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fann MACS II User Manual

Multiple analysis cement system
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Multiple Analysis Cement System
(MACS II)
User Manual
(P/N 101677665)
101796668
Rev. E
P00000

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Summary of Contents for fann MACS II

  • Page 1 Multiple Analysis Cement System (MACS II) User Manual (P/N 101677665) 101796668 Rev. E P00000...
  • Page 2 All rights reserved. No part of this work covered by the copyright hereon may be reproduced or copied in any form or by any means (graphic, electronic, or mechanical) without first receiving the written permission of Fann Instrument Company, Houston, Texas, USA.
  • Page 3 MACS II User Manual Document Conventions The following icons are used in this manual to distinguish elements of text. Contains additional information for the reader that is not safety related. Describes a situation or practice that if ignored, will result in equipment damage or loss of data.
  • Page 4 MACS II User Manual ® Contact FANN Phone TELEPHONE: 281-871-4482 TOLL FREE: 800-347-0450 FAX: 281-871-4358 Mail Fann Instrument Company P.O. Box 4350 Houston, Texas, 77210 USA Location Fann Instrument Company 14851 Milner Road, Gate 5 Houston, Texas, 77032, USA Online www.fann.com...

  • Page 5: Table Of Contents

    ECHANICAL NSTALLATION 4.2.1. Water, Air, and Coolant Connections ....................17 4.2.2. Electric Power Connection ........................19 4.2.3. Power Up MACS II Unit ........................19 4.2.4. Initial Verification of Alignment ......................19 4.2.5. Water Test ............................22 4.3..........................22 OFTWARE NSTALLATION 4.3.1.
  • Page 6 MACS II User Manual 5.5.1. Zero Drive............................46 5.5.2. Calibrate Pressure ..........................47 5.5.3. Calibrate SGS ............................53 5.5.4. Test Repeatability ..........................54 5.6............................. 58 PERATE 5.6.1. Cell Operations ............................ 58 5.6.2. Valve Operations ..........................60 5.6.3. Manual Operation ..........................61 5.6.4.
  • Page 7 MACS II User Manual 10.6. 101723012 ................138 RAME RAWER ECHANICAL SSEMBLY 10.7. SGS T 101636768 ....................... 147 SSEMBLY 10.8. 100072017 ......................149 LURRY SSEMBLY 10.9. , SGS 101636441 ......................151 ADDLE SSEMBLY WARRANTY AND RETURN ..........................155 101796668 Revision E...
  • Page 8 MACS II User Manual Table of Figures Figure 1-1 MACS II Front View (Shown with Customer Laptop) ......2 Figure 1-2 MACS II with Door Open ..............3 Figure 1-3 Turn Table Assembly And Pressure Cell ..........4 Figure 4-1 MACS II Hydraulic and Pneumatic Ports ..........18 Figure 4-2 X Direction Adjustment ..............
  • Page 9 MACS II User Manual Figure 8-8 - Lubrication of Threads ..............89 Figure 8-9 Torque Sensor Tool ................. 90 Figure 8-10 Vise with Soft Jaws ................ 90 Figure 8-11 Spring Pad ................... 91 Figure 8-12 Valve Parts ................... 91 Figure 8-13 Stem and Spring ................92 Figure 8-14 O-ring and Backup Ring ..............

  • Page 10: Overview

    MACS II User Manual Overview Table of Contents OVERVIEW ................................1 1.1. II ....................... 2 ULTIPLE NALYSIS EMENT YSTEM 1.1.1. Thickening Time ............................ 5 1.1.2. Transition Time ............................5 1.2. S ..........................5 PECIAL ONSIDERATIONS 101796668 Revision E...

  • Page 11: Figure 1-1 Macs Ii Front View (Shown With Customer Laptop)

    The Multiple Analysis Cement System (MACS) II is a device that performs static gel strength tests on cement slurry samples. Following are several pictures of the unit. Figure 1-1 MACS II Front View (Shown with Customer Laptop) 101796668 Revision E...

  • Page 12: Figure 1-2 Macs Ii With Door Open

    MACS II User Manual Figure 1-2 MACS II with Door Open 101796668 Revision E...

  • Page 13: Figure 1-3 Turn Table Assembly And Pressure Cell

    The MACS II conducts these tests under simulated down-hole pressure and temperature conditions to determine the following characteristics of cement:  Transition time. In these tests, the MACS II accepts a sample of cement slurry and applies a controlled set of temperature, agitation, and pressure parameters that simulate the 101796668...

  • Page 14: Thickening Time

    Special Considerations 1.2. The MACS II is a unique device that performs analysis for cement slurry. In order to perform reliable tests, the unit generates significant temperatures and pressures. Care and caution should be exercised to minimize the potential for personal injury and/or damage to facilities.
  • Page 15 MACS II User Manual Be alert to symptoms indicating the pressure does not reduce. This may be an indication of a blocked control outlet line or filter. The pressure control is a multi tiered design with separate ports being used for pressure up, absolute overpressure safety, manual release, controlled dump and automatic release.

  • Page 16: Safety

    MACS II User Manual Safety Table of Contents SAFETY ................................. 7 2.1............................9 ACHINE HAZARD 2.1.1. Pressure ..............................9 2.1.2. Temperature............................9 2.1.3. Electrical ............................... 9 2.1.4. Pinch Points ............................10 2.2........................10 RGONOMIC ONSIDERATIONS 2.3......................10...
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  • Page 18: Machine Hazard

    2.1.3. Electrical The power source for the Macs II is 230 Volts. Disconnect the power from the plug before attempting any electrical or mechanical maintenance. 101796668...

  • Page 19: Pinch Points

    The cell drawer can also be controlled in and out of the Macs II. Ensure that the front doors are open and that nothing blocks the drawer when the process is initiated. Do not stand in front of this area while Drawer motion is initiated 2.2.

