MP 1200

MP1200 & MP1200M
Extrusion Plastometer
(Melt Indexer)
MP1200M shown
SYSTEM INSTALLATION AND OPERATION MANUAL.

Part #: 02002100 (MP1200) & 02002101(MP1200M)
Revision 2c Date: 8 August 2013
This document contains confidential and proprietary information of Tinius Olsen

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

1065 Easton Road
Horsham, Pennsylvania 19044-8009 USA
www.TiniusOlsen.com
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Contents
1 Section 1 – Introduction ....................................................................................................................... 1-1

1.1 Overview .......................................................................................................................... 1-1
1.2 Heavy Duty Construction ................................................................................................. 1-1
1.3 Touch Screen Display ...................................................................................................... 1-1
1.4 Prompt Driven Operation ................................................................................................. 1-2
1.5 Timing .............................................................................................................................. 1-2
1.6 Precision Three Zone Band Heater ................................................................................. 1-2
1.7 Test Results ..................................................................................................................... 1-2
1.8 Communications .............................................................................................................. 1-2
1.9 Options and Accessories ................................................................................................. 1-2
1.10 Machine Dimensions: ....................................................................................................... 1-3
1.11 Electrical Requirements: .................................................................................................. 1-3
2 Section 2 - Model MP1200 Digital Controller/Timer ........................................................................... 2-1

2.1 Introduction ....................................................................................................................... 2-1
2.2 MP1200 Controller/Timer ................................................................................................. 2-1
2.2.1 Touch Screen Keyboard ..................................................................................... 2-1
2.2.2 Machine Display .................................................................................................. 2-1
2.2.3 Navigation Keys .................................................................................................. 2-3
2.3 Three-Zone Temperature Control .................................................................................... 2-4
2.4 Timing Systems................................................................................................................ 2-4
2.5 Communications Port ....................................................................................................... 2-4
2.6 Multiple Data Determinations (Captures) ......................................................................... 2-4
3 Section 3 –Operating Tools ................................................................................................................. 3-1
4 Section 4 – Available Options & Accessories ..................................................................................... 4-1

4.1 Weights ............................................................................................................................ 4-1
4.2 Glass Reference Thermometers ...................................................................................... 4-1
4.3 Digital Reference Temperature Measurement System (P/N: 02002184) .......................... 4-1
4.4 PPDT Automatic Timing Switch (P/N 02001505) .............................................................. 4-2
4.5 Automatic Timing Switch Calibrator (P/N 02001531) ...................................................... 4-2
4.6 Manual Cutoff Option (P/N: 02002104) ........................................................................... 4-2
4.7 Automatic Cutoff Option (P/N: 02002105) ....................................................................... 4-2
4.8 Weight Support, Lowering and Lifting Device with Swing–Away Weight Support
Platform (WLD) ................................................................................................................ 4-2
4.9 Corrosion Resistant Accessories ..................................................................................... 4-3
4.10 High Melt Flow Plug ......................................................................................................... 4-3
4.11 Go/No-Go Gauge ............................................................................................................. 4-3
4.12 Flow Rate Ratio Attachment Package (P/N 02001418) ................................................... 4-4
4.13 Semi-Automatic Pneumatic Purge ................................................................................... 4-4
4.14 Semi-Automatic Pneumatic Purge & Clean ..................................................................... 4-5
4.15 Horizon Data Acquisition & Machine Control Software .................................................... 4-5
4.16 Orifice (Die) Options......................................................................................................... 4-5
4.17 Piston Rod Options .......................................................................................................... 4-5
4.18 Piston Foot Options.......................................................................................................... 4-6
4.19 Miscellaneous .................................................................................................................. 4-6

5 Section 5 – Set-Up and Installation..................................................................................................... 5-1
5.1 Unpacking the Machine ................................................................................................... 5-1
5.2 Locating the Machine ....................................................................................................... 5-1
5.3 Leveling the Machine ....................................................................................................... 5-1
5.4 Connections ..................................................................................................................... 5-3
5.5 Updating the Firmware of the MP1200 ............................................................................ 5-5
6 Section 6 - OPTIONAL Programmable Piston Displacement Transducer (PPDT)........................... 6-1

6.1 Installing the PPDT ordered with the MP1200 .................................................................. 6-1
6.2 Field Installation, Setup and Configuration of the PPDT for encoder type ENCI (for
units that were repaired or not originally purchased with the MP1200). .......................... 6-1
6.3 PPDT Arm Length Adjustment ......................................................................................... 6-2
7 Section 7 – MP1200M Motorized Weight Support and Lowering/Raising Device with Swing-
Away Feature (WLD) ........................................................................................................................... 7-1
7.1 Preparation for use of Factory Installed WLD .................................................................. 7-1
7.2 MP1200M Factory Settings .............................................................................................. 7-1
7.3 DC MOTOR CALIBRATION ............................................................................................ 7-2
7.4 Zeroing the Encoder on the WLD (Synchronize with PPDT) ........................................... 7-3
8 Section 8 – Printer (Optional) .............................................................................................................. 8-1
9 Section 9 – Manual & Automatic Extrudate Cut-Off Tools ................................................................. 9-1

9.1 Tools Required: ................................................................................................................ 9-1
9.2 Installation Instructions .................................................................................................... 9-2
9.3 Operation ......................................................................................................................... 9-3
10 Section 10 – Setup & Operation of the Pneumatic Purge / Purge & Cleaning Attachment on a
Model MP1200 Melt Indexer w/WLD ................................................................................................10-1
10.1 Tools Required: .............................................................................................................. 10-1
10.2 Pneumatic Purge/Purge & Clean Attachment Parts List:............................................... 10-2
10.3 Initial Setup Procedures: ................................................................................................ 10-2
10.4 Operation: ...................................................................................................................... 10-5
10.4.1 Manual Operation: ............................................................................................ 10-5
10.4.2 Software Operation ........................................................................................... 10-6
10.5 Operational Notes: ......................................................................................................... 10-7
11 Section 11 – Configuration Mode......................................................................................................11-1

11.1 Machine Settings............................................................................................................ 11-1
11.2 PID Controls ................................................................................................................... 11-2
11.3 Calibrate ......................................................................................................................... 11-5
11.3.1 Calibrate RTD ................................................................................................... 11-5
11.3.1 Calibrate PPDT ................................................................................................. 11-6
11.3.2 Calibrate WLD ................................................................................................... 11-7
11.4 Diagnostic ...................................................................................................................... 11-8

12 Section 12 – User Settings ................................................................................................................12-9
12.1 General Settings. ........................................................................................................... 12-9
12.1.1 Language. ......................................................................................................... 12-9
12.1.2 Printer Selection. ............................................................................................... 12-9
12.1.3 Alarms…………………………………………..…………………………….………12-9
12.1.4 Position. ............................................................................................................ 12-9
12.1.5 Volume. ............................................................................................................. 12-9
12.1.6 Brightness. ........................................................................................................ 12-9
12.2 Calibration Offsets........................................................................................................ 12-10
12.3 Date/Time..................................................................................................................... 12-11
13 Section 13 – Testing Polymers According to ASTM D 1238 “Procedure A” (Manual Cut-Off

Operation) ..........................................................................................................................................13-1
13.1 Getting Started ............................................................................................................... 13-1
13.2 Creating a New Procedure A Program .......................................................................... 13-1
13.3 Test Procedure ............................................................................................................... 13-6
14 Section 14 - Testing Polymers According to ASTM D 1238 Procedure B (Automatically Timed

Flow Rate) when the Melt Density is known. ....................................................................................14-1
14.1 Getting Started ............................................................................................................... 14-1
14.2 Creating a New Procedure B Program .......................................................................... 14-2
14.3 Test Procedure ............................................................................................................... 14-8
15 Section 15 - Testing Polymers According to ASTM D 1238 Procedure B (Automatically Timed

Flow Rate) when the Melt Density is Unknown (Procedure for Calculating the Melt Density of a
Polymer) .............................................................................................................................................15-1
15.1 Introduction .................................................................................................................... 15-1
15.2 Creating a New Procedure B Program .......................................................................... 15-2
15.3 Test Procedure ............................................................................................................... 15-7
16 Section 16 - Cleaning Instructions ....................................................................................................16-1
17 Section 17 - Preventative Maintenance ............................................................................................17-1

17.1 Cleanliness ..................................................................................................................... 17-1
17.2 Motorized Weight Lowering Device (MP1200M) ........................................................... 17-1
17.3 Electrical Checks............................................................................................................ 17-1
18 Section 18 - Calibration/Verification – PPDT Attachment ................................................................18-1

18.1 Calibration/Verification Procedure for PPDT ................................................................. 18-1
18.1.1 Introduction ....................................................................................................... 18-1
18.1.2 Theory of Operation .......................................................................................... 18-1
18.1.3 Arm Length Calculation ..................................................................................... 18-3
18.1.4 Height Offset ..................................................................................................... 18-3
18.2 Temperature Verification/Calibration ............................................................................. 18-4
18.2.1 Suggested Equipment ....................................................................................... 18-4

19 Section 19 - Temperature Control Configuration Mode ...................................................................19-1
19.1 PID Parameters and Tuning -- General ......................................................................... 19-1
19.2 PID temperature control – output terms ......................................................................... 19-1
19.3 PID gains ........................................................................................................................ 19-2
19.4 Recovery Parameters. ................................................................................................... 19-3
19.5 Temperature Controller Status parameters: ................................................................... 19-4
19.6 Automatic Line voltage compensation ........................................................................... 19-4
20 Section 20 - Recommended Spare Parts List ..................................................................................20-1
21 Section 21 - MP1200 Packing/Shipping Instructions .....................................................................21-1

TINIUS OLSEN TESTING MACHINE COMPANY
FACTORY CERTIFICATE
This is to certify that the Tinius Olsen MP1200 Extrusion Plastometer (Melt Indexer) and
Accessories are checked prior to shipment and found to conform to the applicable
portions of ASTM D 1238 and ISO 1133 Test Methods (when used with the appropriate
options).
The verification devices are traceable to the National Institute of Standards and
Technology and are listed below.
The orifices are checked with orifice gauges manufactured and calibrated with
Calibration Standards traceable to the International System of Units (SI) through
NIST.
Piston feet, rods and collars are checked using devices verified with Gage Blocks
traceable to the International System of Units (SI) through NIST.
The weights are calibrated with weights traceable to the International System of
Units (SI) through NIST.
Note: The instrument, and especially components subject to wear during normal use,
should be inspected periodically to insure continued conformance to ASTM D
1238 and ISO 1133.

CAUTIONS
CAUTION: Read the instruction manual thoroughly before attempting to use this
equipment.
CAUTION: This instrument has been designed to determine the melt flow index
property and other thermal processing properties of polymers. It is not intended for any other
use. Any attempt to use this instrument in any fashion other than its intended use may
damage the machine and/or harm the operator.
CAUTION: Do not use a sharp object to press any of the buttons on the Model
MP1200 Controller, as this will damage the LCD screen.
CAUTION: The tools used on the machine may get hot during use.
CAUTION: This machine is designed for indoor use only. It shall be used in a
controlled environment (temperature range 5oC to 40oC, maximum R.H. of 80% at 31oC).
Maximum operating altitude is 3,200 meters. The area that it is located shall be free from
vibrations.
CAUTION: Prior to shipment, the cylinder of the machine is coated with oil to
prevent rust from forming. When the machine is first turned on, it is normal for the machine
to “smoke” as the cylinder comes to temperature and the oil residue burns off. To minimize
the release of smoke, clean the cylinder thoroughly before turning the machine on. Be sure
that a ventilation system is operating at this time.
CAUTION: In some instances an exhaust system may be required to remove the

fumes and/or odors released during a test. These instructions do not address all of the
safety concerns related to ventilation of fumes produced during normal testing operations.
CAUTION: The machine is heavy and care must be used when lifting the
machine from the box or moving the machine. Always lift the machine by the base plate.
DO NOT the machine up by the Motorized Weight Lowering Device (WLD) or by the
furnace assembly.

CAUTION: Do not exceed the flash point of the material being tested.
CAUTION: Possible pinch points associated with the weight-lowering device exist.
One is between the lift cap and the lifter top at the bottom most position of the platform and
the second exists between the weight lowering platform and the piston rod.
CAUTION: The surfaces of the furnace assembly can be extremely hot when the
machine is in operation!
CAUTION: Protective gloves should be worn when operating the machine.
CAUTION: Use caution when working with machines equipped with manual and
automatic extrudate cutters. Wear protective gloves to avoid cuts & burns.
CAUTION: The Motorized Weight Lifting/Lowering Device (WLD) is designed to

apply (and remove) test loads onto the piston. During normal operation a weight support
plate carrying various test loads moves up & down. At its uppermost position, the
mechanism will rotate 90o clockwise to facilitate cleaning of the bore. Ensure that there is
proper clearance for this action at the installation site.
CAUTION: Weight retaining rods must be installed to prevent weights from

falling.
CAUTION: Keep flammable materials from long term contact with the furnace.
CAUTION: Unplug the machine before any attempt to remove covers.

WARRANTY
The Tinius Olsen Testing Machine Company guarantees its products to be free from defects in
material and workmanship under normal use and service for which they were intended, and under
condition of proper maintenance for one year from date of receipt of equipment.
CALIBRATION
Tinius Olsen certifies that this instrument meets all dimensional, temperature control and
performance specifications of ASTM D 1238 and ISO 1133 Parts 1 & 2. That specification
recommends verification of calibration at least once a year. Contact Tinius Olsen’s Field Service
Department at (215) 675-7100 or contact your local Sales & Service Representative to schedule an
appointment.
SERVICE & PARTS SALES
For genuine Tinius Olsen parts and service, contact Tinius Olsen Customer Service
customerservice@tiniusolsen.com.

ATTENTION
 To remove the instrument from the box, use a strap looped around the bottom of the furnace to lift out of
the box as shown in the diagrams below. DO NOT lift by the weight support!! Alternatively, cut down the
sides of the box and lift by the base plate.
Model MP1200 – Net weight 22 kg (47 lbs)
Model MP1200M – Net weight 36 kg (79 lbs)
 Install weight retaining rods (on MP1200M models) before use.

 Check power requirements before use.
 Clean the bore of the furnace prior to use. The machine may emit “smoke“ from the bore as oil coating used to
protect the bore from rust during shipping burns off when first turned on..
 Please note that the MP1200 was calibrated at the factory prior to shipping. .
Thank you for your purchase!

1 Section 1 – Introduction
1.1 Overview
The Tinius Olsen MP1200/MP1200M Extrusion Plastometer (Melt Flow Indexer) with
microprocessor-based Model MP1200 Controller/Timer, is used for measuring the flow rates
of thermoplastics. The unit is a dead-weight piston plastometer with which the extrusion rate
of thermoplastic materials through an orifice of specified dimensions is determined under
prescribed conditions of temperature and pressure in accordance with ASTM Standard Test
Method D1238 & ISO 1133-1 & 2. With minor procedural or equipment modifications, the
MP1200 can also meet BS 2782, DIN 53735, JIS K7210 and other similar standards;
including ASTM D2581, D3364, D4203, D4507 and D4550 (a special orifice is required for D
3364). Other methods, such as D2116, D3159, D3275 and D3307, require the optional
corrosion resistant cylinder, orifice and piston foot.
A basic machine (MP1200) may be used for Procedure A - Manual Operation. A weight (s)
will be required to apply the test load. The amount of load is material dependent, so
weights are sold separately. With the addition of optional accessories (PPDT), Procedures
B & C (ASTM D1238 Procedure C) - Automatically Timed Flow Rate Measurement for Melt
Flow Rate (MVR) and/or Melt Volume Rate (MVR) can be performed.
The MP1200M is equipped with a motorized Weight Lifting/Lowering Device (WLD). It can
also be used for Procedures A, B, C & D when equipped with the optional PPDT (Flow Rate
Ratio Attachment is required for Procedure D). A weight(s) will be required to apply the test
load. The amount of load is material dependent, so weights are sold separately.
CAUTION: This instrument has been designed to determine the flow rate and other thermal
processing properties of polymers. It is not intended for any other use. Any attempt to use
this instrument in any fashion other than its intended use may void the warranty, damage the
machine and/or harm the operator.
1.2 Heavy Duty Construction
Sturdy design includes housing for temperature and timing controls, rugged uprights for
supporting the hardened steel test cylinder, which is heated by a precision three zone
controlled band heater, is insulated and jacketed in an aluminum housing. A set of
operating tools, bottom release orifice feature, mirror and a tool rack are included with each
machine. The unit is semi-portable and contains provisions for leveling the cylinder.
1.3 Touch Screen Display
The touch screen display allows the operator to interact with the unit to easily configure test
programs, run tests, and view results. Testing programs can be stored for recall or
necessary values can be entered at test time. Programs can be set up and stored for a
variety of tests.
Tinius Olsen MP1200 Extrusion Plastometer Page 1-1

Operation Manual # 02002215

1.4 Prompt Driven Operation
The selected program prompts the operator to enter the necessary information when
starting a test, alerts the operator to perform tasks that may be necessary during the test,
prompts for any information that might be necessary after the test, and calculates and
displays the test results.
1.5 Timing
Timing functions up to 9999 seconds in 0.01 second increments are available for preheat
timing, cut-off intervals, elapsed test time, piston displacement timing, operating an
automatic weight support and lowering device as well as other optional features. Audible
alarm features are also provided to prompt the operator to perform functions such as apply
load, cut off extrudate, etc.
1.6 Precision Three Zone Band Heater
310 Watts (nominal) -- contains a special concentric heating element, which is form-fitted
and designed to uniformly maintain the required temperature. The heater and furnace
assembly is rated for use up to 450°C. Three platinum RTD Probes sense the cylinder
temperature, sending signals to the MP1200 Controller, which regulates the temperature of
the upper and lower portions of the cylinder to within ± 0.1°C. The temperature of the lower
portion of the cylinder is displayed as the Actual Temperature (AT).
1.7 Test Results
For Procedure A type tests, Flow Rate (Melt Index) is calculated and displayed for each cut-
off. When Procedure B type tests are performed using the optional PPDT Automatic Timing
Switch, Flow Rate (MFR), and Volume Rate (MVR) may be determined and Apparent
Shear Stress, Shear Rate and Viscosity, and Volume Rate can be selected for calculation
and display. Melt Density may be entered or calculated from cut-off weight. Average
values are calculated when more than one measurement is made during a test.
1.8 Communications
The test information and results can be sent to an optional printer or the machine can be
interfaced to a computer utilizing the serial communications ports (USB and RS232)
provided as standard. Up to ten machines can be interfaced to a single computer.
1.9 Options and Accessories
A variety of options are available, designed to increase testing efficiency and accuracy.


