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iX77 Rheometer Instruction Manual

1. a 7 Figure 9 2 iX77 Mechanical Assembly Inside View Rev J 101625591 Revision G May 2014 129 fann 101625591 4X M8 X 12 OMES WITH MOTOR v AIRFLOW 49 Se 4X 6 32 X 1 75 97 2 42 NL DV BEND THERMOCOUPLE 90 DEG FOR FIT LOWER TOWER ASSY DETAIL 1 77 Instruction Manual 101 3X 10 32 X 1 2 TN 1128 JET 52 53 gt 54 _ 2X 4 40 X 3 16 98 YL e 1 L 4 _ 101 3X 10 32 X 1 2 W 56 M 99 4X 6 32 NUT N p _ 100 4x 6 32 X 1 4 2 100 6X 6 32 X 1 4 UPPER TOWER ASSY DETAIL Figure 9 3 iX77 Mechanical Tower Assembly Rev J Revision G May 2014 130 fann 101625591 1 77 Instruction Manual 09 05 4 5 16 18 X 1 2 4X 24 105 I Van 12 5 9 ms Og 12 2 _ 11 12 7 SG 2 2 10 32 1 25 1 50 Si DE 2X 10 32 NUT 102 fans 4 131 ae 112 3X 1 4 20 X 1 4 PER SIDE 1 PA 12 8 1 5 3 8 16 1 25 07 251107 12 1 N J 08 5 3 8 24 5 8 NOS Nm HYDRAULIC PIPING DETAIL HIGH PRESSURE a ATT 12 6 2 7 12 2 5 Figure 9 4 iX77 Mechanical Hydraulic Piping High Pressure
2. 17772222 Q 12121 2 2 DE 1 S LEO 5 2 3220 SS Z IN 77 JY a SECTION A A d SCALE 1 5 1 DETAILK DO SCALE3 1 lt Figure 9 14 iX77 Cell Assembly Rev E 101625591 Revision G May 2014 145 fann CUP ASSEMBLY DETAIL f A 13 AN T gt 7 45 AA 12 INNER RACE 4 5 1 2 10 SECTION B B SCALE 2 1 G 1 77 Instruction Manual YN ANN V 7 7 7 ASSEMBLY DETAIL X N 12 OUTER RACE r ul LS 5 TN vA SN NS SK SECTION C C 11 2x8 32x1 375 p SCALE 2 1 448 32 x 114 HS N PN adore IA i iy j COUPLING ASSEMBLY DETAIL 3X 18 Figure 9 15 iX77 Cell Cup Rotor Coupling Shaft amp Bob Rev E 101625591 Revision G May 2014 146 2 y T E E 665 SHAFT AND BOB ASSEMBLY SECTION E E SCALE 2 1 gt fann 29 2X 6 32 X 1 TORSION MODULE ASSEMBLY 38 6 32 X 3 16 28 114 REF 36 3 30 4 30 y AN
3. 2 4 104 104 Tescom Valve Maintenance 105 Bec Tm 116 uu 117 Accessories and Spare Parts Lu m uqeaammsenuisnusesnen msjmnii menns 119 Paris EEE NE EE 121 M chanical IP N E S E 121 FF SG OS EE 136 Test Cell Assembly 101511610 144 101625591 Revision G May 2014 iii fa Instruction Manual Wir NIFU 148 VTM 148 TONS TRO TIN RR uuu 148 Figure 7 1 Rear Fluid 105 Figure 7 2 Drawer Latch 106 Figure 7 3 Opened Drawer with Rotated Front 106 Re TT NE BE 107 Figure 7 5 Air Inlet Tubing smaa 107 Figure 7 6 Wrenches for Valve Disassembly 108 Figure 7 7 Clearance in the Disassembling 108 Figure 7 8 Body Assembly Air Actuator Assembly 109 Figure 7 9 Valve Disassembly 109 Figure 7 10 Air Actuator ASSCMDIY Lavrans NU MIR DE 110 Figure 7 11 Internal Sensor Assembly 111 Figure 7 12 Internal Sensor Assembly Removal
4. Rheometer is routinely subjected to high pressure Therefore all fittings and couplings must not be tampered with until the pressure has been relieved to zero This hazard is particularly enhanced when the covers are removed e The cell and shield have been designed to assure safety However all high pressure equipment should be treated with great respect for the potential for destruction that it has The cell is most dangerous when filled with hot water based fluids A major failure of the test cell at high temperature and pressure would result in the explosive release of the contained energy At 30 000 psig and 600 F the water filled test cell has more energy than if it were filled with nitrogen gas under those same conditions Care must be taken to assure that the cell is not mistreated Failure to follow all instructions and exercise appropriate precautions could produce a catastrophic failure of pressure system integrity without warning and result in serious injury or death e Before testing a new fluid sample in the test cell be sure that it is compatible with the metals used in its construction Corrosion pits would render the cell unsafe 2 12 Temperature e Rheometer is routinely subjected to high temperatures The closed shield prevents accidental contact with the hot parts However if the shield 1s opened prior to cooling down there 1 nothing to prevent a person from touching the hot cell or the heate
5. National Instrument NetMeeting 9 IG Online Services Outlook Express QuickTime Roxio 101625591 Date Modified File Falder 212212007 1 29 PM CalibrationReports File Falder 911712007 9 59 Chiller File Folder 2122 2007 1 30 PM data File Falder 2122 2007 1 30 PM pataRecovery File Folder 9127 2007 12 58 PM C LookUpTables File Folder 212212007 1 29 PM IGjReportTemplates File Folder 212212007 1 29 PM TestProfiles File Folder 8129 2007 11 02 AM C TestReports File Folder 10 9 2007 12 43 PM C utilities File Folder 22212007 1 29 PM AutomaticTest ini 1 Configuration Settings 10 9 2007 10 12 AM Sb canfig ini SKB Configuration Settings 88 22 2007 2 36 config M77 ini 4 Configuration Settings 10 10 2007 1 11 CustomCalReport ini LEB Configuration Settings 6 12 2007 7 30 CustomReport ini 1 Configuration Settings 10 8 2007 12 43 PM Default amp uktomaticHeader kxt LEB Document 91812006 12 43 PM DefaultManualHeader txt LEB Text Document 91812006 12 43 PM Errar lng 91 KB Text Document 10 10 2007 12 52 Example CustomReport ini 1 Configuration Settings 8 18 2006 1 23 PM FileSaveHiskory txt 10 KB Text Document 10 19 2007 12 43 PM LastAubtomaticHeader ExE 1 Text Document 1079 2007 10 12 AM LastManualHeader txt 1 KB Text Document 9114 2006 2 08 PM aliases 1 KB ALIASES File Br24r2007 1 57 PM
6. fann Model 77 Viscometer File Edit Operate Tools Window Help Test In Progress Here Test start DataColection Manual Speed Setpoint Temperature Setpoint Manual Pressure Setpoint Status Digital Status Auto Test Calibration ill jo RPM i jo 30000 0 1000 0 Temperature Setpoint 0 0 Temperature 77 0 F Pressure Setpoint 0 0 PSI D Pressure 0 PSI D 0 0 RPM B Shear Stress Inf 1b 100 SqFt C Viscosity Inf cP B Tine 5 4 Min 7 Minutes from Cursor Enlarge This Value Temperature Setpoint Dr 0 0 28000 0 26000 0 24000 0 22000 0 20000 0 18000 0 16000 0 Uu 14000 0 12000 0 10000 0 8000 0 6000 0 4000 0 2000 0 0 0 950 0 900 0 850 0 800 0 750 0 700 0 650 0 600 0 550 0 500 0 450 0 400 0 350 0 300 0 250 0 200 0 150 0 100 0 50 0 0 0 I 0 0 0 5 1 0 2 0 eus 3 0 d 4 0 4 5 5 0 This page displays the current operating values For the M77 in graphical Format lt Minutes fann M77 V0 1 Copyright 2006 Fann Instrument Company Figure 5 14 Current operating values 101625591 Revision G May 2014 46 1 77 Instruction Manual 5 1 4 2 Fill out desired information in the dialog and click Done ui M7 ManualHeader vi Header Test Run On Fann Model 77 R
7. NO 9 9 9 1 g E1 QAM Nc 12V DC e 10V 18V 1 A2 10 10 E2 19 E2 POWER 11 r e SUPPLY 5 SSR2 12 12 I HL1 i Hut 24 voc 2 2 9 L E HL2 RED 14G 2 i HL2 44 POWER gt SUPPLY pc 15 z m 16 16 A2 L I uu PS 3 HS TB HS TB UPPER FAN LL 3 Figure 9 11 iX77 AC System Wiring Diagram Rev J 101625591 Revision G May 2014 141 fa 1 77 Rheometer User Manual FEROGACK CABLE DC SYSTEM WIRING DIAGRAM um on M77 COMMON al i S200 i TOR CAR 5 ET 4 0 seen CON M INPUT BE All wires are 18 AWG PVC Red for the AC Line SPEED COMMAND SERVO ENABLE 61 system P N 208523 55 All wires are 18 AWG PVC Green for the AC i N ib ms Ground system P N 208526 41 CTS PX T Y gd TERS E All wires are 18 AWG PVC Blue for the DC J af p system PIN 208527 i 44 19 TO CONQ SLOT PIN 4 lt fie Any other cable or Cable assembly if different n iex gt shoul
8. TERMINAL FEMALE Q C 25X 032 12 10GA NYLON FULLY 0078 349301 INSULATED FEMALE DISCONNECT WIRE RANG 12 10 AWG TAB SIZE 250 X 032 25 PER PACKAGE TERMINAL FEMALE SLIP ON FULLY INSULATED FOR 10 100032008 100032008 12 GA WIRE 0080 100031673 2 CONNECTOR PLUG THERMOCOUPLE SCREW FLAT HEAD MACHINE 4 40 NC X 1 2 BRASS 0091 100028695 6 NICKEL PLATED 101625591 Revision G May 2014 137 fa B Instruction Manual WIRE HOOK UP 14AWG STRANDED 600V UL 1015 0101 203857 FERRULE INSUL 18 AWG WIRE 0102 102004681 0 I4AWG BLUE 2 5 14 0 3 0 55IN 0 31IN L X 0103 102004682 INSULATED WIRE FERRULES SIZE 1 MM YELLOW 18 AWG 0104 102004685 FERRULE INSULATED WIRE BLUE 14 AWG 2 5 MM2 Table 9 8 iX77 Top Fab Assembly P N 101531616 Rev D 0001 101513362 TOP FRAME ASSY 0002 101513361 TOP COVER ASSY 0003 101513363 FACE PLATE ASSY 0009 101260861 6 SCREW MACHINE PAN HEAD PHILLIPS 10 32 UNF x 0 25 55 0010 100126545 6 WASHER FLAT NO 10 SS 0 5 OD X 0 219 ID X 0 049 THK 101625591 Revision G May 2014 138 fann 101625591 1 77 Rheometer User Manual ex 2X 6 32 X 3 8 45 e AN AAN A 59 16 45 2 6 32X 3 8 60 b 2x 17 44 AX 8 32 X 1 4 E COVER REMOVED SEE DIN RAIL a8 4x 6 32 SEE DIN RAIL 43 6 32 X 1 1 2 DETAIL 3 _
9. 1 77 Instruction Manual 5 Operation 5 1 Software 5 1 1 Starting Software 5 1 1 1 Start the software from the desktop icon 1f it 1s not already running Wait until the software 1s fully loaded up to 2 minutes 5 1 1 2 If the software does not find a conforming calibration the following dialog will be displayed on startup The data From the last calibration FAILS the sticking test It is recommended that veu ensure the mechanical Function of the viscometer and run a new calibration Figure 5 1 Calibration failure dialog 5 1 1 3 If error messages appear upon startup it is likely that the software was unable to find the data acquisition and control hardware If the error messages are cleared but the system still cannot find the necessary hardware it will display a dialog to inform the user it 1s entering simulation mode The system cannot Find the control hardware IE is now in Simulation Mode To return Ehe system to normal operation verify that the system is plugged in and turned on then restart Ehe program Figure 5 2 Simulation Mode dialog 5 1 1 4 When the system detects that it is pressurized on software startup it will use the detected pressure as a manual pressure set point When the operator has ensured that releasing pressure will not cause harm the pressure may be set to zero and the pressure will be released 101625591 Revision G May 2014 39 B 1 77 Instruction Manua
10. 2 2 Ergonomic Considerations e Special consideration should be given for moving and installing the 1 77 because of its weight 350 Ibs and its stature e strong low profile 32 1n bench top 15 recommended for easier cell removal 2 3 Environmental Considerations Properly dispose of pressurizing fluids and testing samples 101625591 Revision G May 2014 fa Fr Instruction Manual 3 Features and Specifications 3 1 Mechanical 3 1 1 Instrument Specifications These instrument specifications are for standard R1 rotor B1 bob and F1 torsion spring module Table 3 1 Instrument Specifications Rotor Speed RPM normal Shear Gap in Annulus cm Torsion Spring constant N cm degree 0 00386 F1 Torsion Spring deflection Bob Surface constant K gt cm 0 01323 B1 Bob Shear Rate constant sec per RPM 1 7023 Overall Instrument Constant K centipoise 300 RPM degree Shear Stress Accuracy Minimum Use Temperature C Maximum Use Pressure psi kPa Viscosity Range cP Minimum Viscosit c Maximum Viscosity cP 101625591 Revision G May 2014 7 fa 1 77 Instruction Manual Instrument Size and Weight Test Cell Size inches cm 16 1 4 high 4 3 4 diameter 41 3 X 12 1 Weight pounds kg 36 16 4 kg 1X771M size inches cm 41 1 2H 43 1 2W 24D 105 4 110 5 Weight pounds kg 350 159 kg 3 1 2 Test Cell Materials The t
11. Inspect connections for leaking fluids and replace O rings as indicated Leaking cell cap cell bottom or port connector O rings Dump valve or control valve not Manually reset dump valve Frequent pumping seating Replace kit in control valve Inspect weep holes at all high Leaking fittings pressure fittings and tighten as indicated No air supply Verify air supply Faulty air operated relief valve air pressure regulator or air operated Call for FANN service control valve Will not vent pressure Slowly manually release pressure Blocked high pressure filter remove filter and clean or replace filter elements Disassemble clean and reassemble Blocked flow restriction tubing Do not over tighten high pressure fitting 101625591 Revision G May 2014 104 B 1 77 Instruction Manual 7 2 Tescom Valve Maintenance 7 2 1 Tools Needed The following items are needed to complete valve repair e 2 inch open end wrench 101582697 e 2inch open end wrench 101582698 e Repair Kit 101629337 e Torque Sensor Tool 101629332 e Loctite 271 e A light lithium or silicone based grease 7 22 Front Panel Removal 7 2 2 Remove the cell assembly from the tower The weight of the cell could cause the instrument to tip when the drawer is opened 7 2 2 2 Remove power and air from the 1X77 7 2 2 3 Ensure the water and drain lines have enough slack to move forward without binding Figure 7 1 Rear Fluid Connec
12. around test cell Replace with larger hose or adjust to lower than system Call Fann Instrument Company Drain hose too small or too high 101625591 Revision G May 2014 116 fa Instruction Manual 7 4 General Table 7 3 General Baffle unscrewed against bob Tighten baffle and inspect bottom vee jewel for damage Torsion magnet touching upper Adjust magnet position and inspect pivot spring bottom vee jewel for damage vee jewel adjusted too far here Angle reading does not change or pen changes erratically Debris between torsion magnet and Clean pivot cap Diryvee Jewel Clean and inspect for damage with microscope Solids caked around torsion spring Thoroughly clean torsion spring or limit stop module Faulty magnetometer Call for FANN service Check pivot bushing rotor bushing and bronze race bushing for wear Cell bearings or bushings worn 0 0156 inch max vertical movement at rotor edge and replace as indicated Confirm rotor speed with optical Rotor speed calibration incorrect tachometer and adjust motor control board Unexpected angle readings but correct with calibration fluid Loosen magnet set screw and verify rotor and magnet holder squarely seat tighten set screw Inadequate calibration fluid volume Recalibrate with correct fluid in cell during calibration volume Contaminated fluid during Clean cell and recalibrate with fresh calibration calibration fluid M Recalibrate with c
13. fa Instruction Manual 025 18855 pe 101540493 1 BRACKET TOWER MECHANICAL ASSY 0024 102246060 BACK COVER Table 9 4 IX77 Tower Rotational Assembly P N 101514172 Rev E GEARBOX GAM DYNA RIGHT ANGLE HOLLOW OUTPUT ER RATIO 10 1 THERMOCOUPLE TYPE J 1 5 SS SHEATH 13 25 LG 36 00 0015 382609 6 SCREW HEXSOC I A20NCX 1 2 SS Table 9 5 iX77 Drive Can Assembly P N 101516026 Rev E 0001 101770520 1 iX77 DRIVE CAN SET W INSULATOR SET AND HARDWARE 0008 205058 1 MAGNETRING 0009 205204 1 ADHESIVE HI TEMP CERAMIC 16 OZ 101625591 Revision G May 2014 126 fa Instruction Manual Table 9 6 77 Drive Can Set P N 101543354 Rev 0001 101519371 DRIVE CAN 0002 101514825 FLANGE ROTATIONAL ASSEMBLY 0003 101514827 DRIVE SHAFT ROTATIONAL ASSEMBLY 0007 100123709 6 SCREW CAP SOCKETHEAD 48 32UNCX3 8SS 7 0008 120127922 6 SCREW 8 32 3 16 SOCHDCAPSS92196A189 101625591 Revision G May 2014 127 1 77 Instruction Manual fann M V w 5 5 Aw On s y zw 2X p VL gt lt 2 of Oy D Figure 9 1 iX77 Mechanical Assembly Front amp Back View Rev J 128 Revision G May 2014 101625591 fa Fr Instruction Manual UPPER TOWER ASSY DETAIL SEE LOWER TOWER ASSY DETAIL a
14. 12 Outer Race 5 4 4 1 1 Removal The oval shaped end of the removal tool 209165 is used to push the outer race from the rotor First remove the drive magnet and the magnet holder by removing the two screws that hold the assembly together Place the rotor 3 on the bench with the closed end down 101625591 Revision G May 2014 85 B 1 77 Instruction Manual Figure 5 49 Rotor and bearing removal tool Insert the small oval shaped end of the bearing removal tool into the small hole in the end of the post in the center of the rotor It will go in slightly stopping on the bushing race Push firmly straight down and the bushing race will pop loose from its seat A gentle tap from a small hammer may be necessary to make it pop loose The tool should only be tapped if the round shoulder 1s above the rotor surface 5 4 4 1 2 Installation Wipe a small amount of the supplied anti seize compound on the outer surfaces of the race Then use the round end of the bushing pressing tool It 1s round on one end and hexagonal on the other Push the bushing all the way into the rotor firmly Try not to use the slide hammer If you must use the slide hammer do it gently to avoid damaging the bushing If the bushing is not pushed all the way in the lower vee jewel may be damaged when the test cell 15 assembled 101625591 Revision G May 2014 86 B 1 77 Instruction Manual Figure 5 50 Placing the bushing oute
15. 5 4 3 1 Disassembly 5 4 3 1 1 Unscrew port connectors from the test cell in the tower Leave the sample port plug in place Some fluid will dribble from the left pressurization connector The mess can be minimized by rotating the test cell in the tower and inserting small corks into the ports 5 4 3 1 2 Place the test cell in the preparation stand and lock it in place with the locking pin 5 4 3 1 3 Unscrew the cell and set it below the bob until the upper portions of the test cell stop dripping Revision G May 2014 fa Fr Instruction Manual 101625591 to catch drips The strap wrench may be required to loosen it 5 4 3 1 4 Unscrew the cap 1 3 and remove it The strap wrench may be required on it also 5 4 3 1 5 Remove the rotor assembly 3 from the cell 1 2 and set it on a non magnetic surface away from magnet materials to drain It is always best to set the rotor down with the magnet end up This helps to avoid collecting nearby magnetic materials on the drive magnet 5 4 3 1 6 Pour out the contents of the cell and allow it to drain If the rotor has not been removed be sure to prevent it from falling out of the cell by holding it with a finger The drive magnet 6 used in the iX77 is a very high energy magnet lt is composed of samarium cobalt iron zirconium copper and rare earths Extreme care should be taken to prevent the magnet from being inadvertently attracted to an
16. Click the Start Test button to begin executing the test sequence fann Model 77 Viscometer File Edit Operate Tools Window Help sert Test messe wa Ter oue 1 3 1 WF do ff 2 M 3 Jo 0 53333 60 3 1 0 do pp 5 16566 60 1 do ft 5 Moes 1 do do jo do Jo 6 0 166665 430 P fo do 5 10 7 3 1120 do 10 2 ti Figure 5 24 Start the test 5 1 5 12 Once the test is running the start button will be disabled By default the test steps will scroll to keep the active step at the top of the list 101625591 Revision G May 2014 IX77M Instruction Manual fann Model 77 Viscometer File Edit Operate Tools Window L4 p DE Misc Visc Td e froe fe qm Je bro 1 Ps Ro Wf CO do 2 Ms Ho 3 ds do do 90 jo Jo do do jo 4 fo bo qd jo 5 Jossssixo f do 59 9 jo do jo 6 p f fo PP bb jo Pd jo 0 83333 200 po jo 59 29 0 0 Figure 5 25 Disabled Start button 5 1 5 13 If for some reason you wish to end a step early you may click Jump To Next Step If you wish to end the test immediately click Abort Test 101625591 Rev
17. Instruction Manual Figure 5 35 Placing the test cell into the hot well 5 2 2 3 Screw the cap onto the coupling hand tight 5 2 2 4 Install a well seal O ring if one is not already in place Stretch it over the bottom of the cell and roll or slide it up into its groove These O rings may be reused until they become hard or unpliable 101625591 Revision G May 2014 66 B 1 77 Instruction Manual 5 2 2 5 Place grease along the outer edge of O ring This will ensure the O ring slides smoothly in place and seals against the hot well 5 2 2 6 Remove the locking pin and pull the test cell from the stand The test cell weighs 36 pounds 16 4 kg and should be handled with two hands 5 2 2 7 the test cell from the test stand and lower it into the hot well of the 1X77 with the capped sample port toward the front A step stool may be useful if the bench 15 too high Slightly rotate the cell each way in the hot well to make sure the O ring seals properly 5 2 2 8 Screw the two port connectors fully into place Hand tight is adequate for good sealing It may be necessary to rotate the test cell slightly to line it up with the connectors Do not lift the test cell or the well seal O ring may be shifted out of position Figure 5 36 Screwing in the port connector 5 2 2 9 Tighten one connector locking screw left or right not both to prevent rotation of the test cell and to place it in exactly the
