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QX Series User`s Manual

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1. Figure 3 11 3 9 2 How to Turn On Your Pump When you turn on your pump watch your two digit display The two digit display is visible in Figure 3 11 Read Section 3 9 3 The Two Digit Display When Pump is Turned On before actually turning on your pump To turn on your pump push the on off toggle switch to 1 The on off toggle switch is located next to where the power cord attaches to your pump 3 9 3 The Two Digit Display When Pump is Turned On Watch the two digit display when you turn on your pump e The first thing the user will see is all segments of the display will light at once briefly e Next the display will flash the boot version number currently version 3 6 The following two sections will explain the Pump Controller Hardware Diagnostics Section 3 9 3 1 and Pump Controller Software Diagnostics Section 3 9 3 2 3 9 3 1 Pump Controller Hardware Diagnostics The basic pump controller diagnostics are performed next Refer to Figure 3 12 and Figure 3 13 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 One segment lights then a second segment lights then a third and so on Each segment that lights is a confirmation that a specific aspect of the pump controller is operating correctly Chandler Engineering QX SERIES PUMP USER MANUAL Two Digit Display Pump Controller Diagnostics e Displ
2. 9 3 2 2 PumpWorks Controller Diagnostics The Pump Controller Diagnostics also called the software diagnostics are 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 all tests passed accept commands from PumpWorks In the final step d0 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 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 9 3 3 Two Digit Display Codes Following is a list of letters that can appear on the two digit display written in block style A brief definition follows each error code AD Auto Deliver e Remote A
3. 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 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 This is a metal alloy that is highly corrosion resistant This is an abbreviation for hastelloy heat sink hierarchy holding extend holding retract home host link host link communications protocol independent cylinder oper ating mode independent constant delta pressure independent constant pressure independent constant pres sure cycled GLOSSARY 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 importance This Pumpworks software motion status message means that a pump cylinder is operating and the p
4. 2 Turn on power to the new pump 3 Click on Communications Search For Pumps PumpWorks will search for your new pump and give you a message that says QX Series found on Com 1 Expander Port A or B C or D Do you wish to install 4 Click on Install 5 PumpWorks will ask you to Enter User Name for New Pump The default pump name is the lowest pump number available as in 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 6 Click on Install 3 13 Chandler Engineering QX SERIES PUMP USER MANUAL 7 PumpWorks brings up the Main Pump Data amp Controls window You will know your pump has been installed because of the following e 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 e The pump data fields will contain numbers instead of question marks 3 10 3 Two Digit Display When Pump Is Installed Onto PumpWorks The two digit display on the pump control panel is a way for the pump to communicate information to the pump user When you install a brand new pump for the first time the error message do will continue to flash alternately with the pump number 1 2 3 4 5 6 7 or 8 on the right hand digit of the two digit display The do stands for digital overpressure As a Safety precaution
5. 9 Feed the drive belt straight up towards the top of the pump Turn the ribbon 90 degrees so the inside of the drive belt will face the front of the pump 10 Loop the drive belt around the cylinder block drive pulley 11 Open the end loop of the drive belt so the loop stays open Firmly grasp the drive belt and pull it up and over the belt pin 12 Replace the tension sensor arm by pushing the drive belt down and towards the center of the pump while pulling the tension sensor arm over the drive belt Chapter 8 MAINTENANCE Figure 8 14 ALLT Figure 8 15 Figure 8 16 Chandler Engineering QX SERIES PUMP USER MANUAL 8 2 5 How to Re assemble the Pump Cylinder Please refer to Section 8 1 9 Re assemble the Pump Cylinder for instructions 8 2 6 How to Re assemble the Pump Case Please refer to Section 8 1 10 Re assemble the Pump Case for instructions 8 2 7 How to Re assemble the Valve Assembly 1 3 To re assemble the valve assembly attach the valve assembly air supply tube by pushing it into the quick release valve The tube should be tightly connected Attach the valve assembly ribbon cable and swing the latches around the cable to secure the cable in place Set the valve assembly back on top of the pump and tighten the four screws that hold it 8 3 Replacing the Return Cable Fully retract both Cylinder A and B using Independent Constant Rate mode Turn off power to the pump and disconnect the p
6. 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 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 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 position display piston stroke piston stroke volume pneumatically actuated pneumatic valve positive displacement pumps pre pressurize GLOSSARY A mode that operates two pump cylinders so they move in equal but opposite directions At the end of the piston stroke both pump cylinders change direction simultaneously at
7. The user s entire experiment is controlled by the Quizix Pump Works software 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 more are entirely in view at the same time The O 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 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 the main power source
8. or a plastic or metal based scour pad Any cleaning solution is okay to use Barrel If your pump does not have a wash area unscrew the seal retaining collar located near the bottom of the pump cylinder barrel and set aside If your pump has a wash area unscrew the wash area collar located near the bottom of the pump cylinder barrel and set aside a Take out the main seal and throw away Now that the seal os Holder retaining collar back up ring and main seal are removed wipe everything dry with a clean paper towel or a clean dry cloth Pull out the back up ring Wipe with a clean dry cloth and set aside Figure 8 6 Look inside of the cylinder barrel Check to make sure the area inside of the cylinder barrel where the seal sits is clean and scratch free If there is a build up or anything is stuck on the cylinder barrel remove it You may use a solvent and rag to clean the cylinder barrel DO NOT use steel wool If you see any scratches inside of the cylinder barrel where the seal sits a new seal may also leak If the seal seat area of the cylinder barrel is scratched you may need to polish the scratches out or purchase a replacement cylinder barrel Chapter 8 MAINTENANCE 8 1 6 Replacing the Pump Cylinder Seal 1 2 3 Gently insert a new main seal so the spring side is no long visible Replace the back up ring You will hear a pop noise as the back up ring pushes the main seal into position Sc
9. 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 9 11 Chandler Engineering QX SERIES PUMP USER MANUAL 9 12 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 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 9 4 3 2 Leak Testing The QX 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 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 i
10. 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 9 4 7 3 Air Supply Requirements IMPORTANT INFORMATION Although the QX Series uses very little air the air supply that is used MUST meet the following conditions e The air must be clean 9 17 Chandler Engineering QX SERIES PUMP USER MANUAL 9 18 e The air must be dry Moisture in the air supply will cause the pilot solenoids to rust and malfunction e The air must be between 60 to 115 PSI 4 to 8 bar e If air pressure exceeds this the pilot e Solenoids may stop working 9 4 7 4 Checking Your Air Supply Connection To check the air supply connection first identify the air inlet Look for the fluid outlet tee on your pump You will see a plastic tube coming from each valve The two tubes join together into a fitting The air inlet is attached to this fitting Make sure a 6 mm tube is inserted into the air inlet fitting and that it is tight and cannot be moved Attached 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 1 4 inch tubing will also work in most cases Nylon tubing is the recommended material for the air tubes however other materials will work 9 4 7 5 Valve and Pilot Solenoid Check Pilot s
11. 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 auxiliary valve cable auxiliary valves auxiliary valve window G 2 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 pump 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 This connects t
12. Cylinder Check 4 3 2 Valve Warning Messages When opening and closing valves there are two possible warning messages that you may get if you are using PumpWorks warnings are not given with the Front Panel They are described below 4 3 2 1 Opening Both Fill and Deliver Valves Warning This warning seeks user confirmation that the valve that is about to be opened will cause both the fill and deliver valves to be opened at the same time By opening both the fill and deliver valves at the same time the fluid inlet and fluid outlet are connected to each other Any pressure differential between the fluid inlet and fluid outlet will be equalized and fluid will be allowed to flow from the fluid inlet to the fluid outlet or vice versa without any restrictions With both the fill and deliver valve open the user must be careful that the fluid is not dumped or siphoned into or out of the fluid reservoir or experiment Press OK if you want this valve to open Chapter 4 SYSTEM CHECKOUT 4 3 2 2 Valve With Pressure Above 100 PSI Warning This warning appears so the user knows the valve about to be opened is attached to a pump cylinder with a pressure above 100 PSI By opening the valve fluid flow will be released which will cause the pressure to drop Press OK if you want this valve to open 4 4 Pump Cylinder Check The Pump Cylinder Check involves running each pump cylinder manually through at least one full piston cycle The motion of
13. Repeat this procedure again until you reach a piston stroke where no air bubbles come out only liquid End with a Retract stroke The cylinder barrel is now full of fluid and all air is flushed out Repeat this procedure for each pump cylinder in your system ending with all pump cylinders full of fluid and the pistons in the Max Retract position 4 9 Chandler Engineering QX SERIES PUMP USER MANUAL 4 10 4 6 Pressure Transducer Check Because the QX Series Pump can reach extremely high pressures very quickly it is absolutely essential that the pressure transducers be thoroughly checked To check the pressure transducers please read the note below then follow the procedure NOTE At this point both pump cylinders need to be full of fluid and both pistons are in the Max Retract position Close both the fill valve and the deliver valve for pump cylinder A using PumpWorks Pump Data amp Controls window Ww IMPORTANT INFORMATION When performing the pump cylinder check STOP THE PUMP CYLINDER if pressure does not start to increase after about 30 seconds To perform the Pressure Transducer Check do the following e Set the flow rate to 1 ml min e With the safety pressure still at 100 PSI 700 kPa and the direction set to EXTEND start the pump cylinder Watch the current pressure reading in PumpWorks main window until it exceeds 100 PSI 700 kPa and is stopped by the digital overpressure control system If the pump cylinde
14. the safety pressure is reset to 400 psi when the pump is turned on The pump number is assigned by PumpWorks based on the first available window position starting from left to right on PumpWorks Main Window NOTE When PumpWorks and the QX Pump 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 QX Series is sending communications to PumpWorks A decimal point will flash on the right side of the left digit which means that PumpWorks is sending communications to the QX Series The right digit decimal point will flash brighter than the left digit decimal point because the QX Series has more data to send to PumpWorks than the amount of data PumpWorks has to send to the QX Series Pump Refer to Chapter 9 QX Series Two Digit Display Section 9 3 for more information regarding the two digit display Included you will find a list of error messages and how to correct them 3 11 Completing System Setup To complete your pump setup go to Chapter 4 Pump Checkout All of the system checkouts must be performed before your pump can be safely operated The following sections are included in the Pump Checkout e When To Perform The Pump Checkout Section 4 1 e Verification of Pump Cable and Plumbing Connections Section 4 2 e Valve and Pilot Solenoid Check Section 4 3 e Pump Cylinder Check Section 4 4 e Connecting and Filling the Pum
15. 1 C rrent Pr Ss rE o moecsoncns diissii ssi 6 9 63 177 Current Offset ir e aa aa 6 10 6 3 1 2 1 Current Pressure si scccaaceceuebist atashiateaatasesede 6 10 T Chandler Engineering QX SERIES PUMP USER MANUAL CHAPTER 7 CHAPTER 8 6 3 1 2 2 AutoZero Pressure test itcie eatin ecties 6 10 6 3 1 2 3 Minimum Offset oi ei cdiecteced eed 6 10 6 3 1 2 4 Maximum Offset sesers 6 10 6 3 1 2 5 Current Offset eeseseeeeeserereeressrserrresse 6 10 6 3 1 2 6 Enter New Offset eesse 6 10 03 12 CIOS mai e a a as 6 11 6 3 1 3 Current Gain isinen istsrss 6 11 6 3 LA Cancel x ccs conmteatacceansamecatusatenlsAaahiat sadiauinnctaseseds 6 11 6 32 Wipdate SoftWare a SEO n ieies 6 11 6 3 3 Pressure Controls nonsnenniieni i n 6 13 0 34 Units Ge Precision an A a a AT EEA 6 14 GA Setting Display Brightness ssssesesssessssseesseessessseesseeessresseesseessees 6 15 6 4 1 Setting Display Brightness on Front Panels with Windows CE I O a a a RES 6 16 6 4 2 Setting Display Brightness on Front Panels with Windows CE 4 2 sesno Gee dinuodes esta sere nina 6 17 SYSTEM ROWER 2 ideecastes ccanledcctirtancenten sectiuat Seca ssuaceanledeactiatenscona aris 7 1 7 1 Basic Power Requirements lt isisisesissssessasasescctsansavcasdseesndes cpavesdesneseetaaes 7 1 7 2 Using Uninterruptable Power Supplies ceccceeeseeeesteceesteeeeeeees 7 1 J Serial Expander Sol ator 26d tasecas onsets a gaskets anes E 7 2 TA Replacing a PUSE niinen neeesa eE EEEE
16. 2 Pump Controller Software Diagnostics 3 12 3 10 Installing A Pump Onto PumpWorks 0 0 0 eeeceesseceesteeeeneeeaees 3 12 3 10 1 Automatic Search For New Pumps ccceeseeeeeseeeeteeees 3 13 3 10 2 User Search For New Pump x 0 2 4 dessgaccesnseceacadstasoeonsneeees 3 13 3 10 3 Two Digit Display When Pump Is Installed Onto Pump W OLKS 355430 slscdats a censadivsdataassiea waesedamiepiaoaredadeeaesedees 3 14 3 11 Completing System Seu pics osetia agetettontoear ei Rated oaastetieees 3 14 PUMP CHECKOUT asiisiciseeaentistiiadinns n iia asiana 4 4 1 When To Perform The Pump Checkout 000 cece eeeceeeeeeeesteeeeneeees 4 4 2 Verification of Pump Cable and Plumbing Connections 4 2 4 2 1 Fluid Plumbing Connection Check cceeeeeeesseeeesteeeeteeees 4 2 4 2 2 Fluid Inlet And Fluid Outlet Connection Check 4 2 4 2 3 Front Panel Connection Check cccceesscceesseceesteceseeeeesseeees 4 2 4 2 4 PumpWorks Connection Check 0 0 0 eeseeseeeseeeeneeesseeneeenees 4 3 4 3 Valve and Pilot Solenoid Check s2 c 5 0st einen iain 4 3 CHAPTER 5 CHAPTER 6 TABLE OF CONTENTS 4 3 1 Valve and Pilot Solenoid Auditory Check eeeeeeeeeeees 4 4 4 3 2 Valve Warning Messages aciiicavec acca 4 4 4 3 2 1 Opening Both Fill and Deliver Valves Warning 4 4 4 3 2 2 Valve With Pressure Above 100 PSI Warning 4 5 44 P mp Cylinder Check 5c lect ahi vac ne va Ss taense des 4 5 4 5 Connecting an
17. 4 1 9 Symbols Used in this Manual 10 0 0 eececeeesceesteceeseeceenaeeeseeeseaeeees 1 4 AO Whereto Find Fhe ics tars cuatts oi ae es haath n E nae 1 4 CHAPTER 2 SAFETY sisnciaiseicniintnpdinian ual aie alida E A RG 2 1 DAS Arey Requirements renin otetatied ng eatets Se Soest e a 2 1 2D Satety PFeat rES id ssid iysbhidite Wicd E E Maat dau te E Rte ER 2 1 2 2 1 Cable Connection Sensing vig caca25 aves scadabscedeyandeaagonsereeetaues cede 2 1 2 2 2 Overpressure Protection Safety Feature ee eeeseeeseeeees 2 1 2 2 3 Underpressure Protection Safety Feature eeeceeeeeeeee 2 2 2 2 4 Equipment Installation 2 0 00 eeeeeeeceesseceeseeceeneeceseeeeenseeeenes 2 2 Zod cov Medium FATA a i ne e Pac E EE 2 2 CHAPTER 3 SYSTEM SET prcnis Ea EE EE E RAE 3 1 3 1 Unpacking the QX Series Pump 2 2 cceci cased Ghats 3 1 3 1 1 QX Series Installation Ii of onc daaccdlsen eee gun hinds 3 1 Sil OX SSMS SS PALS KA 5441 55 Sespsiaseioasteseesey os r a a isi 3 2 3 1 3 Unpacking the QX Pump ys ics295 cd ccaceesgceceldti ceca Qeveeen ees 3 2 3 2 Inspecting Your Pump lt 0 csccisecacsartcavaccestecvansensdencteansecdantedeneredcavactens 3 3 3 3 Connecting Your Air Supply svcscaiscssictisicieanacsedesssassadeassdantaasseaaceats 3 3 3 3 1 Air Supply Requirements os sgh oo sea dG suas ctps Seine Cina Ge aated oa cade 3 3 3 3 2 Connecting Your Air Supply eeeeeeecceesseceesteeeeneeeneeeenes 3 4 3 4 Connecting Your Fluid Plumbing 2 0 0 0
18. Chandler Engineering QX SERIES PUMP USER MANUAL 4 8 THE QX SERIES PUMP PUMP TYPICAL MAXIMUM MODEL CYLINDER VOLUME FLOW RATE QX 500 137 ml 500 ml per minute QX 1500 49 ml 200 ml per minute QX 6000 12 3 ml 50 ml per minute QX 20K 3 3 ml 7 5 ml per minute Dividing the cylinder volume in ml by the flow rate in ml minute is equal to the stroke time in minutes For example the cylinder volume of 137 ml for the QX 500 divided by a flow rate of 100 ml minute equals 1 37 minutes Since one minute is 60 seconds 1 37 minutes is equal to 60 seconds x 1 37 which is 82 2 seconds or 1 minute and 22 2 seconds In this example it should take 82 2 seconds for the piston to make one stroke If your piston stroke is taking considerably longer or shorter than the amount of time it should contact Chandler Engineering at the phone numbers listed on page 2 3 Look at the Cylinder Volume box for pump cylinder A on the monitor When the pump cylinder reaches Max Extend check that the volume count is very close to the stroke volume Start the pump again Run it for one piston stroke so you get the piston back to Max Retract Perform the above Pump Cylinder Check again for pump cylinder B and for any other QX Series pumps in your pump system Completing the Pump Cylinder Check indicates that your pump s cables are correctly connected and the PumpWorks software the pump controller motor driver and the limit switc
19. FLOW RATE VOLUME DIAMETER 500 ml per minute 3 174 cm QX 500 500 PSI 30 liters per hour 137 ml 1 25 inches 200 ml per minute 1 905 cm QX 1500 1 500 PSI 12 liters per hour 49 ml 0 75 inches 50 ml per minute 0 9525 cm QX 6000 6 000 PSI 3 liters per hour 12 3 ml 0 375 inches 7 5 ml per minute 5 07 mm QX 20000 20 000 PSI 0 45 liters per hour 3 3 ml 0 2 inches Pumps are available with either stainless steel or Hastelloy cylinder barrels fluid plumbing and valves Hastelloy provides superior corrosion resistance NOTE ON TERMINOLOGY The QX Series Pump contains two separate pump cylinders When the term cylinder is used it will mean one of the two pump cylinders contained inside the QX Series pump The two pump cylinders are designated as pump cylinder A and pump cylinder B 1 5 Operating Conditions The QX series pumps are intended to be operated indoors and should be operated within the following environmental ranges e Operating Temperature 10 degree C to 50 degree C 50 degree F to 120 degree F e Operating Humidity 95 non condensing himidity maximum e Altitude up to 3000 m 10 000 ft 1 6 Shipping and Storage Environment e Temperature 10 degree C to 50 degree C 14 degree F to 120 degree F e Humidity 95 non condensing humidity maximum 1 7 Approvals Certifications e CE Compliance See Appendix A for the EU Declaration of Conformance 1 3 Chandler Engineering QX SERIES PUMP USER MANUAL 1 8 Symb
20. Fluid When Closed n os 9 18 OS SoftWare Updates ssis atta tent cua R beta uk cont cea cuat te 9 18 CHAPTER 10 QX SERIES USER INTERFACE 1 00 cccsccessssssssorsstesstensssnserssonsesacenores 10 1 10 1 Valve Control Lines a sicencssutitic sendin Matti caea sees teins a ent canara ta 10 1 10 2 Digital Input Lines 2 22302 eye eo dei ae ch a a 10 1 10 3 DipttalOutput LINES 2 co co2 ccteet cc ches arceises es atone iiaia 10 2 10 4 Analog Signal Input Lines 200 0 eee eeeeceesseceesseeeeseeeeeeeeneeeeaees 10 2 10 4 1 Auxiliary Voltage Inputs eee ceeeeeescecseceseeeeeeeaeenes 10 2 10 4 2 Auxiliary Current Inputs 2 20 00 eeceseccesceceneececenteeconteees 10 2 0 5 Em rsency Stop Signal fjsacacsaseseaneisngdedquadzararnceaawegbescanvansedanneneuenety 10 3 10G Power Lines eirca an at a E a a gees 10 3 10 7 Remote Control Interface sesseeseseeseeseeseesrerreeseessrseresressesrresreses 10 3 10 8 Connector PINOUtS ssscsnsesnssenieienssi iieiaei 10 3 APPENDIX A EU DECLARATION OF CONFORMITY 00 cee eeceeseeeeeeeceteeeeeeneeneeens A 1 Chandler Engineering QX SERIES PUMP USER MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Chapter 1 GENERAL OVERVIEW The QX Series Pump is a precision metering pump that can be controlled with a Front Panel attached directly to the pump or it can be connected to your computer and operated through Quizix PumpWorks software PumpWorks allows the user to control up to eight QX Series Pumps at once all
