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Chandler Engineering Ametek Quizix 5000 Series User Manual

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5000 Series Pump System
User's Manual
Rev G – January 2022
P/N: QC-5-1003
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
P.O. Box 470710, Tulsa, Oklahoma 74147

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Summary of Contents for Chandler Engineering Ametek Quizix 5000 Series

  • Page 1 Rev G – January 2022 P/N: QC-5-1003 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 P.O. Box 470710, Tulsa, Oklahoma 74147...
  • Page 2 Neither is any liability assumed for damages resulting from the use of the information contained herein. This publication contains the following trademarks and/or registered trademarks: AMETEK, QUIZIX, and CHANDLER ENGINEERING. These trademarks or registered trademarks and stylized logos are all owned by AMETEK, Inc. All other company, product and service names and logos...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Contents GENERAL OVERVIEW ..................7 Introduction ........................7 Primary Components ....................8 1.2.1 Q5000 Pump Cylinder ..................9 1.2.2 CMD-5000 Dual Controller Driver ..............10 1.2.3 PC–Compatible Computer and PumpWorks Software ........10 1.2.4 Valves, Transducers and Plumbing..............10 1.2.5 Support Stand ....................
  • Page 4 Chandler Engineering 5000 SERIES PUMP MANUAL 5.3.1 Safety Pressure Overpressure (Safety Pressure Setting) ........34 5.3.2 Digital Underpressure ..................34 5.3.3 Analog Overpressure ..................34 5.3.4 Safety Rupture Disk ..................34 Emergency Stop Capability ..................37 CMD-5000 DUAL CONTROLLER DRIVER ............39 The Pump Controller Subcomponent ................39 Motor Driver Subcomponent ..................40...
  • Page 5 TABLE OF CONTENTS Hastelloy Option for Corrosive Fluids ................. 52 Pump Cylinder High Temperature Option ..............52 Pump Cylinders with Optional Wash Ring ..............53 VALVES, TRANSDUCERS AND PLUMBING ............ 55 Valves ........................55 Pilot Solenoids......................56 Air Supply ........................57 Pressure Transducers ....................
  • Page 6 Chandler Engineering 5000 SERIES PUMP MANUAL 11.2.2 Changing the Seals ...................76 11.2.3 Inspecting, Removing, Cleaning, and Re–Installing a Piston ......80 11.2.4 Replacing the Cylinder Barrel ................81 11.3 Maintaining the Pump Cylinder ...................81 11.3.1 Replacing the Cam Rollers Recommended Frequency: ........82 11.3.2...
  • Page 7 TABLE OF CONTENTS 13.1 Valve Control Lines ....................119 13.2 Digital Output Lines ....................120 13.3 Digital Input Lines ....................120 13.4 Analog Signal Input Lines ..................120 13.4.1 Auxiliary Current Loop Inputs ............... 120 13.4.2 Analog Input Lines ..................121 13.5 Emergency Stop Signal .....................
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  • Page 9: General Overview

    The basic building block of the 5000 Series Pump System is the Q5000 pump cylinder. Chandler Engineering manufactures six different models of Q5000 pump cylinders (refer to Table 1-1). They provide different maximum flow rate and pressure specifications. In general, the higher the maximum pressure specification, the lower the maximum flow rate specification.

  • Page 10: Primary Components

    1 PC–compatible computer PumpWorks software PumpWorks software The 5000 Series two–cylinder pump system (known as a Q5210) is shown in Figure 1-1, below. A computer can be supplied by the user or purchased from Chandler Engineering as part of the pump system.

  • Page 11: Q5000 Pump Cylinder

    Chapter 1 GENERAL OVERVIEW Valves Pump cylinders Stand Mounted 5000 Series Pump System Quizix components can also be configured as a closed loop, recirculating system to obtain Steady– State Relative Permeability measurements. Recirculating systems can be set up for one, two, or three fluids, and can maintain a pulse-free constant flow rate of one or more fluids through a sample while maintaining a constant pressure at the outlet of the sample.

  • Page 12: Cmd-5000 Dual Controller Driver

    PC–Compatible Computer and PumpWorks Software A pump system includes PumpWorks Software, which runs on a PC–compatible computer under the Windows operating system. Chandler Engineering can provide a computer with the pump system, if desired. PumpWorks is menu–driven and easy to use. PumpWorks allows the user to set all operating parameters, such as fluid flow rate or pressure.
  • Page 13 Chapter 1 GENERAL OVERVIEW high temperature systems, the CMD-5000 Dual Controller Driver, the pilot solenoids for the valves, and the pressure transducers must be placed outside the oven. High Temperature Stand for the 5000 Series Pump Cylinders [11]...
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  • Page 15: System Setup

    Chapter 2 SYSTEM SETUP SYSTEM SETUP This chapter provides the information necessary to set up a 5000 Series Pump System or change a system’s setup, which includes the following: • Unpacking the System, Section 2.1 • Installing the Pistons, Section 2.2 •...

  • Page 16: Installing The Pistons

    Chandler Engineering 5000 SERIES PUMP MANUAL Installing the Pistons Due to previous experience with pistons being broken during shipment, the pistons of your 5000 Series pump cylinders are not installed in their cylinders for shipment. The pistons are packed separately and must be installed before the pump cylinders can pump fluid.
  • Page 17 Chapter 2 SYSTEM SETUP 8. Next, replace the cylinder barrel. Holding the cylinder barrel straight in front of the piston, insert the barrel onto the piston and push it straight into the cylinder housing until it is fully seated. Be sure that the speedbite tubing ports are oriented vertically above one another.
  • Page 18 Chandler Engineering 5000 SERIES PUMP MANUAL Stand-Mounted Q5200 System [16]...
  • Page 19 Chapter 2 SYSTEM SETUP Expanded Front View of a Stand-Mounted Q5200 System [17]...
  • Page 20 Chandler Engineering 5000 SERIES PUMP MANUAL Stand-Mounted Q5400 System [18]...

