7 With the tip of the switch arm centered under the micrometer
tip, turn the calibrator until the Position Display reads at least 47.000 mm
(1.8500 in.) and then turn it slowly down to the nearest value to 46.000
mm (1.8100 in.). Because of the 0.01 mm (0.0004 in.) resolution of the
system, the display may not show the exact value.
18.1.4.8 Record the reading shown on the Position Display as the

Starting Height, and record the reading from the micrometer. Turn the
micrometer down exactly 6.35 mm (0.250 in.). Record the Position
Display reading. Repeat this process until you have moved the PPDT-600
arm a total of 25.4 mm (1.000 in.).
18.1.4.9 Check the displayed position readings. If the error between the
6.35 mm (0.250 in.) increments is 0.025 mm (0.001 in.) or less; no
changes will need to be made.
NOTE: If any of the errors are too large or are not linear, check to make
sure that the PPDT-600 has been set up as previously described and that
the PPDT-600 has been initialized properly. Improper initialization will
result in non-linearity. Also, you may attempt to reduce the errors by
calculating and entering a new Arm Length and repeating this procedure.
If, after several attempts, the errors have not been reduced or have
increased, you should do a FULL Calibration. This allows you to define
the key points (such as the Lower limit and the Horizontal position) that
are critical to the mathematical determination of the Piston Height. For
the PPDT-600 (ENCI type encoder), the Index pulse will also be found.
Once you have defined the points (see above) and determined the correct
Arm Length, you should get the correct change in position on the display
for the corresponding change in the micrometer reading.
18-5
18.1.5 Arm Length Calculation
18.1.5.1 The physical length of the PPDT-600 Arm, from its tip to the
center of rotation of the encoder shaft, should be about 152.4 mm (6.000
in.).
18.1.5.2 The relationship of the real and displayed Arm Lengths and
Travels (change in position) can be approximated as follows:
(Real Tvl / Real Arm Lgth) = (Displayed Tvl / Displayed Arm Lgth)
18.1.5.3 With some simple algebraic manipulation, the Real Arm Length
can be estimated as:
Real Arm Lgth = (Real Tvl * Displayed Arm Lgth) / Displayed Tvl
18.1.5.4 When doing these calculations, use the total 25.4 mm (1.000
in.) travel. You may need to repeat this several times.
NOTE: Always operate the calibrator downwards when taking readings.
18.1.6 Height Offset
18.1.6.1 Enter the Calibration Mode by selecting Options (4) from the
Idle screen. Then select Calibration (4) and enter the pass code (8 3 5
ENTER). Choose PPDT (2), and then select SHORT calibration to verify
your readings. IMPORTANT: Be certain the PPDT-600 has been
initialized properly BEFORE selecting the SHORT Calibration. If not,
you will lose your calibration, the displayed Piston Height will not
make sense and you will need to do a FULL Calibration.
18.1.6.2 Remove the Calibration device, and replace the orifice and
piston. Place a weight on the piston and position the PPDT-600 arm
beneath the weight. The displayed height should be 0. If not, determine
how much the error is, multiply it by 1, and enter the result as the offset.
Note: The sine operation translates the rotary motion of the encoder into
a linear value. The Offset is simply a value, relative to the true horizontal
position of the PPDT-600 arm, that is added in after the sine correction to
make the PPDT-600 readings agree with the true piston height.
18-6
18.2 Temperature Verification/Calibration
18.2.1 Suggested Equipment
18.2.1.1 Digital Temperature Indicating Unit, Model 4202C (Dual-

Probe) available from;
INSTRULAB, Inc.
1205 Lamar Street, P O Box 98
Dayton, OH 45404-0098
Telephone: (800) 241-2241 / Fax: (937) 223-1705
Website: www.instrulab.com
18.2.1.2 RTD Probe, INSTRULAB, Model 832-154-01 (300C)

18.2.1.3 Miscellaneous Parts from TINIUS OLSEN P/N: 02001451
(See Figure 18-2)
Includes:
10 mm Spacer (Insulator), Part Number 02001474
RTD Sensor Guide, Part Number 02001475
RTD Sensor Bushing, Part Number 02001476
65mm Spacer (Insulator), Part Number 02001477
Stop Setscrew Collar, Part Number 90001065
Part Number Item Number Quantity Description

16 1 INSTRULAB Sensor 832-154-01
02001474 20 1 10 mm Spacer (Insulator)
02001475 21 1 RTD Sensor Guide
02001476 22 1 RTD Sensor Bushing
02001477 23 1 65 mm Spacer (Insulator)
90001065 24 1 Stop Setscrew Collar
Figure 18-2 - RTD Calibration Probe Assembly
18-7
B
18-8
19 Section 19 Temperature Control Configuration Mode
19.1 PID Parameters
Note that the default PID values shown should suffice for most users. However,
further tuning of the PID parameters may be necessary for any given machine in
order to obtain optimum performance for any particular set of test
conditions/requirements. The user should consult a good engineering controls
text to become familiar with the concept of PID parameters before making
adjustments. Refer to page 19-5 for further PID Revisions.
19.1.1 Refer to Section 10 for instructions on entering the Temp CONTROL

Configuration Menu and the SET PID PARAMS Configuration Mode
screen, shown below. The screens will cycle through the TOP settings
and then the BOTTOM settings.
19.1.2 Proportional Band (PB) - The PB directly affects the Proportional

Term, but it also affects the Integrator and Derivative Terms. See the
Proportional Term under View (see Section 10.3.2).
PROP BAND aaa

ww.w C
ENTER NEW VALUE
PRESS ENTER TO CONT
MP 600 Factory Settings For Proportional Band (PB)

115V 230V
Top: 14 Top: 100
Bottom: 8 Bottom: 50
19.1.3 Reset - The Reset affects the Integrator Term. The Reset Term is active
when within the PB. See the Integrator Term under View (see Section
10.3.2).
RESET aaa
w.ww
ENTER NEW VALUE
PRESS ENTER TO CONT
MP 600 Factory Settings For Reset

115V 230V
Top: 0.1 Top: 0.1
Bottom: 0.22 Bottom: 0.22
19-1
19.1.4 Integral Limit Multiplier (ILM) - The Integral Limit Multiplier (w.wwww)
is internally multiplied by the Set Point Temperature to determine the
maximum Integrator Term value that is allowed. This helps prevent
large temperature overshoots on heat up. Note: Once the MP600
settles in at the Set Point Temperature (within +/- 0.1 deg), the current
Integrator Term value becomes the new limit. This helps prevent large
temperature overshoots on recovery.
INTEGRAL LIMIT MULT

w.wwwww
ENTER NEW VALUE
PRESS ENTER TO CONT
MP 600 Factory Settings For Integral Limit Multiplier (ILM)

