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INSTRUCTIONS FOR GURLEY DENSOMETERS

Models 4110, 4118, 4140 & 4190

Description Page

1.0 Assembly & Filling 2

2.0 Calibration Check 2, 3

3.0 Lifting Assembly 3

4.0 General Instructions 4

5.0 Weighted Arm Assembly (#4140 & #4190) 4, 5

6.0 Smoothness & Softness Tests (#4190) 6

7.0 4320 Digital Timing Attachment 7

8.0 General Maintenance & Troubleshooting 7-9

9.0 Replacing Gaskets 9

10.0 Effects of Altitude on Densometer Readings 9-10

11.0 Manufacturers Safety Data Sheet Chevron Oil 11-18

Gurley Precision Instruments


514 Fulton Street Troy, NY 12180
(800) 759-1844
(518) 272-6300
fax (518) 274-0336
www.gurley.com
SET-UP INSTRUCTIONS FOR DENSOMETERS
MODELS 4110, 4118, 4140 & 4190

1.0 ASSEMBLY & FILLING

Before proceeding, please familiarize yourself with the


Instrument and its parts by reading the descriptive
literature enclosed.

1.1 Unpack densometer, set on level surface or use optional


# 31931 instrument leveling base (shown).

1.2 Remove all packing materials from around instrument and anything between clamp and
adaptor plates. Leave clamp lowered. Remove and save plastic bag or sheet from
between clamping plate and adaptor plate.

1.3 Remove inner cylinder, discard paper wrapper or other


packing materials. Do not remove plastic cap over air tube
until after step 1.6.

1.4 Remove 2 screws holding cylinder stop to side of outer


cylinder. Turn stop so it stands up over outer cylinder with
bent tip pointing in. Re-fasten with 2 screws.

1.5 Note the scribed mark on the inside of the outer cylinder,
approximately half way up. Fill the outer cylinder with the oil
provided to this point. Be certain the plastic cap remains over
the air pipe so that no oil spills into pipe.

1.6 Remove plastic cap over air tube. This may require a pair of pliers. Simply grasp firmly,
twist slowly and pull off.

1.7 Insert inner cylinder into outer cylinder. It will drop past cylinder stop and fall to bottom. Lift
up so that cylinder stop catches lip of cylinder and holds inner cylinder in upper position.

1.8 Place the plastic bag or sheet between the clamping plate and adapter plate. Raise the
lower clamping plate by turning either knob, firmly clamping plastic between the lower
clamping plate and upper adaptor plate.

If model is pre-1991 and equipped with screw stem/capstan


method of raising clamping plate (shown at right), simply turn
capstan to raise plate and ignore references to the new type
of lifting assembly (knobs) in these instructions.
Once plastic is clamped in place, release inner cylinder by
grasping its top with one hand and pulling cylinder stop
from under its lip. Slowly lower inner cylinder until it "floats"
within the outer cylinder.

Let instrument sit with inner cylinder floating for one hour.
Observe the level or overall height at which the inner
cylinder is located. If no movement is observed, unit is
working and proceed with checking for calibration.

WARNING: NEVER RAISE INNER CYLINDER UNLESS


CLAMPING PLATE IS LOWERED AND SAMPLE, TEST
PLATE OR PLASTIC SHEET IS REMOVED. FAILURE
TO DO SO CREATES A VACUUM THAT PULLS OIL
INTO THE AIR TUBE AND REQUIRES A THOROUGH
CLEAN-UP. ALSO, DO NOT PUSH DOWN ON A
FLOATING INNER CYLINDER AS IT WILL RESULT IN
OIL OVERFLOWING OUTER CYLINDER.

Sample is still in place!


2.0 CALIBRATION CHECK

2.1 Be certain porosity test plate is clean. Do not wipe plate


with abrasive cleaners or your fingers as oil or other
particles may obstruct orifice. Use alcohol or a solvent as
a cleaner, rinsing out orifice. let air dry. Do not attempt to put any hard object into orifice in
order to clean it out as this can change the calibration of the plate. Soft materials may also
leave a residue. When absolutely necessary, use compressed air to force any
contamination out of orifice.