  • Page 20: Features And Specifications

    MACS II User Manual Features and Specifications Table of Contents FEATURES AND SPECIFICATIONS ......................11 3.1. MACS II I ......................13 NSTALLATION REPARATION 3.2..........................13 HYSICAL EQUIREMENTS 3.3........................13 PERATIONAL ONSIDERATIONS 3.4.......................... 14 OMPUTER PECIFICATIONS 101796668 Revision E...
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  • Page 22: Macs Ii Installation Preparation

    There are certain facility requirements to consider in designating a location for the MACS II system. It is necessary to provide a facility space at which to locate and operate the MACS II system that is properly designed, equipped, and HSE assessed for SGS testing.

  • Page 23: Computer Specifications

    The MACS II system includes state-of-the-art software that runs on a Microsoft Windows-based computer connected via USB. The software can also receive updates via the Internet. Provided with the MACS II is a DVD-ROM containing the software to install on the computer.

  • Page 24: Installation

    ECHANICAL NSTALLATION 4.2.1. Water, Air, and Coolant Connections ....................17 4.2.2. Electric Power Connection ........................19 4.2.3. Power Up MACS II Unit ........................19 4.2.4. Initial Verification of Alignment ......................19 4.2.5. Water Test ............................22 4.3..........................22 OFTWARE NSTALLATION 4.3.1.
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  • Page 26: Pre-Installation Considerations

    4.2.1. Water, Air, and Coolant Connections In order to function, it is necessary to connect the MACS II to water, compressed air, and coolant sources. Ports for connecting these services are on the back of the unit. Component Connect to…...

  • Page 27: Figure 4-1 Macs Ii Hydraulic And Pneumatic Ports

    “Hot Out” ports to drain. Never use a single hose with a T- connector for these two outlets. Figure 4-1 MACS II Hydraulic and Pneumatic Ports Depending on the cooling fluid and ambient conditions at the site, it is possible for drained coolant to be classified as a hazardous waste.

  • Page 28: Electric Power Connection

    4.2.2. Electric Power Connection The MACS II is supplied with a 6 foot (1.83 m), 50 amp power cord to connect to a current protected electrical outlet. Because of the variety of electrical outlets throughout the world, a plug is not already attached. Wire the MACS II directly into an electrical disconnect (circuit breaker) or attach an appropriate plug and connect the MACS II into an electrical outlet with fault interrupt protection.

  • Page 29: Figure 4-3 Y Direction Adjustment

    MACS II User Manual  Y Direction (up-down). Use the bolting mechanism on the actuator to raise or lower the cell bottom. Figure 4-3 Y Direction Adjustment  Z Direction (in-out). Use the drawer cylinder and drawer stop mechanisms to perform this adjustment.

  • Page 30: Figure 4-5 R Direction Adjustment

    There are several switches that limit the motion of the unit. These include a linear actuator which moves the cell up/down, a rotary actuator that controls cell rotation, and actuating cylinders that control drawer in/out and top plate up/down. Figure 4-6 MACS II Limit Switches 101796668 Revision E...

  • Page 31: Water Test

    5. Document any problems found and contact Fann Customer Support. Software Installation 4.3. Fann provides the following software to operate and configure the MACS II on a DVD-ROM included with the system:  MACS II SGS Software Components  Edgeport USB Drivers for Microsoft Windows Install the software on the dedicated computer associated with the unit.

  • Page 32: Software Quick Install

    Software Quick Install Perform the following procedure for a quick install of the MACS II software: 1. Run the Setup program on the DVD to launch the MACS II software installation wizard. 2. Read the dialogs and follow the on-screen prompts.

  • Page 33: Usb Connection Configuration

    The MACS II system uses Universal Serial Bus (USB) plug and play interface technology to communicate with the MACS II SGS software installed on a Microsoft Windows-based computer. To connect the MACS II device for the first time to the computer with the SGS software, setup the USB connection as follows: 1.
  • Page 34 2. Plug the “B” type male connector of one of the two supplied USB cables to one of the USB Standard “B” female plugs located on the back of the MACS II. Plug the other USB cable to the remaining female plug on the MACS II.

  • Page 35: Figure 4-7 Found New Hardware Wizard

    Click Browse to navigate to the path C:\Edgeport which is the folder where the USB driver files were copied from the DVD during the MACS II SGS software installation. Click Next. Figure 4-7 Found New Hardware Wizard 7.

  • Page 36: Figure 4-8 Unable To Import Configuration Settings Dialog Box

    Alternatively, refer to the instructions from the beginning in Section 4.3.3. USB Connection. Figure 4-8 Unable to Import Configuration Settings Dialog Box The MACS II system is ready to perform the post-installation verification procedure. Refer to Section 4.4 Post-Installation Verifications for this information.

  • Page 37: Software Updates

    MACS II User Manual 4.3.4. Software Updates The MACS II system is set up to receive automatic software updates remotely over the Internet. When connected to the Internet, click Help > Check for Updates… and a dialog box displays. Figure 4-9 Software Updates Dialog Box Click Start to check for updates.
  • Page 38 MACS II User Manual 4. Verify that the unit heats up when temperature setpoint is set 20 degrees above ambient 101796668 Revision E...
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  • Page 40: Macs Ii Software

    MACS II User Manual MACS II Software TABLE OF CONTENTS MACS II SOFTWARE ............................31 5.1............................33 OFTWARE ASICS 5.2........................... 33 NTERFACE LEMENTS 5.2.1. Menu Bar ............................. 34 5.2.2. Variable Indicators ..........................34 5.2.3. Status Indicator ............................ 35 5.2.4.
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  • Page 42: Software Basics

    Software Basics 5.1. Fann MACS II software is intuitive to use. If the user has had experience using Microsoft Windows and has basic knowledge about SGS testing, there should be no difficulty understanding the information in this section or using the software.