115V 230V
Top: 0.00080 Top: 0.00024
Bottom: 0.00160 Bottom: 0.00028
19.1.5 Rate Band (RB) - The RB is a multiple of the PB. The Rate Term is
active when within this band.
RATE BAND aaa

ww.w C
ENTER NEW VALUE
PRESS ENTER TO CONT
MP 600 Factory Settings Rate Band (RB)

115V 230V
Top: 3 Top: 1
Bottom: 1 Bottom: 1
19.1.6 Rate - The Rate affects the Derivative Term. It is active within the Rate
Band. See the Derivative Term under View (see Section 10.3.2).
RATE aaa
w.ww
ENTER NEW VALUE
PRESS ENTER TO CONT
MP 600 Factory Settings Rate

115V 230V
Top: 1 Top: 1
Bottom: 0.5 Bottom: 0.5
19-2
19.1.7 INTEGRAL LOCK - This will lock the INTEGRATOR TERMS at the set
temperature and the default setting is LOCK. Sometimes due to power
fluctuations the MP600 will not quite hold the set temperature and
unlocking will allow the integral terms to keep adjusting. This is only
asked after the TOP settings but applies to the BOTTOM as well. This
unlock feature was added as of MP600 EPROM Version 4.0
INTEGRAL LOCK
0=Unlock 1=Lock
After this screen the MP600 will cycle through the BOTTOM settings
Screens.
19.2 MP600 Temperature Control Equations
19.2.1 Proportional Term = (SP AT) / PB
Proportional Term is limited to a range of 1 to +1.

If AT < (SP - PB), Prop. Term = 1.
If AT > (SP + PB), Prop Term = -1.
The Proportional Term works on the current temperature error. A large PB

means a small Kp, a small PB means a large Kp.
19.2.2 Integrator Term = Previous Integrator Term + (Integrator Error / Kit)
Integrator Term is limited to a range of 0 to 1.

If AT < (SP - PB), Integrator Term = 0.
If AT > (SP+PB), Integrator Term = 0.
where:
Integrator Error = (SP AT) / PB
Integrator Error is limited to a range of 1 to +1.

If AT < (SP - PB), Integrator Error = 1.
If AT > (SP + PB), Integrator Error = -1.
Kit = Integrator Gain * 60* Sample Rate

Integrator Gain = 1 / Reset
Sample Rate = 10 samples / second
The Integrator Term works on the sum of the accumulated temperature

errors. Since the Reset values are typically fractional (ex. 0.1), a smaller
Reset means a smaller Integrator term. A larger Reset means a larger
Integrator term.
19-3
19.2.3 Derivative Term = ((AT LT) * 60 * Rate) / PB
Derivative Term is limited to a range of 1 to +1.

Derivative Term is 0 when:
AT < (SP (RB * PB))
AT > (SP + (RB * PB))
The Derivative Term works on the changing temperature. Unlike the other
terms that are added together in the Power formula, the derivative Term is
subtracted from the others.
19.2.4 Power Formula:

Power% = 100 * (Proportional Term + Integrator Term Derivative Term)
The Power (0 100%) is the total of the three terms, multiplied by 100. It
determines how many cycles are ON and how many are OFF for
regulating the power to the heaters. The MP600 can turn the heaters ON
and OFF at 50 or 60 times per second, depending on the line frequency.
For 230V systems, the Power Rating is divided by 4 and limited to 25%.
With twice the voltage and twice the current of the 115V configuration, this
technique will produce the same average power.
19.2.5 Terminology:
SP = Set Point Temperature

AT = Actual Temperature Reading at current time (t seconds)
LT = Last Temperature Reading at previous time (t-1 seconds)
PB = Proportional Band
RB = Multiple of the Proportional Band
Kp = Proportional Gain
Kit = Integrator Gain
Kd = Derivative Gain
Sample Rate = 10 samples per second
19-4
Revised PID Values for the MP 600 Controller
Further work with the MP600 Controller and various changes to the RTD probes has led us to modify the
default PID values used for controlling the temperature. In some cases, a range of values is indicated.
Further tuning may be necessary on a case-by-case basis due to slight variations between machines,
should the end user wish to optimize the performance. However, the default values supplied with the
machine should be adequate for most situations.
MP600 Controller on an MP600 Furnace System (stranded wire probes)

115 VAC 230 VAC
Top Bottom Top Bottom
Prop. Band 14 20 8 12 100 50
Reset 0.05 0.10 0.09 0.22 0.05 0.10 0.11 0.22
ILM* 0.0008 .001 0.0016 0.0002 0.00024 0.00028
Rate Band 23 1 1 1
Rate 1 1.5 0.5 0.6 1 0.5
As of October 2003, the original MP600 stranded wire probes were changed to a solid (nickel alloy)
wire probe and the following default PID Values used.
MP600 Controller on an MP600 Furnace System (solid wire probes)

115 VAC 230 VAC
Prop. Band 20 14 120 70
Reset 0.05 0.07 0.10 0.20
ILM* 0.001 0.0016 0.0002 0.00028
Rate Band 2 1 1 1
Rate 1.5 0.6 1 0.6
The following Table is only for Retrofit Dual Zone Furnace Systems that use a single Dual Zone Probe that
is inserted into the rear off-center well next to the center bore of the furnace; the front off-center well can
be used for an L-shaped thermometer. The thermometer well should be plugged when not being used for
better heat retention and to keep material out of the well. This system is used for retrofitting earlier model
Extrusion Plastometers with a single zone furnace system such the MP 993, MP 987, U.E. or Thermodyne
Models with a MP 600 Controller with a Dual Zone Heater Band.
MP600 Controller on a Retrofit Furnace System (single Dual Zone Probe)

