Micro Motion Manuals & Guides: Brooks Service Tool for QUANTIM Precision Mass Measurement and Control | Micro Motion Manuals & Guides

Installation and Operation Manual
X-BST-Qm-eng Part Number: 541B026AAA July , 2004
Brooks Service ToolTM for QUANTIM
Precision Mass Measurement and Control
www.BrooksInstrument.com
Brooks Service ToolTM for QUANTIM
Essential Instructions
Read this page before proceeding!
Brooks Instrument designs, manufactures and tests its products to meet many national and international standards. Because these instruments are sophisticated technical products, you must properly install, use and maintain them to ensure they continue to operate within their normal specifications. The following instructions must be adhered to and integrated into your safety program when installing, using and maintaining Brooks Products.
Read all instructions prior to installing, operating and servicing the product. If this instruction manual is not the correct manual, please see back cover for local sales office contact information. Save this instruction manual for future reference.
If you do not understand any of the instructions, contact your Brooks Instrument representative for clarification.
Follow all warnings, cautions and instructions marked on and supplied with the product.
Inform and educate your personnel in the proper installation, operation and maintenance of the product.
Install your equipment as specified in the installation instructions of the appropriate instruction manual and per applicable local and national codes. Connect all products to the proper electrical and pressure sources.
To ensure proper performance, use qualified personnel to install, operate, update, program and maintain the product.
When replacement parts are required, ensure that qualified people use replacement parts specified by Brooks Instrument. Unauthorized parts and procedures can affect the product's performance and place the safe operation of your process at risk. Look-alike substitutions may result in fire, electrical hazards or improper operation.
Ensure that all equipment doors are closed and protective covers are in place, except when maintenance is being performed by qualified persons, to prevent electrical shock and personal injury.
Installation and Operation Manual
X-BST-Qm-eng
®
Part Number: 541B026AAA
July , 2004
Handling Procedure:
1. Power to unit must be removed.
2. Personnel must be grounded, via a wrist strap or other safe, suitable means before any printed circuit card or other internal device is installed, removed or adjusted.
3. Printed circuit cards must be transported in a conductive container. Boards must not be removed from protective enclosure until immediately before installation. Removed boards must immediately be placed in protective container for transport, storage or return to factory.
Comments
This instrument is not unique in its content of ESD (electrostatic discharge) sensitive components. Most modern electronic designs contain components that utilize metal oxide technology (NMOS, SMOS, etc.). Experience has proven that even small amounts of static electricity can damage or destroy these devices. Damaged components, even though they appear to function properly, exhibit early failure.
Installation and Operation Manual
X-BST-Qm-eng Part Number: 541B026AAA July , 2004
Dear Customer,
Brooks Service ToolTM for QUANTIM
®
The Brooks Service Tool
TM
is a Windows® - based application that provides expanded control of Brooks QUANTIM® QMA and QMB Mass Flow Control (MFC) devices for servicing tasks that include setup and configuration, troubleshooting, and tuning.
We recommend that you read this manual in its entirety as this will enable efficient and proper use of the Brooks Service Tool. Should you require any additional information concerning the Brooks Service Tool, please feel free to contact your local Brooks Sales and Service Office, see back cover for contact information, or visit us on the web at www.BrooksInstrument.com. We appreciate this opportunity to service your fluid measurement and control requirements,and trust that we will be able to provide you with further assistance in future.