1.10 Machine Dimensions:
MP1200 - 51 cm (20 inches) wide by 38 cm (15 inches) deep and 58 cm (24 inches) in
height. Net weight approximately 21 kilograms (46 pounds), not including any weights or
options.
MP1200M - 51 cm (20 inches) wide by 38 cm (15 inches) deep and 95 cm (38 inches) in
height. Net weight approximately 32 kilograms (95 pounds), not including any weights or
options.
1.11 Electrical Requirements:
The basic Model MP1200 Extrusion Plastometer is arranged for 115 Volts ±10% or 230
Volts ±10%, 50/60 Hz, Single Phase. Check machine label for actual electrical
requirements.
115 Volt
Input Power.................................................................................................................. 500 W
Voltage ....................................................................................................... 115 VAC +/- 10%
Current............................................................................................................................ 4.5A
Frequency................................................................................................................. 50/60HZ
Phase ...........................................................................................................................Single
Line Fuses ........................................................................... Two 5x20 mm slow blow fuses:
Line: 5 A Neutral: 6.3 A
230 Volt
Input Power (Average) ................................................................................................. 500 W
Voltage ......................................................................................................... 230 VAC +/10%
Current............................................................................................................................ 4.5A
Frequency................................................................................................................. 50/60HZ
Phase ...........................................................................................................................Single
Line Fuse ................................................................................................. 5A, 250V GDC/213
Note: The MP1200 monitors the incoming line voltage and automatically compensates for small
changes in the line voltage. However, major line voltage problems (spikes, surges,
dropouts) will have to be addressed externally by the user. A qualified electrician should be
consulted and employed should it become necessary to install isolating/regulating
transformers, etc.
The line filter used in the Power Entry Module typically has a leakage current of 0.25 mA to
ground at 115 VAC, and 0.5 mA at 220 VAC. This current leakage may cause a Ground
Fault Interrupt (GFI) receptacle to trip, therefore a GFI is not recommended.
A standard computer grade surge suppressor is recommended for protection.


2 Section 2 - Model MP1200 Digital Controller/Timer
2.1 Introduction
The MP1200 microprocessor-based Controller/Timer is fully interactive with the operator. It

features a LCD touch screen interface; high visibility display; USB port, serial
communications port (RS232); test parameter storage with power-up in last used
parameters; calibration information stored in flash memory; operating controls and other
related features.
2.2 MP1200 Controller/Timer
2.2.1 Touch Screen Keyboard
A touch-screen LCD display is provided for displaying software prompts and tests results.
Also used for entering required numerical test data and for activating specific functions and
features as required. The touch screen keyboard allows the operator to communicate with
the microprocessor in response to interactive prompts, which appear on the LCD display.
Testing parameters can be stored for recall or the necessary values can be entered at test
time. The Parameters can be set up for conducting flow rate tests under both Procedure A
(Manual Cut-off Procedure) and Procedure B (Automatic Timed Procedure). It also can be
used to obtain results for Procedures C & D of ASTM 1238.
CAUTION: Do not use a sharp object on the Model MP1200 Controller, as this
may puncture the touch screen.
2.2.2 Machine Display
2.2.2.1 Status
Indicates the operating condition of MP1200
2.2.2.2 Temperature
Indicates actual temperature of bottom zone of the furnace
2.2.2.3 Piston Height

Indicates the piston (bottom of piston foot) height, when using the PPDT
Automatic Timing switch, relative to the top of the die in the furnace
2.2.2.4 Heater Indicators

Indicators designate top, middle, and bottom heater operation.


MP1200 Home Screen
MP1200M Home Screen


2.2.3 Navigation Keys
2.2.3.1 Navigation -
Used to access the motorized weight lifting/lowering device (WLD) functions and
purge/purge & clean functions. This key only appears if the WLD or Purge or
Clean functions are turned on in the Configuration Mode.
2.2.3.2 Test Mode

The Test Mode allows the operator to run a test. The operator will have to select
a program from the file list that appears after pressing on the check mark next to
the FILE box. The MP1200 comes from the factory with 7 sample programs
already entered. It is unlikely that any one of these example programs will be an
exact match for the material that is to be tested. They are meant as a starting
point and should be fine tuned the user’s needs. Users may program their own
test before using the Test Mode by using the PROGRAM button on the display
(see instructions below). When properly programmed, the display will indicate
the parameters of the test. The selected program prompts the operator to enter
the necessary information when starting a test, alerts the operator to perform
tasks that may be necessary during the test, prompts for any information that
might be necessary after the test, and then calculates and displays test results.
2.2.3.3 Program
The Program mode allows the operator to select the parameters of the test. The
mode is password protected. The operator can create and store new programs,
select existing programs, edit existing programs or delete programs.
2.2.3.4 Results
The Results mode is used to recall, review and/or print stored test results. For
“Procedure A” type tests, the Flow Rate (Melt Index) is calculated and displayed
for each manual cut-off. When Procedure B type tests are performed using the
optional PPDT Automatic Timing Switch, the Flow Rate (Melt Index), apparent
Shear Stress, Shear Rate and Viscosity, and Volumetric Flow Rate (MVR) can be
selected for calculation and display.
2.2.3.5 User Settings

The User Settings mode allows the operator to select the optional printer, turn
alarms on and off, adjust the volume of alarms, select units, adjust the brightness
of the screen and adjust the Calibration Offsets. The operator can also send logs
to a USB thumb-drive and set the date and time. The mode is password
protected.
2.2.3.6 Configuration
The Configuration mode allows the operator to set the maximum test temperature
and to select which accessories are to be used. It is also used to access the
Calibration and Diagnostics modes. Normally, this information is programmed at
the factory. The mode is password protected.


2.3 Three-Zone Temperature Control
The temperature controller features three-zone proportional, integral, and derivative (PID)
control, assuring spatial temperature variations of less than ± 0.25°C along the test area of
the cylinder. Temperatures up to 450°C are controlled and displayed to ± 0.1°C; utilizing
three platinum RTD’s embedded in the cylinder wall. The controller also has built-in
temperature sensor recognition indicator. If an RTD opens or shorts out (or temperature
control becomes erratic), power to the heater is interrupted and an error message is
displayed.
2.4 Timing Systems
Timing functions up to 999 seconds are available for preheat timing, cut-off intervals,
operating a WLD, as well as other optional features. Piston displacement timing is
displayed in 0.01 second increments up to 1000 seconds and in 0.1 second increments
from 1000 to 3600 seconds. An audible alarm can be activated which will prompt the
operator to perform functions such as applying the load, cutting off the extrudate, etc.
2.5 Communications Port
The test information and results can be sent directly to an optional printer or the machine
can be interfaced to a computer utilizing the serial Communications Ports (USB and EIA-
232) provided as standard. Up to ten machines can be interfaced to a single computer
2.6 Multiple Data Determinations (Captures)
The MP1200, when equipped with the optional PPDT gives the operator the ability to make
up to 10 individual flow rate/volume rate (melt index) determinations within a single sample
charge when performing a test to ASTM Procedure B. While this feature is not required by
ASTM D 1238, it is required for ISO 1133 testing. It can also be useful for checking the
consistency of results and in improving accuracy by isolating sources of error such as air
bubbles and allowing the operator to eliminate obviously flawed data. The multiple capture
features may be used with any material, but it is most often used with materials that have
flow rates greater than 10 g/10 minutes. A typical example of the test parameters used for
a multi-capture test has been preprogrammed in Program #4 (see Table 11-1).


3 Section 3 –Operating Tools
The following tools are included with each MP1200 as standard equipment. Refer to Figure 3-1 for
an illustration. See Section 16 for cleaning instructions.
IMPORTANT: All these tools are made of materials that are softer than the cylinder. This is to
prevent any scoring or damage to the walls of the cylinder. If the cotton cleaning patches
cannot effectively clean the cylinder walls, an optional 0.406” diameter soft brass brush
(available from Tinius Olsen) can be used to help clean the cylinder.
One (1) ASTM Piston Assembly (Items 1A, 1B & 1C, Figure 3-1) - consisting of a
removable stainless steel piston foot (P/N: 02001086); piston guide collar (P/N:
02002149); and ASTM piston rod (P/N: 02002163). The piston rod and foot weighs
100 grams (not including the guide collar). It is considered the first 100 grams of all
test loads.
One (1) Charging Tool (P/N: 02001582), is used to compress the test material down into the
cylinder (cylinder bore), and helps to remove some of the entrapped air when
charging material. Provided with a replaceable tip (P/N: 02001071).
Two (2) ASTM D 1238 Orifice (die), D2 tool steel (P/N: 02001030).
CAUTION: Machines supplied with a nickel-chrome alloy bore should not be used with the
standard tool steel die. Please use either the carbide or satellite die options.
One (1) Level (P/N: 02001271) - used to check the Cylinder Alignment (Level) of the
cylinder. This level is made to fit over the end of the Piston Rod Assembly, with the
piston and orifice in the cylinder.
One (1) Stainless Steel Funnel, (P/N: 02002155) - is used to help introduce a sample of
material into the cylinder.
One (1) Cylinder Cleaning Tool, (P/N: 02001527) is used to clean the cylinder after each
test with the cotton cleaning patches.
One (1) Cutoff Tool, (P/N: 02001090) this U-shaped tool is used to cut-off the extruded
sample at the bottom of the orifice.
One (1) Orifice Drill, (P/N: 02002193) this soft drill bit is used to clean material out of the
inside diameter of the orifice.
CAUTION: The tools used on the machine may get hot during use.


Figure 3-1 – MP1200 Melt Indexer Tools Supplied with Machine
1. Piston Rod Assembly: 4. D2 Tool Steel Orifice (P/N 02001030)

A. Piston Rod (ASTM) (P/N 02002163) 5. Level Assembly (P/N 02001271)
B. Guide Collar (P/N 02002149) 6. Funnel (P/N 02002155)
C. SS Piston Foot (P/N 02001086) 7. Cutoff Tool (P/N 02001090)
2. Cylinder Cleaning Tool (P/N 02001527) 8. Charging Tool (P/N 02001582)
3. Orifice Drill (P/N 02002193)


4 Section 4 – Available Options & Accessories
4.1 Weights
Table 4-1 shows the weights that can be supplied for the standard test conditions in ASTM D
1238 and ISO 1133. The piston rod and piston foot (less the collar) weigh 100 grams. All the
weights are marked in grams. Tinius Olsen certifies that the weights are accurate to within
+/- 0.5% of the stamped weight.
EXAMPLE: To apply a Test Load of 2.16 kilograms you would use the 2,060 gram weight,
adding in 100 grams for the piston rod assembly (less the collar).
Table 4-1 – Weight Loading for Typical Melt Flow Rate Tests
ASTM D 1238
TEST LOAD USE WEIGHT(S) PISTON
TEST CONDITION = +
(GRAMS) (GRAMS) WEIGHT
(Reference Only)
A, D & K 325 = 225 (P/N 02001176) + 100
B, C, E, L, R, T, V & W 2,160 = 2,060 (P/N 02001180) + 100
H&O 1,200 = 1,100 (P/N 02001181) + 100
I 3,800 = 3,700 (P/N 02001186) + 100
2,400 (P/N 02001193) +
J&U 12,500 = + 100
10,000 (P/N 02001187) .
G, P, S & X 5,000 = 4,900 (P/N 02001185) + 100
6,600 (P/N 02001184) +
F 21,600 = 4,900 (P/N 02001185) + + 100
10,000 (P/N 02001187) .
M 1,050 = 950 (P/N 02001183) + 100
N 10,000 = 9,900 (P/N 02001188) + 100
Q 1,000 = 900 (P/N 02001182) + 100
4.2 Glass Reference Thermometers
Tinius Olsen no longer supplies thermometers. Model TO410 is a digital temperature

measuring system that can be used instead of thermometers.
4.3 Digital Reference Temperature Measurement System (P/N: 02002184)
The Model TO410 handheld, battery operated temperature verification kit is designed for use
with Melt Flow Indexers. This device is for use from 100 to 400 degrees C. It has a
resolution of 0.001 degrees C and an accuracy of approximately 0.05 degrees C. It includes
an RTD with tips designed to properly access the temperature of the bore of a Melt Flow
Indexer. Also included is a dual voltage charger with 4 different power outlet adapters.
Calibration certificates from an ISO 17025 accredited laboratory are provided.


4.4 PPDT Automatic Timing Switch (P/N 02001505)
The PPDT is required when conducting Procedure B - Automatically Timed Flow Rate
Measurement tests in accordance with Procedure B of ASTM D 1238, ISO 1133, DIN 53735,
JIS K7210 and other similar methods. It is also necessary for volume measurements (MVR).
The PPDT utilizes a precision optical encoder to monitor piston position and operate the timer
in the MP1200 Controller/Timer. The Starting Positions and Piston Travel Distances for up to
ten “time vs. distance” captures can be preprogrammed into the MP1200 Controller/ Timer.
4.5 Automatic Timing Switch Calibrator (P/N 02001531)
NOTE: To use the Switch Calibrator with the MP1200, add Adapter Assembly, P/N:
02002195.
Used for verifying and calibrating the actual piston travel distances measured by the PPDT.
It can also be used to verify and/or calibrate older style Mechanical and Programmable
Actuating Switches and Programmable Piston Displacement Transducers used on older
Model UE, MP987, MP993, MP993a and MP600 Extrusion Plastometers. However, the
instructions in this Manual cover only the verification/calibration of the PPDT on a melt
indexer equipped with a MP1200 Controller/Timer. Contact the factory for instructions for
verification/calibration when using other types of controllers and actuating switch types.
The Calibrator consists of a 0 to 2” barrel-type micrometer head with 0.001” divisions, a

threaded spacer and a mounting bracket. The mounting bracket permits checking the switch
while it is mounted on the machine. A wooden storage box is also included.
NOTE: Digital version available (02001651). Contact factory for details.
4.6 Manual Cutoff Option (P/N: 02002104)
This optional accessory is available on both the MP1200 & MP1200M. It can be used to cut
the extrudate instead of using the cutoff tool. The operator turns a hand crank to cut the
material.
4.7 Automatic Cutoff Option (P/N: 02002105)
This optional accessory is available on both the MP1200 & MP1200M. It can be used to
automatically cut the extrudate instead of using the cutoff tool.
4.8 Weight Support, Lowering and Lifting Device with Swing–Away Weight Support
Platform (WLD)
This accessory is included with the MP1200M. It is used to raise and lower the test weight(s). It
includes an integrated encoder that permits display and control of the height of the weight support
platform. It can be operated manually by buttons on the touchscreen. When performing
Procedure B, C & D tests, it can be programmed to automatically move to a selected height at the


start of a test and then lower fully to reapply the load after a selected pre-heat period (Release
Time).
The MP1200M is required for automatic operation and is also recommended whenever high
loads are being used in a test. Weights are contained on the weight support platform that
swings-away automatically when in its raised position for easy cylinder cleaning.
4.9 Corrosion Resistant Accessories
A corrosion cylinder and piston feet are available and are recommended for use with
corrosive materials. Both are made from a Ni/Cr alloy. An orifice made from Stellite 6B is
also available (See 4.16).
P/N: MFI-FNICR – Ni/Cr Furnace Assembly, Complete (New Machine)

P/N: 02002190- Replacement Ni/Cr cylinder
4.10 High Melt Flow Plug
A High Melt Flow Plug is available for use with high flow rate materials. The plug is inserted
into the orifice from the bottom of the furnace prior to charging the cylinder. It will keep
material in the bore until the preheat time expires. At that time, it should be removed. Use
caution when removing the plug. Each plug is supplied with a set of 3 spacers. Choose the
spacer that works best.
P/N: 02001483 – Plug for standard die

P/N: 02001481 – Plug for “half” die
4.11 Go/No-Go Gauge
The Go/No-Go gauge is used to check the inner diameter of the standard ASTM D 1238/ISO
1133 orifice (die) for compliance to the test method requirements.
P/N: 02001134: Go/No-Go Gauge, “Half-Die”, CERTIFIED

P/N: 02001133: Go/No-Go Gauge, ASTM D 1238/ISO1133 orifice - CERTIFIED
P/N: 02001034: Go/No-Go Gauge, standard ASTM D 1238/ISO1133 orifice
NOTE: The certified Go/No-Go gauges are only certified by the gage manufacturer. An ISO
17025 certified gage can be supplied at an additional cost.


