VMP Pump Modules. TSi-Vc. Zaxis, Inc S W. Salt Lake City, Utah 84119

Transcription

1 VMP Variable Metering Pump User Manual VMP Pump Modules VMP-OEM, VMP Micro, VMP500-2 TSi-Vc Touch Screen Interface, Teach Pendant. Zaxis, Inc S W. Salt Lake City, Utah Phone: (801) , Fax: (801) Web address: US Patent # 7,708,535 1

2 Table of Contents: Item Description Page 1. Introduction and Overview Safety Instructions Theory of Operation Metering Head Features 5 2. System Components TSi Controller with 8 Pin Cable (RS485 1/2 Duplex) Q Style Metering Head with Couplers Split Body Style Metering Head (SBSMH) Getting Started General Set-up Cables and Connectors TSi Teach Pendant Navigation Mounting the Pump Start from PLC Start without PLC Touch Screen Navigation HOME TOOLS CLIPBOARD Set Pump Number Set Pump PIN (Lock TSi) Outline Specifications (Electrical and Physical) TSi-Vc VMP-OEM Q Heads VMP-OEM VMP-Micro VMP Dispense Volumes Warranty and Spare Parts RS485 and Ethernet Commands Technical Support..40 US Patent # 7,708,535 2

3 1. Introduction The Patented VMP system is a precision metering and fluid dispenser combined with a Touch Screen Interface (TSi) for simple programming and immediate teach and control. This pump technology combines precision ceramic pump components and an electronically controlled linear stepper actuator to make ultra-fine adjustments to pump angle position, thereby changing the volume of metered liquid. This allows the VMP system to provide dynamic fluid displacement to overcome variations in viscosity and surface tension. One of the many attributes of this pump is that it has no valves and has only one moving part, the ceramic piston. This will provide millions of maintenance free cycles (approximately 84,000,000). The pump head used in the VMP system is a rotating and reciprocating ceramic piston design. The ceramic piston and the liner are precision matched sets and the assembly is manufactured to extremely tight tolerances, ensuring the best accuracy and repeatability. This pump design eliminates the need for external supply and discharge valves. The intake port of the pump is never connected to the discharge port. The VMP is the latest in fluid metering and dispense technology Overview The V-Series: VMP: A smart Zaxis system with an embedded micro-controller. This unit will communicate directly to a host device (Computer or PLC) via a serial port, or Ethernet connection. No other controls are needed. The host can be disconnected and the pump and it will continue its current program. VMP + TSi Interface will setup up to 32 pumps. All parameters, Volume, speed, number cycles, are all programmed from the TSi. This system needs an external 24 VDC, 2 amp power source which is available with all VMP Pump Modules. System Attributes. Ceramic and Teflon fluid path available No valves 0.01 ul resolution Programmable Stroke adjustment Embedded micro-controller 100 stored programs Computer interface, RS485, PLC and Ethernet Color Touch-Screen Interface US Patent # 7,708,535 3

4 1.1. Safety Instructions (please read before operating pump and controller) SAFETY INSTRUCTIONS Caution: Before using any equipment read the following safety instructions as well as specific product specifications and operating instructions. Warning! Fire, Electrical shock or explosion may occur if used near combustibles, explosive atmosphere, corrosive air, wet environment or submerged in fluid. Turn off electrical power before checking pump for any problems. Caution! Fire, electrical shock, injury and damage may occur if not Connect motor, controller or any other electrical devices based on VmP specifications. Any unauthorized work performed on the product by the purchaser or by third parties can impair product functionality and thereby relieves VmP of all warranty claims or liability for any misuse that will cause damage to product and/or injury to the individual. used in accordance with VmP specifications and operation instructions. Do not operate drive assemblies that require a hard mount (to be bolted down) unless they are mounted per VmP specifications; if not, injury may occur and/or damage to unit. Power cables and leads should not be bent, pulled or inserted by excessive force. Otherwise there is a threat of electrical shock of fire. Do not touch any rotating pump or motor components, injury may occur. Replace any inline fuses only with fuse rating as specified by Zaxis for the VmP When pump/drive is under operation, never point discharge tubing into face or touch any rotating components of pump. In a power down thermal overload cut-in condition, unplug or turn off power to pump. Always allow a cool down period before restarting: otherwise, injury or damage may occur. Do not run pump dry, unless designed for that service. Running dry is harmful to the pump, and will cause excessive heating due to internal friction. Fittings screwed too tightly into stainless steel pump heads will contact port seals and may cause piston/cylinder damage. Use extra layers of Teflon tape on threads when necessary to avoid such excessive fitting penetration. For 30 seconds after power is removed from pump/drive: do not touch any output terminals. Electrical shock may occur because of residual voltage. Check pump rotation and inlet/outlet pump port orientation before connecting power to pump. If not, injury may occur. Do not operate with wet hands. When pulling cords from outlets do not pull cord, grasp plug to prevent plug damage or electrical shock. VmP drive motors become HOT and can cause a burn. DO NOT TOUCH! US Patent # 7,708,535 4