Yours sincerely, Brooks Instrument
Contents
Brooks Service ToolTM for QUANTIM
Installation and Operation Manual
X-BST-Qm-eng
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Part Number: 541B026AAA
July , 2004
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Paragraph Page Number Number
Introduction Section 1
1.1 Description .....................................................................................................................................1-1
1.2 How to Use This Manual ................................................................................................................1-2
Theory of Operation Section 2
2 Theory of Operation........................................................................................................................2-1
Installation Section 3
3 Installation ......................................................................................................................................3-1
3.1 Installing the Service Tool Application .............................................................................................3-1
3.2 Connecting the PC to the Device....................................................................................................3-1
3.2.1 Hardware Requirements.............................................................................................................3-2
3.2.2 Connection Procedure................................................................................................................3-3
3.2.3 Disconnecting the PC from the Device .......................................................................................3-6
3.3 Device D-Connector Pin-Outs ........................................................................................................3-7
Basic Operations Section 4
4 Basic Operations ............................................................................................................................4-1
4.1 St arting the Service Tool and Opening a New Session ...................................................................4-2
4.2 Main Window Elements.................................................................................................................. 4-4
4.3 Setting the Main Window Options...................................................................................................4-5
4.4 Putting the Service Tool in Indicator or Control Mode .....................................................................4-8
4.5 Trend Graph Functions...................................................................................................................4-9
4.5.1 Trend Graph Elements ...............................................................................................................4-9
4.5.2 Stopping and S tarting T rending.................................................................................................. 4-11
4.5.3 Scrolling a Graph Axis ............................................................................................................... 4-11
4.5.4 Zooming on a Single Graph Axis ...............................................................................................4-12
4.5.5 Zooming on Both Graph Axes....................................................................................................4-13
4.5.6 Zooming on a Region of the Graph............................................................................................4-14
4.5.7 Displaying X and Y Values at a Particular Point .........................................................................4-15
4.5.8 Copying the Graph to the Clipboard...........................................................................................4-17
4.5.9 Saving the Graph to a File .........................................................................................................4-18
4.5.10 Printing the Graph....................................................................................................................4-18
4.6 Closing the Session and Exiting the Service Tool ..........................................................................4-18
Brooks Service ToolTM for QUANTIM
Contents
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Viewing and Setting the Device Configuration Section 5
5 Viewing and Setting the Device Configuration ................................................................................5-1
5.1 Setting Input (Setpoint) and Output Upper and Lower Range V alues ............................................. 5-1
5.2 Viewing and Setting Alarms ............................................................................................................ 5-2
5.2.1 Diagnostic Alarm.........................................................................................................................5-3
5.2.2 Configuring Optional Warnings and Alarms ................................................................................5-4
5.2.3 Modifying Standard Alarm Behavior ............................................................................................5-6
5.3 Viewing and Setting Configuration Parameters ............................................................................... 5-7
5.3.1 Viewing the Control Response Parameters ................................................................................5-8
5.3.2 Viewing and Setting the Control Configuration Parameters ........................................................5-9
5.4 Viewing Device Information ...........................................................................................................5-10
5.5 Viewing and Setting Primary and Secondary Output Parameters ..................................................5-10
5.6 Viewing Sensor Parameters ..........................................................................................................5-12
5.7 Viewing Setpoint Parameters ........................................................................................................ 5-13
5.8 Viewing V alve Parameters.............................................................................................................5-14
5.9 Viewing Device V ariables............................................................................................................... 5-15
5.10 Saving the Current Device Configuration.......................................................................................5-17
5.1 1 Restoring a Saved Device Configuration ....................................................................................... 5-17
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Brooks Service ToolTM for QUANTIM
Diagnostics Section 6
6 Diagnostics.....................................................................................................................................6-1
6.1 Checking the Warning, Alarm, and Diagnostic Status.....................................................................6-1
6.1.1 Clearing Latched Warning and Alarm Conditions........................................................................6-2
6.2 Testing the Primary and Secondary Outputs...................................................................................6-2
6.3 Testing the Input (Setpoint) ............................................................................................................. 6-5
6.4 Capturing Device Log Data to a File ...............................................................................................6-7
6.4.1 Importing a Data Log File into Excel ...........................................................................................6-9
Troubleshooting, Tuning and Calibration Section 7