  • Page 43: Menu Bar

    MACS II User Manual  Variable Indicators  Status Indicator  Start/Stop Test button  Results Graph 5.2.1. Menu Bar The Menu Bar, at the top of the desktop, provides top level control for the program. The available options include: ...

  • Page 44: Status Indicator

    MACS II device, as follows:  Idle – The software is disconnected from the MACS II unit.  Connected – The software is communicating with the MACS II unit and is updating values shown in the indicators.  Running – A test has been started and the software is updating the indicators, the graph, and logging data.

  • Page 45: Results Graph

    MACS II User Manual 5.2.5. Results Graph The Results Graph is the main component and dominant portion of the desktop. It is the large portion of the screen below the variable indicators and status indicator. During a test, the XY Graph displays the temperature, pressure, SGS, and consistency that compose the test results.

  • Page 46: File Menu

    4. The software first automatically adjusts the drive mechanisms. A message displays to notify of this status. 5. The software is now connected to the MACS II unit. The status indicator shows as Connected. 6. The Variable indicators start displaying current measured values.

  • Page 47: Exit

    MACS II User Manual 1. From the File menu, click Save. 2. The software writes the data to the designated drive and file. 5.3.4. Exit The Exit command closes and exits the program. 1. From the file menu, choose Exit.

  • Page 48: Figure 5-3 General Tab Screen

    MACS II User Manual 5.4.1.1. General Tab Click Edit > Machine Settings to display the Edit Machine Settings General screen. The first display in this group is the General tab. Figure 5-3 General Tab Screen Below is the explanation of the individual items on this screen 1.
  • Page 49 MACS II User Manual pressure control activity is suspended. Pressure control is resumed once the measured pressure drifts outside of this tolerance value. The nominal tolerance for the machine is 200 PSI. b. SGS DeadBand – This works in the same manner as “Normal DeadBand”...

  • Page 50: Figure 5-4 Test Header Tab Screen

    MACS II User Manual 5.4.1.2. Test Header Tab From Edit Machine Settings, select Test Header and the Test Header screen displays. Figure 5-4 Test Header Tab Screen Below is the explanation of this tab. 1. Test Header – By adding values here, the user can make these values default so that these values do not have to be input every time the test information is input.

  • Page 51: Figure 5-5 Slurry Cup Paddle Motion Tab Screen

    MACS II User Manual Currently, the events section of this tab is not available. It is necessary for the user to find SGS and Time events manually using the cursor. 5.4.1.3. Motion Tab From Edit Machine Settings, select Motion and the Motion screen displays.

  • Page 52: Figure 5-6 Constants Tab Screen

    MACS II User Manual 3. Set motor speed – Type speed of the motor in conjunction with the units chosen above. 4. Select direction of the motor – The direction can be clockwise (CW) or counter clockwise (CCW). The direction is referenced by standing in front of the machine and looking down at the machine.

  • Page 53: Figure 5-7 Pid Tab Screen

    MACS II User Manual 1. Com Ports - In the Com Ports portion of the screen, use the arrow keys to view a list of available options for Motor Com, Torque Com, and Temp & Press Com. Alternatively, type the appropriate entry in the text boxes.

  • Page 54: Profile Editor

    MACS II User Manual This screen manages the configuration constants for the dynamic and static conditions for temperature control. Note that these are default values and only experienced technicians should change these settings. Click OK to save any changes and close this screen. Click Cancel to exit this screen without saving any changes.

  • Page 55: Calibration Menu

    Click OK to save any changes and close this screen. Click Cancel to exit this screen without saving any changes. 5.5. Calibration Menu The Calibration Menu manages various calibration tasks for the MACS II system. This menu contains the following options.  Zero Drive  Calibrate Pressure ...

  • Page 56: Calibrate Pressure

    MACS II User Manual During the adjusting drive mechanism process, it is imperative to not adjust the drive system. When the adjustments are complete, the following dialog box displays. Figure 5-10 Reference Position Dialog Box Physically rotate the drive mechanism to the marked reference location. When the drive is properly set, select Zero to accept the new reference point.

  • Page 57: Figure 5-12 Calibrate Screen New Calibration (Bottom) Portion

    MACS II User Manual Figure 5-12 Calibrate Screen New Calibration (Bottom) Portion Follow this procedure to calibrate the pressure. 1. Click Start. 2. In the Actual PSI text box, type the actual pressure. If the Read PSI is reading a negative number, then type 0 (zero).
  • Page 58 MACS II User Manual SGS Calibration Setup 1. On the Operate menu, click Cell Operations. 2. When the Operate Cell dialog appears, click Open Cap. 3. After the cap opens, verify that the O-ring and backup ring, located inside the cell cap, are in good condition, properly aligned, and lubricated with approved grease.
  • Page 59 MACS II User Manual 4. Fill the sample cup with water. Assemble the cup and rotate the coupling to ensure free movement. 5. Click Open Drwr. 6. Install the sample cup into the pressure vessel. Rotate the sample cup until it is locked in place.
  • Page 60 MACS II User Manual The pressure entered for calibration should be: 7000 psi for 0 to 10,000 psi tests; 17,000 psi for 10,000 to 20,000 psi tests; and 27,000 psi for 20,000 to 30,000 psi tests. 15. Install the calibration fixture in the calibration position at the front of the unit.
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  • Page 62: Calibrate Sgs

    MACS II User Manual 5.5.3. Calibrate SGS Calibrating SGS must be done with Slurry cup installed and Cell locked. The paddle must be rotating at 0.2 deg/min to simulate a SGS test. Use the calibration fixture to hook the string so that appropriate Weights can be loaded. Before calibrating for SGS ensure that a speed of .2 deg/min turning in the direction of SGS must be...