18. P N 101543382 Rev 121 Table 9 3 iX77 Chassis Assembly Mechanical P N 101514170 Rev 125 Table 9 4 iX77 Tower Rotational Assembly P N 101514172 Rev E 126 Table 9 5 iX77 Drive Can Assembly P N 101516026 Rev 126 Table 9 6 iX77 Drive Can Set P N 101543354 Rev 127 Table 9 7 IX77 Electrical Assembly P N 101531615 Rev 136 Table 9 8 1 77 Top Fab Assembly P N 101531616 138 Table 9 9 iX77 Cell Assembly P N 101511610 Rev 144 101625591 Revision G May 2014 V 1 A fa B 1 77 Instruction Manual Introduction to the 1 77 Rheometer The 1X771M Rheometer 1 a coaxial cylinder type that was developed to measure fluid rheologies under high pressures and temperatures with a high degree of safety The FANN design 1 based on a machine developed by the Sandia National Laboratories It was designed with oil well and geothermal drilling fluids 1n mind but has applications in many other fields It features extensive safety interlocks through not only the internally mounted computer but also mechanical and smart electronic hardware DO NOT TEST hematite limonite FeCOs or other magnetic and or ferrous contai
19. on startup Provision has been made to control an external Chiller by connecting via a serial cable to the chiller The operational parameters for using the chiller will be set up by the installer Optional Chiller e 204160 115 VAC 60 Hz e 381464 230 VAC 50 Hz 101625591 Revision G May 2014 12 fa Fr 1 77 Instruction Manual 3 3 2 Computer Requirements internal supplied with unit Table 3 2 Computer Requirements Processor P4 or equivalent Memory 512 MB 1 GB or more recommended Hard Disk 20 GB Larger recommended Operating System Windows XP Other Full height PCI slot available 3 USB 2 0 ports available 3 3 3 User Requirements It is assumed that the user has an excellent working knowledge of personal computers and the Windows operating system It is further assumed that the user 1 a trained laboratory technician with experience in drilling fluid testing Specifically the user 1s expected to be capable of 1 Preparing a sample and setting up the 1X 771M Rheometer mechanically for the test Starting a program from a screen icon Sending and receiving email Locating and copying files on the computer Using a spreadsheet or other program to create presentation quality reports from gathered data 6 Performing other basic windows tasks minimize maximize etc 3 3 4 Installer Requirements These requirements are at the time of manufacturing or reinstall due to hardware replacement It
20. volts 3000 5 2500 v 2000 D euge 1000 500 RR nen Figure 5 4 Pressure calibration dialog 101625591 Revision G May 2014 40 fann 1X77 Instruction Manual 5 1 3 Calibrating Torque and Speed 5 1 3 1 29 2 5 1 3 3 5 1 3 4 fann amp Model 77 Viscometer File Edit Operate Tools Window Help Test In Progress m Reset Here Test start poses Manual Speed Setpoint Manual Temperature Setpoint Manual Pressure Setpoint Status Digital Status Auto Test Calibration Cancel 700 0 600 0 500 0 400 0 300 0 m n a T a m 200 0 100 0 0 0 Calibration In Progress Prepare the 1 77 Rheometer with a sample of calibration fluid refer to 5 5 Calibration If the data file for the calibration fluid does not exist 1t will need to be created refer to 3 3 14 3 Appendix 1 Calibration Fluid File Format Click on the Calibration tab if it is not already showing Click the Calibrate button The software will begin stirring to ensure that the temperature has equalized 0 cu jo o Calibration In Progress Speed Angle L Save Save Calibration 300 0 250 0 200 0 Angle deg 150 0 100 0 50 0 ut 0 0 0 5 1 0 15 20 25 3 0 3 5 4 0 45 5 0 200 0 400 0 600 0 800 0 1000 0 Speed Command V Shear Rate 1 5 Sav
21. 1 Wo do do do 6 P do do 5 10 20 H b 7 Wossssx fzo Mizo do Wo Wo Wo Wo Po Figure 5 29 Pressure set point is set to zero e Not recommended for most tests e use only when a sudden release of pressure will not harm the system a sudden release of a hot test fluid such as a drilling mud could clog the high pressure filter 5 2 Test Preparation Mechanical 22221 Test Cell Preparation It is assumed that the assembled upper and middle sections of the test cell are properly locked in place on the test cell preparation stand 5 2 1 1 Remove the cap to expose the torsion assembly for inspection It should be clean 101625591 Revision G May 2014 61 fa Fr Instruction Manual 5 2 1 2 cell rotor assembly bob and bob shaft must be clean and free of anything that might contaminate the sample It may be necessary to dissemble and clean the coupling middle and cap top parts of the test cell Wipe any pressurization fluid or sample from the exposed threads and the bottom of the coupling 5 2 1 3 Screw the cell baffle snugly in the bottom of the coupling Pass metal rod through the holes in the baffle to tighten it If the cell baffle is not tightened sufficiently it may unscrew during a test until it touches the top of the bob It may press down hard enough to damage the bob s vee jewel If the displayed angle reading stops changing dur
22. CHECK VALVE 101543077 101485744 HYDRAULIC DRAIN RESERVOIR AN 101485704 ge 101675112 347566 oS _ TESCOM 30K PRESS ime 101516393 L gt nsu VV V L jJ 10002211 HYDRAULIC SW RESERVOIR bo gt x 99 8 ex 70 5 PRESS TRANSDUCER AIR 100022028 21 H2 Ox 100029496 f Q i 30KSI GAUGE HP FILTER e e e e e REFRIGERANT e e e amp 101539542 HP MANIFOLD 101539543 HYDRAULIC A N 30KSI RUPTURE DISK LOW PRESS 101388193 NG 2 pa HYDRAULIC ss HIGH PRESS HP BULKHEAD HANDLE ADAPTER HP HANDLE ADAPTER 101392263 101542807 HP PRESS VESSEL 101542807 Figure 9 13 iX77 Mechanical Schematic Rev B 101625591 Revision G May 2014 143 fa B 1 77 Rheometer User Manual 9 3 Test Cell Assembly 101511610 Parts Table 9 9 iX77 Cell Assembly P N 101511610 Rev E O RING SIZE 2 226 COLOR WHITE 600 DEG F ID 1 984 IN X 0042 208939 RING BACKUP TOP CELL 0043 208940 RING BACKUP BOTTOM 0044 203388 8 32 X 1 4 LG SHSS 101625591 Revision G May 2014 144 1 77 Instruction Manual fann SY SAN AV VAR _ Sr NZ NANA 12 b i 2 ET AEE AE ee AEE Z 7 77 gt a 72722
23. DEG 139 IN WALL O RING SIZE 2 226 COLOR WHITE 600 DEG F ID 1 984 IN X 139 IN WALL DIG EE 2 SIZE 230 VITON 75 DUROMETER 2 484 ID 0 139 W 0011 2407 6 O RING0209IDX 070NITRILE 0016 100123611 6 SCREW SET 6 32 X 3 16 ALLEN KCP SS 0018 101630087 O RINGS FOR P8791 HP 40WEV ORING 212V 138V AND O RING 2 220 VITON 75 DUROMETER 400F 1 359 ID X 0 139 W bd COMPOUND V1475 75 0027 207805 HYDRAULIC FLUID 1 QUART BOTTLE 0028 209165 TOOL BEARING REMOVAL 0029 203367 BUSHING ANGULAR CONTACT A complete sensor assembly for the 30 000 PSI Tescom regulator is available separately from the Tescom repair kit as PN 101629339 101625591 Revision G May 2014 119 fa Instruction Manual Table 8 2 1 77 Rheometer Tool Kit P N 101623037 Rev 0005 208937 TOOL SET 0006 208945 TOOL CALIBRATION 0007 101623038 WRENCH OIL FILTER NYLON STRAP TOOL SENSOR TORQUE 20 000 PSIG AND 30 000 PSIG Mi TESCOM REGULATOR 0009 206557 WRENCH STRAP 5 0010 209165 TOOL BEARING REMOVAL 101625591 Revision G May 2014 120 fa Instruction Manual 9 Parts List 9 1 Mechanical Parts Table 9 1 iX77 Rheometer P N 101543382 Rev Quantity Description 101625591 Revision G May 2014 121 fa Instruction Manual Table 9 2 Mechanical Assembly P N 101516396 Rev N VALVE BACK PRESSURE REGULATOR 30 000 PSI 1 4
24. Figure 5 52 Positioning the bushing inner race 101625591 Revision G May 2014 89 B IX77M Instruction Manual Figure 5 53 Pushing the inner race onto the pivot Figure 5 54 Placing the drive magnet into position 101625591 Revision G May 2014 90 B 1 77 Instruction Manual Figure 5 55 Pushing the rotor bushing into position Figure 5 56 Locking the drive magnet 5 4 4 4 Pivot Bushing 43 5 44 4 1 Removal First remove the angular contact bushing inner race Refer to 5 4 4 2 The Angular Contact Bushing 12 Inner Race Like the inner race the pivot bushing is removed with the puller and the slide hammer First screw the puller onto the threaded end of the slide hammer Then remove the two inner race adapters from the ends of the arms if they are installed The circular slot the fittings at the end of the arms 15 designed to engage the flange at the 101625591 Revision G May 2014 91 1 77 Instruction Manual bottom of the bushing Separate the arms of the puller a little and lower them to the bottom of the cell around the pivot thermowell 5 Now close the arms of the puller engaging the slots on the bushing flange on each side Hold the arms closed with one hand and slide the weight of the slide hammer up with the other banging it against the stop away from the cell After a few moderate blows the bushing should break loose 5 4 4 4 2 Install
25. HIGH ro pee PRESSURE HYD PORTS 0007 208603 ADAPTER 1 4 X 1 8 NPT SPECIAL TAPER SS mm i ELECTRONIC PRESSURE CONTROLLER PID 1 8 NPT INLET PORT 1 4 NPT CONTROLLED OUTLET PORT VALVE HIPCO DIAPHRAGM AIR OPERATED NORMALLY 0010 101539542 FILTER 17 4PH 30000 PSI RATED 1 4 HP PORTS 0011 101539543 GAUGE PANEL MOUNT 0 35 SS 0012 101540494 1 TUBING SET 1 4 HIGH PRESSURE GLAND AUTOCLAVE ANGLE 40 60000 POUNDS PER SQ IN 1 1 0 0 PLUG AUTOCLAVE 1 4 60000 AP40 PSI SS 0018 101516024 1 MANIFOLD 7X HIGH PRESSURE PORTS 30 000 PSI RATED 1 1 1 1 SAFETY HEAD HIGH PRESSURE RATING 60K F RUPTURE 0019 101388193 1 DISK INLET MALE 1 4 HM4 X OUTLET FEMALE 3 8 NPT 0020 100022028 TRANSDUCER PRESSURE 30000 PSI 0021 100029496 TEE SS 60 23HF4 1 4 TUBE 60000 0022 101542809 oa RUPTURE DISC BURST PRESSURE 35000 PSI 72 1 4 ANGLED SEAT 0023 101392264 60K MALE TO MALE 1 4 HIGH PRESSURE CONNECTOR 0024 101474066 MOUNT VIBRATION 5 16 18 FEMALE TO MALE 60K BULKHEAD FOR 1 4 F HIGH PRESSURE X 1 4 F HIGH 0026 203509 BOTTLE 1607 CLEAR PET 63MM 0027 203962 FILTER INTAKE CAST COVER w GLASS JAR ADAPTER HIGH PRESSURE FITTING 30K FEM 1 4 NPT X 0029 100068227 PLUG PIPE 1 4 NPT MALE PIPE VALVE 3 PORT SOLENOID BODY PORTED 1 4 INSTANT ee TUBE FITING 1 4 FNPT P 1 8 FNPT R ELECTRO PNEUMATIC REGULATOR 0 9 MPA POWER 0032 101675112 1 VOLTAGE 24 VDC INPUT SIGNAL 0 5 VDC A
26. Newtonian silicone oils and are available in a number of viscosities The viscosity tables supplied with the fluids are traceable to the National Institute of Standards and Technology The Rheometer will retain its calibration as long as the torsion spring module is not disassembled and 1 kept clean and corrosion free Removing the spring cage assembly from the top of the coupling as a unit should have only a minor effect on the mechanical zero The 1X77 Rheometer uses a smart digital magnetometer to detect the rotation of a magnet at the top of the torsion assembly The influence of the powerful drive magnets inside of the shield the earth s magnetic field the magnetic properties of the shield spring non linearaties magnetic fields and masses in the laboratory non ideal fluid flow and small geometry variations all combine to make the angle display non linear if not compensated The advanced control software allows easy compensation for those effects 5 5 Setting the Mechanical Zero The mechanical zero of the test cell torsion assembly is the angle to which the torsion assembly rotates with no fluid in the cell The zero point is determined by the rotational position of the zeroing sleeve and the torsion magnet These parts are all located in the top of the test cell under the cap Rapidly closing the shield door may cause the shear stress angle sensor to not achieve initial lock on the torsion magnet The angle read will usually be
27. Pour 140 ml of sample into the cell without getting it on 5 3 1 5 the threads of the cell or the seal This sample volume reaches the top edge of the rotor To remove any air pockets and completely fill the space rotate the rotor with a ferrous tool back and forth Slide the cell under the coupling on the stand Then lift it up and screw the cell into place until it bottoms out Jewel backup ring damage will occur 101625591 5 3 1 6 5 3 1 7 If resistance 1 felt before it reaches full make up then stop The seal or backup ring might have slipped out of place or the torsion assembly may be jammed Unscrew the cell and check the position of the backup ring O ring cell baffle and bob Tighten the cell with the strap wrench provided with moderate torque 20 foot pounds Inject 15 ml of the sample through the sample port to bring the level of the sample up in the coupling to just below the sample port This step is important If the level is too high it leads to contamination of the pressurization fluid in the torsion spring area of the cap If the level is too low contamination of the sample with the pressurization fluid is possible Revision G May 2014 71 B 1 77 Instruction Manual Figure 5 41 Injecting the sample Figure 5 42 Installing the cap seal O ring and backup ring 5 3 1 8 Install a well seal O ring if one is not already in place Stretch it over the bottom of the cell a
28. Rev J Revision G May 2014 131 fann 101625591 1 77 Instruction Manual F3 E j c mmm ZN 6 28 119 1 mv 2 8 v dan LL TI AEN ini Pu 60 SUPPLY p T 60 ar DRAIN 6 Y 27 Ye2 Ye 75 27 CONNECT FIND NO 62 TO BULKHEAD USE FIND NO 61 AS AIRPORT TO PREVENT VACUME HYDRAULIC PIPING DETAIL LOW PRESSURE SECTION A A SCALE 3 8 Figure 9 5 iX77 Mechanical Hydraulic Piping Low Pressure Rev J Revision G May 2014 132 fann 101625591 1 77 Instruction Manual z B lt gt 101 2X 10 32 X 1 2 115 2X 10 32 X 1 4 WATER PIPING DETAIL Figure 9 6 iX77 Mechanical Water Piping Rev J Revision G May 2014 133 fa B Fr IX77 M Instruction Manual CHILL OUT CHILL IN 2X 10 32 X 1 2 101 CHILLER PIPING DETAIL Figure 9 7 77 Mechanical Chiller Piping Rev J 101625591 Revision G May 2014 134 fa 1 77 Instruction Manual LJ jis 2 1 4 20 3 8 46 Ce Era a INSTALL ON TESCOM CABLE ELECTIRCAL COMPONENTS NOT SHOWN 91 WIRE 14 GA RED 92 WIRE 18 GA BLUE 93 CABLE 22 GA SHIELDED 2PAIR 94 3 8 HEATSHRINK 95 1 8 HEATSHRINK Figure 9 8 iX77 Mechanical Electrical Components Rev J 101625591 Revision G May 2014 135 fa B 1 77 Instruction Manual 9 2 Electrical Parts Table
29. and only last for a few seconds The advanced control software will reestablish communication and lock automatically Test Cell Mechanical Normal test cell assembly is covered in 5 5 Test Procedure This section 1s intended to cover the situation where a component in the torsion assembly 15 replaced or something 1 done that alters its overall length The torsion module is made up of the bob bob shaft the torsion spring assembly and the pivots and jewels at each end The most common use for this section will be when a jewel usually the bottom jewel 1s replaced The position of the bottom jewel mounted in the bob 1 very critical to the life of the jewel The jewel can be screwed up or down to adjust the vertical position of the Torsion Assembly Its position 1 locked by means of a socket head set screw above it If the jewel 15 adjusted too far toward the top of the bob two things may happen 1 The pivot guide may rest on the post of the rotor causing the bob to rotate with the rotor 2 The limit stop may rest on top of the coupling when the test cell 1s pressurized Either situation will result in erroneous viscosity measurements If the bottom jewel is adjusted too far toward the bottom of the bob the Jewel will be destroyed when the cell is assembled This occurs because the torsion assembly is lifted on the Rotor Pivot as the cell is assembled The motion of the torsion assembly upward 15 limited by the limit stop to pro
30. and steam Four quick connect to pipe adapters are supplied for 1 4 inch tubing If other types of piping or tubing are used the user must supply all fittings to adapt from 1 4 female NPT to whatever is used 230 VAC 50 or 60 Hz 20A single phase electrical power outlet If required an electrical cord adapter to connect the electrical power cord supplied to the available outlet Compressed air supply providing a minimum of 2 5 CFM at 80 100 psi Suitable hose and fittings to adapt to female NPT and connect the air supply to the back right center of the unit 4 1 2 Procedure The following step by step procedure will help to ensure that your 1 77 Rheometer will work properly on startup Revision G May 2014 35 fann 101625591 4 1 2 1 4 1 2 2 4 1 2 3 4 1 2 4 1X77 Instruction Manual Select location for the system which meets local safety requirements This rheometer should be located near a source of tap water and a drain The bench surface should be higher than the drain The bench should be relatively low or provisions for a step stool must be made A bench about 21 inches 53 4 cm high is good The bench should be stiff and adequate to support 400 Ibs 181 4 Kg Lateral stiffness helps to prevent excessive vibrations due to slight imbalance of the rotating drive components Minimum bench surface is 24 inches depth x 45 inches width 61 cm x 114 cm with a recommended size of 30 inches depth x 51 inc
31. are 18 AWG PVC Blue for the DC system P N 208527 Any other cable or Cable assembly if different should be noted on the drawing with designator number HS TB Heater System Terminal Block E Stop Emergency Switch OR1 Optocoupler Relay PS Power Supply SSR Solid State Relay 1 77 Rheometer User Manual e SW Circuit Breaker Switch mde WD Watch Dog Relay e PR Power Relay OT Over Temp Switch AC TB AC Terminal Block m L2 S200 AC INPUT DRIVE 4 FEEDBACK GRN 14G RED 14G RED 14G RED 14G RED 14G E RED 14G RED 14G COMMAND VO NOTAR POWER PE rower C2 C1 x 12 T T f lt aM 1 semal PORT 12 12 12 2 2 E1 G o L Lt MECHANICAL ASSEMBLY POWER SUPPLY ACTB gi G 1 21351415 6 7 8 9 10 11 12 13 14 o eg ee T c Te ee T Et 4 E1 DE s 414 s s af d a BL 1 et 2 E 2 TC 3 iC RED eo 4 E r 4 3 Fog e Ww gi E2 h r fr 5 up 1 HL1 HL1 SSR1 5 4 gt 5 6 6 AA HL2 HL2 ul 1 2 1 HUI 7 SSR3 E lt 1 Ell 7 Et a a I 1 13 c i E2 E2 RELAY PS 1
32. be stored in one place 3 3 13 14 Minimum Start Test Pressure 101625591 Revision G May 2014 30 fa Fr 1 77 Instruction Manual This value 15 used to prevent boiling water in the system due to insufficient pressure If Enforce Minimum Pressure is checked the system will try to prevent boiling until this pressure value is reached 3 3 13 15 Enforce Minimum Pressure If this LED 1 lit the system will use the pressure in Minimum Start Test Pressure as a minimum pressure to avoid boiling water in the system 3 3 13 16 Custom Report Configuration Clicking this button allows the custom report generation to be customized to support a wide variety of test formats 3 3 14 Manual Test Profile Creation 3 3 14 1 How a Test Profile Works A test file 1s a series of steps that are executed in sequence The program will stay on the current step until all of the Wait criteria have been satisfied The wait criteria are e Time MINIMUM time for the step e Speed at the set point the Tolerance e Temperature at the set point the Tolerance e Pressure at the set point the Tolerance e Viscosity at the set point the Tolerance The LEDs above Time Temperature Pressure and Viscosity indicate whether or not the system 1s waiting on that parameter for completion of the current step In order for a step to be complete the Time must be expired AND the Speed Temperature Pressure AND Viscosity must be a
