Chandler Ametek Quizix 6000 Series User Manual

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6000 Series Pump System

User's Manual

Rev F – January 2022

P/N: Q6-C-1099

S/N ____________

2001 N. Indianwood Ave.

Broken Arrow, Oklahoma 74012 U.S.A.

Tel: 918-250-7200 Fax: 918-459-0165

E-mail: chandler.sales@ametek.com

Web: www.chandlereng.com

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Page 1 6000 Series Pump System User’s Manual Rev F – January 2022 P/N: Q6-C-1099 S/N ____________ 2001 N. Indianwood Ave. Broken Arrow, Oklahoma 74012 U.S.A. Tel: 918-250-7200 Fax: 918-459-0165 E-mail: chandler.sales@ametek.com Web: www.chandlereng.com Copyright © 2022, by Chandler Engineering Company, LLC...
Page 2 P.O. Box 470710, Tulsa, Oklahoma 74147 All rights reserved. Reproduction or use of contents in any manner is prohibited without express permission from AMETEK Chandler Engineering Company, LLC. While every precaution has been taken in the preparation of this manual, the publisher assumes no responsibility for errors or omissions.
Page 3: Table Of Contents
TABLE OF CONTENTS Table of Contents General Overview ....................7 Introduction ........................7 Primary Components ....................8 Q6000 Pump Cylinder and Motor Driver ..............9 CN–6000 Pump Controller ..................10 USB/Serial Expander/Isolator ................. 10 PumpWorks Software and Computer ..............10 Valves, Transducers and Plumbing................
Page 4 Chandler Engineering 6000 SERIES PUMP MANUAL 2.13 Connecting the Air Supply ..................31 2.14 Connecting Your Fluid Plumbing ................31 2.15 Setting up a High Temperature System: Oven Installation ...........32 System Checkout and Operation ..............35 When to Perform the System Checkout ...............35 Verification of All Cable and Plumbing Connections ..........35...
Page 5 TABLE OF CONTENTS Pump Controller Subcomponents ................55 6000 Series Pump Cylinder & Motor Driver ............ 57 Q6000 Pump Cylinder ....................57 Important Operating Notes ..................58 Operation at High Pressures ..................58 Orientation of the Pump Cylinder ................61 Primary Mechanical Subcomponents of the Pump Cylinder ........
Page 6 Chandler Engineering 6000 SERIES PUMP MANUAL Motor Cable........................71 Driver Cable .......................71 Sensor Cable .......................71 Transducer and Valve Cable ..................72 Data Link Cable ......................72 RS–232 or USB Cable ....................72 AC Power Cables ......................72 User Interface Cable (Optional)...................73 Front Panel Cable (Optional)..................73 System Power ....................
Page 7 TABLE OF CONTENTS 11.7 Maintenance Reminder ....................93 TROUBLESHOOTING ................... 95 12.1 Troubleshooting Basics ....................95 12.2 PumpWorks Error Messages ..................96 Immediate Errors ....................96 Logged Errors ..................... 97 12.3 CN-6000 Two Digit Display Error Messages .............. 99 The Two Digit Display Does Not Light ............. 100 The Two Digit Display Does Not Complete Its Initial Check.
Page 8 Chandler Engineering 6000 SERIES PUMP MANUAL Pilot Solenoid Check ..................112 Clogged (Obstructed) Valve ................112 Valve Leaks Fluid When Closed ............... 112 12.11 Firmware Updates ....................112 Q6000 SERIES USER INTERFACE ............. 115 13.1 Valve Control Lines ....................115 13.2...
Page 9: General Overview
Introduction Of the three lines of pump systems manufactured by Chandler Engineering, the 6000 Series is the largest. It is designed for users who require greater flow rates or larger fluid volumes than the 5000 Series provides. Several different pump cylinder models are available in the 6000 Series with different maximum flow rate and pressure specifications (see Figure 1-1).
Page 10: Primary Components
Chandler Engineering 6000 SERIES PUMP MANUAL • A high temperature( (160° C) option is available, which allows the user to heat the entire pump cylinder. • The pump system is expandable and is designed to allow the user to add additional pump cylinders, as their needs change.
Page 11: Q6000 Pump Cylinder And Motor Driver
Chapter 1 GENERAL OVERVIEW Figure 1-4 Pump Cylinder Side View, High Temperature NOTE ON NOMENCLATURE: The terms "pump cylinder" and "cylinder" are used interchangeably throughout this manual, and refer to the entire mechanical component used to pump fluid, as shown in Figure 1-3 and Figure 1-4.
Page 12: Cn-6000 Pump Controller
The pump system includes PumpWorks software , which runs using Windows operating systems. The user may supply the computer or purchase a computer system from Chandler Engineering with the pump system. PumpWorks is menu–driven and easy to use. The software allows the user to set operating parameters, such as fluid flow rate or pressure.
Page 13: System Setup
Chapter 2 SYSTEM SETUP 2 System Setup Section 2 provides the information necessary to set up a 6000 Series Pump System for the first time, or change a system’s setup. The following sections are included: • Unpacking the System, Section 2.1 •...