  • Page 21: Setting Up A Stand-Mounted System

    Chapter 2 SYSTEM SETUP 2.3 Setting Up a Stand–Mounted System This section describes how to set up a stand–mounted system. Schematics for a stand– mounted Q5200 two–cylinder system and Q5400 four–cylinder system are shown from the top, front and side in Figure 2-2 and Figure 2-4.
  • Page 22 Chandler Engineering 5000 SERIES PUMP MANUAL 10. For the Q5010 cylinders, connect the valve assembly fittings to the pump cylinders using the following orientation: • the safety rupture disk holders point toward the stand, • the transducers point away from the cylinders, and •...

  • Page 23: Setting Up A High Temperature System: Oven Installation

    Chapter 2 SYSTEM SETUP 17. The CMD-5000 Dual Controller Driver has a two-digit display, which is labeled “Pump Number”. Using letters, numbers, or a combination of the two, this display can convey overpressure or underpressure errors, communication errors, driver errors, or the absence of a cable.

  • Page 24: Cmd-5000 Dual Controller Driver

    Connect the motor and sensor cables to the appropriate cylinder connectors. It is highly advisable to keep the motor cables short. Standard 2–meter motor extension cables are available from Chandler Engineering, but it is recommended not to use these extensions, if possible.

  • Page 25: Cables

    For oven–mounted systems, the location of the pump cylinder, CMD-5000, transducer, 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.

  • Page 26: Requirements For Air Supply

    Chandler Engineering 5000 SERIES PUMP MANUAL If you ordered a computer with your Quizix pump system, it is also set for the voltage in use in your country. See the operating manual for your computer for further information about its power specifications.

  • Page 27: System Checkout

    It is also strongly recommended that you follow these checks and procedures in each of the following situations: • When the pump 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.

  • Page 28: Connection Checklist

    Chandler Engineering 5000 SERIES PUMP MANUAL 3.1.1 Connection Checklist The purpose of this safety check is to make sure that all the cables and tubing are connected in the right places. The system can seriously malfunction if the cables are switched or tubing is connected improperly.

  • Page 29: Valve Check

    Chapter 3 SYSTEM CHECKOUT the port of the safety disk holder for fluid release if the safety rupture disk is activated by excessive pressure. 8. Fluid Inlet and Outlet Be sure to connect your fluid source to the fitting labeled “fluid inlet”. The output of the pump is available through the fluid outlet line and will be at the flow rate or pressure the user specified in PumpWorks.

  • Page 30: Filling The Pump System With Liquid

    Chandler Engineering 5000 SERIES PUMP MANUAL 1. It is assumed that you have just completed the valve check described in the previous section and that PumpWorks is operating. Set the Safety Pressure for the cylinders you are testing to 100 psi (700 kPa) using the Main-Set Pump Safety Pressure window.

  • Page 31: Pressure Transducer Check

    Chapter 3 SYSTEM CHECKOUT 1. To fill a cylinder with fluid, leave the safety pressure at 100 psi and set the flow rate to 50% of the maximum rate (7 ml/min for the Q5000 cylinder). 2. Open the fill valve, close the deliver valve, set the direction to retract, and start the cylinder to initiate the filling process for cylinder 1A.
  • Page 32 Chandler Engineering 5000 SERIES PUMP MANUAL have a pressure transducer failure or the pressure transducer is cross-wired. NEVER operate the system AT ALL if you have any reason to believe a transducer has failed. Repeat this procedure for each cylinder in your system. Do not proceed further until your system has passed this check.

  • Page 33: Pump Operating Basics

    Chapter 4 PUMP OPERATING BASICS PUMP OPERATING BASICS © For instructions on the basics of operating your 5000 Series Pump System using PumpWorks Software, please refer to the PumpWorks User’s Manual. [31]...
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  • Page 35: Safety Features

    Chapter 3, System Checkout Procedures. 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 36: Safety Pressure Overpressure (Safety Pressure Setting)

    Chandler Engineering 5000 SERIES PUMP MANUAL 5.3.1 Safety Pressure Overpressure (Safety Pressure Setting) The most basic of these safety features is safety pressure monitoring, which is performed in the controller firmware. With this feature, the user specifies a safety pressure at a level higher than the expected running pressure.
  • Page 37 Chapter 5 SAFETY FEATURES SAFETY FEATURES Table 5-1 Safety Rupture Disk Ratings Cylinder Maximum Operating Safety Rupture Pressure Disk Rating Model Q5000-2.5K 2,500 psi 3,500 psi Q5000-5K 5,000 psi 6,500 psi Q5000-L-7.5K 7,500 psi 10,000 psi Q5000-10K 10,000 psi 12,500 psi Q5000-L-10K 10,000 psi 12,500 psi...
  • Page 38 The relief fluid exit is a 3/8” NPT fitting, which can be easily adapted so that tubing can vent fluid to a harmless location. To achieve a good seal, Chandler Engineering recommends that 120 ft–lbs (160 Newton meters) be used to torque down a replacement disk rated for 25,000 psi.