4.12 Flow Rate Ratio Attachment Package (P/N 02001418)
Use of this option requires that the MP1200M Extrusion Plastometer is also equipped with the
PPDT Automatic Timing Switch. This package consists of:
a) Load change (lift) pins and extended safety uprights and split collars for weight
containment.
b) Weight change height setting adjuster for setting up typical programs.
c) Available Weight Sets (sold separately):
P/N: 02001658 – 3 Load - I2, I10 & I21 – For MP1200M

- includes 2,060, 7840 and 11600 gram weights
P/N: 02001659 – 3 Load - I2, I10 & I21 – For MP1200M with purge option
- includes 2,060, 7840, 1300 gram weights plus 300 g plug.
P/N: 02001660 – 3 load – I2, I5 & I21
P/N: 02001661 – 3 Load - I2, I5 & I21 – For MP1200M with purge option
- includes 2,060, 2840 and 11600 gram weights plus 300 g plug.
P/N: 02001662 – 2 Load - I2 & I21 – For MP1200M with purge option
- includes 2,060 and 19140 gram weights plus 300 g plug.
P/N: 02001663 – 3 Load - I2, I6 & I21
Using the above components, flow rates can be determined under up to three different loads
using the following automated sequence. After charging the test material and lowering the
weights over the top of the piston rod, the operator starts the “Preheat” period. At the end of the
“Preheat” period, the WLD lowers and applies the selected total load. The time for the first
selected piston travel is measured and stored. As the test progresses, the load on the piston is
reduced automatically and, after a selected distance to allow for equilibration of flow, the time
for the selected second piston distance is measured and stored, and a similar sequence can be
selected to obtain a measurement under a third load.
4.13 Semi-Automatic Pneumatic Purge
The Semi-Automatic Pneumatic Purge Attachment can be used only on MP1200M models
equipped with WLD (Weight Lowering Device). The assembly is attached to the WLD and will
allow users to purge the test charge to a predetermined starting point. The operator will charge
the material into the bore and start the test, lowering the WLD weight platform to a
predetermined height (determined by manually programming the MP1200 controller or using
Horizon software). The purge feature is then engaged, applying a downward force on the
weight to purge the material from the bore until the weight is stopped by the weight platform. At
the end of the pre-programmed release time period, the weight platform fully lowers and the
test will continue normally until its conclusion. At the end of the test, the purge feature can be
activated to purge any remaining material from the bore.
P/N: MFI-02002103 - (New Machine)

P/N: 02002103 - (Existing Machine)


4.14 Semi-Automatic Pneumatic Purge & Clean
The Semi-Automatic Pneumatic Purge and Cleaning Assist Attachment can be used only on
MP1200M models equipped with WLD (Weight Lowering Device). The assembly is attached to
the WLD and will allow users to purge the test charge to a predetermined starting point. The
operator will charge the material into the bore and start the test, lowering the WLD weight
platform to a predetermined height (determined by manually programming the MP1200
controller or using Horizon software). The purge feature is then engaged, applying a downward
force on the weight to purge the material from the bore until the weight is stopped by the weight
platform. At the end of the pre-programmed release time period, the weight platform fully
lowers and the test will continue normally until its conclusion. At the end of the test, the purge
feature can be activated to purge any remaining material from the bore. After the WLD is raised
to its top position and swings out of the way, the piston can be removed from the cylinder using
the Piston Extraction Tool (included). After the orifice (die) is removed, a cleaning rod is placed
in position by the technician. Cleaning patches are then placed over the bore and the ram is
activated, helping the operator to clean the bore.
P/N: 02002102 - (New Machine)

P/N: 02002217 - (Existing Machine)
4.15 Horizon Data Acquisition & Machine Control Software
Tinius Olsen’s Horizon Software Packages are available for connecting a single Melt Indexer or
up to ten Melt Indexers to a computer. Consult the factory or your local representative for
complete details.
P/N: 02001672 Software – Horizon MFI Primary Platform

P/N: 21001127 Software - Horizon- Multiple Machine Package
4.16 Orifice (Die) Options
P/N: 02001030 – Orifice, D2 tool steel (ASTM D 1238, ISO 1133)-Standard

P/N: 02001268 – Orifice, Carbide 0.0413” ID x 0.157” L (“Half Die”)
P/N: 02001033 – Orifice, Carbide (PVC, ASTM D3364)
P/N: 02001032 – Orifice, Stainless Steel (PVC, ASTM D3364)
P/N: 02001031 – Orifice, Carbide (ASTM D 1238, ISO 1133)
P/N: 02001167 – Orifice, Stellite 6B (ASTM D 1238, ISO 1133) corrosion resistant
4.17 Piston Rod Options
P/N: 02002163 - ASTM Piston Rod

P/N: 02002164 - ISO (only) Piston Rod
P/N: 02002165 - Combination ASTM/ISO Piston Rod)
P/N: 02002149 – Guide Collar, MP1200
Note: The piston rods listed above are for the MP1200 model only. Piston rods from the
MP600 and older models will not work with the MP1200.


4.18 Piston Foot Options
P/N: 02001086 Piston Foot, stainless steel (standard foot)

P/N: 02001130 Piston Foot, stainless steel, hardened 30-35C
P/N: 02001441 Piston Foot, D2 tool steel hardened 50-55C
P/N: 02001113 Piston Foot, corrosion resistant alloy (for use with corrosion resistant alloy
cylinder)
P/N: 02001171 ISO 1133 piston foot (2011 version)
Note: in 2011 ISO TC61/SC5 approved a new version of ISO1133. A new design for the piston
foot was part of that revision.
4.19 Miscellaneous
P/N: 02001071 Charging Tool Tips

P/N: 02001136 500 Cleaning Patches
Brass Cleaning Brushes:

A. Handle (P/N: 02001144)
B. Brush, MI Cylinder (P/N: 02001143)
C. Brush 0.0825” Orifice(P/N:02001142)
D. Brush 0.0413” Orifice (P/N: 02001146)


5 Section 5 – Set-Up and Installation
NOTE: Instructions in this Section cover basic machine setup. For instruction on installing and
operating optional accessories supplied with the unit, please refer to the appropriate Section of this
manual.
CAUTION: This machine is designed for indoor use only. It shall be used in a controlled
environment (temperature range 5°C to 40°C (40 to 100°F), maximum R.H. of 80% at 31°C).
Maximum operating altitude is 3,200 meters (10,000 feet).
CAUTION: In some instances an exhaust system may be used to remove the excess heat
and/or fumes/odors released during a test. These instructions do not address all of the
safety concerns related to ventilation of fumes produced during normal testing operations.
5.1 Unpacking the Machine
Locate the packing list and carefully uncrate and remove all packing material from around
the machine. Carefully remove the machine from the crate. Check all parts and accessories
against the packing list.
CAUTION: The machine is heavy and care must be used when lifting the machine from the
box or moving the machine. Always lift the machine by the base plate. Never pick the
machine up by the Motorized Weight Lowering Device (WLD) or by the furnace assembly.
It is advisable to retain all packing materials until the machine has been installed and
commissioned.
5.2 Locating the Machine
Place the machine on a sturdy, level surface. Place the machine in an area that is free from
vibrations. Place the tools on the rack on the right hand side of the machine.
The basic machine is shipped fully assembled (the operator has to attach the PPDT if you
ordered one). There is some assembly required for optional accessories.
5.3 Leveling the Machine
Insert the orifice in the cylinder, and then insert the piston assembly. Place the precision
level over the top of the piston. The piston rod must be straight and the base of the level
seated cleanly on the shoulder of the piston. Level the machine using the screw adjustment
feet on the corners of the base plate. Verify that the machine is level by rotating the level
only and then the piston assembly only. At all level positions, no more than half of the
bubble will be outside the circle. Remove the precision level from the piston and store it in a
safe place. Turn the machine ON using the switch on the right side of the machine.
Depending on the model, one of the two main screens will appears.


Main Screen MP1200
Main Screen MP1200M


5.4 Connections
Figure 5.4 – 1 – USB Connections on Left Side of MP1200 & MP1200M
Figure 5.4 – 2 - Rear of Standard MP1200 & MP1200M


Figure 5.4 – 3 - Rear of MP1200M built for Optional Pneumatic Purge Device
Figure 5.4 – 4 - Rear of MP1200M built for Optional Pneumatic Purge & Cleaning Device


5.5 Updating the Firmware of the MP1200
Tinius Olsen provides a free of charge firmware upgrade that may be downloaded from
Tinius Olsen’s FTP site. To get the latest firmware upgrades, follow the instructions below.
5.5.1 To download this update, go to www.tiniusolsen.com/Lionhead/Login.cfm.
5.5.2 Enter the User Name: MP1200 and the Password: update.
5.5.3 Click on Software under Menu Listing.
5.5.4 Click on the file name Firmware.
5.5.5 Click on MP1200_USB Disk.zip and save on your hard drive or a USB thumbdrive.
(You may also click on and save MP1200 update instructions.doc but the content is
detailed below)
5.5.6 Copy MP1200_USB Disk.zip from your hard drive to a USB thumb drive
5.5.7 Unzip the file and put the contents onto a USB flash drive. Put them right on the
root directory, not into a folder:
5.5.8 Turn off the MP1200.


NOTE: The update installs the following Sample Programs.
TEST 1 FOR GENERIC PE

TEST 2 FOR GENERIC PP
TEST 3 SAMPLE MVR
TEST 4 SAMPLE PROC A
TEST 5 SAMPLE MELT DENSITY CALC
TEST 6 SAMPLE TIME BASED
TEST 7 SAMPLE ISO PROC A
If you happen to have a test program named the same as any of the above, it will be
overwritten. You may want to save your program under a different name.
5.5.7 Plug the USB drive into the MP1200 and turn on the power. There will be a popup
box prompting to upgrade the firmware. Select ‘Yes’ before the progress bar
finishes. No further interaction is required. The MP1200 will then proceed to update
controller and display firmware. There will be several pop-up windows and status
messages. Once finished it will start up the MP1200 and the USB drive can be
removed.
If you have any questions or concerns, please contact helpdesk@tiniusolsen.com.


6 Section 6 - OPTIONAL Programmable Piston Displacement
Transducer (PPDT)
6.1 Installing the PPDT ordered with the MP1200
6.1.1 Tools Required:

3/16 inch hex key (supplied); small slotted screwdriver (not supplied)
6.1.2 Turn the machine off before you begin. Remove the shrink-wrap that secures the
PPDT during transit (if applied). Be careful not to bend the PPDT arm.
6.1.3 Mount the switch mounting bracket to the furnace as shown in Drawing 5-6-549
(located in Appendix A at the rear of this manual). Secure the bracket using the two
1/4”-20 screws provided.
NOTE: The arm and the encoder in the PPDT are very sensitive and can easily be
damaged by misuse or abuse. When moving the arm by hand, never exceed the
upper or lower stops. Never allow the arm to fly up from the down position. The arm
must be gently guided back to the upper position using a finger.
6.1.4 Make sure that the MP1200 is turned off, then plug the PPDT into appropriate port at
the rear of the MP1200 controller cabinet and tighten screws with a small slotted
screwdriver. Be sure cable clamps are tight.
6.1.5 See Section 11 – Configuration Mode for further information.
6.2 Field Installation, Setup and Configuration of the PPDT for encoder type ENCI (for
units that were repaired or not originally purchased with the MP1200).
NOTE: Repaired or replacement PPDT’s have been calibrated at the factory prior to shipment
to the customer.
6.2.1 Mount the switch mounting bracket to the furnace as shown in Drawing 5-6-549
(located in Appendix A at the rear of this manual). Secure the bracket using the two
1/4”-20 screws provided
NOTE: The PPDT arm and the encoder are very sensitive and can easily be damaged by
misuse or abuse. When moving the arm by hand, never exceed the upper or lower stops.
Never allow the arm to fly up from the down position. The arm must be gently guided back to
the upper position using a finger.
6.2.2 Make sure that the MP1200 is turned off, then plug the PPDT into appropriate port at
the rear of the MP1200 controller cabinet and tighten screws with a small slotted
screwdriver. Be sure the cable clamps are tight.


6.3 PPDT Arm Length Adjustment
6.3.1 Because any physical adjustments to the PPDT require a complete

disassembly of the PPDT, it is recommended that the user does not attempt
to physically change the length of the arm of the PPDT. The PPDT is a
precision instrument and should be treated with care. It has been designed
so that it resists damage from everyday use, even if the WLD Weight
Lowering device is lowered onto it when it is not rotated into the proper
position.
6.3.2 The arm on the PPDT is designed so that the tip extends 5 9/16” (nominal)
from the counterweight giving a theoretical length from the center of rotation
of 6 inches. This length was set at the factory and should NOT be adjusted in
the field. If the arm is accidentally bent, it can be bent back into the
approximate original shape and recalibrated (Short Calibration), however, to
be absolutely sure that the PPDT is working correct, the PPDT arm should be
replaced and recalibrated. A brief discussion of this procedure can be found
in Section 19.1.


7 Section 7 – MP1200M Motorized Weight Support and
Lowering/Raising Device with Swing-Away Feature (WLD)
7.1 Preparation for use of Factory Installed WLD
7.1.1 Install the weight retaining rods (Refer to Drawing 5-6-730 located in Appendix A at
the rear of this manual) provided with the WLD. The rods are used to safely contain
the weight(s). When using 3” diameter weights (supplied for Flow Rate Ratio testing
only), three (3) rods are threaded into the inner tapped holes of the weight platform in
a triangular pattern (supplied with FRR attachment hardware).
7.1.2 For larger diameter weights, all four of the rods should be installed using the outer,
square pattern.
CAUTION: Possible pinch points associated with the weight-lowering device exist. One
is between the lift cap and the lifter top at the bottom most position of the platform and the second
exists between the weight lowering platform and the piston rod.
CAUTION: Do not allow the WLD to lower when there is any obstruction between the top
of the furnace and the bottom of the weight platform that would prevent the full lowering of the WLD.
Should the WLD lowering be initiated inadvertently when an obstruction is present, immediately
press the “STOP” button located on the left side of the MP1200 display. Press NAVIGATION if the
WLD buttons are not shown.
WARNING: Do not use the WLD to purge material from the bore after a test.
7.2 MP1200M Factory Settings
NOTE: The machine comes from the factory with the following settings. Under
normal operating conditions, there should be no reason to adjust these settings.
7.2.1 Verify the proper WLD Motor Controller voltage setting. (For 220 V use the
inside pin settings, 110 V use the outside pin settings.)
7.2.2 Verify all of the other jumpers for proper settings.
Jumper Set To
115 or 230
J1A & J1B
(See Step 1)
J2 1.7A
J3 A90
J4 10V
J5 SPD
J6 RTS


7.2.3 Verify WLD Motor Controller pot settings.
7.3 DC MOTOR CALIBRATION
7.3.1 After power up, the MP1200 will always prompt the user to send the WLD (no matter
where it currently is) to its HOME position. This allows the WLD to find the upper
sensor (proximity switch) which it uses for reference. One the home position is
located, the WLD will run up and turn out of the way and come to rest at its READY
position.
7.3.2 Verify the following values (change as required) and press ENTER to continue:
DAC = 32767 (cts for 0 V dc output) Upper Tvl = approximately 24 mm

Full Speed = 100% . Lower Tvl = approximately 212 mm
Slow Speed = 40%........................................Height Scale Factor = 1814.173 cts/mm
Minimum Output = 06%.................................Height Offset = approximately 205 mm
Accel/Decel = 300 counts
7.3.3 Upper Travel - The Upper Travel setting determines how far the weight platform
rotates. The Slow Speed setting is used for the upper swing-away region of the
travel.
7.3.4 Lower Travel – The Lower Travel setting determines how far below the proximity
switch the WLD can run. Do not set this too high or the WLD will go too far and
bottom out. If the value is too small it may not run far enough. The Fast speed
setting is used here.
7.3.5 The Height Offset relates the WLD height display to the actual position of the
platform relative to the top of the die. When the WLD is all the way down, the WLD
display reading is the Lower Travel value subtracted from the Height Offset. So
using the default values above, when the WLD is all the way down the WLD height
display will be 205-212 mm=-7 mm. The Height Offset may be tweaked as needed to
make the WLD display reading as close to the PPDT reading as possible.
7.3.6 Min speed is the smallest value to make the motor run without stalling.
7.3.7 The MP1200M has an Accel/Decel value in terms of counts to quickly ramp up/down
the speed but prevent instant full speed starting. This may mean a very small
overshoot when stopping.


7.4 Zeroing the Encoder on the WLD (Synchronize with PPDT)
7.4.1 Place a clean die in the bore, then place a clean piston it the bore.
7.4.2 From the MP1200 control panel, go to the TEST MODE and then go to the
NAVIGATION mode. Use the Jog Down button to lower the weight until it is
on the piston and the weight support plate is clear of the weight. You should
be able to read the Piston Height and the WLD Height. If you see #### for
Piston Height, gently cycle the PPDT arm down and then gently return it to it
uppermost position. Numbers should now be displayed.
7.4.3 Press the Navigation key, then go into the CONFIGURATION mode. Enter
the Access Code 835.
7.4.4 Press Calibrate on the upper menu line, then Calibrate PPDT, then Short
Calibration. Press Set Zero Offset to zero the Piston Height.
7.4.5 Press Exit.
7.4.6 Press Test Mode to return to the screen where the Piston Height and WLD
are displayed.
7.4.7 Press Navigation, then use the Jug Up key to bring the weight support plate to
the point where it just contacts the weight. The piston Height should still be
zero, or at least very close to zero. Note the WLD height reading.
7.4.8 Press Navigation, then Configuration. Enter the Access code again (835).
Press Calibrate, then Calibrate WLD. Press Height Offset and adjust the value
shown by the reciprocal of the recorded value noted in the previous step.
7.4.9 Press Done, then Test Mode. Save the changes. Piston Height and WLD
Height should be zeroed.


8 Section 8 – Printer (Optional)
8.1 Certain USB printers may be attached to the MP1200. Tinius Olsen does not sell printers at
this time.
8.2 The following printers have been checked for proper operation with the MP1200
HP OfficeJet 6000 (Model E609A)

HP OfficeJet 6500A


9 Section 9 – Manual & Automatic Extrudate Cut-Off Tools
Tinius Olsen now offers manual and automatic extrudate

cutters options to further automate the testing process. Both
the manually operated (hand cranked) and the automatic
(motorized) Cut-Off tool options are designed to use a
precision motion to make a clean cut of the extrudate as it
flows from the orifice of the die during a melt flow
determination. The automatic cutter may be operated from
the LCD touch screen, either manually or its operation can be
preprogrammed into a testing routine. However, the cutters
may not be suitable for use with all materials. Materials that
are sticky in nature may not be suitable for use with these
options.
To work properly, the cutters must be centered on the initial

set up. The idea is to center the tool trajectory at its peak at
the orifice center as shown above. To do this, follow the
steps below. The initial set up should be done with no plastic
n the furnace, but to check performance, a live charge should
be used. Figure 9-1A – Manual Cut-Off
9.1 Tools Required:

1. Allen wrench set (imperial, i.e not metric)
1.1 Ph
oto
Figure 9-1B – Automatic Cut-Off #1


9.2 Installation Instructions
9.2.1 Mount the Extrudate Cut-Off Tool to the base of the MP1200 furnace using
the mounting screws and hardware as shown in Figure 9-2.
Figure 9-2
9.2.2 Center the blade as shown in Figure 9-3. Loosening the locking screws about
1/8 turn to allows the Cut-Off Tool to slide on its base. For fine adjustments,
use the side adjustment screw to move the Cut-Off Tool to the left or right to
center to tool tip at its peak on the orifice bore. The adjustment screw is
spring loaded so it will follow the set screw in or out. Center the blade from
the front to back as well side to side before tightening the screws.
Figure 9-3


Figure 9-4
9.2.3 The blade position may need to be adjusted after the initial mounting. To do
this, refer to Figure 9-4. Adjust the height of the blade at its peak position by
loosening the blade mount screws. Adjust its height so that it scrapes the
bottom of the die. A properly positioned blade will actually cause the die to
“pop up” slightly in the cylinder.
9.2.4 Verify with a live charge that the tool is performing satisfactory. Adjust as
necessary.
9.3 Operation
Note: Operation of the manual version is accomplished by simply rotating the handle in
the direction of the arrow. The instructions below apply to the automatic version.
9.3.1 From The Main screen, press the CONFIGURATION key and enter the
access code 835.
9.3.2 Verify that the Cut setting is in the ON position. Press Save.
9.3.3 Press the Program key and enter the code 852 and press Done.
9.3.4 Select the program that you wish to use, then press Edit Selected Program.
Press Continue. Verify that the Enable Auto Cut Setting is set to On. Finish
the programming sequence and Save as necessary.
At this point, the cutter will automatically operate a full cutting motion when the Start key is
pressed during a Manual Cut test and at the end of each programmed capture period. For an
Automatically Timed Flow Rate test, the cutter will automatically activate at the start of the 1st
capture and at the end of each subsequent capture.