5 1.2. Theory of Operation The valveless pumping function is accomplished by the synchronous rotation and reciprocation of the ceramic piston in a precisely mated ceramic cylinder liner. One complete piston revolution is required for each suction and discharge cycle as shown. The piston always bottoms for maximum fluid and bubble clearing. Moving the pump head position changes the piston stroke length, varying dispense volume and flow rate. Flow rate indication through the TSi allows for accurate and simple linear calibration. The piston rotates and reciprocates. As the piston is pulled back and the piston flat opens to the inlet port, suction is created and fluid fills the pump chamber. As the piston reaches the highest point in the reciprocation cycle, the pump chamber is now at its maximum volume capacity. Continuing the rotation, the and crossover occurs. As the inlet port is sealed and the pump chamber is full, the outlet port opens up. Only one port is open at any time and at no time are both ports interconnected. Continuing the rotation and reciprocation, the piston is forced down and the piston flat opens to the outlet port. Discharge is created and fluid is pumped out. The piston bottoms for maximum fluid and bubble clearing. Continuing the rotation, the outlet port is then sealed and crossover occurs. As the outlet port is sealed and the pump chamber is empty, the inlet port opens to start another suction stroke. Only one port is open at any time and at no time are both ports interconnected Metering Head Features and Components Valveless operation with ceramic Piston and Liner. One moving part in contact with fluid. Variable Displacement. Embedded micro-controller and dual amplifier. Low dead volume. Low liquid shear. Self-priming. Flow Direction Reverse Panel mounting provisions. Self-sealing design. Durability. Chemically inert. Autoclavable. US Patent # 7,708,535 5

6 2. System Components VMP-OEM and VMP Micro (VMP Micro in photo below) vdc, 2 amp power supply kit, Zaxis P/N VMP-PSK 2. Foot Switch (Dry Contact), Zaxis P/N VMP-FS 3. Touch Screen Interface, Zaxis P/N TSi-Vc (complete with 8 Pin RS485 Cable) 4. VMP Micro, Zaxis P/N VMP-MOEM US Patent # 7,708,535 6

7 2.2. Q Style Metering Heads with Couplers CKCST Coupling Kit ( V-BRK-CKC ) CSC Coupling Kit ( V-BRK-CSC ) 13 Item No. Component Description: 1 Piston 2 Gland Nut 3 Gland Washer 4 Lip Seal 5 Cylinder Liner 6 Cylinder Head Seal 7 Cylinder Port Seal 8 Cylinder Case 9 Coupling Screw, 8-32 x 3/4" Lg. PPH 10 CKC Coupler CSCWT Coupling Kit ( V-BRK-CHC ) 21 Item No. Component Description: 11 CKC Pump 12 CSC Coupler 13 CSC Pump CSC/CKC Universal 14 CSCWT Coupler Coupling Kit 15 CSCWT Pump ( V-BRK-CSKC ) 16 WT Coupling Screw 17 Pump Coupler Anchor Screw 18 Pump Coupler Anchor Screw Flat Washer 19 Coupler Knob 20 Coupling Screw, 8-32 x 3/4" Lg. SHCS 21 Universal Coupler US Patent # 7,708,535 7

8 2.3. Split Body Style Metering Head Item No. Component Description: 1 Piston 2 Cylinder Plate 3 Gland Washer 4 Lip Seal 5 Cylinder Liner 6 Cylinder Head Seal 7 Fitting 8 Cylinder Case 9 Cylinder Port Seal 10 Cylinder Head Seal Comp. Nut 11 Cylinder Head Bolts 12 Cylinder Case Bolts 13 Chromatography Fitting 14 US Patent # 7,708,535 8