  • Page 39: Emergency Stop Capability

    Chapter 5 SAFETY FEATURES be replaced. To replace a safety rupture disk, carefully follow the instructions in Chapter 11, Section 11.5. Emergency Stop Capability The CMD-5000 Dual Controller Driver includes an emergency stop capability, which is accessed through the User Interface connector. If you would like to implement an emergency stop function for your pump system, you will need to install a User Interface cable.
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  • Page 41: Cmd-5000 Dual Controller Driver

    Chapter 6 CMD-5000 DUAL CONTROLLER DRIVER CMD-5000 DUAL CONTROLLER DRIVER The CMD-5000 Dual Controller Driver is included in all 5000 Series Pump Systems and operates with Q5000 pump cylinders. The CMD-5000 (CMD stands for Controller Motor Driver) contains two primary subcomponents: 1.

  • Page 42: Motor Driver Subcomponent

    Chandler Engineering 5000 SERIES PUMP MANUAL • Transfers system data back to PumpWorks for viewing and, if desired, recording data in a software data log. • Provides signal conditioning for analog transducers so that they can be calibrated. • Executes rate ramping and valve operations during switch–over from one pump cylinder to another.

  • Page 43: Cable Connections

    Chapter 6 CMD-5000 DUAL CONTROLLER DRIVER 10.2 on Uninterruptable Power Supplies for more details). The power cord supplied is compatible with the voltage and style of plug used in the country to which the pump is shipped. A fuse box is located next to the power cord connector and includes either a fuse for 120 volt or 220- 240 volt operation.

  • Page 44: Front Panel Cable

    Chandler Engineering 5000 SERIES PUMP MANUAL 6.4.5 Front Panel Cable The Front Panel Cable connects the CMD-5000 with the Front Panel, which may be used instead of PumpWorks to control the pump system. It is not available at this time.
  • Page 45 Chapter 6 CMD-5000 DUAL CONTROLLER DRIVER When turning on the pump controller, the user needs to watch the two-digit display. The first thing the user will see when the CMD-5000 is turned on is all segments of the display will light at once, briefly. Next the display will flash the boot version number (currently version 3.6).

  • Page 46: Usb/Serial Expander/Isolator

    Chandler Engineering 5000 SERIES PUMP MANUAL In the final step, “SP” (“do” in firmware versions prior to 60.071) will flash alternately with “0”. The “SP” stands for safety pressure overpressure. As a safety precaution, each time a pump is powered on, the safety pressure is set at -50 PSI.

  • Page 47: Pump Controller Firmware

    • The pump controller firmware, which is stored in the CMD-5000. 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 CMD-5000. New versions of the pump controller firmware can be downloaded directly to your pump controller via PumpWorks.
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  • Page 49: Pump Cylinder

    Chapter 5 SAFETY FEATURES PUMP CYLINDER This chapter describes the 5000 Series Pump Cylinder, also called the Q5000 Pump Cylinder. Included are the following sections: • Q5000 Pump Cylinder, Section 7.1 • Important Operating Notes, Section 7.2 • Primary Mechanical Subcomponents of the Pump Cylinder, Section 7.3 •...

  • Page 50: Important Operating Notes

    (plus the ball screw pitch and motor resolution in the “L” models). Thus, all the information in this chapter applies to any of the Q5000 pump cylinder models manufactured by Chandler Engineering. Figure 7-2 shows a simplified drawing of an ambient temperature Q5000 pump cylinder.

  • Page 51: Primary Mechanical Subcomponents Of The Pump Cylinder

    If any of the pump cylinders are operated at less than 100 psi, the system may not perform optimally. If you plan to operate the system at very low pressures, such as less than 100 psi, contact Chandler Engineering to obtain pressure transducers which are more effective at lower pressures.

  • Page 52: Bearings

    Chandler Engineering 5000 SERIES PUMP MANUAL When the stepper motor rotates in a clockwise direction, the piston retracts and the cylinder barrel fills with fluid (assuming the fill valve is open and the deliver valve is closed). When the motor reverses direction, the piston extends and the pump delivers fluid (assuming the deliver valve is open and the fill valve is closed).

  • Page 53: Pump Cylinder Sensor Board

    Chapter 5 SAFETY FEATURES The seals can easily scratch and must be handled with extreme care during insertion. The ambient temperature seal assembly is shown in Figure 7-3. The back–up ring serves two functions; it supports the seal and it guides the piston. Because the seal has no structural strength, it is supported by the back–up ring, which holds the seal in the seal cavity.

  • Page 54: Pump Cylinder Base Plate

    Chandler Engineering 5000 SERIES PUMP MANUAL Ambient temperature versions of the pump cylinder have clear plastic side covers so that the position of the roller can also be monitored visually. The side covers are marked with a scale from 1 to 10, indicating the full range of the piston’s motion in milliliters.

  • Page 55: Pump Cylinders With Optional Wash Ring

    Chapter 5 SAFETY FEATURES • A different grease is used to lubricate moving parts. • A different CAM Roller is used. Q5000 High Temperature Pump Cylinder High Temperature Seal Assembly Pump Cylinders with Optional Wash Ring On most versions of 5000 Series pump cylinders, the seal retaining nut is a conventional nut that does not include a wash area.
  • Page 56 Chandler Engineering 5000 SERIES PUMP MANUAL nut is incorporated with a wash ring can be ordered on model Q5010. This is screwed into and out of the cylinder barrel in the same way as a normal retaining nut. When internal and external o–rings are added to this wash ring, a chamber is formed called the wash area, as shown in Figure 7-6 below.

  • Page 57: Valves, Transducers And Plumbing

    • High Temperature Option, Section 8.8 Valves Chandler Engineering uses constant–volume, air–actuated valves. 5000 Series pump cylinders use one of three valve types, rated for system pressure requirements and plumbing package configurations. Plumbing configurations include 1/8” tube for operating pressures to 10,000psi, ¼” tube with Autoclave SW250 tube connections for low pressure/viscous fluid applications, and ¼”...