Page 14: Unpacking The System
Chandler Engineering 6000 SERIES PUMP MANUAL Unpacking the System To unpack the 6000 Series Pump System, first prepare a location for the pump cylinders. Ensure that the location can support the weight of the pump cylinders and associated equipment. When assembled, each pump cylinder weighs about 80 kg (175 lbs.) A cart can be used if it is desired to be...
Page 15: Inspecting Your Pump
A component may have been damaged, even if the box has only slight damage. If the pump is damaged in any way, notify the shipping company. After informing the shipping company of any damage, also inform Chandler Engineering. You can reach us at the following numbers:...
Page 16 The pump cylinders are connected together with two angled mounting brackets and two straight mounting brackets and fastened with metric socket screws. The brackets are attached loosely to the pump cylinders during shipping. Contact Chandler Engineering if you need more brackets. Figure 2-3 There are two angled mounting brackets which will be connected to pump cylinder A when shipped.
Page 17 The two straight mounting brackets, shown in Figure 2-4, are located behind the pump controller between cylinders A and B. Chandler Engineering suggests that you use a long handled hex driver tool to tighten the straight brackets, as shown in the Figure 2-5 Users with three or four Q6000 pump cylinders can stack the pump cylinders in a single stack if there is very little space available.
Page 18: Color Coding
Chandler Engineering 6000 SERIES PUMP MANUAL Color Coding The Q6000 Pump Series is color coded for the user’s convenience. A color code has been assigned to each pump cylinder as shown below. PUMP CYLINDER COLOR Pump Cylinder A Green Pump Cylinder B...
Page 19: Connecting Your Q6000 Series Pump To A Computer
If your computer does not have enough serial ports, you will need to purchase a serial port expansion card, or use a USB port and a USB-serial adapter cable as instructed below. Contact Chandler Engineering for suggestions. • Connect the other end of the RS-232 into the serial expander/isolator, shown in Figure 2-8.
Page 20 Chandler Engineering 6000 SERIES PUMP MANUAL 2.5.2.2 Connection of RS-232 Serial Expander/Isolator to a Computer USB Port Connect a USB-Serial adapter cable to a USB port on the computer. The USB adapter must use all 8 communication pins for RS-232 to properly communicate with the pump. Connect the other end of the USB adapter cable to the serial expander/isolator, shown in Figure 2-8.
Page 21: Transducer And Valve Cable
Chapter 2 SYSTEM SETUP Transducer and Valve Cable 1. There is one cable which connects the Pump controller to both the pilot solenoids for the valves and to the pressure transducers. Connect this cable to the receptacle on the pump controller labeled "Pressure Transducer &...
Page 22: Connecting To A Power Source
Chandler Engineering 6000 SERIES PUMP MANUAL 2. Next, connect the strand labeled "Transducer A" to the transducer which will later be mounted onto the first pump cylinder. Connect the strand labeled "Transducer B" to the transducer which will be mounted onto the second pump cylinder.
Page 23: Turning On Your Pump Controller
3. Plug the power cord for your computer into an AC power source. If the computer was ordered from Chandler Engineering with the pump system, 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.
Page 24 Chandler Engineering 6000 SERIES PUMP MANUAL Figure 2-13 Two Digit Display I__ I ___I I___I I___I I___I Figure 2-14 Pump Controller Firmware Diagnostics The controller diagnostics are performed next. This time the left hand digit will light and the right hand digit will not.
Page 25: Uninterruptable Power Supplies (Ups)
Supplies"”. Installing PumpWorks on Your Computer If you purchased a computer from Chandler Engineering with your 6000 Series Pump System, PumpWorks has already been installed for you. Otherwise, make sure the computer you will be using meets the following hardware requirements: •...
Page 26: User Search For New Pump Controller
Chandler Engineering 6000 SERIES PUMP MANUAL 3. 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.
Page 27: Two Digit Display When Pump Is Installed Onto Pumpworks
Chapter 2 SYSTEM SETUP 5. PumpWorks will ask you to “Enter User Name for New Pump” and the pump number. 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.
Page 28: Installing The Cylinder Barrel
The Q6000 pump cylinder must be at the "Max (maximum) Extend" motion status prior to installing the piston. New pump cylinders shipped from Chandler Engineering are at the "Max Extend" position. Look at the PumpWorks main window and confirm that the motion status display shows "Max Extend". If not, use the directions in Section 2.11 to move the pump cylinder...
Page 29 Chapter 2 SYSTEM SETUP • All cables have been connected • The motor driver on the pump cylinder is turned on (black rocker switch on top of driver). • The CN-6000 Pump Controller is turned on, and • The computer is turned on and PumpWorks is operating. 1.
Page 30: Installing The Valves And Transducers
Chandler Engineering 6000 SERIES PUMP MANUAL 4. Set the direction to Retract for each pump cylinder. To do this, click on the Cylinder Direction button on the main window and enter "retract". 5. The valves are not functioning at this point in the installation.
Page 31: Q6000-5K And 10K Pump Systems
Chapter 2 SYSTEM SETUP Q6000-5K and 10K Pump Systems 1. Refer to the Figure 2-19 which shows the three holes at the front of the cylinder barrel (for Q6000-5K and Q6000-10K models). The top hole is the fluid inlet/outlet port of the pump cylinder, where the valve tubing should be installed.
