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SP-5000 User`s Manual

1. In the following procedural steps the numbers in parentheses correspond to the numbers next to the component labels shown in Figure 11 3 1 On cylinder barrels with tapered seal areas place the Hastelloy seal support 1 into the cylinder barrel On cylinder barrels with a step rather than a taper after the seal in the seal area Hastelloy seal supports are not used If the seal support does not sit flat perpendicular to the center axis of the barrel the seal insertion plunger can be used to lightly tap it into place 11 7 Quizix 5000 SERIES PUMP MANUAL 2 Place the PEEK ring 2 into the barrel with its flat side against the Hastelloy seal support and its rounded side toward the front of the cylinder 3 Push the Aflas seal 3 into the cylinder barrel as far as possible until it is up against the PEEK backup ring The Aflas high temperature seal is elastomeric so it can be slightly compressed by hand 4 Place the Teflon rear backup ring 4 into the barrel with its rounded side against the Aflas seal 5 Place the flat PEEK rear support ring 5 against the Teflon bottom backup ring 6 Place the large PEEK backup ring 6 against the rear support ring with the shoulder smaller diameter towards the seal against the Teflon backup ring This last backup ring has a smaller shoulder than the standard ambient temperature seal backup ring If you have both types of backup rings on your work table do not confuse t
2. Quizix 5000 SERIES PUMP MANUAL 12 12 the 01 to 001 ml per minute range become more difficult since fluid can evaporate as fast as it leaks Care and patience are needed to find leaks in this range If you are using brine a salt deposit residue is a clear indication of a leak Extreme care must be used to find leaks below 0 0001 ml per minute since many other factors need to be considered 12 4 3 2 Leak Testing The 5000 Series Pump System can trace volume changes very accurately This volume measurement combined with the pressure measurement can be used to detect fluid leaking from the pump system e To detect a leak in this way the pump cylinder can be pressurized to a set pressure and then stopped and the pressure can be recorded as a function of time This is a truly static leak test in that the piston is not moving with respect to the seal e Alternately the pump cylinder can be operated in constant pressure mode and the volume recorded versus time This is a quasi static method in that the piston will be making slight motions as the pressure control algorithm operates A third method uses gear mode without valves to push fluid from one pump cylinder into the other This is a truly dynamic leak test of the pump cylinders Temperature must be precisely controlled in order to know if a small leak is real or not Depending on the compressibility and fluid used temperature changes cause variation in pressure in a closed fl
3. 4 13 Constant Rate IND CR 4 13 Constant Rate Cycled 4 13 Paired Geared Mode Constant Rate 4 14 Unidirectional Capillary Viscometer 4 14 CYTO WE veraa ae Ponceau eranemiin bic ties 1 1 P Paired Constant Delta Pressure Delivery 4 15 Constant Delta Pressure Receive 4 15 Constant Pressure Bidirectional Half Rate 2622 niaes 4 16 Constant Pressure Delivery 4 15 Constant Pressure Receive 4 15 Constant Rate Delivery 4 15 Constant Rate Receive c0c6 4 15 Geared Mode Constant Rate Without Valves cccceceeeeeee 4 14 Pilot Solenoid o i 8 2 8 8 Check aii scale ana aaa naaa 12 17 Piston n a itean 7 4 11 8 CRC AINA oiiaii n a ea 11 8 Inspectii sed aed earache 11 8 Wins ta Wing dics eisiae siete ia 2 1 Movement Error c ccecceeeeeee 12 14 Position Field is2 25 adiicentecseds 4 4 Position Indicators Physical 12 2 Reinstalling cisicc sitscsetavivsvonaysacductes 11 9 Pl mbmng oss reece iie 1 4 8 1 Picture oeeie i Seabees ass 8 6 Connection Verification 3 1 ROWER roen ea E n 10 1 Basic Requirements c ceeeee 10 1 Changing the Voltage Setting 10 2 Considerations ccccsscscceeseeeeees 2 10 Cord recat tes ascutete dla Maden a 6 2 Cord Receptacle cceceeseesseeeteeees 6 4 Pressure CUITCIE paces ce NBR e a a tee 4 9 EO dob ede ies a eh ede 12 16 Is
4. from CMD 5000 Dual Controller Driver to Transducers and Pilot Solenoid Manifold Make sure each numbered cable branch is plugged into the transducers and pilot solenoids with the same number For example cable branch 1 into pilot solenoid 1 Also make sure each numbered cable branch is plugged into the pressure transducer with the same number For example cable branch A into pressure transducer A mounted on pump cylinder A Data Link Cable From the CMD 5000 to the Serial Expander Isolator Make sure the data link cable from the pump controller is connected to Port A of the serial expander isolator If you have two pump controllers the second one s data link cable should be connected to Port B RS 232 Cable from Serial Expander Isolator to Computer Most users choose serial port 1 on their computer for the pump system Color coded Air Tubing from Pilot Solenoids to Valves At both the solenoid end and the valve end check to ensure that the tubing color matches the color on the fitting For example the orange solenoid fitting should contain orange tubing and the orange tubing should be plugged into an orange labeled valve fitting On 4 cylinder systems each color is used twice The colors used on pump cylinder 1A are used again on pump cylinder 2A The colors used on pump cylinder 1B are used again on pump cylinder 2B The air tubing connected to cylinders 2A and 2B will have a black band in addition to the color used on the air
5. Most logged error messages are very easy to understand and the user is able to correct the problem quickly An example of a logged error is Error Over Pressure on Cylinder 1A This means that the safety pressure in pump cylinder 1A set by the user was exceeded by the pump cylinder and caused a digital overpressure error This error would cause an operating pump to stop While most logged error conditions are self explanatory some are explained in additional detail below 12 2 2 1 Soft Limit Warning A soft limit is a stroke position that is outside the normal operating stroke area A soft limit warning is usually the result of the pump not being able to adjust quickly enough to an operating condition A soft limit will not stop pump operation For example if a pump is maintaining pressure at max extend and the pressure suddenly drops the pump will extend a little further than it would normally and enter the soft limit If a soft limit is reached the pump controller s software keeps the pump operating only in the direction away from the soft limit Since the piston stroke is very limited at this point some variation in pressure or flow rate may occur Soft limit errors do not cause damage to a pump and will not stop a pump s operation If a soft limit occurs however the user should try to determine the operating conditions that led to this error in order to avoid a soft limit error in the future To move a pump cylinder out of the soft
6. Unscrew the retaining ring remove it and pull the cylinder barrel straight out Unpack the piston wipe it clean and place it into the 27 mm socket extension tool Install the piston into the end of the cylinder housing by inserting the piston and socket tool into the housing and screwing it into the piston holder Tighten the piston with moderate force Use a screwdriver and place it into the holes in the socket extension to do this Remove the front SpeedBite plug protectors and the rear dust protection plug Lubricate the end of the piston to ease installation through the main seal in the cylinder barrel Next replace the cylinder barrel Holding the cylinder barrel straight in front of the piston insert the barrel onto the piston and push it straight into the cylinder housing until it is fully seated Be sure that the speedbite tubing ports are oriented vertically above one another Replace the cylinder barrel retaining ring and tighten it securely with the face spanner wrench Ensure that the ring is fully tightened This completes the piston installation Repeat this procedure for each pump cylinder E Z SAFETY RUPTURE DISK 2 EACH SP 5200 PUMP STAND 7 5000 SERIES PUMP CYLINDERS j 5000 SERIES PUMP CYLINDERS 2 EACH Figure 2 2 Stand Mounted SP 5200 CMD 5000 DUAL CONTROLLER DRIVER dNLas WALSAS z 4a deyD v z XIZM SP 5200
7. a tiny white PCB from the space next to the fuseholder The voltage selector is roughly the shape of a square with a plastic voltage indicator a white plastic piece on it Each side of the voltage selector contains a voltage number and an arrow The plastic voltage indicator should be nested in the notch on the opposite edge of the voltage you want to select It should be oriented in the same direction as the arrow next to the selected voltage 5 Tochange the selected voltage slide the plastic indicator around the square making sure it settles into the correct notch on the outside edge and the appropriate space inside the square 6 Press the voltage selector back into its space until it snaps into place Insert it right side up and in the direction of the arrow next to the selected voltage The voltage indicator the white plastic piece is on the outside so that it shows when the fuseholder is replaced 7 Replace the fuseholder in its space Ensure that the white plastic indicator is in the correct setting for the voltage you want 8 To change the voltage setting for the computer you are using with your pump system consult the operator s manual for your computer Many computers have a switch for changing the voltage setting Many monitors have an autoswitch power supply set to 100 250 volts and do not need to be changed 10 4 Replacing a Fuse Ifa fuse blows in the CMD 5000 Dual Controller Driver replace it by following Ste
8. above 80 C the pressure transducers must be mounted outside the oven To facilitate their placement outside the oven high temperature systems are shipped with a longer length of fluid tubing to connect the pressure transducer to the cylinder barrel 8 8 2 Valves and Pilot Solenoids The pilot solenoids for the valves cannot be placed in an oven The pilot solenoids should be placed just outside the oven so that the air tubes connecting the pilot solenoids and the valves are as short as possible See the Valve User s Manual for information about high temperature operation of the CV 310 valves The high temperature valves can be heated to 160 C Chapter 9 SYSTEM CABLES SYSTEM CABLES The Quizix 5000 Series Pump System includes numerous cables that connect the components of the system These cables are labeled so that connecting them should be self explanatory All of the cables necessary to operate the system are described in this chapter Each cable is also described in the chapter s explaining the components to which it is connected 9 1 Motor Cable The motor cable which is part of the motor assembly connects the pump cylinder motor to the CMD 5000 Dual Controller Driver One motor cable is provided for each pump cylinder in the system This cable has a 9 pin D style connector at the CMD 5000 end and is permanently attached to the pump cylinder at the other end The motor cable is a round shielded cable Each motor cable mu
9. conditions hover around the servo and hold conditions The pump cylinder will Servo Extend until the desired pressure is reached Hold Extend for a moment then Servo Extend again Servo Retract because the pressure moved too high then Hold again etc Servo Ret The Servo Retract condition is the same as the Servo Extend position except that the piston is retracting in order to achieve a desired pressure It differs from the Retracting condition because the piston continues to retract only until the desired pressure is reached and then will hold Other Messages Not Inst The pump controller constantly verifies that all of the hardware necessary to properly operate a pump cylinder is present and properly connected If any hardware is not present a Not Inst not installed message appears in the motion status field This message is the result of two or more of the following cables being disconnected motor cable sensor cable or the transducer and valve cable 4 6 Chapter 4 PUMP OPERATING BASICS Table 4 1 Motion Status Parameters 3 of 3 Condition Description Error This message appears as a result of any of the error conditions shown on the Current Error field on the status bar Typical errors may include overpressure conditions or the activation of a soft limit on the sensor board Check the Current System Status on the Error Log menu to find out which error is present Undefined No pump has
10. looking straight down at the motor shaft and its key carefully slide the bearing and spline over the center shaft The orientation of the bearing is very important As shown in Figure 11 10 the two rivets in the bearing should be facing out and the uncovered ball bearings should be in against the motor If this assembly becomes stuck on the motor shaft or if it does not slide completely on repeat Step 5 in this procedure to remove the bearing then try again Use a standard paper clip or equivalent probe to confirm that the key is still in place on the motor shaft by probing in the keyway for the key The flexspline may not slide completely down at first If this occurs gently slide it down into the fixed spline until it feels like it has bottomed out When properly in place the top edge of the flexspline should be slightly below the top surface of the wave generator bearing The snap ring that secures the wave generator bearing to the motor shaft is not flat When seen from the side its shape has a slight bend or curve to it as shown in Figure 11 13 Place the snap ring on a work surface with the concave side down and pick it up with the snap ring tool Be careful not to expand it more than necessary Chapter 11 MAINTENANCE Figure 11 13 Concave View of Snap Ring 22 Open the snap ring just enough to slide it onto the end of the motor shaft and into the shaft s slot 23 Use a 1 standard screwdriver to press do
11. Configuration Section 4 3 12 1 e Pump Cylinder Operation Mode Section 4 3 12 2 e Fluid Flow Direction Section 4 3 12 3 4 3 12 1 Pump Cylinder Configuration The 5000 Series pump cylinders can be configured in either of the following ways e Independent Each pump cylinder works alone for a single stroke volume or cycles for multiple stroke volumes for discontinuous flow e Paired The two pump cylinders work together for continuous flow One pump cylinder delivers fluid while the other pump cylinder is receiving fluid The pressure Chapter 4 PUMP OPERATING BASICS in the standby pump cylinder is matched to the pressure in the active pump cylinder just before switchover occurs 4 3 12 2 Pump Cylinder Operation Mode The 5000 Series pump cylinders can be operated in either of the following ways e Constant rate Pump maintains a constant fluid flow rate e Constant pressure Constant outlet pressure Pump maintains a constant user set outlet pressure Constant delta pressure Pump maintains a constant pressure differential as measured by an external pressure transducer 4 3 12 3 Fluid Flow Direction The 5000 Series pump cylinders can pump in any of the following fluid flow directions Delivery Pump will deliver the fluid to an experiment e Receive Pump will receive the fluid from an experiment Bi directional Pump will deliver or receive fluid as required paired constant pressure mode only 4 3 12 4 Choosing
12. In this mode a single pump cylinder is used to cycle Cycled IND CP C back and forth to hold a constant pressure to an experiment The pump cylinder may deliver or extend to hold pressure When the end of stroke is detected the valves are switched the direction changed and the pump cylinder is refilled During the refill standby retract stroke the rate is determined by the return rate factor and return rate minimum The fluid flow in this mode is discontinuous due to the refill stroke After refilling the cylinder will servo to the set pressure before opening the deliver valve and starting the next stroke As long as pressure does not change much during the refill time which can be less than one minute the system will hold pressure 4 13 Quizix 5000 SERIES PUMP MANUAL Table 4 2 Operating Modes Mode No Operating Mode Description Independent Constant Delta Pressure IND CDP In this mode a single pump cylinder operates at a constant delta pressure as specified by the user The pump cylinder will either extend or retract for one piston stroke The user must set the valves and restart the pump cylinder for each piston stroke The direction of pumping action is determined by whether the piston must extend or retract in order to achieve the specified delta pressure For example across an experiment Paired Operating Modes 4 Paired Unidirectional Capillary Viscometer
13. Not Constant cccccccccceeeeeees 12 16 Overshoots Setting cece 12 16 INDEX Problems 24 nisstecranaicieneadicete varies 12 15 Gt yale sent cde ancien ES 4 9 Changing a Set Pressure 4 9 Changing Multiple Set Pressures 4 9 Pressure Transducer 1 4 8 1 8 4 8 8 11 21 Calibrating w asassacsdexvsssicestastinausaeinn 11 20 Check rrn irei harnda aa 3 5 ETOT e ee ree R E 12 15 What is a Pressure Transducer 11 21 Pump Name sot cc oe th coteae 4 4 NUMDET oe c1ic8 esrnneton asad tink 6 4 Operating Basics ceceeeeeseeeeees 4 1 Safety Features ic siccevccseecc us sictaizeens 5 1 Pump Controller Diagnostics aca steotelectcden ve 6 6 12 6 See also CMD 5000 eee 12 6 BVT EW ALC nia nii S a Ea 6 7 Initialization 0 eects 12 8 Pump Cylinder si cssschcsscsdadtiaideaieres 5 4 7 1 5000 Series Models ccceceeeeeees 1 2 6000 Series Models asiesscesicccaisouiess 1 2 Base Plateren inae n i 7 7 C5000 anana aiiai 1 3 C 5000 Ambient Temperature 2 2 Components i cascidsctermdentawen 1 2 Configurations cceseeseeeeeeeees 4 10 Direction secsen de caass acces eiecencetane eiaccets 4 18 High Temperature ccc ed caiiieces 8 8 High Temperature Option 7 7 Independent Configuration 4 16 Maintaining 2s 23h pcsaley cea deurie ccpne Alone als 11 9 Mixed Configurations 08 4 17 Mixed Modes sccsccncs Mcaeedscaas 4 17 N MDE menre
14. PUMP STAND 7 5000 SERIES PUMP y eS CYLINDERS Z NG a mae i Y a a m J SAFETY RUPTURE E l ISK ee ree i a i 7 Figure 2 3 Expanded Front View of a Stand Mounted SP 5200 TOOL BOX VALVE SOLENOIDS iae a aan CMD 5000 DUAL CONTROLLER N Q AOA o DRIVER 2 EACH l 5 ONE MOU i me Ai i I Lea gt e EE a J SP 5200 PUMP STAND is 3 y a 1 Le ZL 5000 SERIES PUMP CYLINDERS 4 EACH 5 7 A ri 7 oj 2 N P E A e N A CMD 5000 DUAL 26 5 IN j __ CONTROLLER DRIVER au ST 2 SF CM ed 2 EACH A A 2 2 m A Fas X ON j Beon fo 4 V i J a aT J f pe A on y j A 7 ome 5055 a x i SF SAFETY RUPTURE l WSK B P s a T a y Figure 2 4 Stand Mounted SP 5400 System S Z dN13S WALSAS z 13 dey9 Quizix 5000 SERIES PUMP MANUAL 2 3 Setting Up a Stand Mounted System This section describes how to set up a stand mounted system Schematics for a stand mounted SP 5200 two cylinder system and SP 5400 four cylinder system are shown from the top front and side in Figure 2 2 and Figure 2 4 An expanded front view of a two cylinder system is shown in Figure 2 3 1 Loosen the cylinder retaining fingers and orient them at 90 degrees 2 Loosen the three 3 valve assembly slide screws Slide the valve assembly to the left and up as far as it will go Re tighten
15. Pump Works main window shows Errors Present a pump cylinder cannot be operated until the error is cleared The Current Error Log which is located on the Error Log menu of PumpWorks main window will give a description of the error and includes a button where a user can acknowledge that they have read the error The user must also correct the condition that caused the error message See Chapter 12 Troubleshooting for more information regarding error messages and how to clear them 4 19 Quizix 5000 SERIES PUMP MANUAL This page intentionally left blank 4 20 Chapter 5 SAFETY FEATURES SAFETY FEATURES Quizix pump systems are capable of creating and maintaining very high pressures Safe operation of these systems is a primary concern The safety features described in this chapter are designed into all Quizix 5000 Series Pump Systems 5 1 Cable Connections Sensing To verify that all major components are present before a pump system can be operated Pump Works includes a feature that detects the connection of the following cables e Motor cable pump cylinder motor to CMD 5000 Dual Controller Driver Sensor cable pump cylinder sensor board to CMD 5000 Dual Controller Driver e Transducer and Valve cable pressure transducers and valve solenoids to CMD 5000 Dual Controller Driver e Data Link cable CMD 5000 Dual Controller Driver to Serial Expander Isolator Ifa connection is not detected an error message is display
16. Rate mode The plastic or aluminum part that covers the side rails of the pump cylinders These are located under the left and right side covers of the pump cylinders and keep the ball nut from spinning freely when under load or pressure at an angle This switch is located on the sensor board When activated this switch quickly stops the piston from moving any further in the direction it had been moving However the piston is able to move in the opposite direction A computer program which in this case operates the pump system This is a number which indicates which version or code number of the PumpWorks software you are using It is viewed from the menu item titled software versions It also tells you the code number of the software in the control ler Range of values that the user may input to change the zero point setting on a pressure transducer This is a petroleum based product used for cleaning See Autoclave speedbite fitting A plastic insert used to protect speedbite fittings or ports during shipping A solid metal piece that completely seals a fluid port A fluid port designed to fit an Autoclave Speedbite Fitting This is an abbreviation for stainless steel This is a type of steel which is mostly resistant to corrosion When two pump cylinders are being operated in a continuous flow delivery mode the cylinder that is filling with fluid and pre pressurizing is the standby pump cylinder The del
17. SL Soft Limit Warning stroke position outside normal bounds emalfunctioning motion sensor UC Valve Cable Error e valve cable not connected To correct cable errors locate the cable that the problem is reported on and make sure it is fully plugged in For driver or power supply shutdown error try powering the pump off and then back on These devices have overload protection circuits that shut them down when overloaded and are reset when powered on 12 4 Other Pump Troubleshooting Situations Most error messages are very easily understood and resolved Some pump conditions either do not generate an error message or are more complicated to diagnose Below are some pump situations that may occur e Air Supply Problems Section 12 4 1 e Fan Does Not Run Section 12 4 2 e Fluid Leaks Section 12 4 3 e No Fluid Is Being Delivered Section 12 4 4 e Piston Motion Errors Section 12 4 5 e Pressure Problems Section 12 4 6 e Valve Problems Section 12 4 7 12 4 1 Air Supply Problems The valves on the 5000 Series Pump System need a CLEAN DRY air supply between 4 5 and 6 9 bar 65 to 100 PSI to properly operate 12 4 1 1 No Air Escaping Sound When Valves are Opened and Closed The most likely cause of this problem is that the air supply is not dry so the pilot solenoids have rusted and stopped switching To check this turn off your air supply unplug your air line and check if there is any water in the line If the pilot solenoids h
18. Status STOP ALL PUMPS Current Pressure PSI 6 7 89 8 Set Pressure PSI Current Flow Rate ml min 0 0000 0 0000 Set Flow Rate ml min Cylinder Volume ml 0 000000 0 000000 Cumulative Volume ml 0 000 Operating Mode IND CR Piston Direction Retract Retract Fill Valve _Gosed Closed Deliver Valve Closed Closed Status Bar p Active Pumps 1 Data Logging OFF Sequencer OFF Figure 4 1 PumpWorks Main Window 4 2 2 Title Bar The title bar appears at the top of the main window The title bar lists the currently active window PumpWorks 95 NT Main Pump Data amp Controls Figure 4 2 Title Bar 4 2 Chapter 4 PUMP OPERATING BASICS 4 2 3 Menu Bar The menu bar appears at the top of the main window in PumpWorks below the title bar The menu bar has nine pull down menus Each pull down menu contains options which allow the user to regulate an aspect of their pump system See Figure 4 3 Main DataLog AutoOp Other Error Log Configure Communications Windows Help Figure 4 3 Menu Bar 4 2 4 Pump Data amp Controls Window PumpWorks Pump Data amp Controls window also referred to as the main window appears when PumpWorks is initialized See Figure 4 4 below The main window is the core of PumpWorks and displays information and settings for up to eight pump cylinders Pump Data amp Controls Pump Name Pump 1 Cylinder Number Cylinder 14 Cylind
19. System The pump controller operates the pump system according to the settings made in Pump Works It coordinates all system components and maintains the safety and integrity of the pump system 2 The motor driver provides the drive for the stepper motors attached to the C 5000 pump cylinders The motor driver converts the pulse and directional signals from the pump controller to high current motor drive signals The CMD 5000 Dual Controller Driver is a 2 channel unit and can control two C 5000 pump cylinders Pump systems with three or four pump cylinders will include two CMD 5000 s Pump systems with five or six pump cylinders will include three CMD 5000 s The CMD 5000 Dual Controller Driver measures approximately 30 x 19 x 13 centimeters approximately 12 x 7 1 2 x 5 inches It must be used with a Serial Expander Isolator which is also discussed in this chapter For simplicity the CMD 5000 Dual Controller Driver is often referred to as the pump controller in this manual 6 1 The Pump Controller Subcomponent The pump controller portion of the CMD 5000 is the brains of the entire pump system It performs the following specific functions e Controls pump cylinders through real time control of the rate and direction of the stepper motors e Controls the operation of the valves e Monitors fluid pressure as measured by the pressure transducers e Monitors safety shutdowns such as when a safety pressure error occurs
20. The side rails and rollers transfer the torque from the ball nut so that the ball nut does not spin and slide down the ball screw when fluid in the cylinder barrel is at high pressure The torque is transferred from the ball nut to two rollers one on each side and then to the side rails which are directly under the side covers on each side of the pump cylinder 7 4 Cylinder Barrel and Seal Assembly The cylinder barrel contains the fluid being pumped There are two fittings Autoclave 1 8 inch AE speedbite W 125 on the end of the cylinder barrel Tubing that connects to the valves should be inserted into the upper speedbite fitting this tubing serves as the inlet and outlet of the pump cylinder Tubing from the pressure transducer should be connected to the lower fitting so that the transducer can monitor pressure inside the cylinder barrel The C 5000 20K pump cylinder has only one fitting at the end of the cylinder barrel which is an Autoclave F250C This fitting connects to a cross which then connects to the pressure transducer and safety rupture disk assembly The fluid is held in the cylinder barrel by a seal Ambient temperature versions of the C 5000 pump cylinder use a seal constructed of ultra high molecular weight polyethylene UHMW PE which is a soft plastic High temperature versions of the pump contain seals made of Aflas or sometimes PTFE which is a type of Teflon Tests have shown that the seals used in the Quizix
21. an Operating Mode To choose an operating mode e Click on the operating mode button for a particular pump cylinder This is located to the right of the operating mode title The Set Cylinder Operating Mode window opens as shown in Figure 4 6 below 4 11 Quizix 5000 SERIES PUMP MANUAL 4 12 Set Cylinder 1A Operating mode fie E E 5 E E 12 Figure 4 6 Set Cylinder Operating Mode The Set Cylinder Operating Mode window gives the user a list of the possible operating modes available for their pump system An operating mode is grayed if it is not available for the user s pump system To set an operating mode click on the operating mode s number which is to the left of the operating mode name The Set Cylinder Operating Mode screen closes Your pump is immediately changed to the new operating mode Quizix strongly recommends that you become familiar with all of the operating modes A brief description of each operating mode follows however the PumpWorks manual explains operating modes in depth Operating modes should be clearly understood before running any Quizix pump Chapter 4 PUMP OPERATING BASICS Table 4 2 Operating Modes Mode No Operating Mode Description Independent Operating Modes 1 Independent Constant Rate IND CR In this mode a single pump cylinder is operating in constant rate mode at a user set rate When a pump cylinder is operated in this mode it e
22. and reinsert them into the cylinder they were removed from For example the back up ring and piston from cylinder 1A should be re installed into cylinder 1A NOTE Usually some fluid remains in the pump cylinder and spills out when the piston is free from the seal Be prepared to catch or wipe up this excess fluid When the cylinder barrel is completely detached it can then be cleaned and inspected 11 2 2 Changing the Seals Seal life depends on the type of seal used and the operating conditions of the pump pressure flow rate and type of fluid that is pumped The design of all Quizix pump cylinders makes changing seals a simple procedure This section instructs the user how to change seals Included are the following e Cup Type and T Type Seals Section 11 2 2 1 e Seal Removal Procedure for All Seals Section 11 1 2 2 Seal Insertion Procedure for Cup Type Seals Section 11 2 2 3 e Seal Insertion Procedure for T Type Seals Section 11 2 2 4 11 2 2 1 Cup Type and T Type Seals The cup type seal used in Quizix pumps is shown in Figure 11 1 It is asymmetrical with one side flat and one side having an open area around its circumference with a metal spring inside this opening A cross section of this type of seal resembles a cup or the letter U Chapter 11 MAINTENANCE T Type Seals Cup Type Seals High Temperature Ambient Temperature Figure 11 1 T Type and Cup Type Seals Cup type seals are made from ultra high molec
23. both pump cylinders change direction simultaneously at the same time Geared modes are not pulse free The conditions the pump system is set to run within Crossing at a right angle or 90 degrees This screw head has two lines on its head which cross each other at 90 degrees A screwdriver designed to tighten or loosen Phillips head screws An electrically operated air solenoid which controls air flow and is used to open or shut the fluid paths in the CV valves This part takes in air from the air supply and distributes it to the pilot solenoids The pilot solenoids pilot solenoid manifold and air tubing and fittings A cylindrical rod used to displace fluid in the cylinder barrel This is a metal part with a cut out area to support the piston inside of the pump cylinder A hexagonal six sided metal nut that is part of the piston holder The piston nut is used when extracting the piston from they cylinder barrel Quizix 5000 SERIES PUMP MANUAL piston position display piston removal tool piston stroke piston stroke volume pneumatically actuated pneumatic valve positive displacement pumps power connector assembly pre pressurize pressure pressure pulse pressure transducer pressure transducer cable pressure transducer calibration pressure units A bar graph in the PumpWorks software that shows how far the Piston is inserted inside of the Cylinder Barrel This tool supplied with
24. by the single stroke fluid volume Independent cylinder operating modes are not capable of pulseless continuous fluid flow of more than one stroke volume One pump cylinder operates by itself to maintain a constant pressure differential across a portion of a fluid path by changing the fluid delivery rate as needed Continuous operation is limited to a single stroke fluid volume One pump cylinder operates by itself to maintain constant fluid pressure at a user selected value To accomplish this the fluid delivery rate of the pump cylinder will change as needed Continuous operation is limited to a single stroke fluid volume A single cylinder cycles between constant pressure operation and refilling Continuous flow is approximated by automatically refilling after each stroke volume is used up A single cylinder cycles between delivering and refilling Continuous flow is approximated by automatically refilling after each delivery stroke and then restarting fluid delivery One pump cylinder operates by itself at a user specified constant rate Fluid pressure will vary determined by fluid resistance in the fluid path Continuous operation is limited to a single stroke fluid volume An automatic pressure transducer calibration feature used with recirculation systems It is available for viewing only when in the recirculation mode Quizix 5000 SERIES PUMP MANUAL interrupt request kPa lag bolt logging interval lubricate
25. cgciesdardesdosagden taicentesss 11 9 11 3 2 Re Greasing the Ball Screw sesssseesesseseseessesessseesee 11 11 11 3 3 Re Greasing the Harmonic Drive Bearing 11 13 11 4 Cooling Fan Maintenance ciic 5scc 0ssceteseceeseisnsenwendadececareddnacbuaaaes 11 17 11 4 1 High Temperature Systems Asse ccsutilaatetedsi atin 11 17 11 42 CMD 5000 Faniran aie taksia 11 18 11 5 Replacing the Safety Rupture Disk ss sssssssesessessesessseseesesseseese 11 18 11 6 Calibrating the Pressure Transducers ss sssseseesesseseesseeesseseesesse 11 20 11 6 1 What is a Pressure Transducer 0 cccccsceesseceteceeeeeeees 11 21 11 6 2 Methods of Calibrating the Pump System 6 11 21 11 6 2 1 Calibrated Gauge Method cee eeeeeeeeeeee 11 22 11 6 2 2 Calibrated Pressure Source Method 11 24 1 7 VM alive Maintenance 4c eraten na an enaa eaaa eaaa AeneA ARa 11 25 TOC 4 TABLE OF CONTENTS CHAPTER 12 Troubles ROO 952 5004 sae ecndeled dasastne ye Qaadncasahawrcadeed a i 12 1 12 1 Troubleshooting Basics vccscisscsscseeeeiesecina davteevictesciecsta dee ctaaaa cans 12 1 12 2 PumpWorks Error Messages cccccssscesssecsteceeeeeeeceeseeenseenseenaes 12 2 12 2 1 Immediate EOTS a acts sciec at esd eceaseshigctinnldencstaseeciutacetecanagens 12 3 1222 Logged Errose nanei a a onlsues tae 12 3 12 2 2 1 Soft Limit Warning sseseseseesseesessesssesssesessseesese 12 3 12 2 2 2 Communication Err
26. cylinders are set to a paired operating mode all valve operations will be automatically set and controlled by the pump controller The user does not need to preset the valves to achieve proper operation When operating in a paired operating mode starting one of the pump cylinders in the pair starts the cylinder pair The pump cylinder that is started becomes the active pump cylinder and the other pump cylinder becomes the standby pump cylinder until the first switchover The direction of the active pump cylinder is determined by the operating mode selected For delivery operating modes the active pump cylinder extends first and the standby pump cylinder retracts For receive operating modes the active pump cylinder retracts first and the standby pump cylinder extends For example if you want to start a pump cylinder in paired constant rate delivery operation and start with cylinder A it will be the active pump cylinder and will extend first with its deliver valve open and its fill valve closed Cylinder B will be the standby pump cylinder and will retract first with its fill valve open and its deliver valve closed When cylinder A has delivered all of its fluid and reaches Max Extend it will switch with cylinder B Cylinder A becomes the standby pump cylinder and Cylinder B becomes the active pump cylinder The user may choose to use PumpWorks Smart Start setting With the Smart Start feature Pump Works and the pump controller decide the best way
27. end of the motor adapter housing facing down sharply rap the flat surface of the motor adapter housing on a thin piece of cardboard placed on a solid surface See Figure 11 11 Only one or two sharp raps should be needed to dislodge the wave generator bearing the flexspline the motor shaft key and the Lexan washer Any clean slightly cushioning surface will work for this step but wood is not recommended because small wood chips could get lodged in the ball bearings 11 14 Chapter 11 MAINTENANCE Rap Sharply One or Two Figure 11 11 Dislodging the Wave Generator Bearing NOTE The flexspline is the slightly flexible spline that fits on the outside of the wave generator bearing It has external teeth 6 Verify that all four components the wave generator bearing the flexspline the motor shaft key and the Lexan washer dislodge from the motor adapter housing Set them aside NOTE The flexspline may not easily separate from the wave generator bearing If these parts do separate gently slide the flexspline back onto the wave generator bearing If they do not separate proceed with this procedure 7 10 11 12 13 The fixed spline refer to Figure 11 10 will still be attached to the motor adapter housing Visually inspect the fixed spline making sure that there are no obvious signs of broken teeth unusual wear patterns or foreign particles in the grease Using a clean lint free cloth wipe offas m