21. Operating Mode button displays the currently set operating mode Pressing the Operating Mode button brings up the Set Operating Mode window which allows the user to set the desired operating mode See Figure 6 5 below Operating Mode Figure 6 5 Additional modes can be selected by touching the More Modes button Figure 6 6 will appear Chapter 6 OPERATING YOUR FRONT PANEL Figure 6 6 To return to the first mode window the Back button should be touched The currently available operating modes for the Front Panel Software Version 1 100 are as follows Paired Operating Modes e Paired Constant Rate Deliver CR Del e Paired Constant Rate Receive CR Rec e Paired Constant Pressure Bidirectional CP BI e Paired Constant Pressure Delivery CP Del e Paired Constant Pressure Receive CP Rec e Paired Gear Mode Const Rate Del GM DEL e Paired Gear Mode Const Rate NV GM NV Independent Operating Modes e Independent Constant Rate IND CR e Independent Constant Pressure IND CP e Independent Constant Press Cycled IND CP C e Independent Constant Rate Cycled IND CR C Operating modes can only be set when the pump is stopped If an operating mode button is pressed while the pump cylinder is running a warning message will be displayed explaining that the pump must be stopped before an operating mode can be set NOTE When operating in an independent operating mode the valves must be manually set by the us
22. Part 15 Class A European EMC directive 2004 108 EC EN 61326 1 Radio Frequency Emissions EN50011 CISPR11 Conducted Emissions Class A Radiated Emissions Class A EN 61000 3 2 Harmonic Current Emissions Class A EN 61000 3 3 Voltage Fluctuation Flicker EN 61326 1 Immunity EN 61000 4 2 Electrostatic Discharge AKVIBKV EN 61000 4 3 Radiated Immunity 3vim EN 61000 4 4 Electrical Fast Transient Burst 0 5kV 1kV EN 61000 4 5 Surge AkKV TKV EN 61000 4 6 Conducted Radio Frequencies 3Vrms EN 61000 4 11 Voltage Dips and Variations 100 1p 100 0 5 each polarity Safety Compliance Low Voltage Directive 73 23 EEC IEC 61010 1 2001 Electrical Equipment for Measurement Controls and Laboratory Use he Dean Dorris Director of Engineering Ametek Chandler Engineering August 29 2007 AC line noise rejection A D converter acoustic separator activated active pump cylinder air actuated air inlet air supply Allen wrench Allen head screw ambient temperature amplifiers anti seize compound 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
23. Pump Checkout in Chapter 3 The Pump Checkout must be performed before operating your pump The Pump Checkout ensures that all cables have been recommended properly and the pump is ready to operate 8 2 Replacing the Drive Belts There are two drive belts in the QX Series Pump The drive belts propel the piston carriage assembly IMPORTANT INFORMATION The pump cylinder must be at Max Retract before replacing the drive belt If replacing both drive belts both pump cylinders must be at Max Retract Chapter 8 MAINTENANCE 8 2 1 Removing the Pump Panels and Valve Assembly 1 2 10 Before proceeding turn off the air supply to your pump Remove the valve assembly from the top of the pump use the 3 mm hex wrench to loosen the 4 screws that hold the valves to the pump There is a valve assembly ribbon cable that is connected to the bottom of the valve assembly Gently lift the valve assembly forward and lift it partially out of the pump enough to get to the cable Disconnect the valve assembly ribbon cable by pushing the ejector latches outward The valve cable will easily disconnect Figure 8 9 Remove the air supply tube from the valve assembly by pressing on the quick release valve See Figure 8 10 Lift the valve assembly off the pump case and set aside Using a phillips head screwdriver remove the six 6 screws that hold each pump side case Two 2 screws are located in the front of the pump and
24. Re assemble the Valve Assembly cccceeeeeeeeeee 8 10 8 3 Replacing the Return Cable cia is can etinaea da ulanccetaaueceienes 8 10 8 4 Changing the Transducer O Rings eeeeeeceeeeceesteeeesteeeennecesaeeees 8 17 8 4 1 Removing the Pump Case eeeceesseceeeteceesteeeenaeeeneeeenes 8 18 8 4 2 Disconnecting the Transducer Ribbon Cable 8 18 8 4 3 Removing the Transducer Assembly eeecceeeereeeeeeeeees 8 18 8 4 4 Replacing the Transducer O RINg cc eeeceeeeeeeeeeeeeeeeeeeeees 8 18 8 4 5 Reattaching the Transducer Assembly 8 18 8 4 6 Re assembling the Pump Case ceeecesseeceseeeeeeeeeeeeeeees 8 18 8 5 Calibrating the Pressure Transducers ceeeceeeseeesseeeeeteeeeneeees 8 19 8 5 1 What is a Pressure Transducer 00 0 ees eeseceseeseeeeneeeneeeeees 8 19 8 5 2 Methods of Calibrating the Pump System eee 8 19 8 5 2 1 Calibrated Gauge scccudncanuiitansaunucusdar 8 20 8 5 2 2 Calibrated Pressure Source anicssn da isiecissst acesetoacess 8 22 8 6 How to Attach a Fitting to Your Tubing eee eeeeeeeeeeeteeeeeeees 8 23 8 6 1 Completed Connection 0 00 ceeseecesseeceeeeceeeeeceeeeeceeeeeseneeeees 8 23 2 0 2 RESAS SETAE 5 ea aes Guaauicay a a a a eei a 8 23 8 7 Bearings amp Motor 2 sssicnes videsacesaghad oavedendassaeanceansadedausseedett oia 8 23 8 8 Valve Maintenance essssessesessessressessessresressersresresseesreseesseeseeserssee 8 24 S9 Cleaning ee eS ere RE
25. Section 9 4 5 for more information about piston movement errors If the physical piston position indicator does move then the problem is probably with the linear motion sensor The QX Series Pump has a linear motion sensor mounted on each piston carriage near the base plate The linear motion sensor detects the motion of the piston by using a magnetic sensor to read a magnetic scale If fluid leaks past the seal it is possible that the linear motion sensor and or the magnetic scale will obtain fluid deposits on them If 9 5 Chandler Engineering QX SERIES PUMP USER MANUAL this happens the motion of the piston can be affected but generally this magnetic sensor is not susceptible to fluid deposits 9 3 QX Series Two Digit Display The QX Series has a two digit display which is located on the pump control panel 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 e malfunctioning controller or power supply or e the absence of a driver motor sensor or transducer cable If no errors are present the two digit display will display 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 Ligh
26. 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 cylin ders 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 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 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 driver on off switch dual motor driver dust protection plug Dynamic Data Exchange DDE emergency stop switch end err
27. a eae ee 8 24 CHAPTER 9 TROUBLESHOOTING ccsccssscscessccscessesssesscesetencsonsesconetseceaersasenees 9 1 9 1 Troubleshooting Basics acvcnni c 5 c tv ea evar caus Weare Gerda ae 9 1 Chandler Engineering QX SERIES PUMP USER MANUAL 9 2 PumpWorks Error Messages cccsscccssscssssscesssscsssssessnscsessnesenscesens 9 2 9 21 Immediate TTT OES o a ace Leiccasedsa a E 9 2 9 2 2 Eog ged TAIT OUS neien ano a E eae 9 3 9 2 2 1 Soft Limit Warning x ss isisssccccsvsaczasdseesadtashaseavatecvennerds 9 3 9 2 2 2 Communication Errors esssesssssesseessesssesesssersseesseessee 9 3 9 3 QX Series Two Digit Display ssssssssssssessesssessseressseessessersseresseeessees 9 6 9 3 1 The Two Digit Display Does Not Light eee eees 9 6 9 3 2 The Two Digit Display Does Not Complete Its Initial Check 9 6 9 3 2 1 Pump Controller Diagnostics 20 0 eeeeeeeeeeeteeeeeteees 9 7 9 3 2 2 PumpWorks Controller Diagnostics 0 0 eee 9 8 9 3 3 Two Digit Display Codes s c91 secdivedits gaye ease Waconia een 9 8 9 4 Other Pump Troubleshooting Situations 00 0 0 eeeeceeeeeeeeeteeeeeeeees 9 10 9 4 1 Air Supply Problems c51oR sk BG eee 9 10 9 4 1 1 No Air Escaping Sound When Valves are Opened amp Closed E ES 9 10 9 4 1 2 Constant Air Escaping Sound seses 9 11 OA Fan Does Not RUN eneee aeuiel aadesetions eater outa ones 9 11 94 3 Fl rd We ARS gees Pat Sith TL Satish PG aah Paes eteb ines tance dies 9 11 9 4 3 1 Leakage Basics sc
28. again so that no data is lost If a lot of these errors are occurring then communication between the pump and PumpWorks is significantly slowed down It is therefore better to discover and correct the source of these errors when possible NOTE If PumpWorks is not being used the Front Panel software will not record communication errors but commands will still be automatically resent when errors are detected Buffer Overrun Error Chapter 9 QX SERIES PUMP OPERATING BASICS Buffer overrun errors are due to a slow computer This can be corrected by keeping other programs from operating while using PumpWorks 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 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
29. all pumps are carefully checked out before shipment a system checkout is necessary to ensure that no damage has occurred during shipping 2 After making any changes or adjustments to any part of the pump or any of its connections A pump checkout is required after moving or reconfiguring your pump or making any adjustments that require you to disconnect then reconnect the cables or plumbing 3 Ifthe pump has not been operated for more than three months Chandler Engineering QX SERIES PUMP USER MANUAL 4 2 If you have not operated your pump for three months or more a pump checkout is required If you are in doubt how long it has been since the pump was last operated perform a pump checkout 4 2 Verification of Pump Cable and Plumbing Connections For the pump to operate all cable and plumbing connections must be correctly attached otherwise the pump system can malfunction For example if the pump s case has been opened and any cables have been disconnected it is critical that they are properly reconnected PumpWorks can detect if all cables are connected but cannot determine if they are connected to the proper components This section will include the following connection checks e Fluid Plumbing Connection Check Section 4 2 1 e Fluid Inlet And Fluid Outlet Connection Check Section 4 2 2 e Front Panel Connection Check Section 4 2 3 e PumpWorks Connection Check Section 4 2 4 D IMPORTANT INFORMATION Careful
30. 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 inserted into the piston carriage and has hit the top of the cylinder barrel e The piston carriage may be blocked by something e The drum belt may be wrapped in the wrong direction or off the pulleys e Motor or driver is malfunctioning e If the cylinder direction is retract then e The drum belt may be wrapped in the wrong direction or off the pulleys e Motor or driver is malfunctioning 9 4 5 2 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 inserted into the piston carriage e The motion of the piston carriage is blocked by a foreign object e The seal back up ring has clamped down on the piston causing excessive friction e Linear motion sensor is malfunctioning 9 4 5 3 Physical Piston Position Indicator Does Not Move When Pump Cylinder Is Operating There are two physical piston position indicators on every QX Series Pump e Double check that you are watching the physical piston position indicator for the pump cylinder that is operating e Make sure the flow rate that the pump cylinder is operating at will provide observabl
31. connected to one computer The QX Series can be used for fluid metering fluid mixing and oil industry applications such as core analysis Sophisticated Electronics e accurate flow e accurate pressure control e accurate volume measurement e continuous pulseless fluid flow Pumps Fluids at High Pressure e water e oil e brine e many other fluids Choice Of Operating Modes e independent cylinder operation e paired cylinder operation e constant rate e constant pressure e constant delta pressure e fluid recirculation Figure 1 1 Fluid Flow Can Be In Either Direction e delivering fluid or e receiving fluid The Entire QX Series Pump Weighs Only e 25 4 kg 56 lbs The QX Series Pump Measures Only e 21 cm x 49 cm x 63 cm e 8 3 inches x 19 3 inches x 24 8 inches 1 1 Primary Components of the QX Series Pump The QX Series Pump is a completely integrated self contained pump The QX Series contains a pump controller which directs the action of two completely independent positive displacement piston pumps These two piston pumps can each be used individually for single stroke volumes or as a pair to provide pulseless continuous fluid flow for a single fluid 1 1 Chandler Engineering QX SERIES PUMP USER MANUAL 1 2 Each piston pump contains its own motor drive mechanics pump cylinder piston pressure transducer valve and fluid plumbing The user may add additional valves or pressure transducers to
32. 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 9 5 Software Updates The operation of the QX Series Pump is controlled by two separate software programs PumpWorks which is stored on the user s computer and the pump controller software which is stored in the pump s controller New versions of software are periodically released Problems detected after a software is released are resolved in later software versions Chapter 9 QX SERIES PUMP OPERATING BASICS To make sure you have the latest software version available for your pump check which version you have Go to PumpWorks main window On the main menu bar select Help About PumpWorks The version of Pump Works 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 window and interact with The pump s controller is also running a program The controller software 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 PumpWorks available To do this contact Chandler Engineering either by phone or by going to our website at http www chandlere
33. desired settings pressing the OK button will start the pump cylinder s If pump cylinder is operating the button will read Push to Stop The button can then be pressed to stop the pump cylinder Once the pump is stopped the button will again read Push to Start Figure 6 2 6 1 2 Motion Status The possible motion status conditions are as follows Motion Status Conditions Stopped The pump cylinder is not operating Extending The pump cylinder is delivering fluid in a constant rate mode or the standby pump cylinder is dumping fluid in a paired receive mode Retracting The pump cylinder is receiving fluid in a constant rate mode or the standby pump cylinder is refilling in a paired delivery mode Servo Ext The pump cylinder is servoing or maintaining a constant pressure and is currently extending raising pressure Chapter 6 OPERATING YOUR FRONT PANEL Servo Ret The pump cylinder is servoing or maintaining a constant pressure and is currently retracting lowering pressure Hold Extend The pump cylinder is in a deliver mode and is running but not currently moving Hold Retract The pump cylinder is in a receive mode and running but not currently moving Max Extend The pump cylinder is stopped in the maximum extended position Max Retract The pump cylinder is stopped in the maximum retracted position Table 6 1 Motion Status Conditions 6 1 3 Pres
34. distance away from the pump 3 7 2 Connecting Your QX Series to a Computer NOTE If you already have PumpWorks installed go to Section 3 7 3 Adding a QX Series Pump to An Existing PumpWorks System Adding a QX Series Pump to An Existing PumpWorks System Connect your QX Series Pump to the computer where you will install PumpWorks by following the directions below 3 7 2 1 Serial Communication e Connect the RS 232 Cable 9 pin D Connector to Communications Port 1 on the back of the computer that will be used to run PumpWorks Communications Port 1 may be labeled Serial A or Serial 1 on your computer If Communications Port 1 is already in use you may use any other available serial port Please refer to PumpWorks User Manual Communications chapter for more information If your computer does not have enough serial ports you will need to purchase a serial port expansion card Contact Chandler Engineering for suggestions e Connect the other end of the RS 232 Cable into the serial expander isolator You may connect the serial expander isolator directly into the Communications Port 1 on the back of ana your computer instead of to the RS 232 RS 232 Cable By using the RS 232 Cable the Serial Expander Cable to pump can be farther away from the Isolator Computer computer it is connected to Figure 3 10 e Connect one end of the Data Communications Cable phone type into the first available port A B C or D on the
35. error is present Errors that do not apply are grayed as well as pumps that are not installed For ease of viewing pumps 1 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 description 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 e Physical Piston Position Indicators 9 1 Chandler Engineering QX SERIES PUMP USER MANUAL Every QX Series Pump has two physical piston position indicators which are green LED located on the piston carriage They are located on opposite sides of the pump and are visible through the windows on the pump case Each piston position indicator is a physical indication of the position of one of the pistons located inside of the QX Series A pump cylinder s position can be determined by viewing the LED s on the piston carriage as it moves from the maximum retract position near the bottom of the pump case to the maximum extend position near the top of the pump case with the pump in the vertical position e Cylinder Switch Status Window The Cylinder Switch Status is located on PumpWorks Error Log Menu It displays the switch status and current position
36. four 4 are located on the side of the pump Remove the pumps side case and set aside Figure 8 10 Using a phillips head screwdriver to remove the remaining screws that surround the pump about 1 2 inch from the top of the pump Initially three screws are located on each side of the pump two screws are located on the front of the pump and one screw is located on the back of the pump about 1 2 inch from the top Using a phillips head screwdriver remove the 3 screws that are located on the top panel of the pump case For pumps with a wash area lift the pump top panel and disconnect the wash area tubes Set the pump top panel aside For pumps without a wash area lift off and set aside the top panel of the pump case 8 2 2 Removing the Pump Cylinder Follow the instructions in Section 8 1 3 Removing the Pump Cylinder 8 7 Chandler Engineering QX SERIES PUMP USER MANUAL 4 Gently unwind drive belt until you get the other end of the 5 There are 3 loops of belt that go around the capstan on the 8 2 3 Inspecting the Drive Belts To inspect the drive belts lay the pump on its side with the open side of the pump facing up The drive belts need to be inspected once a year for signs of wear and replaced as needed Replacement drive belts must be purchased from Chandler Engineering A drive belt that needs replacing will show any of the following symptoms e The drive belt should be cleanly wrapped over each of the three
37. iE eE E ES 7 2 MAINTENANCE ac seg ra cea at orien e a ate E anda 8 1 8 1 Changing the Pump Cylinder Seals oo eeeeeseecneceeeeeeeeenaeenes 8 1 8 1 1 Tools You Will Need t2s io cea cos aacde Sbsecaes sezets ta dnee oovdapacaaoeneees 8 2 8 1 2 Removing the Pump Case sscccssccs csscsesvncceaets doneneavncecteanoasantane 8 2 8 1 3 Removing the Pump Cylinder eee eescceesteceeeteeeeneeeenaee 8 3 8 1 4 Inspecting the Piston and Piston Holder 0 0 eee eeeeees 8 4 8 1 5 Disassemble and Inspect the Cylinder Barrel ee 8 4 8 1 6 Replacing the Pump Cylinder Seal oo ee eeeeeeeeeeeeereees 8 5 8 1 7 Replacing the Wash Area Seals 0 ceecceeescceesseceesteeeesneeeaees 8 5 8 1 8 Replacing the Pump Cylinder O RingS eee eee eeeeeeeeeereees 8 5 TABLE OF CONTENTS 8 1 9 Re assemble the Pump Cylinder eeeeeeseeeesseeeeseeeenaees 8 5 8 1 10 Re assemble the Pump Case s sic 52 sseccsscnceessteaseceasecad tes catteees 8 6 8 2 Replacing the Drive Belts csiis iniisa neia 8 6 8 2 1 Removing the Pump Panels and Valve Assembly 8 7 8 2 2 Removing the Pump Cylinder eeeeeeeeeeeeseeeeesreerreerrsressesee 8 7 8 2 3 Inspecting the Drive Beltsi 24 045 nina pound 8 8 8 2 4 Replacing the Drive Belt ssc ccsadssavesapeeenes savestedanserecsdeunesecenanees 8 8 8 2 5 How to Re assemble the Pump Cylinder eee eeeeeeeeeee 8 10 8 2 6 How to Re assemble the Pump Case ceecceeeeeeeeeteeeeees 8 10 8 2 7 How to
38. is at Max Retract the cylinder direction has automatically been switched to Extend Go to step 7 If the pump cylinder is at Max Extend the cylinder direction has automatically been switched to Retract Restart the pump watching and listening for proper operation At the end of one piston stroke the pump should be at Max Retract If the pump is at Max Retract the cylinder direction has automatically been switched to Extend Go on to step 7 7 Reset the Cylinder Volume to zero To do this e PumpWorks e Click on Main Reset Volumes to Zero e Click on the Reset Cylinder button for the pump cylinder you are testing e Click on Send Resets to Pump s e Front Panel e Touch the Quizix Logo at the top left of the main window to access the menu e Touch the Reset Volumes button e Touch Yes to verify the reset Start the pump cylinder and time how long it takes for the pump cylinder to reach Max Extend Watch the Piston Position Display on the main window of PumpWorks and the Physical Piston Position Indicator on the pump s outer case to confirm that the piston is moving Listen for the sound of the pump cylinder running and then stopping Check to see if the piston is taking the proper amount of time for the piston stroke To figure out the correct amount of time for one piston stroke use the following formula Cylinder Volume ml Stroke time minutes Flow Rate ml per minute 4 7