33. drain water to splash on anyone An external chiller system may be connected to the CHILL IN and CHILL OUT ports The Chiller input pressure cannot exceed 10 psig differential or leaks will occur around the outer cell O ring The Chiller assemblies supplied by FANN 204160 120V 60Hz and 381464 230V 50 Hz have a built in gauge and bypass valve to limit the input of pressure The test cell must be in place when the Chiller 1s operating If a chiller 1 not used the chiller port may be left open Water and air will be used as the coolant 101625591 HIZO my CHLL DRAIN CHILL OAOA Figure 4 2 HIZO Supply and drain connections Revision G May 2014 37 fa Fr 1 77 Instruction Manual 4 2 101625591 Test Cell Preparation Stand The test cell Preparation Stand supports and protects the test cell and should be used to hold the test cell anytime it is removed from the Hot Well of the Rheometer Four holes are provided to securely mount the test cell Preparation Stand to any sturdy convenient surface adjacent to the unit and all four holes should be used Ideally the test cell Preparation Stand would be mounted on the same bench as the Rheometer and just to the left of the instrument This completes the minimum installation requirements It is suggested all procedures contained in this manual be reviewed before attempting to calibrate and run a test Revision G May 2014 38 B
34. gently into place and verify that it spins freely 5 2 1 10 Place a new cell seal O ring into its groove in the cell just above the rotor Do not reuse an O ring seal 5 2 1 11 Place the metal cell backup ring on the O ring with the flat surface facing up Figure 5 32 Installing rotor in cell 101625591 Revision G May 2014 64 B 1 77 Instruction Manual E E 4 Figure 5 33 Installing cell 5 2 1 12 Lubricate the threads of the coupling with a small amount of anti seize compound to prevent thread galling Severe galling of the threads could ruin the cell assembly 2 22 Verify Mechanical Zero The following steps establish the mechanical zero position of an empty complete test cell without the error that may occur with a sample in the cell Each time the torsion spring module is removed cleaned and re installed the mechanical zero point may shift This verification procedure may be skipped if the fluid to be tested has no gelling tendencies and is of relatively low viscosity 5 2 2 1 Place the cell under the coupling on the stand Lift it up and screw the cell into place until it bottoms out If resistance 15 felt before it reaches full make up stop and investigate The torsion assembly may be jammed 5 2 2 2 Make sure that the torsion assembly 15 free to rotate by pushing the top magnet with a non magnetic wire or rod 101625591 Revision G May 2014 65 7
35. must be resolved prior to calibrating Calibration has FAILED Angle measurement will not stabilize at zero Figure 5 7 Calibration failure dialog 5 1 3 8 Once the angle has stabilized the software will begin slowly ramping the speed of the rotor through a series of values these values may be adjusted by the installer or a qualified technician As it ramps through those values it is building the lookup table for later use assuming that the calibration 1s accepted 101625591 Revision G May 2014 42 1 77 Instruction Manual 5 1 3 9 When the software has finished stepping through the values it will ask if you wish to keep the speed calibration Fx Save Speed Calibration Figure 5 8 Save Speed Calibration dialog 5 1 3 10 If you accept the speed calibration you will be asked if you wish to apply viscosity calibration Would vau like apply a Viscosity Calibration Figure 5 9 Viscosity Calibration dialog 5 1 3 11 If you choose Yes required in order to calibrate the Rheometer you will be asked to choose a file containing the calibration data for the calibration fluid Choose the fluid from the list displayed or browse to select the correct file 101625591 Revision G May 2014 fa IX77M Instruction Manual Choose Enter Path of File Look in 3 CalibrationFluids I e Fe Pil 420 0405 cev M 200 0705 csv T200 0398 csv 3
36. oe 14 UA 15 _ 49 50 gt DIN RAIL DETAIL 4 d DC TB 2 Ta es N o gt 1 swt 1 9 o 3X 6 32 X 1 14 39 2X 4 40 X 112138 H n odd 34 42 SEE DIN RAIL DETAIL 2 L SEE DATA ACQU DETAIL SECTION A A SCALE 1 2 COVER REMOVED Figure 9 9 iX77 Electrical Assembly Main Components Rev H Revision G May 2014 139 fann 101625591 1 77 Rheometer User Manual DIN RAIL 3IN 73 2X 10 32 X 144 ZS SX ax 10 3262 lc let NN 71 DIN RAIL 6 12 IN DETAIL 2 12 gt lt DIN RA 37 2x 10 32 x 1 4 52 2 10 32 Aa DIN RAIL i DETAIL 1 x 8 A T DETAIL 3 AC TB 12 72 DIN RAIL 7 4 IN f ep 2X 10 32 X 1 4 37 gt lt 2X 10 32 52 52 2X 10 32 37 2X 10 32 X 1 4 Nm 2 N 74 DIN RAIL 4IN DIN RAIL DETAIL 4 DC TB DATA ACQU DETAIL 4 Figure 9 10 iX77 Electrical Assembly Din Rail Components Rev H Revision G May 2014 140 fann 230 VAC INLET Y LI py N m STOP OPTOCOUPLER RELAY AC SYSTEM WIRING DIAGRAM M77 All wires are 18 AWG PVC Red for the AC Line system P N 208523 All wires are 18 AWG PVC Green for the AC Ground system P N 208526 All wires
37. showing 5 1 5 3 Click on the Generate Test Sequence button fann amp Model 77 Viscometer E BIK Elle Edit Operate Tools Window Help 4 Visc po Temp Temp Pressure Pat Speed Speed Set Toler Pressure value ance Collect Step Time rint EEE Interval Ode Roper 0 18 Label o 3 jo 5 3 go o jo o fo go go go go Mo go go o 5 3 go jo Figure 5 17 Auto Test tab 101625591 Revision G May 2014 49 fa NN iX77 Instruction Manual 5 1 5 4 The Test Point entry dialog displays SelectTestPoints vi Right Mouse to insert or delete steps Figure 5 18 Test Points dialog 101625591 Revision G May 2014 50 IX77M Instruction Manual 5 1 5 5 Hill in the temperature and pressure test points required for the test to be run If desired the light in the Email After column may be clicked This will send an email with preliminary results after the chosen step is completed Click DONE when finished Select TestPoints vi 120 Figure 5 19 Fill in temperature and pressure test points 101625591 Revision G May 2014 51 IX77M Instruction Manua
38. the top of the torsion magnet 34 and the bottom of the upper pivot spring 35 It should clear by about 1 32 inch to 1 16 inch I mm to 2 mm Remove the pivot cap 33 by first loosening its set screw at least two turns 101625591 Revision G May 2014 98 B Instruction Manual Figure 5 63 Adjusting the torsion spring length 101625591 Revision G May 2014 99 fa Fr 1 77 Instruction Manual The torsion shaft assembly is supported at the center of the bob 4 on a sapphire vee jewel 15 If the assembly is lifted and allowed to drop on the bottom pivot it may damage the vee jewel This will destroy the accuracy of the instrument and require replacement of the vee jewel Removing the torsion magnet 34 could inadvertently lift the torsion shaft assembly 5 5 2 1 6 Note the orientation of the torsion magnet 34 set screw to aid in re assembly Also note the clearance between the bottom of the rotating torsion magnet 34 and the top of the stationary grip mandrel 30 3 It should be 1 32 1nch 1 mm or more Loosen the set screw and remove the torsion magnet 5 5 2 1 7 Unclamp the top spring mandrel 30 4 by loosening the set screw 49 in the zeroing sleeve 11 5 5 2 2 Rotate Top Spring Mandrel Use a calibration tool Part No 208945 to rotate the top spring mandrel slightly Turn it counter clockwise when viewed from the top to lengthen the spring Turning it clockwise will shorte
39. 01625591 1X77 Instruction Manual Custom Calibration Report Configuration e This allows the user to specify an alternate format for the calibration report e If Save in Custom Format is illuminated this produces a second customized calibration report for importing into legacy programs for analysis Save in Custom Format e This instructs the system to save a second copy of the calibration report in a custom format Chiller Enable When illuminated this tells the system to use an external chiller to cool the system as needed to achieve temperature Currently using Calibration e This is the full path name of the calibration file currently in use e If the default name is used it will include the time and date of the calibration Revision G May 2014 fann 3 3 10 fann Model 77 Viscometer File Edit Operate Tools Window Help 16 00 101625591 ga iX77 Instruction Manual The Setup Tab Technician Mode This tab allows access to the parameters that adjust the operation of the 1X77 Rheometer It is vital for both safety and proper function that these parameters are only changed by an experienced technician If you are not absolutely certain that you should change any of these parameters don t 1 00100 000 Jo coo00 Aiso 2000 0 Figure 3 6 Setup tab Revisio
40. 07 1 1 1 1 I 1 I 1 1 1 0 0 ed SHE S s Gel Gps fee best fl tebe Minutes a This page displays the current operating values for the M77 in graphical format f a M77 0 1 Copyright 2006 Fann Instrument Company Figure 5 16 Enter set points 5 1 4 4 Clicking the Data Collection switch again stops the data recording 5 1 4 5 In order to stop cool depressurize the system the operator must set the manual set points to zero 5 1 5 Running an Automatic test The 1X77 Rheometer 1s capable of performing tests that include within the physical capability of the machine arbitrary profiles of temperature pressure and rotor speed The test profile also controls when and at what rate data 1s collected This system of describing and executing tests is very powerful but programming 101625591 Revision G May 2014 B IX77M Instruction Manual and testing a test sequence directly is somewhat arcane To address this issue a test sequence generator has been included in the software This provision drastically simplifies test sequence entry for the vast majority of the anticipated user base This is the method that will be described here To generate an automatic test sequence 5 1 5 1 Prepare the 1X77 Rheometer with the sample you wish to test refer to 5 3 1 Load Sample into Cell 5 1 5 2 Click on the Auto Test tab if it is not already
41. 111 FIGHre 7x19 NNN 111 Figure 7 14 Lubrication of 112 Figure 7 15 Torque Sensor 0 112 SO NS NNUS 113 SOM 0 m C UU T Tm 113 Figure 7 18 Valve Parts 114 Figure 7 19 Stem and 1 114 Figure 7 20 O ring and Backup NN 114 Figure 7 21 Loctite nnne nnn nnne 115 Figure 7 22 Reassembled 5 0 nennen nnne nnns 115 Figure 7 23 Lubricated TDEGSOS pui apu ROS mene iE pu V Oba dod pO 115 Table 9 2 Mechanical Assembly P N 101516396 Rev 122 Figure 9 1 iX77 Mechanical Assembly Front amp Back View 128 Figure 9 2 iX77 Mechanical Assembly Inside View Rev J 129 Figure 9 3 iX77 Mechanical Tower Assembly 130 Figure 9 4 iX77 Mechanical Hydraulic Piping High Pressure Rev 131 Figure 9 5 iX77 Mechanical Hydraulic Piping Low Pressure Rev 132 Figure 9 6 iX77 Mechanical Water Piping 4 133 Figure 9 7 iX77
42. 4V SUPPLY REF 24V 9 REF 24V REF24V2A 10 REF 24V REF 24V T REF 24V REF 24v 12 REF 24V z gt G E gt nN REF 12V e BsF 12 i 24 VDG 2A REF 24V 2A E POWER 24V 2A E N SUPPLY pc meie e 3 mius e mes em aae V HL 1 TESCOM VALVE OT 1 POR fio u TENE VWATLOW VES 51 1 10004 2 moune ee 3 MECHANICAL ASSEMBLY AT TT T C RED 6 us REF24V 7 1 h MC 8 SAFETY ON RELAY yt 4 T REP 24V PLC RSC 24DC 2 Figure 9 12 iX77 DC Wiring System Rev J 101625591 Revision G May 2014 142 fa B 1 77 Rheometer User Manual 101485082 VX2120 02N 5G B FLOW CONTROL CHECK VALVE 101540491 Tc 101622480 eee eee m lt 248 amp _ IN 8 CHILL OUT 101485749 Q 101485082 s VX2120 02N 5G B 8 HOT PORT CHECK VALVE CHECK VALVE 101485749 101543074 101485749 CHILL IN H20 DRAIN SMC AIR REG FILTER DRIER 101485082 FLOW CONTROL VX2120 02N 5G B 100126559 9 30K VALVE L3 101516394 gt 101485177 Anny AIR i IN CHECK VALVE 101543077
43. 7 400 KB Application 8124 2007 1 57 PM SKB Configuration Settings 89 24 2007 1 57 b MainPlot ini 1 Configuration Settings 10 10 2007 1 11 ManualTest ini Configuration Settings 9 98 2006 7 51 AM Sb standardTest ini 1KB Configuration Settings 81 22 2007 11 03 AM 4 2 3 TipStrips ini Configuration Settings 10 10 2007 12 52 PM Figure 3 8 Directory structure 3 3 12 1 Files located in C Program Files Fann EmailLists Email ini e This file contains all of the setup information for automatic and manual email notifications This file must be edited by installer to enable email functionality Revision G May 2014 23 fa Fr 1 77 Instruction Manual 3 3 12 2 Folders located in C Program Files Fann M77 CalibrationFluids e This folder contains all of the calibration fluid data files e Calibration fluid files may be added either by downloading or creating them locally CalibrationReports e This folder is the default location for all of the calibration reports e The system creates these reports for you e There should be at least one file in this folder for the system to use as a look up table Chiller e This folder contains the configuration file for the chiller config ini Data e This folder is used by the program exclusively e No changes of any kind should ever be made manually to anything in this folder DataRecovery e This folder is used to store the d
44. 9 7 iX77 Electrical Assembly P N 101531615 Rev M 0001 101531616 TOP FAB ASSEMBLY PC PANEL MOUNT 15 IN TFT XGA 1 4 PENTIUM M 1 0002 102044894 GIG RAM 1 PCI SLOT WINDOWS XP DATA ACQUISITION SYSTEM 8 SLOT CHASSIS FOR 0004 101462492 POWER SUPPLY 10 15 V DC 0005 101471629 DIN RAIL POWER SUPPLY UNIT 24 V DC 2 A RELAY WATCH DOG TIME DELAY CONTROL SWITCH 0007 101483687 TRIGGER 240 VAC 0008 101462535 RELAY SOCKET 0009 101468850 OPTOCOUPLER RELAY ASSEMBLY FEED THROUGH TERMINAL BLOCKS WITH SPRING CAGE 0010 101483688 2 0012 101391619 one END UNIVERSAL FOR 35 MM X 7 5 MM MOUNTING INLET ELECTRICAL FLANGED 3 WIRE 20 AMP 250 VAC 0019 100031587 TWIST LOCK 0020 101481464 EXTENSION USB CABLE ASSEMBLY PANEL MOUNT THERMAL CIRCUIT BREAKER 15A DPST ROCKER WITH 0021 101471634 UNDER VOLTAGE 0023 101727314 SWITCH EMERGENCY STOP LEGEND PLATE FOR E STOP SWITCH 60 MM DIAMETER PLUG IN BRIDGE FOR CROSS CONNECTIONS IN THE ae TERMINAL CENTER 0037 101260861 8 SCREW MACHINE PAN HEAD PHILLIPS 10 32 UNF x 0 25 SS 101625591 Revision G May 2014 136 fa B n 1 77 Instruction Manual oe Js 4 SCREW MACHINE PAN HEAD PHILLIPS 37 UNGA 150 85 3M VHB FOAM TAPE ADHESIVE BOTH SIDES 4950 0 045 IN os ven THK x I IN WIDE WHITE 0051 101634933 RAIL ADAPTER DIN GRAY 0052 207871 8 WASHER FLAT 10 SS SPRING CAGE GROUND TERMINAL BLOCK AWG 24 TO 14
45. D Parameters These parameters directly impact the heating performance of the Rheometer These should not require adjustment If a change to the system requires that these values be changed it should be done by a trained technician 3 3 13 2 Pressure PID Parameters These parameters directly impact the pressurization performance of the Rheometer These should not require adjustment If a change to the system requires that these 101625591 Revision G May 2014 27 fann 1X77 Instruction Manual values be changed it should be done by a trained technician 3 3 13 3 HeatingParameters These values tell the Rheometer what temperatures to start and stop cooling and whether or not a chiller 1 present It may be necessary from time to time for an experienced technician or installer to adjust some of these parameters 101625591 Max WaterCoolingTemp C This is the maximum temperature at which water cooling will be used If the system requires cooling above this temperature it will use air An experienced technician might adjust this parameter to achieve maximum cooling performance MinWaterCoolingTemp C This is the minimum temperature at which water cooling will be used If the system requires cooling below this temperature it will use the chiller 1f available and enabled An experienced technician might adjust this parameter to achieve maximum cooling performance ChillerPurgeTime s This is the number of seconds that t
46. F 0 Calibration In Progress Pressure Calibration In Progress pe om Speed Save Calibration 700 0 350 0 600 0 300 0 500 0 250 0 400 0 200 0 Angle deg 300 0 150 0 mJ a a ui m a 200 0 100 0 100 0 50 0 0 07 I 1 0 07 I I I I HO frp ale aa sn 8 Sp SE GE GE El 0 0 200 0 400 0 600 0 800 0 1000 0 Speed Command V Shear Rate 1 5 Custom Calibration Report Configuration Save in Custom Format This page is used to calibrate the M77 The M77 needs to be calibrated For speed torque and pressure Speed and torque may be calibrated together by pressing the Calibrate button The M77 may be calibrated For low speed only by moving the slider above to the Calibrate Low Speed position After the calibration run has been completed the system will ask if you wish to apply a viscosity calibration Choosing Yes will open a window to the directory holding the previously stored calibration dei by pressing the Calibrate Pressure button and C gt ChillerEnable 4 C Program Files Fann M771CalibrationReports M77 Calibration 2006 09 26 171642 csv Figure 5 6 Waiting for the angle measurement to return to zero 5 1 3 7 If the angle does not stabilize near zero the calibration fails and is automatically canceled This is usually the result of a mechanical failure or an assembly issue These issues
47. L A200 0403 cev 2 00 1296 csv T500 0128 csv 28 820 0705 5 10 0705 5 88 US00 0605 csv 200 0128 Eh H200 0506 csv 58 v500 0705 csv Si C200 0716 csv 4 o350m 1653021 csv 20 0403 5 Inisp n403 csv 0350 482926 csv PEh z20 1004 csv Desktop ALID200 0205 cev 03500 2445034 csv 10 0403 csv EN 1100 0705 c5v 5 50 0304 5 Bi 100 0403 5 XLIE200 0305 csv 100 0804 csv MELLE 10 0104 AS 100 1104 5 5 0405 5 BRI P 100 0105 csv T Pay F200 0605 csv 100 0605 5 10 0128 5 2500 0104 5 Computer __ xL G50 0705 c5v BS 200 0597 csv w 4 b EIE File name Places Comma Separated Vanable csv Figure 5 10 Choose calibration data file 5 1 3 12 Once a fluid is chosen the software will compute a calibration and check for hysteresis in the system If the calibration 15 acceptable you will see a dialog that asks if you wish to save the calibration The number may be ignored Sticking Test Passed Save Torque Calibration Figure 5 11 Save Torque Calibration dialog 5 1 3 13 If you choose Yes a dialog will appear that allows you to choose where to save the calibration file and what to call it It is recommended that you accept the default that 15 offered 101625591 Revision G May 2014 44 IX77M Instruction Manual Choose or Enter Path of Fi
48. Mechanical Chiller Piping 134 Figure 9 8 iX77 Mechanical Electrical Components Rev 135 101625591 Revision G May 2014 iv fa Instruction Manual Figure 9 9 iX77 Electrical Assembly Main Components Rev 139 Figure 9 10 iX77 Electrical Assembly Din Rail Components Rev 140 Figure 9 11 iX77 AC System Wiring Diagram Rev 4 141 Figure 9 12 iX77 DC Wiring System 142 Figure 9 13 iX77 Mechanical Schematic Rev 2 143 Figure 9 14 iX77 Cell Assembly Rev E 145 Figure 9 15 iX77 Cell Cup Rotor Coupling Shaft amp Bob Rev 146 Figure 9 16 iX77 Torsion Module and Top Jewel Assemblies Rev 147 List of Tables Table 3 1 Instrument 7 Table 3 2 Computer 13 Table 5 1 Torsion Spring 78 VE MELIUS cn 104 EDER VM 116 EN Es 117 Table 8 1 Accessory Parts Kit P N 101625874 Rev 1 119 Table 8 2 1 77 Hheometer Tool Kit P N 101623037 Rev 120 Table 9 1 iX77 Hheometer