28. errors are due to a bad command being received by the pump Noisy communication lines are normally the cause of this type of error Ifan input error occurs PumpWorks automatically retries and corrects for any dropped communications e No Response from Pump Error This error is most likely caused because the computer is busy with another task This can be corrected by keeping other programs from operating while using Pump Works or by getting a faster computer When PumpWorks receives no response it automatically retries and corrects for any dropped communications It should be noted that the Windows 98 operating system is particularly bad at being able to properly handle communications at times We can only hope that Microsoft s next operating system will be better 12 3 CMD 5000 Two Digit Display Error Messages The CMD 5000 Dual Controller Driver has a two digit display which is labeled Pump Number The two digit display relays information concerning the pump s status Using either letters numbers or a combination of the two the digital display can convey the following errors e analog overpressure errors e communication errors e digital overpressure errors e digital underpressure errors e driver fault errors malfunctioning controller or power supply or 12 5 Quizix 5000 SERIES PUMP MANUAL e the absence of a motor sensor or transducer and valve cable If no errors are present the two digit display will disp
29. exceeds what is available from the motor The motor then slips with a fast zipping noise If the cylinder direction was extend then e Check if the current pressure exceeds the pump s maximum pressure e The piston may not be fully seated into the ball screw and has hit the top of the cylinder barrel The ball screw drive may be blocked by something e Motor or driver may be malfunctioning If the cylinder direction was retract then e Motor or driver is malfunctioning 12 4 5 3 Piston Moves But Does Not Complete Its Stroke If the piston is moving normally in most of the operating range but gets stuck at one end or the other then check the following e The piston and piston holder may not be fully tightened into the end of the ball screw The motion of the ball screw drive may be blocked by a foreign object e The seal back up ring may have clamped down on the piston causing excessive friction The motion sensor may be malfunctioning 12 4 6 Pressure Problems The pressure transducers on the 5000 Series Pump System are essential for proper pump operation Any problem with the transducer will mean that the pump will not operate the way it is supposed to Several types of problems with the pressure transducers are covered below 12 4 6 1 Pressure Transducer Errors Ifthe pump reports a pressure transducer cable error this means that the cable from the pump controller to the transducer is no longer connected prope
30. fitted with an Autoclave 1 8 inch Speedbite fitting so that tubing can be attached to vent fluid to a container IMPORTANT Ensure that tubing is installed from the safety rupture disk port to an appropriate receptacle to prevent fluid from spraying into the atmosphere if the rupture disk is activated This is particularly important if you are using flammable or highly corrosive fluids The safety rupture disk included in all Quizix pump systems is a ONE TIME ONLY item that must be replaced if it is activated It is not a pressure relief valve and cannot be tested If you bring the system pressure up to the level at which the disk is designed to activate it will rupture and must be replaced 8 7 Quizix 5000 SERIES PUMP MANUAL 8 8 See Chapter 5 Section 5 3 4 for more information about the safety rupture disk Also see Chapter 14 for instructions on replacing a safety rupture disk after it has been activated 8 7 Hastelloy Option for Corrosive Fluids The Quizix 5000 Series Pump System including all fluid tubing valves safety rupture disk holders and parts of the pump cylinder is composed of either stainless steel SS 316 or Hastelloy C 276 If you pump fluids that are highly corrosive such as brines or oils then a Hastelloy option is available and recommended The Hastelloy option is highly corrosion resistant and substantially extends the life of your pump system When the Hastelloy opt
31. in one hand carefully insert it straight onto the piston then into the cylinder housing A firm pressure and some slight twisting action may be necessary to get the cylinder barrel assembly fully seated in the cylinder housing 4 Screw on and tighten the cylinder retaining ring nut with the face spanner wrench 5 Test the pump for proper operation and seal performance no leaks 11 3 Maintaining the Pump Cylinder This section describes cylinder maintenance It includes the following e Replacing the Cam Rollers Section 11 3 1 e Re Greasing the Ball Screw Section 11 3 2 e Re Greasing the Harmonic Drive Bearing Section 11 3 3 11 3 1 Replacing the Cam Rollers Recommended Frequency e For ambient temperature systems every 2 years of regular use or as required e For high temperature systems every year of regular use or as required Both the left and right side covers on the ambient temperature pump cylinder have vertical lines that are numbered 0 through 10 When the pump is operating the relative position of the piston can be monitored by watching the cam roller which is attached to the ball nut move from one line to the next 11 9 Quizix 5000 SERIES PUMP MANUAL There is a cam roller on each side of the pump cylinder Different cam rollers are used for high temperature and ambient temperature systems These components while simple perform an important job in the pump cylinder But their internal lubrication can d
32. included and described in the PumpWorks User s Manual 1 2 4 Valves Transducers and Plumbing For each pump cylinder the system includes one air actuated three way valve two valve solenoids and one pressure transducer All necessary plumbing fluid tubing and fittings and cables are also included 1 2 5 Support Stand A support stand is available on which all components for an ambient temperature 5000 Series Pump System can be mounted The stand makes the system extremely compact and facilitates installation and operation Two stand sizes are available a SP 5200 stand which holds two pump cylinders Refer to Figure 1 1 and a SP 5400 stand which holds four pump cylinders Chapter 1 GENERAL OVERVIEW A high temperature stand that supports only the pump cylinders but none of the other system components is generally used with high temperature pump systems that are installed inside ovens The high temperature stand which holds two C 5000 pump cylinders is shown in Figure 1 2 In high temperature systems the CMD 5000 Dual Controller Driver the pilot solenoids for the valves and the pressure transducers must be placed outside the oven SAFETY RUPTURE DISK Figure 1 2 High Temperature Stand for the 5000 Series Pump Cylinders Quizix 5000 SERIES PUMP MANUAL This page intentionally left blank Chapter 2 SYSTEM SETUP SYSTEM SETUP This chapter provides the information necessary to set up a Quizix 5000 Series
33. is the piston s maximum or most extended position possible The cylinder barrel has only a residual amount of fluid when the piston is in the Max Extend position Max Retract The piston is retracted as far out of the cylinder barrel as it will go Max Retract is the maximum or most retracted position possible The cylinder barrel is full of fluid when the piston is in the Max Retract position RUN CONDITIONS Extending The piston is in the process of extending or moving forward into the cylinder barrel While the piston is extending it is displacing the fluid causing it to be pumped out of the cylinder barrel This is known as delivering fluid Retracting The piston is in the process of retracting or moving backwards withdrawing from the cylinder barrel While the piston is retracting fluid is being pulled into the cylinder barrel and filling it This is known as receiving fluid Stopping The piston is in the process of stopping It is slowing down Normally the piston is in the stopping condition for only a brief period before it is fully stopped Quizix 5000 SERIES PUMP MANUAL Condition Table 4 1 Motion Status Parameters 2 of 3 Description Hold Ext Both the Hold Extend and Hold Retract conditions indicate that the pump is running but the piston is not moving It is running at a zero rate A hold status message appears when the system is matching a pressure or ser
34. is equal to the temperature in the surrounding room A device which increases the magnitude or amplitude of a signal such as voltage from a pressure transducer A metal plate thicker on one side that is mounted below the pump cylinder and supports the pump housing when it is resting on a table The angle base plate gives the pump cylinder a proper angle for operation This is a grease like mixture applied to the threads of metal nuts which prevents them from locking or seizing together so they can be separated in the future These keys are located on your computer keyboard They are arrows that can move your computer cursor in any of four directions The air that surrounds you The pressure that is present in the air or atmosphere around you Normal atmospheric pressure is about bar or 14 7 psi A 1 8 tube fitting made by Autoclave Inc which is used for sealing high pressure fluids This is the port that the Autoclave Speedbite Fitting connects into A feature of PumpWorks software which allows for the pump system to be operated automatically See Ramping Operations Using PumpWorks software the pump cylinder s will stop pumping after a specified amount of fluid has been pumped Using the PumpWorks software the pump cylinder s will stop pumping after a specified amount of time has passed Quizix pump controllers and PumpWorks software have auxiliary or spare A D channels that can be connected to your p
35. is too viscous or thick to be pulled into the pump It is a good idea at this time to go through the pump and check all fluid fitting connections to make sure they are tight Another possible cause is the pressure transducer may be broken and not reporting the pressure Open the fill valve and listen for pressure being released If there is pressure being released you probably have a pressure transducer failure or the pressure transducer is cross 3 5 Quizix 5000 SERIES PUMP MANUAL wired NEVER operate the system AT ALL if you have any reason to believe a transducer has failed Repeat this procedure for each cylinder in your system Do not proceed further until your system has passed this check After completing each of the above checks you can proceed to operate the system Remember however that if you disconnect any of the major components reconfigure the system change the plumbing or make any other adjustments that involve disconnecting and reconnecting any of the cables or tubing you should do each of these safety procedures again 3 6 Chapter 4 PUMP OPERATING BASICS In this chapter we discuss the basics of operating your 5000 Series Pump System using PumpWorks Software Included in this chapter are the following sections Introduction to Using PumpWorks Section 4 1 e PumpWorks Main Window Section 4 2 Pump Data amp Controls Window Section 4 3 e Set Safety Pressure Section 4 4 e Errors Pre
36. limit area use Independent Constant Rate mode 12 2 2 2 Communication Errors In order for PumpWorks to control a user s pump system communication needs to be established between the user s computer and pump s The following communication errors are covered in the sections below e Communication Cannot Be Established Section 12 2 2 2 1 e Once Communications Has Been Established Section 12 2 2 2 2 12 3 Quizix 5000 SERIES PUMP MANUAL 12 4 12 2 2 2 1 Communication Cannot Be Established If communication cannot be established between the pump and PumpWorks do the following e First check the two digit display labeled Pump Number located on the pump controller There is a right digit decimal point which is located to the right hand side of the right digit There is also a left digit decimal point which is located to the right hand side of the left digit The right digit decimal point flashes when signals are being transmitted from the computer to the pump controller The left digit decimal point flashes when signals are being transmitted from the pump controller to the computer When viewing the two digit display a user should see both decimal points flashing If the decimal points are not flashing there may be a break in the communications cable which carries the signal between the pump and the computer e Next check that the computer is properly connected to your pump To do this perform the Pump Works Connection C
37. locking fitting The compression ring is symmetrical so it can be installed with either side down 7 Screw the fitting finger tight and then use a torque wrench to tighten it to the torque specified on the metal tag attached to the disk The torque depends on the pressure rating of the safety rupture disk The safety rupture disk assembly is now ready to be re installed in the pump system Be sure to also re install tubing into the fitting of the relief fluid exit and plumb it to an appropriate receptacle The Spare Parts Kit included with each pump system includes one replacement safety rupture disk Additional safety rupture disks are available in stainless steel or Hastelloy and may be obtained from Vindum Engineering Quizix s sales agent The safety rupture disk s type and model number is printed on the tag that is attached to it 11 6 Calibrating the Pressure Transducers The pressure transducers on the 5000 Series Pump System need to be recalibrated periodically During normal use they should be recalibrated every 12 months If usage is heavy or if the pump has been subjected to unusual circumstances such as pressures above its rated pressure range then recalibration should be performed Also pressure transducers should be recalibrated after being taken apart and put back together Calibration keeps the two individual pressure transducers on two pump cylinders used as a pair reading the correct pressure The pump controller use
38. pressure entered becomes the set pressure Ifthe pump cylinder is operating when a pressure is changed the pump immediately adjusts to the new pressure 4 3 7 1 Changing a Set Pressure Change a single set pressure by clicking on the Set Pump Pressure button in the main window of Pump Works and entering a new value Each pump cylinder has its own Set Pump Pressure button 4 3 7 2 Changing Multiple Set Pressures To change the set pressure of one or more pump cylinders simultaneously go to Pump Works main window Select Main Set Pump Pressure from the menu bar and enter pressures for one or more pump cylinders in the Enter New Pressure box s Then click on Send Pressures to Pump s All new pressures are sent at the same time 4 3 8 Current Flow Rate The Current Flow Rate field displays the rate or speed that the pump cylinder is extending or retracting at The default unit of measure for flow rate is milliliters per minute ml min The user can set the unit of measure to either milliliters per minute or milliliters per hour Quizix 5000 SERIES PUMP MANUAL 4 10 4 3 9 Set Flow Rate The set flow rate field allows a user to change the set flow rate of a pump cylinder operating in a constant rate mode to a different flow rate The flow rate entered becomes the current flow rate Ifa pump cylinder is operating when a flow rate is changed the pump immediately adjusts to the new flow rate 4 3 9 1 Changing a Set Flow Rate
39. pump are leak free for long periods of use 7 5 Quizix 5000 SERIES PUMP MANUAL 7 6 CAUTION The seals can easily scratch and must be handled with extreme care during insertion The ambient temperature seal assembly is shown in Figure 7 3 The back up ring serves two functions it supports the seal and it guides the piston Because the seal has no structural strength it is supported by the back up ring which holds the seal in the seal cavity The seal and back up ring are held in place by a seal retaining nut Figure 7 3 Ambient Temperature Seal Assembly The size of the seal and the back up ring are determined by the size of the piston C 5000 10K pump cylinders have pistons which are 1 2 inch so the seals are also 1 2 inch As shown on Table 7 1 each pump cylinder model has a different piston size and the seals will be sized accordingly If the seal assembly is disassembled be sure to keep each cylinder barrel seal back up ring and piston from the same pump cylinder together as a group For best operating results the cylinder barrel seal back up ring and piston from a pump cylinder should be re installed into the same pump cylinder For instructions on how to change a seal see Chapter 11 Section 11 2 7 5 Pump Cylinder Sensor Board A sensor board is located under the right side cover of the pump cylinder This board detects the position of the piston at all times by tracking
40. pump system are air actuated Air is taken into the system at the pilot solenoid manifold then air lines connect the pilot solenoids and the valve Refer to Figure 8 2 Airis exhausted from the system through two outlets labeled EA and EB in the manifold The air inlet valve at the bottom of the manifold labeled P contains a 1 4 inch quick disconnect fitting You should insert a section of 1 4 inch tubing into this fitting to connect the system with a pressurized air source that is regulated at 75 120 psi A standard laboratory air supply with an air compressor may be used The air should be clean dry and oil free The manifold supplies air to all of the pilot solenoids Each solenoid actuates one fill or deliver valve through two air lines Each Vindum CV valve has a fill valve and a deliver valve and thus requires a total of four air lines The nylon tubing used as air lines to connect the pilot solenoids to the valves has a 1 8 outer diameter and is color coded See Figure 8 2 Because the air supply is used only when a pilot solenoid opens or closes a valve the system does not require a continuous air flow The amount of air used by the system to switch a valve is extremely small However because the pilot solenoids use a small quantity of air every time the valves are switched operation from a gas bottle is not feasible because the bottle would be emptied too quickly 8 3 Quizix 5000 SERIES PUMP MANUAL Figure 8 2 Air Co
41. standby pump cylinder becomes the active pump cylinder and the active pump cylinder becomes the standby pump cylinder In a paired configuration two pump cylinders can pump fluid continuously for an indefinite period of time Because the standby pump cylinder is pre pressurized to the pressure level of the active pump cylinder the fluid flow is pulseless It is important to note that except in Modes 4 5 and 5A the pump cylinder pair does not alternate in the usual sense the pump cylinders are not just mirror images of each other s motion The standby pump cylinder piston must move at a faster rate than the active pump cylinder piston so that it has time to pre pressurize before switchover 4 3 12 7 Mixed Configurations and Mixed Modes Any combination of independent and paired pump cylinders is possible For example a system with four pump cylinders may be operated as two pairs as four independent pump cylinders or as one pair and two independent pump cylinders However pump cylinders operating as a pair must share the same pump controller For example pump cylinders 2A and 2B can be a pair but pump cylinders 1B and 2A cannot The user can select different operating modes for each pump cylinder or pump cylinder pair For example in a system with three pump cylinders two pump cylinders can be operated in Paired Constant Rate Deliver mode and one pump cylinder can be operated in Independent Constant Pressure mode to provide overb
42. that you should use to service your system Stand mounted systems have a tool box mounted on the stand where these tools and spare parts are located A description of the special tools is described in Table 11 1 The spare parts kit is described in Table 11 2 11 1 Quizix 5000 SERIES PUMP MANUAL 11 2 Table 11 1 Special Tool Kit Item No Tool Description 1 2 inch angled open end wrench The 1 2 inch angled open end wrench is used to tighten the Speedbite fittings and is especially useful for tightening the two ports on the cylinder barrel 22 mm open end wrench The 22 mm open end wrench fits the flat area of the cylinder barrel Itis used to hold the barrel in place while tightening the fluid fittings or while tightening the cylinder barrel retaining ring Adjustable face spanner wrench The adjustable face spanner wrench is used to loosen and tighten the cylinder barrel retaining ring It is also used to remove and install the seal retaining nut or wash ring assembly if your system has one Seal extraction rod The seal extraction rod is a smooth metal rod with the same outside diameter as the piston It is used to extract a seal without damaging the cylinder Seal guide ring This ring guides the seal insertion plunger into the cylinder during seal replacement Seal insertion plunger This is a 3 step cylindrical rod used to push a seal out of the seal guid
43. the 5 In a pump system with two or more pump cylinders the cylinders in a pair are typically labeled A and B For example an SP 5400 would include four pump cylinders labeled 1A 1B 2A and 2B Within Pump Works two pump cylinders working together as a pair are referred to as a pump For example pump 1 consists of pump cylinders 1A and 1B All 5000 Series Pump Systems include the following components 1 2 1 C 5000 Pump Cylinder The pump cylinder is the basic building block of the system It is the component that performs the actual pumping A system can include any number of pump cylinders from one to eight 1 3 Quizix 5000 SERIES PUMP MANUAL depending on the type of experiments the user plans to conduct The user also chooses which of the six available C 5000 models would be best suited to their application The most popular pump cylinder model is the C 5000 10K which has a maximum pressure rating of 10 000 psi and a maximum flow rate of 15 ml minute Two pump cylinders are required to provide continuous flow of one fluid Working as a pair one pump cylinder delivers fluid while the other pump cylinder fills with fluid pre pressurizes and waits for its turn to deliver fluid At the end of one pump stroke the two pump cylinders switch and the pump cylinder that was delivering fluid now re fills pre pressurizes and waits for its turn to deliver fluid again while the pump cylinder that was rec
44. the ball screw pitch and motor resolution in the L models Thus all the information in this chapter applies to any of the C 5000 pump cylinder models manufactured by Quizix Figure 7 2 shows a simplified drawing of an ambient temperature C 5000 pump cylinder Cylinder Barrel Retaining Ring nut Tube attachment for optional Wash Area 23 00 inches Se a aes Right Side Cover Cylinder Barrel Pump Housing Left Side Cover Angle Base Plate Figure 7 2 C 5000 Ambient Temperature Pump Cylinder 7 2 Important Operating Notes This section lists important operating notes for the C 5000 pump cylinders 1 Operation at Low Pressures The C 5000 10K pump cylinder is designed for high pressure operation and uses pressure transducers that operate up to 10 000 psi All of the 5000 Series models are shipped with pressure transducers that correspond to their respective maximum pressure ratings If any of the pump cylinders except the C 5000 2 5K are operated at less than 100 psi the system does not perform optimally If you plan to operate the system at very low pressures such as less than 100 psi contact Quizix to obtain pressure transducers which are more effective at lower pressures 7 3 Quizix 5000 SERIES PUMP MANUAL 2 Orientation of the Pump Cylinder The pump cylinder is designed to operate horizontally It may malfunction if mounted in a vertical position There is a slight upward slant to the cylinder so t
45. the dual motor driver The sensor board is located under the right side cover of the pump cylinder This connects the pump cylinder sensor board to the dual motor driver A programming language available in the Pump Works software to set up and automatically control complex pump operations An interface device which allows up to four Quizix pump units to operate from one computer communication port The serial data cable from your controller plugs into this slot on the back of your computer It is also called the Com Port or the Communications Port A servo operates to keep a selected parameter constant by changing one or more other parameters The piston is in the process of extending in order to achieve the desired pressure The Piston is in the process of retracting in order to achieve the desired pressure This is used in independent operating mode to instruct a specific pump cylinder to either extract or retract The field where the user sets the pressure that the pump will pump at when operating in constant pressure or constant delta pressure mode set flow rate side covers side rails slope soft limit switch software software version software zero offset range solvent speedbite fittings speedbite plug protectors speedbite plugs speedbite tubing port SS stainless steel standby pump cylinder standby time GLOSSARY The user sets the rate the pump flows at when operating in a Constant
46. the location of the ball nut to which the piston is attached It does this by two different sensing techniques First there are six microswitches that are activated by the roller which is attached to the ball nut As the ball Chapter 7 PUMP CYLINDER nut moves down the ball screw each microswitch is activated in succession Secondly a magnet is located just behind the roller The sensor board contains eight reeds that register as the magnet moves across them The piston position data gained from both the microswitches and the reeds is transferred to the CMD 5000 Dual Controller Driver through the sensor cable The piston position is displayed on the PumpWorks main window and even more detailed information is available in the Cylinder Switch Status window Ambient temperature versions of the pump cylinder have clear plastic side covers so that the position of the roller can also be monitored visually The side covers are marked with a scale from to 10 indicating the full range of the piston s motion in milliliters The roller can be used as an indicator of the piston s position High temperature versions of the pump cylinder have an aluminum cover with a slot cut into it for viewing the roller position 7 6 Pump Cylinder Base Plate The pump cylinder is mounted to a base plate with four bolts The base plate has a slight slant to it about 1 degree so that the cylinder is tilted upward when it is mounted This upward tilt permits
47. the oven so that the motor extension tube extends through the oven wall with the entire motor and fan cooling assembly residing outside of the oven Generally one hole must be cut in the oven wall for each cylinder The Quizix High Temperature Stand provides a convenient method of mounting pairs of pump cylinders inside ovens See Figure 2 5 Chapter 2 SYSTEM SETUP Figure 2 5 High Temperature Stand for the 5000 Series Cylinders 2 4 2 CMD 5000 Dual Controller Driver The CMD 5000 must be placed near the pump cylinders and must be outside of the oven Connect the motor and sensor cables to the appropriate cylinder connectors It is highly advisable to keep the motor cables short Standard 2 meter motor extension cables are available from Quizix but it is recommended not to use these extensions if possible 2 4 3 Transducers The standard pressure transducers supplied with the system are designed for operation to 70 C They can be used at temperatures up to 80 C inside an oven without severely shortening their lifetime However for temperatures above 80 C the transducers must be mounted outside the oven 2 4 4 Valves A high temperature version of the valve is available that can be heated to 160 C However the pilot solenoids cannot be placed in an oven The pilot solenoids should be placed outside the oven with air tubes connecting the solenoids and the valves Use high temperature tubing Teflon and compression fi
48. to prevent faulty and malfunctioning 11 23 Quizix 5000 SERIES PUMP MANUAL transducers from being calibrated and giving the illusion of working For more information on calculating offsets and gains see Section 9 1 3 How to Calculate an Offset and Gain in the Pump Works User s Manual 11 6 2 2 Calibrated Pressure Source Method 1 As shown in the Calibration Setup Diagram in Figure 11 15 connect a calibrated pressure source PS to the fluid outlet of your Quizix Pump System Be sure your fill valves are connected to a fill reservoir at atmospheric zero gauge pressure 2 Set the system to zero gauge pressure as follows for the cylinder s being calibrated open the fill valve s so the cylinder pressure is at atmospheric or zero pressure The deliver valve s can also be opened if desired 3 Adjust the offset Go to PumpWorks main window From the menu bar select Other Software Pressure Transducer Calibration In the Software Pressure Transducer Calibration window select Current Offset The easiest way to adjust the offset is to select Auto Zeroing Doing this will result in the computer calculating the necessary offset to have the display read zero pressure The range of zero offset is limited so that a malfunctioning transducer or a transducer with significant pressure accidentally left on it will not be able to be zeroed Alternatively the user can compute the desired offset and ent
49. to start the cylinder pair by selecting which pump cylinder becomes the active pump cylinder and which becomes the standby pump cylinder If the Smart Start feature is not used the user must make these choices Paired Constant Pressure Bidirectional operating mode runs at a constant pressure by switching between delivering and receiving to maintain the set pressure The valves will automatically switch as required Please note that for constant pressure operation the actual pressure compared to the set point determines the direction of the pump cylinder 4 3 5 4 Stopping Pump Cylinders Pump Cylinders can be stopped by using any one of the following methods e Using the Push to Stop button on the main window of PumpWorks Each operating pump cylinder has its own Push to Stop button For independent operating modes each pump cylinder s Push to Stop button will need to be pushed For paired operating modes only one Push to Stop button needs to be pushed to stop the pair of pump cylinders e Selecting Main Start Stop Pumps from the menu bar of the main window of PumpWorks This window displays all pump cylinders in a user s system Any number of pump cylinders can be started or stopped simultaneously using this one window e Using the computer function keys if this option is enabled in PumpWorks System Settings window Each function key is assigned to a particular pump cylinder in order Chapter 4 P
50. tubing from the fluid outlet tee to the user s experiment There is one fluid outlet tee for each pair of pump cylinders The fluid that flows through this tubing is at the user specified rate and or pressure 8 5 2 Stand Supplied Tubing If your pump system is mounted on a support stand which is typically done for ambient temperature pump systems the following plumbing connections are provided See Figure 8 3 e Inlet Tee to Valve Tubing Two sections of tubing are used to connect the fluid inlet tee to the fill side of each valve e Outlet Tee to Valve Tubing Two sections of tubing are used to connect the fluid outlet tee to the deliver side of each valve Cylinder to Valve Tubing Two pieces of tubing connect the upper port on the cylinder barrel to the center section of the valve In between the cylinder barrel 8 5 Quizix 5000 SERIES PUMP MANUAL and the valve is the safety rupture disk holder This tubing functions as both the inlet to and the outlet from the cylinder barrel e Cylinder to Pressure Transducer Tubing One section of tubing connects each pump cylinder to a pressure transducer The pressure transducer tubing connects to the lower fitting on the end of the cylinder barrel A Valve Inlet Tubing B Valve Outlet Tubing C Cylinder to Valve Tubing Two pieces per cylinder D Cylinder to Pressure Transducer Tubing Figure 8 3 Plumbing Components for One Pair of A
51. your hand close to the cooling fins on the outside of the cylinder s stepper motor 2 Verify that a steady flow of cool air is being forced over the cooling fins and that the fan is operating quietly making only a steady whirring sound 11 4 2 CMD 5000 Fan Recommended Frequency every 12 months of regular use The CMD 5000 includes a thermostatically controlled fan Because it is thermostatically controlled it turns off automatically when air is not required for cooling The CMD 5000 also has a set of large black cooling fins mounted to its top panel The left side of these fins rise up perpendicular to the top panel but the right side of the fins rise up at a 40 angle Looking down from the top of the unit the motor driver s cooling fan can be seen at the base of the 40 angled side of these fins When the fan inside the CMD 5000 is on you will be able to feel air flow across the heat sink fins You will also be able to hear the sound of the fan which is a steady quiet whirring sound Because the fan is thermostatically controlled it will not operate continuously You should ensure however that it does turn itself on and off automatically 11 5 Replacing the Safety Rupture Disk Recommended Frequency every 2 years of regular use If you regularly operate your pump system at pressures in the range of 80 to 100 of maximum pressure 8 000 10 000 psi for a C 5000 10K pump cylinder system note that safety rupture dis
52. 00 also includes a thermostatically controlled fan When the fan is on you will be able to feel air flow across the top of the heat sink You will also be able to hear the sound of the fan located inside the CMD 5000 Because the fan is thermostatically controlled it turns off automatically when air is not required for cooling resulting in quieter operation The air holes on the bottom of the CMD 5000 provide the air intake for the fan Both the heat sink and the air holes must have access to fresh room temperature air Do NOT put a CMD 5000 Dual Controller Driver into an oven 6 3 On Off Switch Power Cord and Fuse Holder The On Off switch is a small black rocker switch on the back side of the controller next to the power cord Press it to turn on the CMD 5000 When the CMD 5000 is turned on a sequence of diagnostic tests is run as shown on the two digit display labeled Pump Number In general the user should install all cable connections and have PumpWorks running on their computer BEFORE turning on the controller Watch the two digit display when the controller is turned on see Section 6 5 for important information on this feature WARNING THE PUMP CONTROLLER SHOULD BE TURNED OFF BEFORE CONNECTING OR DISCONNECTING ANY OF THE CABLES A modular power cord receptacle is next to the on off switch The power cord should be connected to an AC power outlet preferably by way of an Uninterruptable Power Supp
53. 00 psi 25 000 psi Figure 5 1 Safety Rupture Disk Assembly 5 3 Quizix 5000 SERIES PUMP MANUAL 5 3 4 1 Safety Rupture Disk Holder All C 5000 Pump Cylinder models except C 5000 20K For systems rated at 10 000 psi or less the safety rupture disk holder shown in Figure 5 1 is a round metal component that is installed between the valve and the pump cylinder The safety rupture disk holder has reversible inlet and outlet openings that use Autoclave W125 1 8 speedbite fittings Located inside the holder is a Fike 3 16 rupture disk that is held in place by a compression ring and locking fitting which is connected to the port on the bottom of the holder If the specified pressure is exceeded the safety rupture disk bursts and fluid is expelled through the relief fluid exit The fluid exit port is also fitted with an Autoclave W125 1 8 speedbite fitting so that tubing can be attached to vent fluid to a harmless location 5 3 4 2 Safety Rupture Disk Holder C 5000 20K Pump Cylinder models For C 5000 20K systems the safety rupture disk holder is a 1 4 high pressure male inlet safety head The holder is connected to the plumbing cross which is then attached to the pump cylinder If the specified pressure is exceeded the rupture disk bursts and fluid is expelled through the relief fluid exit The relief fluid exit is a 3 8 NPT fitting which can be easily adapted so that tubing can vent fluid to a har
54. 2 14 12 4 5 2 Motor Stall Error si 2 syct cease beat means 12 15 12 4 5 3 Piston Moves But Does Not Complete Its Stroke 12 15 12 4 6 Pressure Problems s css 3i cisistiausdiaciisrntin asaasseaunse 12 15 12 4 6 1 Pressure Transducer Errors cceeseeseeeeeetees 12 15 12 4 6 2 Pressure Does Not Increase Within 30 Seconds 12 16 12 4 6 3 Pressure Overshoots Setting in Constant Pressure INGA ccc cg aneaaidnah gal sca ae cadeueeetactve inane tee ees a has 12 16 12 4 6 4 Pressure Is Not Constant in Constant Pressure Mode12 16 12 47 Valve Problems nsnsi ano aae ai 12 16 12 4 7 1 Valve Cable Connection Check 00c000 12 17 12 4 7 2 Checking Your Air Supply ccccceeseereeeeee 12 17 12 4 7 3 Air Supply Requirements ccceeceeceereetees 12 17 12 4 7 4 Checking Your Air Supply Connection 12 17 12 4 7 5 Pilot Solenoid Check e2 cccccccvidensdeacsekadendelces uate 12 17 12 4 7 6 Clogged Obstructed Valve cceeeeeeeeeeeeeee 12 17 12 4 7 7 Valve Leaks Fluid When Closed 0665 12 18 12 5 Software Updates ai ai cccates cactteces cestode atna sauce ae yctee slincact inmates 12 18 Quizix 5000 SERIES PUMP MANUAL TOC 6 1000 Chapter 1 GENERAL OVERVIEW GENERAL OVERVIEW This manual the Quizix 5000 Series Pump System User s Manual provides operating and maintenance instructions for the hardware of all Quizix SP 5000 pump systems A separate manual the PumpWorks User s Man
55. 2s0S sosuts Coors ut atslc otc lanai anak 7 1 7 2 Important Operating Notes oes 20d sancasstavasadiscaad ssa cicedsvstceosectodeatness 7 3 7 3 Primary Mechanical Subcomponents of the Pump Cylinder 7 4 Ted A SEP PEE Motor siririna nen e tie etme E E E T a 7 4 7 3 2 HatMmonie DIVE soi eta Aisne baiaeg Atria ian dw bee aid 7 4 7 3 3 Ball Screw and Ball INUts zssvsstsus tx dhachave cedbandeseasandanstotesdacsdas 7 4 7 3 4 Ball Nut A SSSI Yc asirs ceduleseede ceo unetassnnes eae cuedeateaea tewetabdeadeatavares 7 4 7 3 5 Piston and Cylinder Bartel ic ciccssos ceeds oateatabe palitdsey 7 4 PS CALMING snes sen ectiv ccs oot a a vs Ses eed est e aan aes 7 5 7 3 7 Side Rails and Rollers 34 3 cea sstecsscete ceed seataccy shesees caudate 7 5 7 4 Cylinder Barrel and Seal Assembly 0 cc ccecceeccesseeeteeeteeeeeeeneees 7 5 7 5 Pump Cylinder Sensor Board is cicccctisssecateenteccecsteeteccte tines 7 6 7 6 Pump Cylinder Base Plate scion ciate caisson sie Guient 7 7 7 7 Hastelloy Option for Corrosive Fluids 20 0 0 eee eeeeeeseesteeeteeeeeeeeeeees 7 7 7 8 Pump Cylinder High Temperature Option 0 cccecceeseeeseeseeeteees 7 7 7 9 Pump Cylinders with Optional Wash Ring cc eee ceeeeeeeteeeeeee 7 9 CHAPTER 8 Valves Transducers and Plumbing 00 0 0 ccc ccceceseeesceeseeceteeeeeeeeeeeeaeees 8 1 BL W AIVES Ainoana dese ciate Waa a hides Meee A 8 1 8 2 Pilot SolenGrdss siscuacs aie a a a as 8 2 SS PAE SUIS saxty ascioa