39. new pumps when starting PumpWorks be sure all pumps to be installed are connected and turned on before starting PumpWorks Go to Start Programs and double left click on Quizix PumpWorks PumpWorks will automatically search for new pumps When Pump Works finds a new pump the following message will display QX Series found on Com 1 Expander Port A or B C or D Do you wish to install Click on Install 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 Main Pump Data amp Controls window will be showing You will know that your pump has been installed because e 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 e The pump data fields will contain numbers instead of question marks 3 10 2 User Search For New Pump This method is a good way to install anew pump onto an existing Pump Works system where PumpWorks is already running and the user does not wish to exit PumpWorks in order to perform an automatic search for new pumps It is assumed then that PumpWorks is already operating 1 Be sure the data link cable is connected from the new pump to a serial expander isolator
40. of a pump cylinder It is especially useful for displaying the conditions of the Q5000 and Q6000 models of pump cylinders which use mechanical switch sensors The QX Series does not use mechanical switches to control the end of a cylinder stroke and therefore does not display information in the Cylinder Status Window of Pump Works 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 event 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 Please refer to the PumpWorks User s Manual for more information about Error State Capture Mode 9 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 bar 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 o
41. 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 this is called a pull down menu pump body assembly pump controller pump cylinder pump housing quizix erl quartz transducer query quit option ramping operation rate scalers rate units recirculating recirculating mode recirculating parameters reconfigure GLOSSARY 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 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 syste
42. pressure transducer as it is extremely delicate 8 4 4 Replacing the Transducer O Ring Looking at the pressute transducer you will see an o ring Remove the transducer o ring and replace it sheer Figure 8 20 8 4 5 Reattaching the Transducer Assembly 1 Return the transducer assembly to the pump cylinder support block Using a 3mm hex wrench tighten the two M4 screws that hold the transducer assembly to the pump cylinder support block 2 Reconnectthe pressure transducer ribbon cable and swing the latches around the cable to secure it in place 8 4 6 Re assembling the Pump Case To re assemble the pump case please refer to Re assemble the Pump Case Section 8 1 10 Chapter 8 MAINTENANCE IMPORTANT INFORMATION Perform the Pump Checkout in Chapter 3 The Pump Checkout must be performed before operating your pump The Pump Checkout ensures that all cables have been reconnected properly and the pump is ready to operate 8 5 Calibrating the Pressure Transducers The pressure transducers on the QX Series Pump 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 transduc
43. pulleys two on the piston carriage and one at the pump cylinder support block e The drive belt should be fully on the holding post and neatly wrapped around the main drive drum e The drive belt should have no folds cracks or frays If you see any of the above symptoms replace the drive belt s before you run the pump again Drive belts normally need replacing every 3 years 8 2 4 Replacing the Drive Belt 1 Turn the pump horizontally with the drive belt you are going to replace facing up towards you 2 Push the drive belt down and towards the center of the pump while pulling the tension sensor arm away from the drive belt Figure 8 11 3 Be prepared for approximately 40 pounds of pressure when performing this step Grab the drive belt where it loops over the pump belt pin and pull it away from the pin There will be considerable tension on the belt GENTLY let out the tension Figure 8 12 belt pump Un loop these and unhook the belt from the capstan Figure 8 13 6 Take a new drive belt and hook it together under the capstan If you have hooked it correctly it can be pulled on without releasing 7 Wrap the belt around the capstan 3 times When winding the drive belt through the pump remember the same surface of the drive belt should be in contact with every pulley Be careful not to twist the drive belt 8 Feed the drive belt straight down and loop it around the inner piston carriage piston pulley
44. 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 a5 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 Set the pressure source to bring the pressure up to the desired level 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 to prevent faulty and malfunctioning transducers from being calibrated and giving the illusion of working Chapter 8 MAINTENANCE 8 6 How to Attach a Fitting to Your Tu
45. s ac gseni cesiets cestehenaes 1 1 Mod ls sccscccsesanvccsarewetanetersacctanseents 1 2 Primary Components 00 1 1 System Checkout cceeeeeeeees 4 1 Werehi aeina nii 1 1 Pump Controller Diagnostics 9 7 PumpWorks Advantages ssesseesseesseesserrsseeeseee 1 2 Basie Sii a a aa 5 1 9 1 CONNECUNG 3 r a e Gees 1 2 Error Messages sc c 2 s5ces eaean 9 2 PUMPWORKS BASICS 5 1 9 1 Q QX Series Installation Kit 0 0 0 0 3 1 QX Series Pump See PUMP o aaee tcc ae a 1 1 QX Series Spares Kit eee 3 2 QX Series Two Digit Display 3 11 9 6 Does Not Complete Its Initial Chec kaaita ee teal assets 9 6 Does Not Light lt cSsccccticionscateee 9 6 INDEX QX Two Digit Display Codes snari nisieiinness 9 8 R Replacing the Return Cable 8 10 RS 232 Cable See Cables S Safety Features sssesseeseeeseeeeseeesses 2 1 Overpressure Protection 2 1 Underpressure Protection 2 2 Screwdriver Phillips Head picture 8 2 Seals Changing icscisteseccaasscssdacdavesica eaves 8 1 Sensor Cable See Cables 4c Gea 2 1 Serial Communication cece 3 9 Software Updates cee eeeeeeeeeees 9 18 Supply Problems ccceeeeeeeeeeee 9 10 T The Two Digit Display When Pump is Tumed Oi nnee 3 11 Timing Belts Pict re ssseninicnurissiaiinss 8 6 Tooled nn en a a 8 2 TPANSQUCEE sninn 2 1 Cable See Cables O rings See O
46. solenoid If this doesn t work the pilot solenoid may have to be replaced so it does not constantly leak air 9 4 2 Fan Does Not Run The fan is temperature controlled When a pump is powered on the fan comes on for about 30 seconds after the pump controller test is completed The fan on the QX Series pump is controlled by a temperature sensor on the pump controller s board When the temperature exceeds a preset number the fan turns on When the temperature drops below a preset number the fan will turn off If the fan does not run when the pump is powered on look at the fan through the wire cage on the pump control panel and make sure the fan blades are not obstructed by some foreign object You can also check the fan power connection to the controller PC board which is inside the pump case on the pump control panel 9 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 9 4 3 1 e Leak Testing Section 9 4 3 2 e Does Your Pump Have a Fluid Leak Section 9 4 3 3 e Finding Your Leak Section 9 4 3 4 9 4 3 1 Leakage Basics The QX Series 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
47. stops or has a surge of power G 19 Chandler Engineering QX SERIES PUMP USER MANUAL unresolved vacuum grease valve valve assembly valve cable valve cable extension voltage setting volume voltage setting G 20 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 A Adding a QX Series Pump to An Existing PumpWorks Syste 3 10 Pat Eeak rinsing 4 10 Air Supply Problems eee 9 10 Air Supply Requirements 3 3 9 17 Automatic Search For New Pumps 3 13 B Belts Drive See Drive Belts 00000 8 8 Belts Drive nnana anans 8 6 Buffer Overrun Error ccccee 9 4 C Cable Cable Connection Se
48. the correct polarity and power specifications If the AC lines are wired incorrectly hazardous voltage may be present on the QX Series pump case with respect to the computer or other devices even though the QX Series Pump may still operate properly because it is electrically isolated AC main wiring and proper grounding can easily be checked with a voltage meter 7 4 Replacing a Fuse If a fuse blows in the QX Series Pump follow the instructions below 1 Turn the switch on the power entry module to the OFF position 2 Unplug the QX Series Pump and the data connection to the computer 3 The fuse holder is located on the power entry module below the ON OFF switch Gently pop out the fuse holder by pressing in the tabs located on both sides of the fuse holder Chapter 7 SYSTEM POWER Inspect and replace any bad fuses with a 2 Amp Slow Blow 5 x 20mm fuse Insert the fuse holder back into the power entry module Ensure that is snaps into place on both sides Replace the power cord and the data connection to the computer Turn the switch on the power entry module to the ON position 7 3 Chandler Engineering QX SERIES PUMP USER MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 7 4 Chapter 8 MAINTENANCE QX Series Pump is designed to need very little maintenance Because your pump contains parts that are permanently lubricated and sealed it never needs to be greased or lubricated Inspect and calibrate your pump every
49. wash area collar Put the cylinder bracket back on the cylinder barrel It will fit into a grove on the cylinder barrel Chandler Engineering QX SERIES PUMP USER MANUAL 4 Hold the cylinder barrel with attached cylinder bracket with one hand and the piston with the other hand while insert the pump cylinder into the pump Holding the pump cylinder use a 4 mm hex wrench to tighten the two 2 M5 12 screws located on the piston carriage Push up on the pump cylinder as you are doing the final tightening of the cylinder bracket These screws hold the piston in place and should be hand tightened 5 With your fingers push the piston down into the piston carriage 6 Next replace the piston carriage holder With a 4 mm hex wrench replace the two 2 M5 25 screws which hold the piston carriage holder to the pump Tighten securely 7 Reconnect the pressure transducer ribbon cable and swing the latches around the cable to secure the cable in place 8 Using a3 mm hex wrench tighten the two 2 screws holding the valve fluid tee to the top of the cylinder barrel 9 For those with a wash area reconnect the wash area tubes by pushing each tube into a quick release valve 8 1 10 Re assemble the Pump Case Using a phillips head screwdriver replace the six 6 screws that hold each pump side case Two 2 screws are located in the front of the pump and four 4 are located on the side of the pump IMPORTANT INFORMATION Perform the
50. 100 psi 4 5 Valve and Pilot Solenoid Check 9 18 Valve Cable Connection Check 9 17 Valve Leaks Fluid When Closed 9 18 Valve Problems accra cccdecancscntens 9 17 Volume Cylinder Volume ou eee 4 8 Stroke Volume eee 1 3 4 8 W Warning Opening Both Fill amp Deliver Valye Se nesan e a Ea 4 4 Valve Warning Messages 4 4 Valve With Pressure Above LOO DSi esesescdiseecaeenssccestesenssecenens 4 5
51. 12 months for optimum performance A few components of the pump will need to be replaced on an as needed basis The following information is included in this chapter e Changing the Pump Cylinder Seals Section 8 1 e Replacing the Drive Belts Section 8 2 e Replacing the Return Cable Section 8 3 e Changing the Transducer O Rings Section 8 4 e Calibrating the Pressure Transducers Section 8 5 e How to Attach a Fitting to Your Tubing Section 8 6 e Bearings amp Motor Section 8 7 e Valve Maintenance Section 8 8 8 1 Changing the Pump Cylinder Seals Each pump cylinder has one seal in it The seals should be changed as needed A sure sign that the seals need to be changed is fluid leaking out from your pump For more information on determining if your pump has a leak go to Chapter 9 Fluid Leaks Section 9 4 3 The following step by step guide will show you how to change the seals for one pump cylinder and is separated into the following sections Note if changing seals in both pump cylinders repeat the procedure for the second pump cylinder When changing the cylinder seals in one pump cylinder it is recommended that you also change the cylinder seals in the other pump cylinder e Tools You Will Need Section 8 1 1 e Removing the Pump Case Section 8 1 2 e Removing the Pump Cylinder Section 8 1 3 e Inspecting the Piston and Piston Holder Section 8 1 4 e Disassemble and Inspect the Cylinder Barrel Section 8 1 5 e Replacing t
52. A 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 See PumpWorks User Manual for a complete list of possible errors that can be generated by PumpWorks 9 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 limit area use Independent Constant Rate mode 9 2 2 2 Communication Errors In order for PumpWorks to control a user s pump syst
53. A and B Figure 6 1 6 1 1 Start Stop Buttons The start stop buttons are located directly under the Cylinder A and Cylinder B labels The text and color of these buttons depends on the state of the cylinder If the safety pressure for the pump cylinder has not been set and there are no other errors associated with the pump cylinder this button will be red and will say Set Safety Pres Pressing this button will take you to a keypad to enter a new safety pressure as described in Section 6 2 1 If there are errors associated with the pump cylinder the start stop button will be red and will say Error Pressing on this button will open the Error Status window showing the status of various errors associated with the pump cylinder as described in Section 6 2 4 6 1 Chandler Engineering QX SERIES PUMP USER MANUAL If there are no errors associated with the pump cylinder and the pump cylinder is stopped the button will read Push to Start and the button can be pressed to start the pump cylinder When this button is pressed a confirmation window will appear as show in Figure 6 2 The window shows the valve status and the current safety pressure The valve states can be changed by pressing the appropriate valve button and confirming the change The safety pressure can also be changed by pressing the safety pressure button and entering the new safety pressure with the keypad window When everything is set to the
54. X Series Pump User s Manual Chandler Engineering Company L L C P O Box 470710 Tulsa Oklahoma 74147 0710 U S A Phone 918 250 7200 Fax 918 459 0165 E mail chandler chandlereng com Website http www chandlereng com Copyright 2003 by Chandler Engineering Company L L C All rights reserved Reproduction or use of contents in any manner is prohibited without express permission from Chandler Engineering Company L L C While every precaution has been taken in the preparation of this manual the publisher assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained herein CHANDLER wm AMETEK ENGINEERING PumpWorks Version 6 10 TABLE OF CONTENTS CHAPTER 1 GENERAL OVERVIEW scccscscssosessconserssesorsatsonsennsensensconersscsanrenseonse 1 1 1 1 Primary Components of the QX Series Pump ceeeeeeeseeeesteeees 1 1 1 2 SAG YW Connect saneren a a AT 1 2 1 3 The PumpWorks Advantage cccssscccssscecsecceessccesssccesssceeeeseees 1 2 1 EO Senes P mp Models deen tupede de tenes nueva eoesoinaale 1 2 1 5 Operating ond lone sisie es teal en ae beanies 1 3 1 6 Shipping and Storage Environment 00 0 0 ee eeeeeeeeeeseeeeeeeeeeeseeeenees 1 3 1 7 Approvals Certifications asieszctcatc canta ceiisl eceuietndiet ectapracenaieeeds 1 3 1 8 Symbols Used on Equipment 200 000 eeeccecesececseececeeeeecseeeecnteeeeseees 1
55. 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 This includes the seal seal back up ring and the seal retaining nut seal retaining nut seal support ring sequencer serial port or serial communications port servo servo extend servo retract set direction set pressure set flow rate side rails slope soft limit switch software GLOSSARY 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 A programming language available in the PumpWorks software to set up and automatically control complex pump operations 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 con
56. a source of electrical interference e Input Error Input errors are due to a bad command being received by the pump Noisy communication lines are normally the cause of this type of error If an 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 PumpWorks or by getting a faster computer When Pump Works receives no response it automatically retries and corrects for any dropped communications 9 2 2 3 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 linear motion sensor which is mounted on each piston carriage of a pump cylinder This can be caused by a motor stall faulty gear box broken or mis wrapped carriage drive belt or a faulty linear motion sensor To check these conditions start the pump cylinder and watch the physical piston position indicator on the pump s case If the piston does not move when it is supposed to the user will need to open the pump case and check that the motor is rotating and the drive belts are correctly positioned Please refer to Chapter 8 Replacing the Drive Belts Section 8 2 for information about drive belt inspection Please refer to Piston Motion Errors
57. alibrated and giving the illusion of working 8 21 Chandler Engineering QX SERIES PUMP USER MANUAL 8 22 8 5 2 2 Calibrated Pressure Source 1 As shown in the Calibration Setup Diagram in Figure 8 19 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 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 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
58. assembly away from the pump IMPORTANT INFORMATION QX Series pistons are made of ceramic and may break if dropped Please handle with care 8 3 Chandler Engineering QX SERIES PUMP USER MANUAL 8 4 The cylinder barrel and piston assembly can now be moved to a sink or other appropriate cleaning facility Remove the piston from the cylinder barrel by gently pulling it out of the cylinder barrel and setting it aside Note that some fluid may be left inside the cylinder barrel and will drip out 8 1 4 Inspecting the Piston and Piston Holder It is important that you inspect your piston for scratches or deposits Pumping fluids that contain abrasive particles can cause scratches to the piston 1 8 1 5 Disassemble and Inspect the Cylinder First take a clean soft cloth or paper towel and wipe the piston This is to remove any film or residue that remains Look at the piston It should be smooth with no scratches or indentations on the piston An intermittent leak can be caused by a scratch on the piston If your piston has been severely scratched you may need to order a new piston If something has become stuck to the piston it will need to be removed The QX Series Pump piston is made of a ceramic material Anything that contains silicon carbide boron nitride or diamond based abrasives can scratch the piston and should not be used to clean it Do not use sand paper on the piston This can scratch it You can use steel wool
59. at the fill and deliver valves are operating properly by performing the Chapter 4 Valve and Pilot Solenoid Auditory Check Section 4 3 1 e Check that the air pressure for the valves is between 60 and 115 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 e Remove the pump case and verify the piston is attached to the piston carriage Please refer to Chapter 8 Removing the Pump Case Section 8 1 2 for instructions on removing the valve assembly and pump case 9 4 5 Piston Motion Errors In most cases piston motion problems will cause Pump Works to report a piston motion error such as Motor running No Motion Detected error Please refer to Section 9 2 2 3 Ifa motion error occurs the user needs to determine if the piston is actually moving or not This is done by looking at the physical piston position visible through the windows on the pump case The following piston movement errors will be discussed in this section e Motor Stall Error Section 9 4 5 1 e Piston Moves But Does Not Complete Its Stroke Section 9 4 5 2 e Physical Piston Position Indicator Does Not Move When Pump Cylinder Is Operating Section 9 4 5 3 Chapter 9 QX SERIES PUMP OPERATING BASICS 9 4 5 1 Motor Stall Error A motor stall error occurs when the power needed to move the piston exceeds what is
60. ay lt I Segments 7 i 4 Right Hand a masa Digit Let ho Pana i Decimal Points Digit Figure 3 12 Ist 2nd 3rd 4th Sth 6th 7th Figure 3 13 3 9 3 2 Pump Controller Software Diagnostics The controller diagnostics are performed next This time the left hand digit will light and 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 then 8 As each number lights itis a confirmation that a pump controller software function is operating correctly Each number will flash quickly In the final step do will flash alternately with O The do stands for digital overpressure You will be instructed how to reset the safety pressure in Chapter 4 The O means the pump has not yet been assigned a pump number by Pump Works This will be done in Section 3 10 If your pump follows the above described steps it has been successfully turned on and passed the internal start up diagnostic checks If however your pump stops at one of the steps go to Chapter 9 Section 9 3 QX Series Two Digit Display for help in diagnosing the problem 3 10 Installing A Pump Onto PumpWorks There are two methods for installing your new pump onto PumpWorks We will describe both below We recommend the first method Automatic Search For New Pumps Chapter 3 SYSTEM SETUP 3 10 1 Automatic Search For New Pumps 1 To automatically search for