  • Page 58: Pilot Solenoids

    Chandler Engineering 5000 SERIES PUMP MANUAL Fluid Plumbing Diagram For fluid to flow into the pump cylinder, the fill valve must be open and the deliver valve must be closed. The fluid then flows into the valve through the opened fill valve. For fluid to flow out of the pump cylinder, the fill valve must be closed and the deliver valve must be open.

  • Page 59: Air Supply

    Chapter 5 SAFETY FEATURES 5000 Dual Controller Driver and convert these signals to air pulses that open and close the fluid path in the air–actuated, constant volume valves. The pilot solenoids are connected to the CMD-5000 with a cable called the Transducer and Valve Cable. This cable branches out at the solenoid end, providing one branch with a 2–pin connector for each solenoid.
  • Page 60 Chandler Engineering 5000 SERIES PUMP MANUAL Air Connections for a 4-Cylinder System IMPORTANT Ensure that the air lines between the valves and the pilot solenoids are connected properly, according to the color–coded markings. For example, the brown labeled lines should connect the valve with a brown label to the pilot solenoid with a brown label. If the valves or pilot solenoids are serviced, make sure that all of the color–codes match...

  • Page 61: Pressure Transducers

    Chapter 5 SAFETY FEATURES Pressure Transducers Each Q5000 pump cylinder is plumbed to a pressure transducer that measures the fluid pressure inside the cylinder barrel. The transducer converts this pressure measurement to an electric signal, which is sent to the CMD-5000 Dual Controller Driver through a transducer cable. This cable has a 25–pin D– style connector at the pump controller end, then splits into one 6-pin circular connector for each pressure transducer.
  • Page 62 Chandler Engineering 5000 SERIES PUMP MANUAL • Cylinder to Valve Tubing: Two pieces of tubing connect the upper port on the cylinder barrel to the center section of the valve. (In between the cylinder barrel and the valve is the safety rupture disk holder.) This tubing functions as both the inlet to and the outlet from the cylinder barrel.

  • Page 63: Safety Rupture Disks

    IMPORTANT Carefully check all fluid fittings for leaks. All pump systems are checked thoroughly and are fluid–tight at the time it is shipped. However, Chandler Engineering recommends that you carefully check all the fittings prior to operation and whenever the system is altered or moved. Most system leaks can be traced to fittings.

  • Page 64: Hastelloy Option For Corrosive Fluids

    Chandler Engineering 5000 SERIES PUMP MANUAL The safety rupture disk included in all Quizix pump systems is a ONE-TIME ONLY item that must be replaced if it is activated. It is not a pressure relief valve and cannot be tested. If you bring the system pressure up to the level at which the disk is designed to activate, it will rupture and must be replaced.

  • Page 65: Valves And Pilot Solenoids

    Chapter 5 SAFETY FEATURES 8.8.2 Valves and Pilot Solenoids The pilot solenoids for the valves cannot be placed in an oven. The pilot solenoids should be placed just outside the oven so that the air tubes connecting the pilot solenoids and the valves are as short as possible.
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  • Page 67: System Cables

    Chapter 5 SAFETY FEATURES SYSTEM CABLES The 5000 Series Pump System includes numerous cables that connect the components of the system. These cables are labeled so that connecting them should be self–explanatory. All of the cables necessary to operate the system are described in this chapter. Each cable is also described in the chapter(s) explaining the components to which it is connected.

  • Page 68: Data Link Cable

    Chandler Engineering 5000 SERIES PUMP MANUAL The transducer portion of this cable has two branches. Each branch has a 6-pin circular connector that should be connected to one end of the pressure transducer. The branch labeled “Transducer A” should be connected to Transducer A on pump cylinder A; the branch labeled “Transducer B” should be connected to Transducer B on pump cylinder B.
  • Page 69 Chapter 5 SAFETY FEATURES to conduct long-term experiments, in which the interruption of fluid flow would be detrimental to the experiment’s results. [67]...
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  • Page 71: System Power

    Uninterruptable Power Supply (UPS) with their equipment. 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 recommend that the time required for the unit to switch to back–up power be less than a few milliseconds.

  • Page 72: Changing The Voltage Setting

    Chandler Engineering 5000 SERIES PUMP MANUAL To keep the Quizix pump system operating, only the CMD-5000 Dual Controller Driver needs to be connected to the UPS supply. The computer can be turned off without affecting the operation of the pump system. However, if the computer is used to log data or perform timed operations, such as ramping of rates or pressures with the AutoOp feature, then the computer must also be connected to the UPS.

  • Page 73: Replacing A Fuse

    Chapter 9 SYSTEM CABLES Users conducting long-term experiments, where the interruption of fluid flow would be detrimental to the experiment’s results, should use an Uninterruptable Power Supply (UPS) with the pump. All pumps are shipped with power cords compatible with the voltage and type of outlet used in the country to which they are shipped.

  • Page 74: User Interface Cable (Optional)

    The motor cable can be extended, if necessary. Although Chandler Engineering recommends that the motor cable be kept as short as possible, Chandler Engineering manufactures a 2meter motor cable extension. There are no extension cables available for the sensor cable, transducer and valve cable, or data link cable, but the user can order new cables in a longer length, if necessary.

  • Page 75: Maintenance

    Chapter 5 SAFETY FEATURES MAINTENANCE This chapter describes preventive and corrective maintenance for the 5000 Series Pump system. This chapter includes: • Special Tools and Spare Parts Kit, Section 11.1 • Changing the Cylinder Barrel Seals, Section 11.2 • Maintaining the Pump Cylinder, Section 11.3 •...
  • Page 76 Chandler Engineering 5000 SERIES PUMP MANUAL 22 mm open–end The 22 mm open-end wrench fits the wrench flat area of the cylinder barrel. It is used to hold the barrel in place while tightening the fluid fittings, or while tightening...