115 VAC 230 VAC
Prop. Band 9 7 40 35
Reset 0.10 0.20 0.05 0.10
ILM* 0.002 0.0016 0.00025 0.00025
Rate Band 1 1 1 1
Rate 0.7 0.5 1 0.5
* The ILM (Integrator Limit Multiple) is multiplied by the Set Point temperature to get the
maximum value that the Integrator term is allowed to build up to. As such, it may be necessary to
increase this value at higher Set Point temperatures or with lower line voltages in order for the
machine to make the set temperature.
19-5
B
19-6
20 Section 20 - Communications
20.1 OverviewSerial Port Connection
20.1.1 The MP600 has a 25 pin D-subminiature female connector located on
the rear of the Melt Indexer. All connections to external serial devices (dot-
matrix serial printers or computers) are made through this port. A ribbon cable
inside the console connects this port with the 25 pin serial port on the MP600
controller itself.
20.1.2 The serial communications for the MP600 are Odd parity, 7 data bits, 1
stop bit. Baud rate is selectable (1200 19200). Hardware handshaking signals
are not used by the MP600.
20.1.3 The MP600 can use either EI-232 or EI-485(422) communications.
Communications protocol is selected in the SERIAL PORT Configuration Mode.
See Section 10.
CAUTION: ALWAYS UNPLUG THE 115V/230V POWER CORD BEFORE
REMOVING THE CONTROLLER FROM ITS CONSOLE.
20.1.4 The user selects whether the MP600 will be interfaced to a dot-matrix
serial printer or to a computer through the SERIAL PORT Configuration Mode.
Additionally, if the computer utilizes a COM422 board for communication with
multiple Melt Indexers, a unique device ID number (0-9) must be assigned to the
melt indexer.
20.1.5 A list of the cables and communications standards for each MP600
application is given in these instructions.
20.2 Connecting a Dot-Matrix Serial Printer to the MP600
20.2.1 Connect the dot-matrix serial printer to the MP600 using the Tinius
Olsen 25M/25M Null Modem MI Printer Cable (P/N 90002871).
20.2.2 Configure the printer with the appropriate communications parameters.
The MP600 uses Odd parity, 7 data bits, 1 stop bit. Baud rate is selectable
(1200-19200). An example of the serial configuration for an OKIDATA
MICROLINE 320 (with serial port option) is as follows:
Parity Odd
Serial Data 7 or 8 Bits 7
Protocol Ready/Busy
Diagnostic Test No
Busy Line SSD-
Baud Rate (Set to agree with MP600 selected rate.)
DSR Signal Valid
DTR Signal Ready on Power UP
Busy Time 200 ms
20-1
20.2.3 Configure the MP600 by accessing the SERIAL PORT Configuration
Mode as covered in Section 10. Set Ser Port to 1 and Baud Rate to a rate
compatible with the printer setting.
20.2.4 At the start of a series of tests, the MP600 will transmit the heading
information to the printer. At the completion of each test, the MP600 will transmit
the results to the printer.
20.3 Connecting a single MP600 to a Computer running EP600-Single Software (EIA-

232 protocol)
20.3.1 Use the Tinius Olsen 9F/25M MI-Interface AME Cable (P/N 90002820) to
connect the 9 pin serial port of the computer to the 25 pin serial port on the Melt
Indexer.
20.3.2 Configure the MP600 by accessing the SERIAL PORT Configuration
Mode as covered in Section 10. Set Ser Port to 2, Interface to 1 and Baud
Rate to 19200 when using EP600 software.
20.3.3 Refer to the EP600 Software Manual to run the program. Note that after
the software is installed on the computer, the EP600 Software Verification Key
must be inserted in the USB port of the computer to enable operation of the
software.
20.3 Connecting Multiple MP600 Melt Indexers to the USB Port on a computer using
EP600-Multiple Software Package (EI-232 protocol)
20.3.1 Connect the USB Hub to the USB Port on the computer using the
provided 6 foot long cable.
20.3.2 Connect the first two Melt Indexers to the USB Hub using two 9F/25M MI-
Interface Cables (P/N 90002820).
20.3.3 If more than two Melt Indexers are being connected, Auxiliary
Interconnection Packages (P/N 02001567) are required to connect additional Melt
Indexers. Each of these packages can connect up to two additional Melt Indexers.
20.3.4 Configure each MP600 Melt Indexer for use with EP600 software by
accessing the SERIAL PORT Configuration Mode as covered in Section 10. Set
Ser Port to 2, Interface to 1 and Baud Rate to 19200.
20.4.5 After the software is installed on the computer, the EP600 Software
Verification Key must be inserted in a second USB port on the computer or in the
port on the USB Hub to enable operation of the software.
20.4.6 Refer to the EP600 Software Manual to run the program.
20-2
20.5 Connecting MP600 Melt Indexers to an existing computer system running MFW-2
Multiple Machine Software (EI-485/422 protocol)
20.5.1 These existing computer/MFW-2 software systems normally have a COM