61. bing NOTE To keep dust out of the fluid plumbing a red plastic plug has been inserted in the open hole of the fluid inlet and the fluid outlet Remove and discard these two red plastic plugs before operating the pump 1 The tube s outside diameter must be 1 8 125 001 3 mm tubing WILL NOT work Cut tubing Allow an extra 1 2 12 mm in length for proper fitting engagement After cutting the tube deburr get off any sharp edges or corners from the tube before installing the gland and sleeve Use air or fluid to clean the tubing inside and out to remove any particles left over from cutting 2 Lubricate male threads Lubrication is not necessary if tube nut has Bonded Dry Film Lubricant Slip gland and sleeve onto tubing Make sure larger end of sleeve is toward gland Push tubing into valve or fitting until it bottoms If your usage will permit it a slight amount of inert grease on the nose of the compressions sleeve will improve sealability 3 Tighten gland until sleeve begins to grip tubing 4 Note starting position of wrench Tighten gland approximately 1 1 4 turns for the speedbite type connection 8 6 1 Completed Connection Note the condition of the sleeve and tubing after completion of sleeve seating The sleeve has cut into the tubing as it moved forward into the tapered seat upsetting material ahead of it and establishing a shoulder on the tubing to provide positive mechanical support for the tubing
62. ble 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 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 continuo
63. c level high 5 volts stops pump Logic level low ground starts pump This feature must be enabled through PumpWorks first Please refer to PumpWorks User Manual Section 12 Configure Menu Controller Setup e Remote Rate Control A 4 20mA signal through pins 10 and 11 can control the rate of the QX Series pump A 4mA level corresponds to a setting of 0 0 ml min A 20mA level corresponds to the maximum rate set point available for the pump There is a linear mapping of current to rate setpoint This feature must be enabled through PumpWorks first Please refer to PumpWorks User Manual Controller Setup under the Configuration Menu 10 8 Connector Pinouts The user interface connector is a standard 25 pin DB type female connector Wiring of the user interface connector is as follows PIN NUMBER FUNCTION 1 Valve control line 1 for external valves sink current to ground 2 Valve control line 2 for external valves sink current to ground 3 Valve control line 3 for external valves sink current to ground 10 3 Chandler Engineering QX SERIES PUMP USER MANUAL 10 4 4 Valve control line 4 for external valves sink current to ground 5 Valve control line 5 for external valves sink current to ground 6 Valve control line 6 for external valves sink current to ground 7 Valve control line 7 for external valves sink current to ground 8 Valve control line 8 for
64. cation Status After a few seconds the COM Port Selection for Communication Status window appears Click on the COM port number that your pump is connected on 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 e Check that the data link cable is plugged into Data Link on the pump control panel and NOT into Front Panel e Try plugging pump 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 If the serial expander isolator is NOT present and you are using a serial COM port 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 9 2 2 2 2 Once Communications Has Been Established Once communications is established between PumpWorks and the pump the following communication errors may be reported in the error log These errors are automatically compensated for by PumpWorks which notes the error and then resends the command
65. 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 8 20 4 5 Chapter 8 MAINTENANCE 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 obtain a more accurate calibration 6 For the pump cylinder
66. d Filling the Pump With Fluid ee eeeeeeeeee 4 8 4 6 Pressure Transducer Check icc scssacesseed ealeon dat ccna Sense Avessesd uel stadt 4 10 PUMBWORKS BASICS oiii hoa caudal aug iets eee ate tae 5 1 FRONT PANEL OPERATION ceinetan tual 6 1 6 1 Front Panel Main Window 2ccutse eases arate thease gas len danketeae tance 6 1 6 1 1 Start Stop Buttons yescicesacesscanaesascatgeasserstpeoansestonewenceteactiquaseastes 6 1 6 1 2 Motion Status seriis e T ETE ERa 6 2 GAAS Pressure ma a A OCU LE REO Ne A ERRA 6 3 6 1 A Rate ienna he eed einen 6 3 GMCS VOI ear de cate A E se ton E opnati amen dade 6 3 6 1 6 Set Rate and Set Pressure 20 2 20eck hein Gewese 6 3 6 1 7 Operating MOGs sacs ses cusss ab ecsesdedeccaeaaseus i 6 4 6 1 8 Piston Dinectoneas ice a ACEO Eee ea 6 5 62 Front Pawel Ment nnr uc crs oasmedd voaceas camels tite epee tease tamadas 6 6 6 2 1 Sabety Pressure sic iscscisaspsenctsdunctensesysdsanvennceatesenveslonpansenesanceanen 6 6 0 2 2 Valves oc a Se BA ea ae 6 6 0 2 3 Reset Volumes sau oe eee e eit enue de ai 6 7 62 A COMM BUTS xs cacnssd shaszadetaten stan tuadsteiates tet ea o i lessees iene 6 7 0 2 Syste ETOT S 40 2502 aa cats ta seasons be stonse auaeta a a i N 6 7 6 2 6 Exit ProgtaM isserrat era E A REE EA T 6 8 6 2 7 Cane lisse ia asc ianc isisi E R R E eed 6 8 6 3 Front Panel Configure Window ssaicl pia Aoieasenedinie ceases 6 8 6 3 1 Transducer Calibration eeseseeeseeeeeseeeresressrsresessresserrresreseeee 6 9 6 3 1
67. dler Engineering QX SERIES PUMP USER MANUAL operating mode window operating perameter setup window paired constant delta pressure delivery paired constant delta pressure receive paired constant pressure bidirectional paired constant pressure delivery paired constant pressure receive paired constant rate delivery paired constant rate receive paired cylinder operating mode This PumpWorks software window 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 selected value To accomplish this the fluid delivery rate of the active pump cylinder will change as needed
68. dscaicoamadesisoadnet sarees ta voccalan feaatitee 9 11 DAS Leake VCS HS sonsedos cos E A O E 9 12 9 4 3 3 Does Your Pump Have a Fluid Leak ee 9 12 9 4 3 4 Finding Your Leak 3 pcstetcnsanadintun hanes 9 13 9 4 4 No Fluid Is Being Delivered ss nsonnesonsesssesssssessserrsseressees 9 13 9 4 5 Piston Motion ETTOTS ssesseeeeseseesesessseseresressesrrrsresseserssressesees 9 14 9 4 5 1 Motor Stall Erot zcoin airiai 9 15 9 4 5 2 Piston Moves But Does Not Complete Its Stroke 9 15 9 4 5 3 Physical Piston Position Indicator Does Not Move When Pump Cylinder Is Operating 9 15 94O Pressure Problems sahicaeay er touss ER 9 16 9 4 6 1 Pressure Transducer Errors ceeeeseeseeeseeeeeeeees 9 16 9 4 6 2 Pressure Does Not Increase Within 30 Seconds 9 16 TABLE OF CONTENTS 9 4 6 3 Pressure Overshoots Setting in Constant Pressure Mode weticoc aie eee tele ioe cadets 9 16 9 4 6 4 Pressure Is Not Constant in Constant Pressure Mode sinsero taser 9 17 9AT Valve Problems en mn en eee 9 17 9 4 7 1 Valve Cable Connection Check eeeeeeeeeeeeeeee 9 17 9 4 7 2 Checking Your Air Supply ssssssssessesssessseressresssesse 9 17 9 4 7 3 Air Supply Requirements sssessesssesssesessseessresessseee 9 17 9 4 7 4 Checking Your Air Supply Connection 0 9 18 9 4 7 5 Valve and Pilot Solenoid Check eese 9 18 9 4 7 6 Clogged Obstructed Valve ooo eeeeeeeeereeeseeeeeeees 9 18 9 4 7 7 Valve Leaks
69. e motion Take into account the flow rate units either ml hour or ml minute e Remove the pump s outer case Please refer to Chapter 8 Removing the Pump Case Section 8 1 2 for instructions e Check that the motor is turning for the pump cylinder that is operating e Check to see that the carriage drive belt is on the holding post and neatly wrapped around the main drive drum Refer to Chapter 8 Replacing the Drive Belts Section 8 2 for instructions 9 15 Chandler Engineering QX SERIES PUMP USER MANUAL 9 16 e Check that the piston is securely held in place by the 2 screws and clamp located on the piston carriage To tighten the set screws use a 3 mm hex wrench 9 4 6 Pressure Problems The pressure transducers on the QX Series pump 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 9 4 6 1 Pressure Transducer Errors If the pump reports a pressure transducer cable error this means that the cable from the pump controller to the transducer is no longer connected properly and needs to be fixed To correct this problem do the following e Open the pump case Refer to Chapter 8 Removing the Pump Case Section 8 1 2 for instructions e The transducer cable must be inserted into the connector on the transducer printed circuit board e Check if the cable has bee
70. e cylinder direction to Extend This is because if the piston is already at its maximum retracted position it can go no further in that direction and can only go in the opposite direction which is extend 5 Set the fill valve to open so the air or liquid displaced will not build up pressure The deliver valve may also be opened To do this e PumpWorks e Look at the fill valve button and the deliver valve button on the main window and verify that they say open e Ifthe valve button s says closed click on it to open and then click Yes to verify e Front Panel e Touch the Quizix Logo at the top left of the main window to access the menu e Touch the Valves button Look at the fill valve button and the deliver valve button on the valve window and verify that they say open 4 6 Chapter 4 SYSTEM CHECKOUT e Ifthe valve button s says closed touch it to open and then touch the Yes button to verify 6 Start pump cylinder A by clicking on the Press to Start button Watch and listen for proper operation Watch the Piston Position display on the monitor It should show that the piston is moving Listen for the sound of the pump cylinder running and then stopping This is a low level sound which can be heard if you are in a quiet work area When the piston reaches the end of its stroke it automatically stops and displays either Max Retract or Max Extend in the Motion Status box If the pump cylinder
71. e update files will be QX followed by the software version number followed by the qfp file extension or qf2 file extension for newer model front panels The progress status will initially show Front Panel Not Ready For Code Update Up to this point the user may still cancel the update by clicking on the cancel button Once the actual update has started the user will no longer be able to stop the update before it has completed To start the actual software update the user must now perform the following actions on the front panel From the main front panel window touch the Quizix logo in the upper left corner to access the main menu Touch the configure button Touch the Update Software button The Front Panel Software version is displayed along with a warning message and Yes and No buttons as shown in Figure 6 16 below Chapter 6 OPERATING YOUR FRONT PANEL Figure 6 16 e Press the Yes button to continue the software update procedure Press the No button to cancel it e If the Yes button is pressed the window shown in Figure 6 17 is displayed and the software update will proceed The software update percentage completed is displayed both on the Front Panel and in the PumpWorks software Figure 6 17 When the software update is completed the updated software will be written to flash memory and the Front Panel Software will be re started NOTE Do not remove power from the Fron
72. earings which hold the ball screw in place but allow it to rotate Capable of operating in two directions or to go back and forth 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 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 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 G 3 Chandler Engineering QX SERIES PUMP USER MANUAL color coded communications port component Com port compression ring concave configuration Constant Delta Pressure Mode Constant Pressure Mode Constant Rate Mode continuous flow pumping convex G 4 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 ca
73. ecorded 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 Chandler Engineering The user can change the default names at any time The unit of measure for the default pressure is PSI or pounds per square inch G 5 Chandler Engineering QX SERIES PUMP USER MANUAL 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 driver driver fan driver fuse G 6 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
74. ee assemblies are different and are marked on the underside of the assembly 14 Once the fusee assembly has been replaced the new return cable can be attached to the spring clamp and wrapped around the fusee before reinstalling the spring boxes 15 You may want to temporarily tape the loose end of the return cable to the spring box to ensure that the cable stays wrapped on the fusee when the spring box is reinstalled 8 4 Changing the Transducer O Rings The transducer o rings may need to be changed every 3 years Signs that it is time to change an o ring are as follows e fluid leaks around transducer e hard e cracked or broken e material flaking off Chandler Engineering QX SERIES PUMP USER MANUAL The following sections will provide instructions for changing the transducer o rings 8 4 1 Removing the Pump Case To replace the transducer o rings you will need to remove the pump side case Please follow the directions for Removing the Pump Case Section 8 1 2 8 4 2 Disconnecting the Transducer Ribbon Cable Disconnect the pressure transducer ribbon cable by pushing the ejector latches outward The transducer ribbon cable will easily disconnect 8 4 3 Removing the Transducer Assembly pressure transducer ribbon cable To remove the pressure transducer assembly remove the two screws located on the sides of the pressure transducer assembly Pereey Figure 8 17 NOTE Do NOT touch the pressure diaphragm of the
75. eee eeesceeseceeeteeeenteeeeneeeees 3 4 3 4 1 Fluid Inlet Connections lt avites ek ee ee es 3 4 3 4 2 Fluid Outlet Omnme Cums s2c2susscetial cntcontececebictoncteyictanetancnei 3 5 Chandler Engineering QX SERIES PUMP USER MANUAL CHAPTER 4 3 5 Connecting amp Operating Optional Wash Area eeeeeeeeeeeeeeeeeees 3 5 3 6 Connecting Your Power Source 2 0 6 2 ccackcadenssceasvecdeansdebanttavendocassecss 3 6 3 6 1 Uninterruptable Power Supplies UPS 0 0 eee eeeeeeeeteeeeees 3 7 3 7 Connecting to a Computer or Front Panel 0 e eee eeeeeeeeeeeeeeeeeeees 3 7 3 7 1 Connecting a Front Panel siico3cetviluse de uecce ves ue cade elena deeitess 3 7 3 7 2 Connecting Your QX Series to a Compute eee 3 9 3 7 2 1 Serial Communication sicciesritsosize Mesiawsteaielecacaed 3 9 3 7 2 2 USB Communication ssseeseseeeseseesseerrerrrsressereresresse 3 9 3 7 3 Adding a QX Series Pump to An Existing PumpWorks System 3 10 3 8 Installing PumpWorks Software ssssesssseeesseessesseseseeessresseesseessees 3 10 3 8 1 How To Install Pump WOrks ssseseeeeeeeeeseeeeeseesrseresresseseresresss 3 10 29 urine On our PUMP rra e e E TE ea 3 10 3 9 1 QX Series Two Digit Display ce eecceessceeeteceeeteeeneeees 3 11 3 9 2 How to Turn On Your PUuMp eee eeecceesseceesteeeeneeeenneeees 3 11 3 9 3 The Two Digit Display When Pump is Turned On 3 11 3 9 3 1 Pump Controller Hardware Diagnostics 3 11 3 9 3
76. em communication needs to be established between the user s computer and pump s The following communication errors are covered in the following sections e Communication Cannot Be Established Section 9 2 2 2 1 e Once Communications Has Been Established Section 9 2 2 2 2 9 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 located on the pump s control panel There is a right digit decimal point which is located to the right hand side of the right digit There is 9 3 Chandler Engineering QX SERIES PUMP USER MANUAL 9 4 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 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 Next check that the computer is properly connected to your pump To do this perform the Pump Works Connection Check found in Chapter 4 PumpWorks Connection Check Section 4 2 4 Go to PumpWorks main window From the menu bar select Communications View Communi
77. end load A properly seated sleeve cannot be displaced back and forth along the tubing but may be rotated slightly around the tubing 8 6 2 Re assembly Reassemble a connection by inserting tubing with attached sleeve and gland into valve or fitting Tighten gland finger tight Tighten gland with a wrench approximately 3 8 of a turn for a gas tight seal After frequent reassembles it may take less than 3 8 turn to effect a gas tight seal and as little as 1 8 of a turn may be sufficient DO NOT OVERTIGHTEN Overtightening will deform the sleeve and degrade the sealing ability of the fitting 8 7 Bearings amp Motor The bearings and motor in the QX Series Pump need no greasing or lubrication during the life of the QX Series pump The bearings and motor are designed so that no maintenance is necessary 8 23 Chandler Engineering QX SERIES PUMP USER MANUAL 8 8 Valve Maintenance No user maintenance required for the QX Series Pump valves 8 9 Cleaning Clean exterior surfaces of the QX series pump as required using mild soap and water Dry all surfaces thoroughly and do not expose the internal electrical components of this instrument to water 8 24 Chapter 9 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 9 1 e PumpWorks Error Messages Section 9 2 e QX Series Two Digit D
78. er remove the six 6 screws that hold each pump side case Two 2 screws are located in the front of the pump and four 4 are located on the side of the pump Remove the pump s side case and set aside Figure 8 2 Chapter 8 MAINTENANCE 8 1 3 Removing the Pump Cylinder 1 Disconnect the pressure transducer ribbon cable by pushing the two latches away from the cable 2 Using a3 mm hex wrench remove the two screws holding the valve fluid tee to the top of the cylinder barrel Figure 8 4 3 The piston carriage is a black metal part that guides the piston It is located below the cylinder barrel The piston carriage holds the piston and moves up and down with the cylinder barrel 4 Using a4 mm hex wrench remove two screws from the piston carriage holder Remove the piston carriage holder and set aside This allows the piston to be moved 5 For those with a wash area remove the wash area tubes by pushing the quick release valve and pulling the tube out Remove both wash area tubes Figure 8 5 6 When removing the cylinder barrel and piston assembly some fluid may be pushed out from the top of the cylinder barrel 7 The cylinder bracket holds the pump cylinder and is located above the pressure transducer assembly Using a 4 mm hex wrench remove the two screws holding the cylinder bracket Hold the pump cylinder with one hand while removing the cylinder bracket Gently lift the cylinder barrel and piston
79. er before starting the pump cylinder Refer toValves Section 6 2 2 6 1 8 Piston Direction The Piston Direction buttons show the direction that the pump cylinder pistons are moving or if the pump cylinder is stopped the direction that the piston will move when the pump cylinder is started Pressing the piston direction button brings up a window which allows the piston direction to be changed See Figure 6 7 Chandler Engineering QX SERIES PUMP USER MANUAL If the pump cylinder is running when the Piston Direction is pressed a warning message will be displayed explaining that the pump must be stopped before the piston direction can be changed Figure 6 7 6 2 Front Panel Menu The Front Panel Menu is accessed by pressing the Quizix logo on the top left corner of the main window Figure 6 8 will appear The Front Panel Menu has buttons for the following functions which are described in the sections below Safety Pressure Valves Reset Volumes Exit Program System Errors Configure and Cancel Figure 6 8 6 2 1 Safety Pressure The pump s safety pressure must be set before running the pump The safety pressure setpoint is the pressure at which any running pump cylinders will be automatically stopped To set the safety pressure press the Safety Pressure button and a keypad window will appear which will allow the user to set the safety pressure 6 2 2 Valves Each pump cylinder is connected to two valves a fill valve a
80. ers on the two pump cylinders reading the correct pressure The QX Series controller uses these pressures to match the standby pump cylinder s pressure to the delivery pump cylinder s pressure to eliminate pressure variations at switchover If the two pressure transducers are not matched to each other then 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 transducers connect pump cylinders together and record the pressure of both pressure transducers over the pressure range of interest 8 5 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 QX Series Pump 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 QX Series pump these variations are compensated for in the controller software The process of adjusting the offset and gain compensation values is called calibration 8 5 2 Methods of Calibrat
81. external valves sink current to ground 9 Ground for 5 volt and 24 volt supplies 10 Ground for 5 volt and 24 volt supplies 11 Controller Revision B and earlier Ground for 5 volt and 24 volt supplies Controller Revision D and later Current Loop In 12 Controller Revision B and earlier 5 volt power for logic signals or sensors Controller Revision D and later Current Loop Out 13 5 volt power for logic signals or sensors 14 24 volt power for valves or sensors 15 24 volt power for valves or sensors 16 24 volt power for valves or sensors 17 24 volt power for valves or sensors 18 Digital logic output line 1 for logic control 19 Digital logic output line 2 for logic control 20 Digital logic input line 1 for logic sensing 21 Digital logic input line 2 for logic sensing 22 Input for emergency pump stop 23 Analog input to A D converter channel 1 24 Analog input to A D converter channel 2 25 5 volt power for logic signals or sensors Appendix A Appendix A EU Declaration of Conformity A Declaration of Conformity is found on the following page ANMETEK ENG NDL N G Declaration of Conformity Manufacturers Name Ametek Chandler Engineering Manufacturer s Address 2001 North Indianwood Avenue Broken Arrow OK 74012 Declares thai the product Product Names Quizix QX Series Pump Systems and Serial communications Expander lsolator Conform to the following standards EMC Compliance ANSI C63 4 Class A FCC 47 CFR