  • Page 77: Changing The Cylinder Barrel Seals

    Chapter 5 SAFETY FEATURES CMD-5000 Dual Controller Driver fuse Safety rupture disk. This is used in the safety rupture disk assembly. 11.2 Changing the Cylinder Barrel Seals This section describes how to change the cylinder barrel seals and the piston. It includes the following: •...

  • Page 78: Changing The Seals

    Chandler Engineering 5000 SERIES PUMP MANUAL from the body of the cylinder, continue to pull straight back until the seal and seal backup ring are released from the piston. For best results, remember to keep cylinder barrels, seal back–up rings and pistons together and reinsert them into the cylinder they were removed from.
  • Page 79 Chapter 5 SAFETY FEATURES T-Type and Cup-Type Seals Cup–type seals are made from ultra–high molecular weight polyethylene (UHMW–PE) and used in ambient temperature applications and are normally white. Cup–type UHMW– PE seals have the longest life, one year minimum for normal service and two–plus years are possible. Pressure, flow rate, and fluid type do not significantly affect the life of these seals.
  • Page 80 Chandler Engineering 5000 SERIES PUMP MANUAL Table 11-1 for a description of the seal extraction rod tool.) This procedure creates pressure in the cylinder barrel. This causes the seal to pop out of the seal cavity and remain on the seal extraction rod. If the seal sticks and does not pop out when the rod is inserted, press the rod in again to create pressure in the cylinder.
  • Page 81 Chapter 5 SAFETY FEATURES purpose. Almost any type of lubricating compound will work -- even water, if no oils are available. 2. Apply a light coat of lubrication to the inside surface of the seal insertion guide ring, and the seal insertion plunger. Apply lubricating compound to the cylinder seal cavity entrance.

  • Page 82: Inspecting, Removing, Cleaning, And Re-Installing A Piston

    Chandler Engineering 5000 SERIES PUMP MANUAL Order and Orientation of Aflas Seal Assembly Components and Outer Backup Ring. In the following procedural steps, the numbers in parentheses correspond to the numbers next to the component labels shown in Figure 11-3.

  • Page 83: Replacing The Cylinder Barrel

    Chapter 5 SAFETY FEATURES 4. If some deposits cannot be removed while the piston is installed, or if you want to soak the piston in a solvent, use the 27 mm socket wrench with an extension to remove the piston. Inspect a piston that is removed from the cylinder housing by doing the following: 5.

  • Page 84: Replacing The Cam Rollers Recommended Frequency

    Chandler Engineering 5000 SERIES PUMP MANUAL • Re–Greasing the Harmonic Drive Bearing, Section 11.3.3 11.3.1 Replacing the Cam Rollers Recommended Frequency: • For ambient temperature systems—every 2 years of regular use, or as required. • For high temperature systems—every year of regular use, or as required.

  • Page 85: Re-Greasing The Ball Screw Recommended Frequency

    Chapter 5 SAFETY FEATURES Right–Side Cam Roller Cam Roller Cam Roller Stand-Off Cam Roller and Stand Off 1. Remove the right side cover (two Phillips head screws). 2. Remove the sensor board and set it aside (one 3 mm socket head cap screw). This step is recommended, but not mandatory.
  • Page 86 Chandler Engineering 5000 SERIES PUMP MANUAL • For high temperature systems—every year of regular use, or as required. The Quizix pump cylinder has a side cover on each side of the pump cylinder. The ambient temperature side cover contains a clear, acrylic panel on the outside, through which the sensor board (right side) or the ball screw (left side) can be viewed.

  • Page 87: Re-Greasing The Harmonic Drive Bearing

    If any of these irregularities are evident, the ball screw may need major service or replacement, and Chandler Engineering should be contacted. 5. Use a small brush with short, stiff bristles, or another small applicator, and dip it into a container of grease.
  • Page 88 Chandler Engineering 5000 SERIES PUMP MANUAL Motor Adaptor Housing Motor Assembly Pump Body Assembly Pin Connector Pump Motor Assembly 2. Use a 3 mm right angle Allen wrench to break loose the six M4 socket head cap screws (SHCS) securing the motor adapter housing to the pump body. See Figure 11-9 for the location of the mounting screws that secure the motor adapter to the pump body housing.
  • Page 89 Chapter 5 SAFETY FEATURES Fixed Spline Wave Generator Bearing Snap Ring Flexspline Motor Adaptor Housing Open End of the Motor Housing 5. Holding the motor assembly firmly in one hand with the open end of the motor adapter housing facing down, sharply rap the flat surface of the motor adapter housing on a thin piece of cardboard placed on a solid surface.
  • Page 90 Chandler Engineering 5000 SERIES PUMP MANUAL NOTE: The flexspline may not easily separate from the wave generator bearing. If these parts do separate, gently slide the flexspline back onto the wave generator bearing. If they do not separate, proceed with this procedure.
  • Page 91 Chapter 5 SAFETY FEATURES NOTE: The key is slightly wider than it is high. Place it in the shaft keyway with its wide side down. 17. Grasp the wave generator bearing in one hand and, looking straight down at the motor shaft and its key, carefully slide the bearing and spline over the center shaft.

  • Page 92: Cooling Fan Maintenance

    Chandler Engineering 5000 SERIES PUMP MANUAL IT IS EXTREMELY IMPORTANT THAT THE SNAP–RING IS PROPERLY AND COMPLETELY IN PLACE ON THE MOTOR SHAFT. WHEN PLACING THE SNAP– RING ON THE SHAFT, DO NOT OPEN IT ANY MORE THAN NECESSARY. IF THE SNAP–RING IS NOT PROPERLY IN PLACE, THE WAVE GENERATOR BEARING...