7 Troubleshooting, Tuning and Calibration ........................................................................................ 7-1
7.1 Troubleshooting Strategies.............................................................................................................7-2
7.2 Device Tuning and Calibration Procedures..................................................................................... 7-7
7.2.1 Zeroing the Device’s Sensor.......................................................................................................7-7
7.2.1.1 Accessing the Service Tool’s Zero Sensor Function.............................................................7-7
7.2.1.2 Procedure for Zeroing the Sensor ........................................................................................7-8
7.2.2 Optimizing the V alve Behavior for Process Conditions............................................................... 7-10
7.2.2.1 Tuning the V alve Of fset and Span .......................................................................................7-10
7.2.2.2 Cleaning the Orifice for a QUANTIM QMA ..........................................................................7-13
7.2.2.2.1 Removing and Cleaning the QUANTIM QMA’s Orifice..................................................7-14
7.2.2.2.2 Reinstalling the Orifice and Checking the V alve Offset and S p an Values ......................7-15
7.2.2.2.3 Tuning the Valve Response (Proportional and Integral Gain)........................................7-18
7.2.3 Using V alve Override to Control the Valve Opening ...................................................................7-20
7.2.3.1 Using Pin 12 to Control the Valve Override .........................................................................7-21
7.2.3.2 Using the Service Tool’s Valve Override Function ............................................................... 7-22
7.2.4 Cycling the Setpoint ...................................................................................................................7-22
7.2.5 Calibrating the Device Input (Setpoint)....................................................................................... 7-24
7.2.6 Calibrating the Primary and Secondary Outputs ........................................................................ 7-28
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Installation and Operation Manual
X-BST-Qm-eng
Part Number: 541B026AAA
July , 2004
Index ................................................................................................................................................... Index-1
Warranty, Local Sales/Service Contact Information...................................................................... Back Cover
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Installation and Operation Manual
X-BST-Qm-eng Part Number: 541B026AAA July , 2004
FIGURES
Figure Page Number Number
4-1 Main Window Elements..................................................................................................................4-4
4-2 Process Variables Options ............................................................................................................. 4-6
4-3 Units of Measure Options ...............................................................................................................4-6
4-4 Trend Graph Options......................................................................................................................4-7
4-5 Setpoint Switch in Control Mode.....................................................................................................4-8
4-6 Trend Graph Main Elements........................................................................................................... 4-9
6-1 Setup for Testing Primary Output Volt age.......................................................................................6-2
6-2 Setup for Testing Primary Output Current.......................................................................................6-3
6-3 Setup for Testing Secondary Output Current ..................................................................................6-3
6-4 Setup for Testing Voltage Setpoint..................................................................................................6-5
6-5 Setup for Testing Current Setpoint..................................................................................................6-6
7-1 Setup for Calibrating to a Voltage Setpoint ....................................................................................7-24
7-2 Setup for Calibrating to a Current Setpoint ....................................................................................7-25
7-3 Setup for Calibrating to a Primary Output Voltage .........................................................................7-28
7-4 Setup for Calibrating to a Primary Output Current .........................................................................7-28
7-5 Setup for Calibrating to a Secondary Output Current.....................................................................7-29
Brooks Service ToolTM for QUANTIM
Contents
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TABLES
Table Page Number Number
4-1 Options Window Functions.............................................................................................................4-5
4-2 Summary of Trend Graph Toolbar Functions .................................................................................4-10
4-3 Trend Graph Cursor Options .........................................................................................................4-16
5-1 Alarm/W arning Conditions Fields and Options ...............................................................................5-5
5-2 Alarms A ffected by Alarm Disable Options ..................................................................................... 5-6
6-1 Data Log Configuration Window Functions..................................................................................... 6-8
7-1 LED Indications .............................................................................................................................7-2
7-2 Common Start-Up Problems..........................................................................................................7-3
7-3 Common Operating Problems.......................................................................................................7-4
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Contents
Brooks Service ToolTM for QUANTIM
Installation and Operation Manual
X-BST-Qm-eng
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Part Number: 541B026AAA
July , 2004
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Installation and Operation Manual
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1 Introduction
1.1 Description
The Brooks Service Tool is a Windows-based application that provides expanded control of Brooks QUANTIM QMA and QMB Mass Flow Control (MFC) devices for servicing tasks that include setup and configuration, troubleshooting, and tuning.
Section 1 - Introduction
Brooks Service ToolTM for QUANTIM
®
Brooks Service Tool Main Window
Using an RS-232 connection between a personal computer (PC) and the device’s service port, you can use the Service Tool to view, control, and modify data such as:
•Flow
• Setpoint
• Analog input/output (I/O) configuration
• I/O ranging
• Valve tuning
• Device I/O calibrations
• Diagnostics
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Section 1 - Introduction
Brooks Service ToolTM for QUANTIM
1.2 How to Use This Manual
It is recommended that you read this manual before installing or using the Service Tool.