422 card already installed in the computer.
20.5.2 The first two Melt Indexers are connected to the 9-pin port on the COM
422 card in the computer using Tinius Olsen Main Interface Cable (P/N
02001261).
20.5.3 If more than two Melt Indexers are being connected, the Main Interface
Cable (P/N 02001261) connects to the first machine. Successive machines are
daisy chained together using Auxiliary Interface Cables (P/N 02001246).
20.5.4 Configure each MP600 Melt Indexer for use with the software by
accessing the SERIAL PORT Configuration Mode as covered in Section 10. Set
Ser Port to 2, Interface to 2, Device Address to a unique address number
of 0 to 9, and Baud Rate to 1200.
NOTE: If you are not using the Tinius Olsen software, a list of commands has been
included in these instructions for developing your own software. However, due
to the complexity of the communications, Tinius Olsen strongly recommends
using Tinius Olsen software if data storage and/or machine control through a PC
is desired.
20.6 Communication Parameters:
EIA-232 EIA-485
Odd Parity Odd Parity
7 Data Bits, 1 Stop Bit 7 Data Bits, 1 Stop Bit
1200-19200 Baud 1200-19200 Baud
XON/XOFF Protocol ANSI x3.28 (Full) Protocol
20-3
20.7 MP600 Communication Commands
All characters are transmitted in ASCII. In the command listings below, <sp> denotes a
space character and <cr> represents a carriage return character. The general format
for a write command is =<sp>COMMAND<sp>PARAMETER<sp>DATA<cr>. The
general format for a read command is ?<sp>COMMAND<sp>PARAMETER<cr>.
The EIA-232 uses an XON/XOFF protocol. The computer sends the command in the
format above. The MP600 returns a DC3 (XOFF), then a DC1 (XON) and then any
data requested by a read command followed by a <cr>.
The EIA-485 uses a Full Protocol. The computer sends the DEVICEID<enq>. The
MP600 returns DEVICEID<ack>. The computer sends <stx> Command <etx>. The
MP600 returns an <ack>. The computer sends an <eot>. If the command was a write
command, the MP600 returns an <eot>. If the command was a read command, the
MP600 returns <stx> Data <cr><etx>. The computer sends an <ack> and the MP600
returns an <eot>.
20.7.1 ACT
This read only command returns the measured process temperature of the bottom zone.
There is no decimal point. Format: ?<sp>ACT<cr>.
20.7.2 ACT2
This read only command returns the measured process temperature of the top zone.
There is no decimal point. Format: ?<sp>ACT2<cr>.
20.7.3 ATP
This read/write command accesses the active test parameters. The parameters have
the same ranges as the front-panel displays. The parameter values of NU, TT and PI
will return N, T and P respectively. These characters are also used to set parameters to
NU, TT or PI. The ATP command will only change the volatile copy of the programmed
parameter. This command is not valid while a test is running. Format:
?<sp>ATP<sp>data<cr> or =<sp>ATP<sp>data<sp>value<cr>
DATA VALUES .
0. Test Type 1=Procedure A, 2-Procedure B
1. Sample ID N,T
2. Run Number N,T
3. Set Temperature P
4. Bottom Cal Offset P
5. Load N,T
6. Orifice Diameter N,T
7. Orifice Length N,T
8. Cutoff Time T
9. Density Type 1=Entered, 2=Calculated, N
10. Density N,T
11. Piston Travel No. 1 N,T
20-4
16. Start Point No. 1 N,T
21. Release Time N,T
22. Auto Weight Lower 0=No, 1=Yes, T
31. Preheat Time N,T
32. Flow Rate Constant T
33. Auto Piston Travel 0=No, 1=Yes, T
34. Number of Captures T
35. Rate Display 0=Volume Rate, 1=Flow Rate, N
36. Support Height T
37. Pre-Test Lower T
38. Top Calibration Offset P
20.7.5 BOT
This write only command will move the weight support device to the lower limit. Format:
=<sp>BOT<cr>.
20.7.6 CALAI
This write only command calibrates the RTD inputs. Format:
=<sp>CALAI<sp>resistance<cr>. The controller must be in factory calibration mode
for this command to work. The resistance is entered with decimal point and as
accurately as it is measured.
20.7.7 CAP
This read/write command represents the capture number. A read returns the total
number of valid captures. A write will set the current capture number. The capture
number can range from 1-20 for Procedure A tests and 1-10 for Procedure B tests.
Format: ?<sp>CAP<cr> or =<sp>CAP<sp>data<cr>.
20.7.8 CPxx
This read only command returns the actual time and actual bottom process temperature
for the capture represented by xx. The value xx can range from 1 to 20 (although only
captures 1-10 are valid for Procedure B type tests). If a capture has not been taken the
time and temperature will be zero. There are no decimal points. Format:
?<sp>CPxx<cr>.
20-5
20.7.9 CTxx
This read only command returns the actual time and actual bottom process temperature
for the capture represented by xx. It is used for Procedure B tests only and there are no
decimal points. The value xx can range from 1 to 10. If a capture has not been taken
the time and temperature will be zero. Format: ?<sp>CPxx<cr>.
20.7.10 CUR
This read/write command represents the current program number. It has the same
range as the front panel prompt. Format: ?<sp>CUR<cr> or
=<sp>CUR<sp>data<cr>.
20.7.11 GSP
This read/write parameter is used for setting global setup parameter values that are also
accessible via the front panel. The data values have the same range as the front panel
prompts. Format: ?<sp>GSP<sp>parm<cr> or =<sp>GSP<sp>parm<sp>data<cr>.
Format (NE indicates included for backwards compatibility, has no effect):
Parmeter Data Value
0. Inches/millimeters 1=inches, 2=mm
1. Alarm active 1=on, 2=off
2. Printer/computer 1=printer, 2=computer
3. Offset difference 0 (NE)
4. High temp alarm
5. PPDT type 0=none, 3=encoder, 4=encoder w/index
6. Delay time 0 (NE)
7. Position/arm length
8. Zone select 2 (NE)
9. Intensity adjust 1-4
10. Pretest lower time/position 0 (NE)
11. Date mm-dd-yy
12. Time hh:mm (write with hh-mm)
13. Language 1=english
14. Weight support type 0=NA, 1=AC, 2=DC
15. Weight support encoder resolution
16. Weight support total travel
17. Weight support over travel
18. PPDT offset
19. RTD user calibration slope top x.xxxx (read only)
20. RTD user calibration slope bottom x.xxxx (read only)
21. RTD user calibration offset top x.xxxx (read only)
22. RTD user calibration offset bottom x.xxxx (read only)
23. Model number (read only)
24. Serial number (read only)
25. Date code (read only)
26. DC Motor Offset
27. DC Motor +Full Scale Fast
28. DC Motor Full Scale Fast
29. DC Motor Proportional Band
30. Weight support under travel
31. DC Motor +Full Scale Slow
32. DC Motor Full Scale Slow
20-6
20.7.12 INP
This read only command is used to read the digital inputs and returns a 0 if the input is
off or a 1 if the input is on. Format: ?<sp>INP<sp>parm<cr>. The parm values are:
0. Upper Limit Switch 5. Expand Input Three
1. Weight Support Position Switch 6. Expand Input Four
2. Expand Input One 7. Expand Input Five
3. Expand Input Two 8. Expand Input Six
4. Expand Input Three
20.7.13 KEY
This read only command is used to read the status of the front panel keys. Format:
?<sp>KEY <cr>.
The chart below shows the data returned:
Key Value Key Value
None 0 6 100
0 1 7 200
Decimal 2 8 400
Dash 4 9 800
1 8 Enter 20000
2 10 Start 8000
3 20 Exit 10000
4 40 Clear 1000
5 80
20.7.14 LOC 1
This read/write command determines if the PID Integral Lock is active. This value is
stored in non-volatile memory. Format: ?<sp>LOC or =<sp>LOC<sp>parm.
Parameter settings are 1=Lock & 0=Unlock. (Added as of MP600 Version 4.0)
20.7.15 MAV 1
This write only command is included for backward compatibility. The controller will
toggle between test procedure A and procedure B each time this command is received.
This command will only change the volatile copy of the programmed procedure type. It
will not be valid if a test is running. Format: =<sp>MAV<sp>1<cr>.
20.7.16 MCT
This read/write command is the value of the Maximum Capture Time that is allowed
during the Procedure B tests. The Range is 0 to 3600 seconds. On power-up, the
default is 3600 seconds. Format: ?<sp>MCT OR =<sp>MCT<sp>parm. (Added as
of MP600 Version 4.0)
20.7.17 MDKY 1
This write only command simulates the Enter Key. Format: =<sp>MDKY<sp>1<cr>.
20.7.18 MDL
This read only command returns the unit model number and software version. The
controllers response will be: 600 x.xx yyyyy, where x.xx is the software version and
yyyyy is the software build Format: ?<sp>MDL<cr>.
20-7
20.7.19 MEM
This read only command represents a single byte memory location in the controller.
The address and data returned will be in hex format. Format:
?<sp>MEM<sp>address<cr>.
20.7.20 MEMD
This read only command represents a double byte memory location in the controller.
The address and data returned will be in hex format. Format:
?<sp>MEMD<sp>address<cr>.
20.7.21 MOD
This read only command will return the procedure type that the controller is using. A
query will return 0 for procedure A and 2 for procedure B. Format: ?<sp>MOD<cr>.
20.7.22 MODE
This read only command represents the status of the controller. Format: ?<sp>MODE
<cr>. The return values are:
0. Powerup mode (Initialization prompts)
1. Idle mode (Idle prompt)
2. Results mode (Test results prompts)
3. View mode (View prompts)
4. Program mode (Edit program prompts)
5. Setup mode (Configuration prompts)
6. Service mode (Calibration prompts)
7. Calibration mode (Factory RTD calibration prompts)
8. Select mode (Select prompt)
9. Start mode (Start test prompts)
10. Work mode (Running test prompts)
20.7.23 MOTR
This write only command operates the weight support motor. The weight support will
move to the position specified in data. Note that the data will be interpreted in the
current unit of measure and includes the decimal point. Format: =<sp>MOTR<sp>data
<cr>.
20.7.24 OPT
This read/write command operates the expansion outputs. Format:
=<sp>OPT<sp>parm<cr> or =<sp>OPT<sp>parm<sp>data <cr>. The data is 0=Off
and 1=On.
0. Motor Lower
1. Motor Raise
2. Orifice Plug
3. Cutoff
4. Purge
5. Expand One
6. Expand Two
7. Expand Three
20-8
20.7.25 PGM
This read/write command accesses the current programmed test parameters for the
program selected with the CUR parameter or selected on the display. The parameters
have the same ranges as the front-panel displays. The parameter values of NU, TT and
PI will return N, T and P respectively. These characters are also used to set parameters
to NU, TT or PI. Changes made with the PGM parameter will be saved in non-volatile
memory. This command is not valid while a test is running.
Format: ?<sp>PGM<sp>data<cr> or =<sp>PGM<sp>data<sp>value<cr> The data