9 3. Getting Started Unpack inspect all the components to make sure they are all present and that no damage has occurred General Set-up Connect the VMP to an appropriate power source (24 VDC) through the 12 Pin I/O Cable. Connect the 8 Pin RS485 from the TSi to the RS485 receptacle. For VMP500-2 a separate 110/220VAC will power the unit; see page 10 and 29 for details of PLC connection. See rear of VMP Modules below: 12 and 8 Pin Cables (straight or 90 degree) VMP-OEM and VMP Micro -- VMPXXX /220 VAC Power Cord US Patent # 7,708,535 9

10 VMP Variable Metering Pump User Manual 3.2 Cable and Connector Specifications: AC Power, for VMP500-2 Output connector Product Contacts 3+PE, 4 x 1.5 PVC: female cable connector injection-moulded cable Pole 3+PE Area RD24 Power Series 692/693 Article number Specification Sheets Common values Connector Design Female cable connector Connector locking system screw Termination crimp, injection-moulded cable Wire gauge (mm) 1.50 mm² Wire gauge (AWG) 16 Cable outlet - Upper temperature 80 C Lower temperature -25 C Cable data material housing PVC black Insulation single lead PVC sw 1, sw 2, sw 3, green/yellow Single lead structure 28x0.25 mm Cable sheath Ø 8.6 Conductor resistance Bending radius cable fixed 120 mm Bending radius cable movable 60 mm Approval UL, CSA Electrical values Rated voltage 400 V Rated impulse voltage 6000 V Pollution degree 3 Overvoltage category III Material group III Rated current (40 C) 16 A Volume resistivity 5 mω EMV compliance not shielded Degree of protection IP67 Mechanical operation > 500 mating cycles Material Material of contact CuZn (Brass) Contact plating Ag (Silver) Material of contact body PA 12 Material of housing PUR Contacts 3+PE, 4x1.5 PVC: female cable connector injection-moulded cable, cable length 2 m US Patent # 7,708,535 10

11 3.3 Cables and Connectors 8 Pin and 12 Pin I/O and RS485 Cables, available with straight and right angle connectors, and wire only leads. Series 763: Single-ended cordset, 90 male plug, 2m PUR cable Part # Overmolded non-shielded Contacts: 8 Contact Plating: Gold IP 68 M12 A-Coding Specifications Locking System: M12 A-Coding Number of Contacts: 8 Gender: Male Shell Material: Plastic Maximum Diameter (mm): 14.5 Mounting Style: Cable-mounted Termination: Overmolded Protection: IP 68 Shielding: non-shielded Contact Plating: Gold Rated Voltage (V): 60 Rated Current (A): 2 Cable Length (M): 2 Wire Gauge (max AWG): 24 Form: Right-angle Specifications Series 763: Single-ended cordset, male plug, 2m PUR cable Part # Overmolded non-shielded Contacts: 12 Contact Plating: Gold IP 68 M12 A-Coding This is for the VMP- OEM only. For VMP Dual or VMP Pin Cable please see page 35 Locking System: M12 A-Coding Number of Contacts: 12 Gender: Male Shell Material: Plastic Maximum Diameter (mm): 14.5 Mounting Style: Cable-mounted Termination: Overmolded Protection: IP 68 Shielding: non-shielded Contact Plating: Gold Rated Voltage (V): 30 Rated Current (A): 1 Cable Length (M): 2 Form: Straight US Patent # 7,708,535 11

12 3.4 Mounting the Pump When mounting the pump to the drive, the pump must be oriented as shown in the illustration below. Note: Pump damage will occur if the pump is mounted incorrectly. Once the pump is mounted, the tubing can be connected. For the Inlet (Suction) side of the pump (preferably the lower side), use tubing with the largest inside diameter that your application will allow. This will minimize the chance for cavitation. For the Outlet (Discharge) side of the pump, use tubing with an inside diameter equal to or smaller than the inlet tubing. This will result in best metering performance and minimize fluid variation from the dispensing tip. Revs Per Minute (RPM) recommendations: For fluids of 500cps viscosity or less a stroke rate of RPM maximum is ideal. For fluids with greater than 500cps a slower rate is recommended. X Correct Mounting Orientation Incorrect Mounting Orientation US Patent # 7,708,535 12