10 Section 10 – Setup & Operation of the Pneumatic Purge / Purge &
Cleaning Attachment on a Model MP1200 Melt Indexer w/WLD
The Pneumatic Purge and the Purge/Cleaning Attachment were designed to be used with a
MP1200M Melt Indexer equipped with the Motorized Weight Lowering Device (MWD). The Purge
Cylinder will allow the test charge to be purged to a predetermined starting point prior to a test
and/or to purge the remaining material after the test. The Cleaning Cylinder can be used (after
raising the WLD to its top position) with the Piston Extractor Assembly to remove the piston rod
assembly after a test and with the extended cleaning tool to help to operator clean the bore. Both
features may be operated manually from the LCD touch screen or programmed for semi-automatic
operation when using Tinius Olsen’s Horizon software MI package.
The PPC attachment and mounting hardware/accessories will be packed separately in the shipping
container. The PPC attachment, air regulator w/bracket and exhaust muffler are removed from the
MP1200 for shipment and must be re-installed at set-up. Refer to Drawing 5-6-819 for the Purge
Only system and 5-6-820 for the Purge & Clean system. The air hoses are also marked and
disconnected from the cylinders. Contact Tinius Olsen if you have any questions or problems
during setup.
10.1 Tools Required:
10.1.1 A 1/4” Hex Wrench is needed

for attaching the PPC
attachment to the top of the
weight support plate of the
WLD-600 using the two 5/16 –
18 x 1-1/4” long socket head
cap screws (Item 37 of 5-6-819;
Item 26 on 5-6-820).
10.1.2 A screwdriver is needed for

attaching the Regulator Bracket
to the back of the MP1200.
10.1.3 An adjustable wrench is

needed for mounting the
Exhaust Muffler to the back of
the MP1200.
10.1.4 A 3/8” Hex Wrench is needed

for adjusting the height or angle
of the pneumatic cylinder
mounting brackets.


10.2 Pneumatic Purge/Purge & Clean Attachment Parts List:
10.2.1 The attachment with the pneumatic cylinder(s) already mounted.
10.2.2 The air regulator with mounting bracket.
10.2.3 The exhaust filter muffler.
10.2.4 The extended cleaning rod assembly (disassembled for shipping) if the
cleaning option is ordered.
10.2.5 The piston extractor tool assembly.
10.3 Initial Setup Procedures:
10.3.1 Unpack and setup the MP1200 Melt Indexer and its accessories following the
standard instructions.
10.3.2 Locate the exhaust filter muffler (Item 17 on 5-6-819; 10 on 5-6-820) and
attach to the bulkhead fitting (Item 28 on 5-6-819; 20 on 5-6-820) on the rear
of the lower pan cover using an adjustable wrench. (Refer to Photo #2)
10.3.3 Locate the regulator bracket (Item 16 on 5-6-819; 9 on 5-6-820); remove the
two screws and washers, which were left attached to the lower pan cover.
Mount the bracket to the lower pan cover using a screwdriver. (Refer to Photo
#2)
10.3.4 Locate and mount the regulator assembly on the bracket by the removable
knurled ring on the regulator assembly. (Refer to Photo #2)
Photo #2
10.3.5 Connect the single short air hose to the output side of the regulator by simply
pushing the hose into the quick connect fitting as shown in Photo #2. The
input side (1/4” NPT) of the regulator is left empty and the customer must
attach the appropriate fitting to connect to their clean, dry air supply of at least
50 psi. Do not connect the air supply at this time


10.3.6 Insert an orifice and the piston rod assembly
in the bore, and then move the WLD down
to its lowest position if not already there.
10.3.7 Locate the PPC Attachment with the

pneumatic cylinder(s) already mounted.
The attachment is mounted on top of the
WLD weight support platform. Remove the
two socket head cap mounting screws and
position the attachment as shown in Photo
#1 and replace the screws.
10.3.8 Route the four long hoses to the

appropriate flow control valves on the air
cylinders through the cable clamps
mounted on the cylinder mounting
brackets. (Refer to Photo #3) These hoses
and valves will be match-marked (1 to 4). Photo # 3
The #1 hose should go to the top and the
#3 hose to the bottom of the purge
cylinder, and the #2 hose to the top and the #4 hose to the bottom of the
cleaning cylinder, if present. To connect simply press the hose end into the
quick-connect on each flow valve. To remove, press in the hose and then pull
out.
10.3.9 Using the top of the piston rod assembly as a reference, align the platform so
that the piston is centered in the platform opening. Check the platform
alignment by placing a weight on the piston rod, then running the WLD fully
up and then fully down. The weight should cleanly engage the end of the
piston rod assembly when fully lowered. If not, readjust the platform.
10.3.10 At this point, the main air supply (50 psi minimum) should be connected to the
open end of the regulator. The suggested air pressure setting is 20 psi (140
kPa) and this setting will apply approximately 60 lbs. (27 kgs.) of force to the
purge and cleaning cylinders. DO NOT EXCEED 30 PSI (200 kPa) ON THE
REGULATOR.
10.3.11 Check the operation of the Purge Cylinder as follows:
Power up the MP1200. If the air supply is properly connected, the cylinder(s)
should be retracted at this time if all the hoses were connected correctly.
Follow the on-screen instructions for positioning the WLD in the “HOME”
position. (NOTE: Pressing CANCEL will disable the WLD.) Press the
NAVIGATION key followed by the CONFIGURATION key. Then enter “835”
and press DONE to enter the Machine Settings mode. Verify that the Purge
(and Clean if ordered) settings are set to ON (light green highlighted). Press
the DONE key followed by the NAVIGATION key when finished.


Run the WLD fully down and remove the weight and piston rod assembly if
they are in place. Press the ACCESSORIES key and the PURGE key. The
purge cylinder should extend fully down to within 1 inch (25.4 mm) of the top
of the WLD weight support plate on center. If the purge tool contacts the
platform, the purge cylinder-mounting bracket will need to be loosened and
adjusted up so that it is flush with the top of the lift tube. If the purge tool is
not centered on the platform, loosen the purge cylinder-mounting bracket and
rotate until it is centered. Press the PURGE key again to retract the purge
cylinder.
Note: If the extension speed is too slow or too fast, the bottom flow control valve has
a screw adjustment that can used to change the speed. If the retraction speed is too
slow or too fast, the top flow control valve has a screw adjustment that can used to
change the speed.
10.3.12Check the operation of the Cleaning Cylinder (if present) as follows:
Power up the MP1200. If the air supply is properly connected, both cylinders
should be retracted at this time if all the hoses were connected correctly.
Follow the on-screen instructions for positioning the WLD in the “HOME”
position. (NOTE: Pressing CANCEL will disable the WLD.) Press the
NAVIGATION key followed by the CONFIGURATION key. Then enter “835”
and press DONE to enter the Machine Settings mode. Verify that the Purge
and Clean settings are set to ON (light green highlighted). Press the DONE
key followed by the NAVIGATION key when finished.
Run the WLD fully up and remove the weight and piston rod assembly if they
are in place. Note that the tool end of the cleaning cylinder is free to rotate,
and should be facing squarely toward the front. Insert the ridged tip of the
extended cleaning tool assembly into the top of the bore, and then slide the
handle into the center of the cleaning cylinder tip as shown in drawing 5-6-
563-1. If the ridged tip of the extended cleaning tool does extend below the
top of the bore as shown in drawing 5-6-563-1, the cleaning cylinder
mounting bracket will need to be loosen and adjusted. If the tool end of the
cleaning cylinder is not centered in respect to the bore, loosen the purge
cylinder-mounting bracket and rotate until it is centered.
Press the ACCESSORIES key and the CLEAN key and the cleaning cylinder
should fully extend down and stop. Press the CLEAN key again and the
cleaning cylinder should fully retract.
Note: If the extension speed is too slow or too fast, the bottom flow control
valve has a screw adjustment that can used to change the speed. If the
retraction speed is too slow or too fast, the top flow control valve has a screw
adjustment that can used to change the speed.


10.4 Operation:
The Pneumatic Purge/Cleaning Attachment can be used manually or automatically through
the optional Software Package.
10.4.1 Manual Operation:
The purge feature can be used prior to a test to purge the test charge to a predetermined
starting point. The operator will charge the material into the bore and start the test, lowering
the WLD platform to a predetermined height (set by manually programming the MP1200
controller in the PROGRAM mode). The purge feature is then manually operated by
pressing the ACCESSORIES key and then by pressing the PURGE key. When the PURGE
key is pressed, the key will remain highlighted, and the ram will lower until it is stopped by
the weight contacting the WLD platform. This purges any excess material before a test. At
the end of the programmed Release Time period,
the WLD platform fully lowers and the test will
continue normally until its conclusion. At the end
of the test, the purge feature can be used again to
purge the remaining material from the bore.
The cleaning feature can be used after a test to

assist in cleaning the bore. After the WLD platform
is raised to its top position, the operator can use the
Piston Extractor Tool to remove the piston rod from
the bore by pressing the ACCESSORIES key and
then the CLEAN key to extend the cleaning cylinder
down. Slide the open end of the extractor tool
under the shoulder of the piston rod and insert the
extractor tool handle into the cleaning cylinder end
(as shown in Photo #4). Press the CLEAN key
again to retract the cleaning cylinder, pulling the
piston rod out of the bore. Remove the piston rod
and extractor tool. The operator can then use the
cleaning feature to assist in cleaning the bore of the
barrel. Place a patch in the center of the bore.
Position the extended cleaning tool by placing the
knurled tip into the top of the bore with the patch,
then inserting the handle into the cleaning cylinder
end and pressing the CLEAN key once to go down
and again the retract. Always be sure that the tip of
the cleaning tool in engaged in the end of the bore
before pressing the CLEAN key to go down. This
can be repeated with the same patch or a new
patch until the bore is clean. Sometime it helps to
rotate the extended cleaning tool by hand during up
and/or down stroke.
Photo # 4
Tinius Olsen MP1200 Extrusion Plastometer PhotoPh

1.2 #Page 10-5
Operation Manual # 02002215 4 oto
#4
10.4.2 Software Operation
Go to the Machine Tab for the desired MP1200, then click on Method Editor, then Control
Options.
Check the box next to Pneumatic Purge and Cleaning Device.
Check the box next to Pre-Test Purge and enter the desired time period for the Pre-Test
Purge Delay, if desired. If activated, the Pre-Test Purge will activate automatically ten (10)
seconds after the WLD device has reached the programmed pre-test height and remain
activated until approximately seven (7) seconds are left in the programmed Release Time.
Enter a time for Post Test Purge Operation, if desired. The duration of the post-test purge
can be changed depending on the flow rate of the material. Typically, smaller times are used
for high flow rates and larger times for lower flow rate materials.
Check the box next to Post-Test Piston Retraction, if desired. If this box is checked, the
software will automatically return the WLD Platform up to its top position after the test and
extend the cleaning cylinder down for the Piston Extraction if enabled. The operator then
slides the open end of the extractor tool under the shoulder of the piston rod and inserts the
extractor tool handle into the cleaning cylinder end. Pressing the CLEAN key will retract the
cleaning cylinder, pulling the piston rod out of the bore. Then the operator would remove the
piston rod assembly and extractor tool.
Check the box next to Clean, if auto operation of the cleaning function is desired. Enter the
desired number of strokes and the stroke time. The number of strokes entry will determine
how many up & down cycles will be done, and the stroke time is the amount of time spent at
the bottom of the stroke between the extension and retraction actions.
Click on Save, the return to the Test & Recall tab.
Note: BEFORE using the Cleaning Feature, the WLD MUST be at its top position and
the end of the extended cleaning tool engaged in the barrel.


10.5 Operational Notes:
10.5.1 The air supply must be clean and dry. If not, add the appropriate filters and/or
traps before the air regulator. The 20 psi (140 kPa) should work well and this
setting will apply approximately 60 pounds (27 kgs.) of force to the purge and
cleaning cylinders. DO NOT EXCEED 30 PSI (200 kPa) ON THE
REGULATOR.
10.5.2 Always be sure that the handle is properly inserted and centered in the
Cleaning Cylinder end fixture before activating the ram.
10.5.3 The WLD Platform MUST BE AT ITS TOP POSITION before using the
Cleaning/ Extraction Feature. This sets the proper height and alignment in
relation to the barrel. Operating it from any other position could
damage/break the extended cleaning tool or crash it into any tools in the back
end of the tooling rack mounted on the right side of the furnace.
10.5.4 Always be sure that the ridged end of the extended cleaning tool (with the
patch) is engaged in the top of the barrel before activating the ram.
10.5.5 Special weights must be provided for Flow Rate Ratio testing, the two top
weights will have a 1-1/4” center hole for the purge tool to get to the bottom
weight for the Post-Test Purge. The top weight will be 300 grams less than
standard with a small 300 gram plug weight to fit into the center hole on the
top weight for the Pre-Test Purge and the proper weight application. If the
standard Flow Rate Ratio weights (without center holes) are used the purge
option cannot be used in Flow Rate Ratio testing.


11 Section 11 – Configuration Mode
CAUTION: Machines are shipped with factory settings already entered in the
Configuration Mode. DO NOT CHANGE ANY OF THESE SETTINGS WITHOUT A GOOD
UNDERSTANDING OF THE EFFECT THE CHANGE WILL HAVE ON THE TEMPERATURE
CONTROL CAPABILITY OF THE MP1200.
To begin, use a finger to press the CONFIGURATION button on the left side of the LCD display,
then enter the Program Access Code which is 835, then DONE.
11.1 Machine Settings
11.1.1 Machine Name – Press the box next to Machine Name to bring up a keypad. Use to
keypad to enter a machine name or number (up to 17 characters), if desired. Press
the DONE key when finished.
11.1.2 Max Temperature – Press the box next to Max Temperature to bring up a keypad.
Use the keypad to enter the maximum temperature the machine will achieve. The
upper temperature limit of the MP1200 is 450oC. Press the DONE key when
finished.
11.1.3 PPDT On/Off - If the machine is equipped with a PPDT, press the ON button.
11.1.4 WLD On/Off – If the machine is a MP1200M, press the ON button.
11.1.5 Purge On/Off – If the MP1200M is equipped with a pneumatic purge attachment and
it is to be used, press the ON button.
11.1.6 Clean On/Off - If the MP1200M is equipped with a pneumatic cleaning- attachment
and it is to be used, press the ON button.
11.1.7 Cut On/Off- If the MP1200 is equipped with an automatic cutter attachment and it
is to be used, press the ON button.
Figure 9-1 Machine Settings Screen


11.2 PID Controls
NOTE: The default PID values entered at the factory should suffice for most users. However,
further tuning of the PID parameters may be necessary for any given machine in order to
obtain optimum performance for any particular set of test conditions/requirements. The user
should consult a good engineering controls text or web site to become familiar with the
concept of PID parameters and tuning before making adjustments. More detailed information
is found in Section 19 of this manual.
It is well beyond the scope of these instructions to explain PID controls and tuning in detail
except for where modifications to the classic PID algorithm have been made (see recovery
phase below). Fortunately, there are numerous controls texts and websites that do a good
job of explaining these concepts and even an experienced controls person should review this
material before undertaking tuning the PID values.
11.2.1 After entering the Configuration mode, press the PID button at the top of the screen.
The main PID Controls screen will show buttons that will access the 3 temperature
zones. Each zone will have a live P, I, and D term (i.e. the mathematical output
resulting from the current Set Point temperature, current actual temperature, and the
PID gains for that zone) and the actual temperature reading (shown to the nearest
0.01oC).
Figure 9-2 PID Setting Screen (Values shown are not actual settings)


11.2.2 To view/set the gains, select the Top, Middle, or Bottom button.
11.2.3 The P, I, and D gains are shown on the left side of the screen and can be individually
selected and changed as desired. See Table 9-1 for default PID gains for each
zone. In very basic terms, for each zone, the controller compares the desired
temperature (Set Point) with the actual temperature (RTD probe). The difference is
acted upon by the three gains:
Figure 9-3 – Sample PID Configuration Page (Not actual numbers)
Proportional (P) gain is simply a multiplier. The difference signal is multiplied by this
P gain value and that is the Proportional term.
Integrator (I) looks at the history of the error (the integral or area under the curve)
over time. The Integrator term accumulates to a bigger and bigger value the longer
the actual temperature is below the Set Point. It decreases the longer the actual
temperature is above the Set Point. A large I gain will increase the I term faster but
may also result in oscillations as it builds quickly between too big and too small. It
should be kept fairly small – just enough to boost the output up to the SP temp.
Differential (D) looks at the rate of change of the signal. If the temp is changing
quickly the D will have a higher output than when it is changing slowly. The D term
actually works to slow a heater that is heating quickly in order to prevent overshoot.
Likewise, it will pump a lot of heat into a furnace that is dropping quickly in
temperature to prevent it from getting too cold. The higher the D gain the greater this
effect. But be careful because a D gain that is too high can make the system “noisy”
by magnifying any little fluctuation in temperature.
11.2.4 The controller constantly calculates these three terms and combines them to
calculate the output at each instant (P + I – D). That value is then used to regulate
the power to the heaters by rapidly switching the heater zones on/off. A higher output
value will keep the heaters on longer than a lower output value. The heaters will be
full on when the output is 100%, and full off when 0%.