49. NALOG OUTPUT 1 5 VDC 1 4 PORT PRESSURE DISPLAY UNIT PSI FILTER REGULATOR MIST SEPARATOR 1 4 FEMALE NPT ve pr 3 8 INSTANT TUBE AUTO DRAIN 0034 101485740 NIPPLE 1 4 MALE NPT ALL THREAD 7 8 LENGTH SS WATER SEPARATOR AMG 1 4 NPT PORTS 3 8 INSTANT m eonun TUBE WITH AUTO DRAIN BRACKET 101625591 Revision G May 2014 122 fa Instruction Manual COUPLING INDUSTRIAL QUICK DISCONNECT MALE 1 4 0036 NPT MALE SS c 100126559 1 REGULATOR NPT 1 4 INCH 15 VALVE SOLENOID DIRECT OPERATED 3 PORT COMMON R 1 4 FEMALE 24V DC 4 MM ORIFICE CONNECTOR MALE STRAIGHT 1 4 IN SWAGELOC X 1 4 IN 0040 101485082 VALVE SOLENOID 2 PORT NC 1 4 FEMALE NPT 24V SILENCER NAN GENERAL PURPOSE NOISE REDUCTION ds 35db 1 4 MALE SILENCER NAN BC SINTERED GENERAL PURPOSE NOISE idi HUN REDUCTION 164 1 8 MALE ADAPTER BRANCH UNIVERSAL MALE ELBOW 1 4 MALE NPT TO 2X 1 4 INSTANT PUSH TUBE CONNECTOR MALE SS 1 4 IN O D 1 8 IN MNPT FAN INSTRUMENT 37 CFM 50 60 HZ 230V AC 0062 100023811 9 CONNECTOR PLASTIC TUBING 90 DEG 1 4 TUBE X 1 4 0063 101463367 TRIPLE ELBOW 1 4 MALE NPT TO 3X 1 4 INSTANT 0064 101485749 VALVE CHECK 1 4 INSTANT PUSH TUBE PORTS ADAPTER TRIPPLE UNIVERSAL MALE ELBOW 1 4 MALE JUS 3 8 INSTANT PUSH TUBE 0066 101485750 EN ELBOW 1 4 FEMALE TO 1 4 INSTANT PUSH 101625591 Revisio
50. Operate Tools Window Help Test In Progress Go Here Test start MDataCollection Manual Speed Setpoint a Setpoint Manual Pressure Setpoint Status Digital Status Auto Test Calibration RPM P 0 Calibration In Progress Pressure Calibration In Progress CalibratePressure Ange EE Save Calibration 700 0 600 0 500 0 400 0 Angle 300 0 ce m zm a uw 200 0 100 0 0 07 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 ur ite chi cub vb RHU GHz Cas cH 400 0 600 0 800 0 1000 0 Speed Command V Shear Rate 1 5 Custom Calibration Report Configuration Save in Custom Format This page is used to calibrate the M77 The M77 needs to be calibrated For speed torque and pressure Speed and torque may be calibrated together by pressing the Calibrate button The M77 may be calibrated For low speed only by moving the slider above to the Calibrate Low Speed position After the calibration run has been completed the system will ask if you wish to apply a viscosity calibration Choosing Yes will open a window to the directory holding the previously stored calibration raa uan lean by pressing the Calibrate Pressure button and me emo ChillerEnable 4 C Program FilesiFannjM77YCalibrationReports M77 Calibration 2006 09 26 171642 csv Figure 3 5 Calibration tab options 101625591 Revision G May 2014 19 fann 1
51. additional safety relief All released pressurization fluids are returned to the waste bottle Pressure measurement is made using a strain gauge transducer that is continually monitored by the Smart Controller and then sent to an I O module to be processed by the program and displayed on the computer Pressure readings are compared against both current set points and absolute safety limits When the pressure 15 more than 100 psig below or above the pressure system decides to increase or decrease pressure Pressurizing fluids used must be compatible with type 303 stainless steel Consult an engineering handbook or the fluid manufacturer to verify the compatibility of a specific fluid Any fluid used must be free of suspended solids Solids could erode the pump and cause failure Any of the following hydraulic fluids may be used 1 Water Soluble oil an oil in water emulsion Petroleum hydraulic oils Emulsion water in oil Water glycols po eh ae UM Poly glycols Revision G May 2014 fa Fr Instruction Manual 3 3 Software 3 3 1 Functional Overview The iX77 Rheometer version 1 1 software runs on the Windows XP operating system and was developed using National Instruments LabVIEW control system hardware components are readily available The 1X77 Rheometer controls and records temperature pressure and rotor speed It derives all of the fluid property measurements from the angle of rotation of
52. and bottom surfaces of the coupling because they are sealing surfaces Set the coupling on its side rather than on its ends 101625591 Revision G May 2014 83 fann 1X77 Instruction Manual 5 4 3 4 4 Rinse the parts and use an air jet to dry them off Be especially careful to dry the spring module to prevent corrosion 5 4 3 4 5 Use a solvent moistened cotton tipped applicator to carefully clean the vee jewel in the pivot cap and in the bob The test cell parts are now ready for re assembly after inspection Figure 5 47 Location and orientation of the ball under the torsion spring module 5 4 4 Rotor Busing Replacement Four parts of the rotor bushing system must be replaced periodically These are l 101625591 The bushing inner and outer race 12 which the outer race 1s mounted in the center of the Rotor and rotates with 1t The bushing inner race which is mounted near the top of the pivot thermowell in the center of the cell and 1s stationary The rotor bushing 8 which 1 pressed into the base of the rotor assembly and rotates with it The pivot bushing 10 which 1 also stationary and mounts on the pivot thermowell at its base in the cell cavity Revision G May 2014 84 B IX77M Instruction Manual Figure 5 48 Tool set The numbers in brackets refer to the Test Cell Drawing number 101511610 The following describes how to remove and replace each one 5 4 4 1 The Bushing
53. ata during the running of the test e If power fails while a test is running the system will save a file in this folder on restart e If necessary this file can be used to reconstruct a test report manually LookUpTables e This folder stores the optional lookup tables for the control system e These files should only be edited by a technician or installer ReportTemplates e This folder contains the report templates used to generate Excel spreadsheets e The Basic xlt file may be replaced with one that has been optimized to produce a lab specific report 101625591 Revision G May 2014 24 fa Fr 1 77 Instruction Manual e This requires a high level of expertise in setting up Excel templates and thus 1 typically done by a factory technician TestProfiles e This folder contains the stored test sequences for running standard tests e These files may be edited by an advanced technician if that serves their purpose TestReports e This folder contains the test reports generated by the system 3 3 12 3 Individual files located in C Program Files Fann M77 AutomaticTest ini e This file retains the settings for reporting automatic tests e It should not require manual editing Config ini e This file contains the dimensional data for the rotor bob and spring used in the 1X77 Rheometer e It should not require manual editing Config M77 ini e This file is contains the operational and setup information fo
54. ation The installation of the pivot bushing is essentially the reverse of the removal The slide hammer is used to drive it into position by striking the stop closest to the cell with the slide hammer weight Do not use any locking compound when installing the bushing Make sure it 15 driven all the way down Check this by putting the rotor in the cell and confirming that the bushing 1 supporting it and not the bushing at the bottom If it 1s not all the way down the uplifted rotor will push against the bob when the test cell is assembled preventing proper rotation of the bob Figure 5 57 The Pivot Bushing in the groove of the Puller 5 4 5 Vee Jewels The vee jewels 15 that are used to support the top and bottom of the test cell torsion assembly are constructed of clear synthetic sapphire and mounted in a stainless holder They are most often damaged when excessive force on the torsion assembly jams the 101625591 Revision G May 2014 92 fann 1X77 Instruction Manual jewel onto the point of the pivot shattering the jewel This may occur when the bottom or top vee jewels are not adjusted correctly or if the torsion assembly 15 dropped onto the lower pivot Any surface cracks the spherical apex of the jewel vee will cause sticking of the torsion assembly and a reduction of the Rheometer s accuracy The vee jewel the bottom of the bob 1 the one most frequently damaged The top vee jewel 1 protected to some degree
55. ay 2014 16 fann 3 3 8 101625591 1X77 Instruction Manual Viscosity e This is the current viscosity measured and calculated by the system Angle e This is the current angle of rotation of the bob from the mechanical zero position e This angle is used in conjunction with the calibration table to calculate Shear Stress Viscosity and Dial Reading Offset Setup Offset e This is used to account for minor variations in mechanical setup and allow a small temporary adjustment of the zero point RPM e This is the current rotational speed of the rotor Shear Rate e This is the shear rate calculated from the mechanical geometry of the Rheometer using the RPM Dial Reading e This is the equivalent value you would read on the dial of a FANN Model 35 Rheometer under the current conditions Options on the Auto Test tab There are additional functions available on the Auto Test tab that were not covered in the discussion of running an automatic test above Revision G May 2014 fa Fr IX77M Instruction Manual fann Model 77 Viscometer File Edit Operate Tools Window Help 4 nn o 2 do go 42 3 go 2 Odo go 2 go 2 2 jo o Wo 0 o io io Odo io Odo do o po amp amp io io Figure 3 4 Auto Test tab options Load Blank Test Se
56. bottom of the upper pivot spring 35 It should clear by about 1 32 inch to 1 16 inch 1 mm to 2 mm Remove the pivot cap 33 by loosening its set screw at least two turns This exposes the torsion magnet 34 and its set screw that locks it to the upper pivot pin 30 2 Note the clearance between the bottom of the rotating torsion magnet 34 and the top of the stationary grip mandrel 30 3 It should be 1 32 inch 1 mm or more Loosen the torsion magnet set screw and rotate 1t counter clockwise to correct for excessive positive Angle deg or clockwise for a negative Angle or an Angle above 320 deg s Tighten the set screw securely at the same clearance above the torsion spring as before The torsion magnet should be quite close but must not touch the top of the torsion spring Revision G May 2014 96 B 1 77 Instruction Manual AN 101625591 Figure 5 61 Adjusting the torsion magnet position 5 5 1 7 Replace the pivot cap Check to be sure that the torsion magnet 34 just clears the underside of the upper pivot spring 35 as noted in step 5 5 1 3 Repeat steps 5 5 1 5 through 5 5 1 7 until a near zero 0 Angle deg reading is attained Handle the torsion spring module carefully during cleanup and re assembly so that the mechanical zero settings do not have to be reset again 5 5 1 8 Open the shield top replace the cell cap and close the shield top again 2 942 Calibrating the Torsion Sp
57. by the X shaped pivot spring 35 on which it 1 mounted Remove the bob or pivot cap and clean the vee Jewel for inspection by spinning the tip of a solvent moistened cotton tipped applicator in the jewel vee This should remove any surface contamination The vee jewels are best inspected by means of an optical microscope with reflected light A magnification of 40 has been found suitable Lighting 1s a little difficult but the jewel the bottom of the bob can be inspected without removing it The jewel may appear dark if a dark fluid has been forced behind it by the operating pressures Tilt the jewel so the light hits it at various angles to help highlight any cracks The focus of the microscope should be moved up and down the depth of the vee to sharply focus all parts of the vee s conical surface Pay special attention to the curved surface at the bottom of the vee If any surface cracks are found the vee jewel should be replaced Don t mistake any fibers left from the cotton tipped applicator as cracks Refer to 5 4 1 Test Cell Setup for instructions on proper adjustment of the replacement jewel Figure 5 58 Comparison of bad left and good right jewels 5 5 Calibration Mechanical 101625591 Revision G May 2014 93 fa Fr 1 77 Instruction Manual 101625591 The 1X77 Rheometer is designed to be calibrated with certified calibration fluids available from Fann Instrument Company These fluids are
58. ch a file were opened or created with windows Notepad it would appear as follows F200 0605 csv Notepad File Edit Format View Help 8 4 sa 8 9 sd 4 4 a 6 4 ge p se 2 g 5 Figure 3 9 Calibration file Notepad Revision G May 2014 33 1 77 Instruction Manual If such a file were opened or created with Microsoft Excel it would appear as follows Microsoft Excel F200 0605 csv BX 207 Edit wiew Insert Format Tools Data F Window Help 1 ed 100 R PERS 5 M 4 gt H 200 0605 Figure 3 10 Calibration file in Excel It is recommended that only 200 cP calibration fluid be used to i insure the maximum shear stress can be displayed Lower viscosity standards will limit the maximum shear stress value that will be displayed 101625591 Revision G May 2014 34 fann 4 Installation 4 1 101625591 1 77 Instruction Manual Main Instrument 4 1 1 Tools and Parts Before starting the following should be available Adjustable wrench with maximum opening of about 3 4 inch 19 mm Three other people to help move the instrument Hose of 1 4 inch internal diameter to reach from cold tap water supply and the drain to the back right bottom of the unit It must be capable of withstanding the pressure of the tap water supply for extended periods as well as hot water
59. corrosive fluids This is a particular problem for the bushing in the rotor as rust may lock it into place Corrosion may also affect the torsion spring and its locking mandrels The mandrels are made of an aluminum alloy and the spring is beryllium copper alloy The aluminum in particular may suffer in a corrosive fluid A small ultrasonic cleaner does a good job of cleaning the torsion spring module bob and rotor During tests at high temperatures and low pressures the sample fluid often expands up into the torsion spring area The cleaning solution must be selected based on the sample fluid and the pressurization fluid Oil based fluids are best cleaned by means of a parts washer like those used in automotive repair shops A jet of solvent is very handy for removing stubborn cake in hard to reach places Also bottle brushes of various sizes are very handy Small diameter brushes are most convenient for cleaning the 0 18 inch 4 6 mm diameter holes in the coupling A bottle type brush about 1 5 inches 38 mm in diameter is very useful for cleaning the cell It should be fairly stiff Another bottle brush about 0 5 inches 13 mm in diameter is good for cleaning the central bore of the coupling and the inside of the bob The following steps are not necessarily in the most convenient order but all should be included in a thorough cleaning The numbers in brackets refer to the Test Cell Drawing number 101511610 101625591
60. d be noted on the drawing with a M30 TOCDA ES designator number i I ont RED 7j HS TB Heater system Terminal Block 424 amp OTO 1 e ERED BH TS Bulkhead Terminal Strip n ge te T T E Stop Emergency Switch i 1 OR1 Optocoupler Relay 4 PS Power Supply gt SSR Solid State Relay SW Circuit Breaker Switch WD Watch Dog Relay 1 i 5 1 i PR Power Relay 1 06 i 8 4 15 OT Over Temp Switch T L 10V 15V x TC Thermocouple BULKHEAD IN power na 0 DC TB DC Terminal Block Lr l SUPPLY 2 1 PUR Pressure Up Regulator i 8 5 S AN uss par 5 1 1 BULKHEAD 8 5 511 BIS i hy i 8 4 o t i ir i i i 2 2 3 _ amp 3 SSR3 a Uo PRESS PUMP REF 24V BULKHEAD RELAY No 5 14 PRESS PUMP OR 14 9 4 a ei OPTOCOUPLER f RELAY L VE USB TO R5232 0 089 Cable pom n a AN 1 gt A2 MATER TO CHILLER LI 24V REF 24 DC TB 24V FAN WD 24V gt 1 24V 2A WD 2 24V 2A 9 woe 7 Jane e eI x 24VI2A 5 24V 2A L 24VOC 4A IEF 24 4 REF 24V 4A 24V 4A REF 24V 7 REF 24V N POWER DC ox 24 REF 24V 8 REF 2
61. d out It is not necessary to flush the old fluid from the port connector and tubing on the right side of the shield Pressurization fluid should not be reused due to potential contamination resulting in damage to the pump or other parts The test cell weighs 36 pounds 16 4 kg and should be handled with two hands 5 3 1 15 Remove the locking pin from the stand remove the test cell and set 1t on its bottom a bench 5 3 1 16 Lift the test cell up and lower it into the hot well with the plugged sample port toward the front step stool may be useful if the bench is high 101625591 Revision G May 2014 73 fa Fr 1 77 Instruction Manual 5 4 101625591 5 3 1 17 Screw two port connectors into place all of the way Hand tight 1 adequate for good sealing It may be necessary to rotate the test cell to line it up with the connectors Do not lift it up or the well seal O ring may be shifted out of position 5 3 1 18 Tighten the single connector locking screw to prevent rotation of the test cell and to place it in exactly the same position for each test 5 3 1 19 Slowly close the shield door and push the door pin all the way down to lock the shield closed and to properly position the shear stress angle sensor in the top of the shield door Rapidly closing the shield door may cause the shear stress angle sensor to not achieve initial lock on the torsion magnet The angle read will usually be obviously false
62. dated when there is no fluid sample in the cell Ti f the Angle deg is not within 2 Degrees of the original saved 5 3 Test Procedure Mechanical This section contains the steps representative of a typical procedure to set up and run a test The operator 15 encouraged to modify the steps to meet his needs 101625591 Revision G May 2014 69 B 1 77 Instruction Manual 5 3 1 Load Sample into Cell 5 3 1 1 The mechanical zero of the test cell less than 2 Degrees should have been previously verified This Offset 1s used to calculate the shear stress measurement 5 3 1 2 With the test cell in the test cell stand remove the cell and the cap Place a new cell seal O ring into its groove in the cell just above the rotor Do not reuse an O ring seal The backup ring is designed to prevent O ring extrusion Extrusion could lead to failure of the seal or severe difficulty in opening the test cell after a test Failure of the O ring with an abrasive sample could severely damage the cell and coupling by cutting the sealing surfaces in areas of high stress The backup ring is easily damaged and must be handled carefully to avoid bending it 5 3 1 3 Place the metal cell backup ring on the O ring with the flat surface facing up Figure 5 39 Installing the cell seal O ring and its backup ring 101625591 Revision G May 2014 70 1 77 Instruction Manual Figure 5 40 Tightening the cell 5 3 1 4
63. desirable to use a pressurization fluid that has a high flash point and low toxicity For example some users have been using Dow Corning s SYLTHERM 800 Heat Transfer Fluid for both oil and water based drilling fluids to their satisfaction Rheometer Head Oil P N 207874 may be satisfactory for use with many water based drilling fluids and possibly oil based fluids Dow Chemical Company s Polyglycol 112 2 has been suggested as another possible candidate for both oil and water based drilling fluid applications The user should conduct a test to determine the pressurization fluid s compatibility with the sample Use a syringe with long blunt needle to extract a sample from the bottom of the sample cup avoiding the top layer that contains pressurization fluid This post test sample of the tested fluid could be analyzed for contamination 12 2 Detect Malfunctions Early An initial pressurization leak test a startup test and an test are recommended This startup test and end test can be incorporated in your test sequence Normally the startup test should be conducted at near ambient conditions such as between 120 F and 150 F 50 to 65 and 300 psig 2000 kPa The 101625591 Revision G May 2014 fann 101625591 1 2 3 1X77 Instruction Manual purpose of the startup test 1 to verify proper operation of the instrument Before proceeding the operator should determine if the readings obtained at