  • Page 93: Replacing The Safety Rupture Disk

    Alternatively, you may want to install safety rupture disks with a higher rating. In that case, contact Chandler Engineering for the appropriate specifications. Safety rupture disks are installed to prevent the system from exceeding a specified pressure. (The terms safety burst disk (SBD) and safety rupture disk are used interchangeably in this manual.) The safety...
  • Page 94 Chandler Engineering 5000 SERIES PUMP MANUAL Safety Rupture Disk Assembly To replace a safety rupture disk, use the following procedure: 1. Remove the safety rupture disk assembly from the pump system (this is an important precaution). 2. Unscrew the safety rupture disk locking fitting while securely holding the safety rupture disk holder.

  • Page 95: Calibrating The Pressure Transducers

    The Spare Parts Kit included with each pump system includes one replacement safety rupture disk. Additional safety rupture disks are available in stainless steel or Hastelloy and may be obtained from Chandler Engineering. The safety rupture disk’s type and model number is printed on the tag that is attached to it.
  • Page 96 Chandler Engineering 5000 SERIES PUMP MANUAL pressure read by the Quizix system is adjusted until the system’s transducer readings match the reading by the calibrated gauge (CG). The second method is to use an external pressure source, such as a “dead-weight tester.” With this method the user connects the external calibrated pressure source (PS) to the pump system.
  • Page 97 Chapter 5 SAFETY FEATURES Calibration Setup Diagram Pressure Source Calibrated Gauge Fluid Outlet Deliver Cylinder 1 Fill Pressure Transducer Deliver Cylinder 2 Fill Pressure Transducer Atmospheric Pressure Fill Reservoir Calibration Setup Diagram 11.6.2.1 Calibrated Gauge Method 1. As shown in the Calibration Setup Diagram in Figure 11-15, connect a calibrated gauge (CG) to the fluid outlet of your Quizix Pump System.
  • Page 98 Chandler Engineering 5000 SERIES PUMP MANUAL Calibration window, select “Current Offset”. The easiest way to adjust the offset is to select “Auto Zeroing”. Doing this will result in the computer calculating the necessary offset to have the display read zero pressure. The range of zero offset is limited so that a malfunctioning transducer or a transducer with significant pressure accidentally left on it, will not be able to be zeroed.
  • Page 99 Chapter 5 SAFETY FEATURES being calibrated and giving the illusion of working. For more information on calculating offsets and gains, see Section 10.1.3, “How to Calculate an Offset and Gain”, in the PumpWorks User’s Manual. 11.6.2.2 Calibrated Pressure Source Method 1.

  • Page 100: Maintenance Reminder

    Chandler Engineering 5000 SERIES PUMP MANUAL The user may also calculate the desired gain by hand and then enter the desired value into the software. The range of gains is limited to prevent faulty and malfunctioning transducers from being calibrated and giving the illusion of working. For more information on calculating offsets and gains, see Section 10.1.3, “How to Calculate an Offset and Gain”...

  • Page 101: Troubleshooting

    Chapter 5 SAFETY FEATURES 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 • CMD-5000 Two Digit Display Error Messages, Section 12.3 •...

  • Page 102: Pumpworks Error Messages

    In the event of a problem that the user cannot figure out, these three files can be sent to Chandler Engineering and used to help figure out what caused the error. Please refer to the PumpWorks User’s Manual for more information about Error State Capture Mode.

  • Page 103: Immediate Errors

    Chapter 5 SAFETY FEATURES a maximum file size set by the user). Some errors are “immediate errors” and some are “logged errors”, which we will discuss in the following sections. 12.2.1 Immediate Errors An Immediate Error is generated in response to a command sent by the user. This is generally the result of a user asking the pump to do something that is not permitted.
  • Page 104 Chandler Engineering 5000 SERIES PUMP MANUAL 12.2.2.2.1 Communication Cannot Be Established If communication cannot be established between the pump and PumpWorks, do the following: • First, check the two digit display labeled “Pump Number” located on the pump controller. There is a right digit decimal point, which is located to the right-hand side of the right digit.

  • Page 105: Cmd-5000 Two Digit Display Error Messages

    Chapter 5 SAFETY FEATURES 12.2.2.2.2 Once Communications Has Been Established Once communications is established between PumpWorks and the pump controller, the following communication errors may be reported in the error log. These errors are automatically compensated for by PumpWorks, which notes the error and then resends the command again so that no data is lost.

  • Page 106: The Two Digit Display Does Not Light

    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 fuse for the power supply may need to be replaced. See Chapter 10, Section 10.3 for instructions on replacing a fuse.
  • Page 107 The basic pump controller diagnostics are performed next. The controller begins testing itself. If a test fails, the display will freeze. Report this to Chandler Engineering technical support. The right hand digit will light, the left hand digit will not. One segment of the right hand digit...
  • Page 108 Chandler Engineering 5000 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 109: Two Digit Display Error Code

    • 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 110 Firmware Conflict (changed to CC after firmware version 60.070) • 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. [108]...

  • Page 111: Other Pump Troubleshooting Situations

    Chapter 5 SAFETY FEATURES To correct cable errors, locate the cable that the problem is reported on and make sure it is fully plugged in. For driver or power supply shutdown error, try powering the pump off and then back on.