56. 4 Ball Screw minana a 7 4 Re greasing veccaiisiesaiciiecaus ecceadhaace 11 11 Bearing cee aecen tannau an 7 5 C Cable mienta a Ta EE A 9 1 Connections Marie Gus deeetosans awed 6 3 Connections Sensing cceeeeeees 5 1 Data Link ooeec 3 2 6 3 9 2 EXtensiOns oan Satie 9 3 Front Panel eener 6 4 9 3 Labeling ccscccSisatecs cae adcaraes aan 5 1 Motor cietisisce cb laid 3 2 6 3 9 1 POWE i naa a tik Matar tate oe 9 2 R832 32 ce ene euniee 6 4 RS 232 knanitsrauadautilecanetateepeise 9 2 SCNSOM sates 3 2 6 3 9 1 Transducer and Valve 0 6 3 9 1 User Interface woes 6 4 9 3 Verification asc asaeacistees shaieaen ctegsantines 3 1 Ca libtation sacs Mera Miaies cen a ee 11 24 Calibrated Gauge siescccucscteagvieass 11 22 Calibrated Gauge Method 11 22 Calibrated Pressure Source 11 24 Calibrated Pressure Source Method 11 24 Methods tiveirehcsostt cated aac ees 11 21 Setup Diagram 20 0 0 ceceeeeeeeeeeee 11 22 Cam Roller Pict re esse peste a T EaR 11 10 Replacing ea ieee e 11 9 CMD 5000 seese 1 4 6 1 11 18 High Temperature ccosusedeteaveieacseacane 2 9 Subcomponent sac2 cetscessecusverdaadoanscaes 6 1 Communication Errors DGC ET ORS retien e tate aes 12 3 Conditions Sp Acp419 6 teen cement res reenter renee tre 4 5 Hold Extend jcccseeicirascessanie inde 4 6 Hold Retr ncisetcuisratdcauaian 4 6 Max Exte d nininini oranan iis 4 5 Max Retraction inii 4 5 Retractitig ce
57. Change the current flow rate for a single pump cylinder by clicking on the Set Flow Rate button in the main window of PumpWorks and entering a value Each pump cylinder has its own Set Flow Rate button 4 3 9 2 Changing Multiple Set Flow Rates To change the current flow rate for one or more pump cylinders simultaneously go to Pump Works main window Select Main Set Pump Flow Rates from the menu bar and enter flow rates for one or more pump cylinders in the Enter New Flow Rate box s Then click on Send Rates to Pump s All new flow rates are sent at the same time 4 3 10 Cylinder Volume The cylinder volume field displays the actual volume of fluid that has been pumped by each pump cylinder since resetting the cylinder volume to zero The default unit of measure for cylinder volume is milliliters ml The user can set the unit of measure to either milliliters liters or microliters 4 3 11 Cumulative Volume The cumulative volume field displays the combined volume pumped by a pump cylinder pair 1A and 1B or 2A and 2B and so on This information is valid only when pump cylinders are operating in a paired mode with one fluid continuously pumped alternately by two pump cylinders 4 3 12 Operating Modes The Quizix pump system offers many different operating modes With the exception of two operating modes that are used for recirculating pump operation only each operating mode includes the following three parts e Pump Cylinder
58. D style connectors for motor cables labeled Motor Cable for Cylinder A and Cylinder B If the pump controller is used with only one pump cylinder the connector for Cylinder B will not be used 6 4 3 Transducer and Valve Cable The Transducer and Valve Cable connects the CMD 5000 Dual Controller Driver with both the pressure transducers and the pilot solenoids for the valves This cable has a 25 pin D style connector at the pump controller end and branches out into one cable branch for each pressure transducer and one cable branch for each pilot solenoid There is a 6 pin circular connector at the pressure transducer end for each branch The branches are labeled Transducer 1A and Transducer 1B If there are two controllers the branches on the second controller will read Transducer 2A and Transducer 2B This cable also branches into wires that are connected to the pilot solenoids with 2 pin connectors The wires are numbered and must be connected in the proper order for example wire into pilot solenoid 1 wire 2 into pilot solenoid 2 and so on 6 4 4 Data Link Cable The Data Link Cable connects the CMD 5000 Dual Controller Driver with the Serial Expander Isolator The CMD 5000 for Cylinders 1A and 1B should be plugged into Port A If your system includes two pump controllers the data link cable for the second pump 6 3 Quizix 5000 SERIES PUMP MANUAL controller should be connected to Port B The Data
59. Driver interface connector in order for the controller to be able to read this pressure Decision number three involves how you want fluid to flow in relationship to the pump Will the flow of fluid be out of the pump delivering fluid or into the pump receiving fluid Once you decide what you want the pump to do you then need to use Pump Works and set up your pump to accomplish what you want The following section is a brief introduction to PumpWorks For more detailed information about Pump Works see the Pump Works User s Manual 4 2 PumpWorks Main Window In this section we will discuss the basic parts of the window that opens when Pump Works is initialized 4 1 Quizix 5000 SERIES PUMP MANUAL 4 2 1 Windows PumpWorks is a windows based software program Most of the menu options when accessed cause a window to open When more than one window is open the user can choose to either tile individually arrange or cascade the open windows The tile command arranges all open windows across a screen giving each one the same amount of space The cascade command arranges all open windows so just their title bars show To make a window active click on the desired window Title Bar gt m PumpWorks Pump Data amp Controls Menu Bar gt Main DataLog AutoOp Other Error Log Configure Communications Windows Help Pump Data gt CR AE amp Controls Oylinder Number Cylinder 1A Cylinder 18 Piston Position Motion
60. Link Cable has RJ 22 connectors phone handset type connectors at both ends 6 4 5 Front Panel Cable The Front Panel Cable connects the CMD 5000 with the Front Panel which may be used instead of PumpWorks to control the pump system It is not available at this time 6 4 6 User Interface Cable The optional User Interface Cable allows the 5000 Series Pump System to connect to various external devices which a user may wish to add Additional sensors valves digitally controlled devices and logic inputs as well as power are available on this 37 pin D style connector By connecting any such additional valves digital inputs or analog inputs such as additional temperature or pressure transducer readings to the CMD 5000 the user will have access to them from PumpWorks The User Interface Connector also includes an emergency stop control signal for users who want to implement an emergency stop capability for their pump system See Appendix B of the PumpWorks User s Manual for more information on the User Interface Cable If you have a recirculating pump system a User Interface Cable will be included with your system and will be labeled Recirculating Cable It is used to establish communications between the controllers in recirculating systems 6 4 7 AC Power Cord Receptacle The AC power cord receptacle is located next to the on off switch The power cord supplied will agree with the voltage used in the country the pump was shipped
61. Outlets ccccccccececssseceessseeeeesseees 3 3 Index 2 Fluid P Wa Bin Oss corst ence deievsate coments aieaats 8 5 Fuse Holder ienen naai ere 6 2 Replacing cast soedgacstanetoievccestaeaeecienens 10 3 H Harmonic Drive ccceeeeeseeeseeteeeteeeees 7 4 Re greasing siaciiessiacdxttsladeudentieds 11 13 Hastell oy esp a eed 7 7 8 8 High Temperature CASS ap iera e na E Sed 2 9 CMD 5000 Dual Controller Driver 2 9 Pump Cylinders sii saxsisdeenccghitinas 2 8 Setting UP esnan 2 8 Stand Mounted ccscssccssseesereeees 2 9 Transducers voi sseatesscacelsatcee cares 2 9 V lyes ennnen aa eda ees 2 9 Hold Extend acncccttn nia cccsaacyadetoieas 4 6 Hold Rtg oi ssccvectdscnattsccs nears aes 4 6 I Immediate Error iste laced 12 3 L Liquid Filling Your Pump System With 3 4 Low Pressure Operation c cseee 7 3 M Maintenance scuntenta 11 1 M x Extend cisatcaad vawssesisnt us dataaioon 4 5 Max R CIAO Tn cchetenctancrseaecetecaidterpattacesadses 4 5 Menu Bar oeren uena 4 3 Motor Driver Subcomponentt cceeeesceeseeeeteeees 6 2 Motor Housing iii iahesicdsscasteuteseeecevecs 11 14 Motor SHEDPEL s jcccctecsecesbancegrarct inalis 7 4 O On Off Switch ss fates can aces Macau eo heceps gs edadne 6 2 Operating Modes ccceesceeeeeeteeeteees 4 10 Choosing inigi isk 4 11 Independent Constant Delta Pressure 4 14 Constant Pressure 0e 4 13 Constant Pressure Cycled
62. PAIR CapV This mode is designed especially for capillary viscometry experiments In this mode the pump cylinders operate like they are geared together One pump cylinder is extending delivering while the other is retracting receiving The pump cylinders must be started so that their motions are opposite of each other one fully retracted and one fully extended The valves are operated to keep the fluid flow unidirectional and as free of pressure variations as possible with two pump cylinders Paired Geared Mode Constant Rate PAIR GM CR In this mode two pump cylinders retract and extend continuously The pump cylinder pair pumps at a constant rate and does not match pressures between pump cylinders prior to switchover The system disregards pressure data except for overpressure errors The motion of each pump cylinder is a mirror image of the other because the standby pump cylinder does not pre pressurize prior to switchover This mode is most useful for flushing out a pair of pump cylinders or flushing out the plumbing network You must specify the run rate for this mode Before starting place one pump cylinder at Max Extend and the other pump cylinder at Max Retract 5A Paired Geared Mode Constant Rate Without Valves PAIR GM NV This mode is identical to Mode 5 except that the valves are not switched This mode is extremely useful for dynamic fluid leak tests 4 14 Chapter 4 PUMP OPE
63. Please refer to Section 11 2 Changing the Cylinder Barrel Seals If the leak is no longer present when this test is run then the leak is most likely in the valves Seals generally will have a lifetime of about 1 year With certain fluids seal life decreases To increase the life of the seals the following can be done e Pump clean fluids whenever possible e Filter the fluid being pumped so there are few if any particles in the fluid Ifyou are pumping brine or other corrosive fluid do not let it sit in the pump for a long time Flush the pump with a clean fluid after each use 12 4 4 No Fluid Is Being Delivered If no fluid is being delivered during pump operation try the following e Make sure the fluid inlet plumbing is connected to a fluid source If using an inlet filter try removing it temporarily e Check if the fluid inlet or fluid outlet plumbing is clogged resulting in no fluid entering the pump If you suspect a clog disconnect the tubing and check that fluid can easily flow through the tube in question e Check for loose fittings on the fluid inlet side Check to see if the tubing has a hole or crack which would cause air to be drawn into the tube instead of fluid e Check to see if the fluid is too viscous or thick to be pulled into the pump This can be checked by watching the pressure of the pump cylinder as it starts to fill If the pressure drops too much the fluid will cavitate and not get pulled into th
64. Pump System or change a system s setup which includes the following e Unpacking the system Section 2 1 e Installing the pistons Section 2 2 e Setting up a system mounted on a support stand Section 2 3 Setting up a system installed in an oven Section 2 4 e Power needs and considerations Section 2 5 e Requirements for an air supply Section 2 6 For more information about installing and using Pump Works software see the Pump Works User s Manual 2 1 Unpacking the System Inspect the boxes for shipping damage A component may have been damaged even if the box has only slight damage Itis the customer s responsibility to notify the shipping company immediately of any damage To open the pump cylinder boxes which are long low crates do the following 1 Remove the screws on top of the box and remove the lid 2 Two screws one on either side of the pump cylinder hold the pump base in the shipping crate Remove the two screws and lift the pump out of the shipping crate 3 Remove the protective plastic shipping wrap from the pump cylinder and inspect for any shipping damage or loose parts If you ordered a system mounted on a support stand the remaining components are packed in the stand box To unpack these components do the following 4 Remove the four lag bolts on the bottom of the box There are two bolts on each end of the box The stand assembly is mounted on the bottom of the shipping box 5 Carefully l
65. Quizix 5000 Series Pump System User s Manual Quizix Incorporated 4616 Roseville Road Suite 108 North Highlands CA 95660 Phone 916 331 8000 Fax 916 331 2263 E mail support quizix com Copyright 2000 by Quizix Incorporated All rights reserved Version March 2005 TABLE OF CONTENTS CHAPTER 1 General Overyie wages hs cavetwadeled aai a enacts e a E 1 1 11 Introduction iecore i E thee EE aetna tess A 1 1 1 2 Primary Components x 353 6 sia ua veatativetaasideeodssetatosseetaaeviawanti cel eeeey 1 2 1 2 1 C 5000 Pump Cy lamer a x ases clac zo cakedaseescviesenstenndagiacaetasvecaeadaunste 1 3 1 2 2 CMD 5000 Dual Controller Driver cece eeceenteeeeeeeees 1 4 1 2 3 PC Compatible Computer and PumpWorks Software 1 4 1 2 4 Valves Transducers and Plumbing 0 cceeeeseeesseeeeeeeees 1 4 12 S SUD POU Standa sinea ain wid ees a slau Rear a 1 4 GHAP TER 2 System Setup erena Sic avast alu agsteelaac E ARE E E 2 1 2 1 Unpacking the System seca aas dcatcasgaranerterccast sues duaeeacacalenatanaeaneeanastawers 2 1 2 2 Installing the Pistons 4 asynsctenttriied tdi Aton a vane aegis eels 2 1 2 3 Setting Up a Stand Mounted System 00 ceeeeseeeseeeteeeeeeeeees 2 6 2 4 Setting Up a High Temperature System Oven Installation 2 8 ANP UM Cylinders csc herent sacra ee Coat an E lence eens 2 8 2 4 2 CMD 5000 Dual Controller Driver eeceeeceeeseeeeeeeees 2 9 24 3 THANSAUCETS cy eisitsncdasyen
66. RATING BASICS Table 4 2 Operating Modes Mode No Operating Mode Description Paired Constant Rate Delivery PAIR CR Del In this mode a pair of pump cylinders continuously delivers fluid ata constant rate set by the user Fluid pressure is determined by the pressure drop across the experiment Unlike geared modes the pressure in the standby pump cylinder is brought to the delivery pressure of the active pump cylinder before switchover so fluid flow is pulseless The user sets a flow rate when this mode is selected The user does not set the run pressure or the direction To begin operating a cylinder pair in this mode determine which pump cylinder is to deliver fluid first piston extend and start that pump cylinder key so it will extend while the other standby pump cylinder retracts Note See Starting Pump Cylinders in Paired Operating Modes Section 4 3 5 3 regarding relative piston position before starting up a pump cylinder pair Paired Constant Rate Receive PAIR CR Rec This mode is identical to Mode 6 except that the pump cylinder pair continuously receives extracts fluid from an experiment In this case fluid is received into the fluid outlet and expelled through the fluid inlet Paired Constant Pressure Delivery PAIR CP Del In this mode a pair of pump cylinders continuously delivers fluid at a constant pressure as set by the user The flow rate varies as needed to maintain tha
67. SI bar and pas cals pressurizing printed circuit board or PC Board PCB programmed prompt line proportional error proportional gain or proportional servo gain PSI pull down menu pump body assembly pump controller pump cylinder pump cylinder support block pump housing quizix erl GLOSSARY The process of increasing pressure on a fluid This is accom plished in a pump by extending the Piston which reduces the volume available to the fluid thereby increasing the pres sure A group of electrical components on a flat board There are three types of boards included in an SC 2400 controller rear panel board Main PC Board and DSSIP Board A set of instructions that allow the computer to operate the pump system The prompt line is located in the bottom border of the active window of the PumpWorks software and gives you instruc tions relating to the task at hand The proportional error is multiplied by a constant the Propor tional Gain to generate a rate This rate will change the pump pressure to the set point value The proportional gain is a user set constant which is multiplied by the proportional error which generates a corrected rate for maintaining constant pressure This rate will change the pump pressure to the set point value This stands for pounds per square inch which is a measure of pressure When you click on a word in the PumpWorks software menu a list of choices appear
68. UMP OPERATING BASICS function key F1 to cylinder 1A function key F2 to cylinder 1B and so on Pushing the appropriate function key will stop an operating pump cylinder in the same way that a Push to Stop button does Using the function keys to stop a pump cylinder has the advantage of stopping the pump cylinder quickly even if the Pump Data amp Controls window is not open When operating two pump cylinders in a paired operating mode the pair can be stopped by pressing either of the function keys that correspond to the pair e Using the Stop All Pumps button on the main window of PumpWorks All operating pumps are immediately stopped e Selecting Main Stop All Pumps from the menu bar of the main window of PumpWorks All operating pumps are immediately stopped 4 3 6 Current Pressure The current pressure field displays a measurement of the pressure currently inside of the cylinder barrel This measurement reading is taken from a pressure transducer Each pump cylinder has one pressure transducer connected to it The current pressure of each pump cylinder is displayed on the main window The default unit of measure for pressure is PSI pounds per square inch The user can change the unit of measure displayed to bar millibar kiloPascals or megaPascals 4 3 7 Set Pressure The Set Pressure field allows a user to change the set pressure of a pump cylinder operating in a constant pressure mode to a different pressure The
69. YSTEM POWER SYSTEM POWER This chapter describes the power requirements for the 5000 Series Pump System Included are the following e Basic Power Requirements Section 10 1 e Using Uninterruptable Power Supplies Section 10 2 e Changing the Voltage Setting Section 10 3 e Replacing a Fuse Section 10 4 10 1 Basic Power Requirements The Quizix 5000 Series Pump System has two components that must be connected to a power source the CMD 5000 Dual Controller Driver and the computer All Quizix Pump Systems are set to the voltage of the country to which they are being shipped 110 120 or 215 240 volts The voltage setting of the CMD 5000 Dual Controller Driver can be changed if necessary All 5000 Series Pump Systems are shipped with power cords compatible with the voltage and type of outlet used in the country to which they are shipped If a computer is ordered with a pump the computer is also configured to the power requirements of the country to which it is shipped Users conducting long term experiments in which the interruption of fluid flow would be detrimental to the experimental results should use an Uninterruptable Power Supply UPS with their system 10 2 Using Uninterruptable Power Supplies The 5000 Series Pump System can operate for extended periods of time that is many months without needing to be stopped This capability is perfect for running long term experiments such as steady state rock property measurements In
70. age intentionally left blank Chapter 7 PUMP CYLINDER PUMP CYLINDER This chapter describes the 5000 Series Pump Cylinder also called the C 5000 Pump Cylinder Included are the following sections e Quizix C 5000 Pump Cylinder Section 7 1 Important Operating Notes Section 7 2 e Primary Mechanical Subcomponents of the Pump Cylinder Section 7 3 e Cylinder Barrel and Seal Assembly Section 7 4 e Pump Cylinder Sensor Board Section 7 5 Pump Cylinder Base Plate Section 7 6 e Hastelloy Option for Corrosive Fluids Section 7 7 Pump Cylinder High Temperature Option Section 7 8 e Pump Cylinders with Optional Wash Ring Section 7 9 7 1 Quizix C 5000 Pump Cylinder All Quizix 5000 Series pump cylinders are stepper motor driven positive displacement pumps with precision ball screws The basic operation of the pump cylinder is as follows e When the piston retracts out of the cylinder barrel fluid is pulled into the cylinder barrel through the fill side of the valve e When the piston extends into the cylinder barrel fluid is pushed out of the cylinder barrel through the deliver side of the valve e With both sides of the valve closed the piston extends slightly and pre pressurizes the fluid within the cylinder barrel These operations can be performed independently with the user opening and closing the valves setting the cylinder direction and then starting the pump In most applications however the user chooses t
71. ainst incorrectly wired AC power circuits 6 7 Pump Controller Software The CMD 5000 Dual Controller Driver contains no user serviceable parts The user should NOT open a pump controller and attempt to service it The Troubleshooting chapter of this manual provides details on diagnosing and resolving problems safely If your CMD 5000 is malfunctioning it must be returned to Quizix for service The operation of the 5000 Series Pump System is controlled by two separate software programs e PumpWorks which is stored on the user s computer and e The pump controller software which is stored in the CMD 5000 New versions of both software programs are periodically released by Quizix Problems detected after a software version is released are resolved in later versions In order to update the pump controller software itis NOT necessary to open the CMD 5000 New versions of the pump controller software can be downloaded directly to your pump controller via PumpWorks See Section 12 8 Update Pump Controller Software in the Pump Works User s Manual for more information New versions of the pump controller software can be downloaded directly from the Quizix website at www Quizix com The controller software version number is shown in About Pump Works for Windows under the PumpWorks Help menu If you update your controller software the new version number will appear in that window Quizix 5000 SERIES PUMP MANUAL 6 8 This p
72. al or a cylinder barrel with scratches will result in leaks when operated Ensure that the seal and cylinder seal area are very clean Lint or dirt on a seal can cause seal leakage If possible the seal should be cleaned in an ultrasonic cleaner or with a Q tip just before insertion Figure 11 2 Seal Insertion Tools and Components If both the seal and cylinder are in good condition proceed with the seal insertion If you plan to replace the old seal inspect and clean a new seal prior to installation 11 2 2 3 Seal Insertion Procedure for Cup Type Seals 1 Coat the seal on both the inside and outside surfaces with a light coat of lubricating compound Petroleum jelly or vacuum grease works well for this purpose Almost any type of lubricating compound will work even water if no oils are available Apply a light coat of lubrication to the inside surface of the seal insertion guide ring and the seal insertion plunger Apply lubricating compound to the cylinder seal cavity entrance A small amount of lubricant is sufficient After all surfaces that touch the seal are coated with lubricating compound carefully slide the seal onto the seal insertion plunger The seal spring should face towards the Chapter 11 MAINTENANCE tapered end of the plunger The seal should slide on smoothly and easily Push the seal on until it contacts the plunger shoulder Slide the seal guide ring into the cylinder barrel so that it is pressed again
73. ance This Pumpworks software motion status message means that a pump cylinder is operating and the piston is extending at zero speed When the rate becomes higher than zero non zero the piston will extend This Pumpworks software motion status message means a pump cylinder is operating and the Piston is retracting at zero speed When the rate becomes higher than zero non zero the piston will retract home host link host link communications protocol Inactive Wash Area independent cylinder oper ating mode independent constant delta pressure independent constant pressure independent constant pres sure cycled independent constant rate cycled independent constant rate operation internal offsets GLOSSARY A button on the computer keyboard which will take the cursor that is on the computer screen and move it to the beginning of the line you are working on This is a data link which can be used to link the pump system computer with another computer With such a link a user can export system data to a second computer for real time analysis while an experiment is running or use a second computer to control the pump operation The set of rules the user needs to follow to read data and set data over the host link This is wash Area that does not have the internal or external o rings and therefore cannot be used to circulate fluid to rinse the piston One pump cylinder operates by itself and is limited
74. ant ede vansteaede 12 9 Emergency Stop s cijssecccteettencedeseccess 12 9 Fan Does Not Run eee 12 11 Immediate gases Sdceseasects idee acccen 12 3 Logged ctnensadseansibee uaa 12 3 Low Side Driver cccesseceeeeeees 12 9 Motion arira tiin an rumen 12 9 Motor Runs No Motion Detected 12 14 Motor St ll zsninsreninsaana 12 15 No Fluid Is Being Delivered 12 13 Piston Movement 12 14 12 15 Present ssneivitincs Manes 4 19 Pressen e E 12 16 Sensor Caples serie Ase cies Meow ate 12 9 DOM Late enaren 12 10 Soft Limit Warning eee 12 3 Transducer Cable ccccceceeeeseeees 12 9 Two Digit Display Error Code 12 8 Valve Cables cicvisle ch listen liacipate ees 12 10 Extending 0 yl Suse laectsi alain sit niia 4 5 F Fan Brrr OP ag u u eee ees teint 12 11 Maintenance t2 5ecc5 sh sSicsjasssiiciiexs axe 11 17 Flow RAG cs snari 4 10 Changing A Set Flow Rate 4 10 Changing Multiple Flow Rates 4 10 Changing Single Flow Rate 4 10 Fluid Flow Diagram ccceeeeeeees 4 18 Fluid Flow Direction cceceeeeee 4 11 Bi directional 2855526 day sates snestiaansboases 4 11 Delivery aiseieteri cui drkinadetads 4 11 Receive ae aOR eRe PR a a TA 4 11 Bid Mlet ariani 3 3 Flid Leak ccveascucacsanetiesiies 12 11 12 12 Finding Your Leak eee 12 13 Leak Testitig iactsiuecnectueng 12 12 Leakage Basics 35 iacisccatginceeeecters 12 11 Fluid
75. ate pressure channel A to D for pump cylinders A and B 5 6 check and set pump cylinder location for pump cylinders A and B Quizix 5000 SERIES PUMP MANUAL 7 all tests passed accept commands from Pump Works Two Digit Display Pump Controller Diagnostics l Display Segments 6 2 7 5 3 J q Decimal 4 Point Left Decimal Right Hand Point Hand Digit Digit Figure 6 2 In the final step do will flash alternately with 0 The do stands for digital overpressure As a safety precaution each time a pump is powered on the safety pressure is set at 50 PSI The user must set the safety pressure to a valid operating value each time the pump is powered up The 0 means the pump has not yet been assigned a pump number by PumpWorks As soon as the pump is installed onto PumpWorks the 0 will be replaced with the pump number When PumpWorks and the pump controller are communicating with each other decimal points on the two digit display will flash A decimal point will flash on the right side of the right digit which means the pump controller is sending communications to Pump Works A decimal point will flash on the right side of the left digit which means that Pump Works is sending communications to the pump controller The right digit decimal point will flash brighter than the left digit decimal point because the pump controller has more data to send to PumpWorks than the amount of data PumpWorks has to sen
76. ation refer to Section 7 9 There are six models of 5000 Series pump cylinders available Of the six models the C 5000 10K is the most popular It provides a maximum pumping rate of 15 ml per minute with a maximum pressure of 10 000 psi and a stroke volume of 9 3 ml It has a piston diameter of 1 2 inch Five other models are available for users with different requirements as shown in Table 7 1 Table 7 1 The 5000 Series Pump Cylinders Maximum Maximum Cylinder Piston Model Pressure Flow Rate Barrel Diameter Volume C 5000 2 5K 2 500 psi 60 ml per minute 37 ml 1 00 inch C 5000 5K 5 000 psi 30 ml per minute 21 ml 750 inch C 5000 L 7 5K 7 500 psi 3 75mlper minute 21 ml 750 inch C 5000 10K 10 000 psi 15 ml per minute 9 3 ml 500 inch C 5000 L 10K 10 000 psi 2 0 ml per minute 9 3 ml 500 inch C 5000 20K 20 000 psi 7 5 ml per minute 5 2 ml 375 inch Chapter 7 PUMP CYLINDER The two L models are designed for applications which require extremely low flow rates They use a different ball screw pitch and different motor resolution For example the flow rate resolution of the C 5000 10K is 0 00000078 ml minute 0 78 nanoliters minute the flow rate resolution of the C 5000 L 10K is 0 00000031 ml minute 0 31 nanoliters per minute All C 5000 pump cylinders have the same basic design Only the piston diameter and size of the cylinder barrel are changed between models plus
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79. ave rusted and no longer operate they will need to be replaced The other cause of this type of problem is the air pressure is too low or too high to operate the valves Use a pressure gauge to determine the air pressure If the air pressure is too low e Check that your air tubing has been connected properly e Check that the air supply is on and e Check that the air tubing is not clogged Chapter 12 TROUBLESHOOTING If the air pressure is too high more than 6 9 bar 100 PSD install an air regulator to limit the pressure 12 4 1 2 Constant Air Escaping Sound If you hear a constant air escaping sound when the valves are not being operated then it is likely there is an air leak The pilot solenoid valves should not leak air when they are operating properly e Check each air fitting to see if any fitting is loose e Check each air tube to see if it is cracked e Try using Snoop soap and water solution to detect small leaks by making bubbles appear e Sometimes a pilot solenoid will get stuck part way open or part way closed and allow air passage Try opening and closing the valve to get the pilot solenoid unstuck and moved to a fully open or fully closed position Opening and closing a pilot solenoid a few times may free up a stuck solenoid If this doesn t work the pilot solenoid may have to be replaced so it does not constantly leak air 12 4 2 Fan Does Not Run Ambient temperature pump systems do not ha
80. basic methods of pressure calibration for all Quizix Pump Systems The first method is to attach a secondary calibrated gauge such as a quartz transducer to the system With this method the pressure for the calibration procedure will be generated by the Quizix pump Then the pressure read by the Quizix system is adjusted until the system s transducer readings match the reading by the calibrated gauge CG The second method is to use an external pressure source such as a dead weight tester With this method the user connects the external calibrated pressure source PS to the pump system The pressure is then read by the pump system and adjusted until it matches the pressure being output by the pressure source 11 21 Quizix 5000 SERIES PUMP MANUAL Calibration Setup Diagram Pressure Source Calibrated Gauge Fluid Outlet Deliver Cylinder 1 Fill Pressure Transducer Deliver Cylinder 2 Fill Pressure Transducer Atmospheric Pressure RN TN Fill Reservoir Figure 11 15 11 6 2 1 Calibrated Gauge Method 1 As shown in the Calibration Setup Diagram in Figure 11 15 connect a calibrated gauge CG to the fluid outlet of your Quizix Pump System Be sure your fill valves are connected to a fill reservoir at atmospheric zero gauge pressure 2 Set the system to zero gauge pressure as follows for the p
81. been installed to this location Disabled A pump has been installed but communication between the pump and computer has been turned off Users can choose to disable a pump 4 3 5 Start Stop Pumps A user can start or stop a pump in more than one way 4 3 5 1 Starting Pump Cylinders Pump cylinders can be started by any one of the following methods e Using the Push to Start button on the main window Each operating pump cylinder has its own Push to Start button For independent operating modes each pump cylinder s Push to Start button will need to be pushed For paired operating modes only one Push to Start button needs to be pushed to start the pair of pump cylinders To make certain a user knows the conditions of a pump cylinder before starting it a Start Cylinder Confirmation dialog box appears and displays the pump cylinder s operating mode cylinder direction and safety pressure The question Do you want to start this cylinder requires a yes response before PumpWorks will start the pump cylinder When stopping a pump cylinder no confirmation box appears e From the menu bar select Main Start Stop Pumps This window displays all pump cylinders in a user s system Any number of pump cylinders can be started or stopped simultaneously using this one window No start confirmation box appears when the Start Stop Pump s button is clicked The command is immediately acted upo
82. cause Pump Works to report a piston motion error Ifa motion error occurs the user needs to determine if the piston is actually moving or not This is done by looking through the pump cylinder side cover The following piston movement errors will be discussed in this section e Motor Running No Piston Movement Detected Error Section 12 4 5 1 e Motor Stall Error Section 12 4 5 2 e Piston Moves But Does Not Complete Its Stroke Section 12 4 5 3 12 4 5 1 Motor Running No Piston Movement Detected Error A Motor Running No Piston Movement Detected error is generated when the motor is running but no motion is detected by the sensor board This can be caused by a motor stall or faulty motion sensor To check these conditions start the pump cylinder and watch the physical piston position indicator through the side cover Chapter 12 TROUBLESHOOTING e Double check that you are watching the physical piston position indicator for the pump cylinder that has been started on PumpWorks For example if you started Cylinder 1A then make sure you are looking through 1A s side cover e Make sure that the flow rate that the pump cylinder is operating at will provide observable motion Take into account the flow rate units either ml hour or ml minute e Ifthe piston still cannot be observed moving through the side cover contact Quizix technical support 12 4 5 2 Motor Stall Error A motor stall error occurs when the power needed to move the piston
83. cription of the error The most recent errors are displayed in the Current Errors Log The Previous Errors Log maintains a list of all errors present and past that have been detected by PumpWorks up to a maximum file size set by the user 12 1 Quizix 5000 SERIES PUMP MANUAL 12 2 e Physical Piston Position Indicators Every C 5000 Pump Cylinder has side covers which allow the user to view the piston s position The side covers on ambient temperature cylinders are clear acrylic panels through which the ball screw can be viewed The side covers on high temperature cylinders are black anodized aluminum with a slot cut into them for viewing The user can watch the piston move all along its stroke from its Max Retract position to Max Extend position or vice versa e Cylinder Switch Status Window The Cylinder Switch Status is located on PumpWorks Error Log Menu This window displays the current readings obtained from the motion sensor board of the pump cylinders The sensor board indicates the position of the piston The Cylinder Switch Status window is useful if there is an error message related to the piston position control switches For a complete description of this feature see Section 10 5 of the Pump Works User s Manual e Error State Capture Mode In Error State Capture Mode the user can view an instant replay of the conditions of the pump before and after an error occurred In the same way that a video camera can capture an e
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85. d and then enter the desired value into the software The range of gains is limited to prevent faulty and malfunctioning transducers from being calibrated and giving the illusion of working For more information on calculating offsets and gains see Section 9 1 3 How to Calculate an Offset and Gain in the Pump Works User s Manual 11 7 Valve Maintenance For complete information on servicing the CV 210 and CV 310 valves on the Quizix 5000 Series Pump System refer to The CV 210 and CV 310 High Pressure Valves User 5 Manual from Vindum Engineering which was shipped with your pump system 11 25 Quizix 5000 SERIES PUMP MANUAL This page intentionally left blank 11 26 12 Chapter 12 TROUBLESHOOTING This chapter will help the user solve problems they might encounter when operating their pump It is divided into the following areas e Troubleshooting Basics Section 12 1 e PumpWorks Error Messages Section 12 2 e CMD 5000 Two Digit Display Error Messages Section 12 3 Other Pump Troubleshooting Situations Section 12 4 Software Updates Section 12 5 12 1 Troubleshooting Basics In 5000 Series Pump Systems with two or more pump cylinders the pump cylinders can be compared to each other in order to isolate the cause of some problems Also the removable parts of the pumps are interchangeable and can also be used to help isolate the cause of a problem The removable parts include the cylinder barrels seals pis