64. e in Custom Format Custom FEE EN Report FEE EN uration This page is used to calibrate the M77 The M77 needs to be calibrated For speed torque and pressure Speed and torque may be calibrated together by pressing the Calibrate button The M77 may calibrated For low speed only by moving the slider above to the Calibrate Low Speed position After the calibration run has been completed the system will ask if you wish to apply a viscosity calibration Choosing Yes will open a window to the directory holding the previously stored calibration data Pressure is calibrated by pressing the Calibrate Pressure button and Following the instructions 101625591 Figure 5 5 5 135 5 1 3 6 Currently using Calibration C ChillerEnable 4 C Program Files Fann M77 CalibrationReports M77 Calibration 2006 09 26 171642 csv Waiting for temperature to stabilize This step will continue until the temperature has equalized or the cancel button is pressed After the temperature has equalized the software will wait for the angle measurement to return to zero Revision G May 2014 41 fa Fr 1 77 Instruction Manual fann Model 77 Viscometer File Edit Operate Tools Window Help Test In Progress Go Here on Test start Manual Speed Setpoint Manual Temperature Setpoint Manual Pressure Setpoint DataCollection hon Status Digital Status Auto Test Calibration J 0 RPM
65. e pivot with the flat side down Use the round end of the ball bearing pressing tool Push straight down on the race with the round end until the race 1s at the bottom of the small diameter section of the pivot Do not use the slide hammer The race 15 made of a brittle material and may shatter Wipe any excess locking compound from the race and the pointed end of the pivot Refer to the figures on the next page 5 4 4 3 Rotor Bushing 40 5 44 3 1 Removal Removal of the rotor bushing 1s described in more detail in 5 4 5 2 Rotor Disassembly Basically it 1s just pushed out by hand from the drive magnet 101625591 Revision G May 2014 88 Instruction Manual holder 7 after the holder has been detached from the rotor 3 5 4 4 3 2 Installation Set the rotor down with the open end down Set the magnet holder on the Rotor with the slotted end down Then rotate it until the two screw holes line up with the corresponding holes in the rotor Install the two screws 11 and tighten them snugly Now slide the drive magnet 6 into the slot until it 1s roughly centered Push the rotor bushing into the hole in the magnet holder and into the drive magnet until it stops This helps to temporarily retain the magnet Visually center the drive magnet so that it does not protrude more on one side than the other and tighten the 8 set screw 44 1n the magnet holder This locks the drive magnet into position
66. e upper magnet mount 32 A Refer to Figure 5 43 below Now gently lift the Torsion Magnet until it stops and measure the gap again B The difference between the two measurements usually about 0 065 inch 1 5 mm 1 the total free movement of the torsion assembly B A When screwing the cell 1 2 onto the coupling the torsion magnet should rise about half that distance B A 2 which 1s about 0 030 inch 0 76 mm Loosen the two socket head cap screws that hold the torsion spring module to the coupling Revision G May 2014 75 fann 5 4 1 1 7 1X77 Instruction Manual Loosen them so that the torsion spring assembly can be lifted at least 1 8 inch 5 mm This prevents accidental destruction of the jewel if it is not adjusted correctly Place a backup ring and O ring in the cell and screw the cell onto the coupling completely Figure 5 43 Measuring the vertical movement of the torsion magnet 5 4 1 1 8 5 4 1 1 9 Measure the gap between the top of the zeroing sleeve and the bottom of the upper magnet holder again The torsion magnet should have risen half the total free movement If it rose too far the bottom jewel must be backed away from the pivot toward the top of the bob If it did not rise at all or not enough then the bottom jewel must be screwed further down One revolution of the jewel adjusts the position by about 0 031 inch 0 79 mm Remove the cell and bob and adjust the jewel p
67. ery slightly when the pivot cap is pushed all the way down to its normal position It should bend about 1 64 inch 0 4 mm Excessive bending will cause extra friction of the pivots and decrease the accuracy and repeatability Allow the pivot cap to sit undisturbed until the thread locking compound has cured Torsion Spring Modules Several torsion spring modules are available to optimize the 1X 77 Rheometer to the user s needs Cells are normally supplied with the torsion spring module At 300 RPM the indicated dial reading reads apparent viscosity directly in centipoise The following torsion spring modules are also available Revision G May 2014 77 fa 1 77 Instruction Manual Table 5 1 Torsion Spring Modules Maximum Shear Torsion Spring Constant Stress with k B1 BOB Designation dyne cm deg dynes cm 208950 20895 208952 208953 The F0 2 module will read at five times the deflection of the F1 module for the same shear stress The F0 5 module will read at twice the deflection of the standard F1 module The F2 module will read at one half of the standard F1 module The spring modules are identical except for the installed Torsion spring and its associated mandrels They are supplied as complete Torsion spring Modules because it allows rapid switching from one to the other without readjusting the bottom jewel m The calibration must be performed anytime a new spring module is installed new b
68. est cell is made up of three primary parts the cap top the coupling center and the cell bottom all three made of INCONEL 718 Solution It is in the annealed age hardened condition 44 46 with a minimum 160KSI yield strength These parts must be non magnetic for proper functioning of the magnetic drive and torque sensing The pivot thermowell in the inside center of the cell is made of 17 stainless steel 17 Cr 4 Ni 4 Cu bar stock in the age hardened condition H 1150 m The bottom portion of it acts as a pressure plug Three port adapters screw into the high pressure ports of the test cell and are made of 17 4 PH stainless steel The one used in the sample port would normally come in contact with the fluid at relatively low temperatures In normal operation only the coupling pivot thermowell and cell come in contact with the test fluids Most of the internal non pressure containing parts of the test cell are made of 303 stainless steel The numbers in brackets refer to Drawing 101511610 PDF The exceptions are described as follows In the bottom of the test cell in normal contact with the sample e Sapphire vee jewel 15 e Tungsten carbide pivot 13 30 2 e Bushing 12 wearing part replace as required two piece inner and outer race e Bronze rotor bushing 8 wearing part replace as required 101625591 Revision G May 2014 8 fann 3 2 101625591 Controls 2224 1 77 Ins
69. fa Instruction Manual 1 1 1 2 1 3 2 1 2 2 2 3 3 1 3 2 3 3 4 1 4 2 5 1 5 2 5 3 5 4 9 9 5 6 7 1 7 2 7 3 7 4 9 1 9 2 9 3 Table of Contents Introduction to the iX77 1 FN 1 Test Design PINGIPIES 2 Document 4 5 dm Facio NETTO RTT 5 Ergonomic 6 Environmental Considerations EEE 6 Features and Specifications EV FER Gs 7 Med 7 Seule E 9 SON NR M MIU 12 Fr EET EE EEE 35 Main Mid RTT 35 Test Preparation 38 M P 39 OON 39 Test Preparation 61 Test Procedure 000 0 0000 00 nennen nnn nnns 69 EI 74 Calibration Mechanical tiu un tiu Sad eta Run 93 Chiller Operation nnn nnn nnn 101 Analvzind tua qune 103 Troubleshooting and
70. fits into the thermowell in the test cell as the cell 1 lowered into the heater well The thermowell 1 located in the center of the rotor pivot which supports the rotor outer rotating cylinder This places it near the center of the fluid sample There 15 considerable thermal lag in the system The lag 1 also influenced by the properties of the test fluid and the rate of shear Normally the sample is sheared constantly to aid in minimizing the thermal lag This allows the external flutes on the rotor to Revision G May 2014 fa Fr Instruction Manual generate flow up the inside wall of the test cell It then flows down through the baffle the center of the bob the stationary part of the concentric cylinders and the holes near the bottom of the rotor The holes direct it back to the wall to recirculate The sample thermocouple has multiple safety features integrated through the user interface for multiple failure detection as well as an independent watchdog circuit that turns the motor and heater off in the case of a failure that 1s not sensed by the software Cooling 15 accomplished by injecting a flow controlled flow of tap water or other coolant into the narrow gap between the test cell and the heater well The expended steam and water is vented through a drain in the bottom center of the heater well The top of the gap 15 lightly sealed by an O ring that 1s retained on the test cell and seals against the top of the
71. he chiller is in operation Otherwise the back pressure from the chilled water loop will cause a water leak at the test cell New 1X77 Rheometers have a pre installed hold down Revision G May 2014 101 fa Fr 1 77 Instruction Manual 101625591 clamp in the tower door If this clamp is not present order kit 101893838 from Fann Instrument This clamp can be easily added to the instrument at the customer location Ensure that grease has been placed along the OD of the test cell O ring before the test cell 1s installed 1 the hot well This will allow the O ring to slide freely and properly seat in the hot well Revision G May 2014 102 fa Fr 1 77 Instruction Manual 6 Analyzing Results This page left intentionally blank 101625591 Revision G May 2014 103 fa Instruction Manual 7 Troubleshooting and Maintenance 7 1 Pressure Table 7 1 Pressure Fluid level in pressurizing fluid reservoir lower than pickup tube Excess air in hydraulic system Purge air using manual release valve Observe for continuous fluid return Rupture disc burst in waste bottle with manual release Fill pressurizing fluid reservoir Pump runs but pressure does not increase valve closed replace rupture disc Blocked suction line filter Replace filter or filter element No air supply Verify air supply Pump does not run Faulty electronic air pressure Call for FANN service regulator or pump
72. he data zoomed to a region around the cursor the number of minutes in the Minutes from Cursor box Clear Plot e This button is hidden while data is being collected e tis used to clear the graph area if desired Enlarge This Value e This is a drop down list that allows the user to choose one value from the list and display it in an enlarged font e This is intended to assist the user in viewing the screen from a distance 1f needed Information on the Digital Status tab The Digital Status tab is provided for those users who prefer a numerical display to the graphic display on the Status tab Revision G May 2014 IX77M Instruction Manual fann amp Model 77 Viscometer File Edit Operate Tools Window Help 1500 802 802 3000 3 2 924 335 00 Figure 3 3 Digital Status tab Temperature Setpoint e This is the temperature that the system is currently trying to achieve Temperature e This is the current temperature of the sample thermocouple Heater Temperature e This is the current internal temperature of the heater e This is only used for system tuning and diagnosis it does not indicate sample temperature Pressure Setpoint e This is the pressure that the system is currently trying to achieve Pressure e This is the current pressure of the sample Shear Stress e This is the current shear stress measured and calculated by the system 101625591 Revision G M
73. he system will blow air after using the chiller order to ensure that the coolant has been blown back into the chiller after use WaterPurgeTime s This is the number of seconds that the system will blow air after using cooling water in order to ensure that the water has been blown out the drain after use Absolute Max Heater Temp C This is the highest temperature that the system will allow the heater to achieve Note that this 1s not the sample temperature This should not be adjusted unless the heater has been replaced with one that has a different maximum temperature rating Cooling Threshold C This is the number of degrees that the sample must be over the set point before cooling 15 used An experienced technician might adjust this parameter to achieve maximum cooling performance Revision G May 2014 28 fann 1 77 Instruction Manual UseChiller This tells the system whether or not chiller 1 present 3 3 13 4 Pressure Parameters These values tell the Rheometer how to utilize the pumping and relief systems to regulate pressure It may be necessary from time to time for an experienced technician or installer to adjust some of these parameters Pressure Deadband psi How many psi the regulator will be set above the pump set point This may be adjusted but it can cause erratic performance if it 1 too high or too low Absolute Max Pressure psi The highest value the system will let the relief valve to be se
74. heater well The same control system is used for both heating and cooling The cooling 1 activated automatically when a lower temperature set point 1s entered or the end of the test has been reached The software will automatically turn on the air or water depending on preset default values The cooling feature is primarily intended to rapidly cool the test cell at the end of a test but it can also be used for a lower temperature set point Temperatures below ambient can be reached by connecting an external chiller The software will control the chiller automatically allowing for total automatic cooling and heating integration in the test sequence 2 22 Shear Rate Control The rotor is magnetically driven through the wall of the test cell A powerful samarium cobalt permanent magnet 15 attached to the bottom of the rotor It magnetically locks to a cylindrical permanent magnet which rotates with an insulating can around the heaters of the heater well The insulating can 15 driven through a 10 1 off the shelf right angle box with a brushless servo motor and integrated drive The motor s speed 1 internally sensed and fed back to the control systems The speed response of the system is relatively rapid Speed regulation 1 5 revolutions per minute rotor speed between 1 and 600 RPM 15 available including standard 600 300 200 100 6 and 3 RPM which 1s equal to 1021 511 340 172 10 2 and 5 1 reciprocal seconds 5 3 2 3 Press
75. heometer Path File CA Program M77 Manual Test 2007 09 14 134234 csv Remember Last Header Remember Last Report Directory Figure 5 15 Fill out information and click Done 101625591 Revision G May 2014 47 fa 1 77 Instruction Manual 5 1 4 3 Enter set points for rotor speed temperature and pressure Note that the system will simply try to achieve these set points as rapidly as possible the system will not try to exceed its programmed maximum temperature and pressure regardless of the set points Manual Speed Setpoint Manual Temperature Setpoint Manual Pressure Setpoint o jo de 0 a fann Model 77 Viscometer File Edit Operate Tools Window Help IA i i i Test In Progress Go Here on Test Start B tacollection Manual Speeg etpoint Manual Temperature Setpoint Manual Pressure Setpoint i Heat T RPM 250 10000 Status Digital Status Auto Test Calibration Temperature Setpoint 250 0 AN 30000 0 Temperature 88 9 Pressure Setpoint 10000 0 PSI D Pressure 10374 OE Rate 300 0 Paw 24000 0 Shear Stress Inf 1 100 Sqrt C A Viscosity 20000 0 Tine 8 3 Min IE 16000 0 14000 0 Minutes from Cursor 28000 0 22000 0 12000 0 Enlarge This Value 10000 0 Temperature Setpoint TemperatureSetpont 250 0 ono 4000 0 0
76. hes width 76 cm x 130 cm not including air supply water supply nor drain fiting protrusions Additional bench space is required to securely mount the cell preparation fixture Carefully set the unit into position on the bench It is heavy so obtain help to move it and use caution Confirm that the proper plug and 230 V AC plug is available with at least a 20 amp rating Remove the three tagged bolts 1n the side of the safety shield They are at 120 degree intervals around the shield with one the back and one on each side of the front about 2 inches 5 cm below the row of vent holes These bolts lock the rotating parts of the drive during shipment Accidental over tightening of the bolts could result in damage to the drive Figure 4 1 Shipping bolts with tags Revision G May 2014 36 fann 4 1 2 5 4 1 2 6 4 1 2 7 1X77 Instruction Manual Attach the tap water supply to 2 IN located on the back of the main unit Only one wrench is needed to install the fittings because of the specially designed back up plate mounted on the unit Use the supplied quick connect adapters if 1 4 inch tubing is used Attach the drain line to the H2O DRAIN Anchor the drain end of the hose so that it cannot jump around when the water spurts out of it on cool down The drain water will initially be hot and some steam will also come out of the drain hose Make sure the hose 1 not in a position that will allow the hot
77. hese files but they may also be edited in many other programs such as Windows Notepad Note that 1f you edit these files you will see additional columns that are not displayed in the program The four columns on the far right are for saving the system units under which the test is to be run English or metric Only the values in the first data line affect units and all other information in the first data line 1s 1gnored Alternatively the program can be used to create a test profile This may be done by starting from a blank Test Profile or by loading an existing Test Profile and modifying it If steps need to be added to a blank profile or after the end of an existing profile simply click in one of the columns you wish to edit on the first unused grayed out line below the current test steps After making the edit you will notice that the line 1 no longer eray You may insert a step between two existing steps by right clicking on the step of interest and choosing Insert Element Before from the menu 3 3 14 3 Appendix 1 Calibration Fluid File Format The calibration file should be a text file with a CSV extension It may be created and edited in any text editor or spreadsheet There must be no header and no column labels The file consists of a number of lines each containing a temperature in degrees C a comma and a Revision G May 2014 32 fann 101625591 1X77 Instruction Manual viscosity in centipoise If su
78. iX77 Rheometer Instruction Manual Manual No 101625591 Revision G Instrument No 101543382 amp fann Fann Instrument Company 1 77 Rheometer User Manual iX77 Rheometer User Manual 2014 Fann Instrument Company Houston Texas USA rights reserved No part of this work covered by the copyright hereon may be reproduced or copied in any form or by any means graphic electronic or mechanical without first receiving the written permission of Fann Instrument Company Houston Texas USA Printed in USA The information contained in this document includes concepts methods and apparatus which may be covered by U S Patents FANN reserves the right to make improvements in design construction and appearance of our products without prior notice FANN and the FANN logo are registered trademarks of Fann Instrument Company in the United States and or other countries All other trademarks mentioned in the operating instructions are the exclusive property of the respective manufacturers iX77 is a trademark of Fann Instrument Company Contact FANN Phone TELEPHONE 281 871 4482 TOLL FREE 800 347 0450 FAX 281 871 4358 _ Fann Instrument Company P O Box 4350 Houston Texas 77210 USA Location Fann Instrument Company 14851 Milner Road Gate 5 Houston Texas 77032 USA S Online U www fann com fannmail fann com 101625591 Revision G May 2014 ii