Page 32: Q6000-20K And Q6000-30K Pump Systems
Chandler Engineering 6000 SERIES PUMP MANUAL … … 2. Install the tubing from the center port of the valve into the fluid inlet/outlet port with the tube that is attached to the valve. The valve will extend out from the end of the cylinder barrel. Refer to Figure 2-20.
Page 33: Connecting The Air Supply
Chapter 2 SYSTEM SETUP Air Tube 2.13 Connecting the Air Supply The valves used in the 6000 Series Pump System are air actuated. Air is taken into the system at the pilot solenoid manifold, then air tubes connect the pilot solenoids and the valves. The air inlet fitting at the pilot solenoid manifold, which is labeled "P", has a 1/4"...
Page 34: Setting Up A High Temperature System: Oven Installation
4. Carefully check that all fittings are tightened. If fittings are not tight, leaks can occur. The pump system is fluid-tight at the time it is shipped. However, Chandler Engineering recommends that you carefully check all the fittings prior to operation and use the open end wrench supplied in the Special tool Kit (see Section 11.1).
Page 35 For oven–mounted systems, the location of the pump cylinders, pump controller, pressure transducers, and pilot solenoid manifold determines the length of each cable. Chandler Engineering supplies cables to user–specified lengths for most high temperature systems. If a cable is not long enough for your application, consult Table 2-1.
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Page 37: System Checkout And Operation
When to Perform the System Checkout You should perform the System Checkout in each of the following situations: • When the system is first received from Chandler Engineering. Although all systems are carefully checked before shipment, it is necessary to ensure that no damage occurred during shipment and that the pump system has been properly assembled.
Page 38: Connection Checklist
Chandler Engineering 6000 SERIES PUMP MANUAL The software can detect if all cables are connected, but it cannot determine if they are connected in the right places. For example, if the driver cable from cylinder A is plugged into the connector for cylinder B and the driver cable for cylinder B is plugged into the connector for cylinder A, the system will not operate properly.
Page 39: Valve Check
Chapter 3 SYSTEM CHECKOUT & OPERATION At both the pilot solenoid end and the valve end, check to ensure that the color coding matches. For example, the pilot solenoid fitting with the orange band should match the tubing with the orange band. Fluid Plumbing (Q6005 and Q6010) Make sure the tubing from the center port of each valve goes to the top hole on the end of the cylinder barrel.
Page 40: Pump Cylinder Check
Chandler Engineering 6000 SERIES PUMP MANUAL • If you do not hear a distinct popping sound when each valve opens and closes, then there is not adequate air pressure to operate the valves. Check the tubing from the pilot solenoids to the valves and check your pressurized air supply.
Page 41: Filling The System With Liquid
Chapter 3 SYSTEM CHECKOUT & OPERATION its Max Retract position. Also, listen for the sound of the motor running and then stopping. You should also ensure that the fan is operating. 8. Repeat this procedure for each pump cylinder. Set the direction to Extend for one piston stroke, then Retract for one stroke.
Page 42 Chandler Engineering 6000 SERIES PUMP MANUAL 3. With the safety pressure still set at 100 psi (700 kPa), and the direction set to Extend, start the pump cylinder. Watch the current pressure reading until it exceeds 100 psi (700 kPa) and is stopped by the safety pressure control system. If the pump cylinders are filled with liquid, this should occur with less than 3 ml of fluid displaced within the cylinder barrel.
Page 43 Chapter 3 SYSTEM CHECKOUT & OPERATION make any other adjustments that involve disconnecting and reconnecting any of the cables or plumbing, you need to do each of these safety procedures again. [41]...
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Page 45: Pump Operating Basics
Chapter 4 PUMP OPERATING BASICS Pump Operating Basics © For instructions on the basics of operating your 6000 Series Pump System using PumpWorks Software, please refer to the PumpWorks User’s Manual. [43]...
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Page 47: Safety Features
Section 3. Cable Labeling Chandler Engineering labels all cables at both ends and labels the device to which they connect with unique label names. Color–coding is also used to simplify the identification of proper connector locations.
Page 48: Safety Pressure Overpressure
Chandler Engineering 6000 SERIES PUMP MANUAL Safety Pressure Overpressure The most basic of these safety features is safety pressure monitoring, which is performed in the pump controller firmware. With this feature, the user specifies a safety pressure at a level higher than the expected running pressure.
Page 49 Chapter 5 SAFETY FEATURES Model Maximum Pressure Safety Rupture Disk of Pump Activation Pressure Q6005 5,000 psi 6,500 psi Q6010 10,000 psi 12,800 psi Q6020 20,000 psi 25,000 psi Q6030 30,000 psi 32,500 psi IMPORTANT It is very important that you install tubing into the fitting of the fluid outlet and that it is plumbed to an appropriate receptacle.
Page 50: Emergency Stop Capability
Alternatively, you may want to install safety rupture disks with a higher rating. In that case, contact Chandler Engineering for the appropriate specifications.
Page 51 Chapter 5 SAFETY FEATURES The emergency stop signal can be configured to normally open or normally closed via PumpWorks. For more information on using this feature, please refer to the PumpWorks manual. [49]...