86. d to the pump controller Refer to Chapter 12 Section 12 3 3 for more information regarding the two digit display Included you will find a list of error messages and how to correct them 6 6 Serial Expander lsolator The Serial Expander Isolator see Figure 6 3 is a device which takes one serial port of a computer and expands it into four data ports The serial expander isolator is important for two main reasons First since computers come with a limited number of serial ports the serial expander isolator allows up to four CMD 6 6 Chapter 6 CMD 5000 DUAL CONTROLLER DRIVER 5000 Dual Controller Drivers to be connected to a single computer serial port Therefore one computer serial port with one serial expander isolator connected to it can operate up to eight C 5000 pump cylinders or a combination of C 5000 C 6000 and QX Series pumps The serial expander isolator also serves a second purpose it provides electrical isolation between the computer running Pump Works and the C 5000 Pump Cylinders The RS 232 data signals from the computer are optically isolated via an opto coupler from the electrical data signals of the CMD 5000 Thus each pump cylinder is electrically isolated from the computer and from every other pump cylinder This isolation is provided to prevent ground loops and system grounding problems when the CMD 5000 unit s and computer are plugged into different power circuits It is not designed to protect ag
87. d value To accomplish this the fluid delivery rate of the active pump cylinder will change as needed The fluid pressure for the active pump cylinder remains the same at a user selected value To accomplish this the fluid delivery rate of the active pump cylinder will change as needed paired constant rate delivery paired constant rate receive paired cylinder operating mode paired geared mode constant rate operation parameters perpendicular Phillips head screw Phillips screwdriver pilot solenoid pilot solenoid manifold pilot solenoid assembly piston piston carriage piston nut GLOSSARY A pair of pump cylinders delivers fluid at a constant rate by maintaining constant piston velocity Pressure varies depending on flow resistance A pair of pump cylinders receives fluid at a constant rate by maintaining constant piston velocity Pressure varies depending on flow resistance Paired modes use two pump cylinders which are automatically controlled to provide continuous pulse free fluid flow The active pump cylinder will be delivering or receiving fluid while the standby pump cylinder will be refilling and pre pressurizing Switch over to the standby pump cylinder is accomplished without introducing pressure pulses into the system to allow pulse free continuous fluid flow operation A mode that operates two pump cylinders so they move in equal but opposite directions At the end of the piston stroke
88. e Data Link Cable connects the CMD 5000 Dual Controller Driver with the serial expander isolator There will be one data link cable for each CMD 5000 in your pump system The data link cable s should be plugged into the serial expander isolator ports in sequence For example controller 1 connects with port A controller 2 connects with port B and so on The data link cable has RJ 22 connectors phone handset type connectors at both ends 9 5 RS 232 Cable The RS 232 cable connects the serial expander isolator to the system computer This cable has a 9 pin D style connector at both ends The male end connects to the serial expander isolator receptacle the female end connects to one of the computer s serial ports Most users connect the RS 232 cable to serial port 1 However you can choose another serial port to connect the RS 232 cable to if you specify this in the system communications Use the Configure Communications window in the PumpWorks software The standard RS 232 cable can be extended with any standard straight through one to one 9 pin cable 9 6 AC Power Cables The CMD 5000 Dual Controller Driver has a power cord with a 3 prong connector that must be connected to AC power preferably by way of an Uninterruptable Power Supply See Chapter 10 for more information The power plug conforms to the standard outlet in the country to which the system is shipped A standard IEC 320 appliance connector is used at the con
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90. e Monitors the fluid volume and position of the piston in each pump cylinder e Monitors system status such as cable connections power turned on etc e Monitors any analog signal inputs that may be added to the pump system such as other pressures or temperatures e Communicates with PumpWorks to translate user commands into actual pump operation Transfers system data back to PumpWorks for viewing and if desired recording data in a software data log e Provides signal conditioning for analog transducers so that they can be calibrated 6 1 Quizix 5000 SERIES PUMP MANUAL e Executes rate ramping and valve operations during switch over from one pump cylinder to another e When required executes pressure control algorithms to maintain a specified pressure level 6 2 Motor Driver Subcomponent The motor driver portion of the CMD 5000 Dual Controller Driver provides the drive for the stepper motors attached to the C 5000 pump cylinders The motor driver runs at an extremely high number of steps per motor revolution which permits the excellent flow rate resolution of the 5000 Series pump systems For example the C 5000 10K pump cylinder has a flow rate resolution of 0 00000078 ml per minute 0 78 nanoliters per minute which represents the amount of fluid delivered with one step of the motor driver A heat sink is located on top of the CMD 5000 which is used to carry excess heat away from the motor driver The CMD 50
91. e added to this wash ring a chamber is formed called the wash area as shown in Figure 7 6 below The wash area allows residue to be washed off the piston to prevent a buildup of corrosive residue Wash areas are not necessary except in special circumstances such as when very corrosive fluids are pumped Wash areas are NOT normally needed for pumping brine Figure 7 6 Wash Ring Option Holes with fittings are located on the top and bottom of the pump cylinder for fluid to flush through the wash area When installing plumbing to these holes the fitting on the bottom of the pump cylinder should be used as the fluid inlet and the fitting on the top should be used as the fluid outlet so that trapped gas can escape An active wash area is one where both pairs of 0 rings are installed and fluid is used regularly to rinse the piston An inactive wash area is one without the internal and external o rings Do not leave any of the o rings in the wash ring if the pump system is used without any fluid circulating through the wash area and around the piston This situation will cause the o rings to abrade creating debris that can cause seal leakage If your C 5000 10K Pump Cylinder includes a wash area option your Spare Parts Kit will also include replacement o rings Refer to Table 7 2 Quizix 5000 SERIES PUMP MANUAL Table 7 2 Spare Parts Kit Wash Ring Option Item No Spare Part Pointed wooden sticks These sticks are used to rem
92. e first thing the user will see when the CMD 5000 is turned on is all segments of the display will light at once briefly Next the display will flash the boot version number currently version 3 6 The basic pump controller diagnostics are performed next Refer to Figures 6 1 and 6 2 The right hand digit will light the left hand digit will not One segment of the right hand digit will light at a time starting with the top segment as shown in Figure 6 1 One segment lights then a second segment lights then a third and so on lst 2nd 3rd 4th 5th 6th 7th I I I I 1 I I I I I Teor I I I Figure 6 1 Each segment that lights is a confirmation that a specific aspect of the pump controller is operating correctly Segment 1 RAM test OK Segment 2 move code OK Segment 3 Boot CRC OK Segment 4 Block 1 CRC check Segment 5 Block 2 CRC check Segment 6 Block 3 CRC check Code CRC OK Jump to program The pump controller software initialization is performed next The left hand digit will light the right hand digit will not The left hand digit will display number 1 then 2 then 3 then 4 then 5 then 6 then 7 Each number that lights is a confirmation that a pump controller software function is operating correctly The numbers will flash quickly The numbers on the left hand digit represent the following tests performed by the controller s software 0 1 2 load program into RAM and initialize variables 3 4 calibr
93. e main power source stops or has a surge of power Still exists not yet solved or corrected A type of grease used to lubricate the CV valves An air actuated valve manufactured by Vindum Engineering that controls the flow of fluid A collection of CV valves tubing air lines and pilot solenoids This cable connects the pump controller to the pilot solenoids This is an extension that can be added to the valve cable to allow the pilot solenoids to be located a longer distance from the controller The power your system is set to run on either 110 to 120 or 215 to 240 volts This must match the electric supply for your country A measured quantity or capacity usually measured in milliliters or liters This is the voltage range the equipment is set to operate on This must match the electric supply that your country oper ates on either 110 to 120 or 215 to 240 volts G 23 Quizix 5000 SERIES PUMP MANUAL wash area An optional feature used to wash corrosive fluids off of the piston as it retracts wave generator bearing This is part of the harmonic drive and is located inside of the motor adapter housing G 24 INDEX A Air Connections Diagram 0 0 8 4 Air Supply 2nstans ania 8 3 NCCE sriain 12 17 Connection 3 is seater Sai 12 17 Probles eseina i 12 10 Requirements cc eee 2 11 12 17 Air Tubing oscinina ane a dais 3 2 B Ball NUG wn acuauGucateueusedanneeecces 7 4 Assembly elainn canis 7
94. e pump Typically 12 13 Quizix 5000 SERIES PUMP MANUAL 12 14 pressure drops only to 2 PSI when the pump cylinder is pulling in fluid Water will cavitate if the pressure during filling drops more than 6 PSI e Check the motion of the piston by doing the following 1 Set the operating mode to Independent Constant Rate 2 Set the flow rate to 50 of the maximum flow rate of the C 5000 model you are using Set the cylinder direction to either extend or retract whichever is appropriate 4 Open the fill valve 5 Start the pump cylinder and watch the physical piston position indicator through the side cover for proper movement from max retract to max extend If there is no piston movement contact Quizix technical support e Make sure the valve assembly is installed in the correct position and that all valve fittings are securely tightened e Check the transducer and valve cable Make sure it is properly connected to both the transducers and the pilot solenoids Check that the fill and deliver valves are operating properly by performing the Valve Check in Section 3 2 e Check that the air pressure for the valves is between 60 and 100 PSI If the air pressure is too low or too high the pilot solenoids can malfunction e Is the air clean and dry The pilot solenoids are constructed of soft magnetic iron and can easily rust when exposed to moisture 12 4 5 Piston Motion Errors In most cases piston motion problems will
95. e ring and into the cylinder barrel 27 mm socket on extension tube This socketis inserted into the cylinder housing to engage the piston nut during piston removal or replacement Speedbite plugs and nuts 2 each These parts are used to close off the fluid ports during seal extraction Chapter 11 MAINTENANCE Table 11 2 Spare Parts Kit Item No Spare Part 1 Seals Depending on the type of pump system that is ordered the seals included are one of the following e Cup type ambient temperature seals made of ultra high molecular weight polyethylene white UHMW P E e T type high temperature seals made of Aflas black with accompanying Teflon back up ring 2 CMD 5000 Dual Controller Driver fuse 3 Safety rupture disk This is used in the safety rupture disk assembly 11 2 Changing the Cylinder Barrel Seals This section describes how to change the cylinder barrel seals and the piston It includes the following e Removing the Cylinder Barrel Section 11 2 1 e Changing the Seals Section 11 2 2 e Inspecting Removing Cleaning and Re Installing a Piston Section 11 2 3 e Replacing the Cylinder Barrel Section 11 2 4 Recommended frequency for this maintenance section e For ambient temperature systems every 1 year of regular use or as required e For high temperature systems every 6 months of regular use or as required 11 2 1 Removing the Cylinde
96. ead View Figure 11 7 Pump Cylinder Side View To grease the ball screw use the following procedure 1 Remove the left side cover the side opposite the sensor board 2 Extend the pump to the Max Extend position 3 Use a small flashlight to look into the long cut out opening in the side of the pump cylinder where the ball screw is clearly visible 4 Visually inspect the ball screw and ensure that there is at least a small amount of lubricant on it that there is no visible rust on any surface and that any visible lubricant is not dried out or granular If any of these irregularities are evident the ball screw may need major service or replacement and Quizix should be contacted Chapter 11 MAINTENANCE 5 Use a small brush with short stiff bristles or another small applicator and dip it into a container of grease The type of grease to use is listed below e For ambient temperature systems use HD Systems HC 1 grease or an equivalent e For high temperature systems use DuPont Krytox GPL 216 grease or an equivalent 6 Apply the grease along the entire visible section of the ball screw WARNING ANY SMALL APPLICTOR MAY BE USED TO APPLY THE GREASE A STIFF SHORT BRISTLED BRUSH IS ADEQUATE BUT USE CAUTION TO ENSURE THAT ABSOLUTELY NO BRISTLES ARE LEFT ON THE BALL SCREW ORIN THE GREASE 7 Operate the pump at low speed until the ball screw retracts one half turn so that the greased side has
97. ed by the user to a dump location in case of ruptured disk activation and fluid release The metal enclosure that holds the safety rupture disk A drawing of electrical or fluid connections The main window of the PumpWorks software has a left and right arrow in a bar along the bottom of the window This allows you to move or scroll left or right to view all of the pump cylinders G 19 Quizix 5000 SERIES PUMP MANUAL seal assembly seal extraction rod seal insertion guide ring seal insertion plunger seal retaining nut seal support ring sensor board sensor cable sequencer serial expander isolator serial port or serial communications port servo servo extend servo retract set direction set pressure G 20 This includes the seal seal back up ring and the seal retaining nut A tool supplied with your tool kit that is used to extract a seal without damaging the pump cylinder This ring guides the seal and the seal insertion plunger into the pump cylinder during seal installation A tool supplied with your tool kit that is used to push a seal out of the seal guide ring and into the cylinder barrel This is a threaded nut used to keep the seal and seal back up ring inside of the cylinder barrel This is a cylindrical ring which sits inside the cylinder barrel and is used to support high temperature seals This board keeps track of where the piston is and sends that information to
98. ed on the system monitor and the pump cylinders stop operating Itis important to note that the cable connection sensing feature is only able to detect the presence of a cable it cannot detect if it is the correct cable where more than one of a certain type of cable may be connected For example if the sensor cables are reversed for example the cable from cylinder A is plugged into the receptacle for cylinder B and vice versa PumpWorks cannot detect the problem This is why it is of the utmost importance to always carefully check cable connections as described in Chapter 3 System Checkout Procedures 5 2 Cable Labeling Quizix labels all cables at both ends and labels the device to which they connect with unique label names Color coding is also used to simplify the identification of proper connector locations IMPORTANT All cables are uniquely labeled and color coded It is important that components be mounted in their correct locations and all cable markings match 5 3 Overpressure Protection Safety Features To prevent the 5000 Series Pump System from reaching excessively high pressures multiple safety features are implemented They are described in this section 5 3 1 Digital Overpressure Safety Pressure Setting The most basic of these safety features is digital overpressure which is monitored in the controller software With this feature the user specifies a safety pressure at a level highe
99. egarding the valves Chapter 12 TROUBLESHOOTING 12 4 7 1 Valve Cable Connection Check The transducer and valve cable connects the pump controller to the pilot solenoids Make sure each cable branch with a 2 pin connector is properly connected to the pilot solenoid with the same number 12 4 7 2 Checking Your Air Supply The valves used in Quizix pump systems are air actuated Air is taken into the system through the air inlet and distributed to the pilot solenoid manifolds The pilot solenoids then distribute and control the air flow to the valves Nylon tubes connect the pilot solenoids to the valves Check the tubing for cracks clogs or other problems Check the color coded fittings at both ends to be sure they are properly connected the colors should match the fittings at both ends of the tubes 12 4 7 3 Air Supply Requirements IMPORTANT Although the 5000 Series Pump System uses very little air the air supply that is used MUST meet the following conditions e The air must be clean e The air must be dry Moisture in the air supply will cause the pilot solenoids to rust and malfunction The air must be between 65 to 100 PSI 4 5 to 6 9 bar If air pressure exceeds this the pilot solenoids may stop working 12 4 7 4 Checking Your Air Supply Connection To check the air supply connection first identify the air inlet Make sure a 1 4 tube is inserted into the air inlet fitting and that it is tight and cannot be moved A
100. eiving fluid now delivers it 1 2 2 CMD 5000 Dual Controller Driver The pump controller is the controlling unit for the entire pump system It coordinates the operation of all the other pump components and operates the system according to the settings made by the user within PumpWorks software The CMD 5000 Dual Controller Driver includes both The pump controller which is the electronic brains of the entire system and The motor driver which drives the stepper motors which are part of the pump cylinders The part number CMD 5000 stands for Controller Motor Driver for the 5000 Series Pump Systems The CMD 5000 Dual Controller Driver can operate two C 5000 pump cylinders If your system includes three or four pump cylinders you will need two CMD 5000 units If your system includes five or six pump cylinders you will need three CMD 5000 units 1 2 3 PC Compatible Computer and PumpWorks Software A pump system includes Quizix PumpWorks Software which runs on a PC compatible computer under the Windows operating system Quizix can provide a computer with the pump system if desired Pump Works is menu driven and easy to use PumpWorks allows the user to set all operating parameters such as fluid flow rate or pressure The software also provides the user with full system status information at all times Data logging capabilities are available allowing the user to automate data collection Many other useful features are also
101. elivery or receive rate for this mode is one half of the rate for Mode 8 or Mode 9 because the piston has only half of the full piston stroke available 14 15 3 5 or 7 Cylinder Recirculating nCyl RECIRC Reset Recirculating Mode Recirculating operating modes are used when a fixed amount of fluid is to be circulated in a closed loop through a sample Steady state conditions can be achieved with this method of fluid flow All recirculation modes require special software and hardware that can be ordered from Quizix as an option The 3 cylinder recirculating mode can circulate a single fluid The 5 cylinder recirculating mode can circulate two different fluids The 7 cylinder recirculating mode can circulate three different fluids This is not an operating mode per se butis a setting used only by recirculating systems to exit the 3 5 or 7 cylinder Recirculating Mode Mode 14 4 16 4 3 12 5 Independent Cylinder Configuration In independent operating modes 1 2 and 3 a single pump cylinder pumps fluid The pump cylinder runs for only one piston stroke then stops At the end of each piston stroke the user must open or close the valves and restart the pump cylinder using Pump Works Pump Data amp Controls window The basic limitation of the independent pump cylinder configuration is that the amount of fluid that can be delivered or received continuously is limited to the volume of
102. er 1B Piston Position Motion Status STOP ALL PUMPS Current Pressure PSI SetPressure PSI Current Flow Rate ml min Set Flow Rate ml min Cylinder volume ml Cumulative Volume mil Operating Mode L IND CR Cylinder Direction Fill Valve Deliver Valve Figure 4 4 Pump Data amp Controls Window 4 2 5 Status Bar The status bar appears at the bottom of the main window in PumpWorks The status bar displays messages regarding the status of the pump controller s data logging sequencer and error messages See Figure 4 5 Active Pumps Data Logging OFF Sequencer OFF No Errors Figure 4 5 Status Bar 4 3 Quizix 5000 SERIES PUMP MANUAL 4 2 6 Dialog Boxes Pump Works makes extensive use of dialog boxes when some menu selections or commands are initialized Dialog boxes contain information and a box or checklist for the user to enter information 4 3 Pump Data amp Controls Window The Pump Data amp Controls window contains key operating information about all pump cylinders in a user s pump system This information is continually updated while the pumps are running Titles appear in the left column and data appears to the right of the titles The following information is available Pump Name Set Flow Rate Button Cylinder Number Cylinder Volume Piston Position Cumulative Volume Motion Status Operating Mode Button Stop All Pumps Button Cylinder Direction Button direction
103. er Isolator Connect the RS 232 cable between the Serial Expander Isolator to a serial port on the computer usually serial port 1 or COM 1 Then connect the keyboard and monitor cables to the computer Connect an air supply to the valve solenoids This supply is connected with a 1 4 plastic tube to the bottom of the valve solenoid manifold The air supply should be clean dry air regulated between 60 and 100 psi 4 0 and 6 8 bar IMPORTANT User supplied tubing should also be installed from the port of each of the Safety Rupture Disks to an appropriate receptacle in order to prevent fluid from spraying into the atmosphere in case the rupture disk is activated For more information about the Safety Rupture Disks refer to Chapter 5 and Chapter 11 16 17 18 If you purchased a computer with your system the computer is set up with the Windows operating system and the necessary Quizix Pump Works programs If you did not purchase a computer with your system refer to the PumpWorks User s Manual for additional instructions on installing PumpWorks on your computer Insert the Pump Works disk into your computer Using either Windows Explorer or File Manager double click on or run setup exe The PumpWorks wizard application guides you through the software installation Do not start PumpWorks yet The CMD 5000 Dual Controller Driver has a two digit display which is labeled Pump Number Using le
104. er this value into the appropriate box With this option the user can have the display show a value other than zero pressure on the display when zero pressure is present This can be used if absolute pressure readings are desired 4 Set the pressure to 90 of the system s maximum rated pressure 5 Set the safety pressure to 95 of the system s maximum rated pressure NOTE If your system is typically operated at significantly less than the pump s maximum rating for example typical usage at 100 PSI for a 5 000 PSI pump then the pressure in this step may be set at the system s typical operating pressure to obtain a more accurate calibration 6 For the pump cylinder s being calibrated open the deliver valve s and close the fill valve s 7 Set the pressure source to bring the pressure up to the desired level 8 Adjust the gain Go to PumpWorks main window From the menu bar select Other Software Pressure Transducer Calibration In the Software Pressure Transducer Calibration window select Current Gain The easiest way to adjust the gain of a pressure transducer is to enter the current pressure value into the Enter Known Pressure box When this is done PumpWorks calculates the necessary gain and adjusts the pressure reading to display this value automatically Please remember to always adjust the offset prior to adjusting the gain 11 24 Chapter 11 MAINTENANCE The user may also calculate the desired gain by han
105. failure NEVER operate the system AT ALL if you have any reason to believe a transducer has failed 12 4 6 3 Pressure Overshoots Setting in Constant Pressure Mode Pressure control in a constant pressure mode is set by the proportional and differential gain constants Please refer to the PumpWorks User Manual to learn how to set the servo gains for desired pressure operation This problem can also be caused by having a gas liquid mixture The piston will accelerate to compress the mixture and shoot past the set pressure before it can slow down If you must use a gas liquid mixture you will need to carefully set the servo constants to keep the pump from exceeding the safety pressure 12 4 6 4 Pressure Is Not Constant in Constant Pressure Mode Pressure control in constant pressure mode is set by the proportional and differential gain constants Please refer to PumpWorks User Manual to learn how to set the servo gains for desired pressure operation 12 4 7 Valve Problems The air actuated flow control valves are a vital part of the operation of the 5000 Series Pump System They control the direction of the fluid flow The valves used on the pump system are highly reliable However as with any mechanism problems can occur In this section we will present some basics on how the valves are used in the pump system Refer to the Vindum Engineering Valve User Manual included with your pump which has detailed maintenance and troubleshooting information r
106. fully extended called Max Extend or somewhere in between Chapter 4 PUMP OPERATING BASICS e When at Max Extend the piston is fully extended into the cylinder barrel and the black portion on the piston position display extends all the way to the right side of the Piston Position field showing a solid black box e When at Max Retract the piston is fully retracted out of the cylinder barrel and the piston position box displays a 10 black area on the left hand edge of the box The piston position field is a graphic display of the position of the piston The motion status field is a written display of the position and current status of the piston Watching the piston position and the motion status fields the user can see and read an exact description of each piston s location and its actions 4 3 4 Motion Status The motion status field describes what each pump cylinder s piston is doing at any given time Table 4 1 explains the possible motion status conditions which are divided into two main categories stopped conditions and run conditions Table 4 1 Motion Status Parameters 1 of 3 Condition Description STOPPED CONDITIONS Stopped The piston is stopped See the piston position display to see how far the piston is extended into the cylinder barrel The piston can be stopped near Max Extend near Max Retract or anywhere in between Max Extend The piston is extended as far into the cylinder barrel as it will go This
107. h uses the Autoclave F250C fitting port 8 Loosen the retaining screws on the valve assembly and slide the assembly down and to the right so that the Autoclave Speedbite fittings engage the pump cylinder barrels Some adjustment may be necessary to get a good fit 9 First tighten the fittings by hand then finish tightening them using the angle wrench provided in the special tool kit 10 For the C 5000 20K cylinders connect the valve assembly fittings to the pump cylinders using the following orientation e the safety rupture disk holders point toward the stand e the transducers point away from the cylinders and 2 6 11 12 13 14 15 Chapter 2 SYSTEM SETUP e the valves mount away from the stand When the stand is fully assembled and placed in the desired location adjust the leveling feet so that the cylinders slope upwards from the motor to the cylinder barrel This slope is recommended so that any trapped gas in the cylinder barrel is expelled when the cylinder fills with liquid Connect the power cords to the appropriate power connection preferably through an Uninterruptable Power Supply UPS See Chapter 10 Do NOT turn on the CMD 5000 however until steps 13 16 have been completed Connect the data link cable from the CMD 5000 to Port A of the Serial Expander Isolator If you have two controllers in your system then connect the data link cable from the second CMD 5000 to Port B of the Serial Expand
108. h a ecctteniees 4 5 S Safety Features scssccteuhdeeitesseaetveastions 5 1 Safety Pressure Set cccccsssscesssceees 4 19 Safety Rupture Disk 0 ee 5 2 8 7 Holder oe enen oae E ONTE 5 4 RANES annin ie etisi 5 3 11 19 REDIACING ssisesitars inttiin 11 18 Seal Assembly 5 c53 seeds caepsiadectysadeis Coteeduttvaus 7 5 Seals Changing Peres canned vauheeN ade Mesures 11 4 Cup Typeset 11 4 Seal Insertion Procedure 11 6 Cup Type Picture 0 0 cece eee 11 5 Removal Procedure ceeeeee 11 5 Seal Insertion Tools 0 0 0 0 11 6 Index 4 Me VNC AE E EEE E E 11 4 T Type Seal Insertion Procedure 11 7 T Type Picture sec asdadesisaeeeteaats 11 5 Serial Expander Isolator cesses 6 6 Side RAIS vcdieesdeassearteatasmuccelbedisenains 7 5 Software Updates ccsscssssssseeeees 12 18 Spare Parts Kit o ae 11 1 11 3 Status Bar socere iin e a nte 4 3 Stopped Conditions See Conditions SOPPER AS 4 5 Support Stand fh secuyss5Ansieaesacadaueseesticneds 1 4 T TGS Bar Ae a beeen teamagenietec as 4 2 TOONS onsi a eeu Seas 11 1 Special Tool Kit cee oiceestentuaneds 11 2 Troubleshooting cccceeseeeeeeeteeeteees 12 1 AGIOS sorse eaea iiit 12 1 Situations sesssesseseeeseessessrssressesse 12 10 Tubing eana a S 8 5 Components Picture 0 0 0 0 eee 8 7 Cylinder to Pressure Transducer 8 6 Cylinder to Valve sasciass cae nscectiasiass 8 5 PUIG eeno nanei 3 2 Inlet Tee
109. h liquid just use air If the pumps contain liquid you can proceed with the test but be aware that with liquids pressures can rise rapidly when the pump cylinders are extending 3 3 Quizix 5000 SERIES PUMP MANUAL It is assumed that you have just completed the valve check described in the previous section and that PumpWorks is operating Set the Safety Pressure for the cylinders you are testing to 100 psi 700 kPa using the Main Set Pump Safety Pressure window Set the Operating Mode to Mode 1 which is the Independent Constant Rate mode Set the Flow Rate at approximately 20 of the maximum allowable flow rate 3 milliliters per minute for an C 5000 10K cylinder The maximum flow rate is shown by PumpWorks in the Set Flow Rate window At this rate a full piston stroke takes about three minutes Set the direction to retract for each cylinder However if the piston position reading for any of the pump cylinders is at Max Retract set the direction for that cylinder to extend This is because if the piston is at its maximum retracted position the piston must now extend Set the valves so that the air or liquid displaced will not build up pressure Usually this means opening all fill valves deliver valves may also be opened Start cylinder 1A by pressing the Press to Start button View pump cylinder 1 A through the side cover to see the piston move Ensure that the cylinder labeled Cylinder 1A is actually the cylinde
110. hact e a E A E E ENa 8 3 8 4 Press re Transducers onenari i s 8 4 8 5 Fl id PIM Gs siti aalydiadaxtawes studs bake a a aea a ai aE a Enn 8 5 8 5 1 User Supplied Tubing ts ccjeesiccsasteccatedatac esata tacdemedeaciires 8 5 8 5 2 Stand Supplied Tl Wa isos car dvieaen acchaidaducatatinnaied 8 5 8 6 Safety Rupture DISK Se Leccasgee Mean suececcan gseduesen aadeas tas eancdavcuacarierdeenueenet 8 7 8 7 Hastelloy Option for Corrosive Fluids 0 0 0 eceeceesseeeeeeeeeeeteeeeseeees 8 8 8 8 High Temperature Option isei2c asc aicbstt teeta snis niveaddea aah ead tamer 8 8 8 8 1 Transducer S 2 cc lie i a Mae gd wedule ca erates ea Atenas 8 8 8 8 2 Valves and Pilot Solenoids so253sco5 50 ceases cabeariacaobarsoasuaressdiosas 8 8 TOC 3 Quizix 5000 SERIES PUMP MANUAL CHAP VER 9 System Cables ier cistentawae navelwadeedstnraeiact he diucusshaweeedeled e a a 9 1 OA Motor Cables a hae a a a AE 9 1 9 2 Sensor Cable nianna oi Ak NO ase ak a a OU ea 9 1 9 3 Transducer and Valve Cap lec c cecal antuetadastec exeaauteo scene eesamisecauon tangas 9 1 le Data Tink Cable sios aane Re Den RU Se een re 9 2 9 5 RS 232 CADIS iee eens rten atan aea anaE AE EE AR ATSR EA EE 9 2 9 6 AC Power Cables ssis3 ccsssasiccrssenitietecniante saunter Giarcentneas 9 2 9 7 User Interface Cable Optional sires iiecnssiasciadalatacs daunwae 9 3 9 8 Front Panel Cable Optional sci cseccasscsdeass Gocaceteecewteedianes tadsseaaveees 9 3 9 9 Cable EXtEnSionS esna n
111. hapter 10 System Power for further information on UPSs 2 6 Requirements for Air Supply The valves used in the Quizix Pump System are air actuated Air is taken into the system at the solenoid manifold then air tubes connect the solenoids and the valves The air inlet fitting at the bottom of the manifold which is labeled P has a 1 4 quick disconnect fitting You should insert a 1 4 tube into this fitting to connect the system with a pressurized air source A standard laboratory air supply or an air compressor may be used The air should be clean dry oil free and regulated at 60 100 psi 4 0 6 8 bar See Chapter 8 for further information regarding the valves pilot solenoids and air supply 2 11 Quizix 5000 SERIES PUMP MANUAL 2 12 This page intentionally left blank Chapter 3 SYSTEM CHECKOUT SYSTEM CHECKOUT This chapter provides important safety checkout procedures designed to help ensure the safe operation of your 5000 Series Pump System IMPORTANT The safety procedures are essential to safe operation of the Quizix pump system It is strongly recommended that you follow them carefully Because of the extremely high pressures achieved by Quizix pumps the importance of these safety measures cannot be overemphasized If they are followed the Quizix 5000 Series Pump System is designed to operate safely However as with most machinery system safety depends on follo
112. hat the barrel is not perfectly horizontal The outer end of the cylinder barrel where the plumbing is attached is its highest point so that trapped gas can be expelled through the plumbing The base plate to which the cylinder is bolted places the cylinder in the proper orientation with a slight upward tilt 7 3 Primary Mechanical Subcomponents of the Pump Cylinder Starting at the motor end of the pump cylinder the following five subcomponents comprise the basic drive train of the C 5000 pump cylinder 7 3 1 Stepper Motor The motor attached to the pump cylinder is a stepper motor which rotates in the direction and at the speed dictated by the CMD 5000 Dual Controller Driver A heat sink is attached to the motor to provide adequate cooling High temperature versions of the pump cylinder also have a fan attached to the motor 7 3 2 Harmonic Drive The harmonic drive gear reduction assembly uses a 100 1 ratio The output of the harmonic drive rotates once for every 100 revolutions of the stepper motor and turns the ball screw 7 3 3 Ball Screw and Ball Nut The ball screw and ball nut convert the rotary motion of the motor and harmonic drive into linear motion The ball nut moves back and forth on the ball screw as the ball screw rotates Two versions of ball screws are used One has a pitch of 0 5 inches and the other which is used on the two L models has a 0 2 inch pitch 7 3 4 Ball Nut Assembly Attached to the ball n
113. he computer must also be connected to the UPS The monitor does not have to be connected to the UPS unless you want to view data or manually change parameters during a power outage Although many devices provide wattage W ratings most UPS systems are rated in volt amps VA Both ratings are listed for Quizix components in Table 10 1 Table 10 1 UPS Ratings Component Wattage Volt Amp CMD 5000 Dual Controller Driver 2 pumps stopped 30 40 2 pumps fully loaded 80 120 Typical Windows computer 60 400 80 500 Typical Windows monitor 50 200 70 250 The next item that should be considered is the length of time a power outage is likely to last Enough battery capacity must be available at the load required to last for the length of the power outage Most UPS systems list how long their battery can supply full and half load power This information can be used to determine the expected run time with the load from the above calculation Extra battery packs can be obtained for most UPS systems In case of an unusually long power outage considerable power can be saved by turning off the monitor or both the monitor and the computer Further power savings can be obtained by stopping the motors or running them at slower rates Turning off equipment of course requires that the user be present If power to the motor driver is lost motors de energized the pump cylinders will back drive and lose volume informatio