and values for this command are the same as for the ATP command.
20.7.26 PPDT
This read only command is used to read the current position of the PPDT. Note that the
data will be interpreted in the current unit of measure and includes the decimal point. If
the PPDT Type is set to ENCI and the index has not yet been detected, the data
returned will be #####. Format: ?<sp>PPDT<cr>.
20.7.27 PTxx
This read only command is used to read the actual piston travel for capture xx. The
value xx can range from 1 to 10 since this command is only used for Procedure B. The
value return includes decimal places and is in the current units. Format: ?<sp>PTxx
<cr>.
20.7.28 RAW
This read only command represents the raw A/D counts of the controller inputs. Format:
?<sp>RAW<cr>. The response will be in the form: top a/d<sp>bottom
a/d<sp>reference a/d<cr> in hex format.
20.7.29 RCTO
This read only command gets the specified cutoff weight for the passed capture number
for procedure A or B. Format: ?<sp>RCTO<sp>capture_number<cr>.
20.7.30 RES
This is a read/write command. On a write it stops the current test and returns the unit
to the idle mode, clearing all test parameters. On a read it returns zero to be compatible
with older units. Format: ?<sp>RES<sp>1<cr> or =<sp>RES<sp>1<cr>.
20.7.31 RST
This write only command restores the factory calibration if the system is at the restore
prompt. Format: =<sp>RST<sp>1<cr>.
20.7.32 RUN
This read only command will return a 1 if running a test (Start mode, Work mode or
Results mode). Returns 0 otherwise. Format: ?<sp>RUN<cr>.
20-9
20.7.33 SER
This read/write command represents the temperature control configuration prompts.
The prompts have the same range as in the front panel displays. Format:
?<sp>SER<sp>parm<cr> or =<sp>SER<sp>parm<sp>data<cr>. Parm settings are:
0. Proportional Band, Bottom 6. Reset, Top
1. Reset, Bottom 7. Rate, Top
2. Rate, Bottom 8. Rate Band, Top
3. Rate Band, Bottom 9. Integral Limit Multiplier, Bottom
4. Integral Limit Multiplier, Top 10. Voltage Setting (1=115, 2=230)
5. Proportional Band, Top
20.7.34 SP1
This read/write command represents the current setpoint that both zones are controlling
to. A write will change only the volatile copy of the programmed setpoint. The data has
the same range as the front panel prompt. There is no decimal point. Format:
=<sp>SP1<sp>data<cr>.
20.7.35 SST
This is a read/write command. On a write it starts a test running if the system is in the
Idle mode or stops a running test if the system is in Work mode (the stop has the same
results as pressing the Exit key). On a read it will return a value of zero. Format:
?<sp>SST<sp>1<cr> or =<sp>SST<sp>1<cr>.
20.7.36 TIM
This read/write command represents either preheat time for procedure A or release time
for procedure B. It changes only the volatile copy of the programmed time. Format:
?<sp>TIM<cr> or =<sp>TIM<sp>data<cr>.
20.7.37 TLT
This read only command represents the total time for capture 1, capture 2, and capture
3. Format: ?<sp>TLT<cr>. The data is returned without a decimal point.
20.7.38 TOP
This write only command will move the weight support device to the upper limit. Format:
=<sp>TOP<cr>.
20.7.39 WRN
This read/write controls the 10 second cutoff interval alarm used in Procedure A tests.
This value is stored in non-volatile memory. Format: ?<sp>WRN or
=<sp>WRN<sp>parm. Parameter settings are: 1=Enable & 0=Disable. (Added as of
MP600 Version 4.0)
20.7.40 WTSP
This read only command represents the weight support position. Note that the data will
be interpreted in the current unit of measure and includes the decimal point. Format:
?<sp>WTSP<cr>.
20-10
21 Section 21 - Troubleshooting
21.1 System Warnings - If the data that is required to run a test has not been entered,
a warning will be flashed on the display. The following is a list of the meaning of
the warnings that may be displayed.
Warning Priority
Description Corrective Action
Code Code
1 1 Not used N/A
A PPDT type must be entered in
2 2 No pickup type entered
order to run a type B test.
3 3 Not used N/A
4 4 Not used N/A
5 5 Not used N/A
6 6 Not used N/A
Bottom temperature within 0.5C of
Temperature differential
7 7 setpoint and top temperature is
between zones too great
>10% off of setpoint.
21-1
21.2 System Errors - These errors appear on the display if the system detects a
problem with any of the hardware.
Error Priority
Description Corrective Action
Code Code
1 N/A Not Used N/A
2 N/A Not Used N/A
3 N/A Not Used N/A
4 N/A Not Used N/A
A read or write to the EEPROM did not
5 1 EEPROM Error
complete correctly.
A/D error - Temp reads 0
6 2 Power Cycle the MP600 to correct.
C
7 N/A Not Used N/A
8 N/A Not Used N/A
9 N/A Not Used N/A
10 N/A Not Used N/A
The measured resistance on the sensor input
Open Sensor Bottom
11 8 is higher than that allowed for the range of the
Error
sensor or the A/D is not functioning properly.
Shorted Sensor Bottom
12 9 is higher than that allowed for the range of the
Error
13 10 Open Sensor Top Error is higher than that allowed for the range of the
14 11 Shorted Sensor Top Error is higher than that allowed for the range of the
15 N/A Not Used N/A
The actual process has exceeded the high
16 7 High Temperature Bottom
temperature alarm value.
The actual process has exceeded the high
17 8 High Temperature Top
temperature alarm value.
18 N/A Not Used N/A
19 9 RTC Battery Error The real time clock battery is bad.
The motor output is on but no pulses have
Weight Support Encoder
20 10 been received from the encoder for at least 0.5
Error
sec. (refer to Section 21.4)
21 N/A Not Used N/A
The sensor inputs have not been calibrated.
22 11 Sensors Not Calibrated
Restore factory settings and recalibrate.
Zero crossing detection interrupt for the SCRs
23 12 No Zero Cross
is not working. Check AC power.
21-2
21.3 Electrical Checks
21.3.1 The MP600 Controller will need to be removed for these checks. BE
SURE THE POWER IS DISCONNECTED from the melt indexer
Controller before removing.
21.3.2 The heater bands can be checked with an ohm meter by measuring the
resistance at the Main Terminal Strip located on the rear of the MP600
Controller. The resistance between Terminals 5 and 14 (Heater
Terminals T and C) should be 75 ohms 5%. The resistance between