79. incidental indirect consequential or punitive damages Notwithstanding any specification or description in its catalogs literature or brochures of materials used in the manufacture of its products Fann reserves the right to substitute other materials without notice Fann does not warrant in any way equipment products and material not manufactured by Fann and such will be sold only with the watranties if any that are given by the manufacturer thereof Fann will only pass through to Customer the warranty granted to it by the manufacturer of such items Returns For your protection items being returned must be carefully packed to prevent damage in shipment and insured against possible damage or loss Fann will not be responsible for damage resulting from careless or insufficient packing Before returning items for any reason authorization must be obtained from Fann Instrument Company When applying for authorization please include information regarding the reason the items are to be returned Our correspondence address Our shipping address Fann Instrument Company Fann Instrument Company P O Box 4350 14851 Milner Road Gate 5 Houston Texas USA 77210 Houston Texas USA 77032 Telephone 281 871 4482 Toll Free 800 347 0450 FAX 281 871 4446 Email fannmail fann com Revision G May 2014 148
80. ing a test this is probably the cause 5 2 1 4 Apply a light coat of lubricant P N 210435 a nonmetallic anti seize compound to the threads of the bob shaft both ends X Do not overtighten the bob shaft into the bob and limit stop If this connection is too tight the assembly could be damaged 5 2 1 5 Screw the bob snugly onto the bob shaft using a round shaft or dowel rod through the holes in the bob shaft to hold it 5 2 1 6 Hand tighten the bob shaft assembly into the limit stop BG The assembly only requires 8 to 10 in pounds of torque to tighten it Do not overtighten 101625591 Revision G May 2014 62 fann 1 77 Instruction Manual Figure 5 30 Installing type 5 baffle Figure 5 31 Installing bob shaft assembly 24b 7 5 2 1 8 101625591 If necessary replace the pivot bushing rotor bushing inner race and the rotor bushing outer race Use the tools provided and follow the procedures outlined in 5 4 4 Rotor Bushing Replacement Remove the cell seal O ring and backup ring if they are installed Revision G May 2014 63 B IX77M Instruction Manual carefully to avoid bending them Handled very carefully they can The metal backup rings are easily damaged and must be handled be used many times 5 2 1 9 Place the rotor assembly into the cell being careful to not hit it against the pivot point Do not drop it into place as it may damage the rotor bushing Lower it
81. ion G May 2014 109 1 77 Instruction Manual 4122 25 15 Remove and set the Air Actuator Assembly aside Figure 7 10 Air Actuator Assembly 7 2 3 Rebuilding Internal Valve Body The following steps are performed to rebuild the internal valve body including all stems seats and seals 7 2 3 1 Locate and remove the internal sensor assembly 101625591 Revision G May 2014 110 Instruction Manual Figure 7 11 Internal Sensor Assembly Location Figure 7 12 Internal Sensor Assembly Removal 7 2 3 2 Remove the Seat Retainer with a medium flat blade screw driver Figure 7 13 Seat Retainer 7 2 3 3 Lubricate and reinstall the threads After the lubrication replace the seat in the retainer i Refer to the valve drawings and BOM in this document for detailed parts and lubrication information 101625591 Revision G May 2014 111 IX77M Instruction Manual Figure 7 14 Lubrication of Threads 7 2 3 4 Use the torque sensor tool to disassemble and reassemble the sensor Figure 7 15 Torque Sensor Tool 101625591 Revision G May 2014 112 gt 1 77 Instruction Manual 7 2 3 5 Using soft jaws chuck the flats sensor assembly in vise with the stem facing up Figure 7 16 Soft Jaws 7 2 3 6 Unscrew the sensor from the spring pad Figure 7 17 Spring Pad 7 2 3 7 Replace the sensor and valve parts as shown below Reasse
82. is allowed to drop naturally as the temperature falls 101625591 Revision G May 2014 59 IX77M Instruction Manual Option 2 Maintain Last Pressure fann Model 77 Viscometer File Edit Operate Tools Window Help Temp Temp Pressure Toe Data 1 3 1 2 do ff fff 2 M 3 doe 0 0 53333 60 1 do 02 jo 5 16566 60 1 b 5 1 Wo do do 6 P do do 5 10 20 H b 7 Wo Wo Figure 5 28 Maintain Last Pressure Foruse when a sample needs to stay at the last pressure after the test has ended e The pressure set point at the end of the test becomes the manual pressure set point and the pump is used to maintain it The operator must set the manual pressure set point to zero in order to release pressure on the system 101625591 Revision G May 2014 60 IX77M Instruction Manual Option 3 Pressure set point is set to zero fann Model 77 Viscometer File Edit Operate Tools Window Help Temp Temp Pressure Data EE EE 1 3 1 2 Wo do Pdo Wo 0 2 3 duo do do do Wo 0 0 53333 den 3 1 do do 20 59 do 20 Jo 5 16566 60 1 do b 5
83. is assumed that the person installing the DAQ hardware and software has the skills of a good PC technician Specifically the installer 1s expected to be capable of 1 Meeting all of the requirements of a user above 2 Installing USB DAQ devices 3 Installing driver software 4 Installing application software 5 Editing INI files to alter program setup 101625591 Revision G May 2014 13 fa 1 77 Instruction Manual 3 3 5 Entering Technician Mode 3 3 5 1 Click the Enter Technician Mode button on the Calibration tab 3 3 5 2 Enter the password assigned by the installer CheckPassword vi Enter Password Figure 3 1 Enter password 3 3 5 3 Toleave technician mode click the Leave Technician Mode button on the Status tab or simply wait until the preset time has expired This time defaults to 60 seconds but may be changed by the installer 3 3 6 Additional Functions on the Status Tab a fann Model 77 Viscometer File Edit Operate Tools Window Help Status Digital Status Auto Test Calibration 9 Test Run By Temperature Setpoint 120 0 F AN 30000 0 1000 0 600 0 600 0 Temperature 82 3 a 575 0 575 0 Pressure Setpoint 2057 5 PSD PE 900 0 550 0 550 0 26000 0 Eom Pressure 2450 PSI D 25 850 0 500 0 500 0 Rate 300 0 Paw 24000 0 800 0 475 0 475 0 Shear Stress 74 15 100 sqrtjc MI aar 450 0 450 0 Visc
84. ision G May 2014 57 IX77M Instruction Manual fann Model 77 Viscometer File Edit Operate Tools Window 1 15 2 3 3 do do 3 Wo o 4 joies feo ds Wo 5 3 Wo Jo o 6 0 16565 do Jo Jo qo Jdo amp Email A Tact Daa m Sa Figure 5 26 Jump To Next Step Abort Test options 101625591 Revision G May 2014 58 IX77M Instruction Manual 5 1 5 14 When the test ends the temperature set point will be set to zero There are three options for controlling pressure at the end of the test Option 1 Hold Pressure until Flushed DEFAULT fann Model 77 Viscometer File Edit Operate Tools Window Help Temp Temp Pressure en Data A amp EEE EEE 1 3 10 Wd Wo do 5 5 2 13 duo do do Wo 0 1 o 5 165665 60 1 b 5 1 do jo 6 0 16665 P do do 5 Bo 10 20 7 do Wo Wo Po Figure 5 27 Hold Pressure until Flushed e Recommended for most tests e practical purposes this mode does not release any fluid until the operator presses the Release Pressure button e The pressure
85. l 5 1 1 5 The temperature 1s always set to zero on startup no heating will occur until a set point has been given 5 1 1 6 If the chiller is set up to do so it may turn on at startup 5 1 2 Calibrating Pressure 5 1 2 1 Prepare the 1X 77 Rheometer by filling the cell with a suitable pressurization fluid it is not necessary to include the bob rotor etc in this assembly Place the closed cell assembly into the heater well and make sure that all of the pressure connections are made properly 5 1 2 2 Click the Calibrate Pressure button Manual Temperature Setpoint Manual Pressure Setpoint 0 0 i alibrabePreszure i In Progress Save Calibration Figure 5 3 Click Calibrate Pressure 5 1 2 3 A dialog will appear to guide you through the pressure calibration AutomaticPressureCalibrationM77 vi The machine will step through a series of pressures When the machine has reached a stable pressure reading the Take Pressure Data button will activate Enter the pressure reading from you calibrated gauge then click Take Pressure Data The machine will then adjust to the next pressure Click cancel at any time to abort the callibration When all data points are collected choose to accept or ignore the calibration millivolts 1000 1500 2000 2500 3000 Applied Pressure PST Pressure Reading Please wait for 5000 pressure to Percent Complete stabilize 4500 4000 3500 PressureReading
86. l 5 1 5 6 The automatically generated test sequence will be displayed fann Model 77 Viscometer BIK Ele Edit Operate Tools Window Help 1 3 JR 2 do 2 Ms 3 Rf do do do 3 ds 20 do Wo Ro Jo 4 0 16665 120 do do do 1 0 fd jo o 5 Ws Wo Wo fo 6 amp qo ORG 7 fosfor ds 20 do 5 Po jo Figure 5 20 Automatic test sequence 101625591 Revision G May 2014 IX77M Instruction Manual 5 1 5 7 This test profile can be saved to a file for later use by clicking Save Test Sequence and retrieved by clicking Load Test Sequence fann Model 77 Viscometer File Edit Operate Tools Window Help 4 5 ere vi Ter seee 1 3 1 2 do b Jdo 2 M 3 Ro do 0 0 3 1 do do o o 5 16666 feo 10 do do 2 fk o 5 Moes Wo do do Jdo 6 5 15666 fan p b b 7 0 53333 20 1 2 5 doe Wo Figure 5 21 Save and retrieve files 101625591 Revision G May 2014 53 IX77M Instruction Manual 5 1 5 8 To begin testing the fluid you must create a test report header Click Create Test Repo
87. le Save irr Calibration T m Calibration 2006 09 02 121357 csv MiIM77 Calibration 2007 03 01 092 s aL M77 Calibration 2006 09 02 143249 csv M77 Calibration 2007 06 11 151t M77 Calibration 2006 09 02 145436 csv M77 Calibration 2007 07 16 kim M77 Calibration 2006 09 05 194655 csv 77 Calibration 2006 09 05 203959 csv M77 Calibration 2006 09 26 163719 csv M77 Calibration 2006 09 26 171642 csv M77 Calibration 2006 10 02 145422 csv M77 Calibration 2006 10 02 162451 csv M77 Calibration 2006 10 05 111655 csv M77 Calibration 2006 10 05 125000 csv M77 Calibration 2007 01 24 090046 csv M77 Calibration 2007 01 24 092749 csv 3 M77 Calibration 2007 01 24 100729 csv 3 M77 Calibration 2007 02 19 124923 csv My Documents Desktop Documents E Computer Er LECI g dy L y ey ed elg Led Im E Filename Places P Save as type All Files 541 Figure 5 12 Choose the path to save the calibration file 5 1 3 14 The file path will appear on the Calibration tab until the next time a calibration is performed 5 1 4 Running a Manual Test 5 1 4 1 Click the Data Collection switch on the front panel to begin recording data one sample per second Test Start pee Manual 51 Figure 5 13 Data Collection switch 101625591 Revision G May 2014 fann 1X77 Instruction Manual
88. lt 4 36 6 32 X 3 16 6 30 f N x UOU KY E REF 27 SECTION G G 27 6 32 X 1 4 2126 ke 25 6 32 X 3 16 1X77 Instruction Manual 6 32 X 3 16 28 2 6 32 1 29 __ NN 4 ff N W 4 3 16 SS BALL 39 4 _ ASSEMBLY il 70 m m gt U 35 33 SECTION H H ASSY EXPLODED VIEW SCALE 1 3 Figure 9 16 iX77 Torsion Module and Top Jewel Assemblies Rev 101625591 Revision G May 2014 fa B mn 1 77 Rheometer Model 77 User Manual 10 Warranty and Returns 10 1 10 2 101625591 Warranty Fann Instrument Company warrants only title to the equipment products and materials supplied and that the same are free from defects in workmanship and materials for one year from date of delivery THERE ARE NO WARRANTIES EXPRESS OR IMPLIED OF MERCHANTABILITY FITNESS OR OTHERWISE BEYOND THOSE STATED IN THE IMMEDIATELY PRECEDING SENTENCE Fann s sole liability and Customer s exclusive remedy in any cause of action whether in contract tort breach of warranty or otherwise arising out of the sale lease or use of any equipment products or materials is expressly limited to the replacement of such on their return to Fann or at Fann s option to the allowance to Customer of credit for the cost of such items In no event shall Fann be liable for special
89. mble the parts 101625591 Revision G May 2014 113 IX77M Instruction Manual Figure 7 19 Stem and Spring Figure 7 20 O ring and Backup Ring 101625591 Revision G May 2014 114 IX77M Instruction Manual 7 2 3 8 Before assembling the Spring Pad and Sensor apply one drop of Loctite on the threads Figure 7 21 Loctite Application 7 2 3 9 Reassemble in reverse order using the valve drawings as a reference Observe the torque and lubrication requirements in the drawing notes Weng 4 Figure 7 22 Reassembled Sensor Figure 7 23 Lubricated Threads 101625591 Revision G May 2014 115 fa Instruction Manual 7 3 Temperature Table 7 2 Temperature System automatically sensed J y Reset heat fault problem in heating time Does not heat Heater failed Call Fann Instrument Company Thermocouple failed Call Fann Instrument Company Bad solid state relay Call Fann Instrument Company Cell temperature below 100 F ae cool down disabled below No water supply Verify water supply Post test Cool Down fails Faulty cooling valve or cooling valve solenoid valve Blocked drain hose Verify drain hose is open Does not chill to set Low pressure output from external Verify chiller output pressure and temperature chiller repair as indicated Cell to heater well O ring damaged Inspect and replace as indicated Cooling water leaks Heating well drain holes blocked
90. n G May 2014 fann 3 3 11 fann Model 77 Viscometer File Edit Operate Tools Window Help 4 101625591 IX77M Instruction Manual Information on the Raw Data Tab Technician Mode This tab displays information that will be helpful to an installer or technician in troubleshooting the 1X77 Rheometer It should not be needed for routine operation of the 1X 77 Rheometer BE 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 Figure 3 7 Data tab Revision G May 2014 22 fann 3 3 12 Edit view Favorites Tools 1X77 Instruction Manual 1X77 Rheometer Program Resources The software uses various resources while running Of particular interest are the files used to store various operating parameters test profiles and reported data These files are organized under the Program Files Fann family of directories where the Program Files directory is the Windows Program Files directory i e C Program Files Help Back gt 7 E q Search Es Folders ix x l HBE iss CiProgram lt FS Program Files O Adobe Common Files ComPlus Application Danaher Motion El Fann chiller EmailLists IG m77 Generic Halliburton Intel Internet Explorer Interwise Java Messenger IG Microsoft Activesvri IG microsoft Frontpage 9 Microsoft Office Microsoft IG Movie Maker msn gaming zone
91. n G May 2014 123 fa Instruction Manual FEED THROUGH TERMINAL BLOCKS WITH SPRING CAGE 0079 101483688 10 CONNECTION CROSS SECTION 0 2 2 5 MM WIDTH 5 2 MM GRAY RELIEF SIZE 18 10 NO 16 CRIMP PIN CONTACT 0097 101251844 8 SCREW 6 32 x 1 3 4 SOCKETHEAD 7 0110 382649 SCREW HEX SOC 1 4 20NC X 1 2 SS 0111 100123897 SCREW CAP SOCKET HEAD 1 4 20 X 5 8 SS 0112 100161058 SCREW CAP SOCKET HEAD 1 4 20 NC X 1 4 SS 0113 100020616 ADAPTER TUBE SWAGELOK 1 4 TUBE 1 8 MNPT 0114 101540491 VALVE AIR FLOW CONTROL 1 4 FNPT 2000PSI 0115 100123797 SCREW CAP SOCKET HEAD 10 32 UNF X 1 4 SS 0 375 SS ADAPTER STRAIGHT 1 4 FEMALE NPT BULKHEAD TO 1 4 INSTANT TUBE 0117 101470447 0118 204056 BULKHEAD FEMALE 1 4T X 1 4 0119 347556 TEE 1 4 NPT 0116 101260903 SCREW MACHINE PAN HEAD PHILLIPS 0 25 DIA 20 UNC x 101625591 Revision G May 2014 124 fa Instruction Manual STEEL OIL DIPPED FINISH RAMSEY RRN 800 0130 209359 LABEL SET FLUID RESERVOIR 0131 204607 O RING 0 209 ID X 070 NITRILE pone isss PLATED SIZE 16 16 22 AWG WIRE oss 9 psp 1622 AWO WIRE o o OOP PLATED SIZE 16 16 22 AWG WIRE CONTROL INSTRUMENT COMPUTER Table 9 3 iX77 Chassis Assembly Mechanical P N 101514170 Rev J 0014 100112806 HEAD CAP 10 32 UNF X 3 8 SS HEX 101625591 Revision G May 2014 125
92. n it One quarter revolution will change the angle reading by about 3 percent Visualizing the amount of rotation is easier if an index mark is placed on the end or side of the calibration tool It is easier to make adjustments if you turn the loosened spring assembly against the stop in the direction you are going to adjust then turn the calibration tool 5 5 2 3 Reassembly Reassemble as described below 5 5 2 3 1 Re clamp the top spring mandrel with the set screw in the zeroing sleeve Make sure that the top of the top mandrel 1 even with the top of the clamping sleeve 31 The spring might have to be stretched or compressed slightly to accomplish this step 5 5 2 3 2 Install the torsion magnet and position it at the same clearance above the spring grip as noted before The clearance between the bottom of the rotating torsion magnet 34 and the top of the stationary grip mandrel 30 3 should be 1 32 inch I mm or more The torsion magnet 101625591 Revision G May 2014 100 fa Fr 1 77 Instruction Manual 5 6 101625591 should be quite close but must not touch the top of the torsion spring Tighten its set screw 5 5 2 3 3 Install the pivot cap pushing it all the way down and tighten its set screw When properly adjusted the upper pivot spring 35 should bend very slightly upward without touching the torsion magnet If the upper pivot spring bends more than about 1 64 inch 0 4 mm the Top Jewel Adjustment
93. n the file LastAutomaticHeader txt e This file contains the text that is used in the header portion of a test report when Remember Last Header 15 checked e This may be edited as desired use Notepad to edit LastManualHeader txt e This file contains the text that 1 used the header portion of a test report when Remember Last Header is NOT checked e This may be edited as desired use Notepad to edit Revision G May 2014 26 fa Fr 1 77 Instruction Manual M77 ini e This is a system file that should never be edited MainPlot ini e This file stores the settings for the main plot e This is not user editable ManualTest ini e This file retains the settings for reporting automatic tests e It should not require manual editing StandardTest ini e This file contains the information that determines how an automatic test sequence 1 generated e It can be edited by a skilled technician or installer e If this file is not found by the software when test generation 15 invoked dialog will appear that allows configuring the options TipStrips ini e This file contains the Tip Strip text for when the mouse hovers over control on the software s front panel e This file may be edited by an experienced technician to allow the customization of the tips for an individual machine or lab e If this file is deleted it will be recreated with the default values 3 3 13 Setup Glossary 3 3 13 1 Heater PI
94. nd roll or slide it up These O rings may be reused until they become hard or un pliable Slide a new cap seal O ring into the groove around the base of the torsion spring assembly Metal Backup Rings are easily bent and must be handled carefully 101625591 Revision G May 2014 72 fa Fr 1 77 Instruction Manual 5 3 1 9 Place seal backup ring over the O ring with its flat face up 5 3 1 10 Lower the cap carefully over the torsion spring assembly and screw it onto the coupling If hard resistance 1 felt before full make up by hand stop and investigate Use the strap wrench to tighten the cap with light torque 12 ft lbs 16 3 5 3 1 11 Inspect the O ring on the sample port plug for damage replacing it 1f necessary and screw the sample port plug into place Light hand torque is adequate 5 3 1 12 Inspect the O rings of the two port connectors on the 1X77 for damage and replace them if necessary 5 3 1 13 Inspect the hot well to ensure that nothing has plugged the drain holes in the bottom around the temperature sensor which projects up in the center 5 3 1 14 If the pressurization fluid has been changed to a different fluid flush the hydraulic lines and air operated pump Fill the reservoir bottle with the correct fluid and operate the pump at 600 1000 psig until the new fluid 1 expelled from the port connector on the left side of the shield Use a container to catch the old fluid as it is pumpe