82. f all errors present and past that have been detected by PumpWorks up to a maximum file size set by the user Some errors are immediate errors and some are logged errors which we will discuss in the following sections 9 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 window with an error message 9 2 Chapter 9 QX SERIES PUMP OPERATING BASICS 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 9 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 window The status bar of the PumpWorks main window displays Error Present or Check Error Log 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 1
83. f pressure units are in psi or 700 if pressure units are in kPa and then touch the Enter button 2 Set the Flow Rate at approximately 25 of the maximum allowable flow rate The maximum pump cylinder flow rate is displayed in the Set Flow Rate box of the main window At the rate shown a full piston stroke takes about one minute To change the Flow Rate 4 5 Chandler Engineering QX SERIES PUMP USER MANUAL e PumpWorks e From the menu bar select Main Set Pump Flow Rates e Inthe Enter New Flow Rate text box enter 100 ml min for the QX 500 or 50 ml min for the QX 1500 or 10 ml min for the QX 6000 2 ml min for the QX 20K e Click on Send Rates to Pump s e Front Panel e Touch the Set Rate button e Using the numbers on the keypad enter the appropriate rate and then touch the Enter button 100 ml min for the QX 500 or 50 ml min for the QX 1500 or 10 ml min for the QX 6000 2 ml min for the QX 20K 3 Set the Operating Mode to Mode 1 for pump cylinder A which is Independent Constant Rate To set the operating mode e Click on the Operating Mode button in the main window and a list of operating modes will appear e Click on Independent Constant Rate Operation mode number 1 4 Set the direction to Retract for each pump cylinder To do this e Click on the Cylinder Direction button on the main window However if the piston position reading is at Max Retract as shown in the Motion Status box set th
84. f the pressure transducers is important for optimum operation in paired modes where the inter operation of the pump cylinders require matching pressure values for pulse free operation The following window Figure 6 12 is displayed when the Transducer Calibration button is pressed Figure 6 12 6 3 1 1 Current Pressure The current pressure of Cylinder A and Cylinder B are displayed Chandler Engineering QX SERIES PUMP USER MANUAL 6 10 6 3 1 2 Current Offset The Current Offset buttons display the pressure transducer offset values If one of the Current Offset buttons is pressed the Pressure Transducer Offset window for that pump cylinder will be displayed as shown in Figure 6 13 Figure 6 13 The Pressure Transducer Offset window allows the user to set the pressure transducer offset for Cylinders A or B The pressure transducer offset can either be set manually using the Enter New Offset button or automatically using the AutoZero Pressure button NOTE Make sure that the pump cylinder that is displayed in the window title is open to atmospheric pressure before using the AutoZero function For example the fill or deliver valve that connects the pump cylinder to atmospheric pressure is open 6 3 1 2 1 Current Pressure The current pressure transducer reading of the specified pump cylinder is shown here 6 3 1 2 2 AutoZero Pressure Pressing this button will automatically adjust the offset value so that the pressure value
85. for the specified pump cylinder reads zero As noted above make sure that the pump cylinder is open to atmospheric pressure before using this function 6 3 1 2 3 Minimum Offset Minimum Offset is the lowest allowable entry for pressure offset 6 3 1 2 4 Maximum Offset The maximum offset is the highest allowable entry for pressure offset 6 3 1 2 5 Current Offset The current offset is the current pressure offset for the specified pump cylinder 6 3 1 2 6 Enter New Offset Pressing the Enter New Offset button will bring up the keypad window and allow the user to enter a new pressure offset value Chapter 6 OPERATING YOUR FRONT PANEL 6 3 1 2 7 Close Pressing the Enter New Offset button will bring up the keypad window and allow the user to enter a new pressure offset value 6 3 1 3 Current Gain The Current Gain buttons display the pressure transducer gain values The gain values are available for reference only and are not set by the user 6 3 1 4 Cancel The Cancel button closes the current window and returns the user to the main window 6 3 2 Update Software The Front Panel Software can be updated using the Quizix PumpWorks software Use the following procedure to update the Front Panel software e Make sure the pumps pump controllers you wish to update are powered on and communicating but pump cylinders are not running ramping under auto volume control or in recirculating mode In addition ensure that PumpWorks is not currentl
86. he Pump Cylinder Seal Section 8 1 6 e Replacing the Wash Area Seals Section 8 1 7 e Replacing the Pump Cylinder O Rings Section 8 1 8 e Re assemble the Pump Cylinder Section 8 1 9 Chandler Engineering QX SERIES PUMP USER MANUAL e Re assemble the Pump Case Section 8 1 10 8 1 1 Tools You Will Need You will need the following tools to change the seals e 3mm hex wrench e 4mm hex wrench e Phillips head screwdriver 8 1 2 Removing the Pump Case Before beginning It is best to pump the fluid out of the pump cylinders 1 The pistons for both pump cylinders need to be between Max Retract and 1 cm 1 2 inch away from Max Extend The preferred position is 1 cm 1 2 inch away from Max Extend Look at the piston position through the pump case window If the pistons are not at the proper position set the operating mode to 1 Independent Constant Rate Operation IND CR Next open either the fill or deliver valve or both so the displaced fluid has a place to go Set the operating direction to extend and start the pump cylinder Look at the piston position display and stop the pump at the correct position Do this for both pump cylinders if you are going to change the seals on both pump cylinders 2 Close both the fill and deliver valves Figure 8 1 3 Turn off your pump Unplug the power cord from the power outlet and from the pump It is important to do this for safety reasons 4 Using a phillips head screwdriv
87. he pump controller to the auxiliary pilot solenoid valve manifold The Quizix controller and PumpWorks software have the capability 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 back drive ball screw pitch BAUD rate bearings bidirectional cable clips cable connection sensing cable extension cable retainers calibrate capillary viscometer cascade ceramic GLOSSARY 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 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 b
88. he status of various errors for each pump cylinder For each field the color green indicates no error the color red indicates an error and the color gray indicates either a communication error or an uninstalled cylinder Chandler Engineering QX SERIES PUMP USER MANUAL Figure 6 10 6 2 6 Exit Program Press the Exit Program button to close the Front Panel Software for access to the underlying Windows CE operating system This action is required to gain access to the TPC Configuration program which is used to set the brightness of the liquid crystal display To set the brightness of the liquid crystal display refer to Setting Display Brightness Section 6 4 6 2 7 Cancel Pressing the Cancel button returns the user to the main window 6 3 Front Panel Configure Window To access the Configure Window touch the Quizix Logo in the top left corner of the main window and then touch the Configure button The configure window has buttons for the following functions which will be explained in the sections below Transducer Calibration Update Software Pressure Control Units and Precision and Cancel Chapter 6 OPERATING YOUR FRONT PANEL Figure 6 11 6 3 1 Transducer Calibration The QX pump has two pressure transducers one attached to each pump cylinder The front panel software allows the pressure transducer gain and offset values to be viewed and the offset values to be adjusted The ability to adjust or zero the offset values o
89. he top right corner of the window Chandler Engineering QX SERIES PUMP USER MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6 20 Chapter 7 SYSTEM POWER This chapter describes the power requirements for the QX Series Pump Included are the following e Basic Power Requirements Section 7 1 e Using Uninterruptable Power Supplies Section 7 2 e Serial Expander Isolator Section 7 3 7 1 Basic Power Requirements The QX Series Pump needs only one power connection The QX Series Pump has a universal input modular plug power supply which accepts any voltage from 85 to 264 volts with frequency in the range of 47 to 63 Hertz The QX Series Pump have a user replaceable fuse in the power entry module See Section 7 4 for replacement Users conducting long term experiments where the interruption of fluid flow would be detrimental to the experiment s results should use an Uninterruptable Power Supply UPS with the pump All pumps are shipped with power cords compatible with the voltage and type of outlet used in the country to which they are shipped 7 2 Using Uninterruptable Power Supplies The Quizix pump can operate for extended periods of time even many months without needing to be stopped This capability is perfect for running long term experiments such as steady state rock property measurements For long term experiments however the pump must have a source of AC power available at all times Electronic equipment such as com
90. hes in the pump cylinders are all working properly 4 5 Connecting and Filling the Pump With Fluid If your pump does not have liquid in it add it at this point Complete the following procedure for each pump cylinder you wish to fill with fluid 1 Connect the fluid inlet to a fluid supply and connect the fluid outlet to a drain or a container For more information please refer to Chapter 3 Section 3 4 Connecting Your Fluid Plumbing To fill a pump cylinder with fluid leave the safety pressure at 100 PSI 700 kPa Set the flow rate to about 50 percent of the maximum flow rate For the QX 500 set the flow rate to 300 ml min For the QX 1500 set the flow rate to 100 ml min For the QX 6000 set the flow rate to 25 ml min To set the flow rate do the following 10 Chapter 4 SYSTEM CHECKOUT e PumpWorks e From the menu bar select Main Set Pump Flow Rates e Inthe Enter New Flow Rate text box enter the flow rate at about 50 of the rate shown in the Maximum Value box e Click on Send Rates to Pump s Front Panel e Touch the set rate button e Using the numbers on the keypad enter the flow rate at about 50 of the rate shown in the Maximum Value box and then touch the Enter button Set the operating mode to mode 1 for pump cylinder A which is Independent Constant Rate To set the operating mode do the following e Click on the Operating Mode button in the main window and a list of operating m
91. ic pump controller diagnostics are performed next The controller begins testing itself If a test fails the display will freeze Report this to Chandler Engineering technical support Figure 9 1 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 9 2 below One segment lights then a second segment lights then a third and so on Each segment that lights is a confirmation from Pump Works that a specific aspect of the pump is operating correctly Ist 2nd 3rd 4th Sth 6th 7th I I I I 1 I I_I I I ISI I I I Figure 9 2 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 Chandler Engineering If segments 4 5 6 or 7 do not light start Pump Works and load the program code PumpWorks will know that the program is bad and will prompt the user for the program file name Chandler Engineering QX SERIES PUMP USER MANUAL 9 8 Two Digit Display Pump Controller Diagnostics 1 lt q Display aa Segments ey Decimal Point A Left Decimal Right Hand Point Hand Digit Digit Figure 9 3
92. ications port On some computers Communications Port 1 may be called Serial Port 1 or Serial Port A Isolator Serial Expander RS 232 Cable to Computer The other end of the RS 232 cable should be connected to the serial expander isolator Figure 4 1 2 Data Communications Cable e Make sure the data communications cable phone type is connected to Data Link on the pump control panel The other end of the data communications cable should be connected to the first available serial expander isolator port usually Port A 4 3 Valve and Pilot Solenoid Check The fluid valves are air operated valves The pilot solenoids control the air that operates the fluid valves The pilot solenoids are electrically operated to control air flow The pilot solenoids are located on a manifold underneath the valve on a QX Series Pump There are two pilot solenoids for each of the four valves Pilot solenoids are used to open or close the fluid inlets inside the valves The pilot solenoid manifold takes in air from the user s air supply and distributes that air to the pilot solenoids This section contains the following e Valve and Pilot Solenoid Auditory Check Section 4 3 1 e Valve Warning Messages Section 4 3 2 Chandler Engineering QX SERIES PUMP USER MANUAL 4 4 First perform the Pilot Solenoid Auditory Check for pump cylinder A s fill valve Then perform the check for pump cylinder A s delivery valve pump cyl
93. inder B s fill valve and pump cylinder B s delivery valve At this point it is assumed that the following are true e the pump is turned ON e the user can control the valves either by PumpWorks or a Front Panel e the air supply is ON 4 3 1 Valve and Pilot Solenoid Auditory Check Open and close each valve in turn Listen for an air escaping sound when the pilot solenoid opens and closes The sound should be easy to hear It will not be a clicking sound The clicking sound you may hear is simply the pilot solenoid opening or closing The air escaping sound is the same as when you open a can or bottle that is under pressure and you hear an immediate gust of air It is important that you hear this sound when the pilot solenoid opens and closes If you do not hear the air escaping sound when each valve is opened and closed then there is not adequate air pressure to operate the valves Go back and check that your air tubing has been connected properly and that it is securely attached If your air supply has a switch to turn it on make sure the switch is turned on Once you have performed the pilot solenoid auditory check on pump cylinder A s fill valve perform the same checks for pump cylinder A s deliver valve pump cylinder B s fill valve and pump cylinder B s deliver valve When you have successfully completed the Valve and Pilot Solenoid Auditory Check for all the valves in your system go to Section 4 4 Pump
94. ing A Pump Onto PumpWorks 3 12 Installing PumpWorks Software 3 10 L Leak Testing ayip enina a 9 12 Eeakag Basics nitestimntutoia ses ontes 9 11 Leaks Does Your Pump Have a Fluid DCA aerianas 9 12 Finding Your Leak 9 13 Fl id Leaks lonii 9 11 Leak Testing oc sticecccasegavensatcnsece 9 12 Leakage Basics s 2 ccccsetsecesicctenes 9 11 Valve Leaks Fluid When Closed 9 18 Liquid See Fluid M Maintenance eseeeeseseeeereereerrrersere 8 1 Medium Handling ee eeeeeeeeee 2 2 NIG COR aa keticc tase e e es thomas 8 23 N No Air Escaping Sound When Valves are Opened amp Closed 9 10 No Fluid Is Being Delivered 9 13 O Operating Modes ceeeeeeeeeeeeeeees 1 1 Other Pump Troubleshooting Situations beesini Sed 9 10 P P umpWorks Controller Diagnostics 9 8 Physical Piston Position Indicators 9 1 Piston Diameter 5 ic55 4s c0c8 th tpccalecenastste 1 3 Piston Motion Errors ccceeeees 9 14 Power Requirements ceeeeeeseeeeseeeees 7 1 Syste eenn e aae 7 1 Pressure Maxim m eiaa s 1 3 Pressure Transducer Errors 9 16 PressureTransducer BLOKE DE oi ieat gria Oss 4 10 CHECK sora sasccaineasateiaresiedees enedes 4 10 CTOSS WAKER hupia 4 10 Pump Case Re assembling 0 0 0 eee 8 6 Removing 2 lt 58se0ssdcesvecciveteeens 8 2 Connections tssc12H a6 eeiosiscted eases 1 2 Cylinder Removing coiere gers 8 3 Seals See Seals Dimensions
95. ing for a substitute panel which will be compatible with a front panel lL e Figure 3 7 3 7 Chandler Engineering QX SERIES PUMP USER MANUAL 2 Unpack the Front Panel assembly The mounting bracket should already be in the 90 degree position as shown in Figure 3 8 If not loosen the larger screws on the sides of the Front Panel rotate the bracket and tighten the screws Figure 3 8 3 Connect the Front Panel to the front lower panel of the QX pump with two M4 screws included as shown in Figure 3 9 Figure 3 9 4 With power to the QX Pump still OFF connect the Dsub 9 pin connector located on the Front Panel to the connector in the slot of the front lower panel of the QX Pump The connector should be oriented with the screw jack on the right and the cable exiting to the left Tighten the screw jack on the connector with a screw driver 5 Your Front Panel is now installed onto the QX Pump and will power on when the pump is turned on Do not turn on power to your pump yet You will be instructed to turn on your pump in Section 3 9 6 The Front Panel has an adjustable tilt and lock mechanism and can be rotated to the desired viewing position by loosening two large screws one on each side of the Front Panel Re tighten the screws after positioning the front panel as desired 3 8 Chapter 3 SYSTEM SETUP NOTE A cable can be supplied which allows the Front Panel to be removed and placed a
96. ing 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 9 4 3 3 Does Your Pump Have a Fluid Leak A pump cylinder can be checked for fluid leakage by following the steps below 1 Fill the pump with the fluid to be tested Chapter 9 QX SERIES PUMP OPERATING BASICS 2 Set the pump to constant pressure independent mode 3 Close both the fill and deliver valves 4 Select an appropriate test pressure 5 Start the pump 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 If the 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 You may use the reading from the internal temperature sensor as a guide to temperature changes 9 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 i
97. ing the Pump System There are two basic methods of pressure calibration for the Quizix Pump System 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 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 8 19 Chandler Engineering QX SERIES PUMP USER MANUAL system The pressure is then read by the system and adjusted until it matches the pressure being output by the pressure source Calibration Setup Diagram Pressyge Source Calibrgted Gauge Fluid Outlet Deliver Cylinder 1 Fill Transducer Cylinder 2 Deliver Pressure Transduce Pll nospheric Pressure Fill Reservoir Figure 8 19 8 5 2 1 Calibrated Gauge 1 As shown in the Calibration Setup Diagram in Figure 8 19 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 cylinder s being calibrated open the fill valve s so the
98. 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 window 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 operation in the backward or retract direction There are subcomponents or smaller parts that make up a mechanical assembly of the pump metal ferrules minimum value modes modular power cord connector motion status motor assembly motor cable motor resolution in steps motor shaft not inst not installed num lock numeric keypad offset open end wrench operating mode GLOSSARY Metal compression rings used to attach teflon tubing to air actu ated valves in high temperature systems The lowest number or value that can be entered See Operating Modes A modular power cord connector which allow
99. isplay Section 9 3 e Other Pump Troubleshooting Situations Section 9 4 e Software Updates Section 9 5 9 1 Troubleshooting Basics The QX Series pump contains two completely separate pump cylinders To isolate the cause of a problem the pump cylinders can be compared against each other 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 pistons and valves 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 QX Series pump there are several PumpWorks feature 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 PumpWorks Items in green indicate that no errors are present and items in red indicate that an
100. iston 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 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 One pump cylinder operates by itself and is limited 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 ope
101. l requirements associated with handling potentially flammable liquids or otherwise hazardous agents are the responsiblilty of the customer Chapter 3 SYSTEM SET The QX Series Pump is easy to connect For Front Panel users just connect your Front Panel plug in the AC power cord and connect the air supply For PumpWorks users connect the communications cable to your computer connect the air supply and plug in the AC power cord That is all you need to do to connect your pump You will find the following information in this chapter e Unpacking the QX Series Pump Section 3 1 e Inspecting Your Pump Section 3 2 e Connecting Your Air Supply Section 3 3 e Connecting Your Fluid Plumbing Section 3 4 e Connecting amp Operating Optional Wash Area Section 3 5 e Connecting Your Power Source Section 3 6 e Connecting to a Computer or Front Panel Section 3 7 e Installing PumpWorks Software Section 3 8 e Turning On Your Pump Section 3 9 e Installing A Pump Onto PumpWorks Section 3 10 e Completing System Setup Section 3 11 3 1 Unpacking the QX Series Pump If you ordered the PumpWorks software this will be packed in the same box as your pump If you ordered a Front Panel it will be packed and shipped separately Multiple pumps will be shipped in separate boxes Unpack the following items which are contained in the inner box 3 1 1 QX Series Installation Kit Unpack the QX Series Installation Kit as shown below 1 In