  • Page 112: Fan Does Not Run

    ALWAYS be running when the pump cylinder is operating. If the fan does not come on when the CMD-5000 is powered on, or if it stops while the pump is running, stop the pump cylinder immediately. Contact Chandler Engineering for a replacement fan. 12.4.3 Fluid Leaks Although Quizix pumps are made to a high standard, a fluid leak can occur.
  • Page 113 Chapter 5 SAFETY FEATURES 12.4.3.2 Leak Testing The 5000 Series Pump System can trace volume changes very accurately. This volume measurement, combined with the pressure measurement, can be used to detect fluid leaking from the pump system. • To detect a leak in this way, the pump cylinder can be pressurized to a set pressure and then stopped, and the pressure can be recorded as a function of time.

  • Page 114: No Fluid Is Being Delivered

    Chandler Engineering 5000 SERIES PUMP MANUAL volume versus time, the leak rate can be determined. Any changes in temperature during this test time will also show up as changes in volume, so care must be used in analyzing this data.

  • Page 115: Piston Motion Errors

    4. Open the fill valve. 5. Start the pump cylinder and watch the physical piston position indicator through the side cover for proper movement from max retract to max extend. If there is no piston movement, contact Chandler Engineering technical support. •...

  • Page 116: Pressure Problems

    • If the piston still cannot be observed moving through the side cover, contact Chandler Engineering technical support. 12.4.5.2 Motor Stall Error A motor stall error occurs when the power needed to move the piston exceeds what is available from the motor.
  • Page 117 Chapter 5 SAFETY FEATURES 12.4.6.1 Pressure Transducer Errors If the pump reports a pressure transducer cable error, this means that the cable from the pump controller to the transducer is no longer connected properly and needs to be fixed. To correct this problem, do the following: •...

  • Page 118: Valve Problems

    Chandler Engineering 5000 SERIES PUMP MANUAL 12.4.7 Valve Problems The air actuated flow control valves are a vital part of the operation of the 5000 Series Pump System. They control the direction of the fluid flow. The valves used on the pump system are highly reliable.

  • Page 119: Firmware Updates

    The rest of the digits are the controller firmware version. Next you need to check which version of the pump controller available is the latest. To do this contact Chandler Engineering, either by phone or by going to our website at: http:// www.chandler.sales@ametek.com. Please refer to the PumpWorks User’s Manual for firmware update procedures.
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  • Page 121: Q5000 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 CMD-5000 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 122: Digital Output Lines

    Chandler Engineering 5000 SERIES PUMP MANUAL 13.2 Digital Output Lines Two logic level output lines are available on pins 10 and 29. These are CMOS type logic level signals which, when at a logic zero (low level), put out a voltage close to ground (guaranteed to be less than 0.2 volts for a 20 milliamperes maximum current sink).

  • Page 123: Analog Input Lines

    Chapter 13 Q5000 Series User Interface 13.4.2 Analog Input Lines Three analog input channels are available for use with external sensors. These lines are connected with a 16 bit analog to digital (A/D) converter on the CMD-5000 controller printed circuit board. The A/D used for this conversion is preset to an analog input range of -10 to +10 volts.