Terminals 6 and 14 (Heater Terminals B and C) should be 80 ohms
5%. The resistance between Terminals 5 and 6 (Heater Terminals T
and B) should be 155 ohms 5%. The resistance between any of the
wires to the case of the heater should be above 10 Megohms.
21.3.3 The RTD probes can be checked with an ohmmeter. Each probe has
three wires. With the two common colored wires shorted, check the
resistance between the common colored wires and the odd colored wire.
The resistance measured will vary with the temperature of the probe.
This resistance should be approximately 100 ohms at 0C and about
109 ohms at 23C. There should be no continuity between any of the
wires and the case of the probe. If any of these tests fail, replace the
probe and recalibrate.
21.3.4 The MP600 Controller, with both heater zones on full, draws about 3 to
4 Amps at 115 VAC service and about 4.5 Amps at 230 VAC service.
21.3.5 The motor for the optional Motorized Weight Lowering Device draws
about 1.0 Amps.
NOTE: The line filter used in the Power Entry Module typically has a leakage current of
0.25 mA to ground at 115 VAC, and 0.5 mA at 220 VAC. This current leakage
may cause a Ground Fault Interrupt (GFI) receptacle to trip, therefore a GFI is
not recommended.
21.4 MP600 Error 20
21.4.1 Every occurrence of Error 20 that has been documented has been due to
a blown fuse in the motorized weight-lowering device (MWLD). To access
this fuse, the covers on the MWLD must be removed as follows:
21.4.1.1. Tools Required
A 3/16 Hex Key, a 5/32 Hex Key 3/32, a Hex Key, and a #1
Phillips Screw Driver
21.4.1.2 Remove the 2 screws that attach the weight platform to the
MWLD using the 3/16 Hex Key.
21.4.1.3 Remove the 2 screws that come in from the rear and attach the
MWLD to the furnace using the 5/32 Hex Key.
21.4.1.4 Remove the 4 screws that retain the upper cover using the
3/32 Hex Key.
21-3
21.4.1.5 Remove the 5 screws that retain the aluminum sheet metal
cover using the #1 Phillips Screw Driver.
21.4.1.6 Carefully flex the sheet metal cover enough to remove the upper
cover, and then remove the sheet metal cover by raising it.
21.4.1.7 Replace the fuse in the in-line fuse holder with a 250 V, 2 Amp,
3AG Slow Blow Fuse, Tinius Olsen part number SRE01505.
21.4.1.8 Replace the covers and screws in reverse order.
21.4.1.9 Do not add grease to the grease fitting under the weight
platform unless the weight lowing device is completely lowered.
21.4.1.10 Adjust the weight platform so that a weight centered on the
platform will find its way on to a piston rod and when the MWLD
is raised, the weight will freely release from the piston rod.
21.4.1.11 Adjust the weight platform so that a weight centered on the
platform will find its way on to a piston rod and when the MWLD
is raised, the weight will freely release from the piston rod.
21.4.2 After replacing the fuse, one should check to see if there is an obvious
reason for the fuse to have blown. Adjust the weight platform so that a
weight centered on the platform will find its way on to a piston rod and when
the MWLD is raised, the weight will freely release from the piston rod.
21.4.2.1 A fuse may blow due to surges in the power line supplying AC
power to the equipment.
21.4.2.2 The fuse may blow if the device is overloaded by doing things
such as purging material be tested with the MWLD.
21.4.2.3 The fuse may blow if the upper switch does not work properly.
21.4.2.3.1 Turn the machine off with the MWLD in the down position.
21.4.2.3.2 Turn the machine on and follow the instructions to raise the
MWLD using the 9 key. If the MWLD goes all the way up,
turns 90 and jams, there is something wrong with the switch.
21.4.2.4 The fuse may blow if the device tries to lower too far and hits
the mechanical stops. In this case, the TOTAL TRAVEL must
be adjusted.
21.4.2.5 The fuse may blow if grease is added to the MWLD with the
device anywhere except in the totally lowered position.
21.4.2.6 The fuse may blow if the device tries to raise too far and hits the
mechanical stops.
21.4.2.6.1 Turn the machine off with the MWLD in the down position.
21.4.2.6.2 Turn the machine on and follow the instructions to raise
the MWLD using the 9 key.
21.4.2.6.3 Initialize a test, and then press the UP (7) key to raise the
platform the rest of the way.
21.4.2.6.4 If the platform turns more than 90 from the front position,
the OVER TRAVEL parameter in the MWLD configuration
options must be reduced. If this needs to be done,
reduce the OVER TRAVEL by about 0.5 mm and reduce
the TOTAL TRAVEL by the same amount.
21-4
21.4.3 To access the OVER TRAVEL and TOTAL travel parameters:
21.4.3.1 Turn power on.
21.4.3.2 At the SET POINT Screen and CAL OFFSET Screens, press 0
and ENTER. This will keep the furnace at room temperature.
Be certain to initialize the PPDT by moving the arm up and
down through its full travel before proceeding (going into
Calibration). Otherwise, the reference points get lost and you
need to do a Full Calibration on the PPDT.
21.4.3.3 At the main IDLE Screen, press 4 (OPTION) key to enter the
options.
21.4.3.4 At the OPTION Screen, press 4 (CALIBRATE) key.
21.4.3.5 Enter the access code, press 8 3 5 and ENTER.
21.4.3.6 At the SELECT CAL FUNCTION Screen, press 1 (WT
SUPPORT).
21.4.3.7 At the WEIGHT SUPPORT Screen, press ENTER, note, it
should be defaulting to DC, if not, press 2 (DC) and ENTER.
21.4.3.8 At the DC MOTOR CALIBRATION Screen, press 2 (CONFIG
WT SUPPORT). Verify the following values (change as
required) and press ENTER to continue:
21.4.3.8.1 ENC RES = 46080
21.4.3.8.2 DC MOTOR OFFSET = 0%
21.4.3.8.3 DC MOTOR FS FAST = 100% (up)
21.4.3.8.4 DC MOTOR FS SLOW = 40%
21.4.3.8.5 DC MOTOR FS FAST = -100% (down)
21.4.3.8.6 DC MOTOR FS SLOW = -40%
21.4.3.8.7 DC MOTOR PROP BAND = 1
21.4.3.8.8 TOTAL TRAVEL = Approx. 9.070 (inch, or 230.38 mm).
This is one of the values that may need to be changed.
21.4.3.8.9 OVER TRAVEL = Approx. 0.800 (inch, or 20.32 mm).
This is one of the values that may need to be changed.
21.4.3.8.10 UNDER TRAVEL = Approx. 0.150 (inch, or 3.8 mm). This
value may need to be adjusted to have platform position
agree with PPDT position.
21.4.3.8.11 Return to the DC MOTOR CALIBRATION Screen, by
pressing EXIT several times.
21.4.4 Check the OVER TRAVEL again by:

21.4.4.1 With the weight support down, turn off the Mp600 and turn it
back on. Following the directions on the screen press and hold
the 9 (UP) key to raise the platform until it stops.
21.4.4.2 At the SET POINT Screen and CAL OFFSET Screens, press 0
and ENTER. This will keep the furnace at room temperature.
21.4.4.3 At the main IDLE Screen, press 1 (TEST) key to enable the
weight-lowering device. Press the 9 (UP) key and jog the weight
support as far as it will swing around. The weight support must
stop at about 90 and not go any further.
21-5
B
21-6
22 Section 22 Recommended Spare Parts List
22.1 The following list of items is included to help prevent lost time in the use
of this piece of equipment due to normal wear of parts, electronic
component failure and accidental breakage.
Booklet Recommended
Description Part Number
Reference Quantity
1
Piston Foot 02001086 Figure 3-1 2
(ASTM Stainless Steel)
1
Piston Rod 02001085 Figure 3-1 1
(w/ ASTM Scribe Lines)
Orifice
02001030 Figure 3-1 2
(D2 Tool Steel)
Charging Tool Tip 02001071 Figure 3-1 2
L-Shaped Specify (C)
Figure 4-2 1 (each Temp.)
Thermometers Temperature
RTD Temperature W/D
02001407 2
Sensor Probe 8-12-1366
Barrel Brush 2
02001144 Not Shown 1
Handle (only)
0.406 dia. brass 2
Barrel Brush tips
0.090 dia. brass 2
Orifice Brush
2-1/2 square
02001136 Not Shown Bag of 500
Cotton Patches
Notes:
1. There is now a combination Piston Rod available with both the ASTM & ISO Scribed
Lines (P/N 02001439), a ISO (only) Piston Rod (P/N 02001665) and a Piston Foot
(P/N 02001440) to ISOs tolerances.
2. The Barrel Brush Handle (P/N 02001144) does not come with any brushes: order the
0.406 dia. barrel brush tips (P/N 02001143) with 8/32 threads for the Barrel Brush
Handle. The 0.090 dia. brass Orifice Brushes (P/N 0201142) are used when the
orifice will not pass the minimum ID requirement. DO NOT USE STEEL BRUSHES.
22-1
B
22-2
23 Section 23 MP600 Packaging/Shipping Instructions
IMPORTANT: Each Melt Indexer order is packaged slightly different depending upon which
options were ordered with the machine. Please keep all packing materials that the machine
was sent with in order to ship the machine properly!
23.1 Place the Accessories pocket into the box making sure that it is on the right-hand side
of the box (Refer to Figure 23-1). The Accessories Pocket is used to store the
Automatic Timing Switch Calibrator - P/N 02001531 (optional); Load Change Collar
(optional w/ flow rate ratio package, see manual pg. 15-2 Figure 15-1 #4); and any
extra weights, should they be ordered.
23.2 Install the X-shaped cardboard separator (for the weights) at the bottom of the box.
(Refer to Figure 23-1). This must be installed due to the fact that this supports the
machine from getting damaged during shipment. It is advisable to wrap all weights in
foam prior to placing the in the box.
Figure 23-1 (This picture shows the accessories pocket on the right-hand side and X
cardboard separator on bottom left next to the accessories pocket with the
cardboard sub-floor ready to be placed on top.)
23-1
NOTE: If only one weight is ordered it is placed in the parts box and not in the lower
compartment.
NOTE: If a full set of weights are ordered by the customer, they will be packed into a
separate box and shipped separately from the box containing the Melt Indexer.
(This is done due to the weight of the package.)
23.3 Place cardboard sub-floor on top of the X-shaped cardboard separator after placing any
weights to be shipped with the unit.
23.4 Place cardboard spacer on top of the cardboard sub-floor. (Refer to Figure 23-2)
Figure 23-2 (Shows cardboard spacer installed)
23.5 Place the MP600 Melt Indexer into the box making sure that it is sitting flat and
securely on the cardboard spacer. (Refer to Figure 23-3)
23.6 Place a piece of foam on the table in the front and back of the digital display unit.
This will keep the cardboard divider from scratching the table.
23-2
23.7 Next place the cardboard divider (looks like a U) around the digital display unit. (Refer
to Figure 23-3)
Figure 23-3 (This picture shows the Melt Indexer securely in place with the foam on the
table under the cardboard divider.)
23.8 Pack up the parts box (Refer to Figure 23-4). The parts must be placed in the box in
the following order:
23.8.1 PPDT-600 Automatic Timing Switch - P/N 02001505 (optional - wrap in foam)
& bracket (in plastic bag) Place this box in the bottom right-hand corner of the
parts box.
23.8.2 Thermometers (optional place this box on top of the Automatic Timing
Switch, make sure that it is on top due to the weight of the switch)
23.8.3 System Installation & Operation Manual - P/N 02001560
23.8.4 Weight (optional) wrapped in foam NOTE: The only time that the weight is in
the parts box is when there is only one weight that was ordered.
23.8.5 Electric Cord
23-3
23.8.6 Retaining Rods (optional - standard for weight lowering device MWLD in
plastic bag, see manual pg. A-5, 5-6-543 Item #1)
23.8.7 Level Assembly (Level base - P/N 02001226 & Circular Level - P/N 02001227)
23.8.8 Any extra parts ordered
23.8.9 Standard Tools (in plastic bag)
23.8.9.1 Orifices - P/N 02001030