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Page 53: Cn-6000 Pump Controller
Chapter 6 CN-6000 PUMP CONTROLLER CN-6000 Pump Controller The CN-6000 Pump Controller controls the operation of the entire 6000 Series Pump System. The pump controller operates the system according to the settings used in PumpWorks. It coordinates all system components and maintains the safety and integrity of the system. The CN-6000 Pump Controller is a 2-channel unit and can control two Q6000 pump cylinders.
Page 54 Chandler Engineering 6000 SERIES PUMP MANUAL Figure 6-1 CN-6000 Pump Controller The On/Off switch is a red button on the right side of the controller. Press it in to turn on the controller. When the CN-6000 Pump Controller is turned on, a sequence of diagnostic tests is run, as shown on the two-digit display labeled “Pump Number”.
Page 55: Cable Connections
Chapter 6 CN-6000 PUMP CONTROLLER Cable Connections Driver Cable The Driver Cable connects the CN-6000 Pump Controller with the motor driver attached to each Q6000 pump cylinder. Each pump controller includes two 9-pin, D-style connectors for driver cables, labeled “Driver A” and “Driver B”. If the controller is used with only one pump cylinder, the “Driver B”...
Page 56: User Interface Cable
Chandler Engineering 6000 SERIES PUMP MANUAL User Interface Cable The optional User Interface Cable allows the 6000 Series Pump System to connect to various external devices, which can be useful to the user for building a complete experimental system. Additional sensors, valves, digitally controlled devices and logic inputs, as well as power, are available on this 37-pin D-style connector.
Page 57: Usb/Serial Expander/Isolator
• The pump controller firmware, which is stored in the CN-6000. New versions of both software/firmware programs are periodically released by Chandler Engineering. Problems detected after a software/firmware version is released are resolved in later versions. In order to update the pump controller firmware it is NOT necessary to open the CN-6000 to change a PROM.
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Page 59: 6000 Series Pump Cylinder & Motor Driver
All of the Q6000 cylinder models have the same basic design; only the piston diameter is different between models. The information in this chapter applies to all of the Q6000 pump cylinder models manufactured by Chandler Engineering. All Quizix pump cylinders are stepper motor–driven, positive–displacement pumps with precision ball screws.
Page 60: Important Operating Notes
Chandler Engineering 6000 SERIES PUMP MANUAL • When the piston extends, the pump cylinder empties as fluid is pushed out of the pump cylinder and through the deliver side of the valve. Please refer to Figure 7-2 and Figure 7-3 for mechanical drawings of the ambient temperature Q6000 pump cylinder and high temperature Q6000 pump cylinder.
Page 61 Chapter 7 6000 SERIES PUMP CYLINDER & MOTOR DRIVER … Figure 7-2 [59]...
Page 62 Chandler Engineering 6000 SERIES PUMP MANUAL … Figure 7-3 [60]...
Page 63: Orientation Of The Pump Cylinder
Chapter 8 VALVES & PLUMBING Orientation of the Pump Cylinder The pump cylinder is designed to operate horizontally. It may malfunction if mounted in a vertical position. Primary Mechanical Subcomponents of the Pump Cylinder Starting at the motor end of the pump cylinder, the following subcomponents comprise the basic drive train of the pump.
Page 64: Side Rails And Cam Rollers
Chandler Engineering 6000 SERIES PUMP MANUAL Side Rails and Cam Rollers The side rails and cam rollers transfer the torque from the ball screw to two rollers (one on each side of the pump), then to the side rails which are directly under the side covers on each side of the pump cylinder.
Page 65: Pump Cylinder Sensor Board
Chapter 8 VALVES & PLUMBING The back–up ring serves two functions: it supports the seal and it guides the piston. Because the seal has no structural strength, it is supported by the back–up ring, which holds the seal in the seal cavity.
Page 66: Q6000 Pump Cylinder Motor Driver
Chandler Engineering 6000 SERIES PUMP MANUAL The high temperature version of the Q6000 pump cylinder is designed so that the cylinder barrel and valves can be heated, thus eliminating temperature gradients in the fluid flow system. However, the stepper motor, motor driver, and sensor board cannot be heated. The pump cylinder must be placed in the oven so that the main pump housing extends through the oven wall, with the entire motor and fan cooling assembly residing outside of the oven.
Page 67: Valves And Plumbing
• Pressure Transducers, Section 8.4 • Fluid Plumbing, Section 8.5 • Safety Rupture Disks, Section 8.6 • High Temperature Option, Section 8.7 Valves Chandler Engineering uses constant–volume, air–actuated valves. 6000 Series Pump Systems use the following 3–way valves: Valve Pump Pressure...
Page 68: Pilot Solenoids
Chandler Engineering 6000 SERIES PUMP MANUAL Fluid Plumbing Diagram … Figure 8-1 For fluid to flow into the pump cylinder, the fill valve must be open and the deliver valve must be closed. The fluid then flows into the valve, past the fill valve and out through the tube leading to the pump cylinder.
Page 69: Air Supply
Chapter 8 VALVES & PLUMBING 6000 Pump Controller and convert these signals to air pulses that open and close the fluid path in the air–actuated, constant volume valves. The pilot solenoids are connected to the pump controller with a valve cable. This cable branches out at the pilot solenoid end, providing one branch with a 2–pin connector for each pilot solenoid.