11.2.5 Default values are shown in Table 9-1. The user may tune the furnace further if
desired, but he should have a background in PID controls before attempting this.
There are several tuning methods (e.g. Ziegler-Nichols) which can be employed to
help find desirable PID gains.
11.2.6 The Integrator lock trigger, PID modifiers, and Integrator Lock and Anti-Lock times
are shown on the right side of the screen. These values are used during the
recovery phase. The recovery phase is when a significant disturbance is introduced,
such as dropping a cold piston rod into the barrel or charging the barrel with a
sample. This phenomenon can be reproduced for experimentation by using an
aluminum slug.
11.2.7 Target Parameters
Target Parameters determine the conditions the controller uses to determine if it is

stable and “ready” (indicated by green temperature display on Main screen).
The Target Parameters button (on PID screen) sets the range for the Top, Middle,
and Bottom zones and the time period. When the temp for each zone is within this
range (+ or -) of the SP temp for the specified time period, the controller is
considered stable. It then discontinues the recovery mode and resumes the normal
PID control (normal gains, Integrator unlocked). Also, the temperature display on
the screen will be green to indicate go ahead with the testing. If any temperature is
outside of this range the machine is considered not yet stable and the temperature
display will be red. Note: You can still proceed with the next test in this mode, it’s
simply a warning. It may also be that the Target parameters are overly conservative,
especially if the material is not all that temperature sensitive. See Table 9-2.
Top Middle Bottom

Prop. Gain 25 50 25
Int. Gain 0.05 0.05 0.025
Der. Gain 120 660 330
Int. Trigger 0.05 0.05 0.05

Prop Mod. Falling 100 1000 350
Der. Mod. Falling 100 1000 125
Prop. Mod. Rising 100 1000 1000
Der. Mod. Rising 100 1000 1000
Lock Time 180 180 180

Anti-Lock Time 30 30 30
Table 9-1 – Default Factory PID Settings
Top 1 oC
Middle 1 oC
Bottom 0.2 oC
Period 30 s


Table 9-2 – Default Target Parameters
11.3 Calibrate
11.3.1 Calibrate RTD
RTD Calibration is accessed by selecting CONFIGURATION (passcode 8 3 5), then

CALIBRATE, then CALIBRATE RTD.
Choice of Factory Calibration or Service Calibration. Factory Calibration IS NOT TO BE

USED except by qualified in-house technicians with the proper calibration equipment and
procedures. It is password protected to prevent access.
Service Calibration will be necessary for a new calibration or if changes have been made to
the machine, such as a new RTD installed.
The Service Calibration consists of a screen showing three Set Point temperatures of 190,
230, and 300 oC and three temperatures (three zones) for each.
Figure 11-4 Service RTD Calibration screen (Not actual values)
The technician uses a reference thermometer (or preferably, a RTD with digital readout such
as the TO410) to measure the temperature at each zone for each temperature and enter it in
the appropriate field.
Begin by selecting 190oC (press where it displays the 190oC Set Point). A dot to the left
indicates this SP temp has been selected.
When the machine stabilizes, begin entering the reference thermometer’s (or RTD probe)
measurements into the 3 fields for 190. It is recommended that you begin at the Bottom (10
mm above the top of the die), then proceed to the Middle (45 mm above the top of the die),
then finally the Top (75 mm above the Top of the die).
Allow adequate time for the readings to stabilize between each movement of the reference

thermometer. (10-15 min recommended).
You can take all three measurements and then enter them at one time, or take a reading and
enter it, then move on the next zone. Expect to have to do each zone several times. Hint:
For the first several attempts don’t enter the exact thermometer reading. Calculate about
half the difference between that reading and the Set Point and enter that. For example, at
190oC if the thermometer reads 192.0oC enter 191.0oC. This may help save time.
Otherwise the controller may overcompensate and you have to bounce back and forth until
you home in on it.
After you make an adjustment to any zone, go back and recheck the other zones. When you
move the reference thermometer down in the barrel allow extra time to stabilize.
When the 190oC check is complete, move on to 230oC, and then to 300oC. It will take about
half an hour to an hour to reach a new temperature and stabilize.
When finished, it will be necessary to enter the calibration Offsets. This is found under the
User Settings (pass-code 8 3 4), Cal Offsets. See Section 12 for more information.
11.3.1 Calibrate PPDT
PPDT Calibration is accessed by selecting CONFIGURATION (pass-code 8 3 5), then

CALIBRATE, then CALIBRATE PPDT. It will only be active if the PPDT selection on the
Machine Settings screen is set to ON.
Select the PPDT TYPE. In most cases it will be ENCODER WITH INDEX PULSE.
Confirm that the ENC. LINES is set to 25000.
Full Calibration – Full Calibration is used to set the index pulse of the encoder inside of the
PPDT. To perform a Full Calibration, press the Full Calibration key and follow the
instructions prompted on the screens.
Short Calibration – Short Calibration is used to enter the arm length (after repair or
replacement) and to zero the PPDT. Press the Short Calibration key. This will display the
Final Calibration Step screen.


Figure 11-5 - Final Calibration Step screen (Not actual values)
Piston Height – Displays the current position of the “point” of the PPDT arm. To zero
the PPDT, place a clean die (orifice) in the bore, and then place a clean piston in the
bore. Place a weight on the piston rod, and then position the PPDT arm so that the
arm is under the weight. Press the Set Zero Offset button to zero the PPDT.
Arm Length – The Arm Length of the PPDT is determined during calibration and
should not change under normal conditions. The arm length is determined at the
factory and entered into each machine prior to shipment. It is also recorded on the
calibration work sheet supplied with each new instrument. For repaired PPDT or
PPDT supplied for instruments in the field, the arm length is written on a tag attached
to the PPDT when sent from the factory.
11.3.2 Calibrate WLD
WLD Calibration is accessed by selecting CONFIGURATION (passcode 835), then

CALIBRATE, then CALIBRATE WLD. It will only be active if the WLD selection on the
Machine Settings screen is set to ON.


11.4 Diagnostic
There are no user serviceable/adjustable features in the diagnostics mode.


12 Section 12 – User Settings
On the General Settings screen, the operator can select the optional printer, turn alarms on
and off, adjust the volume of alarms, select units, adjust the brightness of the screen and
adjust the Calibration Offsets. The operator can also send logs to a USB thumb-drive and
set the date and time.
To begin, use a finger to press the USER SETTINGS button on the left side of the Main
Screen, then enter the Program Access Code which is 8 3 4, in succession, then DONE.
12.1 General Settings - To access, press the GENERAL SETTINGS button at the top
of the screen.
12.1.1 Language – Press the box next to LANGUAGE and select the desired language.
12.1.2 Printer Selection – Press the box next to PRINTER and select the printer that is
connected to the MP1200, if any.
12.1.3 Alarms – Turn the alarms ON or OFF as desired.
12.1.4 Position (Units of Measure) – Select the desired units of measure, millimeters (MM)
or inches (IN).
12.1.5 Volume – Use the slider to adjust the volume of the alarms.
12.1.6 Brightness – Use the slider to adjust the brightness of the display.


12.2 Calibration Offsets
The “Calibration Offsets” are a correction factor for the small difference in temperature
between the Actual Temperature displayed on the MP1200 Controller and a NIST (National
Institute of Standards and Technology) traceable temperature measuring device placed in
the test area of the cylinder. In other words, the “Calibration Offset” value entered adjusts
the displayed temperature to agree with the temperature standard in the cylinder.
Because of the wide range of temperatures that the MP1200 Controller may be used, it may
be necessary to enter Calibration Offsets for each test temperature (set temperature).
The actual cylinder temperature was determined at the factory using a NIST traceable RTD
probes placed 10, 45 & 75 mm above the upper face of the standard 8 mm (0.315”) long
orifice. The digital electronic temperature display is also NIST traceable. This procedure is
described in the current version of ASTM D 1238. For ISO 1133 machines, the machine is
calibrated to ISO 1133-2.
For new machines, a MP1200 Configuration/Calibration Settings Worksheet will be

provided showing the Actual Cylinder Temperature, the Machine Displayed temperature,
and the Calibration Offset settings at 190°C, 230°C and 300°C unless other temperatures
are requested.
If the desired test temperature is not on the MP1200 Configuration/Calibration Settings

Worksheet, enter the offset values for the closest calibrated temperature. The next time the
machine is due for calibration, be sure to tell your Tinius Olsen Field Service Manager the
set temperatures that are desired.
12.2.1 Press the CALIBRATION OFFSETS button at the top of the screen.
12.2.2 To add an offset value, press the ADD OFFSET button, then enter the desired test
temperature and the top, middle and bottom offsets (found on the MP1200
Configuration/Calibration Settings Worksheet). Press on the box below the heading
to activate the keypad.


12.2.3 The Cal Offsets screen (include screen shot) shows each desired SP Temp and the
adjustment added for each zone (Top , Middle, and Bottom) to make the displayed
temperature for each zone match the reference thermometer at that point.
12.2.4 The MP1200 normally only shows the temperature at the Bottom zone. However all
three zone readings can be seen on the PID tab found under Configuration (include
screen shot).
12.2.5 The Cal Offset is the value that must be added to the current display reading to make
it match the actual thermometer reading. For example, if the SP is 200 oC and the
Bottom zone is showing a stable reading of 200.0 oC but the thermometer (at the
Bottom zone, 10 mm above the top of the die) reads 199.5 oC, then the Cal Offset
should be -0.5 (add this to any existing offset that may currently exist). That will then
make the controller read 199.5 oC. That tells the controller it needs to add a little
more power to get back to 200 oC. When it does show 200.0 oC, it should match the
thermometer. It may take several attempts to get the Cal Offset correct. And a
change to one zone may affect the others so you will need to check them after
making any change.
12.2.6 If the zone reading, for example the Middle zone (shown on PID screen), reads 200.0
o
C, but the thermometer in the middle position (45 mm above the top of the die)
reads 200.4 oC. You would enter a Cal Offset of 0.4 for the middle zone. (Add this to
any existing offset that may exist).That would make the middle zone display read
200.4 oC. The controller would then know to reduce the power to the middle zone
until it drops to 200.0 oC, which should then match the thermometer. Again, it may
take several attempts to get the Cal Offset correct. And a change to one zone may
affect the others so you will need to check them after making any change.
12.2.7 Just about any number of SP temperatures can be entered in this table. Each
program in the MP1200 has a SP temperature entered. That will then reference the
appropriate Cal Offsets for that SP temp in the look up table. If that SP temp doesn’t
exist in the table the user will be prompted with a warning.
12.2.8 If the Service Calibration has been done properly, most Cal Offsets will be fairly
small. In no case can they exceed +/- 10 deg C. Cal Offsets for 190, 230, and 300
o
C should be close to 0 if the Service Cal was done properly.
To remove an offset, press the REMOVE OFFSET button.
12.3 Date/Time
12.3.1 Press the DATE/TIME button at the top of the screen.
12.3.2 Enter the date and time, if desired.
12.3.3 Press OK when finished.


13 Section 13 – Testing Polymers According to ASTM D 1238
“Procedure A” (Manual Cut-Off Operation)
CAUTION: Do not use a sharp object to press any of the buttons on the Model MP1200
Controller, as this might damage the LCD display.
CAUTION: Prior to shipment, the cylinder of the machine is coated with oil to prevent
rust from forming. When the machine is first turned on, it is normal for the machine to
“smoke” as the cylinder comes to temperature and the oil residue burns off. To reduce the
amount of smoke that forms, clean the cylinder thoroughly before turning the machine on.
Be sure that a ventilation system is operating at this time.
NOTE: The instructions in this Section are based on ASTM D 1238. This test method should
be thoroughly studied by all operators prior to using the MP1200. Copies of the standard are
available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 USA
Telephone: (610) 832-9721.
To perform tests to ASTM D 1238 Procedure A, only the basic machine is required, along
with the appropriate weight(s) for the polymer to be tested. If the machine is equipped with
a PPDT Automatic Timing Switch, simply rotate the switch in a counter-clockwise direction
until it is out of the way. A laboratory scale, (not supplied by Tinius Olsen), having a
resolution of 0.001 grams is also required.
13.1 Getting Started
13.1.1 The MP1200 is now ready for operation. Check nameplate to verify the
correct voltage is being used. Connect the MP1200 to a suitable power
supply (500 WATT MINIMUM) and turn on the power switch on the side of the
machine (near the power cord). Turn the machine ON using the switch on the
right side of the machine.
13.1.2 When first turned on, the machine will display the Tinius Olsen logo while it is
booting up.
13.2 Creating a New Procedure A Program
13.2.1 To begin, use a finger to press the PROGRAM button on the left side of the
LCD display


13.2.2 Enter the Program Access Code which is 8 5 2, in succession, then DONE.
13.2.3 Press the Create New Program button
13.2.4 For a Procedure A program, press Manual cut on the display.
13.2.5 Select the units, either millimeter or inches.
13.2.6 Press the Set Temperature box. A keypad is shown next. Enter the desired
test temperature. Press the DONE button when finished.
TEST TIP: If the operator is unfamiliar with melt index testing procedures and machine
operations, it might be beneficial to turn off the heaters at this point. Enter a temperature
near or below the ambient temperature (or enter 0°) and then press the DONE button. A
0° setting should also be entered when the Calibration Offset screens are displayed.
13.2.7 Press the Test Load box. Again, a keypad is shown next. Enter the desired
test load in kilograms. Press the DONE button when finished.


13.2.8 Press the Orifice Diameter box. Again, a keypad is shown next. Enter the
desired orifice diameter. The nominal orifice diameter for ASTM D 1238 is
2.095 mm (0.0825 in.). Enter the numeric value of the orifice diameter to
have Shear Stress calculated. Press the DONE button when finished.
13.2.9 Press the Orifice Length box. Again, a keypad is shown next. Enter the
desired orifice diameter. The nominal orifice length for ASTM D 1238 is 8.00
mm (0.315 in.). Press the DONE button when finished.
13.2.10Press the Preheat box. Again, a keypad is shown next. Enter the desired
preheat period. Press the DONE button when finished.
13.2.11Press the CONTINUE button to go to the next screen.
13.2.12Enter the desired number of cuts. Up to 10 cuts are allowed. Technically, the
first cut is considered to be the ASTM result, while ISO 1133 requires multiple
cuts. Press the DONE button when finished.
13.2.13Enter the Cut off Interval. The cut off interval is the number of seconds the
test will run. Cut off intervals will vary according to the expected melt flow rate
of the material. ASTM D1238 suggest that fractional melt material (under 1
gram/10 minutes) should have a cut off interval of 6 min; materials that have
flow rates >1.0 to 3.5 g/10 minutes should have a cut off interval of 3 min;
materials that have flow rates >3.5 to 10 g/10 minutes should have a cut off
interval of 1 min; materials that have flow rates >10 to 25 g/10 minutes should
have a cut off interval of 30 seconds; materials that have flow rates >25 g/10
minutes should have a cut off interval of 15 seconds.
These are estimates. To determine the cut time needed, set it for 60 seconds and
run a test, making sure the preheat interval is met, to get an idea of the flow rate. If
no material is left, set the cut time to a lower setting. If the material has a low flow
rate, set the cut off interval to a higher setting using the above paragraph as a guide.
In all tests, make sure the preheat time (420 +/- 30 seconds) is observed and then
start making cut(s) after the lower scribe line on the piston disappears.