114. he steps in Section 2 3 to complete the process of setting up your system and installing the pumps onto PumpWorks Before using the high temperature system perform the system checkout procedures provided in Chapter 3 2 5 Power Considerations The CMD 5000 operates on AC current at 120 220 or 240 volts The CMD 5000 is compatible with the voltage and type of outlet used in the country to which the pump system was shipped At the 120 volt setting Quizix components operate over a 100 130 volt range and 47 63 Hz At both the 220 and 240 volt settings Quizix components operate over a 200 250 volt range and at 47 63 Hz The voltage setting on the CMD 5000 can be changed if necessary See Chapter 10 Section 10 3 If you ordered a computer with your Quizix pump system it is also set for the voltage in use in your country See the operating manual for your computer for further information about its power specifications Electronic equipment such as computers and the Quizix controller can be affected by brief power interruptions and by power line surges and spikes An Uninterruptable Power Supply UPS can provide back up power capabilities to prevent any interruption in pump operation when power interruptions or surges occur It is strongly recommended that users interested in obtaining continuous fluid flow over extended periods of time use a UPS with their system Chapter 2 SYSTEM SETUP to prevent disruption to an experiment See C
115. heck found in Chapter 3 Section 3 2 e Go to PumpWorks main window From the menu bar select Communications View Communication Status After a few seconds the COM Port Selection for Communication Status window appears Click on the COM number that your pump system is connected to then click on OK The PumpWorks Communication Status for Com window appears At the top left corner check to see if the serial expander isolator is present or not present If the expander is present the problem is between the serial expander isolator and the pump controller e Check that the data link cable is plugged into Data Link on the pump controller and NOT into Front Panel e Try plugging the pump controller into a different port on the serial expander isolator Ports A B C or D are possible Search for pumps again by selecting Communication Search For Pumps NOTE Each time you alter any item during this troubleshooting process you need to search for pumps so that PumpWorks can establish communication with the pump s Ifthe serial expander isolator is NOT present then the problem is between the computer and the serial expander isolator Check the RS 232 cable try a different serial port on the computer or try using a different computer 12 2 2 2 2 Once Communications Has Been Established Once communications is established between PumpWorks and the pump controller the following communication errors may be reported in
116. hem 7 Gently force the seal insertion plunger through this set of seals and rings to align them 8 Coat the seal retaining nut threads with an anti seize compound then screw it into the cylinder barrel to hold the seal back up ring and seal in place Tighten this nut using the face spanner wrench Use the 22 mm wrench to hold the cylinder barrel 11 2 3 Inspecting Removing Cleaning and Re Installing a Piston WARNING THE PISTONS ARE MADE OF SILICON CARBIDE AND ARE VIRTUALLY UNSCRATCHABLE BUT THEY ARE SLIGHTLY BRITTLE AND CAN BREAK KEEP SIDE FORCES TO A MINIMUM AND DO NOT DROP THEM 11 2 3 1 Inspecting and Cleaning a Piston A piston that is installed in a pump can be inspected by doing the following It is assumed that the cylinder barrel has already been removed as described in Section 11 2 1 1 Operate the pump to move the piston to the Max Extend position 2 Inspect the piston carefully looking for deposits or obvious damage then wipe it clean with a clean lint free cloth 3 Ifdeposits are found clean the piston with a solvent and a nylon Scotchbrite type scrub pad 4 Ifsome deposits cannot be removed while the piston is installed or if you want to soak the piston in a solvent use the 27 mm socket wrench with an extension to remove the piston Inspect a piston that is removed from the cylinder housing by doing the following 5 Inspect the piston carefully looking for dep
117. hreads on which the ball nut turns Together the ball nut and the ball screw convert the rotary motion of the motor and harmonic drive into linear motion for the piston The ball screw is machined with a specific number of threads per inch or pitch The ball nut will advance this distance for each revolution of the ball screw For example if the ball screw has 8 threads per inch then the ball screw will require 8 full rotations in order for the ball nut to advance one inch This is the speed of the electrical communication signal used by the controller and the computer For example is 28 8 kilobaud is twice as fast as 14 4 kilobaud Inside of the pump cylinder are radial bearings and thrust bearings which hold the ball screw in place but allow it to rotate Capable of operating in two directions or to go back and forth G 3 Quizix 5000 SERIES PUMP MANUAL cable clips cable connection sensing cable extension cable retainers calibrate cam rollers capillary viscometer cascade ceramic color coded communications port component Com port compression ring concave configuration The metal clips mounted on an assembly controller or driver that lock around the end of the cable connector to keep the connector and attached cable firmly in place This is a controller and pumpworks software safety feature that detects the presence or absence of certain cables in a system The cables supplied with
118. i 2 0 ml per minute 9 3 ml 500 inch C 5000 20K 20 000 psi 7 5 ml per minute 5 2 ml 375 inch Table 1 2 The 6000 Series Pump Cylinders Piston Model Maximum Maximum Stroke Piston Pressure Flow Rate Volume Diameter C 6000 5K 5 000 psi 400 ml per minute 550 ml 2 00 inch C 6000 10K 10 000 psi 200 ml per minute 275 ml 1 41 inch C 6000 20K 20 000 psi 100 ml per minute 135 ml 1 00 inch 1 2 Primary Components The Quizix 5000 Series Pump System is designed as a modular component system Pump systems can include from one to eight C 5000 pump cylinders using any of the pump cylinder models shown in Table 1 1 above Two pump cylinders are necessary for continuous flow of a single fluid A standard SP 5200 two cylinder pump system and standard SP 5400 four cylinder pump system typically include the following components Table 1 3 Primary Components SP 5200 2 Cylinder System SP 5400 4 Cylinder System 2 pump cylinders choice of models 4 pump cylinders choice of models 2 CV 310 valves 4 CV 310 valves 2 pressure transducers 4 pressure transducers 1 CMD 5000 Dual Controller Driver 2 CMD 5000 Dual Controller Drivers 1 two cylinder support stand 1 four cylinder support stand Plumbing and cables Plumbing and cables 1 PC compatible computer 1 PC compatible computer Quizix PumpWorks software Quizix PumpWorks software Chapte
119. ift the box straight up and high enough to clear the stand assembly The stand is held onto the base of the shipping box by four clamps two on each side at the base of the stand 6 Inspect for shipping damage Remove the manual and unpack the tool kit 2 2 Installing the Pistons Due to previous experience with pistons being broken during shipment the pistons of your 5000 Series pump cylinders are not installed in their cylinders for shipment The pistons are packed separately and must be installed before the pump cylinders can pump fluid 2 1 Quizix 5000 SERIES PUMP MANUAL This section describes how to install the pistons into the pump cylinders A more detailed description of this procedure is included in Chapter 11 The piston which is made of silicon carbide is extremely corrosion and scratch resistant but is also brittle and may break if dropped CYLINDER BARREL a P Pa c Cylinder Barrel Retaining Ring nut _ __TUBE ATTACHMENT FOR WASH AREA _ Tube attachment for optional Wash Area 23 00 inches O RightSide Cover Cylinder Barre Pump Housing e LER Side Cover ANAIE RASE PIATI Angle Base Plate T Figure 2 1 C 5000 Ambient Temperature Pump Cylinder Required Tools Face spanner wrench and 27 mm socket extension tool Refer to Figure 11 1 on Page 11 1 for a photograph of these tools 1 Remove the cylinder barrel retaining ring using the face spanner wrench supplied in the tool kit
120. ight individual on off switches located on the back of the SC 2400 controller These switches are preset by the manufacturer and set up the pump cylinder configurations Located on the rear panel This tells you the version of the con troller hardware you are using The metal side panels of the controller are available in three types stand mounted rack mounted or table Four sets of eight each LED Indicators which show the SC 2400 controller is operating The outside curve as in the outside of a bowl Fluids or chemicals that gradually wear down or eat away at the pump system G 5 Quizix 5000 SERIES PUMP MANUAL cup type seals current value cursor cycled mode cylinder barrel cylinder barrel assembly cylinder barrel retaining ring cylinder barrel volume cylinder support block cylinder retaining fingers data log data log parameters debug deburr default default names G 6 A seal that looks like a U on cross section The value or number that is operating or applies now A blinking element on your computer screen that shows the space where the next letter or number will appear Individual pump cylinder operating mode where only one cyl inder is used to approximate the activity of a cylinder pair The round metal part that extends out from the pump housing where the user s fluid is held The piston enters the cylinder barrel during fluid pumping The cylinder barrel asse
121. in all Quizix pump systems is a one time only item that must be replaced after it is activated It is not a pressure relief valve and cannot be tested If you bring the system pressure up to the level at which the disk is designed to activate it breaks and must be replaced To replace a safety rupture disk carefully follow the instructions in Chapter 11 Chapter 5 SAFETY FEATURES 5 4 Emergency Stop Capability The CMD 5000 Dual Controller Driver includes an emergency stop capability which is accessed through the User Interface connector If you would like to implement an emergency stop function for your pump system you will need to install a User Interface cable Pin 19 of the user interface connector is tied to the emergency stop signal of the pump controller By setting a jumper inside the controller this line can be made to be 1 a pull to ground for emergency stop or 2 a loop signal which ifit is interrupted causes an emergency stop For more information see Appendix B of the PumpWorks User s Manual 5 5 Quizix 5000 SERIES PUMP MANUAL 5 6 This page intentionally left blank Chapter 6 CMD 5000 DUAL CONTROLLER DRIVER The CMD 5000 Dual Controller Driver is included in all 5000 Series Pump Systems and operates with C 5000 pump cylinders The CMD 5000 CMD stands for Controller Motor Driver contains two primary subcomponents 1 The pump controller which controls the operation of the entire 5000 Series Pump
122. ion is specified all metal parts that come in contact with a fluid are made of Hastelloy C 276 These parts include the fluid wetted parts in the C 5000 pump cylinder the CV 310 valves the safety rupture disk and its holder the tubing for the fluid plumbing and the fittings and tees The pressure transducers however are only available in stainless steel Non metal parts that come into contact with a fluid include PEEK in the valves Teflon or UHMW seals and o rings of various materials 8 8 High Temperature Option The Quizix pump system is available in a high temperature version that allows the pump cylinders and valves to be heated up to 160 C The following changes are made to the plumbing in high temperature systems Tubing used for the air connections between the pilot solenoids and valves are constructed of Teflon instead of nylon e The fittings on the CV 310 valves into which the air tubes are inserted are Swage type fittings instead of plastic quick disconnect fittings The Swage fittings have metal ferrules which should be screwed tight when the air line is inserted When setting up a high temperature system the following information regarding the valves pilot solenoids and transducers should be considered 8 8 1 Transducers The standard pressure transducers operate at 70 C They can be used at temperatures up to 80 C inside an oven without severely shortening their lifetime However for temperatures
123. iston retracts and the deliver valve needs to be closed To deliver fluid the deliver valve needs to be open and the fill valve needs to be closed Refer to the fluid flow diagram below which shows the basic fluid plumbing for a pump system with two pump cylinders If the user needs to service the valves refer to the Valve User Manual for information Fluid Plumbing Diagram DELIVER FILL VALVE A X X VALVE A 1 z FLUID N _ FUD OUTLET eile niles INLET FLUID FLUID OUTLET INLET TEE TEE DELIVER FILL VALVE B VALVE B Y CYLINDER TUBING CONNECTION 4 PIECES TUBING 2 PIECES Figure 4 7 Fluid Plumbing Diagram Chapter 4 PUMP OPERATING BASICS 4 4 Set Safety Pressure Pump Works includes a safety pressure feature Pump Works will automatically stop a pump cylinder when the user set safety pressure has been reached When the pump is first powered up the safety pressure is initialized to a negative pressure so that the user is required to enter a value that is correct for their pump An errors present message will display on the status bar of the main window of PumpWorks until the user sets the safety pressure To set the safety pressure go to PumpWorks main window and on the menu bar click on Main Set Safety Pressure Enter a pressure which is higher than the maximum pressure level you expect to reach during the normal course of your experiment 4 5 Errors Present When the status bar of
124. ither extends or retracts for only one piston stroke The user sets the valves and the direction of the pump and the flow rate then starts the pump cylinder for each piston stroke 1C Independent Constant Rate Cycled In this mode a single pump cylinder is used to cycle IND CR C back and forth to deliver fluid to an experiment The active pump operates at the set rate When the end of stroke is detected the valves are switched the direction changed and the pump cylinder is refilled During the refilling standby retract stroke the rate is determined by the return rate factor and the return rate minimum parameters The fluid flow in this mode is discontinuous due to the refill stroke After refilling the cylinder will servo to the measured pressure at the end of the last stroke then open the deliver valve and start the next stroke Independent Constant Pressure In this mode a single pump cylinder is operating in IND CP constant pressure mode at a user set pressure Like Mode 1 when a pump cylinder is operated in this mode it either extends or retracts for one piston stroke The user sets the valves and restarts the pump cylinder for each piston stroke The direction of pumping action is determined by whether the piston must retract depressurize or extend pressurize in order to achieve the specified pressure level The user also sets the run pressure 2C Independent Constant Pressure
125. iver driver air holes GLOSSARY The unit of measure for the default pressure is PSI or pounds per square inch The unit of measure for the default rate is in milliliters per minute To pump or push fluid from a pump cylinder into a user s experiment or sample This valve controls the flow of fluid from the pump cylinder to a user s experiment or sample The measured amount of pressure or force across a section or portion of the system To reduce the pressure on the fluid inside the cylinder barrel of a pump To reduce the pressure inside a cylinder barrel This is accomplished by retracting the piston thereby increasing the fluid volume inside the cylinder barrel The place or point where the fluid is going This is a window in the PumpWorks software that contains a form or checklist for you to fill out This is the measured rate at which the actual pressure is approaching the set point pressure The amount by which you multiply the differential error to convert it to a rate of change for the pump cylinder so that the actual pressure is matched to the set point This controller software safety feature causes the cs to stop pumping if the user set safety pressure is exceeded This controller software safety feature causes the pump cylinders to stop pumping if the pressure transducer voltage drops below a factory preset level This PumpWorks software window allows you to choose the unit of measure to use
126. iver valve of the standby pump cylinder is always closed The time it takes for the standby pump cylinder to fill and pre pressurize G 21 Quizix 5000 SERIES PUMP MANUAL status bar steady state stepper motor stopped conditions stroke volume symmetrical system level integration T type seals tab key teflon tiled tilt angle time formats titles torque torque wrench G 22 This is the horizontal bar that is on the bottom of the main win dow in PumpWorks software and provides messages regarding the status or condition of the controller s data logging sequencer and error messages constant or unchanging The motor attached to the pump cylinder which rotates in the direction and at the speed dictated by the controller Text messages in the motion status to tell you if the piston is in Max Extend or Max Retract or if it is stopped in between these two points The amount of fluid the pump cylinder is capable of pumping during one piston stroke Something that is the same on both sides The user s entire experiment is controlled by the Quizix Pump Works software A type of seal that is shaped like a sideways T and is usually made of an elastomer Press the Tab key on your computer keyboard to move from one box to the next A unique polymer with excellent anti friction and anti corrosion properties The computer positions the open files so all that are open two or m
127. justs the fluid rate or fluid volume to account for either expansion or contraction of the fluid as it is heating up or cooling down This is a unit of measure for rate It is stated in either milliliters per minute or milliliters per hour To run through the pump system more than once A special pump operating mode where fluid is continuously pumped from a pump cylinder through a sample and back into another pump cylinder without the fluid being depressurized and without pressure pulses This PumpWorks software window is where you set your parameters for recirculating mode To configure the system again or to give the computer a new set of instructions to change the operation of the pump system The switch used to provide piston position information Reed switches are located on the sensor board of the pump cylin der This is the only way to properly exit from recirculating operation The display volume for any pump cylinder can be set to zero at any time using this button A deposit that remains on a surface after fluid has been removed A mechanical part which holds a pump cylinder into the cylinder support block on a pump stand Brings a window that is minimized into full view again retract retracting return rate multiplier return rate minimum RS 232 cable run conditions rupture safety pressure safety rupture disk safety rupture disk assembly safety rupture disk exhaust port safet
128. ks can weaken after extended use at these pressures If you frequently operate at such high pressures you should replace the safety rupture disks ona regular basis as part of their scheduled system maintenance Alternatively you may want to install safety rupture disks with a higher rating In that case contact Quizix for the appropriate specifications Safety rupture disks are installed to prevent the system from exceeding a specified pressure The terms safety burst disk SBD and safety rupture disk are used interchangeably in this manual The safety rupture disk is activated if there is a transducer failure that cannot be detected by the normal safety systems or in the extremely unlikely event of a hardware or software failure in which the pump system does not respond to normal controls In this situation this disk protects the Quizix pump from damage The safety rupture disk included in Quizix pump systems is a one time only item that must be replaced after it has been activated It is not a pressure relief valve and cannot be tested If the system pressure is brought to a level that activates the disk it ruptures and must be Chapter 11 MAINTENANCE replaced Refer to Chapter 5 for more information about safety rupture disks Generally the pressure at which the safety rupture disk activates should be slightly higher than the maximum pressure rating of the pump cylinders in your system See Table 11 3 for the safety rupture disk rating u
129. l happen is all segments of the display will light at once briefly e Next the display should flash the boot version number currently version 3 6 12 3 2 1 Pump Controller Diagnostics The basic pump controller diagnostics are performed next The controller begins testing itself If a test fails the display will freeze Report this to Quizix technical support The right hand digit will light the left hand digit will not One segment of the right hand digit will light at a time starting with the top segment as shown in Figure 12 1 below One segment lights then a second segment lights then a third and so on Each segment that lights is a confirmation from PumpWorks that a specific aspect of the pump controller is operating correctly 12 6 Chapter 12 TROUBLESHOOTING I I I I 1 I I I I I Wet I I I Figure 12 1 The segments on the right hand digit represent the following tests performed by the pump Segment 1 RAM test OK Segment 2 Move code OK Segment 3 Boot CRC OK Segment 4 Block 1 CRC check Segment 5 Block 2 CRC check Segment 6 Block 3 CRC check Segment 7 Code CRC OK Jump to program If segments 1 2 or 3 do not light call Quizix Ifsegments 4 5 6 or 7 do not light start Pump Works and load the program code Pump Works will know that the program is bad and will prompt the user for the program file name 12 7 Quizix 5000 SERIES PUMP MANUAL Two Digit Display Pump Controller Diagnostics a Displa
130. lay the pump number 1 2 3 and so on The following two digit display errors are discussed in this section e The Two Digit Display Does Not Light Section 12 3 1 The Two Digit Display Does Not Complete Its Initial Check Section 12 3 2 Pump Controller Diagnostics Section 12 3 2 1 e Pump Controller Software Initialization Section 12 3 2 2 e Two Digit Display Error Code Section 12 3 3 12 3 1 The Two Digit Display Does Not Light If the two digit display does not light when power is turned on to the pump controller do the following e Check that the power cord is fully plugged in e Check that power is available to the electric outlet Try turning the pump controller s power switch off and then back on again Ifthe two digit display still does not light either the power supply or the pump controller has failed and needs to be replaced at Quizix The fuse for the power supply may need to be replaced See Chapter 10 for instructions on replacing a fuse 12 3 2 The Two Digit Display Does Not Complete Its Initial Check Each time a segment of the two digit display lights during the initial pump start up a specific aspect of the pump controller is being checked If the two digit display fails to complete its initial pump start up check that is an indication that the pump controller s printed circuit board needs to be replaced at Quizix Watch the two digit display when you turn on your pump The first thing that wil
131. ly see Chapter 10 on Uninterruptable Power Supplies for more details The power cord Chapter 6 CMD 5000 DUAL CONTROLLER DRIVER supplied is compatible with the voltage and style of plug used in the country to which the pump is shipped A fuse box is located next to the power cord connector and includes either a fuse for 120 volt or 220 240 volt operation To change the fuse simply pop out the fuse holder and replace the fuse Use a fuse with a rating appropriate to the voltage you are using 1 5 amps for 120 volts 0 75 amps for 240 volts Your CMD 5000 Dual Controller Driver has been set up to use either 120 or 240 volt power depending on the standard voltage in your country To change from one voltage to another see the instructions in Chapter 10 6 4 Cable Connections 6 4 1 Sensor Cable The Sensor Cable connects the CMD 5000 Dual Controller Driver with the sensor board on each C 5000 pump cylinder The purpose of the sensor board is to detect the position of the piston within the cylinder barrel Each pump controller includes two 15 pin D style connectors for the sensor cables labeled Sensor Cable for Cylinder A and Cylinder B If the pump controller is used with only one pump cylinder the connector for Cylinder B will not be used 6 4 2 Motor Cable The Motor Cable connects the CMD 5000 Dual Controller Driver with the stepper motor attached to each C 5000 pump cylinder Each pump controller includes two 9 pin
132. main menu bar main window manifold max extend maximum extend maximum value max retract maximum retract mechanical subcomponents metal ferrules microswitches minimum value A PumpWorks software communication method An example is when the controller sends information to the PumpWorks about a pump cylinder it first must request to interrupt the computer s current task This is an abbreviation for kilo pascals which is a unit of measurement for pressure A type of bolt that is used to attach the top cover of a stand mounted pump shipping box to the base of the box Data will be taken at a user specified interval or time span and recorded in the PumpWorks software data log file To apply a liquid to the surface to reduce friction This is the rectangular shaped bar that is horizontal across the top of the PumpWorks software main window and contains key words for the pull down menus This screen appears each time PumpWorks software is started It displays information about each pump cylinder and allows for the user to read data and set operating parameters This supplies air to the Pilot Solenoids which actuate the CV valves See maximum extend The furthest or maximum that the piston can move during nor mal operation in the forward or extend direction The highest number or value that can be entered See maximum retract The furthest or maximum that the Piston can move during normal ope
133. mbient Temperature C 5000 Cylinders For high temperature systems the tubing supplied with dual cylinder high temperature stands are very similar to the tubing supplied with the ambient temperature systems The major difference is the long length of tubing back to the pressure transducer which is mounted outside the oven Refer to Figure 8 4 for the identification of each of the following parts Valve inlet interconnect tubing Valve outlet interconnect tubing Cylinder to valve tubing Cylinder to pressure transducer tubing VAP Chapter 8 VALVES AND PLUMBING Valve Inlet Tubing Valve Outlet Tubing Cylinder to Valve Tubing Two Pieces per cylinder Cylinder to Pressure Transducer Tubing Figure 8 4 Tubing Components Supplied with the High Temperature System IMPORTANT Carefully check all fluid fittings for leaks All pump systems are checked thoroughly and are fluid tight at the time it is shipped However Quizix recommends that you carefully check all the fittings prior to operation and whenever the system is altered or moved Most system leaks can be traced to fittings 8 6 Safety Rupture Disks Safety rupture disks are installed on each pump cylinder to prevent the system from exceeding a specified pressure If the specified pressure is exceeded the rupture disk bursts and fluid is expelled from the safety rupture disk fluid exit port The fluid exit port is
134. mbly consists of the cylinder barrel cylinder seal seal back up rings and seal retaining nut A ring that screws into the pump housing to keep the cylinder barrel in place The cylinder barrel volume consists of the dead volume and the piston stroke volume the volume displaced by one piston stroke Use pump cylinder support block Small metal pieces which hold the pump cylinder in the cylinder block on a stand mounted pump system This PumpWorks software feature allows you to automatically record data from your experiment onto a computer hard disk This is where you decide which data items you want recorded in your data log A PumpWorks software option that provides access to the Quizix controller so the manufacturer will be able to assist you in resolving any problems that might occur To deburr is to remove any sharp edges or corners The default option is a pre set value chosen by PumpWorks when the user decides not to pick a different option The name given to a pump cylinder pilot solenoid valve or auxiliary valve when a pump system is initially shipped from Quizix The user can change the default names at any time default pressure unit default rate unit deliver deliver valve delta pressure depressurize depressurizing destination dialog box differential error differential gain or differential servo gain digital overpressure digital underpressure display units and precisions dr
135. mless location To achieve a good seal Quizix recommends that 120 ft lbs 160 Newton meters be used to torque down a replacement disk rated for 25 000 psi 5 3 4 3 All C 5000 Pump Cylinder Models For all pump systems each safety rupture disk is shipped with a tag that shows the specified pressure level at which it will activate and a torque specification To operate properly the retaining fitting must be torqued to the level shown on the tag for a 12 500 psi disk the torque is specified at 45 foot pounds If you unscrew the locking fitting in the vent port make sure to screw it back to the specified torque level Safety rupture disk holders are available in either stainless steel or Hastelloy If you have purchased a system with the Hastelloy option then a Hastelloy safety rupture disk holder is provided Also safety rupture disk holders may be placed in an oven for high temperature pump systems If you regularly operate your pump system at pressures in the range of 80 to 100 of maximum pressure 8 000 10 000 psi for a standard SP 5200 10K system note that rupture disks can weaken after extended use at these pressures If you frequently operate at such high pressures you should replace the rupture disks on a regular basis as part of their scheduled system maintenance Alternatively you may want to install rupture disks with a higher rating In that case contact Quizix for the appropriate specifications The rupture disk included
136. mp cylinder at the extension Refer to Chapter 1 Figure 1 2 7 7 Quizix 5000 SERIES PUMP MANUAL e A fan assembly is attached to the stepper motor to prevent overheating of the motor The fan operates when the CMD 5000 is on and should have access to air at all times e The side covers are made of aluminum not plastic e The seal is made of Aflas or sometimes PTFE teflon not UHMW polyethylene The high temperature seal assembly contains more parts than the ambient temperature seal assembly Refer to Figure 7 5 e A different grease is used to lubricate moving parts e lt A different CAM Roller is used Cylinder Barrel lt _______ Pump Housing Cylinder Barrel Retaining Ring Right Side Cover Left Side Cover p gt Angle Base Plate gt High Temperature Motor Extensions Harmonic Drive Assembly Figure 7 4 C 5000 High Temperature Pump Cylinder A Figure 7 5 High Temperature Seal Assembly 7 8 Chapter 7 PUMP CYLINDER 7 9 Pump Cylinders with Optional Wash Ring On most versions of Quizix C 5000 pump cylinders the seal retaining nut is a conventional nut that does not include a wash area However a special version of the pump cylinder in which the seal retaining nut is incorporated with a wash ring can be ordered on model C 5000 10K This is screwed into and out of the cylinder barrel in the same way as a normal retaining nut When internal and external o rings ar
137. n a E TE RR 9 3 CHAP LER IQ System POWE cora hera te ath narra a ate aan Aon a 10 1 10 1 Basic Power Requirements 06jiadeiicGasteaiicslcaasatcsasataeans 10 1 10 2 Using Uninterruptable Power Supplies ssssssessssessessseessesesssresse 10 1 10 3 Changing the Voltage Setting 2 2 20 fini sees caste aoe datl lua 10 2 10 4 Replacing a Fuse si cds Waser cares tse odtcas tases Warastoen meee tacaaaenr andes 10 3 CHAPTER 11 Maintenance soia penina a a n E 11 1 11 1 Special Tools and Spare Parts Kat s sssnneeseeesesseeseesessseessesessesse 11 1 11 2 Changing the Cylinder Barrel Seals 20 0 0 eeeeccecceseceteeneeeeeeneees 11 3 11 2 1 Removing the Cylinder Barrel cescgiacestesncesideedeicavoeeectesanene 11 3 11 2 2 Changing the Seals sas ediescctealtsesuucSuntivanathuegeveeradeuciens 11 4 11 2 2 1 Cup Type and T Type Seals cceeeeeeeeteees 11 4 11 2 2 2 Seal Removal Procedure for All Seals 11 5 11 2 2 3 Seal Insertion Procedure for Cup Type Seals 11 6 11 2 2 4 Seal Insertion Procedure for T Type Sealls 11 7 11 2 3 Inspecting Removing Cleaning and Re Installing a Piston11 8 11 2 3 1 Inspecting and Cleaning a Piston eee 11 8 11 2 3 2 Re installing the Piston cececesceseeeeeseees 11 9 11 2 4 Replacing the Cylinder Barrel eeeeeceeceseceeeteeneeeaee 11 9 11 3 Maintaining the Pump Cylinder 4 3 lt scssclisiccniieneicaaecs 11 9 11 3 1 Replacing the Cam Rollers cciscciiscs
138. n by Pump Works e Using the computer function keys If this option is enabled in PumpWorks System Settings Window Each function key is assigned to a particular pump cylinder in order function key F1 to cylinder 1A function key F2 to cylinder 1B and so on Pushing the appropriate function key will start a stopped pump cylinder in the same way that a Push to Start button does Pushing the function key of an operating pump cylinder will stop that pump cylinder 4 3 5 2 Starting Pump Cylinders in Independent Operating Modes When a pump cylinder is set to an independent operating mode the user needs to set the cylinder direction to either extend or retract as desired This is done on PumpWorks main window using the cylinder direction button If fluid is to be taken into the pump cylinder the cylinder direction is set to retract If fluid is to be delivered out of the pump cylinder the cylinder direction is set to extend Quizix 5000 SERIES PUMP MANUAL 4 8 In independent operating modes the user also needs to set the positions of the fill and deliver valves These valves can be opened or closed depending on how the fluid is to flow If the fluid is to be taken into the pump cylinder the fill valve is opened and the deliver valve is closed If fluid is to be delivered out of the pump cylinder the fill valve is closed and the deliver valve is opened 4 3 5 3 Starting Pump Cylinders in Paired Operating Modes When the pump
139. n if the cylinder pressure is above 2000 psi For pressures below 2000 psi the residual holding torque of the motors combined with the friction of the mechanics can hold the piston in place For pressures above 2000 psi the pressure forces on the piston are high enough to cause the ball screw to rotate and push the piston backward until the cylinder pressure drops below 2000 psi 10 3 Changing the Voltage Setting The Quizix 5000 Series Pump System can operate at 110 120 or 215 240 volts If you must change the voltage setting in a system with 5000 Series pump cylinders you can do so by changing the fuses and settings on the CMD 5000 Dual Controller Driver Follow the instructions below 1 Unplug the CMD 5000 and the computer On the controller note the modular power connector assembly which includes a receptacle for the power cord a fuseholder and a Chapter 10 SYSTEM POWER voltage selector in one unit Note that there is a very small white indicator displaying the voltage for which the controller is currently set 2 Pop out the fuseholder located directly next to the power cord receptacle Use a small screwdriver in the slot hole to loosen the fuseholder 3 Change the fuse to the appropriate amperage rating for the voltage you want to use The following shows the appropriate fuse ratings e For 120 Volts 1 5 am fuse e For 220 240 Volts 0 75 amp fuse 4 Using a small set of pliers pull out the white voltage selector
140. ng the Pump System with Liquid If your pum system does not have liquid in it add it at this point Connect the fluid inlet tubing to a fluid supply and the outlet tubing to a drain Fill each cylinder manually by doing the following procedure To fill a cylinder with fluid leave the safety pressure at 100 psi and set the flow rate to 50 of the maximum rate 7 ml min for the C 5000 10K cylinder Chapter 3 SYSTEM CHECKOUT 2 Open the fill valve close the deliver valve set the direction to retract and start the cylinder to initiate the filling process for cylinder 1A 3 When the cylinder reaches the Max Retract position close the fill valve open the deliver valve switch the direction to extend then press Press to Start to initiate the pumping process for cylinder 1A On this first pumping stroke mostly air is delivered out of the fluid outlet fitting 4 Wait until the Max Extend position is reached then repeat Steps 2 and 3 three times ending with a retract stroke so that the cylinder barrel is full and all air is flushed out Check to see that fluid has been taken from the fluid supply and that some fluid has been pumped out through the fluid outlet during this process 5 Repeat this procedure for each cylinder in your system ending with all cylinders full of fluid and the pistons in the Max Retract position 3 5 Pressure Transducer Check Because the pump system can reach extremely high pressures very quickly it i