102. ler Engineering QX SERIES PUMP USER MANUAL 2 2 Due to momentum if the piston is moving forward at a fast rate when the overpressure event is detected the system pressure will exceed the safety pressure before the pump cylinder comes to a complete stop 2 2 3 Underpressure Protection Safety Feature The QX Series Pump also has a digital underpressure safety feature built into it When the QX pump s pressure transducer is at zero pressure the pressure transducer s output is at a factory preset level above zero The pump controller has a safety feature which generates an error message if the pressure transducer voltage drops below that pre set level In this case PumpWorks assumes that there is a pressure transducer failure A digital underpressure error message will be displayed on the status bar of PumpWorks main window and the pump cylinders will stop pumping 2 2 4 Equipment Installation The QX series pumps are designed to be operated as table top equipment as such attention should be given to the placement of the equipment with regard to ventilation accessibility and proximity to an approved grounded electrical outlet Do not encase any portion of the QX pump within an enclosure while in operation The QX series pumps should be lifted from by grasping underneath the bottom of the unit 2 2 5 Medium Handling The particular safety requirements associated with the handling of the medium to be pumped especially the additiona
103. let and Outlet Gland Nuts and Ferrule Sleeves Type is dependent on fluid option ordered 2 Air tubing 6 mm diameter 2 meter length Not Pictured 3 Power Cable 1 each with connector appropriate for destination country s power outlet Not Pictured 4 Wash Area Option Polyurethane Wash Tubing 4 mm diameter 1 meter length 2 each 3 1 Chandler Engineering QX SERIES PUMP USER MANUAL 3 1 2 QX Series Spares Kit Unpack the QX Series Spares Kit as shown in Figure 3 1 below O90 REAN E S amp 1 Main Seal 2 each 00000000 OS Sean 2 Face O Ring Fluid Seals 8 each 3 Cylinder Adapter to Case O C2 oooo0o0o0o00 Ring Seals 2 each 4 Cylinder to Adapter O Ring Seals 2 each 5 Valve Air O Rings 8 each 6 Transducer O Rings 4 each e000000 O000 Figure 3 1 Pumps with Wash Areas also get the following 7 Wash Area Internal O Rings 2 each 8 Wash Area Plug O Ring Seals 8 each 9 Wash Area Seals 2 each same as Main Seal not pictured 3 1 3 Unpacking the QX Pump 10 Unpack the front panel if ordered 11 Unpack the PumpWorks software disk RS 232 serial cable and serial expander isolator if ordered PumpWorks CD will be in the front pocket of the Pump Works manual 12 To unpack the QX Series Pump from the shipping box put each hand around the outer pump case where the foam is cut away as shown in the arrows in Figure 3 2 Gently lift the pump out of the box and place it on you
104. lse so the flow of the wash fluid is approximately 3 ml per minute when either piston is in motion 3 6 Connecting Your Power Source The QX Series Pump requires an AC voltage input within the range of 85 to 264 volts 47 63 Hz in order to operate Power consumption is less than 200 Watts at all times QX Series Pumps are built to accommodate a universal AC voltage range so the user does not need to set the voltage The power cord supplied with the pump will agree with the voltage in the user s country e Plug the provided AC power cord into the QX Series Pump The power receptacle is located near the bottom center on the pump s back panel Refer to Figure 3 6 e Plug the other end of the power cord into an 85 to 264 volt 47 63 Hz AC source Do not start your QX pump at this time You will be instructed to turn on your QX pump in Section 3 9 If a computer was ordered from Chandler Engineering with the pump it is set for the voltage in use in your country See the operating manual that came with your computer for further information about its power specifications Figure 3 6 Chapter 3 SYSTEM SETUP 3 6 1 Uninterruptable Power Supplies UPS Electronic equipment including the QX Series Pump and your computer can be affected by brief power interruptions and by power line surges or spikes An Uninterruptable Power Supply UPS can provide back up power to your equipment during such occurrences This will prevent yo
105. lting 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 9 13 Chandler Engineering QX SERIES PUMP USER MANUAL 9 14 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 the pump Typically pressure drops only 1 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 pistons by doing the following 1 Set the operating mode to Independent Constant Rate 2 Set the flow rate to 50 of maximum flow rate For the QX 500 set the flow rate to 250 ml min For the QX 1500 set the flow rate to 100 ml min and for the QX 6000 set the flow rate to 25 ml min for a QX 20K set to 3 5 ml min 3 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 for proper movement from max retract to max extend e Check for proper valve operation Make sure it is properly connected Check th
106. ly double check all cable and plumbing connections each time you disconnect and the reconnect them After double checking your connections complete all system checkouts before operating your pump 4 2 1 Fluid Plumbing Connection Check The end of the cylinder barrel is directly underneath each valve It is a 31mm 1 1 4 inch diameter circular metal part that sticks out about 12 mm 1 2 inch Connected to each cylinder barrel is a fluid plumbing tee which connects to the fill and deliver valves At the other end of each valve there is fluid plumbing which connects the valve to the fluid inlet or the fluid outlet tee Trace all fluid plumbing connections to make sure the fittings are properly tightened Make sure the M 4 screws holding the valve fluid tees to the cylinders are tight 4 2 2 Fluid Inlet And Fluid Outlet Connection Check Check that you have a fluid source and a fluid outlet sink or container Make sure all fittings are tight 4 2 3 Front Panel Connection Check If you are using a front panel this check is to make sure it is properly connected Chapter 4 SYSTEM CHECKOUT Check thatthe DB 9 connector from the Front Panel is connected to the connector on the front of the pump 4 2 4 PumpWorks Connection Check If you are using PumpWorks follow this check to make sure the computer is properly connected to your pump system 1 RS 232 Cable e Check that the RS 232 cable is connected to the computer s commun
107. m 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 adjusts 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 G 15 Chandler Engineering QX SERIES PUMP USER MANUAL reset recirculating mode reset volumes residue restore retract retracting return rate multiplier return rate minimum RS 232 cable run conditions rupture safety pressure sche
108. m Wattage Volts Amps QX Series Pump 200 Less than 230 Typical Windows compatible computer 60 400 80 500 Typical Windows compatible monitor 50 200 70 250 After determining your power consumption 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 power consumption 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 using the power consumption figure you have determined 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 running the motors at a slower rate Turning off equipment of course requires that the user be present 7 3 Serial Expander Isolator The serial expander isolator provides electrical isolation between the computer running PumpWorks and any QX Series pumps Each pump is electrically isolated from the computer and from every other pump in the pump system This isolation is provided to prevent ground loops and system grounding problems when the pump s and computer are plugged into different power circuits It is not designed to protect against incorrectly wired AC power circuits Itis the user s responsibility to check all AC power circuits for
109. matic scroll seal assembly 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 Brings a window that is minimized into full view again 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 cyl inders 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 drawing of electrical or fluid connections The main window of the PumpWorks software has
110. n that the piston will be making slight motions as the pressure control algorithm operates e 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 fluid system In a typical QX Series 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 r
111. n the fluid scratching the lips of the seals If fluid is leaking out of the bottom of your pump you are very likely to have a seal leak If a 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 without taking the case apart try removing the fitting at the top 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 Please refer to Chapter 8 Changing the Pump Cylinder Seals Section 8 1 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 e 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 9 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 resu
112. n 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 9 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 e 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 e 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 9 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 pressu
113. nd a deliver valve The fill valve connects the pump cylinder to the input fluid line while the deliver valve connects the pump cylinder to the output fluid line NOTE In Receive operating modes the output line is actually used to receive fluid and the input line is used to dump fluid Chapter 6 OPERATING YOUR FRONT PANEL The QX Valves Window is displayed when the user presses the Valves button on the front panel menu as shown in Figure 6 9 below Figure 6 9 The state of the fill and deliver valves for both pump cylinders are displayed on the QX Valves window The state of a pump cylinder can be changed by pressing on the desired valve button A confirmation message will then appear In paired operating modes whether the valves are opened or closed is controlled automatically to provide continuous pulse free delivery and cannot be set while the pump is running In independent operating modes the valves can be opened or closed while the pump is running 6 2 3 Reset Volumes When the Reset Volumes button is pressed a confirmation message appears When the user confirms the volumes are to be reset the cylinder volumes are reset to zero 6 2 4 Configure Pressing the Configure Button on the Menu brings up the Configure window which will be explained in Front Panel Configure Window Section 6 3 below 6 2 5 System Errors Selecting the System Errors button will open the Error Status window shown in Figure 6 10 displaying t
114. nect the other end of the tubing there Figure 3 5 3 5 Connecting amp Operating Optional Wash Area A wash area option is available on QX Series Pumps and consists of the following e Two wash collars to wash each piston located below the A amp B cylinder seals 3 5 Chandler Engineering QX SERIES PUMP USER MANUAL 3 6 e An internally mounted solenoid pump The wash collars are plumbed in series with the pump The QX pump controller s board pulses the solenoid pump approximately once per second when either piston is in motion and for an additional two minutes after piston motion has stopped The user can disable the pulsing of the wash pump through PumpWorks Under the Configure menu the Controller Setup selection has a wash pump on off button The default is ON for pumps with wash areas To operate the wash area the user only needs to provide a reservoir of wash fluid and a container for waste fluid There are Inlet and Outlet fittings for the wash area located on the top of the QX pump behind the valves Use 4 mm or 5 32 inch polyurethane tubing to connect the inlet and outlet to the reservoirs The solenoid pump is located just below the top cover of the QX pump The solenoid pump will operate within a static head range of 0 75 to 0 75 meters 30 to 30 inches so the wash fluid reservoir should be within that vertical distance measured from the top of the QX pump the solenoid pump delivers 50 uL with every pu
115. nected For example if the sensor cables are reversed that is the sensor cable for Cylinder A is plugged into the receptacle for Cylinder B and vice versa Pump Works cannot detect this problem In the QX Series Pump the transducer cable sensor cable valve cable and driver cable are inside of the pump case If the pump case has not been opened the transducer cable sensor cable valve cable and driver cable will normally be connected properly Ifa connection is not detected an error message is displayed on the status bar of PumpWorks main window and an error code is displayed on the pump s two digit display and the pump cylinders will stop operating For more information about the two digit display error code please refer to Chapter 9 Section 9 3 3 Two Digit Display Codes 2 2 2 Overpressure Protection Safety Feature The QX Series Pump is kept from reaching excessively high pressures by a digital overpressure safety feature which is set in PumpWorks and monitored by the QX Series pump controller With this feature the user specifies a safety pressure at a level higher than the expected run pressure If the pump reaches the user set safety pressure a digital overpressure error message is displayed on the computer monitor and the pump controller stops the pump cylinders For example if the pressure is set at 700 PSI and the safety pressure is set at 800 PSI the pump cylinder will stop if pressure reaches or exceeds 800 PSI 2 1 Chand
116. ngineering com Please refer to the PumpWorks User Manual for software update procedures 9 19 Chandler Engineering QX SERIES PUMP USER MANUAL This page intentionally left blank 10 Chapter 10 QX Series User Interface The QX Series Pump has a user interface connector that allows the user to control and read data from additional sensors and control devices from PumpWorks Specifically the QX Series has the following capabilities available on the 25 pin DB style connector e 3 each auxiliary voltage input A D channels e 1 each auxiliary current input A D channels e 8 each valve pilot solenoid controls e 2 each digital logic input channels e 2 each digital logic output channels e 5 volt and 24 volt power 10 1 Valve Control Lines The valve control lines have been designed to operate the pilot solenoids which are used to activate air operated On Off control valves used on the QX Series Pump to control fluid flow Each On Off valve requires two pilot solenoids one to turn the valve On and one to turn the valve Off These pilot solenoids are available in many different voltages however the Quizix QX Series pumps use 24 volt versions The user interface was designed with the expectation that 24 volt pilot solenoids would be used so 24 volt power is available on four nearby pins numbers 14 15 16 and 17 The 24 volt supply is connected to the positive lead of the pilot solenoids and the ground side of the pilot solenoid is co
117. nnected to the desired control line The valve control lines are low side drivers they sink current and are capable of sinking in excess of 100 milliamperes ma each The 24 volt power supply however is only capable of supplying a combined total of 500 milliamperes 150 milliamperes with Front Panel attached The pilot solenoids used by Chandler Engineering only draw about 20 milliamperes each so eight pilot solenoids can easily be operated from the QX Series user interface If other types of pilot solenoids are to be used then their current requirements must be checked The valve control lines can also be used to sink current from the 5 volt supply An external supply can be used with these sink type drivers however voltages of greater than 24 volts are not permitted Devices other than pilot solenoids can also be controlled such as indicator lamps relays and other actuators NOTE Since these lines pull only to ground you cannot use a volt meter directly connected to these lines to check their operation To check these lines with a volt meter use a resistor greater than 1 kiloohm to tie the line to a power supply line either 5 or 24 volts 10 2 Digital Input Lines Two logic level input lines are available on pins 20 and 21 These are CMOS type logic inputs with a 47 kiloohm pullup resistor to the 5 volt logic supply These inputs are ESD protected These signals can be activated by an external microswitch or a digital output from a
118. nother digital logic system The input voltage range for a logic low signal is 0 to 1 4 volts 10 1 Chandler Engineering QX SERIES PUMP USER MANUAL 10 2 and a logic high is a signal from 3 6 to 5 volts Signal levels should not go above the 5 volt logic power supply voltage or below ground A typical use for this signal would be to detect an oven door opening with a microswitch on the door 10 3 Digital Output Lines Two logic level output lines are available on pins 18 and 19 These are CMOS type logic level signals which when at a logic zero low level put out a voltage close to ground guaranteed to be less than 0 2 volts for a 2 milliamperes maximum current sink and when at a logic one high level put out a voltage close to the 5 volt supply guaranteed to be greater than 4 6 volts while sourcing up to 20 milliamperes These signals will either source or sink current but are limited to a maximum of 20 milliamperes These digital output lines can be used to interface with an external digital system or light an LED type indicator 10 4 Analog Signal Input Lines 10 4 1 Auxiliary Voltage Inputs Three analog voltage input channels are available for use with external sensors These lines are connected with a 16 bit analog to digital A D converter on the QX Series controller printed circuit board The input range for the A D used for this conversion is 10 to 10 volts An analog voltage that is within the 10 to 10 volts range is su
119. ns Cable 4 3 Diagnostics ania aa ER bends 3 11 Hardware oaie Gee 3 11 Pump Controller Hardware 3 11 Pump Controller Software 3 12 SoftWare isseire 3 12 Does Your Pump Have a Fluid Beak ran e NNR 9 12 Drive Belts Jnspecting cn Saeco e 8 8 Driver Cable See Cabletron 2 1 Dynamic Data Exchange DDE 1 2 E Equipment Installation 0 0 2 2 Emr LOS oaan ek 9 1 Error Messages cocesenicsseastocssdiveccccatseys 9 2 Error State Capture Mode 9 2 Errors Buffer Overrun Error seese 9 4 Communication Errors 9 3 CRC Check Error oe eee 9 5 Immediate Errors eee 9 2 Incorrect Number of Bytes received 24 jueiesulielivetle 9 5 Top t ETO esotere s 9 5 Logged Errors i660 cts 9 3 Motor Running No Piston Movement Detected Error 9 5 Motor Stall Error eee 9 15 No Response from Pump Error 9 5 Soft Limit Warning eee 9 3 Index 1 Chandler Engineering QX SERIES PUMP USER MANUAL F Fan Does Not Run necese 9 11 Fan Does Not Run eee 9 11 Flow Rate Maximum Flow Rate 05 1 3 Maximum Pumping Rate 4 8 Fluid Clogged sesini ian 4 10 Connecting and Filling The Pump With Flid aen 4 8 Insufficient Fluid in the Pump 4 10 Fluid Flow Direction cou ttes igion isus 1 1 Fluid Leaks sssicass sscsatavageacaeanapeandaes 9 11 Fluid Plumbing Diagram aaar aes 4 2 Fluid Plumbing Connecti
120. nsing 2 1 Data Communications Cable Connection 00 cecceeeeesereees 4 3 Diversa aa oss a NS 2 1 RS 232 Connection 00 cccceceeeeeeeereees 4 3 RS 232 Cable dist casksaaseesssaeieae 4 3 SONS OP a a inl eet eet 2 1 Transcrie iie 2 1 VaVe T eae S 2 1 Verification of All Cable Connections oo ce eceeeeesereees 4 2 Calibration cccccsesscececeeeeeeees 8 22 Calibrated Gauge ceeeeeeee 8 20 Calibrated Pressure Source 8 22 Calibrating Pressure Transducers 8 19 Checking Your Air Supply 9 17 Checking Your Air Supply Connection nesune ee 9 18 Clogged Obstructed Valve 9 18 Communication Cannot Be Established 9 3 Once Communications Has Been Established anina 9 4 Completing System Setup 3 14 Connecting a Front Panel eeen 3 7 Fluid Inlet Connection 3 4 Fluid Outlet Connection 3 5 to a Computer or Front Panel 3 7 Your Air Supply e ec eeeeeeeeees 3 4 INDEX Your Fluid Plumbing 3 4 Your Power Source secsec 3 6 Your QX Series to a Computer 3 9 Connecting amp Operating Optional Wash Area 5st Ae nies 3 5 Connecting Your Air Supply 3 3 3 4 Constant Air Escaping Sound 9 11 CRC Check Error jis tesa ctecsctayns 9 5 Current System Status Window 9 1 Cylinder Barrel Tnspectint oirin a 8 4 Cylinder Switch Status Window 9 2 D Data Communicatio
121. nuous operation G 13 Chandler Engineering QX SERIES PUMP USER MANUAL pressure pressure pulse pressure transducer pressure transducer cable pressure transducer calibration pressure units pressurizing printed circuit board or PC Board PCB programmed prompt line proportional error proportional gain or proportional servo gain PSI pull down menu 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 PSI bar and pas cals 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
122. nut installed on the end of it Two fluid gland nuts and two fluid ferrule sleeves have been provided for you in the QX Series Installation Kit NOTE If you need instructions to install a fluid ferrule sleeve and a fluid gland nut onto your fluid tubing please refer to Chapter 8 Section 8 6 How to Attach a Fitting to Your Tubing NOTE If you need instructions to install a fluid ferrule sleeve and a fluid gland nut onto your fluid tubing please refer to Chapter 8 Section 8 6 How to Attach a Fitting to Your Tubing If you would like to purchase additional fluid ferrule sleeves or fluid gland nuts please contact Chandler Engineering 3 4 1 Fluid Inlet Connection To connect your fluid source follow the steps below First make sure your 1 8 inch tubing has a fluid ferrule sleeve and a fluid gland nut already attached The QX Series Pump has two fluid inlets one for Cylinder A and one for Cylinder B as shown in Figure 3 4 Insert the 1 8 inch tubing into the fluid inlet connection Now put the other end of the same tubing into your fluid supply Chapter 3 SYSTEM SETUP Figure 3 4 3 4 2 Fluid Outlet Connection To connect your fluid outlet follow the steps below First make sure your 1 8 inch tubing has a fluid ferrule sleeve and a fluid gland nut already attached Insert the 1 8 inch tubing to the fluid outlet connection as shown in Figure 3 5 Decide where your fluid will go when the QX Series pumps the fluid out and con