Page 70: Fluid Plumbing
Chandler Engineering 6000 SERIES PUMP MANUAL This window allows the user to set an offset value and a gain value for each pressure transducer. See Section 11 in this manual and Section 10 in the PumpWorks User’s Manual for more information on calibration.
Page 71: Safety Rupture Disks
The pump system is checked thoroughly and is fluid–tight at the time it is shipped. However, Chandler Engineering recommends that you carefully check all the fittings prior to operation and when the pump system is altered. Most pump system leaks can be traced to fittings.
Page 72: Transducers
Chandler Engineering 6000 SERIES PUMP MANUAL Transducers The standard pressure transducers operate at 70° C. They can be used at temperatures up to 80° C inside an oven without severely shortening their lifetime. However, for temperatures above 80° C, the pressure transducers must be mounted outside the oven. To facilitate their placement outside the oven, high temperature systems are shipped with a longer length of fluid tubing to connect the pressure transducer to the cylinder barrel.
Page 73: System Cables
Chapter 9 SYSTEM CABLES 9 System Cables The 6000 Series Pump System includes numerous cables that connect the components of the system. These cables are labeled so connecting them should be self–explanatory. All of the cables necessary to operate the 6000 Series Pump System are described in this chapter. Each cable is also described in the chapter(s) which explain the components the cables are connected to.
Page 74: Transducer And Valve Cable
Chandler Engineering 6000 SERIES PUMP MANUAL Transducer and Valve Cable The transducer and valve cable connects the CN-6000 Pump Controller to the pressure transducers and the pilot solenoids for the valves. There will be one transducer and valve cable for each CN-6000 Pump Controller in your system.
Page 75: User Interface Cable (Optional)
Chapter 9 SYSTEM CABLES The power plug conforms to the standard outlet in the country to which the system is shipped. Standard IEC–320 appliance connectors are used at the pump controller end of these cables. The motor driver has a power cord with a 3–prong connector that must be connected to 120 volts AC power.
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Page 77: System Power
The CN-6000 Pump Controller is configured to the power requirements of the country to which it was shipped. If a computer was purchased from Chandler Engineering as part of your pump system, its power is also configured to the voltage and type of outlet used in the country it was shipped to.
Page 78 Chandler Engineering 6000 SERIES PUMP MANUAL Chandler Engineering recommends a UPS that provides continuous on–line filtering and good AC line noise rejection, as well as power backup capabilities. Also, it is recommended that the time required for the unit to switch to back–up power be less than a few milliseconds.
Page 79: System Maintenance
Chapter 11 SYSTEM MAINTENTANCE 11 System Maintenance This chapter describes how to do preventive and corrective maintenance to the 6000 Series Pump System. This chapter includes: • Special Tools and Spare Parts Kits, Section 11.1 • Maintaining the Cylinder Barrel, Section 11.2 •...
Page 80: Maintaining The Cylinder Barrel
Chandler Engineering 6000 SERIES PUMP MANUAL Figure 11-1 Special Tools Kit - Q6000 (10K, 20K and 30K) Figure 11-2 Special Tools Kit – Q6000 (5K) Table 11-2 Spare Parts Kit Item No. Description Seals - Depending on the type of pump system that is ordered, the seals included are one of the following: •...
Page 81: Removing The Cylinder Barrel
Chapter 11 SYSTEM MAINTENTANCE • Reinstalling the Cylinder Barrel, Section 11.2.7 Recommended frequency for performing this maintenance on ambient temperature systems is every 12 months of regular use, or as required. For high temperature systems the recommended maintenance frequency is every 6 months of regular use, or as required. For the purposes of this manual, the term “regular use”...
Page 82: How To Change The Seals
Chandler Engineering 6000 SERIES PUMP MANUAL 10. Remove the seal and the back–up ring. For high temperature systems also remove the seal support ring. Clean the seal area with a clean lint-free cloth. Inspect the piston for any scratches on the metal where the seal makes contact. Scratches may cause fluid leaks.
Page 83 Chapter 11 SYSTEM MAINTENTANCE Figure 11-3 Seal Cross-Sections IMPORTANT For maximum performance from the seals, great care must be used when handling and inserting them. Seals are especially sensitive to damage by scratches that are not easily visible to the unaided eye. The seals can be easily scratched by any sharp object, including fingernails.
Page 84: Removing The Piston (Optional)
Chandler Engineering 6000 SERIES PUMP MANUAL Removing the Piston (Optional) 1. To remove the piston, extend the piston to the Max Extend position and proceed with the following steps. Be careful not to bump the exposed piston from the side.
Page 85: Changing The Ambient Temperature Seals
Chapter 11 SYSTEM MAINTENTANCE Figure 11-5 Ambient Temperature Seal Components Changing the Ambient Temperature Seals 1. Manually place a new seal into the cylinder barrel and press it gently and evenly into place. The side with the spring is inserted first. 2.
Page 86: Reinstalling The Cylinder Barrel
Chandler Engineering 6000 SERIES PUMP MANUAL 6. Insert the large, back–up ring with the flange or stepped side facing down on top of the PEEK ring. … 7. Screw in the seal nut and tighten using a spanner wrench. Reinstalling the Cylinder Barrel 1.