95. ning compounds solutions suspensions elixirs etc 1 1 Function Specifications of the iX77 allow operation to 600 F 316 C and 30 000 psig 206 840 kPa Optionally a chiller may be attached and controlled by the software to allow operation below lab temperatures The control software is intended to automate the operation data collection reporting and notification functions of the 1X77 Rheometer to the greatest extent practical thus allowing the operator maximum flexibility The goal in designing the software was to automate as much as possible while still permitting the machine to be configured and operated as needed by an advanced user The one piece bench top design makes it suitable for use on a well site as well as ina laboratory Special consideration should be given for moving and installing this instrument because of its weight 350 Ibs and its stature A strong low profile 32 in bench top is recommended for easier cell removal It uses a unique magnetic sensor to detect the motion of the jewel mounted torsion assembly in the test cell The sensor system can be calibrated to one degree equivalent to one centipoise at 300 RPM Test pressures are generated by an air operated high pressure hydraulic pump and controlled by a smart back pressure controller high pressure valve and pressure transducer The pressurization fluid fills the upper portion of the test cell The pressurization fluid 1 in direct contact with the q
96. ob is replaced or any adjustments are made to the internal cell assembly As a rule anytime there is a question about whether or not to calibrate then calibrate that 1s required 1s to remove the two screws that hold the torsion spring module to the top of the coupling and replace the module pivot cap and calibrate When installing a new torsion spring module the top jewel must be adjusted for proper tension This need be done only once unless some component of the lower torsion assembly 1 changed like the bob or lower jewel The torsion spring assembly 1 shipped without locking the upper jewel into place with thread locking compound to ease the initial installation Follow the steps of 5 4 1 2 Top Jewel Adjustment 5 4 3 Test Cell Disassembly and Cleaning Proper cleaning of the test cell 1 absolutely essential for reliable performance Sealing surfaces that have not been cleaned can lead to seal failure and damage to the parts Caked solids left in the torsion spring module may prevent proper rotation of the torsion shaft If the jewel in the bottom of the bob 15 not cleaned the same thing can happen 101625591 Revision G May 2014 78 fann 1X77 Instruction Manual The test cell should be cleaned as soon as possible after use to avoid corrosion and solids settling The bushing in the center of the Rotor and its race on the top of the rotor pivot in the cell are made of hardened carbon steel They will rust if left in
97. obviously false and only last for a few seconds The advanced control software will reestablish communication and lock automatically The numbers in refer to the Test Cell Drawing number 101511610 5 5 1 1 Place the assembled test cell into the hot well Connect the port connectors and tighten one connector locking screw This places the cell in exactly the position it would be in for a normal test 5 5 1 2 Remove the test cell cap Revision G May 2014 fann 101625591 5 5 1 3 5 5 1 4 1X77 Instruction Manual Use a non magnetic non ferrous tool an ordinary wooden pencil is good to gently push the torsion magnet 34 in a counter clockwise direction until it stops Note the amount of return rotation It should rotate 1 to 3 degrees If it does not loosen the set screw 44 in the spring cage 33 that locks the zeroing sleeve 37 in place Rotate the zeroing sleeve as required and retighten the set screw Check the rotation again before proceeding Slowly close the shield door and lock it in place with the locking pin If the Angle deg from the Digital Status page 15 greater than 2 5 degrees then continue with this procedure Figure 5 59 Adjusting the zeroing sleeve Revision G May 2014 95 fann 1 77 Instruction Manual Figure 5 60 Removing the pivot cap 5 5 1 5 5 5 1 6 101625591 Open the shield door and note the clearance between the top of the torsion magnet 34 and the
98. orrect calibration Wrong calibration chart used rn Rotor and magnet holder incorrectly assembled 101625591 Revision G May 2014 117 fa Instruction Manual Table 7 3 General continued Damaged spring module Call Fann Instrument Company Set mechanical zero see 5 5 1 Setting the Mechanical Zero Instrument will not calibrate Mechanical zero misadjusted Remove the three shipping screws see 4 1 2 Procedure Faulty motor drive circuit Call Fann Instrument Companyl Loosen drive magnet set screw Rotor bushing misaligned reposition the bushing tighten the set screw Shipping screws not removed Rotor does not rotate Rotor does not freely rotate in cell Bent pivot thermowell straighten in Rotor touches inside of cell place with tube slipped over it as a This is a live document The blank spaces in the tables above are provided as a convenient area for the user to document problems and solutions as they arise and are solved 101625591 Revision G May 2014 118 fa Fr Instruction Manual 8 Accessories and Spare Parts Table 8 1 Accessory Parts Kit P N 101625874 Rev I 0001 100072235 CORD SET ASSEMBLY ELECTRIC 230V 0002 353294 KEYBOARD SM W TOUCH PAD BLACK USB 0003 205532 LAN CAT 5 PATCH CABLE 4 PAIR RJ45 M M 25 FEET FILTER ELEMENT HIGH PRESSURE 25 MICRON 304 WIRE 0004 101626358 MESH 3B FILTER 0008 101736752 6 O RING SIZE 2 220 COLOR WHITE 600
99. osition as required If the jewel must be screwed further first use the set screw to push the pivot guide down the required amount Using the jewel to do this may damage it Be sure to lock the jewel in position with the set screw Be careful sometimes the set screw will screw the jewel in further as it 1s tightened Watch the jewel from the bottom of the bob while tightening the set screw to observe any Jewel rotation 101625591 Revision G May 2014 76 fann 5 4 2 101625591 1X77 Instruction Manual 5 4 1 1 10 Replace the cell on the Coupling and measure the gap again If it 1s satisfactory the two screws holding the torsion spring module can be tightened again 5 4 1 2 Top Jewel Adjustment The top jewel 1s located at the top of the pivot cap and 1 mounted on a spring which helps to protect the jewels from shock and thermal expansion of the test cell 54 1 2 1 5 4 1 2 2 o ARA 5 4 1 2 4 5 4 1 2 5 Remove the Pivot Cap 33 and the Cap 1 3 Remove the jewel 15 and clean the threads of the jewel and the upper pivot spring 35 with a non oily solvent It may be necessary to heat the jewel to about 212 F 100 C to release any old thread locking compound Place a drop of thread locking compound such as LOCTITE 242 on the threads of the jewel and start it in the upper pivot spring Quickly adjust the top jewel with a screw driver so that the upper pivot spring 35 can just be seen to bend v
100. osity 69 0 cP B nu 700 0 74250 425 0 20000 0 400 0 400 0 Tine 0 9 Min 650 0 375 0 lt 18000 0 600 0 350 0 350 0 325 0 325 0 Zoom Plot 10 500 0 300 0 gt 300 0 14000 0 Minutes from Cursor 450 0 275 0 275 0 12000 0 400 0 250 0 250 0 2250 225 0 350 0 Enlarge This Value 10000 0 200 0 200 0 300 0 Temperature Setpoint 175 0 175 0 22 Temperature Setpoint vf 8000 0 250 0 150 0 150 0 120 0 6000 0 200 0 125 0 125 0 L 150 0 100 0 100 0 4000 0 75 0 75 0 50 0 50 0 50 0 25 0 25 0 0 0 0 0 1 1 I 1 170 0 qu BH 292 IER Elapsed Time 00 02 18 0 HH MM SS 00 02 18 Minutes 2000 0 This page displays the current operating values the M77 in graphical Format f M77 V0 1 Copyright 2006 Instrument Company Figure 3 2 Cursor Values The Status tab has the following convenience features 101625591 Revision G May 2014 fann 3 3 7 101625591 1X77 Instruction Manual Cursor e The cursor will be at the far left of the main plot on startup but can be dragged to any position of interest e Dragging the cursor illuminates the Cursor Values enunciator and activates the display of those values on the box next to the plot Zoom Plot e Clicking this button will display a plot of t
101. other magnet or to any ferrous object Pinching could occur Also the material is brittle and could shatter upon impact Two of these drive magnets will attract each other from several inches away The magnet should also be kept away from sensitive mechanical devices such as wrist watches and meters Magnetic data recording media like computer disks and tapes and credit cards should also be kept well away 5 4 3 2 Rotor Disassembly 5 4 3 2 1 Remove the two slotted head screws 11 in the bottom of the rotor Lift off the magnet holder 7 and press out the bronze rotor bushing 8 in the bottom of it Remove the drive magnet 6 and place it on a non magnetic surface It should be cleaned separately Place all of the parts except the drive magnet in cleaning solution or ultrasonic cleaner and clean them thoroughly Do not attempt to clean the drive magnet in an ultrasonic cleaner as it may damage the cleaner Revision G May 2014 80 B IX77M Instruction Manual Figure 5 44 Disassembling the rotor Figure 5 45 Removing the bushing 12 5 4 3 2 2 Remove the rotor from the cleaning solution and use the removal tool oval shaped end to press the bushing 12 out of the middle of the rotor small hammer may be used to gently tap the bushing out but be careful because the bushing 1s brittle and may shatter making removal difficult Thoroughly clean or replace the bushing Use a brush to clean the small bore of the
102. procedures of 5 4 1 Test Cell Setup should be performed If the upper pivot spring touches the torsion magnet the magnet must be repositioned lower on the upper pivot pin 30 2 5 5 2 3 4 Follow the procedures of 5 5 1 Setting the Mechanical Zero 5 5 2 3 5 Repeat steps of this section until the error 1 below 2 The calibration must be performed anytime a new spring module is installed new bob is replaced or any adjustments are made to the internal cell assembly As a rule anytime there is a question about whether or not to calibrate then calibrate Chiller Operation The optional chiller is used to cool the cell below room temperature for cold water testing The chiller temperature range is 10 to 35 depending on the antifreeze used The 1X77 will control the chiller operation when properly connected to maintain a user selected temperature A DB9 style cable connects the chiller to the controller in the 1X 77 On the calibration tab select the Chiller Enable button When the chiller is on and connected a red dot will appear on the chiller panel indicating that it 1 communicating and being controlled by the 1X77 If the 1X77 software is not in current use the chiller operation can also be selected by modifying the config M77 ini file located in C Program Files Fann M77 The user must ensure that both instances of UseChiller FALSE are changed to UseChillerZ TRUE The test cell must be held in place when t
103. quence e This is used to clear out the current test steps Purge e This initiates a purge cycle that helps purge air from the test chamber before pressurization e tis not required for routine operation Up Down e These buttons allow scrolling to view the all of the steps in a sequence e If Auto Scroll is lit and the test advances to a new step that step will be placed at the top of the viewing area Auto Scroll e Used to determine if the test step display is synchronized to the current test step e Auto Scroll is automatically turned off when Edit Lock is turned off Edit Lock 101625591 Revision G May 2014 18 B 1 77 Instruction Manual e Used to prevent accidental changes to test steps while a test is in progress e be turned off to edit test steps while test is running e Edits to a running test are only effective for steps that have not yet been started Email a Test Result e This allows the user to select a file on the local computer and send it to a specified email address View File Save History e This allows the user to see the full path of the last one hundred files written by the software Save Preliminary Report e This allows the user to generate an interim report before the test 15 completed 227 Options on the Calibration Tab There are options available on the Calibration tab that were not described in Calibrating above a fann Model 77 Viscometer File Edit
104. r race in place for pressing 5 4 4 2 The Bushing 12 Inner Race 5 4 4 2 1 Removal The inner race is removed by using the slide hammer and the puller which has two pivoted arms Onto the fittings at the end of each arm first attach the small adapter fitting which enables the arm to close around and grasp the race A slot in the adapter fitting engages the rim of the race on each side After placing the adapter fitting over the pin on each arm rotate the lock to hold it in place Screw the puller onto the threaded end of the slide hammer Separate the arms slightly and lower them into the cell on each side of the pivot Close the arms on the inner race engaging the slots with the rim of the race A few light taps of the weight on the slide hammer against the stop on the end away from the cell should remove the race 101625591 Revision G May 2014 87 B Instruction Manual Figure 5 51 Removing the bushing inner race or the pivot bushing 5 4 4 2 2 Installation Before installing the race make sure that the pivot bushing 10 has been installed at the base of the pivot thermowell 5 in the cell It can not be installed with the inner race in place Clean both the inner race and the small end of the pivot thermowell where it mounts with a non ereasy solvent Allow them to dry Then apply a drop of high temperature thread locking compound to the hole 1n the inner race Use pliers to start the inner race on th
105. r the 1X 77 Rheometer e The system will generally maintain this file e There are some circumstances under which a trained technician or installer may need to edit this file CustomCalReport ini e This file contains the information used by the system to create the Custom Calibration Report e This file can be generated by the system or shared between labs to ensure a uniform report CustomReport ini e This file contains the information used by the system to create the Custom Report 101625591 Revision G May 2014 25 fann 101625591 1X77 Instruction Manual e This file can be generated by the system or shared between labs to ensure uniform report DefaultAutomaticHeader txt e This file contains the text that 1 used in the header portion of a test report when Remember Last Header is NOT checked e This may be edited as desired use Notepad to edit DefaultManualHeader txt e This file contains the text that 1s used in the header portion of a test report when Remember Last Header is NOT checked e This may be edited as desired use Notepad to edit Error log e This file contains a log of the errors detected by the system e This file will be recreated if deleted e The latest error will be the first entry in the file FileSaveHistory txt e This file contains a list of the files that have been created by the software e This file will be recreated if deleted e The latest file will be the first entry i
106. r well plate upon which it sits We recommend that the shield not be opened until the cell has cooled to at least 100 F 38 and the pressure has been completely relieved e If the Rheometer is depressurized before the sample has cooled enough the possibility exists that the sample would flash to vapor leading to possible injury 101625591 Revision G May 2014 fann 1X77 Instruction Manual During water cool down hot water is expelled from the drain hose on the 1X77 The first few minutes of a high temperature cool down are somewhat vigorous and the drain will emit steam and occasionally sputter boiling water Be sure that the vent hose is secured so that no one will be splashed The sample being tested and the pressurization fluid used in the pump may be flammable In the case of a seal failure these flammable liquids could hit a hot surface within the shield and present a fire hazard The location of the test system should be selected with that in mind Appropriate fire extinguishing equipment should be nearby and the operators trained in its use 2 1 3 Electrical The covers serve to separate the user from potential high pressure electric shock rotating parts high temperature and other hazards The covers must be in place for normal use and should not be removed except when maintenance 1 being performed When the covers are removed many hazards exist and extraordinary care must be exercised to prevent injury
107. reater effect on their properties than pressure For this reason pressure changes of less than 1 000 psig 6 895 kPa are rarely useful Note the resolution of the pressure display is 1 psig Temperature and Pressure Variations Consider varying only the temperature or pressure between data points It is easier to recognize unusual behavior or equipment malfunction if only one variable is changed at a time Revision G May 2014 B 1 77 Instruction Manual 1 3 101625591 Document Conventions The following icons are used in this manual as necessary NOTE Notes emphasize additional information that may be useful to the reader CAUTION Describes a situation or practice that requires operator awareness or action in order to avoid undesirable consequences MANDATORY ACTION Cives directions that if not observed could result in loss of data or in damage to equipment WARNING Describes an unsafe condition or practice that if not corrected could result in personal injury or threat to health ELECTRICITY WARNING Alerts the operator that there is risk of electric shock HOT SURFACE Alerts the operator that there is a hot surface and that there is risk of getting burned if the surface is touched EXPLOSION RISK Alerts the operator that there is risk of explosion Revision G May 2014 fa Fr 1 77 Instruction Manual 2 Safety 2 1 Machine Hazard 2 1 1 Mechanical e
108. ring The basic torsion spring calibration 1s not overly critical because the Advanced Control Software will correct for minor torsion constant errors during the automatic calibration procedure Adjustment is achieved by making the effective length of the Revision G May 2014 97 fann 1X77 Instruction Manual spring longer or shorter The spring is shortened to cause the torsion shaft to rotate less within given load More rotation results when the effective length 1 increased The torsion springs are factory calibrated and should not normally require adjustment However it may be recalibrated 1f desired by the steps as outlined below The numbers in brackets refer to the Test Drawing number 101511610 5 5 2 1 Torsion Spring Recalibration Follow the steps 5 5 1 1 through 5 5 1 8 of 5 5 1 Setting the Mechanical Zero except fill the cell with the appropriate calibration fluid commonly 200 cP with the spring 9 9 2L 2212 5 3 2 1 4 SS Operate the Rheometer at a speed of 300 RPM for 200 cP fluid Note the displayed Angle deg and lemperature Compare the Angle deg to the Calculated Angle Centipoise from the calibration fluid table for the indicated temperature An error of 2 1s acceptable If adjustment is required continue to the next step Stop the Rheometer open the shield door and remove the cap 1 3 from the test cell Note the clearance between