13.2.14If the MP1200 is equipped with the Auto-Cutter option, you can turn it on or off
on this screen. Press the CONTINUE button.
13.2.15The next screen that appears allows the operator to select the Standard
Identifiers used to identify the specimens. Use of the Standard Identifiers is
optional.
13.2.16If desired, press the box next to Sample ID. This will allow the operator to
enter the sample ID, in alphanumeric format, prior to the test. A check mark
will appear in the box to confirm the selection. This is used only for
identification purposes on a printed test report.
13.2.17If desired, press the box next to Run Number. This will allow the operator to
enter the run number, in alphanumeric format, prior to the test. A check mark
13.2.18If desired, press the box next to Operator. This will allow the operator to enter
the name of the operator that is conducting the test, in alphanumeric format,
prior to the test. A check mark will appear in the box to confirm the selection.
13.2.19If desired, press the box next to Procedure. This will allow the operator to
enter the procedure, prior to the test (in this case, it would be Procedure A). A
check mark will appear in the box to confirm the selection.
13.2.20If desired, press the box next to Test Method. This will allow the operator to
enter the test method, prior to the test. A check mark will appear in the box to
confirm the selection.
13.2.21Comments (Pre-Test) - If desired, press the box next to Comments (Pre-

Test). This will allow the operator to enter comments, prior to the test. A


13.2.22Comments (Post-Test) - If desired, press the box next to Comments (Post-
Test). This will allow the operator to enter comments after the test. A check
mark will appear in the box to confirm the selection.
13.2.23Enable Custom Identifiers – If the factory programmed identifiers are not

sufficient, custom identifiers may be created and selected here. To create the
custom Identifiers, return to the Program mode, Select Edit Custom
Identifiers, then Add Identifier. When the blank box appears, tap on it which
will cause a keyboard to appear. Type in the desired identifier, then press the
Done key. Press Save. Resume programming.
13.2.24 Custom ID’s - If desired, press the box next to Enable Custom Identifiers. This will
allow the operator to enter custom identifiers, prior to the test. A check mark will
appear in the box to confirm the selection.
13.2.26The next screen allows the operator to select the results that will be displayed
at the end of the test. Press on the box next to the desired result. A check
mark will appear in the box indicating the selection is confirmed. The operator
may also activate alarms in the same manner. Press Exit when finished.
13.2.27 The next screen will allow the operator to Save changes.
13.2.28Cancel - Press Cancel to return to the Program mode.
13.2.29Don’t Save – Press Don’t Save to return to the Select Program screen.
13.2.30Save As – Press Save As to save a new program. Use the keyboard that
appears to enter the desired program name.
13.2.31Save – Overwrites existing file


13.3 Test Procedure
13.3.1 Thoroughly clean the inside of the cylinder and orifice (see Section 16 for
Cleaning Instructions), then drop the orifice into the cylinder. The orifice
should fall freely to the bottom of the cylinder with an audible click. If not,
remove the orifice and visually inspect the orifice and cylinder for any defects
or obstructions. Clean the cylinder and orifice again if necessary. It is
imperative that the cylinder has a mirror finish and that no residue remains on
the outside or the inside diameter of the orifice.
13.3.2 Check that the piston rod assembly is clean and that the guide collar slides
freely along the piston rod. Clean as needed and insert the piston into the
cylinder. Allow it to remain there at least 15 minutes.
13.3.3 Once the machine has stabilized at the set temperature (+/- 0.2°C), remove
the preheated piston and place it in the tool rack. Verify that the orifice is at
the bottom of the cylinder.
13.3.4 From the main screen, press the Start Test button.
13.3.5 If Sample Identifiers are used, the next screen (Pre Test) allows you to enter
the data. Also, if the operator elected to enter Pre-Test Comments, a box will
appear that allows the operator to put them in the test results. Press
Continue, when finished, to move to the next screen.
13.3.6 The display will prompt the user to Charge Cylinder Now while indicating the
Elapsed Time. Charge the cylinder with the material that is to be tested.
Refer to ASTM D 1238, Table 1 (Table 2 in earlier versions) for suggestions
on the amount of polymer to use for a test. To charge the cylinder, insert the
funnel into the cylinder, and then slowly pour the material into the funnel. Do


not dump it in all at once as it will melt and stick to the funnel. Press Continue
when finished.
13.3.7 NOTE: The ASTM D 1238 Method allows one minute to charge the cylinder,
insert the piston, and start the preheat time of test.
CAUTION: The funnel, when placed in the cylinder, can become extremely hot when
the machine is at operating temperature! The time that the funnel is allowed to sit in the
cylinder should be kept to a minimum.
13.3.8 After charging the cylinder, reinsert the piston and place the appropriate
weight on the piston. Press Start to move to the next screen.
NOTE: Materials with high melt flows may require the orifice to be plugged in addition to
supporting the weight. Use the optional Tinius Olsen High Melt Flow Orifice Plug (TO P/N
02001455).
13.3.9 The next screen will countdown the previously entered preheat time. At the
end of the preheat time an alarm will sound (if enabled). At that time, the first
(lower) scribe line on the piston rod should be close to entering the guide
collar. ASTM D 1238 requires a preheat time of 7 +/- 0.5 minutes (420 +/- 30
seconds). If the scribe line has not entered the guide collar during the
preheating period, the amount of material charged should be reduced.
Alternatively, the material in the cylinder can be manually purged. Manual
purging must be completed 2 minutes before the first capture (sample) is
taken.
13.3.10After the first scribe line on the piston disappears into the cylinder, use the
cutoff tool to cut off the material that has extruded from the orifice during the
preheating period, while at the same time pressing the Start button (All cut-
offs must be made directly at the bottom of the orifice. This is the actual start
of the test.


13.3.11At the end of the cut off time an alarm will sound indicating the test is nearly
over. Cut the material that was extruded during the cut off period and weigh it
on a scale (a resolution of 0.001 grams is preferred) and record the weight (in
grams) on the Extrudate Weight screen, then press Done. Press Continue.
13.3.12If the Post-Test Comments option was selected, the operator can enter any
appropriate comments on the screen that appears next. Press Done to move
on.
13.3.13The next screen allows the operator to view test results. Record the results or
print them to an optional printer if desired. Press Done when finished to
return to the main screen.
13.3.14Allow the remaining material to purge from the cylinder and then, if the
machine is equipped with the optional WLD, press the [7] (TOP) button to
raise the weight support platform.
13.3.15Thoroughly clean the piston, cylinder and orifice as described in Section 16.
IT IS IMPERATIVE THAT THE MACHINE IS CLEANED AFTER EACH
TEST. If no more tests are needed, remove the piston and orifice from the
furnace before turning the MP1200 off to prevent them from being welded in
place as any material left in the barrel hardens.


TEST # 1 for Generic PE TEST # 2 for Generic PP TEST #3 Sample MVR TEST # 4 Sample Proc A
Auto Timed Flow Auto Timed Flow Auto Timed Flow Manual Cut
Units Units Units Units
mm mm mm mm
Set Point Set Point Set Point Set Point
190.0 230.0 190.0 190.0
Load Load Load Load
2.16 2.16 2.16 2.16
Orifice Diameter Orifice Diameter Orifice Diameter Orifice Diameter
2.096 mm (0.0825 in.) 2.096 mm (0.0825 in.) 2.096 mm (0.0825 in.) 2.096 mm (0.0825 in.)
Orifice Length Orifice Length Orifice Length Orifice Length
8.001 mm (0.315 in.) 8.001 mm (0.315 in.) 8.001 mm (0.315 in.) 8.001 mm (0.315 in.)
Preheat Time Preheat Time Preheat Time Preheat Time
390 390 390 390
Melt Density Melt Density Melt Density Number of Cuts
Entered Entered Entered 1
Melt Density Value Melt Density Value Melt Density Value Cutoff Interval
0.7636 0.7386 1.0 60
Enable Auto Cut Enable Auto Cut Enable Auto Cut Enable Auto Cut
OFF OFF OFF OFF
No of Captures No of Captures No of Captures Standard Identifiers
1 1 1 Sample ID
Start Height #1 Start Height #1 Start Height #1 Standard Identifiers
46.00 mm (1.811 in.) 46.00 mm (1.811 in.) 46.00 mm (1.811 in.) Operator
Piston Travel Cap 1 Piston Travel Cap 1 Piston Travel Cap 1 Standard Identifiers
6.35 6.35 6.35 Test Method
Enable WLD Enable WLD Enable WLD Test Results
OFF OFF ON Total Preheat
WLD Height WLD Height WLD Height Test Results
None None 52.0 Cut Off Time
Time Limit Time Limit Time Limit Test Results
0 0 OFF MFR g/10 min
Time Limit Value Time Limit Value Time Limit Value Alarm:
None None None At End of Preheat
Standard Identifiers Standard Identifiers Standard Identifiers Alarm
Sample ID Sample ID Sample ID Capture Start
Standard Identifiers Standard Identifiers Standard Identifiers Alarm
Operator Operator Operator Capture End
Standard Identifiers Standard Identifiers Standard Identifiers
Test Method Test Method Test Method
Test Results Test Results Test Results
Total Preheat Total Preheat Total Preheat
MFR g/10 min MFR g/10 min MFR g/10 min
Melt Density Melt Density Test Load
Alarm: Alarm: Alarm:
At End of Preheat At End of Preheat At End of Preheat
Alarms Alarms Alarms
Capture Start Capture Start Capture Start
Alarms Alarms Alarms
Capture End Capture End Capture End
Table 11-1 Factory Programmed MP1200 Example Test Parameter Screens


TEST # 5 Melt Density Calc TEST # 6 Sample Time Based TEST #7 ISO 1133 Proc A
Auto Timed Flow Auto Timed Flow Manual Cut
Units Units Units
mm mm mm
Set Point Set Point Set Point
190.0 190.0 190.0
Load Load Load
2.16 2.16 2.16
Orifice Diameter Orifice Diameter Orifice Diameter
2.096 mm (0.0825 in.) 2.096 mm (0.0825 in.) 2.096 mm (0.0825 in.)
Orifice Length Orifice Length Orifice Length
8.001 mm (0.315 in.) 8.001 mm (0.315 in.) 8.001 mm (0.315 in.)
Preheat Time Preheat Time Preheat Time
390 390 300
Melt Density Melt Density No of Cuts
Calculated Entered 4
Melt Density Value Melt Density Value Cutoff Interval
NONE 0.7636 60
Enable Auto Cut Enable Auto Cut Enable Auto Cut
OFF OFF OFF
No of Captures No of Captures Standard Identifiers
1 1 Sample ID
Start Height #1 Start Height #1 Standard Identifiers
46.00 mm (1.811 in.) 46.00 mm (1.811 in.) Operator
Piston Travel Cap 1 Travel Time Standard Identifiers
25.4 360 Test Method
Enable WLD Enable WLD Test Results
ON OFF Time
WLD Height WLD Height Test Results
52 None Cut-Off Time
Time Limit Time Limit Test Results
OFF OFF MFR g/10 min
Time Limit Value Time Limit Value Test Results
0 0 Capture Weight
Standard Identifiers Standard Identifiers Alarm:
Sample ID Sample ID At End of Preheat
Standard Identifiers Standard Identifiers Alarms
Operator Operator Capture Start
Standard Identifiers Standard Identifiers Alarms
Test Method Test Method Capture End
Test Results Test Results
Total Preheat Total Preheat
MFR g/10 min MFR g/10 min
Melt Density Melt Density
Alarm: Alarm:
At End of Preheat At End of Preheat
Alarms Alarms
Capture Start Capture Start
Alarms Alarms
Capture End Capture End


14 Section 14 - Testing Polymers According to ASTM D 1238 Procedure
B (Automatically Timed Flow Rate) when the Melt Density is known.
CAUTION: Do not use a sharp object to press any of the buttons on the Model MP1200
Controller, as this might damage the LCD display.
CAUTION: Prior to shipment, the cylinder of the machine is coated with oil to prevent
rust from forming. When the machine is first turned on, it is normal for the machine to
“smoke” as the cylinder comes to temperature and the oil residue burns off. To reduce the
amount of smoke that forms, clean the cylinder thoroughly before turning the machine on.
Be sure that a ventilation system is operating at this time.
NOTE: The instructions in this Section are based on ASTM D 1238. This test method
should be thoroughly studied by all operators prior to using the MP1200. Copies of the
standard are available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-
2959 USA Telephone: (610) 832-9721.
To perform tests to ASTM D 1238 Procedure B, the basic machine is required, along with
the PPDT Automatic Timing Switch option and the appropriate weight(s) for the polymer to
be tested. If the machine is equipped with a PPDT, simply rotate the switch in a counter-
clockwise direction until it is out of the way.
The Melt Density (density of the polymer when it is in its molten stage) is required for a
Procedure B test. The value for the melt density is a multiplier used to convert the volume
measurement into a mass (g/10 min) result.
14.1 Getting Started
machine (near the power cord). Turn the machine ON using the switch on the
right side of the machine.
booting up.
14.1.3 From The main screen, press CONFIGURATION.
14.1.5 The next screen that appears is the Machine Settings screen. You can turn
on various features on this screen but the important feature is the PPDT
option, Press ON to activate the PPDT. Press the DONE button when
finished. Other optional items can also be activated at this time.


14.2 Creating a New Procedure B Program
LCD display.
14.2.3 Press the Create New Program button.
14.2.4 For a Procedure B program, press AUTOMATIC TIMED FLOW on the

display.
14.2.6 Press the Set Temperature box. A keypad is shown next. Enter a fixed
temperature between 0 and 450 C. Press the DONE button when finished.
TEST TIP: If the operator is unfamiliar with melt index testing procedures and machine operations,
it might be beneficial to turn off the heaters at this point. Enter a temperature near or
below the ambient temperature (or enter 0°) and then press the DONE button. A 0°
setting should also be entered when the Calibration Offset screens are displayed.

test load. Press the DONE button when finished.
preheat period. ASTM D 1238 requires a preheat time of 7 +/- 0.5 minutes
(420 +/- 30 seconds). However, refer to the appropriate ASTM material
specification to determine the recommended preheat time for the material that
is to be tested. Enter 390 seconds (minimum preheat time) or other
appropriate time. Press the DONE button when finished.
NOTE: If the MWLD is being used in a test, the Preheat time may be used as a release time for
the weight lift platform. Set the release time (which is dependent on the expected flow rate
and may take some experimentation to determine the proper value) so that the test starts
7 min +/- 30 seconds after the test starts.
14.2.12Press the Entered button next to MELT DENSITY TYPE (assuming that the
melt density value for the material being tested is known).
14.2.13Press on the Entered Value box and use the keyboard that appears to enter
the melt density value.


Note: The melt density value is required to calculate Flow Rate in a Type B test. ASTM D1238
Table 3 lists melt density values for generic virgin PP (0.7386 g/cm3) & PE (0.7636
g/cm3). However, it is more accurate to measure the actual melt density of the specific
resin being tested. The procedure to do this is described in the following chapter. Do not
use the room temperature density normally stated in the material specifications which is higher.
14.2.14If the machine is equipped with an automatic cutter and if it is desired to use
it, press the ON button located next to Enable Auto Cut.
14.2.15Press on the Number of Captures box and use the keyboard that appears to
enter the desired number of captures.
Note: Generally, the first capture of 0.25 or 1.0 inch of travel is considered to be the ASTM
defined test result (the actual travel distance that is selected depends on the expected flow
rate of the material). However, the machine can be set up to take discrete measurements
(captures) at defined intervals within the 0.25 or 1.0 inch of travel.


14.2.16Press Continue to advance to the next screen
14.2.17Press the box next to Start Height #1 to enter the start height for capture # 1.
ASTM defines the start of the test to be when the bottom of the piston foot is
46 +/- 2 mm above the top of the orifice.
14.2.18Press the box next to Travel Distance # 1 to enter the desired travel for the
first capture. Press the Done button when finished.
14.2.19If more than one capture is desired, press the Auto Fill button to have the
MP1200 calculate the start heights for the additional captures. The Starting
Heights are automatically set back-to-back based on the “Piston Travel Cap
1” distance, but can also be overwritten. The starting height of a subsequent
capture must be programmed not to occur prior to the finishing height of the
previous capture.


14.2.20Press Continue to advance to the next screen.
14.2.21If the machine is equipped with a WLD and if it is desired to use it, press the
ON button located next to Enable Auto Cut.
14.2.22Time Limit – Enter a value of 30 minutes or less for the time limit desired for
the test. Press Continue to advance to the next screen.
optional.
enter the procedure, prior to the test (in this case, it would Procedure B or C).
A check mark will appear in the box to confirm the selection.
14.2.29Comments (Pre-Test) - If desired, press the box next to Comments (Pre-



Test). This will allow the operator to enter comments, after the test. A check
mark will appear in the box to confirm the selection.



14.3 Test Procedure
14.3.4 From the main screen, press the Start Test button.
on the amount of polymer to use for a test. It may require some trial and error
to determine the correct amount of material. It is important that the test does
not start until after the minimum preheat time has expired. To charge the
cylinder, insert the funnel into the cylinder, and then slowly pour the material


into the funnel. Do not dump it in all at once as it will melt and stick to the
funnel. Press Start when finished.
NOTE: The ASTM D 1238 Method allows one minute to charge the cylinder, insert the piston, and
start the preheat time of test.
CAUTION: The funnel, when placed in the cylinder, can become extremely hot when the
machine is at operating temperature! The time that the funnel is allowed to sit in the
14.3.7 After charging the cylinder, lightly tamp the material down with the charging
tool (P/N 02001582) in order to remove some of the trapped air. (Depending
on the amount of material to be charged, you may have to tamp the material
down more than once to load it all into the cylinder). Reinsert the piston, rotate
the PPDT clockwise so that the end of the arm is close to the piston rod, and
place the appropriate weight on the piston (either manually or with the WLD
(MP1200M only). Press Start to move to the next screen.
supporting the weight. Use the optional Tinius Olsen High Melt Flow Orifice Plug
(P/N 02001471 for standard D1238 die or 02001481 for “half-die”).
14.3.8 The next screen will countdown the previously entered preheat time. At the
end of the preheat time an alarm will sound (if enabled). At that time, the first
(lower) scribe line on the piston rod should be close to entering the guide
collar. If the scribe line has not entered the guide collar during the preheating
period, the amount of material charged should be reduced. Alternatively, the
material in the cylinder can be manually purged. Manual purging must end 2
minutes before the start of the first capture.


TEST TIP: When testing materials with high melt flow rates (> 10g/10 minutes), the
weight platform of the WLD can be used to prevent excessive polymer from running out of
the cylinder prior to the end of the preheating period. The actual position of the weight
support platform will vary with flow rate. One example is to lower the weight platform so
that the top surface of the platform is approximately 25 mm (1 inch) above the 46 mm
(1.81 inch) start position of the test measurement. The weight platform will now catch the
weight as it falls and support it, temporarily reducing the load on the material in the
cylinder. When the Release Time reaches 420 seconds (or other time entered above in
13.2.13), the weight platform will lower fully and allow the test to continue. Note that to
achieve the total preheat time of 420 +/- 30 seconds, it may be necessary to reduce the
Release Time. The total time from start of test to the start of test measurement can be
observed by watching the elapsed time “ET” display.
14.3.9 The Elapsed Time (ET) display will reset to zero and begin to count up, in
seconds. Material will begin to extrude through the orifice.
CAUTION: If the optional WLD is being used in the automatic mode, and the Weight Support
has been programmed to run to a height less than its maximum height, the weight platform
will automatically begin to lower the weight(s) when the [START] button is pressed. Keep
hands clear!
14.3.10When the elapsed time (ET) reaches the “Release Time” (Preheat Time) that
was entered in 14.2.10, an alarm will sound (if enabled). The first (lower)
scribe line on the ASTM piston rod should now be close to entering the guide
collar.
14.3.11 The WLD will automatically begin to lower the weight(s) at the end of the
preheating period (Release Time), provided that it has not already been
lowered all the way at the start of the test. Keep hands clear!
Note: ASTM D 1238 requires the test measurement to be started at 46+/-2 mm (1.81+/-
0.079 inches) above the top of the orifice and 7+/-0.5 minutes (420+/-30 seconds) after
starting the release (preheat) time. If the preheat time criteria is not met, the amount of
material charged and/or the release time used should be changed accordingly.
14.3.12When the weight drives the arm of the PPDT to the “Start Capture 1” Height, a
momentary alarm will sound. The MP1200 will automatically start recording
the time it takes for the piston to travel the programmed “Piston Travel CAP 1”
distance entered in 14.2.18.
NOTE: There is no need to cut off the extrudate during a typical Procedure B test when the
Melt Density value has been entered.