  • Page 63: Test Repeatability

    MACS II User Manual The machine should not be unattended during the calibration process with a weight installed. Only 0.2 deg/min revolution should be used for the deadweight calibration process. Click Calibration > Calibrate SGS to display the Calibrate SGS screen.

  • Page 64: Figure 5-14 Test Repeatability Step One Dialog Box

    MACS II User Manual Figure 5-14 Test Repeatability Step One Dialog Box 1. Click Data File to display a standard Windows dialog box to select a file. Click Next for the next step. 2. The next step in the Test Repeatability is to zero the drive. Click Zero Drive and follow Section 5.5.1 Zero Drive...

  • Page 65: Figure 5-16 Test Repeatability Step Three Dialog Box

    MACS II User Manual 3. The last step is to set parameters such as temperature, pressure and motor speed to begin the repeatability check. Generally, the motor is rotated at 36 deg/min clockwise (CW) direction with no pressure and temperature. This generates one revolution every five minutes.

  • Page 66: Figure 5-17 Test Repeatability Results Screen

    4. Click Finish to begin the test. With motor turning, the system measures and displays the SGS value. It is possible to run repeatability tests for any length of time. Fann recommends to run at least two full revolutions at speeds less than 36 deg/min.

  • Page 67: Operate Menu

    MACS II User Manual 5.6. Operate Menu The Operate Menu is where the user controls the physical actions of the device. This section contains the following options:  Cell Operations  Valve Operations  Manual Operations  Release Pressure 5.6.1.
  • Page 68 7. Open Drwr, Close Drwr – These buttons push in or pull out the drawer from the frame so that a slurry cup can be loaded inside the cell. Note that the MACS II unit does not perform certain operations due to mechanical interference. For example, if the cell is raised, then it is not possible to pull out the drawer.

  • Page 69: Valve Operations

    MACS II User Manual 5.6.2. Valve Operations Click Operations > Valve Operations to view the Valve Operations screen. Figure 5-19 Valve Operations Screen This screen allows the user to interactively operate the various valves in the system. Every valve (colored Red/Green) is clickable and operates the respective valve.

  • Page 70: Manual Operation

    MACS II User Manual 5.6.3. Manual Operation Click Operations > Manual Operations to access the Manual Operations dialog box. Figure 5-20 Operate Manually Dialog Box This screen allows control of temperature, pressure and motor subsystems independently and immediately for verification and diagnostics.

  • Page 71: Release Pressure

    General Tab, the system will not release any pressure. 5.7. Help Menu The Help Menu provides access to help and support topics for the MACS II software. This menu contains the following options.  Online Help  Check for Updates ...

  • Page 72: Step One

    MACS II User Manual  Finish – Close the wizard and initiate the test.  Cancel – Exit the wizard without performing test. If chosen, it is necessary to go through the steps to restart the test.  Help – Launch context-sensitive help.

  • Page 73: Figure 5-22 Mandatory Text Boxes

    MACS II User Manual  Test ID  Tested By  File name - Click Data File to open a standard window file dialog and navigate to the folder to save the data file. Type a file name and click OK.

  • Page 74: Step Two

    MACS II User Manual  Events SGS – Type SGS values at which to record the time  Events Time – Type the time in hh:mm format at which to record the SGS. Default settings for Customer List, Comment Types, Strength, and Time Events can be set by the Configure System menu item from the main screen.

  • Page 75: Step Three

    MACS II User Manual 5.8.3. Step Three This step performs the task to zero the drive of the motor. Follow instructions in Section 4.5.1 and zero the drive. 5.8.4. Step Four At this point, prepare the cement sample and load it into the cell. Notice that the cell operations screen is embedded here to perform the relevant steps to load the slurry cup.

  • Page 76: Step Five

    MACS II User Manual Note that all cell operations is unavailable (gray) if the cell is found to have pressure in it. Figure 5-24 Cement Sample Cell Dialog Box 5.8.5. Step Five At this point in the process, it is possible to start the test. Before starting the test, ensure that certain physical actions are complete before beginning the test.

  • Page 77: Figure 5-25 Wizard Complete Screen

    MACS II User Manual If any of the verifications fail, make appropriate changes or Cancel to exit the wizard. Figure 5-25 Wizard Complete Screen In addition to the check boxes, the user can set initial parameters for pressure and speed the unit needs to attain before the test can begin.

  • Page 78: Test Run

    MACS II User Manual 5.9. Test Run After the Start Test wizard completes, the software sets the initial parameters for the test run, as follows: The software sets the initial pressure, prompting with the dialogs shown in the images on the right.
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  • Page 80: Instrument Operations

    MACS II User Manual Instrument Operations Table of Contents INSTRUMENT OPERATIONS ........................71 6.1........................73 TART IZARD ODULE 6.2........................73 HYSICAL QUIPMENT CTIVITY 6.3..............................76 EMENT 101796668 Revision E...
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  • Page 82: Start Test Wizard Module

    6.2. Physical Equipment Activity With MACS II software is on the Load Cement Sample step, attention focuses on the physical unit itself. Verify that the cell O-ring and backup ring are in place. Change and lubricate if necessary.
  • Page 83 MACS II User Manual Figure 6-1 Complete Slurry Cup and Paddle Assembly (Eng. Drawing #101636768) 101796668 Revision E...

  • Page 84: Figure 6-2 Slurry Cup And Paddle (Eng. Drawing #101636768)

    MACS II User Manual Prepare the SGS slurry cup. Figure 6-2 Slurry Cup and Paddle (Eng. Drawing #101636768) 1. Grease the plug threads and bottom sleeve threads that accepts the base. 2. Install the bottom (#1-6) and top baffles (#1-7), O-ring (#1-8), top cap (#1- 9), and lock ring (#1-12) in the top of the slurry cup as shown in the assembly (DWG # 101636768).