109. rotor 101625591 Revision G May 2014 81 fann 1X77 Instruction Manual 5 4 3 3 Cell Top Disassembly 5 4 3 3 1 5 4 3 3 2 mechanical zero 5 4 3 3 3 Remove the pivot cap 33 at the top of the test cell by loosening the 6 set screw on its side about 2 turns and lifting the cap off This exposes the torsion magnet 34 Note whether solids are evident in the torsion spring 30 1 7 area If they are special diligence will be required to make sure the spring 1s clean Grasp the bob 4 and unscrew the bob and bob shaft 17 from the torsion spring module at the top Turn the bob clockwise when viewed from above The bob may unscrew from the bob shaft If 1t does place a small rod through the holes in the bob shaft and unscrew it If not already separated unscrew the bob from the bob shaft and place them the cleaning solution In cleaning the bob special care must be taken to remove caked solids from the top recess where the bob shaft screws in and the vee jewel 15 and pivot guide 14 on the bottom A small stiff brush and a wash bottle filled with a suitable solvent are handy for this Run a brush through the bob shaft to clean the bore Handle the torsion spring module with care Rough handling may change the calibration The torsion magnet 34 is relatively easy to move on its shaft That would result in a change in the Remove the two socket head cap screws 28 that hold the torsion spring module
110. rs and springs 3 3 13 8 Calibrate Each Bob This allows a separate torque calibration to be used for each bob 3 3 13 9 Disable Leak Detect There are three levels of leak detection available of these are intended to prevent the system continuing to heat and pump fluid when the system exhibits symptoms ofaleak Any or all of these can be disabled by clicking the LED next to the description In general the Sudden Loss should not be disabled The Pump Integral and Pump Cycling are more sensitive and will generate some false leak detects They may be disabled unless the Rheometer is in a particularly leak sensitive environment 3 3 13 10 Reset Mechanical Zero This 1s used on initial setup and after a mechanical change to the Rheometer It should only be used when the cell 1s assembled properly for that purpose 3 3 13 11 Default From Email This 1s the email address that any email updates sent from the software will appear to be from It does not need to be a real email address 3 3 13 12 XLSTemplatePath This allows the system to be set up with a custom location for report templates This could be a network location which would allow a master template to be kept in a single location and used on several Rheometers 3 3 13 13 DataStoragePath This allows the system to be set up with a custom location for test reports This could be a network location which would allow all of the reports from several Rheometers to
111. rt Header fann Model 77 Viscometer E BIK Ele Edit Operate Tools Window Help o0 Visc Visc Temp Temp Toler Wait Toler Collect O ex Jes 9 JP je jum coe 1 3 Ho do Jo Jo do Jo 2 Jeo Ho Wo 3 3 Jo jo 0 16665 feo 120 do do jo o 5 WMjossssxiso ds 1 go o Wo Jo 6 0 16665 30 fo do jo 7 ds fo Jo jo Figure 5 22 Create test report header 101625591 Revision G May 2014 54 fann IX77 Instruction Manual 5 1 5 9 The dialog displays sil M7 TestReportHeader vi Header Test Run By On Fann Model 77 viscometer Path File Name CA Program FilesYFann M77 TestReports M77 Automatic Test 2007 09 17 140957 Email Results To RepartOptians Show Raw Data Show Test Steps Remember Last Header Q p g Show Newtonian Results Use Excel Format Use Separate Files Remember Last Report Directory O Remember Last Email Address Figure 5 23 Test Report Header dialog 5 1 5 10 Edit the header and file name as desired and adjust any options as needed Click Done when finished 101625591 Revision G May 2014 55 IX77M Instruction Manual 5 1 5 11 The Start Test button is now enabled unless the Angle is too far away from zero indicating a mechanical issue
112. same position for each test 101625591 Revision G May 2014 67 B 1 77 Instruction Manual h Do not tighten both connector locking screws If both are tightened cooling fluid may leak Figure 5 37 Tightening the connector locking screw 5 2 2 10 Slowly close the shield door and push the door pin all the way down to lock the shield closed and to properly position the shear stress angle sensor in the top of the shield door Rapidly closing the shield door may cause the shear stress angle sensor to not achieve initial lock on the torsion magnet The angle read will usually be obviously false and only last for a few seconds The advanced control software will reestablish communication and lock automatically 101625591 Revision G May 2014 68 B IX77M Instruction Manual Figure 5 38 Locking the shield door 5 2 2 11 Refer to Figure 3 3 Digital Status Tab The Angle deg display will be used to properly set the Mechanical Zero value the setup offset button will be grayed out and not selectable If the Angle deg is not within 4 Degrees the start test button will also be grayed out and not selectable The magnet position has either slipped on the spring the zero knob has slipped or the torsion spring assembly has loosened at the upper pivot nut The mechanical problem must be corrected before trying to set the Angle deg zero The Angle deg zero is only properly adjusted or up
113. startup compare favorably with measurements taken at the same temperature in an unpressurized instrument A FANN Model 34 or 35 Rheometer or RheoVADR Rheometer could be used for this purpose The reference and startup test should be conducted at the same temperature The end test should be conducted with the same conditions as the startup test It will aid 1n detecting sample contamination by the pressurization fluid and permanent sample changes caused by the combinations of temperature pressure and shear used during the test Minimize Temperature Changes Temperature changes are time consuming because of the system s high thermal lag A temperature tolerance should be preselected and used uniformly Normally 3 F 2 C is adequate Measurements should be taken as long as the test 1 within the temperature tolerance and pressure tolerance Don t wait for the exact temperature Select meaningful temperature steps Experience has shown that temperature changes of less than 50 28 are rarely useful 1 2 4 1 2 5 Minimize Pressure Adjustments The system pressure will rise with temperature due to the sample s expansion With experience a pressure can be selected before heating which will result in a pressure slightly below the desired pressure after heating The pressure is automatically controlled to within 100 psi regardless of the pressure or temperature setting With most samples temperature has a much g
114. t at The only reason to change this would be to accommodate a hardware change Air Line Pressure psi Actual pressure of the air supplied to the machine This is used to scale the pump output value This should be set by the installer Pump Pressure Ratio The ratio input to output pressure on the high pressure pump Used for scaling the output The only reason to change this would be to accommodate a hardware change PumpLeakIntegral A number that represents how much pumping is allowed before the Pump Integral detects a leak Adjusting this will affect the detection of leaks if the Pump Integral leak detect has not been disabled Analog Out Max V Maximum voltage of the output to the pressure regulator Used for scaling the output The only reason to change this would be to accommodate a hardware change 3 3 13 5 Percent Change to Plot Data The software waits until a measured or imposed parameter shown on the main plot has changed by at least this amount before recording data If this value 1 set too low software performance will be affected due to the rapid recording of data If it 1s set too high the plot will appear artificially jagged 3 3 13 6 Save Setup 101625591 Revision G May 2014 29 fa Fr 1 77 Instruction Manual Ensures that any changes are written immediately to the proper INI files 3 3 13 7 Mechanical Setup This allows the user to set the Rheometer up with optional or custom bobs Roto
115. t the specified set point all at the same time If a tolerance 15 set to zero then the program will not wait for that parameter If a step has a Repeat Count then all of the PRECEDING SEQUENTIAL steps that have the same Cycle Label will be repeated until the repeat count is reached The steps will execute at least once even if the Repeat Count is zero If and only if Report Data is set to one the data collected on this step will be included in the preformatted 101625591 Revision G May 2014 31 fann 101625591 1X77 Instruction Manual reports Newtonian or Power Law All data is included in the Raw Data output The data collection interval in seconds may be set for each step Any value at or below 0 1 seconds will result in data collection about every 0 1 seconds If you do not wish to collect any data set this value higher than the length of the step Note that the data collection rate does not determine the screen update rate Note that any test step may be edited while the test is in progress Changes take effect the next time a step 1s executed That means that a change to the current step or a previous step will only take effect 1f the step 1s repeated using the Repeat Count or if the test is run again 3 3 14 2 Creating and Editing a Test Profile Several example profiles are installed with the software and these may be copied and edited to produce new profiles Microsoft Excel 1 a good tool for editing t
116. tect the torsion spring and upper jewel When the torsion assembly runs out of Revision G May 2014 74 fann 101625591 1X77 Instruction Manual freedom to move upward great force develops at the bottom of the jewel vee where it is pressed by the sharp tip of the rotor pivot It will crush the sapphire jewel Any cracks in the bottom of the jewel vee will cause the torsion assembly to stick slightly giving erroneous viscosity measurements and making calibration very difficult 5 4 1 Test Cell Setup It is suggested the cell be placed on the preparation stand while performing the following procedures The numbers in brackets refer to the Test Cell Drawing number 101511610 5 4 1 1 Bottom Jewel Adjustment 5 4 1 1 1 5 4 1 1 2 5 4 1 1 3 SALA 5 4 1 1 5 5 4 1 1 6 The pivot guide 14 presses onto the bob 4 With the set screw 16 and jewel 15 still out of the bob use soft material like piece of plastic or wood to push the guide all the way onto the bob Screw the jewel all the way into the bob from the top until it stops Do not force it Lock it in place with the set screw Install the bob on the bob shaft 17 and install it in the coupling 1 1 in the normal manner Make sure the 2 1s screwed tightly into place Loosen the 6 set screw in the side of the pivot cap 33 Remove the pivot cap Measure the gap between the top of the zeroing sleeve 37 and the bottom of th
117. the internal bob as reported by the magnetometer and calibrated using a standard fluid There are two data collection modes manual and automatic In manual mode the user turns on data collection from the screen and provides the necessary set points In the automatic mode a test profile is either generated from a list of pressure and temperature test points or retrieved from a file The automatic profile generation 1s based on a template set up by the installer In addition to the testing functions the software provides for calibration setup and tuning to allow the 1X77 Rheometer to be used for a wide variety of tests The shear stress values are calculated based on a look up table developed during calibration The calibration file 1s loaded on startup and evaluated for evidence of hysteresis Excessive hysteresis indicates a likely mechanical problem and a dialog 1 displayed when it 15 detected The software may be run in Simulation Mode for training and support purposes In this mode the software pretends that it is a fully functional 1X 77 Rheometer This mode is for training and support purposes only and the results generated should never be construed as meaningful If the system starts up and detects 1t 1s under pressure for instance after a power failure it will use the detected pressure as its manual pressure set point This 1s done to avoid decompressing the system suddenly Temperature set point 1 always set to zero
118. tions 7 2 2 4 Remove the six screws from the sides of the front panel 7 2 2 5 Pull the oil bottle drawer out 7 2 2 6 Rotate the front panel gain access to the Tescom valve 7 2 2 7 Locate the latch behind the Tescom valve 101625591 Revision G May 2014 105 e 1 77 Instruction Manual Figure 7 2 Drawer Latch Location 7 2 2 8 Push the latch sideways and pull the bottom drawer out E 4 F 5 y k p 4 m E ty 3 he E d INL Fd Figure 7 3 Opened Drawer with Rotated Front Panel 101625591 Revision G May 2014 106 fa Instruction Manual 7 2 2 9 Disconnect the control cable Figure 7 4 Control Cable 7 2 2 10 Remove the air inlet tubing Figure 7 5 A Air Inlet Tubing 101625591 Revision G May 2014 107 Instruction Manual 7 2 2 11 Use the 2 and 2 1 2 inch wrench for valve disassembly Figure 7 6 Wrenches for Valve Disassembly 7 2 2 12 Ensure there 1 ample clearance to use the wrenches dame TE C alla en m qm Figure 7 7 Clearance in the Disassembling Area 101625591 Revision G May 2014 108 1 77 Instruction Manual 71 22 13 Loosen the right hand threaded Body Assembly from the Air Actuator Assembly Figure 7 8 Body Assembly Air Actuator Assembly 7 2 2 14 Spin the valve off by hand once it 1s loosened Figure 7 9 Valve Disassembly 101625591 Revis
119. to the coupling 1 1 refer to Figure 5 46 Place the torsion spring module into the cleaning solution This module must be cleaned carefully Make sure that any caked solids in and around the pivot stop 25 and the torsion spring are removed A jet of cleaning solution is useful 101625591 Revision G May 2014 82 fann 1 77 Instruction Manual Figure 5 46 Removing the torsion spring module 5 4 3 3 4 Use a small magnet to lift and retain the small ball 39 that was underneath the spring module on top of the coupling refer to Figure 5 47 This ball acts as a check valve to prevent excessive dribbling of pressurization fluid when the port connectors are disconnected in the tower 5 4 3 4 Disassembly of the Coupling 5 4 3 4 1 5 4 3 4 2 5 4 3 4 3 Unscrew the baffle 2 from the bottom of the coupling and wash it in the cleaning solution Use a small brush to clean its bore and threads Remove the sample port plug from the coupling and clean it in the cleaning solution A small brush is helpful Inspect the O ring and 1f damaged remove and replace it Remove the coupling from the stand and wash it Be sure to run a brush through the central bob shaft bore the three ports the sample port bore from the bottom of the coupling and the two bores at the top of the coupling and the two threaded holes Use a brush to scrub the large threads of the coupling at each end While cleaning do not scratch the top
120. truction Manual e Samarium cobalt rare earth driven magnet 6 e 17 4PH stainless steel pivot bushing 10 wearing part replace as required e 17 4 stainless steel backup ring 43 e Titanium bob shaft 17 In the top portion of the test cell where these parts normally contact only the pressurization fluid e Alnico V upper torsion magnet 34 e Sapphire vee jewel 15 e Tungsten carbide pivot 13 30 2 e Titanium upper magnet mount 32 and limit stop 24 e Beryllium copper torsion spring 30 7 and jewel spring holder 35 Aluminum spring mandrels 30 3 4 5 clamping sleeves 31 30 6 and the zeroing sleeve 37 e 17 4 stainless steel backup ring 42 Temperature Control Test sample heating 1 produced by an electric resistance heater attached to the wall of the heater well During a test the sample portion of the test cell rests in the heater well Heat transfers through a narrow gap from the wall of the heater well directly to the wall of the test cell The heater 1s rated at 700 watts 115 VAC with a built in thermocouple The unit operates using 230 VAC the heater temperature is monitored and automatically controlled to a limit not to exceed 750 F allowing the lower voltage heater to be safely used The sample temperature 15 sensed by means of a single J type thermocouple that is permanently mounted in the center of the heating well It projects up from the center bottom of the well It
121. uiescent sample above the sample in the measurement area The contact area 15 small to minimize mixing Ti The inlet air pressure must be quickly supplied to the system through quarter turn valve or push on quick connect 101625591 Revision G May 2014 fa Fr Instruction Manual The inlet air Filter Dryer Regulator system has an automatic drain that vents through the system drain when excess water 15 detected When the inlet air 1 initially supplied the automatic drain 1s open and requires a quick pressure input to cause the automatic drain to seat 1 2 Test Design Principles Careful test design will avoid many problems including test repetitions and will minimize test time The following principles should be followed while designing a test L24 Select the Proper Pressurization Fluid Thoughtful selection of the pressurization fluid will help prevent false test results Two choices are available 1 The pressurization fluid can be the same as the sample if it is free of suspended solids and has minimal gelling tendencies Suspended solids would quickly damage the pumping and venting system by eroding the sealing surfaces If the fluid gelled around the torsion assembly it would cause inaccurate measurements 2 The pressurization fluid must be of lower density than the sample lower specific gravity and immiscible in the sample so that it will float on the top of the sample without mixing It is also
122. ure Control and Measurement Test sample pressurization 1s achieved by a Maxpro Technologies Maximator air operated gate valve controlled piston pump with a 1 440 air input to hydraulic output pressure ratio The air pressure to this pump 1 controlled by a SMC Electro Pneumatic 101625591 Revision G May 2014 10 fann 101625591 1X77 Instruction Manual Proportional Valve for reaching the pressure with minimal overshoot The pressure is then finely controlled by Tescom Smart Controller ER3000 coupled with Tescom 30 000 psi Back Pressure Air Op Valve and a Pressure Transducer The Air Op Valve is protected from solids during the pressure control sequence with an inline 30 000 psi filter with replaceable cartridge media Pressure release 1 primarily through high pressure air operated non rotating stem valve that 1s operated as a dump valve at the end of the test and activated through a solenoid valve The air control valve and the dump valve which are air controlled are protected with check valves so pressure 15 not lost due to an unplanned power or air loss A high pressure manual valve is also provided and is primarily used to purge the system if a loss of pressure occurs while heating to expel any whole mud out of the system without damaging the control valves The manual valve could also be used if all other systems failed to safely remove pressure from the system A nominal 35 000 psig replaceable rupture disc provides

iX77 Rheometer Instruction Manual

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