14.3.13When the arm of the PPDT reaches the end of the capture distance, the alarm
will beep.
machine is equipped with the optional WLD, raise the weight support platform.
14.3.15Rotate the PPDT counter-clockwise so that its arm is toward the rear of the
furnace. This will prevent damage to the arm during cleaning operations.
14.3.16Clean the piston, cylinder and orifice thoroughly as described in Section 16. IT
IS IMPERATIVE THAT THE MACHINE IS CLEANED AFTER EACH TEST.
If no more tests are needed, remove the piston and orifice from the furnace
before turning the MP1200 off to prevent them from being welded in place as
any material left in the barrel hardens.


15 Section 15 - Testing Polymers According to ASTM D 1238 Procedure
B (Automatically Timed Flow Rate) when the Melt Density is
Unknown (Procedure for Calculating the Melt Density of a Polymer)
NOTE: The instructions in this Section are based on ASTM D 1238. This test method should
be thoroughly studied by all operators prior to using the MP1200. Copies of the standard are
available from ASTM at 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, USA –
Telephone: (610) 832-9721.
15.1 Introduction
15.1.1 The MP1200/MP1200M must be equipped with the PPDT Automatic Timing
Switch in order to perform a test according to ASTM D 1238, Procedure B.
The test also requires the appropriate weight(s) for the polymer to be tested.
The optional Motorized Weight Lowering Device (WLD) may be used if
desired.
machine (near the power cord).
booting up.
15.1.4 If the WLD on the MP1200M is being used, it is good practice to manually
lower the weight onto the piston prior to testing in order to check the
alignment of the piston with respect to the hole in the weight. After checking
the alignment, raise the weight platform to its upper position.
15.1.5 From The main screen, press CONFIGURATION.
15.1.7 The next screen that appears is the Machine Settings screen. You can turn
on various features on this screen but the important feature is the PPDT
option, Press ON to activate the PPDT. Press the DONE button when
finished.


15.2 Creating a New Procedure B Program
LCD display
15.2.3 Press the Create New Program button
15.2.4 For a Procedure B program, press AUTOMATIC TIMED FLOW on the

display.
15.2.6 Press the Set Temperature box. A keypad is shown next. Enter the desired
test temperature. Press the DONE button when finished.
TEST TIP: If the operator is unfamiliar with melt index testing procedures and machine
operations, it might be beneficial to turn off the heaters at this point. Enter a temperature
near or below the ambient temperature (or enter 0°) and then press the DONE button. A 0°
setting should also be entered when the Calibration Offset screens are displayed.


test load. Press the DONE button when finished.
preheat period. ASTM D 1238 requires a preheat time of 7 +/- 0.5 minutes
(420 +/- 30 seconds). However, refer to the appropriate ASTM material
specification to determine the recommended preheat time for the material that
is to be tested. Enter 390 seconds (minimum preheat time) or other
appropriate time. Press the DONE button when finished.
15.2.12Press the Entered button next to MELT DENSITY TYPE (assuming that the
melt density value for the material being tested is known).
15.2.13Press on the Entered Value box and use the keyboard that appears to enter
the melt density value.


Note: The melt density value is required to calculate Flow Rate in a Type B test. ASTM D1238
Table 3 lists melt density values for generic virgin PP (0.7386 g/cm3) & PE (0.7636 g/cm3).
However, it is more accurate to measure the actual melt density of the specific resin being
tested. The procedure to do this is described in the following chapter. Do not use the room
temperature density normally stated in the material specifications which is higher.
15.2.14If the machine is equipped with an automatic cutter and if it is desired to use
it, press the ON button located next to Enable Auto Cut.
15.2.15Press on the Number of Captures box and use the keyboard that appears to
enter the desired number of captures.
Note: Generally, the first capture of 0.25 or 1.0 inch of travel is considered to be the ASTM defined
test result (the actual travel distance that is selected depends on the expected flow rate of the
material). However, the machine can be set up to take discrete measurements (captures) at
defined intervals within the 0.25 or 1.0 inch of travel.


15.2.16Press Continue to advance to the next screen
15.2.17Press the box next to Start Height #1 to enter the start height for capture # 1.
ASTM defines the start of the test to be when the bottom of the piston foot is
46 +/- 2 mm above the top of the orifice.
15.2.18Press the box next to Travel Distance # 1 to enter the desired travel for the
first capture. Press the Done button when finished.
15.2.19If more than one capture is desired, press the Auto Fill button to have the
MP1200 calculate the start heights for the addition captures. the Starting
Heights are automatically set back-to-back based on the “Piston Travel Cap 1”
distance, but can also be overwritten. The starting height of a subsequent
capture must be programmed not to occur prior to the finishing height of the
previous capture.


15.2.20Press Continue to advance to the next screen.
15.2.21If the machine is equipped with an WLD and if it is desired to use it, press the
ON button located next to Enable Auto Cut.
15.2.22Time Limit – Enter a value of 30 minutes or less for the time limit desired for
the test. Press Continue to advance to the next screen.
optional.
enter the procedure, prior to the test (in this case, it would Procedure B or C).
A check mark will appear in the box to confirm the selection.
15.2.29 Comments (Pre-Test) - If desired, press the box next to Comments (Pre-Test).
This will allow the operator to enter comments, prior to the test. A check mark will
appear in the box to confirm the selection.



15.3 Test Procedure
15.3.4 Verify that the Program File shows the desired program and that all
information displayed on the screen is correct. Press the Start Test button to

move to the next screen.
on the amount of polymer to use for a test. It may require some trial and error
to determine the correct amount of material. It is important that the test does
not start until after the minimum preheat time has expired. To charge the
cylinder, insert the funnel into the cylinder, and then slowly pour the material
into the funnel. Do not dump it in all at once as it will melt and stick to the
funnel. Press Start when finished.
NOTE: The ASTM D 1238 Method allows one minute to charge the cylinder, insert the
piston, and start the preheat time of test.
CAUTION: The funnel, when placed in the cylinder, may become extremely hot when
the machine is at operating temperature! The time that the funnel is allowed to sit in the
15.3.7 After charging the cylinder, lightly tamp the material down with the charging


tool (P/N 02001582) in order to remove some of the trapped air. (Depending
on the amount of material to be charged, you may have to tamp the material
down more than once to load it all into the cylinder). Reinsert the piston,
rotate the PPDT clockwise so that the end of the arm is close to the piston
rod, and place the appropriate weight on the piston (either manually or with
the WLD (MP1200M only). Press Start to move to the next screen.
supporting the weight. Use the optional Tinius Olsen High Melt Flow Orifice Plug (TO P/N
02001455).
15.3.8 The next screen will countdown the previously entered preheat time and show the
total elapsed time. At the end of the preheat time, an alarm will sound (if enabled).
At that time, the first (lower) scribe line on the piston rod should be close to entering
the guide collar. If the scribe line has not entered the guide collar during the
preheating period, the amount of material charged should be reduced. Alternatively,
the material in the cylinder can be manually purged. Manual purging must end 2
minutes before the start of the first capture.
TEST TIP: When testing materials with high melt flow rates (> 10g/10 minutes), the
weight platform of the WLD can be used to prevent excessive polymer from running out of
the cylinder prior to the end of the preheating period. The actual position of the weight
support platform will vary with flow rate. One example is to lower the weight platform so
that the top surface of the platform is approximately 25 mm (1 inch) above the 46 mm
(1.81 inch) start position of the test measurement. The weight platform will now catch the
weight as it falls and support it, temporarily reducing the load on the material in the
cylinder. When the Release Time reaches 420 seconds (or other time entered above in
13.2.13), the weight platform will lower fully and allow the test to continue. Note that to
achieve the total preheat time of 420 +/- 30seconds, it may be necessary to reduce the
Release Time. The total time from start of test to the start of test measurement can be
observed by watching the elapsed time “ET” display.
15.3.9 The Elapsed Time display will reset to zero and begin to count up, in seconds.
Material will begin to extrude through the orifice.
CAUTION: If the optional WLD is being used in the automatic mode, and the Weight
Support has been programmed to run to a height less than its maximum height, the
weight platform will automatically begin to lower the weight(s) when the START button is
pressed. Keep hands clear!
15.3.10When the elapsed time reaches the preheat time that was entered in 15.2.10,
an alarm will sound (if enabled). The first (lower) scribe line on the ASTM
piston rod should now be close to entering the guide collar.
CAUTION: If the optional WLD is being used, and has been set to “Yes”, the WLD weight
support platform will automatically begin to lower the weight(s) at the end of the
preheating period (Release Time), provided that they have not already been lowered all
the way at the start of the test. Keep hands clear!


15.3.11Observe the “PISTON HT” on the display. When the weight drives the arm of
the PPDT to the “Start Capture 1” Height, i.e., 46 mm (1.81“), a single beep
will sound. Simultaneously with this single beep, use the Cut-Off Tool to cut
off and discard the material that has extruded through the orifice during the
preheat period. The MP1200 will automatically start recording the time it
takes for the piston to travel the programmed travel distance entered in
13.2.18.
15.3.12When the arm of the PPDT reaches the end of the capture distance, the alarm
will sound again. Simultaneously with this alarm, cut off the material that has
extruded through the orifice during the capture time.
TEST TIP: For best accuracy it is important that the cut-offs are made directly at the bottom of the
orifice and precisely at the sound of the single and double beeps.
15.3.13The display will now prompt the user to enter the weight of the sample that
was cut off. Weigh the material cut off in 15.3.12, using the numeric buttons
to enter its weight (in grams). Press DONE when finished. The next screen
that appears confirms the weight entry. Press Continue to advance to the test
results.
15.3.14The pre-selected test results will be displayed. A test report can be printed
out, if desired. If a printer is not being used record any data as required.
machine is equipped with the optional WLD, raise the weight support platform.
15.3.16Rotate the PPDT counter-clockwise so that its arm is toward the rear of the
furnace. This will prevent damage to the arm during cleaning operations.
15.3.17Clean the piston, cylinder and orifice thoroughly as described in Section 16. IT
IS IMPERATIVE THAT THE MACHINE IS CLEANED AFTER EACH TEST. If
no more tests are needed, remove the piston and orifice from the furnace
before turning the MP1200 off to prevent them from being welded in place as
any material left in the barrel hardens.


16 Cleaning Instructions
16.1 It is absolutely imperative that the cylinder, die and piston are cleaned thoroughly
after EACH test.
16.2 After the test has been completed, allow the weight to remain on the piston until all the
excess material in the barrel has extruded through the orifice.
CAUTION: The piston rod assembly and the orifice become hot during use.
16.3 Remove the weight and the piston. If a WLD is being used, raise the weight platform all the
way up until the weight platform swings out of position. Wipe the piston thoroughly using a
cloth made from a natural fiber (cotton). The cloth must be clean and free from oil or grease
of any type as they may affect future test results. Place the piston on the tool rack or on an
insulated surface that will prevent it from rolling.
16.4 Remove the orifice from the bottom of the cylinder. Clean the outside of the orifice with the
clean, natural fiber cloth. Clean the bore of the orifice with the orifice drill. If necessary, the
orifice bore can be brushed, using a 0.090” diameter brass brush available from Tinius
Olsen. There should be no residue on the orifice after cleaning.
16.5 Clean the cylinder by placing a cotton patch over the cylinder, then pushing the patch
through the cylinder using the Cylinder Cleaning Tool in a manner similar to cleaning a gun
barrel. Change the patch and repeat at least 3 times or until there is no visual evidence of
material remaining on the cylinder wall. If necessary, the cylinder can be brushed, using a
0.406” diameter brass brush tip and barrel brush handle available from Tinius Olsen. 2-1/2”
square Cotton patches are available from Tinius Olsen.
16.6 Drop the orifice in the cylinder. It should fall to the bottom easily and there should be an
audible click when it hits the bottom of the cylinder. If not, remove the orifice and re-clean it
and the cylinder.
16.7 Always replace the piston and orifice back into the furnace as soon as possible so that they
are up to temperature for the next test.
Note: If no more tests are needed, ALWAYS remove the piston and orifice from the furnace
before turning the MP1200 off to prevent them from being welded in place as any material
left in the barrel hardens.


17 – Preventative Maintenance
17.1 Cleanliness
17.1.1 The most important factor in maintaining the accuracy of a melt index machine is
cleanliness. It is absolutely necessary that the cylinder, orifice and piston be cleaned
after each test. However, be aware that, despite the best efforts, some material will
build up on the components, causing them to appear tarnished or discolored. Tinius
Olsen does not recommend any other cleaning practices besides those detailed in
ASTM D 1238. Refer to Section 16.
17.1.2 Some components of a melt indexer, including the cylinder, piston foot and orifice,
are considered to be consumable, meaning that normal wear will cause them to go
out of tolerance over time. Check the orifice bore frequently using the Go/No-Go
gauge. Inspect the piston foot for nicks or scratches, or for signs of wear on the
edges. Check the cylinder visually for nicks and or scratches. Any obviously
damaged components shall be discarded and replaced.
17.2 Motorized Weight Lowering Device (MP1200M)
17.2.1 For lubrication of the Motorized Weight Lowering Device refer to assembly drawing
No. 5-6-730 in Appendix A of these instructions. Lubrication should be done
approximately once a year or every 1,000 hours of use.
17.2.2 To lubricate the Acme screw & nut, lower the WLD weight platform to its bottom
position. Remove all weights from the weight platform. Using an extreme pressure
grease NLGI consistency #2, add grease through grease fitting (Item 34).
17.2.3 Run the weight platform up and down a few times to check alignment and evenly
distribute the grease.
17.3 Electrical Checks
17.3.1 BE SURE THE POWER IS DISCONNECTED from the melt indexer Controller before
continuing.
17.3.2 Refer to Drawing 8-12-1478. Heater connection is J16. Fuse F1 is Bottom, F2 is

Middle and F3 is Top. F4 is common L1 for all 3 zones.


17.3.3 The heater bands can be checked with an ohm meter by measuring the resistance at
the Main Terminal Strip located on the board of the MP1200 Controller (under
baseplate). The Bottom heater zone is approximately 132 ohms; the Middle is
approximately 220 ohms and the Top is approximately 88 ohms. The resistance
between any of the wires to the case of the heater should be above 10 Megohms.
17.3.4 The RTD probes can be checked with an ohmmeter. Each probe has three wires.
With the two common colored wires shorted, check the resistance between the
common colored wires and the odd colored wire. The resistance measured will vary
with the temperature of the probe. This resistance should be approximately 100
ohms at 0C and about 109 ohms at 23C. The resistance between any wire and the
case/sheath should be open (indefinite). (Continuity implies a low resistance check
using lowest range of meter instead of the highest). If any of these tests fail, replace
the probe and recalibrate.
17.3.5 The MP1200 Controller, with all heater zones on full, draws about 3 to 4 Amps at 115
VAC service and about 4.5 Amps at 230 VAC service.
17.3.6 The motor for the optional Motorized Weight Lowering Device draws about 1.0 Amp.
NOTE: The line filter used in the Power Entry Module typically has a leakage current of 0.25 mA to
ground at 115 VAC, and 0.5 mA at 220 VAC. This current leakage may cause a Ground
Fault Interrupt (GFI) receptacle to trip, therefore a GFI is not recommended.


18 – Calibration/Verification – PPDT Attachment
NOTE: ASTM D 1238 recommends that the melt indexer should be thoroughly inspected and
verified for compliance to the specification at least annually. Follow the guidelines as detailed
in the current version of ASTM D 1238, or contact Tinius Olsen Field Service to arrange to
have the machine verified by Tinius Olsen personnel. Tinius Olsen’s Field Service Department
is accredited by A2LA for the calibration/verification of melt flow indexers and maintains NIST
traceable calibration equipment and can issue the calibration/verification certificates that are
required by many quality programs. Contact the Tinius Olsen Field Service Department for
more information.
18.1 Calibration/Verification Procedure for PPDT
18.1.1 Introduction
18.1.1.1 Accurate calibration and verification of the measuring capabilities of the PPDT can be
accomplished using the optional PPDT Calibrator (Part Number 02001531) and adapter
assembly (P/N 02002195). The calibrator consists of a “0 -2" barrel type micrometer head
and a mounting bracket. The micrometer has a resolution of 0.001 inch. See drawing 5-
6-554 in Appendix A.
18.1.1.2 The instructions in this section only cover the calibration of the PPDT when used with the
MP1200 Controller. Please contact the factory for information on calibrating other types of
actuating switches and controllers.
18.1.1.3 Before proceeding, read and comprehend the information on the PPDT theory of
operation found in Section 19.1.2. Only then should you proceed with the PPDT
Verification/Calibration.
18.1.2 Theory of Operation

This section will describe how the calibration parameters affect the operation of the
PPDT.
The distance of the piston above the zero position is calculated using the angle from the
horizontal reference, the PPDT Offset and the PPDT Arm Length using the equation in
Section 19.1.2.1.


Index Pulse
(ENCI)
Arm
Length
Angle
Horizontal Reference Position
PPDT Offset
Zero
Position
18.1.2.1 Normal Operation
There are three options for PPDT type that are programmed in the Calibration
Mode: type 0 (none), type 1 (encoder without index pulse) and type 2 (encoder with
index pulse). Select type 2 for the PPDT.
The PPDT is mechanically and electrically structured so that the index pulse will
trigger just as the arm starts to move down from its upper-most (resting) position.
The relationship between the index pulse and the horizontal position are established
during the calibration process. By detecting the index pulse and knowing the
horizontal position (defined under calibration), the controller knows the position of
the tip (height of piston) at any time.
The angle, relative to horizontal (0 degrees), is as follows.
PPDT Angle Calculation
Where counts is the number of encoder counts.
The distance of the piston above the orifice is calculated as follows.
Piston Position Calculation
Position = Offset + (ArmLength * sin (Angle))
Where the Offset and ArmLength are defined in the Calibration Mode and Angle is
defined in the equation above. The Arm Length multiplied by the sine of the angle
(relative to the horizontal) gives the linear position (relative to the horizontal). The
Offset is added in to give the height above the top of the orifice (Piston Height).