  • Page 85: Cement Test

    Spin the coupling to insure no excessive drag on the shaft. 13.Place the filled slurry cup in the MACS II pressure chamber. 14.To install the cup, lower the cup with the supplied bail into the pressure chamber and rotate the cell until the pins on the bottom of the cup engage in the holes on the plate in the bottom of the pressure chamber.

  • Page 86: Results Analysis

    MACS II User Manual Results Analysis Table of Contents RESULTS ANALYSIS ............................77 7.1. MACS II S ............................. 79 OFTWARE 7.1.1. Show Cursor ............................79 7.1.3. Show Torque ............................79 7.1.4. Autoscale X ............................79 7.1.5. Autoscale Y ............................79 7.2.
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  • Page 88: Macs Ii Software

    MACS II User Manual MACS II Software 7.1. The MACS II software controls the functionality of the physical machines. In addition to controlling the software, there is functionality available for viewing and understanding data. Right click in the Results Graph to invoke a set of tools. The following tools are available to analyze data.

  • Page 89: Data Interpretation

    MACS II User Manual 7.3. Data Interpretation Interpreting the data is easy because the individual graphs for temperature, pressure, SGS, and Torque are color coded to respective scales. The software plots all of the data with respect to these parameters.

  • Page 90: Maintenance And Troubleshooting

    MACS II User Manual Maintenance and Troubleshooting Table of Contents MAINTENANCE AND TROUBLESHOOTING .................... 81 8.1.......................... 83 REVENTIVE AINTENANCE 8.1.1. Pneumatic Maintenance ........................83 8.1.2. Hydraulic Maintenance ........................83 8.1.3. Mechanical Maintenance ........................94 8.2............................94 ROUBLESHOOTING 101796668...
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  • Page 92: Preventive Maintenance

    Hydraulic Maintenance 8.1.2.1. Inline Filter The inline (30 microns) filter should be cleaned every thirty (30) days of operations. If the inline filter is damaged or deformed, replace it. Fann recommends keeping a spare filter for this purpose. 8.1.2.1.1 Filter Disassembly 8.1.2.1.1.1 Turn bowl off in counter-clockwise direction.
  • Page 93 MACS II User Manual The element life is based upon cleaning cycles and pressure drop. The estimated life of the element is 10 to 15 cleaning cycles. If the element has exceeded this level, discard and replace. Recommended cleaning fluids are acetone, mineral spirits and a variety of others.

  • Page 94: Figure 8-1 High Pressure Valve Location

    MACS II User Manual Loctite 271  A light lithium or silicone based grease  8.1.2.2.1 Locating the Tescom high pressure valve The Tescom high pressure valve can be most easily accessed from the back of the unit. Figure 8-1 High Pressure Valve Location 8.1.2.2.2...

  • Page 95: Figure 8-2 Items To Disconnect

    MACS II User Manual 8.1.2.2.2.3 Disconnect the electrical plug and inlet tubing as shown in the figure below. Figure 8-2 Items to Disconnect 8.1.2.2.2.4 Use the 2 and 2-1/2 inch wrenches for valve disassembly. 8.1.2.2.2.5 Ensure that there is ample clearance to use the wrenches.

  • Page 96: Figure 8-3 Wrenches On Valve

    MACS II User Manual 8.1.2.2.2.6 Loosen the right hand threaded body assembly from the air actuator assembly. Figure 8-3 Wrenches on Valve 8.1.2.2.2.7 Spin the valve off by hand once it is loosened. 8.1.2.2.2.8 Remove and set the air actuator assembly aside.

  • Page 97: Figure 8-5 Internal Sensor Assembly Location

    MACS II User Manual 8.1.2.2.3.1 Locate and remove the internal sensor assembly. Figure 8-5 Internal Sensor Assembly Location Figure 8-6 Internal Sensor Assembly Removal 101796668 Revision E...

  • Page 98: Figure 8-7 Seat Retainer

    MACS II User Manual 8.1.2.2.3.2 Remove the Seat Retainer with a medium flat blade screw driver. Figure 8-7 Seat Retainer 8.1.2.2.3.3 Lubricate and reinstall the threads. After the lubrication, replace the seat in the retainer. Refer to the valve drawings and BOM in this document for detailed parts and lubrication information.

  • Page 99: Figure 8-9 Torque Sensor Tool

    MACS II User Manual 8.1.2.2.3.4 Use the torque sensor tool to disassemble and reassemble the sensor. Figure 8-9 Torque Sensor Tool 8.1.2.2.3.5 Using soft jaws, chuck the flats on the sensor assembly in vise with the stem facing up. Figure 8-10 Vise with Soft Jaws...

  • Page 100: Figure 8-11 Spring Pad

    MACS II User Manual 8.1.2.2.3.6 Unscrew the sensor from the spring pad. Figure 8-11 Spring Pad 8.1.2.2.3.7 Replace the sensor and valve parts (as shown below). Reassemble the parts. Figure 8-12 Valve Parts 101796668 Revision E...

  • Page 101: Figure 8-13 Stem And Spring

    MACS II User Manual Figure 8-13 Stem and Spring Figure 8-14 O-ring and Backup Ring 101796668 Revision E...

  • Page 102: Figure 8-15 Loctite Application

    MACS II User Manual 8.1.2.2.3.8 Before assembling the Spring Pad and Sensor, apply one drop of Loctite on the threads. Figure 8-15 Loctite Application 8.1.2.2.3.9 Reassemble in reverse order using the valve drawings as a reference. Observe the torque and lubrication requirements in the drawing notes.