2.2 Raise inner cylinder until it rests in upper position on the cylinder stop.

2.3 Place calibration plate on lower clamping plate and raise


until firmly clamped and sealed against adaptor plate.

2.4.1 If instrument is not equipped with automatic digital timer,


turn inner cylinder so that numeric scale faces operator.
Release inner cylinder by pulling cylinder stop away from
top flange and lowering cylinder slowly until it floats.

2.5 Using stopwatch, measure the time required for 100 cc of air to pass through test plate.
Always use the same area on the scale for readings. This test should be run three times
with results averaged. Compare results with calibration card. If within 5%, test is
acceptable. Note that you may consider running a second test after turning the test plate
over, averaging the results from both sides.

2.6 If instrument is equipped with automatic digital timer, please refer to its instructions in
addition to steps 8 to 10.
IF POROSITY TEST PLATE IS BENT, DENTED, CORRODED OR SCRATCHED, DO NOT USE.

Note that results will vary at higher altitudes. See Section 10.0.

Please refer to Section 8.3 for information regarding calibration plates.

3.0 INSTRUCTIONS FOR USING NEW STYLE LIFTING ASSEMBLY


ON GURLEY DENSOMETERS

When using your densometer, it is not necessary to lower the lifting assembly and its lower
clamping plate any further than to allow sufficient space for inserting the sample to be tested.

DESCRIPTION: The knobs to either side of the instrument base are connected to a cam
which when turned, raises and lowers the clamping plate. Cam position is
self-locking at any position when knob is turned.

WARNING: Never raise inner cylinder unless clamping plate is lowered and sample, test
plate or plastic sheet is removed. Failure to do so creates a vacuum that pulls
oil into the air tube and requires thorough clean-up.

(Always start with inner cylinder in upper position against the cylinder stop)

3.1 Insert sample between upper adaptor plate and lower clamping plate.

3.2 Turn knob to raise clamping plate.

3.3 Run test by releasing inner cylinder.

3.4 At completion of test, turn either knob in opposite direction to unlock and lower clamping
plate.

3.5 Remove sample.

3.6 Raise inner cylinder until "locked" at upper position.

NOTE: Densometers manufactured prior to 1991 feature a screw type


lifting assembly. When using such instruments, please adhere
to these instructions. Any reference to "turning knobs" may also
be interpreted as "turn capstan wheel on screw stem" with the
results being identical.
4.0 GENERAL INSTRUCTIONS FOR MODELS 4110, 4118, 4140 & 4190 (AFTER SET-UP)

4.1 Be certain clamping plate is lowered.

4.2 Lift inner cylinder until cylinder stop (spring) locks inner cylinder in upper position.

Note: If inner cylinder is raised with a specimen clamped between plates, oil will spill into
the air tube. Always lower clamp plate and remove specimen before lifting inner
cylinder.

4.3 Insert specimen between lower clamping plate and adaptor plate.

4.4 Turn either knob to raise and lock clamping plate.


For models #4140 & #4190, refer to Weighted Arm Assembly Instructions (Section 5.0).

4.5 Release inner cylinder by pulling cylinder stop away from cylinder flange and lowering
cylinder gently until it "floats" in oil.

4.6 If using stopwatch, graduated scale should face operator. Begin watch when zero line
reaches top edge of outer cylinder. Stop watch after desired volume of air (25, 50, 100,
150, 200, 250 or 300cc) has been reached). Operator may also start at 100 cc mark. In
this case, use either 100 to 200 on graduated scale or reflective bands for measurement of
10, 25, 50 or 100cc. Always use the same starting point for all tests.

4.7 After each test always remember to lower clamp and remove specimen before lifting inner
cylinder.

4.8 If using automatic digital timer, turn desired reflective band towards reading head. Reset
counter by pressing button on control box. Release inner cylinder by pulling cylinder stop
away from cylinder flange and lower cylinder gently until it "floats" in oil.

Be certain desired band faces reading head. Wait for timer to start as cylinder descends.
Once timer stops, record time and reset instrument by first lowering clamp plate; second
removing specimen, lifting inner cylinder until latched in upper position and fourth,
pushing reset button on control box.