23.8.9.2 Carbide Orifice (optional)
23.8.9.3 Orifice Drill - P/N 02001075
23.8.9.4 Cylinder Cleaning Tool - P/N 02001527
23.8.9.5 Charging Tool - P/N 02001582
23.8.9.6 Cutoff Tool - P/N 02001090
23.8.9.7 Piston Assembly - Stainless Steel Piston Foot - P/N 02001086,
Piston Guide Collar - P/N 02001088 & ASTM Piston Rod - P/N
02001085 (fully assembled)
23.8.9.8 Orifice Remover - P/N 02001073
23.8.9.9 Stainless Steel Funnel - P/N 02001091
Figure 23-4 (Shows the parts that are packed into the parts box)
23.9 Place the parts box on the left-hand side of the box on top of the cardboard divider.
(Refer to Figure 23-5) The parts box may protrude out of the box a little bit (this is
normal). By closing the lid, this will push the parts box down. Once the box is banded,
it will secure the machine in place for shipment.
23-4
Figure 23-5 (This is how the box should look like before closing.)
23-5
B
23-6
APPENDIX A
TYPICAL ASSEMBLY DRAWINGS
WITH PARTS LIST & WIRING DIAGRAMS.
A-1
B
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10

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MP600 Extrusion Plastometer

SYSTEM INSTALLATION AND OPERATION MANUAL.

This document contains confidential and proprietary information of Tinius Olsen

TINIUS OLSEN TESTING MACHINE COMPANY

MP600 Extrusion Plastometer

Version 5b - 15 October 2010

Section 16 Cleaning Instructions

Additional Accessories & Instructions Provided:

Version 5b - 15 October 2010

CAUTION: Thermometers contain mercury! When a thermometer is being used,

CAUTION: In some instances an exhaust system may be used to remove the

Note that Cautions are continued on the next page.

CAUTION: Possible pinch points associated with the weight-lowering device

1.1 Basic Unit

The Tinius Olsen Extrusion Plastometer with microprocessor-based Model MP600

1.2 Single Unit Construction

1.3 Precision Temperature Sensors

1.4 Precision Dual Zone Band Heater

300 Watts (nominal) -- contains a special concentric heating element, which is

(Standard Unit) 51 cm (20 inches) wide by 38 cm (15 inches) deep and 58 cm

1.6 Electrical Requirements:

115 Volt Units

The MP600 microprocessor-based Controller/Timer is fully interactive with the

2.1.1 Two-Zone Temperature Control

The temperature controller features two-zone proportional, integral, and

2.1.2 Calibration Offsets

For new machines shipped with optional thermometers, a MP600

2.1.4 Built-in Timer

2.1.5 Membrane Keyboard

The membrane keyboard allows the operator to communicate with the

2.1.5.2 Numeric Key Pad

2.1.5.3 Up (^) Key (numeric key 9)

2.1.5.4 Down (v) Key (numeric key 3)

2.1.5.6 Bottom (vv) Key (numeric key 1)

2.1.5.7 Stop Key (numeric key 4)

2.1.5.12 Heater LED Indicators

2.1.5.13 Capture LED Indicator

2.1.5.14 Power On/Off Switch

2.1.7 Test Set-Up and Storage

The MP600 Controller can store up to 25 different sets of test parameters,

2.1.8 Test Results

2.1.9 Communications Port

1. Piston Rod Assembly 6. Funnel

4.2 Glass Reference Thermometers

Caution: Thermometers contain mercury! Extreme care must be taken not to

4.2.1 Extrusion Plastometer thermometers may be used as a reference for

To reduce the potential of breaking the reference thermometer, it is recommended

4.2.2 Mercury Separation

Extrusion Plastometer thermometers have expansion chambers (see Figure 4-2).

Figure 4-6 Figure 4-7

Always store any unused thermometers in a vertical position.

Caution: In case of thermometer breakage while in the melt indexer, contact

P/N: 02001005 120C P/N: 02001012 235C

4.3 PPDT-600 Automatic Timing Switch (P/N 02001505)

The PPDT-600 is required when conducting Procedure B - Automatically Timed