13 3.5 Start the Pump from PLC Start the VMP-OEM from PLC: US Patent # 7,708,535 13

14 3.6 Start the Pump Start the VMP-OEM from power supply kit- (3 Pump version below as reference) US Patent # 7,708,535 14

15 4.0 Touch Screen Navigation TSi-Vc Teach-Pendant Navigation - Navigating around the TSi Touch-Screen is quite simple. The TSi-Vc information screen provides the TSi s and VMP s firmware revisions as well as the serial number. You can always contact Zaxis direct for technical support. US Patent # 7,708,535 15

16 4.1 Home Screen [ Home 1 ] Screen Tab: These are the control buttons of the VMP pump [ = ]: Stroke Adjustment will move to ZERO then to program setting. [ Pump# ] Program number of the pump. The Display will communicate to 32 pumps concurrently. A host CPU will communicate with many more [ Program Name ] You can name a program by selecting this field. Run =The current program will run at the current settings. Direction of pumping. Piston flat is towards inlet and arrow indicates flow direction [ MAX ] This function is to automatically adjust to full stroke, (purge). By pushing the equals (=) button, the pump will return to program volume. This allows the pump to pump continuous. US Patent # 7,708,535 16

17 [ Home 1 ] Screen Tab Continued- This allows the pump to perform a dispense. Dispense can be multiple revolutions. [ Prog ] This allows the user to being up a keypad to select a stored program. [ Volume ] This allows the user to being up a keypad to select Volume in milliliters. The pump is repeatable to.2 microliter. [ Current Volume ] This is the actual volume of the pump. Only after the run button is selected [ RPM ] Speed can be controlled from 60 to 1000 RPM, and while in continuos mode, you can adjust speed up or down without stopping the pump. There are limitations to speed and pressure, based on the fluidic system. [ Revolutions ] This allows the user to being up a keypad to select the number of Cycles. The pump rotates 360 Degrees per cycle. If pullback is used, then the pump makes up the pullback, then rotates 360 degrees. [Total] number is the product of the Volume and the Revs. This allows the user to stop the dispensing. Used when large volume is being dispensed. Program Linking is factory set to OFF. See Home Screen 2 for details US Patent # 7,708,535 17

18 [ Home 2 ]Link Screen Tab These buttons are extended functions. [ Pullback ] This allows the user to reverse the pump direction for suck-back. It is in percentage of rotation, for example 100 would be one rotation. Then the pump makes up the suck back and dispenses the next shot. [ Linked Prog# ] This allows the user to link to another program. [ Delay ] This allows the user to select the delay time in seconds before the next linked program runs. [ Cycles ] LOOP CYCLES This allows the user to enter the number of loops to the next program. This is not the same as REVS. The pump will perform the REVS, in a saved program, then the link occur and repeat as programmed US Patent # 7,708,535 18

19 [ Home 2 ] Advanced Motor Controls [ Acceleration ] This allows the user to modify the VMP acceleration [ Deceleration ] This allows the user to modify the VMP deceleration [ Approx. Time ] This field displays the time for a full revolution [ Motor Current ] This allows for the user to adjust motor current, saving power, or to reduce heat [ RPM ] This allows for change to RPM, same as Home screen page 1 [ Initial RPM ] This allows the user to adjust the initial RPM [ Final RPM ] This allows the user to adjust the final RPM Please consult the factory before changing any default settings. Advanced controls are useful for special applications that need to optimize pumping performance. For example, high and low viscosity fluid. US Patent # 7,708,535 19

20 4.2 Tools [ Tools ] Screen Tab [ Bore ] This is the bore size of the piston in inches. VMP pump heads are interchangeable and the new bore size can be entered if a different pump piston size is used. [ Cal Factor ] This is determined by the factory for each model of VMP pump The radial buttons are used to select pump model and type, including the the pitch screw of the stroke volume adjustment motor. These are factory settings and you should consult the factory before changing anything. On pages 25 and 26 there is a procedure for locking this part of the controller. US Patent # 7,708,535 20

21 4.3 Clipboard [Clipboard] Ethernet Settings Select the Ethernet Settings button and you will see the below screen with factory defaults for TCP/IP Settings. The VMP pump can be controlled by Ethernet commands on pages 39 and 40. The most basic way to use Ethernet is through a terminal emulation program like HyperTerminal, and a crossover Ethernet cable. US Patent # 7,708,535 21