Page 87: Re-Greasing The Ball Screw
Chapter 11 SYSTEM MAINTENTANCE 3. Look at the steel side rails on which the cam rollers roll. Do they have any marks on them other than a straight wear path parallel to the sides of the rails? If so, the cam rollers should be replaced.
Page 88: Re-Greasing The Planetary Gear
3. Using a grease gun, apply grease into the grease fitting through the hole for re-greasing the ball screw. Use Aerospace Lubricants Tribolube–37 RPC/MS grease. This grease is available from Chandler Engineering. The system is now ready for normal use.
Page 89: Cooling Fan Maintenance
11.4 Cooling Fan Maintenance The cooling fan is mounted to the motor. If the fan stops operating, or if it is operating erratically in any way, contact Chandler Engineering for motor driver fan replacement. 11.5 Servicing the Valves and Safety Rupture Disk Replacing the Safety Rupture Disk The recommended frequency for replacing the safety rupture disk is every 2 years of regular use.
Page 90: Q6005 And Q6010 Models
Chandler Engineering 6000 SERIES PUMP MANUAL to Section 5.3.4 for more information about safety rupture disks and a table of the pressure ratings to be used. Figure 11-11 Safety Rupture Disk Q6005 and Q6010 Models To replace a safety rupture disk for the Q6005 and Q6010, use the following procedure. See Figure 11-11.
Page 91: Calibrating The Pressure Transducers
(42) 25,000 163 (120) Additional safety rupture disks may be obtained from Chandler Engineering. 11.6 Calibrating the Pressure Transducers The pressure transducers on the 6000 Series Pump System need to be recalibrated periodically. During normal use they should be recalibrated every 12 months. If usage is heavy, or if the pump has been subjected to unusual circumstances such as pressures above its rated pressure range, then recalibration should be performed.
Page 92: Methods Of Calibrating The Pump System
Chandler Engineering 6000 SERIES PUMP MANUAL Methods of Calibrating the Pump System There are two basic methods of pressure calibration for all Quizix Pump Systems. The first method is to attach a secondary calibrated gauge, such as a quartz transducer, to the system. With this method, the pressure for the calibration procedure will be generated by the Quizix pump.
Page 93 Chapter 11 SYSTEM MAINTENTANCE Figure 11-12 Calibration Setup Diagram… 11.6.2.1 Calibrated Gauge As shown in the Calibration Setup Diagram in Figure 11-12, 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.
Page 94 Chandler Engineering 6000 SERIES PUMP MANUAL IMPORTANT When you raise the system’s pressure, the temperature of the pump’s internal fluid will temporarily rise. As this fluid cools, the system pressure will drop. In this situation it is best to wait five minutes after reaching your high pressure before proceeding, so that the pressure is not changing while you are trying to calibrate.
Page 95: Maintenance Reminder
Chapter 11 SYSTEM MAINTENTANCE 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.
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Page 97: Troubleshooting
Chapter 12 TROUBLESHOOTING 12 TROUBLESHOOTING This chapter will help the user solve problems they might encounter when operating their pump. It is divided into the following areas. • Troubleshooting Basics, Section 12.1 • PumpWorks Error Messages, Section 12.2 • CN-6000 Two Digit Display Error Messages, Section 12.3 •...
Page 98: Pumpworks Error Messages
Chandler Engineering 6000 SERIES PUMP MANUAL • 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.
Page 99: Logged Errors
Chapter 12 TROUBLESHOOTING A dialog box immediately appears on the screen with an error message. The text in the dialog box clearly explains what prevents the requested action from being executed. An immediate error is NOT logged to the Current Error Log or the Previous Error Log. The status bar of the PumpWorks main window reads “No Errors”...
Page 100 Chandler Engineering 6000 SERIES PUMP MANUAL 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.
Page 101: Cn-6000 Two Digit Display Error Messages
Chapter 12 TROUBLESHOOTING • 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/USB port, the USB/serial expander/isolator or the pump is not working on the proper frequency.
Page 102: The Two Digit Display Does Not Light
Try turning the pump controller’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.
Page 103 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 PumpWorks and load the program code. PumpWorks will know that the program is bad and will prompt the user for the program file name.
Page 104: Two Digit Display Error Code
Chandler Engineering 6000 SERIES PUMP MANUAL 12.3.2.2 Pump Controller Firmware Initialization The pump controller firmware initialization is performed next. The left hand digit will light, the right hand digit will not. The left hand digit will display number 1, then 2, then 3, then 4, then 5, then 6, then 7.
Page 105 • The firmware that has been downloaded to the pump controller does not match the pump controller type. Download new firmware that matches the controller type, or contact Chandler Engineering for assistance. Communication Error • unable to decode communication from computer Communication Lost (* = pump number 1-8) •...
Page 106: Air Supply Problems
• The firmware that has been downloaded to the pump controller does not match the pump controller type. Download new firmware that matches the controller type, or contact Chandler Engineering for assistance. To correct cable errors, locate the cable that the problem is reported on and make sure it is fully plugged in.