  • Page 124: Power Lines

    Chandler Engineering 5000 SERIES PUMP MANUAL 13.7 Power Lines The user interface has +5, +12 and +24 volt power available on various pins. This is to make it easy to hook up external sensors and devices. However, the amount of current available is limited. The +5 volt power can supply 500 milliamperes total current and the +12 volt power can supply 800 milliamperes of current.
  • Page 125 Chapter 13 Q5000 Series User Interface +24 volt power Auxiliary Analog Input Channel 3 Emergency Stop +12 volt power +12 volt power +12 volt power +12 volt power +12 volt power +12 volt power +12 volt power +12 volt power Auxiliary Digital Input 2 (can be used for remote start) Auxiliary Digital Output 2 +5 volt power...
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  • Page 127 Appendix A: A Declaration of Conformity is found on the following page. [125]...
  • Page 128 EN 61000-4-11 Voltage Dips and Variations 100% - 1p, 100% 0.5 each polarity Safety Compliance Low Voltage Directive 73/23/EEC: IEC 61010-1:2001 Electrical Equipment for Measurement, Controls, and Laboratory Use R. Dean Dorris Director of Engineering Ametek, Chandler Engineering April 26, 2006 [126]...
  • Page 129 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 130 Chandler Engineering 5000 SERIES PUMP MANUAL ambient temperature Temperature that is equal to the temperature in the surrounding room. Amplifiers A device which increases the magnitude or amplitude of a signal, such as voltage from a pressure transducer. angle base plate...
  • Page 131 GLOSSARY auxiliary valve cable This connects the pump controller to the auxiliary pilot solenoid valve manifold. auxiliary valves The Quizix controller and PumpWorks software have the capability of operating additional valves that the user may add to the pump system. auxiliary valve window This PumpWorks software window controls any auxiliary valve(s) the user has added to the pump system.
  • Page 132 Chandler Engineering 5000 SERIES PUMP MANUAL cable connection sensing This is a controller and PumpWorks software safety feature that detects the presence or absence of certain cables in a system. cable extension The cables supplied with the pump system can be extended with additional cable.
  • Page 133 GLOSSARY The active pump cylinder’s fluid pump rate remains constant at Constant Rate Mode the user specified value. The active pump cylinder’s fluid pressure is set by the system flow resistance. The system flow resistance is the degree of ease or difficulty at which fluid will pass through a system.
  • Page 134 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 135 GLOSSARY depressurizing To reduce the pressure inside a cylinder barrel. This is accomplished by retracting the piston, thereby increasing the fluid volume inside the cylinder barrel. destination The place or point where the fluid is going. dialog box This is a window in the PumpWorks software that contains a form, or checklist, for you to fill out.
  • Page 136 Chandler Engineering 5000 SERIES PUMP MANUAL dual motor driver The dual motor driver provides the motor drive for two pump cylinders and relays status information to the pump controllers. dust protection plug A plastic cover used to protect parts from dust and dirt during shipping.
  • Page 137 GLOSSARY Firmware version This is a number which indicates which version, or code number, of the controller firmware you are using. flexspline A circular, metal part that is part of the harmonic drive. The flexspline fits around the outside of the wave generator bearing, flexure A mechanical assembly used to equalize side forces on a ball...
  • Page 138 Chandler Engineering 5000 SERIES PUMP MANUAL hard limit switch A switch on the pump cylinder that stops the pump controller from moving the piston in either direction. This is a back-up safety feature that normally will not be activated. harmonic drive A gear mechanism which reduces the motor rotation speed.
  • Page 139 GLOSSARY independent cylinder One pump cylinder operates by itself and is limited by the single operating mode stroke fluid volume. Independent cylinder operating modes are not capable of pulseless continuous fluid flow of more than one stroke volume. independent constant delta One pump cylinder operates by itself to maintain a constant pressure pressure differential across a portion of a fluid path by...
  • Page 140 Chandler Engineering 5000 SERIES PUMP MANUAL main menu bar This is the rectangular shaped bar that is horizontal across the top of the PumpWorks software main window and contains key words for the pull-down menus. main window This screen appears each time PumpWorks software is started.
  • Page 141 GLOSSARY motor cable This cable is permanently attached to the motor and connects the motor to the motor driver. motor driver This provides power for the pump cylinder and relays status information to the pump controllers. motor extension A mechanical assembly which lengthens the distance between the motor and the pump housing in high temperature pump systems.
  • Page 142 Chandler Engineering 5000 SERIES PUMP MANUAL operating mode window This PumpWorks software screen allows the user to select an operating mode and displays which operating mode is currently being used. operating parameter setup This allows the user to change the default value of the return rate...
  • Page 143 GLOSSARY paired geared mode A mode that operates two pump cylinders so they move in equal, constant rate operation but opposite directions. At the end of the piston stroke, both pump cylinders change direction simultaneously (at the same time). Geared modes are not pulse-free. parameters The conditions the pump system is set to run within.
  • Page 144 Chandler Engineering 5000 SERIES PUMP MANUAL positive displacement A pump where a solid object is used to physically displace the pumps pump fluid. power connector assembly The power connector assembly includes a receptacle for the power cord, a fuse holder and a voltage selector in one unit.
  • Page 145 GLOSSARY proportional gain or The proportional gain is a user set constant which is multiplied proportional servo gain by the proportional error which generates a corrected rate for maintaining constant pressure. This rate will change the pump pressure to the set-point value. This stands for pounds per square inch which is a measure of pressure.
  • Page 146 Chandler Engineering 5000 SERIES PUMP MANUAL recirculating mode A special pump operating mode where fluid is continuously pumped from a pump cylinder, through a sample and back into another pump cylinder without the fluid being depressurized and without pressure pulses.
  • Page 147 GLOSSARY run conditions The various text messages that are displayed in the motion status field when the pump cylinder is operating. rupture A breaking or opening. safety pressure This is the pressure which, if exceeded, the pump cylinders will stop pumping. Quizix pumps have three built-in safety pressure systems: digital safety pressure, the analog safety pressure and the safety rupture disk pressure.
  • Page 148 Chandler Engineering 5000 SERIES PUMP MANUAL sensor cable This connects the pump cylinder sensor board to the dual motor driver. sequencer A programming language available in the PumpWorks software to set up and automatically control complex pump operations. serial expander/isolator...
  • Page 149 GLOSSARY software version This is a number which indicates which version, or code number, of the PumpWorks software you are using. . software zero offset range Range of values that the user may input to change the zero point setting on a pressure transducer. solvent This is a petroleum based product used for cleaning.
  • Page 150 Chandler Engineering 5000 SERIES PUMP MANUAL system level integration The user’s entire experiment is controlled by the Quizix PumpWorks software. T-type seals A type of seal that is shaped like a sideways “T” and is usually made of an elastomer.
  • Page 151 GLOSSARY uninterruptible power supply A source of power that will continue if the main power source (UPS) stops or has a surge of power. unresolved Still exists, not yet solved or corrected. USB/serial expander/isolator An interface device which allows up to four Quizix pump controllers to operate from one computer communication port.
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  • Page 153 INDEX INDEX Air Connections Diagram, 58 Fluid, 26, 59 Air Leaks, 109 Motor Cable, 26, 41, 65 Air Supply, 57 Pilot Solenoids, 57 Connection, 116 Power, 42, 66 Problems, 109 Pressure Transducers, 59 Requirements, 24, 116 RS-232/Serial, 66 Air Tubing Sensing, 33 Color Coded, 26 Sensor Cable, 26, 41, 65...
  • Page 154 Chandler Engineering 5000 SERIES PUMP MANUAL Hard Limit, 108 Testing, 111 Immediate Errors, 101 Liquid Logged Errors, 101 Filling the Pump System, 28 Motion, 108 Low Pressure Operation, 48 Motor Stall, 114 Maintenance, 73 No Fluid is Being Delivered, 112...
  • Page 155 INDEX INDEX Pump Cylinder, 9, 47 Spare Parts Kit, 73 Ambient Temperature, 14, 48 Stepper Motor, 49 Base Plate, 52 Support Stand, 10 Components, 8 Tools, 73 High Temperature, 22, 52 Transducers. See Pressure Transducers Maintaining, 81 Troubleshooting, 99 Maximum Flow Rate, 8 Air Supply, 109 Maximum Pressure, 8 Basics, 99...

This manual is also suitable for:

Ametek quizix q5002Ametek quizix q5005Ametek quizix q5007Ametek quizix q5010Ametek quizix q5020

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