22 [Clipboard Continued] Set Pump Number To change a pump number, select the radial button for the number of the pump you want it to be. Now select the Send Change Command top Pumps. You now have 10 seconds to push the pump set button on the VMP drive. See photo below. You will know the selection is complete after the serial number of the pump is now located at the radial button and pump number you have selected. Pump Set button US Patent # 7,708,535 22

23 [Clipboard Continued] Ready Input and Touchscreen Calibration The ready is factory closed (OFF). Ready can be used a safety interlock before a pump start signal can be allowed. Please see the start diagram below for reference and page 13 for PLC control. Use this button to calibrate the TSi-Vc US Patent # 7,708,535 23

24 4.4 [ Pump# ] Set Pump Number Screen Tab The radial buttons for pump# allows you to view and select which pump you want to program. The pump s serial number will appear if it is in serial connection (RS485) to the TSi. Up to 32 VMP pumps can be connected to one TSi. If you select ALL, the TSi will communicate and run every pump on the RS485 connection. Select the Pump# button to return to the HOME screen to run selected pump(s) [ Lock TSi ] Screen Tab 1 US Patent # 7,708,535 24

25 4.5 [ PIN] Set and Enter PIN Press the LOCK button to assign a PIN to the TSi US Patent # 7,708,535 25

26 [ Lock TSi ] Screen Tab 2 If you entered a PIN, the lower right hand corner will change to lock position and color blue. To unlock, press the blue button (in locked positon) and enter your PIN. The factory default is NO pin, just select ENTER. PIN must be four numbers. To change PIN, go to CLIPBOARD and select Change Pin. You will need to enter your old PIN then assign a new PIN, re-enter, then proceed. US Patent # 7,708,535 26

27 5.1 Outline Specifications Touch Screen Interface, TSi-Vc Electronic Controller Material of Construction: Painted Polyvinyl Chloride (PVC). Physical Specifications: Dimensions: 7.5 x 5 x 1 Weight: 12 oz.. Electrical Specifications: Power: 5 VDC, 1/2 Duplex RS485 (Typical power received from VMP module) US Patent # 7,708,535 27

28 5.2 VMP OEM (Q Pump) Motor Module Mounting: The motor module can be bulkhead or panel mounted. It also has an optional stand that allows it to set on a bench or tabletop. Materials of Construction: Piston and cylinder lining are sapphire hard (fused crystalline alumina, 99% Aluminum Oxide). The motor module body is constructed from 6061 aluminum with surface black anodizing. Physical Specifications: Dimensions: 9 x 4.44 x 3.0 Weight: 4 lbs. Panel Cut-out Dimensions US Patent # 7,708,535 28

29 5.3 VMP OEM Motor Module Mounting: The motor module can be bulkhead or panel mounted. It also has an optional stand that allows it to set on a bench or tabletop. Materials of Construction: Piston and cylinder lining are sapphire hard (fused crystalline alumina, 99% Aluminum Oxide). The motor module body is constructed from 6061 aluminum with surface black anodizing. Physical Specifications: Dimensions: 9 x 4.44 x 3.0 Weight: 4 lbs. US Patent # 7,708,535 29

30 5.4 VMP Micro Mounting: The motor module can be bulkhead or panel mounted. It also has an optional stand (shown with stand below) that allows it to set on a bench or tabletop. Materials of Construction: Piston and cylinder lining are sapphire hard (fused crystalline alumina, 99% Aluminum Oxide). The motor module body is constructed from 6061 aluminum with surface black anodizing. Physical Specifications: Dimensions: 208 x 75 x 101 (mm) Weight: 7 lbs. US Patent # 7,708,535 30

31 US Patent # 7,708,535 31

32 5.5 VMP500-2 Mounting: The VMP500-2 is a dual channel filling and metering system. It is typically mounted on a shelf, rack, or cart system, It comes complete with mounting provision front and back, as well as rubber feet. Materials of Construction: Piston and cylinder lining are sapphire hard (fused crystalline alumina, 99% Aluminum Oxide). The Pump wetted path is Ceramic, Teflon, and 316LSS, including a IP45 SS Enclosure intended for Food and Pharma GMP applications. Product shown with V3SAN pump head module Physical Specifications: Dimensions: 400 x 191 x 186 (mm) Weight: 23 lbs. US Patent # 7,708,535 32