141. nic drive harmonic drive adapter harmonic drive assembly hastelloy HC heat sink hierarchy holding extend holding retract A pumping mode that operates two pump cylinders so they move in equal but opposite directions at the user set rate At the end of the piston stroke both pump cylinders change direction simultaneously at the same time and continue to run at the set rate This mode does not provide pulseless fluid flow To control or dominate This quick disconnect plastic fittings which are located on the pilot solenoids and the CV valves are used to connect the air lines necessary to operate the valves The top surface of the guide rail where the cam rollers move or roll on the guide rail A switch on the pump cylinder that stops the pump controller from moving the piston in either direction This is a back up safety feature that normally will not be activated A gear mechanism which reduces the motor rotation speed It is located inside the pump housing near the motor A mechanical part that holds one half of the harmonic drive gear assembly This is the harmonic drive plus the motor housing adapter and harmonic drive adapter This is a metal alloy that is highly corrosion resistant This is an abbreviation for hastelloy A metal part with fins or ribs that carries excess heat away from the heat source The SC 220 dual motor driver and some pump motors use heat sinks Ranked according to import
142. nnection Ambient temperature and high temperature sensor cables are not interchangeable 9 3 Transducer and Valve Cable The transducer and valve cable connects the CMD 5000 Dual Controller Driver to the pressure transducers and the pilot solenoids for the valves There will be one transducer and valve cable for each CMD 5000 Dual Controller Driver in your system This round shielded cable has a 25 pin D style connector at the controller end 9 1 Quizix 5000 SERIES PUMP MANUAL The transducer portion of this cable has two branches Each branch has a 6 pin circular connector that should be connected to one end of the pressure transducer The branch labeled Transducer A should be connected to Transducer A on pump cylinder A the branch labeled Transducer B should be connected to Transducer B on pump cylinder B The pilot solenoid portion of this cable has four branches one for each pilot solenoid There are two pilot solenoids for each valve Each numbered branch has two wires each with a 2 pin connector that goes to a numbered pilot solenoid If you reconfigure or move the pump system this cable should be disconnected at the pump controller end and not at the pilot solenoid end Because the transducer and valve cable is designed for two pressure transducers and four pilot solenoids if a user s pump system has an odd number of pump cylinders there will be cable strands which are not used 9 4 Data Link Cable Th
143. nnections for a 4 Cylinder System IMPORTANT Ensure that the air lines between the valves and the pilot solenoids are connected properly according to the color coded markings For example the brown labeled lines should connect the valve with a brown label to the pilot solenoid with a brown label If the valves or pilot solenoids are serviced make sure that all of the color codes match between the valves and solenoids See Figure 8 2 For 4 cylinder pump systems with 8 pilot solenoids and 16 air lines each main color is used twice The second set of pilot solenoids numbers 5 8 contain a second black band For example there is a brown labeled air tube leading to the fill portion of solenoid 1 for valve 1 and a brown and black labeled air tube leading to the fill portion of pilot solenoid 5 for valve 3 8 4 Pressure Transducers Each C 5000 pump cylinder is plumbed to a pressure transducer that measures the fluid pressure inside the cylinder barrel The transducer converts this pressure measurement to an 8 4 Chapter 8 VALVES AND PLUMBING electric signal which is sent to the CMD 5000 Dual Controller Driver through a transducer cable This cable has a 25 pin D style connector at the pump controller end then splits into one 6 pin circular connector for each pressure transducer The pressure transducers included in each system correspond to the maximum pressure of the pump cylinders in the system For e
144. o have PumpWorks operate the cylinders automatically so that each cylinder barrel fills and empties continuously The 5000 Series Pump System is designed to include anywhere from one to eight pump cylinders Continuous fluid flow requires two pump cylinders per fluid Working as a coordinated pair one pump cylinder the active cylinder pumps fluid while the other pump cylinder the standby cylinder fills and pre pressurizes When the first cylinder is empty they switch and the second cylinder becomes the active cylinder and pumps out its fluid Operated in this manner the pair of cylinders can pump continuously for any length of time For this reason most users have two pump cylinders for continuous flow of one fluid or four cylinders for continuous flow of two fluids 7 1 Quizix 5000 SERIES PUMP MANUAL The following three options are available for the 5000 Series pump cylinder pump cylinders Figure 7 1 SP 5200 Pump System e Hastelloy C 276 wetted parts are available and recommended for users who pump highly corrosive fluids e A high temperature option permits users to heat the pump cylinder so that the fluid delivered is at reservoir temperatures This option allows temperatures of up to 160 C to be maintained within the pump See Section 7 8 for more information about the high temperature option e An optional wash area is available to wash highly corrosive fluids off of the piston as it retracts For more inform
145. of piston movement Current Pressure Fill Valve Button Set Pressure Button Deliver Valve Button Current Flow Rate In the following sections we will discuss each of the above items in depth 4 3 1 Pump Name Quizix assigns a default name for each pump each pump includes two C 5000 pump cylinders The default names are Pump 1 Pump 2 and so on The user has the option of entering a different name for each pump at any time The user assigned name can be something that clarifies the pump s use as in Oil Pump or Brine Pump or something that clarifies the type of pump as in C 5000 10K Pump If English is not the user s primary language the pump name can be entered in the user s own language 4 3 2 Cylinder Number Quizix assigns a default number for each pump cylinder which is Cylinder 1A and Cylinder 1B for Pump 1 Cylinder 2A and Cylinder 2B for Pump 2 and so on This is considered paired numbering The pump cylinders can also be numbered individually which is Cylinder 1 Cylinder 2 for Pump 1 Cylinder 3 and Cylinder 4 for Pump 2 and so on To change the cylinder numbers between paired and individual go to Pump Works System Settings window on the Configure menu 4 3 3 Piston Position The piston position field displays the position of the piston for each pump cylinder The display is read from left to right which is consistent with English text The piston can be either fully retracted called Max Retract
146. order to operate however the pump system must have a source of AC power available at all times Electronic equipment such as computers and the CMD 5000 Dual Controller Driver can be affected by brief power interruptions and power line surges or spikes These power fluctuations can be caused by the power company or lightning strikes and can cause the pump to stop operating It is therefore strongly recommended that users interested in obtaining data over extended periods of time use an Uninterruptable Power Supply UPS with their equipment Quizix recommends a UPS that provides continuous on line filtering and good AC line noise rejection as well as power backup capabilities Also it is recommend that the time required for the unit to switch to back up power be less than a few milliseconds The proper size for a UPS must be determined based on your specific pump system and the type of power losses that are normally experienced The first item that must be determined is the pump system s power consumption This can be determined using Table 10 1 10 1 Quizix 5000 SERIES PUMP MANUAL 10 2 To keep the Quizix pump system operating only the CMD 5000 Dual Controller Driver needs to be connected to the UPS supply The computer can be turned off without affecting the operation of the pump system However if the computer is used to log data or perform timed operations such as ramping of rates or pressures with the AutoOp feature then t
147. ore are entirely in view at the same time The 0 to 15 degree angle that the pump cylinders are positioned at There are three options for recording time the actual time and date as set on your computer elapsed time or cumulative time PumpWorks software allows you to provide your own column headings or titles for you Data Log A turning or twisting force A wrench that has a gauge built into it which allows the user to tighten nuts and bolts to a specified degree of force or torque transducer assembly transducer cable transducer calibration trapped gas trigger switch tubing unacknowledged unidirectional uninterruptible power sup ply UPS unresolved vacuum grease valve valve assembly valve cable valve cable extension voltage setting volume voltage setting GLOSSARY The transducer assembly includes the transducer transducer cable and fluid tubing This cable connects the pump controller to the pressure transducers See calibrate Gas that cannot be easily expelled or removed from the pump system This switch on the sensor board is sensed by the PumpWorks software to automatically tell the controller that the Piston has reached the end of its stroke 1 8 and 1 4 tubing is used to connect the pump cylinders valves and Pressure Transducers in the pump system Not yet corrected Moving or operating in one direction only A source of power that will continue if th
148. ors s ssssseseesesseseeseeseesesseseesesse 12 3 12 3 CMD 5000 Two Digit Display Error Messages cccceeeeeee 12 5 12 3 1 The Two Digit Display Does Not Light eee 12 6 12 3 2 The Two Digit Display Does Not Complete Its Initial Check 12 6 12 3 2 1 Pump Controller Diagnostics 0 0 0 eeeeeeeeeeteenee 12 6 12 3 2 2 Pump Controller Software Initialization 12 8 12 3 3 Two Digit Display Error Code cececceesceseeeeeeeteeeeseees 12 8 12 4 Other Pump Troubleshooting Situations 2 0 0 0 eeeeeeeceteeneeeee 12 10 12 4 1 Air Supply Problems cycisz s5eegsaeu sss creck Gens sie aedltanveies 12 10 12 4 1 1 No Air Escaping Sound When Valves are Opened AN EOS A sates te cereale Geran nas ey a ote ect teas 12 10 12 4 1 2 Constant Air Escaping Sound eee 12 11 12 4 2 Fan Does Not Rut 2 cs0 d stetoiaa de eetiesce averse 12 11 12 43 Fl id Leaks tanninen a a aaa 12 11 12 4 3 1 Leakage Basics 6 0 utes snes atomniwiereansmenneene 12 11 12 4 3 2 SGA T stihg soisiu ae aoa Geshu caleynials 12 12 12 4 3 3 Does Your Pump Have a Fluid Leak 12 12 12 4 3 4 Finding Your Leak cscssccsscceseccsecsesecesaces 12 13 12 4 4 No Fluid Is Being Delivered ceccsscceseccsescsecesncees 12 13 12 4 5 Piston Motion Errors cccscesseeceeeeceseceeecneeeseeeeeeeeeeseeeaes 12 14 12 4 5 1 Motor Running No Piston Movement Detected BOP eae dct estas ost tot tee ie atte da tenes 1
149. osits or obvious damage and wipe it clean with a clean lint free cloth 6 If deposits are found clean the piston with a solvent and a nylon Scotchbrite type scrub pad or soak it in a cleaning solvent until deposits are removed 11 8 Chapter 11 MAINTENANCE 7 If deposits are not found re install the piston as described in the next section 11 2 3 2 Re installing the Piston 1 Wipe the piston clean with a clean lint free cloth Coat the piston s threads with an anti seize compound then use the 27 mm socket wrench with an extension to re install it into the pump housing 2 To prepare to re install the cylinder barrel into the cylinder housing coat the tip of the piston with a lubricating compound such as petroleum jelly or vacuum grease or water if oils are not permitted A small amount is sufficient to cut seal insertion friction 3 Operate the pump to move the piston to its Max Retract position to protect the piston in preparation for re installing the cylinder barrel 11 2 4 Replacing the Cylinder Barrel 1 Ensure that the pump is at its Max Retract position 2 Ifyour pump system has an active wash ring inspect the two wash ring external o rings for signs of nicks or deterioration If necessary replace them Using a lubricant like vacuum grease coat the outside o rings completely around their circumference This allows the o rings to be inserted without binding 3 Holding the cylinder barrel assembly
150. ove the o rings that are located in the wash ring When extracting o rings these sticks prevent scratching the o ring sealing area of the wash ring Never use a metal tool to extract the o rings Spare wash ring internal o rings 2 each Spare wash ring external o rings 2 each Chapter 8 VALVES AND PLUMBING 8 VALVES TRANSDUCERS AND PLUMBING This chapter describes the following components of a 5000 Series Pump System e Valves Section 8 1 e Pilot Solenoids Section 8 2 e Air Supply Section 8 3 e Pressure Transducers Section 8 4 Fluid Plumbing Section 8 5 e Safety Rupture Disks Section 8 6 e Hastelloy Option for Corrosive Fluids Section 8 7 e High Temperature Option Section 8 8 8 1 Valves Quizix uses constant volume air actuated valves manufactured by Vindum Engineering All pump systems with 5000 Series pump cylinders except model C 5000 20K use CV 310 valves These valves are rated at 10 000 psi Systems with C 5000 20K pump cylinders typically use CV 320 valves which are rated up to 20 000 psi There is usually one valve per pump cylinder in a pump system although some 3 cylinder systems may use only two valves A high temperature option allows valves to be heated to 160 C The valves use a 3 way T formation design so that there are two internal valves or gates that control the flow of fluid into and out of the pump cylinder That is each CV 310 valve includes bo
151. oving forward in the cylinder barrel which causes fluid to be delivered out of the pump to the user s experiment To begin To load fluid into a cylinder barrel as the piston retracts This is the valve that is between the pump cylinder and the sup ply of fluid The fill valve controls the process of bringing the fluid into the pump cylinder A circular metal part that is part of the harmonic drive The flexspline fits around the outside of the wave generator bearing A mechanical assembly used to equalize side forces on a ball nut assembly The user specified rate the pump cylinder operates at when operating in a Constant Rate Mode The tubing used to connect the fluid inlet tee to the fill side of each valve The tubing used to connect the flluid outlet tee to the deliver side of each valve No leaks occurring in the system The fluid is contained within the pump system without escaping The tubing which carries the fluid through different parts of the pump system This consists of fluid tubing tees ferrules and nuts An electrical safety device containing an element that protects an electric circuit by melting when overloaded by a malfunc tion A mechanical part that contains a replaceable fuse It is located next to the power cord connector Quizix 5000 SERIES PUMP MANUAL geared mode governs QD fitting or quick disconnect fitting guide rail roller surface hard limit switch harmo
152. play written in block style A brief definition follows each error code 12 8 AO CE DC DE DO DP DU ES LE PC PE SC Chapter 12 TROUBLESHOOTING Analog Overpressure Error e pressure transducer signal abnormally high e transducer or transducer cable failure e analog to digital converter problem Communication Error e unable to decode communication from computer Driver Cable Error edriver cable not connected Driver Status A or B e the motor driver has a fault possibly overheated or shorted turn off power to reset driver Digital Overpressure Error cylinder pressure exceeds safety pressure When a pump is powered on it will have this condition until the safety pressure is set Driver Power e the motor power supply has shut down turn off power to reset power supply Digital Underpressure Error e pressure transducer signal abnormally low e transducer or transducer cable failure e analog to digital converter problem E Stop e user has activated the emergency stop signal on the user interface connector Low Side Driver Error e a valve wire is not connected pilot solenoids on valves Pressure Transducer Cable Error e pressure transducer cable not connected Motion Error Position Error e malfunctioning linear motion sensor edrive train problem slipped gear or ball screw problem Sensor Cable Error e sensor cable not connected 12 9 Quizix 5000 SERIES PUMP MANUAL 12 10
153. ps 1 2 and 3 in Section 10 3 Then replace the fuseholder Step 7 10 3 Quizix 5000 SERIES PUMP MANUAL This page intentionally left blank 10 4 Chapter 11 MAINTENANCE MAINTENANCE This chapter describes preventive and corrective maintenance for the Quizix 5000 Series Pump system This chapter includes e Special Tools and Spare Parts Kit Section 11 1 e Changing the Cylinder Barrel Seals Section 11 2 e Maintaining the Pump Cylinder Section 11 3 e Cooling Fan Maintenance Section 11 4 e Replacing the Safety Rupture Disk Section 11 5 e Calibrating the Pressure Transducers Section 11 6 e Valve Maintenance Section 11 7 NOTE For the purposes of this manual the term regular use is defined as using the pump system 2 to 3 days per week every week at pressures above 35 of the rated pump pressure or at rates above 35 of the maximum pumping rate If you are operating at lower pressures very low rates or infrequently then the stated service intervals can be increased Some conditions may require servicing the pump system more often CAUTION As a general safety precaution always verify that there is no pressure in the pump before performing any service procedures To accomplish this open the valve typically the fill valve which vents the system to atmosphere 11 1 Special Tools and Spare Parts Kit Each Quizix pump system is shipped with a set of special tools and a spare parts kit
154. r 5 1 Quizix 5000 SERIES PUMP MANUAL 5 2 than the expected running pressure If the system exceeds the safety pressure setting a digital overpressure error message is displayed on the system monitor and the cylinders stop pumping The controller stops the pump when the safety pressure is reached Due to momentum if the piston is moving forward at a fast rate when the overpressure event is detected the system pressure may exceed the safety pressure before the cylinder comes to a complete stop 5 3 2 Digital Underpressure The transducer for the Quizix pump system has been selected so that at zero pressure the transducer output is 0 5 volts The controller includes a safety feature that provides an error message if the transducer voltage drops below a certain level or pressure signals are not received by the controller In this case Pump Works assumes that there is a transducer failure A digital underpressure error message is displayed on the system monitor and the cylinders stop pumping 5 3 3 Analog Overpressure The analog overpressure feature is implemented in the controller hardware whereas the digital overpressure and underpressure features are part of the software The analog overpressure feature limits the maximum value allowed from the A D converter It is fixed at approximately 5 over the maximum pressure specification of the pump system It cannot be set by the user If an analog overpressure error occurs the cylinders
155. r The Current Error Log which is located on the Error Log menu will list the error date what time it was when the error occurred and give a description of the error The error will also be recorded in the Previous Error Log where a list is maintained of all errors present and past that have been detected by Pump Works up to a maximum file size set by the user Chapter 12 TROUBLESHOOTING Some errors are immediate errors and some are logged errors which we will discuss in the following sections 12 2 1 Immediate Errors An Immediate Error is generated in response to a command sent by the user This is generally the result of a user asking the pump to do something that is not permitted An example is trying to open or close a valve or change the operating mode of a pump cylinder that is currently running A dialog box immediately appears on the screen with an error message The text in the dialog box clearly explains what prevents the requested action from being executed An immediate error is NOT logged to the Current Error Log or the Previous Error Log The status bar of the PumpWorks main window reads No Errors and the motion status display does not show an error status for that pump cylinder 12 2 2 Logged Errors A logged error is entered into the Current Error Log and Previous Error Log but no dialog box appears on the screen The status bar of the PumpWorks main window displays Error Present or Check Error Log
156. r 1 GENERAL OVERVIEW The 5000 Series two cylinder pump system known as an SP 5200 is shown in Figure 1 1 below A computer can be supplied by the user or purchased from Quizix as part of the pump system pump cylinders Figure 1 1 Stand Mounted SP 5200 Pump System Quizix components can also be configured as a closed loop recirculating system to obtain Steady State Relative Permeability measurements Recirculating systems can be set up for one two or three fluids and can maintain a pulse free constant flow rate of one or more fluids through a sample while maintaining a constant pressure at the outlet of the sample This type of system requires an additional pump cylinder and specialized software NOTE ON NOMENCLATURE The terms pump cylinder and cylinder are used interchangeably throughout this manual and refer to the entire mechanical component used to pump fluid as shown and labeled in the picture above Pump cylinder part numbers begin with a C For example C 5000 10K is a 5000 Series pump cylinder with a maximum pressure rating of 10 000 psi The term pump system refers to one or more pump cylinders together with one or more pump controllers valves transducers plumbing and PumpWorks software The part number for an entire pump system begins with SP For example an SP 5200 10K pump system includes two C 5000 10K cylinders The number of pump cylinders in a system is given by the number following
157. r Barrel NOTE This procedure is the same for both ambient and high temperature systems IMPORTANT Excessive side loads on the piston during cylinder barrel installation or removal may break the piston 1 Ensure that the piston is fully retracted before removing or installing the cylinder barrel This minimizes the side forces on the piston during cylinder barrel removal and 11 3 Quizix 5000 SERIES PUMP MANUAL 11 4 installation Operate the pump so that the piston is in its Max Retract position before proceeding 2 Remove the Speedbite fittings from the end of the cylinder barrel and tip the cylinder downward to drain its fluid 3 Use the adjustable face spanner wrench to remove the cylinder barrel retaining ring nut Refer to Chapter 7 Chapter 7 2 if needed 4 Grasp the cylinder barrel by hand and pull it straight out from the cylinder housing Be sure to pull it straight out and away from the cylinder housing Never put any sideways force on the cylinder barrel because this may break the piston If an active wash assembly is used a firm pull and some twisting back and forth may be necessary to get the cylinder barrel to move initially Once the cylinder barrel is released from the body of the cylinder continue to pull straight back until the seal and seal backup ring are released from the piston For best results remember to keep cylinder barrels seal back up rings and pistons together
158. r in which the piston is moving Ifa different cylinder operates when you press the Press to Start button for cylinder 1A then a cable connection is wired improperly and needs to be corrected On ambient temperature systems the piston can be viewed through the plastic side covers on the cylinder The piston is not visible in the high temperature systems that have metal side covers If you have a high temperature system listen for the sound of the piston running and stopping Also watch the piston position that is displayed on Pump Works When the piston reaches the end of its stroke it automatically stops and displays Max Retract as the position The direction automatically switches from retract to extend for cylinder 1A Start the pump cylinder again and view the piston through the side cover until it reaches its Max Extend position Also listen for the sound of the piston running and then stopping Repeat this procedure for each pump cylinder Set the direction to retract for one piston stroke then extend for one stroke Look and listen each time for correct operation This check indicates that PumpWorks the controller and the limit switches in the pump cylinder are all working properly and the system is cabled correctly If you do not see the piston moving in the correct cylinder or hear the motor running each time you must do additional troubleshooting Do not proceed further until your system has passed this check 3 4 Filli
159. ration in the backward or retract direction There are subcomponents or smaller parts that make up a mechanical assembly of the pump Metal compression rings used to attach teflon tubing to air actu ated valves in high temperature systems Microswitches are used to detect the movement of the piston There are two triggers two soft limit switches and two hard limit switches one each for the retract direction and one each for the extend direction The lowest number or value that can be entered modes modular power cord connector motion status motor adapter housing motor assembly motor cable motor driver motor extension motor extension cable motor resolution in steps motor shaft motor shaft key not inst not installed num lock GLOSSARY See Operating Modes A modular power cord connector which allows electrical power from different countries to be plugged into the same device The motion status indicates what the piston is doing at any given time The display field for motion status is located at the top of the main window below the Cylinder title A mechanical part on which is mounted the stepper motor and one half of the harmonic drive at the back of the pump cylinder This includes the stepper motor motor cable cable connector motor adapter housing and associated parts This cable is permanently attached to the motor and connects the motor to the motor driver This pro
160. rculating pump system a User Interface Cable will be included with your system and will be labeled Recirculating Cable It is used to establish communications between the controllers in recirculating systems 9 8 Front Panel Cable Optional The optional Front Panel Cable connects the CMD 5000 Dual Controller Driver with the Front Panel which may be used instead of PumpWorks to control the pump system The Front Panel is not currently available 9 9 Cable Extensions Quizix supplies the correct cable lengths for stand mounted ambient temperature systems and for high temperature systems where the pump cylinders and valves are placed in an oven and the other pump system components are outside the oven If a user converts an ambient temperature system to a high temperature system or reconfigures a pump system in any way that requires longer cables replacement cables can be ordered in longer lengths The motor cable can be extended if necessary Although Quizix recommends that the motor cable be kept as short as possible Quizix manufactures a 2 meter motor cable extension There are no extension cables available for the sensor cable transducer and valve cable or data link cable but the user can order new cables in a longer length if necessary The RS 232 cable can easily be extended with a standard straight through one to one 9 pin cable Quizix 5000 SERIES PUMP MANUAL This page intentionally left blank 10 Chapter 10 S
161. re version is shown next to Controller Version The last two digits are a special part of the controller software called the boot code The rest of the digits are the controller software version Next you need to check which is the latest version of the pump controller available To do this contact Quizix either by phone or by going to our website at http www Quizix com Please refer to the PumpWorks User s Manual for software update procedures AC line noise rejection A D converter acoustic separator activated active pump cylinder active wash area adjustable face spanner wrench aflas air actuated air inlet air supply Allen wrench Allen head screw GLOSSARY This term refers to the reduction of the magnitude of voltage spikes and noise on an AC power line Some uninterruptible power suppliers and surge suppressors are able to reduce voltage spikes and noise to help protect the electronic equip ment connected to them An A D analog to digital Converter takes an analog electrical signal and converts it to a digital signal that can be displayed as a number An example would be to take an electrical signal from a pressure transducer and convert that signal so the pressure is displayed as a number on the computer This is a device that uses ultrasonic signals to measure fluid volume PumpWorks software allows for the pump system to interface with an acoustic separator To put into action or
162. rly and needs to be fixed To correct this problem do the following 12 15 Quizix 5000 SERIES PUMP MANUAL 12 16 The transducer and valve cable must be inserted into the transducers properly Check the 6 pin circular connector at each transducer e Check if the cable has been worn or cut If there is an analog overpressure or digital underpressure reading this can be the result of a controller failure a transducer cable problem or a transducer failure e Check the transducer cable first and then try swapping transducers and transducer cables If there is a faulty component it will need to be replaced 12 4 6 2 Pressure Does Not Increase Within 30 Seconds If the pressure does not start to increase in a pump cylinder when it is running then the most likely cause is no fluid in the pump which can be caused by any of the following e A leak in the inlet fluid tubing allowing air to be pulled into the pump cylinder instead of fluid The fluid inlet tubing is clogged preventing fluid from entering the pump cylinder e Fluid is too viscous or thick to be pulled into the pump Other causes of this problem could be that the fill valve is leaking the cylinder seal is leaking the pressure transducers are cross wired or the fluid being delivered is leaking out some where in its fluid path Open the fill valve and listen for pressure being released If there is pressure being released you probably have a pressure transducer
163. rotated away from you 0 25 inches of travel for the cam rollers and again apply the grease along the entire visible length of the screw 8 Replace the left side cover The system is now ready for normal use 11 3 3 Re Greasing the Harmonic Drive Bearing Recommended Frequency For all systems every 2 years of regular use 1 Power down the complete pump system especially the CMD 5000 Dual Controller Driver and disconnect the 9 pin connector on the motor cable from the CMD 5000 See Figure 11 8 for the three major assemblies discussed in this procedure Motor Adaptor Housing Motor Assembly Body Assembly 9 Pin Connector Figure 11 8 Pump Motor Assembly 2 Use a3 mm right angle Allen wrench to break loose the six M4 socket head cap screws SHCS securing the motor adapter housing to the pump body See Figure 11 9 for the 11 13 Quizix 5000 SERIES PUMP MANUAL location of the mounting screws that secure the motor adapter to the pump body housing A ball end Allen driver can then be used to remove the screws Figure 11 9 M4 Socket Head Screw Locations 3 Set the pump body assembly aside 4 Viewing the open end of the motor adapter housing remove the snap ring from the motor shaft See Figure 11 10 Wave Generator y ks E Flexspline Da g Adaptor Housing Figure 11 10 Open End of the Motor Housing 5 Holding the motor assembly firmly in one hand with the open
164. ry out over time especially on the high temperature pump systems This procedure explains how to confirm the cam rollers are working properly are lubricated correctly and if necessary how to replace them Refer to Figure 11 4 and Figure 11 5 The cam roller and stand off shown in Figure 11 5 is shown magnified and with the roller slightly unscrewed for clarity Allen Head Screw that Secures the Sensor Board Figure 11 4 Right Side Cam Roller Cam Roller Stand Off Figure 11 5 Cam Roller and Stand Off 1 Remove the right side cover two Phillips head screws 2 Remove the sensor board and set it aside one 3 mm socket head cap screw This step is recommended but not mandatory 3 To determine if the cam roller needs replacing check the following 11 10 Chapter 11 MAINTENANCE a Grasp the cam roller with two fingers and make sure it feels smooth and non binding when it is rotated b Ifthe steel guide rails see Figure 11 4 on which the rollers roll have any marks on them other than a straight wear path parallel to the sides of the rails the rollers should be replaced c Ifa high temperature system has more than two years of regular use at high temperatures the rollers should be replaced 4 Use a 10mm open end wrench and slide it over the flats of the cam roller stand off which is screwed into a ball nut bracket 5 While holding the stand off in place place a 1 8 inch Allen wrench into the cen
165. s 5 4 5 3 4 3 All C 5000 Pump Cylinder Models 5 4 5 4 Emergency Stop Capability 2c acca ceh see owas oeeaiedncaweidaeaamaes 5 5 CMD 5000 Dual Controller Driver cesinsissteccdededdiesacensieaseadcacialaisnsiatdoes 6 1 6 1 The Pump Controller Subcomponent s sssssessesessseesseseesseessesssseesees 6 1 6 2 Motor Driver Subcomponent si c se0 sacessadjesued sholgaussanreaddaraacaae ies 6 2 6 3 On Off Switch Power Cord and Fuse Holder c cece 6 2 TABLE OF CONTENTS 64 Cable Connectio s lt atoschs ter cid t antes yess cd ucsasbateteca teed dienes Waban aug eateas 6 3 6 4 1 Sensor Cale so son re i a E E AR E A cee 6 3 6 4 2 Motor Cablecceni enr E E Gn eco ER 6 3 6 4 3 Transducer and Valve Cable snssnsnesessseeseesessseessesessseessesee 6 3 6 4 4 Data LMK Cables naa 6 3 G43 Front Panel Cable 22 0 set ssuxssavestenstctoazsabsese cea handoataoagsduaslatsreiatias 6 4 6 4 6 User Interface Cable iis cctitesiviussnaecornestectebtem qisreansaas ens 6 4 6 4 7 AC Power Cord Receptacle ssc eis seeaiadliindadiceuns 6 4 6 4 8 R22 42 Cab let cig ren a X agree e A a R 6 4 6 5 Pump Number Two Digit Display ccccecceecceeeeeteeeeteeeteeeseees 6 4 6 6 Serial Expander Isolator sccsccccessciaietbedcausesancdosnge casgabaetsegernceucacseces 6 6 6 7 Pump Controller Software cs isecewsthn do donee wis aaa 6 7 CHAPTER 7 Pump Cylinder coh isscesetica sino ienuisindaiaviseinad Manisa hanes 7 1 7 1 Quizix C 5000 Pump Cylinder sioc
166. s absolutely essential that the pressure transducers be checked carefully To do this use the following procedure 1 Itis assumed that at this point each cylinder is full of liquid and each piston is in the Max Retract position Close both valves fill and deliver for cylinder 1A 2 Set the rate to 20 of the maximum rate 3 ml min for C 5000 10K model cylinders 3 With the safety pressure still set at 100 psi and the direction set to extend start the cylinder Watch the pressure reading on the software s Main Window until it exceeds 100 psi and is stopped by the digital overpressure control system If the cylinders are filled with fluid this should occur with less than 0 5 ml of fluid pumped 4 Stop the pump cylinder if The pressure reading does not stop increasing when it reaches 100 psi 700 kPa You must do further trouble shooting due to an apparent pressure transducer or pump controller malfunction The likely cause of this is either the pressure transducer or the motor is cross wired For example pump cylinder 1A s pressure transducer may be connected to pump cylinder 1B s connector The pressure reading does not begin to increase after several seconds The most likely cause of this problem is there is no fluid in the pump which can be caused by 1 an air leak in the fluid tubing allowing air to enter the pump system 2 the fluid inlet tubing is clogged preventing fluid flow in the tubing or 3 the fluid
167. s are connected but it cannot determine if they are connected in the right places Use the cable connection checklist shown in Section 3 1 1 This is the most basic and most important checkout All plumbing and cables are labeled and many are color coded 3 1 Quizix 5000 SERIES PUMP MANUAL IMPORTANT It is strongly recommended that you carefully double check all cable and tubing connections each time you disconnect and then reconnect them 3 1 1 Connection Checklist The purpose of this safety check is to make sure that all the cables and tubing are connected in the right places The system can seriously malfunction if the cables are switched or tubing is connected improperly 1 Motor Cables from Pump Cylinder to CMD 5000 Dual Controller Driver Make sure each motor cable is plugged into the correct connector for that cylinder For a 4 cylinder system connect cylinder 1A into the receptacle labeled Cylinder A on the first CMD 5000 connect cylinder 1B into the Cylinder B receptacle connect cylinder 2A into the receptacle labeled Cylinder A on the second CMD 5000 and connect cylinder 2B into the receptacle labeled Cylinder B Sensor Cables from Pump Cylinder to CMD 5000 Dual Controller Driver Make sure each sensor cable is plugged into the correct connector for that pump cylinder The sensor cables follow the same pattern as the motor cables Transducer amp Valve Cables
168. s these pressures to match the standby pump cylinder s pressure to the active pump cylinder s pressure to eliminate pressure variations at switchover If the two pressure transducers are not matched to each other than the pressure in one pump cylinder will not be the same as the pressure in the other pump cylinder even though the readings on the display will match The easiest way to check if the pump cylinders are matched is to use one pump cylinder to pressurize both pressure Chapter 11 MAINTENANCE transducers connect pump cylinders together and record the pressure of both pressure transducers over the pressure range of interest 11 6 1 What is a Pressure Transducer A pressure transducer is a device that converts a pressure to an electrical signal proportional to that pressure In the CMD 5000 Series controller the signal generated by the pressure transducer is sent directly to an A D analog to digital converter which converts the analog electrical signal of the amplifier to a 20 bit digital signal that is displayed on the computer Each individual pressure transducer will have slight variations in zero pressure output voltage zero offset and its output voltage at full pressure gain In the 5000 Series Pump System these variations are compensated for in the controller software The process of adjusting the offset and gain compensation values is called calibration 11 6 2 Methods of Calibrating the Pump System There are two