  • Page 103: Mechanical Maintenance

    Inspect the timing belt for any fraying and/or wear indicating increased torque. Troubleshooting 8.2. This section lists potential problems with the MACS II unit and solutions. If the problem is not correctable, contact Fann for assistance. 230 volts may be present so only a qualified technician should perform these actions.
  • Page 104 MACS II User Manual Item Problem Cause Solution MACS II unit does not power Main power inlet Check plug and up. No fan or controller and plug. circuit breaker panel displays. for 230 volts MACS II power Turn “on” switch.
  • Page 105 Soft psig but holds at high Goods Kit (P/N values>8000 psig. 101629340). MACS II holds pressure at low Bad Tescom valve Rebuild Tescom values <3000 psig but does stem and seat. valve with Repair Kit not hold at high values>8000 (P/N 101629342).
  • Page 106 Clean by line to filter. reverse pressure flow or replace lines. MACS II does not? Pump when No air supply to Connect air supply pressure is requested. system or regulator and ensure regulator turned down.

  • Page 107: Accessories And Schematics

    MACS II User Manual Accessories and Schematics Table of Contents ACCESSORIES AND SCHEMATICS ......................98 9.1. MACS II T ............................. 100 9.2. MACS II A ....................... 100 CCESSORY ARTS 9.3. MACS II C ........................102 ALIBRATION 9.4. MACS II S ..........................
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  • Page 109: Macs Ii Tool Kit

    MEASUREMENT SYSTEM, 50 OZF 101711419 / A IN, 10000 RPM 12 VDC BEARING REMOVAL TOOL, 0011 101711420 SNAPTITE MAGNEDRIVE30B- 101711420 / A 1957 MACS II Accessory Parts Kit 9.2. Find # Name Drawing/Rev Quantity Reference Description 101708367 KIT, ACCESSORY PARTS, MACS II...
  • Page 110 MACS II User Manual Find # Name Drawing/Rev Quantity Reference Description FILTER, 40 MICRON, 304 WIRE 0002 101626358 101626358 / A MESH, 3B FILTER KIT, 3 ORINGS FOR P8791-HP- 0003 101630287 40WEV 101630287 / A ORING 212V, 138V, AND 138VP...

  • Page 111: Macs Ii Calibration Kit

    MACS II User Manual 9.3. MACS II Calibration Kit Find # Drawing/Rev Quantity Reference Name Description 101780235 KIT, CALIBRATION, MACS II WEIGHT HANGER 50gm 0001 204178 / A D4026 ALUMINUM WEIGHT SLOTTED BRASS 0002 204179 / A D4027 50gm WEIGHT SLOTTED BRASS...
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  • Page 120: Parts List

    MACS II User Manual Parts List Table of Contents PARTS LIST ..............................111 10.1. 101677665 ......................... 113 ASTER SSEMBLY 10.2. 101676548 ....................115 LECTRICAL SSEMBLY 10.3. 101595348 ......................121 ECHANICAL SSEMBLY 10.4. 101723011 ................... 128 LATE AND RESSURE 10.5. 101723010 ......................135...
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  • Page 122: 10.1. Master Assembly 101677665

    MACS II User Manual 10.1. Master Assembly 101677665 101796668 Revision E...
  • Page 123 MACS II User Manual Find Name Drawing # Quantity Description 101677665 101677665 MASTER ASSEMBLY, MACS II ANALYZER D00339141 DOES NOT INCLUDE COMPUTER. 101595348 101595348 MECHANICAL ASSEMBLY, MACS II, FANN 101676548 D00335007 ASSEMBLY, ELECTRICAL BOX, MACS II D00335008 D00335006 101676548 101780235...

  • Page 124: 10.2. Electrical Box Assembly 101676548

    MACS II User Manual 10.2. Electrical Box Assembly 101676548 101796668 Revision E...
  • Page 125 MACS II User Manual 101796668 Revision E...
  • Page 126 MACS II User Manual Find # Name Drawing Quantity Description 101676548 101676548 ASSEMBLY, ELECTRICAL BOX, MACS II D00335008 D00335006 D00335007 101443963 101443963 CHASSIS, ELECTRICAL BOX, MACS II 101443926 101443926 FILTER, INTAKE, 9.38 X 7.50 X .50 THICK FRAME, 30 PPI GRAY QUADRAFOAM II...
  • Page 127 MACS II User Manual Find # Name Drawing Quantity Description 101613246 FAN, 4.73IN SQ X 1.50IN THK, 230 VAC, 105 CFM 100033128 70.81602 RAIL, MOUNTING, 35MM, X 1 METER, DIN,46277, SYMMETRICAL 101391619 CLAMP, END, UNIVERSAL, FOR 35 MM X 7.5 MM MOUNTING RAIL, E/NS 35 N 101462159 COVER, 2.2MM X 48.5 MM PHOENIX CONTACT 3030417...
  • Page 128 MACS II User Manual Find # Name Drawing Quantity Description 101443936 KIT, PANEL HOUSING, 6 POSITION, 22A, 400V, 22-12 AWG WIRE 101443935 KIT, CABLE HOOD, 6 POSITION, 22A, 400V, 22-12 AWG WIRE 101443937 PANEL THERMOCOUPLE JACK, ROUND HOLE, RMJ MINIATURE...
  • Page 129 MACS II User Manual Find # Name Drawing Quantity Description 100032007 70.76196 TERMINAL, FEMALE, SLIP ON, FULLY INSULATED, FOR #18-22 GA WIRE, XS09778, HOLLINGSWORTH 349301 TERMINAL FEMALE Q.C,.25X.032 12-10GA THOMAS & BETTS TNF10-250FD NYLON FULLY INSULATED FEMALE DISCONNECT WIRE RANG 12/10 AWG TAB SIZE .250 X .032 25 PER PACKAGE...