123. odes will appear e Click on Independent Constant Rate Operation mode number 1 If you are at the Max Retract position then go on to 6 If you are not at the Max Retract position then open the fill valve close the deliver valve and set the direction to Retract Start the pump cylinder to initiate the filling process Make sure the fluid outlet plumbing is connected to a drain or a container When the pump cylinder is at the Max Retract position close the fill valve and open the deliver valve Make sure the cylinder direction is set to extend Start the pump cylinder On the first pumping stroke mostly air is delivered out of the fluid outlet You may start to see liquid coming out of the tubing by the end of the first piston stroke If you put your fluid outlet into a container holding liquid you will see bubbles when the air comes out of the fluid outlet To check if fluid is coming out of the plumbing lift the fluid plumbing slightly out of the liquid but leaving it inside of the container Watch for the fluid to drip out When you have reached Max Extend close the deliver valve and then open the fill valve Start the pump Wait until the pump cylinder reaches Max Retract and stops The pump cylinder will be pulling in fluid If the fill container is small enough the user may observe the fluid level start to drop as fluid is pulled into the pump cylinder On the next forward piston stroke the pump cylinder should deliver fluid
124. olenoids 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 4 Valve and Pilot Solenoid Auditory Check Section 4 3 1 for information on checking your pilot solenoids 9 4 7 6 Clogged Obstructed Valve It is possible for the valve inlet to become clogged with particles from the fluid being used If a 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 encountered so that this problem does not reoccur 9 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
125. ols Used on Equipment Symbol Meaning Protective Conductor Terminal On Supply Q Off Supply 1 9 Symbols Used in this Manual Symbol Meaning ey Note Important Information VAN Warning Potential Hazard 1 10 Where to Find Help In the event of problems either the local sales representatives will be able to help or the personnel at Chandler Engineering can be contacted e Telephone 918 250 7200 e FAX 918 459 0165 e Email chandler chandlereng com e Website www chandlereng com Chapter 2 SAFETY 2 1 Safety Requirements 2 2 Safety Features The QX Series Pump is capable of reaching and maintaining very high pressures Safe operation of the pump is a primary concern The safety features described in this chapter are designed into all Quizix Pumps and include the following e Cable Connection Sensing Section 2 2 1 e Overpressure Protection Safety Feature Section 2 2 2 e Underpressure Protection Safety Feature Section 2 2 3 2 2 1 Cable Connection Sensing PumpWorks includes a Cable Connection Sensing feature which detects the connection of the following cables e Transducer Cable pressure transducers to pump controller e Sensor Cable sensor board to pump controller e Valve Cable pilot solenoids to pump controller and e Driver Cable motor driver to pump controller The cable connection sensing feature can only detect the presence of a cable it cannot detect if it is the correct cable that is con
126. ompletely 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 deliver valve of the standby pump cylinder is always closed The time it takes for the standby pump cylinder to fill and pre pressurize 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 system level integration tab key teflon tiled tilt angle time formats titles torque torque wrench transducer assembly transducer cable transducer calibration trapped gas trigger switch tubing unacknowledged unidirectional uninterruptible power sup ply UPS GLOSSARY
127. on Chek deiren ian eran 4 2 Pict re aeisi tinrin 4 2 Verification of All Plumbing Connections scrcctycsssceascenetetits 4 2 Fluid Tubing How to Attach A Fitting To Your Tubing sccis seieesietiandes 8 22 8 23 Front Panel rotnn nas 1 2 CONPSUTE siirsin einasi 6 7 Configure Screen ceecee 6 8 Connection Check lt i63scascsenacics 4 2 Display Brightness 6 15 Main SCreem teis sio tei 6 1 Menu Screen ssssssesssseeeserssseressee 6 6 Motion Status s snot 6 2 Operating Modes eeeeeeeeeees 6 4 Operating Your Front Panel 6 1 Piston Direction 0 eeeeeeeeeees 6 5 Pressure eion niee 6 3 Pressure Control 00 eee 6 13 Rate ss sissasuicns nutan 6 3 Reset Volumes 1 004 ccsteidcnscsaestecaee 6 7 Safety Pressure ecese 6 6 Set Pressure ea aet eine 6 3 Set Pressure Servo Gains 6 13 Set Rate nrin e nR i 6 3 Software Update eee 6 11 Start Stop Buttons ee 6 1 Index 2 System Errors 20 25 casccssnacaeSeap scene 6 7 Transducer Calibration 6 9 Units amp Precision 0 00 6 14 Val VES Goce focetvests dens osaccas onde 6 6 Volume serso 6 3 H How TO spernenn 3 10 Install PumpWorks 00 3 10 How to Turn On Your Pump 0 3 11 How To Install PumpWorks 3 10 I Inspecting Drive Belts sicisiniiiusainudadis 8 8 Piston and Piston Holder 8 4 Inspecting Your Pump eee 3 3 Install
128. or error log errors present exit options extend extended A D values extending execute GLOSSARY This on off toggle switch allows power going to the driver to be turned on or off 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 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 Some of the PumpWorks software windows have certain op
129. ore attempting to operate the pump however read the PumpWorks Software Manual Remember to repeat the safety checks in this chapter if e any of the major components have been replaced e the pump system has been reconfigured e the plumbing has changed or e any adjustments were made that involved disconnecting and reconnecting any of the pump s cables or plumbing Chandler Engineering QX SERIES PUMP USER MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4 12 Chapter 5 PUMPWORKS BASICS PumpWorks is a software program that allows complete and automated control of Quizix fluid pumps and runs on Windows based computers PumpWorks is easy to install and can be used with any Quizix pump or an entire pump system Please refer to the PumpWorks User manual for details on usage 5 1 Chandler Engineering QX SERIES PUMP USER MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5 2 Chapter 6 FRONT PANEL OPERATION This chapter explains how to operate your Front Panel The following sections are included in this chapter e Front Panel Main Window Section 6 1 e Front Panel Menu Section 6 2 e Front Panel Configure Window Section 6 3 e Setting Display Brightness Section 6 4 6 1 Front Panel Main Window The Front Panel will power on when the QX Pump is turned on and the Front Panel Main Window shown in Figure 6 1 below will appear The Front Panel Main Window shows pump operating data and control buttons for QX Pump Cylinders
130. ower cord data cable and air line Remove the side panels of the pump Release the brake to allow the carriage to fully retract until it is resting against the support platform gt Brake Plunger Figure 8 17 With a small screwdriver lift and compress the spring surrounding the brake plunger A small slot in the brake plunger will then become visible Place the end of the small screwdriver in the brake plunger slot and lift the plunger This will release the motor mechanism and the carriage should freely move down until it reaches the support 8 Chapter 8 MAINTENANCE platform If the carriage does not move freely when the brake plunger is lifted then ensure that the plunger is fully lifted and have another person pull down on the drive belt to start the motion of the carriage Remove the rear panel of the pump Place the pump back side down on a foam pad to avoid any damage to the pump electronics Remove the bottom panel of the pump by removing the necessary Phillips screws If the return cable is intact it is necessary to use the supplied Fusee Sticks to turn the fusee and create some slack in the return cable The fusee sticks can be used alternately one and then the other on adjacent holes in the fusee to create as much slack as possible in the return cable 10 11 Retaining Slot Lower Pulley Fusee Figure 8 18 Once there is slack in the return cable move the return cable off the lower
131. p With Fluid Section 4 5 and e Pressure Transducer Check Section 4 6 4 Chapter 4 PUMP CHECKOUT This chapter explains important checkout procedures for the QX Series Pump These procedures are necessary because the Quizix QX Series Pump is capable of reaching extremely high pressures By performing the pump checkout procedures each part of the pump is being carefully checked to confirm the pump is ready to operate safely The following are included in this chapter e When To Perform The Pump Checkout Section 4 1 e Verification of Pump Cable and Plumbing Connections Section 4 2 e Valve and Pilot Solenoid Check Section 4 3 e Pump Cylinder Check Section 4 4 e Connecting and Filling the Pump With Fluid Section 4 5 e Pressure Transducer Check Section 4 6 AN WARNING System checkout procedures are important to ensure safe operation of the Quizix QX Series Pump You must perform them carefully NOTE When a pump is new no liquid will be in the pump The system checkouts can be performed without adding fluid After system checkouts are completed you will be instructed how to add fluid If your pump has already been in use you may do these checkouts with fluid in the pump but be careful fluid pressure can build very rapidly 4 1 When To Perform The Pump Checkout You should perform the pump checkout procedures in each of the following situations 1 When a pump is first received from Chandler Engineering Although
132. pplied to the appropriate channel The A D converter digitizes the signal then the 16 bit result is displayed by PumpWorks PumpWorks allows for linear scaling of the data so that convenient units can be obtained for the signal The electrical characteristics of the input allow for signals up to 15 volts and as low as 15 volts without damage The input resistance is about 20 kiloohms Signals are referenced to the ground of the QX Series pin numbers 9 and 10 of the user interface A typical application could involve an external pressure transducer which is supplied by the 24 volt supply and has an output voltage which goes from 0 to 5 volts After wiring this transducer to the QX Series user interface and setting up the linear scaling in PumpWorks the pressure detected by this pressure transducer could then be displayed and recorded by Pump Works 10 4 2 Auxiliary Current Inputs One analog current input channel is available for use with external sensors This line is connected with a 16 bit analog to digital A D converter on the QX Series controller printed circuit board The input range for the A D used for this conversion is 0 32mA An analog voltage that is within the 0 32mA range is supplied to the appropriate channel The A D converter digitizes the signal then the 16 bit result is displayed by PumpWorks PumpWorks allows for linear scaling of the data so that convenient units can be obtained for the signal The electrical characteristic
133. pulley then from the bottom push the end of the return cable forward in its retaining slot The end of the return cable can then be lifted slightly to align with the extraction slot and then pulled out of the assembly Once the end of the return cable is free it can then be unwrapped from the fusee and the other end can be freed from the spring cable Figure 8 19 8 11 Chandler Engineering QX SERIES PUMP USER MANUAL 12 If the fraying or breakage of a return cable is due to wear from the fusee the fusee should be replaced with a new fusee with a teflon power coating See Fusee Replacement section below NOTE Before replacing a fusee both return cables will need to be replaced so that the spring box es can be removed 13 The new return cable can be installed in the reverse order of removal of the old Following are several images to help guide the process NOTE The images do not show the drive belts however the return cable replacement can be done without removing the drive belts just make sure that the drive belts are positioned properly on their pulleys at the end of the process Chapter 8 MAINTENANCE Chandler Engineering QX SERIES PUMP USER MANUAL 8 14 Chapter 8 MAINTENANCE 8 15 Chandler Engineering QX SERIES PUMP USER MANUAL 8 16 Chapter 8 MAINTENANCE 13 The spring boxes can then be removed and the fusee assembly can be replaced NOTE Cylinder A and Cylinder B fus
134. puters and the QX Series Pump 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 Chandler Engineering recommends a UPS that provides continuous on line filtering good AC line noise rejection and power back up capabilities It is also recommended that the time required for the unit to switch to back up power be less than 10 milliseconds The proper size of a UPS must be determined based on your pump and connected equipment and the type of power losses that are normally experienced The computer does not have to be powered in order for the pump to operate However if you are using a computer to log data or perform timed operations the computer must also be connected to the UPS The computer monitor does not have to be connected to the UPS unless you want to view data or manually change parameters during a power outage To determine the power consumption 7 1 Chandler Engineering QX SERIES PUMP USER MANUAL 1 2 of your pump and computer see Table 7 1 below Although many devices provide wattage ratings most UPS s are rated in volts amps Both ratings are listed in Table 7 1 Table 7 1 UPS Ratings Ite
135. r work area vertically The pump weighs approximately 25 4 kg 56 pounds gt Figure 3 2 Chapter 3 SYSTEM SETUP 3 2 Inspecting Your Pump Before doing anything else STOP and inspect your new pump Do not install your new pump if you suspect it has been damaged in transit To make sure no damage has occurred to the pump during shipping inspect the components No scratches or dents should be visible The tubing should not be crimped or have any irregular bends It is your responsibility to notify the shipping company immediately of any damage e Check the box for damage Then check the corresponding area on the pump The pump may have been damaged even if the box has only slight damage If the pump is damaged in any way notify the shipping company e Check the pump s outer case There are two windows on either side of the pump which allow viewing of internal components e Inspect the valves The valves should be smooth with no scratches and evenly spaced and aligned After informing the shipping company of any damage also inform Chandler Engineering You can reach us at the following numbers Chandler Engineering Phone 918 250 7200 9 00 a m to 5 00 p m CST Fax 918 459 0165 24 hours a day 7 days a week E mail chandler chandlereng com 24 hours a day 7 days a week 3 3 Connecting Your Air Supply The valves used in Quizix Pumps are air actuated Air is taken into the system through the air inlet and dis
136. ration 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 Chandler Engineering QX SERIES PUMP USER MANUAL independent constant rate cycled independent constant rate operation internal offsets interrupt request kPa logging interval lubricate main menu bar main window manifold max extend maximum extend maximum value max retract maximum retract mechanical subcomponents G 10 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 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 Data will be taken at a user specified
137. re Chapter 9 QX SERIES PUMP OPERATING BASICS 9 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 Figure 9 4 9 4 7 Valve Problems The air actuated flow control valves are a vital part of the operation of the QX Series pump They control the direction of the fluid flow The valves used on the QX Series pump 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 QX Series pump Refer to the Valve User Manual included with your pump which has detailed maintenance and troubleshooting information regarding the valves 9 4 7 1 Valve Cable Connection Check The valve cable connects the pump controller to the pilot solenoid control board The ribbon type valve cable comes to the bottom of the valve manifold inside the pump case Make sure the valve cable is plugged into the pilot solenoid control board The valve cable should be firmly seated If it has come loose simply slide it into the receptacle until the ejector latches swing around and lock the valve cable in place If the valve cable is not connected an error message is generated by PumpWorks 9 4 7 2 Checking Your Air Supply The valves used in Quizix Pumps are air actuated
138. ready been installed for you Go to Section 3 9 Turning On Your Pump It is assumed that at this point the user has completed the following e the air supply is connected e a fluid supply is connected e the pump is connected to a power source and e acomputer is connected to the pump and turned on 3 8 1 How To Install PumpWorks Please refer to PumpWorks User manual Section 2 Installing PumpWorks 3 9 Turning On Your Pump It is assumed at this point that the user has completed the following e the air supply is connected e a fluid inlet and outlet supply is connected e the pump is connected to a power source e the front panel is connected if ordered e acomputer is connected to the pump if PumpWorks was ordered and Chapter 3 SYSTEM SETUP e PumpWorks if ordered has been installed on the computer connected to your QX Series pump 3 9 1 QX Series Two Digit Display The QX Series has a two digit display located on the front panel of the pump 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 When turning on your pump the user needs to watch the two digit display For more information please refer to Section 3 9 3 of this chapter The Two Digit Display When Pump is Turned On
139. rew the seal retaining collar back onto the cylinder barrel 8 1 7 Replacing the Wash Area Seals 1 2 Pumps with a wash area have additional seals which may need to be replaced Remove the 2 screws located on the bottom of the wash area collar Remove the wash area plate and set aside Remove the wash area seal and throw away Replace with a new wash area seal so that the spring is not visible Screw the wash area plate back onto the wash area collar Figure 8 7 8 1 8 Replacing the Pump Cylinder O Rings The pump cylinder contains two o rings which can be replaced if needed 1 The cylinder barrel o ring is located about 1 cm 4 inches from the top of the cylinder barrel To replace the cylinder barrel o ring simply pry off and slide the cylinder barrel o ring off the cylinder barrel Once this o ring has been removed throw it away Place a new cylinder barrel o ring on the cylinder barrel making sure it is properly seated into the groove on the cylinder barrel Figure 8 8 The face o ring is located on the top of the cylinder barrel If the face o ring needs replacing simply pry it off the cylinder barrel and throw it away Place a new o ring on the top of the cylinder barrel and press it into place 8 1 9 Re assemble the Pump Cylinder 1 2 3 Insert and push the piston into the cylinder barrel until the piston is fully seated If your pump has a wash area reattach the wash area tubes to the
140. rings lt 5 suspaseselteaeese 8 17 Re assembling the Transducer 8 18 See also Pressure Transducers 4 10 Troubleshooting ccceeeeeeeeseeeeeteees 9 1 Air Supply Requirements 9 17 BASiCS nisa eN 9 1 Checking Your Air Supply 9 17 Checking Your Air Supply Connection siessideissieasveereccnes 9 18 Physical Piston Position Indicator Does Not Move When Pump Cylinder Is Operating 9 15 Piston Moves But Does Not Complete Its Stroke 9 15 Pressure Does Not Increase Within 30 Seconds 0 9 16 Index 3 Chandler Engineering QX SERIES PUMP USER MANUAL Pressure Is Not Constant in Constant Pressure Mode 9 17 Pressure Overshoots Setting in Constant Pressure Mode 9 16 Pressure Problems 006 9 16 Valve Cable Connection Check 9 17 Valve Problems 9 17 Turning On Your Pump 3 10 Two Digit Display When Pump Is Installed Onto PumpWorks 3 14 U Uninterruptable Power Supplies 7 1 RAGES te neei ra a ei 7 2 Uninterruptable Power Supplies CUPS ated a E 3 7 Unpacking the QX Pump 3 2 Unpacking the QX Series Pump 3 1 USB Communication eee 3 9 User Search For New Pump 3 13 V yal Vereses ees canted acted hit 4 4 Index 4 Removing the Valve Assembly 8 2 Warning Messages seses 4 4 Opening Both Fill and Deliver Valves saene isna 4 4 Pressure Above
141. rs are filled with fluid this should occur with less than 1 ml of fluid pumped or there is a fluid leak e Repeat this procedure for all the pump cylinders in your system If you had to stop the pump cylinders because the pressure did not start to increase within 30 seconds the most likely reason is 1 Insufficient Fluid in the Pump This can be caused by e An Air Leak in the fluid tubing e The Fluid inlet tubing is clogged so no fluid can enter the pump e Fluid is too viscous or thick to be pulled into the pump Go through the pump and check all of the air fitting connections to make sure they are tight If the fittings are all tight go back to Connecting and Filling the Pump With Fluid Section 4 5 When finished try the Pressure Transducer Check again 2 The Pressure Transducer has Malfunctioned This can be caused by e The pressure transducer is broken and not reporting the pressure e The pressure transducer is cross wired To check this open the fill valve and listen for pressure being released If there is pressure being released you probably do have a pressure transducer failure or the pressure transducer is cross wired Chapter 4 SYSTEM CHECKOUT NEVER operate the pump if you have any reason to believe a pressure transducer or pump controller is malfunctioning Do not proceed further until your pump system has passed all checks After completing the safety checks in this chapter the pump is ready for use Bef