169. sed with each C 5000 pump cylinder model Table 11 3 Safety Rupture Disk Ratings Cylinder Maximum Safety Model Operating Rupture Disk Pressure Rating C 5000 2 5K 2 500 psi 3 500 psi C 5000 5K 5 000 psi 6 500 psi C 5000 L 7 5K 7 500 psi 10 000 psi C 5000 10K 10 000 psi 12 500 psi C 5000 L 10K 10 000 psi 12 500 psi C 5000 20K 20 000 psi 25 000 psi 11 19 Quizix 5000 SERIES PUMP MANUAL 11 20 To replace a safety rupture disk use the following procedure 1 Remove the safety rupture disk assembly from the pump system this is an important precaution 2 Unscrew the safety rupture disk locking fitting while securely holding the safety rupture disk holder 3 Remove the locking fitting compression ring and the old safety rupture disk 4 Carefully and completely clean out the seating area for the safety rupture disk in the safety rupture disk holder Also clean the new safety rupture disk and compression ring so that they are free of any dirt or contaminating particles 5 Insert the new safety rupture disk into the safety rupture disk holder making sure the bulge in the disk is outwards convex NOTE It is very difficult to see if the disk is convex or concave by looking at it It is better to take a smooth rod and feel if the disk is in place so that the center is higher than the edges 6 Place the compression ring on top of the safety rupture disk then screw in the
170. send data such as rates or pressures to one or more programs while allowing another program to control pump operation This immediately shuts off all pulses to the dual motor driver and will cause a sudden stop of the pump cylinders This is to be used in emergency only It is located on the front panel of the SC 2400 controller A button on the computer keyboard which will take the cursor on the computer screen and move it to the end of the line you are working on An error is a fault that has happened somewhere in the pump system that requires the user to take action to resolve it before the pump system can be operated again This PumpWorks software feature is a time record of the errors that have happened to a pump system This PumpWorks software message means that there is currently an error in the pump system that has not been acknowledged or resolved exit options extend extended A D values extending execute fill fill valve flexspline flexure flow rate fluid inlet tubing fluid outlet tubing fluid tight fluid tubing fluid plumbing fuse fuse holder GLOSSARY Some of the PumpWorks software windows have certain options which the user selects to exit that menu i e Exit No Change or Yes Accept Change The forward direction for the piston PumpWorks can handle an additional 16 A D channels if the user adds a special card to their computer The action of the piston m
171. seniseednisiieiaans 4 5 Rume ere ar eee eae ret rene ene er 4 5 Stopped rerna i ated 4 5 Stopping scari aiins aren at i aRt 4 5 Connection Checklist 2 0 0 0 ceeeeeeeeeeee 3 2 Controller See CMD 5000 nisser 1 4 Corrosive Fluids ccccececeeeeeeees 7 7 8 8 Current System Status Window 12 1 Cylinder Barrel tsh sew ias dead 7 4 7 5 RG MOVIND 253ssasaatueriseesdccs tadestedsintease 11 3 Replacing ianen n ie 11 9 Seals Changing eessessseeseesesssseseesresesssee 11 3 Cylinder Switch Status Window 12 2 D Dialog Boxes steely nstedeeiaslea Nas 4 4 Digital OW GED FESSUTO ni oat ahs Sonat ees 5 1 Underpressure os exicets ikshecucaviocasaeeaats 5 2 E Emergency Stop lt ccisiceciiecsse assescosseccescdes 5 5 Error Code See Two Digit Display 12 8 Emori Oseni gain Get the ua 12 1 Error WIESSABES snicle uotis 12 2 Error State Capture Mode 0 06 12 2 Errors Analog Overpressure c0e 12 9 Communication cccccceeees 12 3 12 9 Buffer Overrun cis s cacdeersiavisees 12 5 Cannot be Established 12 4 CRC CHECK oseaan lates 12 5 Input EL ErOL ccadeccctsceademarcnes 12 5 Index 1 Quizix 5000 SERIES PUMP MANUAL No Response from Pump 12 5 Digital Overpressure cceeeeee 12 9 Digital Underpressure eeee 12 9 Driver Cable ciaconiadss deena masa 12 9 Driver Power xiivs centile takin 12 9 Driy r Stats 22 sciscniics g
172. sent Section 4 5 4 1 Introduction to Using PumpWorks The 5000 Series Pump System is operated using Quizix PumpWorks Software which runs on a PC compatible computer 486 or Pentium based 66 mhz minimum using Windows 95 Windows 98 Windows NT Windows 2000 or Windows XP operating system To use your 5000 Series Pump System effectively you must know what you want to do with the fluid you are pumping and how to utilize Pump Works to accomplish this The 5000 Series Pump System uses operating modes to pump fluid in a wide variety of ways First the user must decide whether to choose an independent or paired operating mode Ifa single stroke volume the amount of fluid the cylinder barrel holds is sufficient for the desired flow then independent cylinder operation is possible If multiple stroke volumes are needed but discontinuous flow is acceptable then an independent cycled mode may be a good choice If smooth continuous fluid flow of more than one cylinder stroke volume is needed then paired cylinder operation is required The second decision is whether the flow should be at constant rate or constant pressure For constant pressure operation decide if the output pressure of the pump is to be held constant or if the pressure across a portion of the flow loop is to be held at a constant constant delta pressure Constant delta pressure requires the user to interface an external delta pressure transducer to the CMD 5000 Dual Controller
173. ser s Manual for help with this step Use the Pump Data amp Controls window in PumpWorks to open and close each cylinder s fill and deliver valves Begin by selecting the fill valve for Cylinder 1A click on its button to open and close it Verify that the light on the solenoid marked 1 is OFF when Cylinder 1A s fill valve is closed Open this valve and verify that the light for Solenoid 1 goes ON Also listen for a popping sound as the valve opens and closes e Ifthe light goes ON and OFF for a different solenoid than the one you are controlling on the computer the valve solenoid cables are switched and must be reconnected properly e Ifthe light does not go ON or OFF either the controller or the solenoid is malfunctioning Ifyou do not hear a distinct popping sound when each valve opens and closes then there is not adequate air pressure to operate the valves Check the tubing from the solenoids to the valves and check your pressurized air supply e Repeat this procedure for the cylinder 1A deliver valve and for each of the other valves in your system See Figure 8 2 in Chapter 8 for an illustration of all of the valve connections to be checked 3 3 Pump Cylinder Check This safety check involves running each pump cylinder manually through one full piston stroke retract and extend and watching the piston move Ideally this test should be run with no liquid in the system Unless the pumps are already filled wit
174. st be plugged into the correct receptacle on the CMD 5000 Dual Controller Driver The motor cable from Cylinder A should be plugged into the receptacle labeled Cylinder A the motor cable from Cylinder B goes to the Cylinder B receptacle If your system includes 3 or 4 pump cylinders the motor cables from the third and fourth cylinders will connect in the same way to the second CMD 5000 in your system 9 2 Sensor Cable The sensor cable connects the pump cylinder sensor board to the CMD 5000 Dual Controller Driver There is one sensor cable for each pump cylinder in the system The sensor cable is a flat ribbon cable and has a 15 pin D style connector at the controller end Like the motor cable each sensor cable must be connected to the correct receptacle on the controller If you have three or four pump cylinders their sensor cable will connect to the second CMD 5000 At the pump cylinder end there is a 14 pin ribbon connector with a key The key is a ridge that fits into a corresponding slot on the receptacle The connector fits only one way into the receptacle You should not disconnect this cable at the pump cylinder end it is more convenient to disconnect the controller end when re configuring or moving the system Users with both a high temperature pump system and an ambient temperature pump system should note that the high temperature sensor cable differs from the low temperature sensor cable at the sensor board co
175. st the seal cavity When properly seated only a very small gap should exist between the seal guide ring and the end of the cylinder barrel Use the seal insertion plunger to press the seal into the cavity Press the plunger down as far as possible until it contacts the seal guide ring At the last 0 5 cm of insertion a small amount of pressure is felt as the seal compresses to slide into the cavity When the seal is fully inserted retract the seal insertion plunger with a twisting motion leaving the seal fully inserted in the seal cavity of the cylinder barrel Carefully insert the seal backup ring with its shoulder smaller diameter towards the seal Coat the seal retaining nut threads with an anti seize compound Screw the seal retaining nut into the cylinder barrel to hold the seal back up ring and seal in place Hand tighten the nut using the 22 mm wrench to hold the cylinder barrel and the face spanner wrench on the seal retaining nut 11 2 2 4 Seal Insertion Procedure for T Type Seals There are two major differences between high temperature Aflas seals shown in Figure 11 3 and the cup type seals discussed in the previous sections The differences are the following There are five components in the Aflas seal assembly e There are no assembly tools used in the insertion of this seal assembly All parts are inserted by hand Figure 11 3 Order and Orientation of Aflas Seal Assembly Components and Outer Backup Ring
176. stall PumpWorks will ask you to Enter User Name for New Pump The default pump name is Pump 1 Pump 2 and so on If you don t want to change the name now you may do so at any time from PumpWorks main window Click on Install When PumpWorks starts the Pump Data amp Controls window will be showing You will know that your pump has been installed because the pump name will appear in black letters either Pump 1 Pump 2 and so on or the user given pump name If no pump is present the default pump name appears in gray letters Also the pump data fields will contain numbers instead of question marks Before using the system perform the system checkout and operation procedures provided in Chapter 3 Use the connection checklist in Chapter 3 for an easy way to ensure that all cables and plumbing are properly connected Chapter 3 also guides you through the initial process of checking out the valves and pump cylinders and filling the system with fluid 2 4 Setting Up a High Temperature System Oven Installation The Quizix 5000 Series Pump System is available in a high temperature version to allow fluid delivery at reservoir temperatures When installing a high temperature system into and near an oven follow these guidelines for each component 2 4 1 Pump Cylinders The high temperature version of the C 5000 pump cylinder has a 6 extension between the cylinder housing and the motor The cylinders must be placed in
177. stop pumping and an error message is displayed on the system monitor 5 3 4 Safety Rupture Disk The safety rupture disk is the final safety feature designed to prevent the pump system from exceeding a specified pressure For example for pump cylinders rated at 10 000 psi the safety rupture disk activates at approximately 12 500 psi see Table 5 1 for other models The safety rupture disk is activated if there is a transducer failure that cannot be detected by the normal safety systems It is also activated in the unlikely event of a hardware or software failure where the pump system does not respond to normal controls In this case the safety rupture disk activates to protect the pump tubing and external components from damage IMPORTANT It is very important that the you install tubing into the fitting of the relief fluid exit and that it is plumbed to an appropriate receptacle This prevents fluid from spraying into the atmosphere in case the rupture disk is activated This is particularly important if you are using flammable or highly corrosive fluids Chapter 5 SAFETY FEATURES Table 5 1 Safety Rupture Disk Ratings Cylinder Maximum Operating Safety Rupture Model Pressure Disk Rating C 5000 2 5K 2 500 psi 3 500 psi C 5000 5K 5 000 psi 6 500 psi C 5000 L 7 5K 7 500 psi 10 000 psi C 5000 10K 10 000 psi 12 500 psi C 5000 L 10K 10 000 psi 12 500 psi C 5000 20K 20 0
178. t pressure Specify a run pressure when selecting this mode You need not set a flow rate or direction The direction of this mode is to deliver fluid through the fluid outlet To begin start the pump cylinder you want to deliver fluid first 10 Paired Constant Pressure Receive PAIR CP Rec Paired Constant Delta Pressure Delivery PAIR DP Del This mode is identical to Mode 8 except the pump cylinder pair continuously receives extracts fluid from the experiment This mode is effectively a back pressure regulator This mode maintains a constant pressure differential by increasing or decreasing the flow rate to the fluid outlet The fluid delivery rate and pressure varies as needed to maintain that differential pressure 11 Paired Constant Delta Pressure Receive PAIR DP Rec This mode is identical to Mode 10 except the cylinder pair continuously receives extracts fluid through the fluid outlet 4 15 Quizix 5000 SERIES PUMP MANUAL Table 4 2 Operating Modes Mode No Operating Mode Description Paired Operating Modes 12 Paired Constant Pressure Bidirectional Half Rate PAIR CP Bl This mode is similar to Mode 8 in that it continuously maintains fluid at a constant pressure However in this mode the piston is at the halfway point at switchover and will either deliver or receive fluid to maintain the specified pressure level The maximum continuous d
179. tain a more accurate calibration For the pump cylinder s being calibrated open the deliver valve s and close the fill valve s Use Pump Works to set the pump cylinder you are calibrating to extend in Constant Rate Independent Mode 1 at 1 ml minute Start the pump cylinder and monitor the pressure with the calibrated gauge Stop the pump when pressure reaches 90 of the system s maximum pressure IMPORTANT When you raise the system s pressure the temperature of the pump s internal fluid will temporarily rise As this fluid cools the system pressure will drop In this situation it is best to wait five minutes after reaching your high pressure before proceeding so that the pressure is not changing while you are trying to calibrate 9 Adjust the gain Go to PumpWorks main window From the menu bar select Other Software Pressure Transducer Calibration In the Software Pressure Transducer Calibration window select Current Gain The easiest way to adjust the gain of a pressure transducer is to enter the current pressure value into the Enter Known Pressure box When this is done PumpWorks calculates the necessary gain and adjusts the pressure reading to display this value automatically Please remember to always adjust the offset prior to adjusting the gain The user may also calculate the desired gain by hand and then enter the desired value into the software The range of gains is limited
180. taining nut using the face spanner wrench while holding the cylinder barrel with the 22 mm wrench 2 If desired remove the seal back up ring 3 Plug both cylinder barrel ports with Speedbite plugs 4 Fill the cylinder barrel approximately 3 4 full with fluid water is best and firmly press the seal extraction rod through the seal and into the cylinder barrel Refer to Table 11 1 for a description of the seal extraction rod tool This procedure creates pressure in the 11 5 Quizix 5000 SERIES PUMP MANUAL 11 6 cylinder barrel This causes the seal to pop out of the seal cavity and remain on the seal extraction rod If the seal sticks and does not pop out when the rod is inserted press the rod in again to create pressure in the cylinder Then pull back on the rod to extract the seal Remember if you plan to re use the seal handle it very carefully once it is removed Inspect both the seal and the cylinder barrel for scratches the presence of foreign objects and sharp edges Using a magnifying glass examine the outer surface of the seal for scratches along the piston axis Examine the inside lips of the seal for scratches or deformations Pay close attention to the area around the joint in the tensioning spring This area should be smooth and not show deformities due to the spring joint Examine the cylinder barrel cavity for scratches The cavity surface should be smooth clean and free of contaminants NOTE A se
181. ter of the cam roller and unscrew the cam roller from the stand off 6 Replace the faulty cam rollers with the proper type either high or ambient temperature by holding the stand off in place with a 10 mm open end wrench and using a 1 8 inch Allen wrench to screw the cam roller into the stand off Always replace them in pairs never as single rollers NOTE The recommended cam roller to use for ambient temperature systems is the McGill Model CCF 1 2 N SB For high temperature systems the recommended roller is the McGill CCF 1 2 NB WIK Repeat Steps through 6 for the left side cam roller disregarding references to the sensor board 11 3 2 Re Greasing the Ball Screw Recommended Frequency e For ambient temperature systems every 2 years of regular use or as required For high temperature systems every year of regular use or as required The Quizix pump cylinder has a side cover on each side of the pump cylinder The ambient temperature side cover contains a clear acrylic panel on the outside through which the sensor board right side or the ball screw left side can be viewed The high temperature covers are black anodized aluminum with a slot cut into them for viewing Refer to Figure 11 6 for a view of the pump cylinder clarifying the left and right sides and Figure 11 7 for a view of the pump cylinder cam roller and ball screw 11 11 Quizix 5000 SERIES PUMP MANUAL 11 12 Figure 11 6 Pump Cylinder Overh
182. th a fill valve that controls the flow of fluid into the pump cylinder and a deliver valve that controls the flow of fluid out of the pump cylinder The CV 310 valve has an inlet tube at the fill side an outlet tube at the deliver side and a tube that leads to the pump cylinder in the center See Figure 8 1 8 1 Quizix 5000 SERIES PUMP MANUAL Fluid Plumbing Diagram DELIVER FILL VALVE A VALVE A FLUID f _ FLUID OUTLET oS J INLET FLUID FLUID OUTLET INLET TEE TEE DELIVER FILL VALVE B poo VALVE B amp CYLINDER i i TUBING CONNECTION 4 4 PIECES TUBING 2 PIECES Figure 8 1 For fluid to flow into the pump cylinder the fill valve must be open and the deliver valve must be closed The fluid then flows into the valve through the opened fill valve For fluid to flow out of the pump cylinder the fill valve must be closed and the deliver valve must be open The fluid is then pumped out of the pump cylinder and through the opened deliver valve and the fluid outlet tube Both the fill valve and the deliver valve are controlled by two air tubes from a pilot solenoid Air flows through one of the tubes to open the valve and air flows though the other tube to close the valve When two C 5000 pump cylinders are operated in paired mode the valves open and close automatically so that one pump cylinder is filling while the other is delivering fluid The Quizix pump system is designed so that the switchover process be
183. the cylinder barrel With only one pump cylinder operating the piston can perform a single stroke then has to stop to be refilled or emptied if it is receiving fluid The stroke volume of each of the Quizix C 5000 pump cylinders is shown in Table 4 3 Chapter 4 PUMP OPERATING BASICS Table 4 3 C 5000 Pump Cylinders Stroke Volume Model Stroke Volume Typical C 5000 2 5K 37 ml C 5000 5K and C 5000 L 7 5K 21 ml C 5000 10K and C 5000 L 10K 9 3 ml C 5000 20K 5 2 ml For example a C 5000 5K pump cylinder with a full cylinder barrel in Independent Constant Rate mode mode 1 at a flow rate of 1 ml min would deliver fluid for 21 minutes and then stop because it had reached the end of its piston stroke and was empty Operation of an individual pump cylinder is most useful to provide overburden pressure to a core sample or when the volume to be pumped is less than the stroke volume so that the single piston stroke limitation is irrelevant 4 3 12 6 Paired Cylinder Configuration Two pump cylinders can operate together as a pair to provide continuous flow The two pump cylinders take turns being the active and standby pump cylinder For example in a deliver mode the active pump cylinder is delivering fluid and the standby pump cylinder fills with fluid and pre pressurizes to the delivery pressure level of the active pump cylinder When the active pump cylinder has completed its piston stroke there is a switchover The
184. the error log These errors are automatically compensated for by PumpWorks which notes the error and then resends the command again so that no data is lost If a lot of these errors are occurring then communication between the pump controller and Pump Works is significantly slowed down It is therefore better to discover and correct the source of these errors when possible Chapter 12 TROUBLESHOOTING e Buffer Overrun Error Buffer overrun errors are due to a slow computer This can be corrected by keeping other programs from operating while using Pump Works or by getting a faster computer When a buffer overrun error occurs PumpWorks automatically retries and corrects for any dropped communications e CRC Check Error CRC check errors mean the communication line is noisy Either the data communications cable is too long or it is placed next to a source of electrical interference Correct the problem and the error should go away If the CRC check errors continue however either the computer s serial port the serial expander isolator or the pump is not working on the proper frequency Try using a different serial port on your computer or a different computer e Incorrect Number of Bytes Received Incorrect number of byte errors can be caused by a slow computer or by a noisy communication line Noisy lines can be caused by the data communications cable being too long or being too near a source of electrical interference e Input Error Input
185. the fluid to be tested Set the pump cylinder to constant pressure independent mode Close both the fill and deliver valves Select an appropriate test pressure Saad ae eee Chapter 12 TROUBLESHOOTING 5 Start the pump cylinder Next the pump will pressurize and hold the set pressure After allowing for thermal effects to subside about 15 minutes set the volume of the pump cylinder to zero and watch for fluid volume changes Ifthe pump continues to move forward then there is a leak By logging the volume versus time the leak rate can be determined Any changes in temperature during this test time will also show up as changes in volume so care must be used in analyzing this data 12 4 3 4 Finding Your Leak If you detect a leak then the next step is to find it The most likely places for a leak to occur are at the piston seal interface or in the valves Seal leaks are most often caused by particles in the fluid scratching the lips of the seals If fluid is leaking out of the bottom of your pump cylinder you are very likely to have a seal leak Ifa fluid leak is present and no evidence of fluid leakage is present at the valve leak ports or around any of the fluid tubing fittings then most likely there is a seal leak To test more thoroughly try removing the fitting at the front of the cylinder barrel and replacing it with a plug then running the leak test again If you still have a leak then it is almost for sure a piston seal leak
186. the pump system can be extended with additional cable A metal clip on each side of the cable connector which allows the cable to be locked firmly in place with cable clips To check or adjust a measuring instrument so it remains accurate A cam roller is located on each side of the pump cylinder and allows the user to view the position of the piston A tube that develops pressure drop proportional to flow The computer positions all open files so that only the top of each window is displayed The pistons are made from ceramic a material that is almost unscratchable and highly corrosion resistant but is slightly brittle and breakable Each pump cylinder has a different color band which corresponds to the color used to display information about that pump cylinder in the pumpworks software The serial data cable from your controller plugs into the serial communications port connector on the back of your computer It is sometimes referred to as a com port or comm port One part or piece of the pump system See communications port The compression ring holds the safety rupture disk in place inside of the safety rupture disk holder The inside hollow of a curve as in the inside of a bowl The particular arrangement of the parts that make up your pump system Constant Delta Pressure Mode Constant Pressure Mode Constant Rate Mode continuous flow pumping controller fuse controller on off switch controller op
187. the slide screws to hold the valve assembly out of the way while the cylinders are installed 3 Select the bottom cylinder by matching the number on the stand to the cylinder number on the cylinder label Lift it into the cylinder support blocks Ensure that the pump base plate is inserted into the slot provided in the stand assembly Also ensure that the sensor cable is on top of the pump 4 Route the sensor cable from its connection at the pump side cover to the cable retainer above the pump Insert the sensor cable in the four cable retainers that are mounted on the stand 5 Plug the sensor cable into the appropriate connector on the CMD 5000 6 Connect the motor cable to the CMD 5000 7 Loosen the cylinder retaining fingers then tighten them so that they hold the cylinder in place Repeat this procedure for the other pump cylinders in your system IMPORTANT Be sure to install each cylinder into the correctly numbered space Stands for two cylinders have Cylinder A on top and Cylinder B on the bottom A 3 cylinder system mounted on a 4 cylinder stand has the cylinders in the following order going from top to bottom 2A 2B not installed 1A and 1B A 4 cylinder system has the cylinders in the following order going from top to bottom 2A 2B 1A 1B NOTE The plumbing for the 5000 Series pumps uses the Autoclave W125 Speedbite fitting port The one exception is systems with pump cylinder model C 5000 20K whic
188. this is called a pull down menu The pump housing plus all of the internal components These include the motor assembly and ball screw ball nut assembly The pump controller is an electrical subsystem which directs all pump operations The pump controller communicates to the user through the PumpWorks software A mechanical assembly that allows fluid to be pumped A metal part with a cut out area which supports a pump cylinder on stand mounted pump systems The main mechanical body which covers or houses the working parts of the pump cylinder The name of a computer file which contains a listing of errors that have happened in the pump system Quizix 5000 SERIES PUMP MANUAL quartz transducer query quit option ramping operation rate scalers rate units recirculating recirculating mode recirculating parameters reconfigure reed switches reset recirculating mode reset volumes residue retaining fingers restore G 18 An extremely accurate and stable pressure transducer which can be used to calibrate a typical pressure transducer A question presented by the computer that requires you to answer or make a choice A feature in the DOS version of PumpWorks which allows you to exit the PumpWorks software Using the PumpWorks software the pump system can change gradually from one flow rate or pressure to another over a user determined period of time A PumpWorks software feature that ad
189. tion switches controller serial number controller side panels controller status indicators convex corrosive fluids GLOSSARY The system will pump fluid at a constant pressure differential across a core sample To maintain this constant pressure differential the fluid delivery rate of the active pump cylin der will change as needed The fluid pressure for the active pump cylinder remains the same at a user selected value To accomplish this the fluid delivery rate of active pump cylinder will change as needed The active pump cylinder s fluid pump rate remains constant at the user specified value The active pump cylinder s fluid pressure is set by the system flow resistance The system flow resistance is the degree of ease or difficulty at which fluid will pass through a system The pump system can pump fluid for any length of time with out stopping This is accomplished by two pump cylinders working together for one fluid One pump cylinder the active cylinder will pump or deliver the fluid while the other pump cylinder the standby pump cylinder fills and pre pressurizes Pulseless continuous flow is achieved by precisely coordinating the switching between the two cylinders An electrical safety device that protects the electric circuit going to the controller by melting when overloaded by a malfunction This on off toggle switch allows power going to the controller to be turned on or off Four sets of e
190. to The power cord should be connected to an AC power outlet preferably by way of an uninterruptable power supply See Chapter 10 for more information about uninterruptable power supplies 6 4 8 RS 232 Cable The RS 232 Cable connects the Serial Expander Isolator with the computer This cable has a9 pin D style connector at both ends The male end connects to the Serial Expander Isolator port the female end connects to one of the serial ports on the computer You can use any serial port on your computer but must specify which port you selected in the system communications using the Configure Pump Communications window in Pump Works When shipped PumpWorks is configured for the serial expander isolator to connect to serial port 1 6 5 Pump Number Two Digit Display Under the label Pump Number is a two digit display which allows the pump controller to communicate information to the user Using letters numbers or a combination of the two the two digit display can convey overpressure or underpressure errors communication errors driver errors or the absence of a cable If no errors are present the two digit display will show the pump number 1 2 3 and so on The pump number is assigned by Pump Works based on the first available screen position starting from left to right on PumpWorks main window Chapter 6 CMD 5000 DUAL CONTROLLER DRIVER When turning on the pump controller the user needs to watch the two digit display Th
191. to Valve cccussss eon cok 8 5 Outlet Tee to Valve lt ccccssectsncctctsdtae 8 5 Two Digit Display 0 0 eee 6 4 12 6 Erro Codeseira ai 12 8 Error Messages is ccsessccessssesecthcasees 12 5 Does Not Complete Initial Check 12 6 Does Not Light ci 5n ccc 12 6 U Uninterruptable Power Supply 10 1 Rating S naa eR 10 2 Vv Valyer oeda 1 4 8 1 8 8 11 25 Cable Connection Check 12 17 Check oane neei aa 3 3 Clogged Obstructed 0 0 0 12 17 Fill and Deliver sacceecetecuaccawuecss 4 18 Leaks arster na a ERN A 12 18 Problems a andar aE 12 16 Volume Cumulative oo cccccccccesseeeceesteeeees 4 10 WwW Warning DOLE LAN eencorpactncradaieiaeenat 12 3 VY Asin MN ed co cra ce E actrees vaeseanaast 7 9 INDEX Diagrami eieiei 7 9 Spare Parts Kit secccseccsscseececlseereens 7 10 Wave Generator Bearing 06 11 15 WO WS nacasecceotonce eave nii a 4 2 Meni a eles coisas sat Salaun eis a 4 3 PumpWorks Main Window 4 2 Set Cylinder Operating Mode 4 12 TALUS ISAM een iene ER ERTE 4 3 Index 5 Quizix 5000 SERIES PUMP MANUAL This page intentionally left blank Index 6
192. to start working The pump cylinder that is delivering fluid to or receiving fluid from a users experiment The deliver valve must be open and the fill valve closed A wash area with both internal and external o rings installed that is capable of containing wash fluid A tool supplied with your system that is used to loosen and tighten the cylinder barrel retaining ring and remove or install the seal retaining nut An elastimer seal material used in high temperature systems Aflas works especially well with oil industry fluids The operation is begun by a force of air This is sometimes referred to as pneumatically actuated The connection port where the user s air supply comes into the pump system Either an air compressor or bottled gas supplied by the user for operating the air actuated valves This tool is used to tighten or remove six sided Allen head screws It is also known as a hex wrench This is a screw with an indented six sided head It is also known as a socket head cap screw G 1 Quizix 5000 SERIES PUMP MANUAL ambient temperature amplifiers angle base plate anti seize compound arrow keys atmosphere atmospheric pressure Autoclave speedbite fitting Autoclave speedbite fitting port Auto Op or automatic operation auto ramping Operation Automatic Volume opera tion automatic time operation auxiliary A D channel auxiliary digital input sig nals Temperature that
193. tons transducers and valves Note that the transducers can be interchanged but will require recalibration if this is done An example is pump cylinder A is leaking and continues to leak after replacing the seal The user needs to determine if the problem is the cylinder barrel or the piston To find out a user could exchange the cylinder barrels between pump cylinders A and B If the leak moved from pump cylinder A to pump cylinder B then we know the problem is either the cylinder barrel or the seal that is inside of the cylinder barrel If however the leak continued coming from pump cylinder A then we know there is a problem with the piston such as a scratch or hard deposit When trying to figure out the cause of a problem within the 5000 Series Pump System there are several PumpWorks features that could give the user more information They are e Current System Status Window The Current System Status window located on the Error Log menu shows the current state of all pumps being controlled by Pump Works Items in green indicate that no errors are present and items in red indicate that an error is present Errors that do not apply are grayed as well as pumps that are not installed For ease of viewing pumps through 4 are shown in one window while pumps 5 through 8 are displayed on a separate window e Error Log PumpWorks maintains a log of all errors Each error entry consists of the date and time the error occurred as well as a des
194. trapped gas to escape from the cylinder barrel through the uppermost hole at the end of the barrel to which the valve tubing is attached 7 7 Hastelloy Option for Corrosive Fluids The most popular pump cylinder model the C 5000 10K is available with either stainless steel SS 316 or Hastelloy C 276 wetted parts In the other C 5000 models Hastelloy is standard In Hastelloy pump cylinders all metal parts that come in contact with the pumped fluid are constructed of Hastelloy C 276 Hastelloy is highly corrosion resistant and will extend the life of the pump substantially if you are pumping highly corrosive fluids 7 8 Pump Cylinder High Temperature Option The C 5000 pump cylinder is available in a high temperature version that allows the cylinder to be heated to 160 C The high temperature version of the C 5000 10K cylinder is shown in Figure 7 4 The following lists the changes made to the high temperature version of the C 5000 10K pump cylinder e The pump cylinder includes a motor extension which is a 6 extension between the cylinder housing and the motor The entire pump cylinder housing and cylinder barrel can be placed inside an oven The motor extension provides a place for the oven wall to touch the cylinder so that the entire housing is inside the oven while the motor and harmonic drive protrudes outside the oven wall Generally a hole is cut in the oven wall where the motor extension is located so the wall intersects the pu
195. troller end of this cable The computer and monitor to be used with your system should also be connected to AC power Like the CMD 5000 Dual Controller Driver itis best to use an Uninterruptable Power Supply if you wish to conduct long term experiments in which the interruption of fluid flow would be detrimental to the experiment s results Chapter 9 SYSTEM CABLES 9 7 User Interface Cable Optional The User Interface Cable allows the 5000 Series Pump System to connect to various external devices which the user may wish to add Additional analog sensors valves digitally controlled devices and logic inputs as well as power are available on this 37 pin D style connector By connecting auxiliary valves digital inputs or analog inputs such as additional temperature or pressure transducer readings to the CMD 5000 the user will be able to access them from PumpWorks The User Interface Connector also includes an emergency stop control signal for users who want to implement an emergency stop capability for their system Refer to Appendix B of the PumpWorks User s Manual for more information on the User Interface Cable including the connector pin outs Refer to Chapter 9 of the PumpWorks User s Manual for more information on Auxiliary Analog Input Signals Section 9 2 Auxiliary Digital Input Signals Section 9 3 and Auxiliary Valves Section 9 4 as they are viewed or controlled with Pump Works If you have a reci