  • Page 130: 10.3. Mechanical Assembly 101595348

    MACS II User Manual 10.3. Mechanical Assembly 101595348 101796668 Revision E...
  • Page 131 MACS II User Manual 101796668 Revision E...
  • Page 132 MACS II User Manual 101796668 Revision E...
  • Page 133 FRAME DRAWER, MECHANICAL ASSEMBLY, MACS II 101636768 101636768 SGS TEST CUP ASSY, MACS II 101667558 101667558 THERMOCOUPLE, J TYPE, MACS II, TOP, 30000 PSI RATED, 56 IN LEADS 101595801 BEARING, PILLOW BLOCK, 3/4 IN SHAFT SIZE 101595822 SHAFT, COLLAR, D SHAPE, .75 IN ID. 101595624 SHAFT, LINEAR PRECISION, .75 DIA, 16 IN LENGTH...
  • Page 134 MACS II User Manual Find Drawing / Name Quantity Description 100032885 70.80372 MUFFLER, EXHAUST, PNEUMATIC, 1/4, MOSIER EM-2 CONNECTOR, PLASTIC TUBING, 90 DEG, 1/4 TUBE X 1/4 MPT, MILLER 100023811 INSTANT TUBE, LEGRIS, 31095614 101485082 VALVE, SOLENOID, 2 PORT, NC, 1/4 FEMALE NPT, 24V SCREW, THREADED, CAP, SOC HEAD (US) - 0.25 DIA -20 UNC x 0.50 - 18-8...
  • Page 135 MACS II User Manual Find Drawing / Name Quantity Description 207377 TUBING SOFT COPPER 1/4 X .032 120147184 ELBOW MALE SS-400-2-4 101671856 101671856 THEROMCOUPLE, TYPE J, UNGROUNDED, 1.125 30000 PSI, MALE HP PORT 101671154 TEE, 1/4 HP, 600000 PSI RATING WITH SPECIAL MOUNTING HOLES...
  • Page 136 POSITION SENSOR, BIMBA HSKX-17 100072379 800.61514 ELBOW, FITTING, FEMALE, AUTOCLAVE, CL4400, F250C 100016383 22.2003 ELBOW, 90 DEG, STREET, 1/4, BRASS 208447 CABLE CONTROL SINGLE PAIR 22 A 101645179 Locknut 1/4-20 SS 101791035 101791035 MOUNT PLATE, ELECTRO-PNEUMATIC REGULATOR, MACS II 101796668 Revision E...

  • Page 137: 10.4. Top Plate And Pressure Cell Body 101723011

    MACS II User Manual 10.4. Top Plate and Pressure Cell Body 101723011 101796668 Revision E...
  • Page 138 MACS II User Manual 101796668 Revision E...
  • Page 139 MACS II User Manual 101796668 Revision E...
  • Page 140 MACS II User Manual 101796668 Revision E...
  • Page 141 101710014 O-RING, ULTRA PARAFLUOR, ID 2.984, COLOR WHITE, SIZE 2-234, DUROMETER 75 101723009 101723009 MAG COUPLING, MACS II MAG DRIVE TO PADDLE AND SAMPLE CUP 390009 PUMP, LIQUID, AIR OPERATED, 1:440 RATIO MAXIMATOR MAXPRO PP189-2 101443954 MAGNEDRIVE, HIGH PRESSURE, 33,000 PSI...
  • Page 142 Drawing # Quantity Description 101710024 101710024 TORQUE CALIBRATION RING, MACS II 101596797 TIMING BELT, 240XL, 120 TEETH, 3/8 WIDTH, 0.20 PITCH 101727314 SWITCH, Emergency-stop non illuminated, ribbon cable, twist release, 32mm diameter for 22.5mm mounting, foolproof to EN 60947-5-5, EN 418, 250V, 3...
  • Page 143 ADAPTER, STRAIGHT, 1/8 MALE NPT TO 1/4 INSTANT TUBE 207783 GROMMET RUBBER 1/4in. ID X 3/8in. 101443948 101443948 BACKUP RING, MAG DRIVE, MACS II 101710015 O-RING, ULTRA PARAFLUOR, ID .739, COLOR WHITE, SIZE 2-018, DUROMETER 100028829 70.44830 SCREW, SET, #10-32 NF X 3/8, CUP PORT, HEX SOCKET, STAINLESS STEEL...

  • Page 144: 10.5. Turn Table Assembly 101723010

    MACS II User Manual 10.5. Turn Table Assembly 101723010 101796668 Revision E...
  • Page 145 MACS II User Manual Find # Name Drawing # Quantity Description 101723010 101723010 TURN TABLE ASSEMBLY, MECHANICAL ASSEMBLY, MACS II 101591604 101591604 MOUNT, ROTATION PLATE, MACS II 101643875 101643875 MOUNT, CUP RISER, MACS II 101485177 VALVE, 3 PORT SOLENOID, BODY PORTED, 1/4 INSTANT TUBE FITING (A), 1/4...
  • Page 146 MACS II User Manual Find # Name Drawing # Quantity Description 100034542 70.88705 NIPPLE - 2.75 IN LONG - 1/4 AE HIGH PRESSURE - 60000 PSI - F250C CONNECTION 100001771 70.24702 GLAND, AUTOCLAVE, ANGLE 40, 60000 POUNDS PER SQ IN, FOR 1/4 TUBE,...