Page 107: Constant "Air Escaping" Sound
The fan must ALWAYS be running when the pump cylinder is operating. If the fan does not come on when the motor driver is powered on, or if it stops while the pump is running, stop the pump cylinder immediately. Contact Chandler Engineering for a replacement fan. 12.6 Fluid Leaks Although Quizix pumps are made to a high standard, a fluid leak can occur.
Page 108: Leak Testing
Chandler Engineering 6000 SERIES PUMP MANUAL 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.
Page 109: Does Your Pump Have A Fluid Leak
Chapter 12 TROUBLESHOOTING 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 2. Set the pump to constant pressure independent mode. 3.
Page 110: Piston Motion Errors
5. Start the pump cylinder and watch the physical piston position indicator through the side cover for proper movement from max retract to max extend. If there is no piston movement, contact Chandler Engineering technical support. • Make sure the valve assembly is installed in the correct position and that all valve fittings are securely tightened.
Page 111: Motor Running, No Piston Movement Detected Error
• Make sure that the flow rate that the pump cylinder is operating at will provide observable motion. Take into account the flow rate units, either ml/hour or ml/minute. • If the piston still cannot be observed moving through the side cover, contact Chandler Engineering technical support.
Page 112: Pressure Problems
Chandler Engineering 6000 SERIES PUMP MANUAL • The motion sensor may be malfunctioning. 12.9 Pressure Problems The pressure transducers on the 6000 Series Pump System are essential for proper pump operation. Any problem with the transducer will mean that the pump will not operate the way it is supposed to.
Page 113: Pressure Is Not Constant In Constant Pressure Mode
Chapter 12 TROUBLESHOOTING desired pressure operation. This problem can also be caused by having a gas-liquid mixture. The piston will accelerate to compress the mixture and shoot past the set pressure before it can slow down. If you must use a gas-liquid mixture, you will need to carefully set the servo constants to keep the pump from exceeding the safety pressure.
Page 114: Checking Your Air Supply Connection
Chandler Engineering 6000 SERIES PUMP MANUAL Checking Your Air Supply Connection To check the air supply connection, first identify the air inlet. Make sure a 1/4” tube is inserted into the air inlet fitting, and that it is tight and cannot be moved. Attached to the other end of the tube should be your pressurized air source.
Page 115 The rest of the digits are the controller firmware version. To determine the latest version of PumpWorks available, contact Chandler Engineering, either by phone or by email at: chandler.sales@ametek.com. Please refer to the PumpWorks User’s Manual for firmware update procedures.
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Page 117: Q6000 Series User Interface
100 milliamperes (ma.) each. The 12 volt power supply, however, is capable of supplying a combined total of 800 ma. The pilot solenoids used by Chandler Engineering only draw about 80 milliamperes each, so 8 pilot solenoids can easily be operated from the CN-6000 user interface. If other types of pilot solenoids are to be used, then the current (ma) requirements of these pilot solenoids must be checked.
Page 118: Digital Input Lines
Chandler Engineering 6000 SERIES PUMP MANUAL level) they put out a voltage close to the 5 volt supply (guaranteed to be greater than 4.6 volts when sourcing up to 20 milliamperes). These signals will either source or sink current but are limited to a maximum of 20 milliamperes.
Page 119: Emergency Stop Capability
Chapter 13 Q6000 SERIES USER INTERFACE A typical application could involve an external 4-20mA pressure transducer. After wiring this transducer to the CN-6000B user interface and setting up the linear scaling in PumpWorks, the pressure detected by this pressure transducer could then be displayed and recorded by PumpWorks 13.5 Emergency Stop Capability The CN-6000 controller driver includes an emergency stop capability, which provides the ability to abruptly stop the pump cylinders in an emergency.
Page 120 Chandler Engineering 6000 SERIES PUMP MANUAL Pin Number User Interface Function Connector Valve control line 1 for external valves, sink current to ground Valve control line 2 for external valves, sink current to ground Valve control line 3 for external valves, sink current to ground...
Page 121 Chapter 13 Q6000 SERIES USER INTERFACE +12 volt power normally used for pilot solenoids +12 volt power normally used for pilot solenoids Analog signal ground Analog signal ground Analog signal ground Power and signal ground for all power supplies Power and signal ground for all power supplies Power and signal ground for all power supplies Power and signal ground for all power supplies User Interface Connector listed by Pin Number...
Page 122 Chandler Engineering 6000 SERIES PUMP MANUAL +12 volt power +12 volt power +12 volt power +12 volt power +12 volt power +12 volt power +12 volt power Digital input signal 2 [DI 17] Digital output signal 2 [DO 7] +5 volt power...
Page 123 Appendix A Q6000 SERIES PUMP MANUAL Appendix A: How to Attach a Fitting to Your Tubing CAUTION 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.
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Page 125 GLOSSARY MASTER GLOSSARY AC line noise rejection 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 equipment connected to them.
Page 126 Chandler Engineering 6000 SERIES PUMP MANUAL amplifiers A device which increases the magnitude or amplitude of a signal, such as voltage from a pressure transducer. anti-seize compound 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.
Page 127 GLOSSARY type) and power is lost to the motor driver, pressure forces on the piston 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.
Page 128 Chandler Engineering 6000 SERIES PUMP MANUAL calibrate To check or adjust a measuring instrument so it remains accurate. cam rollers A cam roller is located on each side of the pump cylinder and allows the user to view the position of the piston.