33 US Patent # 7,708,535 33

34 US Patent # 7,708,535 34

35 VMP500 External Wiring, PLC and DC Power Warning! Special connections VMP-500, Dual VMP rear 12 pin Connector 24 VDC & Input/Ouput Pump Receptacle P/N Pin No. Label Mating Cable: Right angle flying leads: Straight cable: Series 763: Female receptacle, rear-mounted, PCB solder, 6mm contact length Part # PCB solder 1. I/O + Brown 2. I/O - Blue 3. Busy A (out) White 4. Count A (out) Green non-shielded 5. Start A (In) Pink Contacts: 8 6. Ready A (In) Yellow Contact Plating: Gold 7. Busy B (out) Black IP Count B (out) Grey M12 A-Coding 9. Start B (in) Red 10. Ready B (in) Purple 11. Not used Grey /Pink 12. Not Used Red/blue Start In Ready In Busy Out Count Out US Patent # 7,708,535 35

36 6.0 Dispense and Metering Volumes Below are the maximum dispensing volumes for each VMP pump head. It is recommended to use the pump head max and size that is nearest your dispense volume. If you are planning to make frequent volume changes and or continuously meter with the VMP pump, please contact the factory for a suggested pump head size to meet your specific needs. Each VMP pump is factory inspected and verified at 100%, 50% and 10% of max volume. If you require specific calibration process, please contact Zaxis factory. VMP Pump Heads Pump Bore Volume (ml) ml/min 1/4" /8" /2" VMP Micro Pump Heads 1/4" /16" /8" Metering Volumes The VMP drive is capable of 1000 RPM in some applications. For continuous metering volumes please see the chart above. For applications of 500mL or higher you will require a minimum of 1/2 ID tubing. Low flow applications that require a flow rate of less than 50 ml/min should consider low flow options from Zaxis. Please contact Zaxis factory for any questions. US Patent # 7,708,535 36

37 6. Warranty ONE YEAR LIMITED WARRANTY Zaxis, Inc. Limited Warranty ZAXIS INC. products are manufactured to a high level of mechanical precision from materials that are resistant to attack by many corrosive chemicals. These products, however, may be self-destructive when used with non-compatible fluids or when located in physically hostile environments or when operated under non-specification voltage or pressure conditions. ZAXIS INC., therefore, warrants only as follows: Each metering head has been test operated with water to rated pressure prior to shipment from the factory. The qualifying performance of each metering head is recorded by serial number in a permanent record of the company. If at any time with-in the first year after any ZAXIS INC. product has been shipped to a customer (user), it fails to perform according to ZAXIS INC. literature, the product, with written explanation of the problem, may be returned, freight prepaid, to ZAXIS INC. for examination, repair or replacement at ZAXIS INC. expense (labor and material). All such returns must have prior ZAXIS INC. customer service authorization before returning. If, upon examination, ZAXIS INC. determines that abusive practices, non-compatible fluids or destructive environment of operation or a combination of these factors is responsible for improper performance of the product, all labor and materials costs involved shall be at the expense of the customer. ZAXIS INC. is not liable for special, indirect or consequential damages that may result from use, failure or malfunction of the product, and any recovery against ZAXIS INC. may not be greater than the purchase price paid for the product. No person is authorized to change the terms of this warranty. 7.1 Recommended Spare Parts List Please contact the factory for recommended spares to your VMP pump model. The VMP pump is designed for millions of maintenance free cycles. Each application will vary in the basic need for preventive maintenance (PM). It is common to have a spare pump head in most applications. Please contact the factory for return authorization if you would like to return a VMP Pump. US Patent # 7,708,535 37

38 VMP Commands, RS485 (For Ethernet-do not use a preceding number for pump ID US Patent # 7,708,535 38

39 VMP Commands Continued VMP Query Commands US Patent # 7,708,535 39

40 7. Technical Application Support: Please call Zaxis and let us know about your application. Zaxis metering and dispense pumps are the latest in positive displacement technology. Zaxis, Inc S S. Salt Lake City, Utah Phone: (801) , Fax: (801) Web address: US Patent # 7,708,535 40