If the reading you get is below 6 seconds (100cc volume), this may be the wrong instrument to test
these materials. Contact your dealer or the Gurley factory for advice on other models or additional
accessories that will correct the situation. Accessories include clamping and adaptor plates in 0.10
and 0.25 square inch sizes. Normal instrument include only the 1.0 square inch orifice (except
Model #4118 which features 0.1 square inch).
5.0 USING THE WEIGHTED ARM ASSEMBLY
(Models 4140 & 4190 only)

The purpose of the weighted arm assembly is to exert a repeatable


clamping force on the sample for purposes of consistency in
testing. It is used occasionally when testing for porosity and
exclusively when testing for smoothness and softness. Depending
on your application, and orifice size there are three weights and
related pressures possible.

For applications using a 1.0 square inch orifice:


Arm alone with no additional weight 6.52 psi
Arm with .34 lb weight 19.6 psi
Arm with 2.0 lb weight 82.5 psi

For applications using a .25 square inch orifice:


Arm alone with no additional weight 7.57 psi
Arm with .34 lb weight 22.7 psi
Arm with 2.0 lb weight 95.7 psi

For applications using a .10 square inch orifice:


Arm alone with no additional weight 6.71 psi
Arm with .34 lb weight 20.1 psi
Arm with 2.0 lb weight 84.9 psi

For applications using a smoothness test plate:


Arm alone with no additional weight 3.20 psi
Arm with .34 lb weight 9.60 psi
Arm with 2.0 lb weight 40.5 psi

For applications using a softness test clamping plate:


Arm alone with no additional weight 102 psi
Arm with .34 lb weight 308 psi
Arm with 2.0 lb weight 1,300 psi

FOR SPECIFIC PROCEDURES IN PERFORMING SMOOTHNESS AND SOFTNESS TESTS,


REFER TO Section 6.0.

To use weighted arm, follow these steps:

5.1 Crank handle should be in "up" position. Lower the lifting assembly and remove any
sample. Raise inner cylinder so that cylinder stop is supporting inner cylinder flange.

5.2 Select appropriate weight (if any) and slide over arm so that hanger rests in notch.
5.3 Raise lifting assembly by turning either knob until the separation between the lower and
upper plates allows the sample to be easily inserted and removed. Remember that
activating the weighted arm, will lift the lower plate to clamp the sample in place.

BEFORE THE NEXT STEP, BE CERTAIN INNER CYLINDER IS IN RAISED POSITION

5.4.1 Insert sample between upper and lower plates. For convenience, sample should be at
least 2" x 2" (5cm x 5cm).

5.5 Turn handle (crank) "down" to activate arm. Sample should be firmly clamped in place. If
sample remains loose, go back to step #3 and raise lower clamping plate.

5.6 If equipped with an automatic digital timer, press reset.

5.7 Release inner cylinder. Test is complete when the appropriate volume of air has passed
through specimen. This is determined by observing the appropriate scale. After test, record
data including model used, orifice, volume of air and time elapsed. Notations should also
be made regarding specimen condition or special attributes.

5.8 Turn handle (crank) "up". Remove sample. Raise and lock inner cylinder. For next sample,
start at step #4.

If you do not wish to utilize the weighted arm in testing for porosity, be certain the handle or lever
to the right of the instrument is in the "up" position. This releases the lever. Also be certain there
is no weight on the arm. Follow the routine steps on page 4.

6.0 MODEL 4190 ONLY SMOOTHNESS AND SOFTNESS TESTS INSTRUCTIONS

For smoothness tests, a solid lower clamping plate (white Teflon-coated) is used with the optically
flat upper clamping plate. For softness tests, a lower clamping plate is used with the optically flat
upper clamping plate.

Smoothness Plate Softness Plate

(Four nearly flat plugs)

The lower softness clamping plate has four polished steel plugs, (each approximately .002" high).
When the clamping lever is actuated, these plugs are forced into the test sample. The softer the
material, the deeper the penetration, and thus the slower leakage. The longer time indicates a
softer paper. Care must be taken to avoid scratching either of these surfaces, as results obtained
when a rough surface is used are inaccurate.
Set-up for Smoothness Test:

6.1 Remove lower porosity clamping plate with four holes. Place blank
lower plate smoothness plate without any holes on lifting assembly.