  • Page 147: 10.6. Frame Drawer, Mechanical Assembly 101723012

    MACS II User Manual 10.6. Frame Drawer, Mechanical Assembly 101723012 101796668 Revision E...
  • Page 148 MACS II User Manual 101796668 Revision E...
  • Page 149 MACS II User Manual 101796668 Revision E...
  • Page 150 MACS II User Manual 101796668 Revision E...
  • Page 151 MACS II User Manual Find # Name Drawing # Quantity Description 101723012 101723012 FRAME DRAWER, MECHANICAL ASSEMBLY, MACS II 101586871 101586871 FRAME, MACS II 101569355 CLYLINDER, COMPACT GUIDE, 100MM BORE, 100MM STROKE 101586874 101586874 ADAPTER, LINEAR TO ROTATIONAL, MACS II 101595347 ROTARY ACTUATOR, RACK &...
  • Page 152 MACS II User Manual Find # Name Drawing # Quantity Description 101712396 SOLENOID VALVE, 5 PORT, 3 POSITION CENTER CLOSED, FOR MANIFOLD, 24V 101710635 COVER PLATE, FOR VVQZ200 MANIFOLD 101485667 SILENCER, NAN, GENERAL PURPOSE, NOISE REDUCTION: 35db, 1/4 MALE NPT...
  • Page 153 MACS II User Manual Find # Name Drawing # Quantity Description 120170870 HI PRES 1/8`` FEM TO 1/4`` MALE 100068597 685.40729 UNION, BULKHEAD, 1/4 IN OD TUBE X 1/4 IN OD TUBE 101539545 ADAPTER, ELBOW, BRANCH, 1/4 MNPT, 2X 3/8 TUBE, SMC KQ2Z11-35S...
  • Page 154 MACS II User Manual Find # Name Drawing # Quantity Description 100123752 SCREW, MACHINE, 10-32 X 3/8, BUTTON, ALLEN, SS1(UNBRAKO) 101265343 SCREW, THREADED, CAP, SOC HEAD (US) - NO. 8 -32 UNC x 1.75 - 18-8 SS 101696683 SCREW, 3/8-24 X 1.5, SS, SOCKET HEAD CAP 101265322 SCREW, THREADED, CAP, SOC HEAD (US) - NO.
  • Page 155 MACS II User Manual Find # Name Drawing # Quantity Description 101708752 CROSS, 3/8 TUBE 101485964 TUBING, 3/8 IN O.D. POLYURETHANE, BLUE, TIUB11BU-20 101645666 ADJUSTABLE STOP, STANDARD, CARR LANE 101645668 BLOCK, SIDEWAYS MOUNTING, CARR LANE 101266411 SCREW, THREADED, CAP, SOC HEAD (US) - 0.50 DIA -13 UNC x 4 - 18-8 SS 101266378 SCREW, THREADED, CAP, SOC HEAD (US) - 0.50 DIA -13 UNC x 1 - 18-8 SS...

  • Page 156: 10.7. Sgs Test Cup Assembly 101636768

    MACS II User Manual 10.7. SGS Test Cup Assembly 101636768 101796668 Revision E...
  • Page 157 SGS TEST CUP ASSY, MACS II 101837418 800.03006 SLURRY CUP ASSEMBLY, MACS 2 101636441 101636441 PADDLE ASSEMBLY, SGS, MACS II 101698207 101698207 CUP COUPLING, MACS II MAG DRIVE TO PADDLE AND SAMPLE CUP 100001522 70.10643 RING, RETAINING, EXTERNAL, 0.25 SHAFT, STAINLESS STEEL 101796668 Revision E...

  • Page 158: Slurry Cup Assembly 100072017

    MACS II User Manual 10.8. Slurry Cup Assembly 101837418 101796668 Revision E...
  • Page 159 MACS II User Manual Find # Name Drawing # Quantity Description 100072017 800.03006 SLURRY CUP ASSEMBLY, AUTO MINI MACS 100007912 800.59772 PLUG, BASE, SLURRY CUP, MINIMACS 101836939 101836939 GASKET, CUP PLUG, HIGH TEMPERATURE MACS 2 100072323 800.59771 BASE, SLURRY CUP, MINMACS...

  • Page 160: 10.9. Paddle Assembly, Sgs 101636441

    MACS II User Manual 10.9. Paddle Assembly, SGS 101636441 101796668 Revision E...
  • Page 161 MACS II User Manual Find # Name Drawing Quantity Description 101636441 101636441 PADDLE ASSEMBLY, SGS, MACS 2 101636267 101636267 SHAFT, MODIFIED, SLURRY CUP, MACS 2 100007913 800.59774 BLADE, UPPER, SGS PADDLE, MINIMACS 100021371 800.59774 PIN, ROLL, 1/16 X 1/2, STAINLESS STEEL 100002427 800.59774...
  • Page 162 MACS II User Manual 10.10. Spares 1 Year MACS II Analyzer 101877938 Quantity Description PREMIUM GRADE; TYPE JJ CALIBRATION T/C WITH SPECIAL LIMITS OF +/- 0.4%; 0.063 IN OD; SINGLE UNGROUNDED JUNCTION; 21 IN LONG; 316SS MATERIAL; LEAD WIRE: 20AWG TEFLON INSULATED LEAD WIRE; 68 IN 101667558 LONG;...
  • Page 163 MACS II User Manual 10.11. Spares 2 Year MACS II Analyzer 101877945 Quantity Description 101667558 PREMIUM GRADE; TYPE JJ CALIBRATION T/C WITH SPECIAL LIMITS OF +/- 0.4%; 0.063 IN OD; SINGLE UNGROUNDED JUNCTION; 21 IN LONG; 316SS MATERIAL; LEAD WIRE: 20AWG TEFLON INSULATED LEAD WIRE; 68 IN LONG;...
  • Page 164 Fann or, at Fann's' option, to the allowance to Customer of credit for the cost of such items. In no event shall Fann be liable for special, incidental, indirect, consequential or punitive damages.
  • Page 165 MACS II User Manual Texas USA 77210 Telephone: 281-871-4482 Toll Free: 800-347-0450 FAX: 281-871-4446 Email fannmail@fann.com Our shipping address is: Fann Instrument Company 15112 Morales Road Gate 7, Houston, Texas USA 77032 101796668 Revision E...

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