Page 129 GLOSSARY continuous flow pumping The pump system can pump fluid for any length of time without 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.
Page 130 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. default pressure unit The unit of measure for the default pressure is PSI, or pounds per square inch.
Page 131 GLOSSARY digital overpressure This controller firmware safety feature causes the pump cylinders to stop pumping if the user set safety pressure is exceeded. digital underpressure This controller firmware safety feature causes the pump cylinders to stop pumping if the pressure transducer voltage drops below a factory preset level.
Page 132 Chandler Engineering 6000 SERIES PUMP MANUAL error log This PumpWorks software feature is a time record of the errors that have happened to a pump system. errors present This PumpWorks software message means that there is currently an error in the pump system that has not been acknowledged or resolved.
Page 133 GLOSSARY fuse An electrical safety device containing an element that protects an electric circuit by melting when overloaded by a malfunction. fuse holder A mechanical part that contains a replaceable fuse. It is located next to the power cord connector. geared mode A pumping mode that operates two pump cylinders so they move in equal, but opposite directions, at the user set rate.
Page 134 Chandler Engineering 6000 SERIES PUMP MANUAL home 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. host link This is a data link which can be used to link the pump system computer with another computer.
Page 135 GLOSSARY interrupt request 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.
Page 136 Chandler Engineering 6000 SERIES PUMP MANUAL motion status 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.
Page 137 GLOSSARY paired constant delta A pair of cylinders which work together to pump fluid at a pressure delivery 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. paired constant delta A pair of pump cylinders which work together to extract fluid pressure receive...
Page 138 Chandler Engineering 6000 SERIES PUMP MANUAL parameters The conditions the pump system is set to run within. perpendicular Crossing at a right angle, or 90 degrees. Phillips-head screw This screw head has two lines on its head which cross each other at 90 degrees.
Page 139 GLOSSARY pressure A measurement of the magnitude of a force. This can be measured in different units, which include PSI, bar or pascals. pressure pulse A change in pressure which lasts a short duration. pressure transducer A device that measures fluid pressure and converts it to an electrical signal.
Page 140 Chandler Engineering 6000 SERIES PUMP MANUAL pump body assembly The pump housing, plus all of the internal components. These include the motor assembly and ball screw/ball nut assembly. pump controller The pump controller is an electrical subsystem which directs all pump operations. The pump controller communicates to the user through the PumpWorks software.
Page 141 GLOSSARY reset recirculating mode This is the only way to properly exit from recirculating operation. reset volumes The display volume for any pump cylinder can be set to zero, at any time, using this button. residue A deposit that remains on a surface after fluid has been removed.
Page 142 Chandler Engineering 6000 SERIES PUMP MANUAL safety rupture disk exhaust Located on the safety burst disk assembly, this port should be port connected by the user to a dump location in case of ruptured disk activation and fluid release. schematic A drawing of electrical or fluid connections.
Page 143 GLOSSARY set pressure The field where the user sets the pressure that the pump will pump at when operating in constant pressure or constant delta pressure mode. set flow rate The user sets the rate the pump flows at when operating in a Constant Rate mode.
Page 144 Chandler Engineering 6000 SERIES PUMP MANUAL standby pump cylinder 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.
Page 145 GLOSSARY titles PumpWorks software allows you to provide your own column headings, or titles, for you Data Log. torque A turning or twisting force. torque wrench 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.
Page 146 Chandler Engineering 6000 SERIES PUMP MANUAL valve cable extension 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. voltage setting The power your system is set to run on, either 110 to 120, or 215 to 240 volts.
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Page 148 Index Air Leaks, 105 Pump to Computer, 17 Air Supply, 31, 67 Transducers and Valves, 19, 28 Checking, 111 Connector Pinouts, 117 Connection, 112 Controller. See Pump Controller Problems, 104 Corrosive Fluids, 58, 63, 107 Requirements, 111 Current System Status Window, 95 Analog Overpressure, 46, 102 Cylinder Barrel, 61, 62 Auxiliary Analog Inputs, 116...
Page 149 Index Soft Limit Warning, 97, 104 Re-greasing, 84 Two Digit Display, 99 Ball Screw, 85 Does Not Complete Initial Check, 100 Helical Gears, 86 Does Not Light, 100 Planetary Gear, 86 Error Codes, 102 Reminder, 93 Expander/Isolator, 55 Rupture Disk, 87 Seals, 80, 83 Maintenance, 87 High Temperature, 83...
Page 150 Index Update, 55 Safety Features, 45 On/Off Switch, 51 Safety Pressure, 46, 103, 104 Pump Cylinder, 9, 57 Safety Rupture Disk. See Rupture Disk Ambient Temperature Seals Diagram, 8, 59 Assembly, 62 Ball Screw/Nut, 61 High Temperature, 62 Bearings, 61 Changing, 80 Cylinder Barrel, 61 High Temperature, 83...
Page 151 Index Valves, 65 Connections, 53 Air Supply Reqirements, 67 High Temperature, 33, 70 Auxiliary, 115 Leaks, 107 Cable, 19 Problems, 111 Checking, 37 Warnings. See Errors and Warnings [149]...