6.2 Remove adapter plate from air tube by simply twisting and pulling
down. In most cases it is necessary to have the lower clamping
plate (step 6.1) out to allow for clearance. Very old models may
not have an adapter plate.

6.3 Remove lower porosity clamping plate with four holes. Place blank
lower plate smoothness plate without any holes on lifting assembly.

6.4 Remove adapter plate from air tube by simply twisting and pulling
down. In most cases it is necessary to have the lower clamping
plate (step 6.1) first to allow for clearance. Very old models may
not have an adapter plate.

6.5 Place sample between upper clamp plate and lower smoothness plate. Either turn the cam
mechanism (or capstan wheel with older models) or use the weighted arm assembly to
secure the sample (see section 5.0 for weighted arm instructions).The 0.34 or 2.0 pound
weights are suitable for most grades.

6.4 Release the cylinder and note the amount of time required for 100cc of air to pass over the
sample. A longer test time designates a smoother sample than one with a lower test time.
Make sure to note the clamp settings for each test - consistent clamping will insure
repeatability and accuracy.

Set-up for Softness Test:

6.5 Remove lower porosity clamping plate with four holes. Place blank
lower plate softness plate with four polished plugs on lifting
assembly.

6.6 Remove adapter plate from air tube by simply twisting and pulling
down. In most cases it is necessary to have the lower clamping
plate (step 6.1) out to allow for clearance. Very old models may
not have an adapter plate.

6.7 Prepare specimen by punching a hole in the center of a paper


sample. The sample is then inserted between the top clamping
plate and a softness test plate on the bottom.

6.8 Raise inner cylinder until locked in upper position by cylinder stop.

6.9 Insert sample (described above) between upper and lower clamping plates, with hole
located approximately in the center of the plates.
6.10 Raise lower plate until it touches upper clamping plate, then back off slightly leaving just
enough room for sample to slide in or out.

6.11 Lower weighted arm by turning handle (crank) down. For flat papers, the weight of the arm
alone is sufficient to perform the test. Curled, stiff or rough samples that cannot be
clamped securely by the lever arm alone, may instead be clamped by using either of the
two weights on the lever arm. Be certain to record what weight is used and to consistently
use that arrangement in future tests.

6.11 Reset timer (optional)

6.12 Release inner cylinder

6.13 Time test for 100 cc airflow or other convenient volume (10, 25, 50 cc).

6.14 At conclusion of test, record data.

7.0 MODELS 4320 DIGITAL TIMING ATTACHMENT

Assembly

7.1 The digital timing attachment consists of 3 parts

-Control panel

-Reading head with cable

-AC power supply

-Mounting Bracket (Optional, See attached instructions.)

7.2 Attach the cable from the reading head to the Control Box.

7.3 With the inner cylinder "at rest" on the cylinder stop, install the reading head on the clamp
at the top of the densometer. The "window" or pointed end should be
adjusted so that it is squarely aligned with the cylinder. The reading head
should be as low as possible in the clamp bracket for most applications.

7.4 Turn the inner cylinder so that the reflective portion is facing the reading
head. Second largest band is 100ccs (shown at right).

7.5 Plug in AC power cable and turn power on.

NOTE: FOR FURTHER INSTRUCTIONS AND INFORMATION PLEASE REFER TO THE


ATTACHED USER'S GUIDE
8.0 GENERAL MAINTENANCE 7 TROUBLESHOOTING

Routine Maintenance

8.1 Gaskets: The two gaskets on the adaptor plate should be checked frequently (weekly) on a
routine basis for evidence of loosening, abrasion, tearing or foreign material buildup. If
dirty, rinsing with alcohol and drying with a lintless cloth or toweling is recommended.

If torn, abraded or loose, gasket should be replaced. See instructions for gasket
replacement in section 12.

8.2 Oil Level: Unless an accidental spill occurs, the oil level should remain constant for years.
This does not eliminate the need to check the level on a routine but occasional basis. In
normal usage, we recommend verifying the oil level is at the scribe mark on the inside of
the outer cylinder every three months. If a spill has occurred, add oil as necessary.