142. s being calibrated open the deliver valve s and close the fill valve s 7 Use PumpWorks 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 8 Stop the pump when pressure reaches 90 of the system s maximum pressure 9 T IMPORTANT INFORMATION 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 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 to prevent faulty and malfunctioning transducers from being c
143. s 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 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 is the number of steps the motor takes to complete one complete turn or one revolution The portion of the motor that 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 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 Chan
144. s of the input allow for signals up to 24 volts and as low as 12 volts without damage The input resistance is about 10 60 ohms A typical application could involve an external 4 20mA pressure transducer After wiring this transducer to the QX Series user interface and setting up the linear scaling in Pump Works Chapter 10 QX SERIES USER INTERFACE the pressure detected by this pressure transducer could then be displayed and recorded by Pump Works 10 5 Emergency Stop Signal Pin 19 of the user interface connector is tied to the emergency stop signal of the pump controller This signal is a pull to ground to activate the emergency stop function It can be pulled to ground using a switch that connects it to any of the digital ground pins 10 6 Power Lines The user interface has 5 and 24 volt power available on various pins This is to make it easy to hook up external sensors and devices However the amount of current available is limited The 5 volt power can supply 500 milliamperes total current and the 24 volt power can supply 500 milliamperes of current 150 milliamperes with Front Panel attached Do not exceed these amounts If more current is needed to operate a device use an external power supply 10 7 Remote Control Interface The following remote control capabilities are available via the user interface connector The remote control features can be enabled disabled via PumpWorks e Start Stop Available on Pin 21 Logi
145. sensor e drive train problem broken belt or excess friction Sensor Cable Error e sensor cable not connected Soft Limit Warning e stroke position outside normal bounds 9 9 Chandler Engineering QX SERIES PUMP USER MANUAL e malfunctioning linear 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 9 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 9 4 1 e Fan Does Not Run Section 9 4 2 e Fluid Leaks Section 9 4 3 e No Fluid Is Being Delivered Section 9 4 4 e Piston Motion Errors Section 9 4 5 e Pressure Problems Section 9 4 6 e Valve Problems Section 9 4 7 9 4 1 Air Supply Problems The valves on the QX Series pump need a CLEAN DRY air supply between 4 and 8 bar 60 to 115 PSI to properly operate 9 4 1 1 No Air Escaping Sound When Valves are Opened amp Closed The most likely cause of this problem is that the air supply is not dry so the pilot solenoids have r
146. serial expander isolator e Connect the other end of the data communications cable to Data Link on the QX Series Pump Your pump is now connected to a computer Go to Section 3 8 Installing PumpWorks Software 3 7 2 2 USB Communication NOTE Some pump controllers may have a USB connection Even though a physical USB port may be present pump controllers do not support USB connections 3 9 Chandler Engineering QX SERIES PUMP USER MANUAL 3 7 3 Adding a QX Series Pump to An Existing PumpWorks System To add a QX Series Pump to an existing pump system which already uses PumpWorks you can either follow the steps in Section 3 7 2 to connect your pump via the USB port or follow the steps below to use the serial connection Up to four Quizix pumps can be operated from one serial port via the serial expander isolator 1 Connect the data communications cable into Data Link on the QX Series pump control panel 2 Connect the other end of the data communications cable into the serial expander isolator Use the first available port Port A B C or D Since you are adding a pump to an existing PumpWorks system it is assumed that your serial expander isolator is already connected to an RS 232 communications cable which is connected to a computer 3 Go to Section 3 9 Turning On Your Pump 3 8 Installing PumpWorks Software If you purchased a computer from Chandler Engineering with your QX Series Pump PumpWorks has al
147. stant delta pressure mode The user sets the rate the pump flows at when operating in a Constant Rate mode 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 Chandler Engineering QX SERIES PUMP USER MANUAL 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 status bar steady state stepper motor stopped conditions stroke volume symmetrical 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 c
148. sure The current pressure of the pump cylinder is displayed in psi 6 1 4 Rate The current rate of the pump cylinder is displayed in ml min milliliters per minute 6 1 5 Volume The cylinder volume is displayed in ml It is recommended that the volumes be reset when the pump cylinders are in the maximum retracted position Max Retract The cylinder volumes will then accurately indicate the position of the pump cylinder 6 1 6 Set Rate and Set Pressure When the pump is set to a Constant Rate operating mode the front panel window will display Set Rate ml min Press this button and a keypad window appears so that the desired pump rate can be set See Figure 6 3 below et Flow Rate ml min Figure 6 3 6 3 Chandler Engineering QX SERIES PUMP USER MANUAL When the pump is set to a Constant Pressure mode the front panel window will display Set Pressure psi Press this button and a keypad window appears so the user can set the desired pump pressure See Figure 6 4 below Figure 6 4 If the pump is already running when the rate or pressure is changed the pump will immediately adjust to the entered rate or pressure setpoint If the pump is not running then the setpoint will be stored and will take effect when the pump is started If the pump cylinder is in a Paired operating mode then a rate or pressure setpoint entry will immediately be applied to both pump cylinders 6 1 7 Operating Mode The
149. t Section 9 3 1 e The Two Digit Display Does Not Complete Its Initial Check Section 9 3 2 e Pump Controller Diagnostics Section 9 3 2 1 e Two Digit Display Codes Section 9 3 3 9 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 do the following e Check that the power cord is fully plugged in e Check that power is available to the electric outlet e Try turning the pump s power switch off and then back on again If the two digit display still does not light either the power supply or the pump controller has failed and needs to be replaced at Chandler Engineering The power fuse for the power supply is not user replaceable 9 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 Chandler Engineering Chapter 9 QX SERIES PUMP OPERATING BASICS Watch the two digit display when you turn on your pump e The first thing that will 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 9 3 2 1 Pump Controller Diagnostics QX Two Digit Display The bas
150. t Panel unit while the flash is being re written Doing so could leave the Front Panel in an inoperable state 6 3 3 Pressure Control Pressing the Pressure Control button on the Configure window brings up the Set Pressure Servo Gains window as shown in Figure 6 18 below Chandler Engineering QX SERIES PUMP USER MANUAL Figure 6 18 To change any of the gain values press the corresponding button The keypad window will be displayed so the desired gain value can be entered Press Close to exit the Set Pressure Servo Gains window 6 3 4 Units amp Precision The user can control the units of measurement and displayed precision for pressure rate and volume by touching the Units and Precision button The Units and Decimal Places window shown in Figure 6 19 will appear Figure 6 19 e To change the units of measurement touch on the appropriate current unit of measurement and then touch the button for the new desired units Chapter 6 OPERATING YOUR FRONT PANEL e To change the number of digits displayed to the right of the decimal place touch the appropriate precision button and then use the keypad to enter the desired number of digits to be displayed to the right of the decimal place 6 4 Setting Display Brightness To adjust the brightness of your Front Panel display follow the instructions below e Stop the pump if is running e Exit the Front Panel Software by pressing the Exit Program b
151. the QX Series if desired 1 2 Easy to Connect The only connections the user must make when setting up the QX Series Pump are outside of the pump case and include e Front Panel Users connect the Front Panel to the pump e PumpWorks Users connect the data communications cable to the computer through the serial expander isolator e All Pump Systems AC power connection amp air connection for the air actuated valves and fluid inlet and outlet connections for the user s fluid 1 3 The PumpWorks Advantage PumpWorks software operates on at least a 486 or Pentium compatible computer using Microsoft Windows 95 98 NT ME 2000 and XP operating systems PumpWorks is easy to install and operate PumpWorks features include e The user has complete control over all operating parameters e PumpWorks allows system wide integration of the user s experiment or application by displaying data from any additional valves transducers A D signals or acoustic separators e Data received from the experiment or application can be logged or recorded to the user s computer e Data received from the experiment or application can be exported using Dynamic Data Exchange DDE 1 4 QX Series Pump Models Below is a list of the QX Series Pump models that are available and their specifications Chapter 1 GENERAL OVERVIEW THE QX SERIES PUMP SERIES MAXIMUM MAXIMUM STROKE PISTON MODEL PRESSURE
152. the piston can be observed by watching through the window on each side of the pump The piston position is indicated by the green LED on the piston carriage If you have not yet connected your fluid source DON T You should perform the initial pump cylinder check with no liquid in your system just air If the pump cylinders already contain liquid you can proceed with the pump cylinder check however be sure to have the fluid plumbing connected and a container at the end of the fluid inlet plumbing and the fluid outlet plumbing During the pump cylinder check fluid will be pumped out of and drawn into the pump cylinder Also be aware that with liquids pressures can rise rapidly when the pump cylinders are extending At this point it is assumed that the user has completed the following e the computer is turned on e the QX Series Pump is turned on and e PumpWorks or the Front Panel is operating e all previous checks in this chapter have been passed 1 Setthe Safety Pressure for pump cylinder A to 100 PSI 700 kPa by doing the following e PumpWorks e From the menu bar select Main Set Pump Safety Pressure e Inthe Enter New Pressure text box of pump cylinder A enter 100 for PSI 700 for kPa e Click on Send Safety Pressures to Pump s e Front Panel e Touch the Quizix Logo at the top left of the main window to access the menu e Touch the Safety Pressure button e Using the numbers on the keypad enter 100 i
153. 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 bar graph in the PumpWorks software that shows how far the Piston is inserted inside of the Cylinder Barrel 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 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 conti
154. tions 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 moving forward in the cylinder barrel which causes fluid to be delivered out of the pump to the user s experiment To begin G 7 Chandler Engineering QX SERIES PUMP USER MANUAL fill fill valve flexure flow rate fluid inlet tubing fluid outlet tubing fluid tight fluid tubing fluid plumbing fuse fuse holder geared mode governs QD fitting or quick disconnect fitting hastelloy HC G 8 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 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
155. tness on Front Panels with Windows CE 4 2 If the TPC Configuratior is open close it by pressing the X in the top right corner of the window Otherwise if Quizix Front Panel Software is running stop the pumps and exit the Front Panel Software by pressing the Exit Program button from the menu accessed by pressing the Quizix logo At this point you should see the desk top shown in Figure 6 20 To set the brightness do the following e Touch the bottom left corner of the front panel until the start menu pops up as shown in Figure 6 24 Figure 6 24 e Touch Settings Another pop up menu will appear as shown in Figure 6 25 Figure 6 25 e Touch Control Panel The Control Panel Window will appear as shown in Figure 6 26 Chandler Engineering QX SERIES PUMP USER MANUAL Figure 6 26 e Double press the Display icon The window shown in Figure 6 27 will appear Figure 6 27 e Press on the BackLight Tab The window will change to the one shown in Figure 6 28 Chapter 6 OPERATING YOUR FRONT PANEL Figure 6 28 e Press the Advanced button The window in Figure 6 29 will appear Figure 6 29 e Press the and buttons to adjust the contrast and brightness to the desired settings e When finished press the OK button on the top right corner of the window e Press the OK button on the top right corner of the Display properties window e Close the Control Panel window by pressing on the X in t
156. tributed to the pilot solenoid manifold The pilot solenoids then distribute and control the air flow to the valves 3 3 1 Air Supply Requirements IMPORTANT INFORMATION Although the QX Series 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 because moisture in the air supply will cause the pilot solenoids to rust and malfunction Chandler Engineering QX SERIES PUMP USER MANUAL e The air must be between 60 to 115 PSI 4 to 8 bar If air pressure exceeds this the pilot solenoids may stop working 3 3 2 Connecting Your Air Supply To connect the air supply first identify the air inlet located on the back panel of the QX Pump Please refer to in Figure 3 3 Insert a 6 mm diameter tube into the air inlet fitting until itis tight and cannot be moved Attach the other e end of the tube into your pressurized air source If your air supply has a switch to turn it on turn it on now so that air will be supplied to the pump Note that 1 4 inch tubing will DRY COMPRESSED AIR also work in most cases Nylon tubing is the recommended pee material for the air tubes however other materials will work gt a au Figure 3 3 3 4 Connecting Your Fluid Plumbing The fluid tubing you use to connect your fluid plumbing should be 1 8 inch tubing 3mm tubing is not recommended since it will not hold pressure The tubing needs to have a ferrule and gland
157. ur pump from stopping when power interruptions or fluctuations occur To prevent disruption to an experiment it is strongly recommended that users who are interested in obtaining continuous fluid flow over extended periods of time use a UPS with their pump system For more information about choosing a UPS see Chapter 7 Section 7 2 Using Uninterruptable Power Supplies 3 7 Connecting to a Computer or Front Panel This section instructs the user how to connect their pump to the user interface Please follow the instructions in one or more of the sections listed below for instructions on connecting the user controls for your particular pump system e Connecting a Front Panel Section 3 7 1 e Connecting Your QX Series to a Computer Section 3 7 2 e Adding a QX Series Pump to An Existing PumpWorks System Section 3 7 3 3 7 1 Connecting a Front Panel If you ordered a Front Panel with your pump it will be shipped in a separate box to better protect it during shipping Perform the following steps to install the Front Panel onto your QX Series Pump 1 Unpack the QX Pump and place it on a surface that allows access to the front of the pump Verify that the front lower panel of the pump is compatible with the Front Panel assembly It should look like the drawing in Figure 3 7 with a Dsub 9 pin connector visible in the slot at the bottom If the front lower panel does not have the slot and visible connector please contact Chandler Engineer
158. us flow is achieved by precisely coordinating the switching between the two cylin ders The outside curve as in the outside of a bowl corrosive fluids cup type seals current value Cursor cycled mode cylinder barrel cylinder barrel assembly cylinder barrel volume cylinder support block data log data log parameters debug deburr default default names default pressure unit GLOSSARY Fluids or chemicals that gradually wear down or eat away at the pump system 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 assembly consists of the cylinder barrel cylinder seal seal back up rings and seal retaining nut 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 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 r
159. usted 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 have 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 e If the air pressure is too high more than 6 9 bar 100 PSD install an air regulator to limit the pressure Chapter 9 QX SERIES PUMP OPERATING BASICS 9 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 QX Series 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
160. uto Start Mode active pump running See Chapter 10 Section 10 7 Remote Control Interface AO AS CE dC dF dO dP dU ES LE PC PE SC SL Chapter 9 QX SERIES PUMP OPERATING BASICS Analog Overpressure Error e pressure transducer signal abnormally high e transducer or transducer cable failure e analog to digital converter problem Auto Start Mode e Remote Auto Start Mode enabled pump not running See Chapter 10 Section 10 7 Remote Control Interface Communication Error e unable to decode communication from computer Driver Cable Error e driver cable not connected Driver Status A or B e the motor driver has a fault possibly overheated or shorted e turn off power to reset driver Digital Overpressure Error e 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 e 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
161. utton and the following window will be visible The Exit Program button is located on the Front Panel Menu AD ANTECH Figure 6 20 e The next step will depend on which version of Windows CE is running on your front panel To determine this double press the TPC Configurative icon and the window shown in Figure 6 21 will appear If there is a Display tab at the top of the window as shown in Figure 6 21 follow the steps in Section 6 4 1 If there is not a Display tab on the top of this window follow the steps in Section 6 4 2 Figure 6 21 Chandler Engineering QX SERIES PUMP USER MANUAL 6 4 1 Setting Display Brightness on Front Panels with Windows CE 3 0 If you haven t already done so open the TPC Configurator as described in Section 6 4 Press the Display tab The window shown in Figure 6 22 will appear Figure 6 22 e Slide the brightness bar to optimize the viewing of the window When done press the Apply button e The setting will now need to be saved to flash Press the Misc tab to display the window shown in Figure 6 23 below Figure 6 23 e Press the Save button to save the current registry settings A window showing the progress of the registry save will appear When the registry save has been completed you can restart the Front Panel Software by turning off power to the pump then turning it on again Chapter 6 OPERATING YOUR FRONT PANEL 6 4 2 Setting Display Brigh
162. would be to take an electrical sig nal 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 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 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 Temperature that is equal to the temperature in the surrounding room A device which increases the magnitude or amplitude of a sig nal such as voltage from a pressure transducer 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 Chandler Engineering QX SERIES PUMP USER MANUAL arrow keys atmosphere atmospheric pressure Autoclave speedbite fitting
163. y sequencing or in error state capture mode e From the menu bar select Communications Update front Panel Software The window shown in Figure 6 14 opens Front Panel Selection for Software Update Cancel Figure 6 14 Choose the pump you wish to update by doing the following e Click on the arrow to the right of Transfer Software to Front Panel text box e Click on the pump number you wish to update or click on All Software Upgradeable Pumps Only pumps with front panels are available in this menu Non QX Series pumps uninstalled pumps or pumps running in recirculating mode are examples of pumps that would not be included in this menu e If PumpWorks is in a state that does not allow upgrading of the selected pump if pump cylinders are currently running ramping under auto volume control in recirculating mode sequencing or in error state capture mode an error will be given Otherwise the Specify Front Panel Program File window opens as shown in Figure 6 15 6 11 Chandler Engineering QX SERIES PUMP USER MANUAL 6 12 Specify Front Panel Program File for Pump 1 File name ax ofp Files of type Program Files qtp Cancel T Open as read only Z Figure 6 15 Double click on the file where the software update is located These files are available from Chandler Engineering Examples of updates for the front panel are shown in the example above The naming convention for front panel softwar

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