18.1.3 Arm Length Calculation
18.1.3.1 The physical length of the PPDT Arm, from its tip to the center of rotation of the encoder
shaft, should be about 152.4 mm (6.000 in.).
18.1.3.2
The relationship of the real and displayed Arm Lengths and Travels (change in position)
can be approximated as follows:
(Real Tvl / Real Arm Lgth) = (Displayed Tvl / Displayed Arm Lgth)
18.1.3.3 With some simple algebraic manipulation, the Real Arm Length can be estimated as:
Real Arm Lgth = (Real Tvl * Displayed Arm Lgth) / Displayed Tvl
18.1.3.4 When doing these calculations, use the total 25.4 mm (1.000 in.) travel. You may need to
repeat this several times.
NOTE: Always operate the calibrator downwards when taking readings.
18.1.4 Height Offset
18.1.4.1 Remove the Calibration device, and replace the orifice and piston. Place a weight on the
piston and position the PPDT arm beneath the weight.
18.1.4.2 Press the ZERO button to zero the PPDT.
Note: The sine operation translates the rotary motion of the encoder into a linear
value. The Offset is simply a value, relative to the true horizontal position of the
PPDT arm, that is added in after the sine correction to make the PPDT readings
agree with the true piston height.


18.2 Temperature Verification/Calibration
18.2.1 Suggested Equipment
18.2.1.1 Tinius Olsen Model TO410 Digital Temperature Meter

Includes:
Tip, Part Number 02002173

Heat Sink, Part Number 02002172
RTD Sensor, Part Number 02005177
Insulator, Part Number 02002174
Collar, Part Number 02002189
Part Number Item Number Quantity Description

02002173 5 1 Tip
02002172 4 1 Heat Sink
02005177 2 1 RTD Sensor
02002174 6 1 Insulator
02002189 7 1 Collar
Figure 16-1 - RTD Calibration Probe Assembly, Model TO410


19 – Temperature Control Configuration Mode
19.1 PID Parameters and Tuning -- General
It is far beyond the scope of these instructions to explain all the finer points of PID
(Proportional, Integral, and Derivative) temperature control and tuning. Where necessary,
these instructions will provide some explanation of concepts that are different from standard
PID control.
The default PID values shown should suffice for most users. However, further tuning of the
PID parameters may be necessary for any given machine in order to obtain optimum
performance for any particular set of test conditions/requirements. The user should consult
a good engineering controls text or web site to become familiar with the concept of PID
parameters and tuning before making adjustments. Some helpful resources are shown
below:
Process Control Instrumentation Technology, by Curtis D. Johnson
Microprocessor –based Process Control, by Curtis D. Johnson
https://controls.engin.umich.edu/wiki/index.php/PIDTuningClassical#Temperature
http://www.expertune.com/tutor.aspx
19.2 PID temperature control – output terms
The PID temperature control is found under Configuration – PID tab.
This screen will show the 3 temperature zones. Each zone will have a live P, I, and D term
(i.e. the mathematical output resulting from the current Set Point temperature, current
actual temperature, and the PID gains for that zone) and the actual temperature reading
(shown to the nearest 0.01 deg C).


19.3 PID gains
To view/set the PID gains, select the Top, Middle, or Bottom zone button.
The P, I, and D gains are shown on the left and can be individually selected and changed
as desired.
In very basic terms, for each zone, the controller compares the desired temperature (Set
Point) with the actual temperature (RTD probe). The difference is acted upon by the three
gains:
Proportional (P) gain is simply a multiplier. The difference signal is multiplied by this P gain
value and that is the Proportional term.
Integrator (I) looks at the history of the error (the integral or area under the curve) over time.
The Integrator term accumulates to a bigger and bigger value the longer the actual
temperature is below the Set Point. It decreases the longer the actual temperature is above
the Set Point. A large I gain will increase the I term faster but may also result in oscillations
as it builds quickly between too big and too small. It should be kept fairly small – just
enough to boost the output up to the SP temp.
Derivative (D) looks at the rate of change of the signal. If the temp is changing quickly the D
value will have a higher output than when it is changing slowly. The D term actually works
to slow a heater that is heating quickly in order to prevent overshoot. Likewise, it will pump
a lot of heat into a furnace that is dropping quickly in temperature to prevent it from getting
too cold. The higher the D value the greater this effect. But be careful because a D value
that is too high can make the system “noisy” by magnifying any little fluctuation in
temperature.
The controller constantly calculates these three terms and combines them to calculate the
output at each instant (P + I – D). That value is then used to regulate the power to the
heaters by rapidly switching the heater zones on/off. A higher output value will keep the
heaters on longer than a lower output value. The heaters will be full on when the output is
100%, and full off when 0%.


Default values are shown in the PID parameters table in these instructions.
19.4 Recovery Parameters.
The Integrator lock trigger, PID modifiers, and Integrator Lock and Anti-Lock times are
shown on the right side. These values are used during the recovery phase. The recovery
phase is when a significant disturbance is introduced, such as dropping a cold piston rod
into the barrel or charging the barrel with a sample. This phenomenon can be reproduced
for experimentation by using an aluminum slug.
19.4.1 Explanation of additional heater factors used to improve cold slug response.
When a cold slug is introduced to the furnace it is detected by observing a sudden drop in
temperature. If the drop in temperature for any of the zones is greater than that zone's
trigger then the integrator lock is activated for all zones. While the integrator lock is active,
the proportional gain and differential gain are also adjusted in order to reduce the overshoot
that their normal response would cause.
As soon as the sharp temperature drop is detected the integrator lock is active. It remains
active for a pre-set time. While the differential term is positive, the temperature is still falling
so the system is in the falling phase. When the differential term is negative, that indicates
that the system is in the rising phase.
For the ideal response to the cold slug introduction we should apply just enough extra
energy at the beginning to heat up the cold slug to the operating temperature of the
furnace. With only the integrator lock applied and no other adjustment to the PID
parameters it was observed that response of both the differential and proportional terms
was too large which resulted in a significant overshoot. Without locking the integrator, the
effect was greater and persisted for longer due to the integrator wind-up.
Eliminating the P and D terms while locking the integrator resulted in a very slow response
and effectively made the control system open-loop. Divide down the gains of both the P
and D terms by different amounts during each phase in order to reduce their effect just
enough that the additional energy in the system matches that required to heat the cold slug
from ambient to the target temperature, and no more.
By default in the falling phase the Prop gain is halved and the Diff gain quartered. In the
rising phase the Prop gain is quartered and the Diff gain halved. This reduces the gradient
while approaching the set-point again further to avoid over-shoot.
Once the lock time has elapsed, the system returns to its normal PID parameters. It is
expected that the system will have returned to close to the set-point by now, and that it is
relatively stable again. This integral value may not be exactly correct following the change
in load within the furnace and unlocking it again after the set time allows for this to be
corrected.


The integrator lock cannot be activated when either of the integral terms is zero. This is for
the case where the system has been running at a high temperature and then switched off
(so the temperature is falling quickly) and then it is set to go back to that temperature.
Without the anti-lock, an integral value of zero would be held and the other 2 gains would
be reduced so that the system struggles (if at all) to get to the set-point again. The anti-lock
time should be set long enough that, in this case, the integral term can rebuild and the prop
and diff terms can resist the drop so that once the anti-lock time expires there won't be any
false cold-slug detection.
The values for the P and D modifiers are in thousandths, so a value of 1000 equals a
multiplier of 1, a value of 100 equals a modifier of 0.1, and so on. For example the values
used may be such that the integrator lock is triggered by 0.06oC/0.2s for either the top or
middle zone. The P and D gains are divided down as described above. It lasts for 300
seconds (5 minutes). When either of the zones has zero integral value, the integrator lock
is prevented for 120 seconds to avoid vicious cycles when reset at high temperature.
19.4.2 Integrator-lock/Anti-lock early reset.
If the system recovers to the defined “Ready state” (see below) during either the integrator-
lock period or the anti-lock period, both of the locking mechanisms will be reset, and the
system will be ready to respond to another cold charge in the furnace. In the circumstance
where the system recovers sooner than either of those periods, this will allow for a faster
turn-around from one cold-charge to the next, without having to wait unnecessarily for the
locking periods to time-out.
19.5 Temperature Controller Status parameters:
The target range of temperatures and the period over which those targets must be met
before the system is considered ready can be configured by the user.
The Target Parameters button (on PID screen) sets the range for the Top, Middle, and
Bottom zones and the time period. When the temp for each zone is within this range (+ or -)
of the SP temp for the specified time period, the controller is considered stable. It then
discontinues the recovery mode and resumes the normal PID control (normal gains,
Integrator unlocked). The temperature display on the screen will be green to indicate
"ready" to go ahead with the testing. If any temperature is outside of this range the machine
is considered not yet stable and the temperature display will be red. Note: You can still
proceed with the next test in this mode, it’s simply a warning that the temperature control
response may suffer. It may also be that the Target parameters are overly conservative,
especially if the material is not all that temperature sensitive.
For example, the Target Parameters could be set for +/- 0.055C in zone A(bottom), +/-
0.25oC in zone B(middle) and +/- 0.500C in zone C(top). The period of time for all zones to
be within the stated tolerances before the system is considered ready is 100 ADC
samples which, as the ADC reports at 5Hz, means 20 seconds.
19.6 Automatic Line voltage compensation
The MP1200 monitors the incoming line voltage and automatically compensates for small
and medium sized changes in the line voltage and continues to attempt to do so for more
extreme cases. However, major line voltage problems (spikes, surges, dropouts) will have


to be addressed externally by the user. A qualified electrician should be consulted and
employed should it become necessary to install isolating/regulating transformers, etc. Do
not use a GFI receptacle as the small leakage current to ground from the internal filter may
cause it to trip. A standard computer grade surge suppressor is recommended for
protection.


20 Recommended Spare Parts List
20.1 The following list of items is included to help prevent lost time in the use of this piece
of equipment due to normal wear of parts, electronic component failure and
accidental breakage.
Booklet Recommended
Description Part Number
Reference Quantity
1
Piston Foot
02001086 Figure 3-1 2
(ASTM Stainless Steel)
1
Piston Rod
02002163 Figure 3-1 1
(w/ ASTM Scribe Lines)
Orifice
02001030 Figure 3-1 2
(D2 Tool Steel)
Charging Tool Tip 02001071 Figure 3-1 2
RTD Temperature Sensor
02002137 1
Probe (TOP)*
Probe (MIDDLE)* 02002138 1

Probe (BOTTOM)* 02002139 1
Barrel Brush 2
02001144 Figure 3-1 1
Handle (only)
0.406” dia. brass 2
02001143 Figure 3-1 4
Barrel Brush tips
0.090” dia. brass 2
02001142 Figure 3-1 2
Orifice Brush
2-1/2” square
02001136 Not Shown Bag of 500
Cotton Patches
Notes:
1. There is now a combination Piston Rod available with both the ASTM & ISO Scribed Lines (P/N 02002165), a ISO
(only) Piston Rod (P/N 02002164) and a Piston Foot (P/N 02001171) to ISO‘s tolerances (2011).
2. The Barrel Brush Handle (P/N 02001144) does not come with any brushes: order the 0.406” dia. barrel brush tips
(P/N 02001143) with 8/32” threads for the Barrel Brush Handle. The 0.090” dia. brass Orifice Brushes (P/N
0201142) are used when the orifice will not pass the minimum ID requirement. DO NOT USE STEEL BRUSHES.
* It is recommended that all 3 probes be replaced at the same time. Recalibration of the machine is necessary after
probe replacement.


21 MP1200 Packing/Shipping Instructions
IMPORTANT: Each Melt Indexer order is packaged slightly different depending upon
which options were ordered with the machine. Please keep all packing materials that the
machine was sent with in order to ship the machine properly!
19.1 Place the Accessories pocket into the box making sure that it is on the right-hand
side of the box (Refer to Figure 19-1). The Accessories Pocket is used to store
the Automatic Timing Switch Calibrator - P/N 02001531 (optional); Load Change
Collar (optional w/ flow rate ratio package); and any extra weights, should they be
ordered.
19.2 Install the X-shaped cardboard separator (for the weights) at the bottom of the
box. (Refer to Figure 19-1). This must be installed due to the fact that this
supports the machine and prevents it from being damaged during shipment. It is
advisable to wrap all weights in foam prior to placing them in the box
.
Figure 19-1 (This picture shows the accessories pocket on the right-hand side and X
cardboard separator on bottom left next to the accessories pocket with the
cardboard sub-floor ready to be placed on top.)
NOTE: If only one weight is ordered it is placed in the parts box and not in the
lower compartment.


NOTE: If a full set of weights are ordered by the customer, they will be packed into
a separate box and shipped separately from the box containing the Melt
Indexer. (This is done due to the weight of the package.)
19.3 Place cardboard sub-floor on top of the X-shaped cardboard separator after placing
any weights to be shipped with the unit.
19.4 Place cardboard spacer on top of the cardboard sub-floor with the cutout positioned
to protect the plugs at the rear of the machine.. (Refer to Figure 19-2)
Figure 19-2 (Shows cardboard spacer installed)
19.5 Place the MP1200 Melt Indexer into the box making sure that it is sitting flat and
securely on the cardboard spacer. (Refer to Figure 19-3)
19.6 Place a piece of foam over the digital display unit making sure it covers the base
plate as well.. This will keep the cardboard divider from scratching the table.
19.7 Next place the cardboard divider (looks like a U) around the digital display unit.
(Refer to Figure 19-3)


Figure 19-3 (This picture shows a non motorized MP1200 securely in place with the
foam on the table under the cardboard divider.)
19.8 Pack up the parts box (Refer to Figure 19-4). The parts must be placed in the box
in the following order:
19.8.1 PPDT Automatic Timing Switch - P/N 02001505 (optional - wrap in foam) &
bracket (in plastic bag) – Place this box in the bottom right-hand corner of
the parts box.
19.8.2 System Installation & Operation Manual - P/N 02002215
19.8.3 Weight (optional) wrapped in foam NOTE: The only time that the weight is
in the parts box is when there is only one weight that was ordered.
19.8.4 Electric Cord
19.8.5 Retaining Rods (if MP1200M was ordered)
19.8.6 Level Assembly (P/N: 02001271)
19.8.7 Any extra parts/accessories - including software & cables - ordered


19.8.8 Standard ASTM Tools (in plastic bag)
19.8.8.1 Die/Orifice - P/N 02001030 – Quantity 2

19.8.8.3 Orifice Drill - P/N 02002193
19.8.8.4 Cylinder Cleaning Tool - P/N 02001527
19.8.8.5 Charging Tool - P/N 02001582
19.8.8.6 Cutoff Tool - P/N 02001090
19.8.8.7 Piston Assembly - Stainless Steel Piston Foot - P/N 02001086,
Piston Guide Collar - P/N 02002149 & ASTM Piston Rod - P/N
02002163 (fully assembled)
19.8.8.8 Stainless Steel Funnel - P/N 02002155
Figure 19-4 (Shows the standard operating tools that are packed into the parts box)
19.9 Place the parts box on the left-hand side of the box on top of the cardboard divider.
(Refer to Figure 19-5). By closing the lid, this will push the parts box down. Once
the box is banded, it will secure the machine in place for shipment.


Figure 19-5 (This is how the box should look like before closing.)



APPENDIX A
TYPICAL ASSEMBLY DRAWINGS
WITH PARTS LIST & WIRING DIAGRAMS.
A-1
Version 5b – 15 October 2010

A-2
Version 5b – 15 October 2010

A-4

A-5


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MP1200 & MP1200M

SYSTEM INSTALLATION AND OPERATION MANUAL.

Revision 2c Date: 8 August 2013

This document contains confidential and proprietary information of Tinius Olsen

TINIUS OLSEN TESTING MACHINE COMPANY

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1 Section 1 – Introduction ....................................................................................................................... 1-1

2 Section 2 - Model MP1200 Digital Controller/Timer ........................................................................... 2-1

3 Section 3 –Operating Tools ................................................................................................................. 3-1

4 Section 4 – Available Options & Accessories ..................................................................................... 4-1

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6 Section 6 - OPTIONAL Programmable Piston Displacement Transducer (PPDT)........................... 6-1

8 Section 8 – Printer (Optional) .............................................................................................................. 8-1

9 Section 9 – Manual & Automatic Extrudate Cut-Off Tools ................................................................. 9-1

11 Section 11 – Configuration Mode......................................................................................................11-1

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13 Section 13 – Testing Polymers According to ASTM D 1238 “Procedure A” (Manual Cut-Off

14 Section 14 - Testing Polymers According to ASTM D 1238 Procedure B (Automatically Timed

15 Section 15 - Testing Polymers According to ASTM D 1238 Procedure B (Automatically Timed

16 Section 16 - Cleaning Instructions ....................................................................................................16-1

17 Section 17 - Preventative Maintenance ............................................................................................17-1

18 Section 18 - Calibration/Verification – PPDT Attachment ................................................................18-1

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20 Section 20 - Recommended Spare Parts List ..................................................................................20-1

21 Section 21 - MP1200 Packing/Shipping Instructions .....................................................................21-1

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

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CAUTION: Protective gloves should be worn when operating the machine.

CAUTION: The Motorized Weight Lifting/Lowering Device (WLD) is designed to

CAUTION: Weight retaining rods must be installed to prevent weights from

CAUTION: Unplug the machine before any attempt to remove covers.

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SERVICE & PARTS SALES

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Model MP1200 – Net weight 22 kg (47 lbs)

Model MP1200M – Net weight 36 kg (79 lbs)

 Install weight retaining rods (on MP1200M models) before use.

Thank you for your purchase!

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1.2 Heavy Duty Construction

1.3 Touch Screen Display

Tinius Olsen MP1200 Extrusion Plastometer Page 1-1

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1.6 Precision Three Zone Band Heater

1.7 Test Results

1.9 Options and Accessories

Tinius Olsen MP1200 Extrusion Plastometer Page 1-2

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1.11 Electrical Requirements:

A standard computer grade surge suppressor is recommended for protection.

Tinius Olsen MP1200 Extrusion Plastometer Page 1-3

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The MP1200 microprocessor-based Controller/Timer is fully interactive with the operator. It

2.2 MP1200 Controller/Timer

2.2.1 Touch Screen Keyboard

2.2.2 Machine Display

2.2.2.3 Piston Height