NOTE: Use only Genuine GurleyTM parts and supplies in servicing these instruments.

8.3 Calibration: This brass plate must not be bent, folded, dented Plate or scratched as it may
adversely affect the results of testing. DO NOT RUB PLATE OR ORIFICE WITH YOUR
FINGERS.

To clean plate, rinse with a solvent using standard precautions. If orifice is obstructed,
direct solvent stream into opening. If still obstructed, use a soft stick (toothpick) to gently
force material out at risk of destroying the plate by widening the orifice. Pat dry with lintless
cloth.

Procedure for Maintaining


Archival Calibration Plates
In order to provide a higher level of quality assurance, the following procedure is
recommended when using porosity testers manufactured by Gurley Precision Instruments.
Every Genuine GurleyTM instrument is provided with a calibration plate or strip. During
everyday use, these pieces may become damaged which may affect their specified
performance. In order to assure proper calibration, follow these simple steps:

NOTE: ALWAYS FOLLOW MANUFACTURERS GUIDELINES REGARDING THE USE


AND CARE OF CALIBRATION PLATES AND STRIPS.

1. Start with two calibration plates. These will become the "archival" and "working"
calibration pieces respectively. Do not change their designations.

2. Compare the test results of the two plates in the same instrument. They should match
their respective specified values. Store the archival" piece in a safe location. Use the
"working" piece for regular (daily) calibration.

3. Once monthly (or more often if you feel it is necessary), remove the "archival" plate from
storage. Compare test results of both pieces, using the "archival" as the master. Note any
deviation from the specified values.
4. If the results from the "archival" and "working" pieces are beyond 5% of the specified
value, it is probable that the instrument requires service. If only the 'working' calibration
piece is off, it alone probably requires replacement. If both deviate from the given value,
then both should be replaced.

5. After testing, carefully return the "archival" piece to storage.

6. If either the "working" or "archival" plate become unusable, order a replacement for that
particular part, do not rotate plates.

IF YOU SUSPECT AN OIL LEAK ...

Our experience has been that it is misuse of a densometer that causes it to overflow. Occasionally,
the user will push the inner cylinder down while the sample is clamped in place. This causes the oil
to rise, overflow and run down the outside of the outer cylinder.

More frequently, some one will lift the inner cylinder while a specimen is still beneath the adaptor
plate. This creates a vacuum which causes the oil to rise and run down the air tube.

The remedy in either case is to blot up any excess oil then use alcohol to flush oil from crevices.
Clamping and adaptor plates should be removed and cleaned. Air pipe should be cleaned by
pushing a piece of towel or cloth through, followed by similar towel saturated with alcohol. Upper
clamp plate should not be removed, but may be flushed with solvent and blotted dry.

It may be more convenient to empty outer cylinder of oil before cleaning, but this is not necessary.
Be certain to follow instructions for setup if refilling oil.

WARNING: Follow prescribed safety procedures when using alcohol or any solvents. Use of
other solvents may affect painted finish of base. If instrument continues to leak oil,
contact factory for assistance.

9.0 PROCEDURE FOR REPLACING GASKETS ON DENSOMETER ADAPTOR PLATES

MATERIALS NEEDED:

Pliobond contact cement or equivalent (PN: 136-115)

Gasket: #27637 for 1 sq in. adapter plates

#26146 for 0.25 sq in. adapter plates

#26147 for 0.10 sq in. adapter plates

Solvent (MEK or equivalent)


PROCEDURE for Gasket Replacement:

1. Remove adaptor plate from instrument.

2. Clean off any oil or dirt.

3. Remove gasket (by pulling it off).

4. Clean gasket trough with solvent and remove all adhesive and rubber residue.

5. Be certain new gasket and trough are clean.

6. Apply thin even coating of Pliobond to one surface of gasket and trough of adaptor plate.

7. Let both surfaces dry to touch.

8. Carefully align glued areas of gasket and plate to each other and press in place.

9. Use solvent to remove any excess adhesive (very lightly, do not saturate).

10. Resume use of adapter plate.