196. ttached to the other end of the tube should be your pressurized air source If your air supply has a switch to turn it on make sure it is turned on so that air will be supplied to the pump Note that 6 mm tubing will also work in most cases Nylon tubing is the recommended material for the air tubes however other materials will work 12 4 7 5 Pilot Solenoid Check Pilot solenoids are used to open or close the fluid pathways inside the valves The pilot solenoid manifold takes in air from the user s air supply and distributes that air to the pilot solenoids Please refer to Chapter 3 Section 3 2 for information on checking your pilot solenoids 12 4 7 6 Clogged Obstructed Valve It is possible for the valve inlet to become clogged with particles from the fluid being used Ifa valve becomes clogged then fluid can no longer be pulled into a pump This can be detected by watching the pressure in the pump cylinder as the piston retracts The pressure should not drop more than 1 2 PSI If it drops more than this the fluid may not be getting into the pump cylinder due a clogged inlet tube or valve The outlet side of the valve is unlikely to clog due to the fact that the pump can generate high enough pressures to push most particles out of the valve It may be possible to clear a clog on the inlet side by using the pump to push the particles out of the inlet It would be advisable to clean all tubing and components thoroughly if a clog has been enco
197. tters numbers or a combination of the two this display can convey overpressure or underpressure errors communication errors driver errors or the absence of a cable If no errors are present the two digit display will show the pump number 1 2 3 and so on Locate this display on the CMD 5000 Watch the two digit display when you turn on your pump controller First you will see all segments of the display light at once briefly Next the display will flash the boot version number currently 3 6 Next the right hand digit will light one segment at a time to indicate that the basic pump controller hardware diagnostics are being performed Next the software diagnostics are performed and the left hand digit will display numbers 1 8 in succession In the final step do will flash alternately with 0 The do stands for digital overpressure As a safety precaution systems are shipped with a safety pressure set at 50 psi You will need to reset the safety pressure before operating the system 2 7 Quizix 5000 SERIES PUMP MANUAL 2 8 19 20 21 22 23 Now you are ready to install your C 5000 pump cylinders onto PumpWorks Go to Start Programs and double click on Pump Works 95 NT Pump Works will automatically search for new pumps When PumpWorks finds a new pump the following message will display CMD 5000 found on Com 1 expander Port A or B C or D Do you wish to install Click on In
198. ttings 2 4 5 Cables For oven mounted systems the location of the pump cylinder CMD 5000 transducer and pilot solenoid manifold determines the length of each cable Quizix supplies cables to user specified lengths for most high temperature systems If a cable is not long enough for your application consult Table 2 1 Quizix 5000 SERIES PUMP MANUAL 2 10 Table 2 1 Cabling Chart Cable Label Connection Remedy motor cable cylinder to CMD 5000 Order a motor cable extension 2 meters long Note If possible avoid this extension because of high frequency signals sensor cable cylinder to CMD 5000 Order the correct length transducer amp CMD 5000 to Order the correct length valve cable transducers and pilot Note If possible avoid long cables to solenoid manifold reduce extraneous noise RS 232 cable serial expander isolator Available at computer stores as a 9 pin to computer male to female RS 232 cable Data link cable CMD 5000 to serial Order the correct length expander isolator More information about the differences between the standard version of each component and the high temperature version of the component is available in the High Temperature Option section of Chapter 7 C 5000 Pump Cylinder and Chapter 8 Valves and Plumbing For a full description of all plumbing and cables to be connected see Chapter 8 Valves and Plumbing and Chapter 9 System Cables Refer to t
199. tubing connect to cylinders 1A and 1B Fluid Tubing Make sure the tubing from the center port of each valve goes to a safety rupture disk holder and then into the top hole on the end of the cylinder barrel The tubing from the transducer connects to the lower fitting on the end of the cylinder barrel For C 5000 20K cylinders one port on the cylinder barrel connects to a cross onto which a safety Chapter 3 SYSTEM CHECKOUT rupture disk and transducer should be connected Trace all tubing connections to make sure the plumbing is complete and fittings are properly tightened Connect tubing to the port of the safety disk holder for fluid release if the safety rupture disk is activated by excessive pressure Fluid Inlet and Outlet Be sure to connect your fluid source to the fitting labeled fluid inlet The output of the pump is available through the fluid outlet line and will be at the flow rate or pressure the user specified in PumpWorks 3 2 Valve Check Ensure that the valves are working properly by conducting a visual and auditory check There are small red indicator lights on the pilot solenoids The light is ON when the corresponding valve is open the light is OFF when the corresponding valve is closed 1 Turn on the computer and the controller Connect the compressed air supply to the pilot manifold It is assumed that PumpWorks is installed on your computer already and is running If not refer to the PumpWorks U
200. ture readings and accessing them with Pump Works e PumpWorks allows the user to record all operating data in a data log on the computer and to export data using a host link e A high temperature 160 C option is available which allows the user to heat the entire pump cylinder for reservoir condition experiments The basic building block of the 5000 Series Pump System is the C 5000 pump cylinder Quizix manufactures six different models of C 5000 pump cylinders refer to Table 1 1 They provide different maximum flow rate and pressure specifications In general the higher the maximum pressure specification the lower the maximum flow rate specification The two L models are designed for applications where extremely low flow rates are required For comparison purposes Table 1 2 shows the three pump cylinder models available in the 6000 Series Users who require higher flow rates or fluid volumes than the 5000 Series provides can use a 6000 Series pump cylinder 1 1 Quizix 5000 SERIES PUMP MANUAL Table 1 1 The 5000 Series Pump Cylinders Piston Model Maximum Maximum Stroke Piston Pressure Flow Rate Volume Diameter C 5000 2 5K 2 500 psi 60 ml per minute 37 ml 1 00 inch C 5000 5K 5 000 psi 30 ml per minute 21 ml 750 inch C 5000 L 7 5K 7 500 psi 3 75 ml per minute 21 ml 750 inch C 5000 10K 10 000 psi 15 ml per minute 9 3 ml 500 inch C 5000 L 10K 10 000 ps
201. tween pump cylinders is extremely precise and a constant rate or constant pressure is maintained at all times During most pumping operations the valves operate automatically opening and closing as necessary for the operating mode that is selected However the PumpWorks software allows the user to control the valves individually when desired For further information about the features and specifications of the valves refer to the Valve User s Manual from Vindum Engineering which was shipped with the pump system 8 2 Pilot Solenoids The valves used in the Quizix pump system are air actuated and require the use of electrically operated valve solenoids and a solenoid manifold The valve solenoids receive Chapter 8 VALVES AND PLUMBING electrical signals from the CMD 5000 Dual Controller Driver and convert these signals to air pulses that open and close the fluid path in the air actuated constant volume valves The pilot solenoids are connected to the CMD 5000 with a cable called the Transducer and Valve Cable This cable branches out at the solenoid end providing one branch with a 2 pin connector for each solenoid The small cable branches and solenoids are numbered so that they can be connected in the proper order such as cable into solenoid 1 etc When moving or re configuring the pump system this cable should be disconnected at the pump controller end not the pilot solenoid end 8 3 Air Supply The valves used by the
202. ual discusses the software which operates all Quizix pump systems This chapter provides an introduction to the Quizix 5000 Series Pump System and includes an overview of its components 1 1 Introduction The Quizix 5000 Series Pump System provides continuous pulse free fluid flow for use in core analysis and related research Key features of the system include the following e Itis designed for pumping fluids at high pressure and provides precise pressure control e Sophisticated electronics provide highly accurate fluid flow rates and volume measurement e The system works well with water oil or brine Fluid wetted parts are available in Hastelloy C 276 for users pumping highly corrosive fluids The pump system is operated using Quizix PumpWorks Software which runs on a PC compatible computer 486 or Pentium based 66 mhz minimum using Windows 95 Windows 98 Windows NT Windows 2000 or Windows XP operating system The software provides the user with complete control over all operating parameters The pump system can be operated in many different operating modes including Constant Rate Constant Pressure and Constant Delta Pressure The pump system can also operate in both directions it can either deliver or receive fluid e Pumpworks permits system level integration of the user s entire experiment by allowing the user to add additional valves digital signals or analog sensors such as transducers or tempera
203. uch grease as possible from the internal teeth on the fixed spline then apply HD Systems HC 1 grease or equivalent to all of the internal teeth Repeat Steps 7 and 8 for the dynamic spline which is clearly visible and accessible on the pump body assembly Perform the same visual inspection described in Step 7 to the wave generator bearing looking closely at its open side where its bearings are exposed Manually spin the bearing assembly making sure that it rotates smoothly Using a clean lint free cloth wipe off as much grease as possible from the exposed ball bearings If desired the entire bearing assembly may be soaked in an appropriate solvent to remove the grease Apply HC 1 grease or equivalent to the entire area of the wave generator bearing where the ball bearings are exposed If the flexspline has been separated from the wave generator bearing carefully slide it back onto the outer bearing race 11 15 Quizix 5000 SERIES PUMP MANUAL 11 16 14 15 16 Set the motor assembly with the motor adapter housing facing up as shown in Figure 11 10 Slide the Lexan washer onto the motor shaft Replace the key in the motor shaft using a small amount of grease to make it stick in the keyway Figure 11 12 View of Keyway NOTE The key is slightly wider than it is high Place it in the shaft keyway with its wide side down 17 18 19 20 21 Grasp the wave generator bearing in one hand and
204. uid system In a typical pump cylinder pressure can change 50 to 100 PSI per degree C Therefore if you want to detect small leaks temperature must be held steady and even then long tests are usually needed to get reliable data Not only does external temperature need to be controlled time must be allowed for thermal equilibrium of the fluids in the pump system When a fluid is pressurized it heats up This heated fluid inside the pump cylinder then starts to cool down to the cylinder barrel temperature As it does this the fluid contracts and the pressure falls This fall in pressure can look like a fluid leak Allow at least 15 minutes after pressurization for the temperature to equalize When looking for small leaks there are several other considerations to be aware of The seals and o rings in the system are elastic With pressure and time they tend to creep which increases volume in the cylinder barrel and looks like a fluid leak This problem is most noticeable when a new seal or o ring is installed but can also show up in dynamic tests as the seals and rings wear and lose material to the outside Other factors that can affect the results of leak tests include pressure transducer drift fluid property changes gas bubbles and fluid permeation or absorption into the seals and o rings 12 4 3 3 Does Your Pump Have a Fluid Leak A pump cylinder can be checked for fluid leakage by following the steps below Fill the pump cylinder with
205. ular weight polyethylene UHMW PE and used in ambient temperature applications and are normally white Cup type UHMW PE seals have the longest life one year minimum for normal service and two plus years are possible Pressure flow rate and fluid type do not significantly affect the life of these seals High temperature applications normally use a T type seal made of Aflas Some high temperature applications however have used carbon loaded Teflon cup type seals The high temperature seals have a shorter lifespan which is strongly dependent on pressure and is related to flow rate and the type of fluid that is pumped A normal effective life for these seals is six months of continuous use 11 1 2 2 Seal Removal Procedure for All Seals IMPORTANT To get maximum performance from the seals great care must be used when handling and inserting them The high temperature Teflon seals are especially sensitive to damage by scratches that are not easily visible to the unaided eye The seals can be easily scratched by any sharp object including fingernails The cylinder seal cavity can also be scratched easily Therefore do not use any sharp or hard objects to remove a seal or to clean a pump cylinder The assembly tools and components for ambient temperature UHMW P E and high temperature Teflon seals are shown in Figure 11 2 1 When the cylinder barrel is removed from the cylinder housing remove the seal re
206. ump cylinder s being calibrated open the fill valve s so the cylinder pressure is at atmospheric or zero pressure The deliver valve s can also be opened if desired 11 22 4 2 Chapter 11 MAINTENANCE Adjust the offset Go to PumpWorks main window From the menu bar select Other Software Pressure Transducer Calibration In the Software Pressure Transducer Calibration window select Current Offset The easiest way to adjust the offset is to select Auto Zeroing Doing this will result in the computer calculating the necessary offset to have the display read zero pressure The range of zero offset is limited so that a malfunctioning transducer or a transducer with significant pressure accidentally left on it will not be able to be zeroed Alternatively the user can compute the desired offset and enter this value into the appropriate box With this option the user can have the display show a value other than zero pressure on the display when zero pressure is present This can be used if absolute pressure readings are desired Set the pressure to 90 of the system s maximum rated pressure Set the safety pressure to 95 of the system s maximum rated pressure NOTE If your system is typically operated at significantly less than the pump s maximum rating for example typical usage at 100 PSI for a 5 000 PSI pump then the pressure in this step may be set at the system s typical operating pressure to ob
207. ump system to display signals such as pressure and temperature Quizix controllers and PumpWorks software have the capability of sensing and displaying user logic signals such as from a contact opened or closed by a microswitch auxiliary valve cable auxiliary valves auxiliary valve window back drive ball nut ball nut assembly ball screw ball screw pitch BAUD rate bearings bidirectional GLOSSARY This connects the pump controller to the auxiliary pilot solenoid valve manifold The Quizix controller and PumpWorks software have the capa bility of operating additional valves that the user may add to the pump system This PumpWorks software window controls any auxiliary valve s the user has added to the pump system If the pump cylinder pressure is above a critical pressure which varies from 1 000 to 5 000 psi depending on pump type and power is lost to the motor driver pressure forces on the pis ton are so strong that the ball screw will rotate as the piston is pushed backwards The pump cylinder pressure will then drop until the pressure is reduced below the force necessary to back drive the piston The ball nut works with a ball screw to convert the rotary motion of the motor and harmonic drive into linear motion for the piston This includes the Ball nut ball screw and the mechanical parts which support the ball nut and ball screw such as the flexure and ball nut flange The ball screw has t
208. untered so that this problem does not reoccur 12 17 Quizix 5000 SERIES PUMP MANUAL 12 18 12 4 7 7 Valve Leaks Fluid When Closed There is a possibility that the valve will not fully close and fluid can leak across the closed valve If this occurs the valve will not hold pressure If you pressurize a pump and it is not holding pressure fluid may be leaking out of a seal or it could be leaking out across the valve One way to check if a valve is leaking fluid is to swap valve A and valve B Refer to the Valve User Manual for maintenance and repair instructions 12 5 Software Updates The operation of the 5000 Series Pump System is controlled by two separate software programs PumpWorks 95 NT which is stored on the user s computer and the pump controller software which is stored in the CMD 5000 Dual Controller Driver New versions of software are periodically released Problems detected after a software version is released are resolved in later software versions To make sure you have the latest software version available for your pump check which version you have Go to Pump Works main window On the main menu bar select Help About PumpWorks The version of Pump Works 95 NT that is installed is displayed in the top center box after the words Software Version This software runs on the computer and is what you see on the computer screen and interact with The pump controller is also running a program The controller softwa
209. urden pressure to a core sample 4 17 Quizix 5000 SERIES PUMP MANUAL 4 18 4 3 13 Cylinder Direction Direction of Piston Movement The piston which is inside of the cylinder barrel either extends into the cylinder barrel or retracts out of the cylinder barrel As the piston moves forward it extends into the cylinder barrel causing fluid to be displaced and pumped out of the cylinder barrel The pump cylinder is therefore delivering the fluid either to an experiment or to a container As the piston retracts it pulls out of the cylinder barrel As the piston pulls out of the cylinder barrel fluid is pulled into the cylinder barrel The pump cylinder is therefore receiving fluid either from an experiment or from a container The cylinder direction then refers to the pump cylinder either delivering the fluid extend or receiving the fluid retract 4 3 14 Fill and Deliver Valves The fill and deliver valves which are the two sides of a single Vindum Engineering CV Valve are important for the successful operation of the pump cylinder operating modes Pump Works color codes the fill and deliver valve buttons green when the valve is open and orange red when the valve is closed The fill and deliver valves are opened or closed depending on the operating mode chosen and whether the pump cylinder is delivering or receiving fluid To fill a pump cylinder with fluid the fill valve needs to be open allowing fluid to enter the pump as the p
210. ut is a ball nut assembly where the piston is screwed in Rollers and side rails are used to counteract the torque 7 3 5 Piston and Cylinder Barrel The piston screws into the ball nut assembly so that it can be replaced easily The piston moves back and forth in the cylinder barrel following the motion of the ball nut The piston is made of highly polished silicon carbide which is extremely corrosion and scratch resistant Chapter 7 PUMP CYLINDER CAUTION The piston is quite brittle and therefore should never be dropped or handled roughly When the stepper motor rotates in a clockwise direction the piston retracts and the cylinder barrel fills with fluid assuming the fill valve is open and the deliver valve is closed When the motor reverses direction the piston extends and the pump delivers fluid assuming the deliver valve is open and the fill valve is closed Fluid is brought to pressure when both valves are closed and the piston extends to compress the fluid When the piston is maintaining a specific pressure the motion is referred to as Servo in the PumpWorks software In addition to the five primary parts described above the following parts are necessary to properly direct and contain the mechanical forces of the cylinder drive train 7 3 6 Bearings The pump cylinder contains both radial bearings and a thrust bearing that secure the ball screw in place 7 3 7 Side Rails and Rollers
211. ve a fan connected to the pump cylinder while high temperature pump systems do On high temperature versions of the C 5000 pump cylinder the fan must ALWAYS be running when the pump cylinder is operating If the fan does not come on when the CMD 5000 is powered on or ifit stops while the pump is running stop the pump cylinder immediately Contact Quizix for a replacement fan 12 4 3 Fluid Leaks Although Quizix pumps are made to a high standard a fluid leak can occur The following sections explain what to do if you have a fluid leak e Leakage Basics Section 12 4 3 1 Leak Testing Section 12 4 3 2 e Does Your Pump Have a Fluid Leak Section 12 4 3 3 e Finding Your Leak Section 12 4 3 4 12 4 3 1 Leakage Basics The SP 5000 is a pump system that uses a piston to push fluid out of a cylinder barrel The fluid is contained in the cylinder barrel by a seal which has a static connection to the cylinder barrel and a dynamic moving interface to the piston For a continuous flow system valves pressure transducers and interconnecting tubing and fittings are also required to control the flow of fluid Any of these components can be the source of a fluid leak Detecting a leak can sometimes be difficult Large leaks in the range of 0 01 ml per minute are easy to find since these can be observed by the eye a typical drop of liquid is about 0 05 ml or detected with a bubble snoop leak detection solution for gases Smaller leaks in 12 11
212. vent PumpWorks can capture an error If an error occurs PumpWorks records the error and all pump operating information The captured information is saved to the computer s hard drive from 180 seconds before until 30 seconds after the error occurred This data can then be viewed by switching to the Error State Capture Mode located on the Error Log menu Once in Error State Capture Mode the user double clicks on an error in the Previous Errors Log Control Error State Capture then becomes an option on the Error Log menu Control Error State Capture is used to scroll through the error transactions so the user can view the flow rates pressures and volumes the pump was reporting before and after the error occurred The Error State Capture Mode data is stored in two files Pumpworks est and Quizix erl These two files plus the Pumpworks ini file contain the complete error information By viewing the data in the Error State Capture Mode the user can usually figure out what has gone wrong In the event of a problem that the user cannot figure out these three files can be sent to Quizix and used to help figure out what caused the error Please refer to the PumpWorks User s Manual for more information about Error State Capture Mode 12 2 PumpWorks Error Messages When PumpWorks recognizes that an error has occurred in the pump system an error message is generated Errors Present will appear against a red background on the status ba
213. vides power for the pump cylinder and relays status information to the pump controllers A mechanical assembly which lengthens the distance between the motor and the pump housing in high temperature pump systems This allows the Pump Housing to be heated inside of an oven while keeping the motor and harmonic gearing unheated outside of the oven This cable with a 9 pin DB type connector at each end connects the dual motor driver to the motor It is used when the driver needs to be at a greater distance from the pump cylinders This is the number of steps the motor takes to complete one complete turn or one revolution The portion of the motor that rotates This part keeps the Harmonic Drive from turning when the motor shaft rotates This message will appear in the motion status field when the controller cannot detect the presence of a pressure transducer motor driver or pump cylinder No pump cylinder actions can be taken through the PumpWorks soft ware when a pump cylinder is detected as not installed A key on the computer keyboard which when pressed will allow you to use the numbers on your numeric keypad Quizix 5000 SERIES PUMP MANUAL numeric keypad offset open end wrench operating mode operating mode window operating perameter setup window paired constant delta pressure delivery paired constant delta pressure receive paired constant pressure bidirectional paired constant pressure deliver
214. voing on a given pressure At the moment that the pressure is matched correctly resulting in no need to retract or extend further a hold status message appears By setting the flow rate to zero the hold conditions also provide a way for the user to stop a pair of pump cylinders without cycling the valves or changing the pressure in them The Hold Extend message indicates that when the rate is later changed to a non zero value or when the piston moves again as it servos ona specific pressure it will extend It indicates the next direction the piston will move Hold Ret The Hold Retract condition is the same as Hold Extend except that the piston will retract when it moves again Servo Ext Both the Servo Extend and Servo Retract conditions indicate that the pump cylinder is in the process of servoing ona given pressure Servoing means the pump is trying to achieve or match a given pressure This occurs in paired operating modes when the standby pump cylinder is brought to the delivery pressure of the active pump cylinder It also occurs when the pump cylinder is being operated in a constant pressure mode The Servo Extend condition indicates that the piston is in the process of extending to achieve the desired pressure It differs from the Extending condition because the piston will continue to extend only until the desired pressure is reached and then will hold When a pump cylinder is servoing you can watch the motion status
215. when displaying pressure rate and volume and to specify the resolution or number of decimal places displayed An abbreviation or shorter name for the motor driver These are located on the bottom of the driver and provide air intake for the driver fan G 7 Quizix 5000 SERIES PUMP MANUAL driver fan driver fuse driver on off switch driver serial numbe r driver side panels dual motor driver dust protection plug Dynamic Data Exchange DDE emergency stop switch end error error log errors present G 8 The driver fan is located at the end of the driver next to the heat sinks and keeps the driver cool during operation A safety device containing an element that protects the electric circuit going to the driver by melting when overloaded by a malfunction This on off toggle switch allows power going to the driver to be turned on or off Located on the rear panel of the driver this will also tell you the driver version If no driver version is stated you have version 1 The side panels of the driver are available in three options side mount rack mount or table The dual motor driver provides the motor drive for two pump cylinders and relays status information to the pump controllers A plastic cover used to protect parts from dust and dirt during shipping A Windows software capability that allows multiple programs to share data in real time This capability allows PumpWorks to
216. wing proper operating procedures Carelessness can be dangerous It is also strongly recommended that you follow these checks and procedures in each of the following situations e When the pump system is first received from Quizix Although all systems are carefully checked before shipment it is necessary to ensure that no damage occurred during shipment e After any changes are made to any of the components or plumbing That is after moving the system reconfiguring it or making any other adjustments that require you to disconnect and then reconnect the cables or plumbing e Ifthe system has not been operated for more than one month 3 1 Verification of All Cable and Plumbing Connections It is absolutely essential that all cable and plumbing connections are made correctly The system can seriously malfunction if cables are switched or tubing is connected improperly For example on the CMD 5000 Dual Controller Driver if the motor cable from cylinder A is plugged into the connector for cylinder B and the cable for cylinder B is plugged into the connector for cylinder A the system will not operate properly It could generate high pressures resulting in the rupture of the safety burst disk As another example if the valve cable strand labeled 5 were plugged into solenoid 6 the system would not operate properly Only a careful and thorough visual check can prevent this situation Pump Works software can detect if all cable
217. wn on the top convex surface of the snap ring until it fully snaps into its slot See Figure 11 13 WARNING IT IS EXTREMELY IMPORTANT THAT THE SNAP RING IS PROPERLY AND COMPLETELY IN PLACE ON THE MOTOR SHAFT WHEN PLACING THE SNAP RING ON THE SHAFT DO NOT OPEN IT ANY MORE THAN NECESSARY IF THE SNAP RING IS NOT PROPERLY IN PLACE THE WAVE GENERATOR BEARING MAY COME OFF OF THE MOTOR SHAFT AND SERIOUS DAMAGE TO THE QUIZIX SYSTEM WILL RESULT 24 Use the six M4x40 SHCS to secure the motor assembly and motor adapter housing to the pump body making sure that the cable is down towards the base of the pump 25 Turn on power to the pump system run the cylinder and listen carefully to ensure that all motor sounds are normal 11 4 Cooling Fan Maintenance This section describes cooling fan maintenance for both the high temperature pump cylinders and the CMD 5000 Dual Controller Driver 11 4 1 High Temperature Systems Recommended Frequency every 12 months of regular use 11 17 Quizix 5000 SERIES PUMP MANUAL 11 18 On Quizix C 5000 High Temperature Pump Cylinders the pump cylinder stepper motor has a cooling fan attached to it to prevent the motor from overheating This fan operates when the motor driver in the CMD 5000 is on It should have access to fresh air at all times To determine if it is operating properly do the following 1 With the CMD 5000 Dual Controller Driver turned on place
218. xample a SP 5200 10K pump system includes pressure transducers that are rated for 10 000 psi An SP 5200 5K would include 5000 psi pressure transducers an SP 5200 20K would include 20 000 psi pressure transducers If you plan to operate your pump system at a pressure under 500 psi it will perform better with a pressure transducer with a lower pressure rating than the one supplied with your pump system The pressure transducers must be calibrated properly for the pump system to provide pulseless flow The pressure transducers can be calibrated by using the Pressure Calibration window in Pump Works This window allows the user to set an offset value and a gain value for each pressure transducer See Chapter 11 in this manual and Chapter 9 in the Pump Works User s Manual for more information on calibration 8 5 Fluid Plumbing The Quizix 5000 Series pump cylinders use 1 8 inch tubing for all plumbing connections Quizix 6000 Series pump cylinders use 1 4 inch tubing for fluid flow sections of plumbing and 1 8 inch tubing for the pressure transducer connections This section describes the types of tubing that are necessary for system operation 8 5 1 User Supplied Tubing For the fluid inlet connect a section of tubing from the fluid source to the tee labeled fluid inlet There is one fluid inlet tee for each pair of pump cylinders A 4 cylinder pump system has two fluid inlet tees For the fluid outlet connect a section of
219. y Segments 2 7 5 3 e 4 Decimal 4 Point Left Decimal Right Hand Point Hand Digit Digit Figure 12 2 12 3 2 2 Pump Controller Software Initialization The pump controller software initialization is performed next The left hand digit will light the right hand digit will not The left hand digit will display number 1 then 2 then 3 then 4 then 5 then 6 then 7 Each number that lights is a confirmation that a pump controller software function is operating correctly The numbers will flash quickly The numbers on the left hand digit represent the following tests performed by the controller s software 0 1 2 load program into RAM and initialize variables 3 4 calibrate pressure channel A to D for cylinder A and B 5 6 check and set pump cylinder location for cylinder A and B 7 alltests passed accept commands from PumpWorks In the final step do will flash alternately with 0 The do stands for digital overpressure As a safety precaution each time a pump system is powered on the safety pressure is set at 50 PSI The user must set the safety pressure to a valid operating value each time the pump system is powered up The 0 means the pump has not yet been assigned a pump number by PumpWorks As soon as the pump is installed onto Pump Works the 0 will be replaced with the pump number 12 3 3 Two Digit Display Error Code Following is a list of letters that can appear on the two digit dis
220. y paired constant pressure receive This is located on the right hand side of your computer keyboard It has numbers arrows and cursor movement options The electrical shift of a signal around the zero reading This is a wrench with a U shaped or open end that is used to loosen or tighten bolts This term refers to the way the pumps are operated An operating mode is a particular configuration or set up that allows the pump system to be operated in a specific pre determined manner This PumpWorks software screen allows the user to select an operating mode and displays which operating mode is currently being used This allows the user to change the default value of the return rate multiplier the return rate minimum the proportional servo gain and the differential servo gain A pair of cylinders which work together to pump fluid at a constant pressure differential to a core sample To maintain this constant pressure differential the fluid delivery rate of the active pump cylinder will change as needed A pair of pump cylinders which work together to extract fluid at a constant pressure differential from a core sample To maintain this constant pressure differential the fluid delivery rate of the active pump cylinder will change as needed A pair of cylinders maintains a constant pressure by either delivering or receiving fluid The fluid pressure for the active pump cylinder remains the same at a user selecte
221. y rupture disk holder schematic scroll GLOSSARY The direction the piston moves when it backs out of the cylinder block The motion of the piston as it pulls back out of the cylinder barrel to fill with fluid The return rate multiplier is the number that is used to multiply the set rate to determine the return rate This number is always or greater so that the return rate is equal to or faster than the set rate A faster return rate is used in a pair of cylinders so the returning stand by cylinder has enough time to prepressurize The lowest rate or speed that the standby pump cylinder will retract at The cable that connects the Pump controller to the computer and carries the serial data communications The various text messages that are displayed in the motion status field when the pump cylinder is operating A breaking or opening This is the pressure which if exceeded the pump cylinders will stop pumping Quizix pumps have three built in safety pressure systems digital safety pressure the analog safety pressure and the safety rupture disk pressure A metal disk that is installed in a safety rupture disk assembly This includes the safety burst disk holder the safety rupture disk compression ring locking fitting and relief fluid exit One is installed on each pump cylinder to burst in the case of overpressure caused by a malfunction Located on the safety burst disk assembly this port should be connect
222. your system is inserted into the pump housing to engage the piston nut during piston removal or replacement This is a 27 mm socket welded on an extension tube The length of travel that the piston can move either retracting or extending The volume displaced by a one stroke of the piston pneumatically actuated or air actuated means the operation is begun by a force of air A valve which is operated by the force of air A pump where a solid object is used to physically displace the pump fluid The power connector assembly includes a receptacle for the power cord a fuse holder and a voltage selector in one unit The process of the standby pump cylinder building up pressure to match the pressure in the active pump cylinder then staying ready until it is needed Because the standby pump matches the pressure of the active pump pressure pulses are avoided during continuous operation A measurement of the magnitude of a force This can be measured in different units which include PSI bar or pas cals A change in pressure which lasts a short duration A device that measures fluid pressure and converts it to an electrical signal This signal is sent to the pump controller for conversion and display as a number The cable that goes from the pressure transducer to the control ler The process of checking and adjusting a pressure transducer so that its readings are accurate Units of measure for pressure which include P

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