The manual is organized into the following sections: Section 1 Introduction
Section 2 Theory of Operation Section 3 Installation Section 4 Basic Operations Section 5 Viewing and Setting the Device Configuration Section 6 Diagnostics Section 7 Troubleshooting, T uning, and Calibration Index Back Cover Warranty, Local Sales/Service Cont act Information
Installation and Operation Manual
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Part Number: 541B026AAA
July , 2004
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2 Theory of Operation
A typical mass flow measurement and control system consists of two components:
Mass flow meter. A mass flow meter incorporates a sensor that measures the amount of mass flow and generates an electrical output signal directly proportional to the mass flow rate.
Control valve. Mating a control valve with a mass flow meter provides a mass flow
controller (MFC). Implementing a mass flow controller requires using the mass flow output
signal as one input and a user-supplied setpoint signal as another input into a comparator circuit. These two signals are then compared and a control signal is generated to operate the opening or closing of the valve. The setpoint signal is, in effect, a request that the mass flow controller maintain a fixed mass flow rate.
Section 2 - Theory of Operation
Brooks Service ToolTM for QUANTIM
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A setpoint signal can come in many forms. The Brooks QUANTIM QMA and QMB devices are analog—the input/output (I/O) signals between the mass flow device and the user’s control side are represented as a voltage (0–5 Vdc) or current (4–20 mA).
The Brooks Service Tool, which communicates with the device through an RS-232 connection between the PC and the device’s service port connector , uses a digital signal based on a proprietary protocol. The Service Tool has two operating modes:
Indicator, in which the Service Tool is reporting on the data sent to it
from the device, which is being controlled by the normal setpoint source.
Control, in which the Service Tool user specifies the setpoint,
overriding the normal setpoint source.
In either arrangement, the device will attempt to manage the opening and closing of the control valve to maintain the amount of mass flow as requested by the setpoint source.
Note that the Brooks Service Tool is meant to be used as a startup and troubleshooting tool. It is not intended to be permanently connected to the device in your application.
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Section 2 - Theory of Operation
Brooks Service ToolTM for QUANTIM
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3 Installation
This section describes how to install the Service Tool application onto a personal computer (PC), and how to connect the PC to the device.
3.1. Installing the Service T ool Application
The Service Tool application can be installed on a Windows PC under the following requirements:
• Windows 95, 98, Me, NT 4, 2000, or XP
• PC running at a minimum of 450 MHz, with at least 64 MB of RAM and a CD-ROM drive
Section 3 - Installation
Brooks Service ToolTM for QUANTIM
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3.2. Connecting the PC to the Device
To install the Service Tool application, load the Service Tool CD-ROM
into the drive. On the CD-ROM disk, find the installation file, Setup.exe, and double-click it to launch the installation wizard. Follow the installation instructions in the wizard.
The following topics list the hardware requirements and describe the procedure for connecting the PC running the Service Tool to the device’s service port.
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Section 3 - Installation
Brooks Service ToolTM for QUANTIM
3.2.1 Hardware Requirements
The following tools and cables are required to connect the PC serial port to the device’s service port:
• RS-232 to TTL communications interface adapter.
• Standard RS-232 serial cable (between your PC’s serial connector and
the communications interface adapter).
NOTE: If the distance between the PC and the device is short enough, the RS-232
cable is not necessary. Plug the communications interface adapter directly into the PC serial port.
• 3-wire communications cable (between the interface connector and the
device’s service port connector)
• Straight (flat blade) screwdriver
• 3/16-in. nut driver
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Communications interface adapter
3-wire communications cable
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3.2.2 Connection Procedure
To connect the PC to the device’s service port:
1. Turn off power to the device.
2. Remove the standard cable from the device’s 15-pin D-connector.
3. Remove the screw at the center of the top cover and the two 3/
4. Remove the cover.
Brooks Service ToolTM for QUANTIM
16-in. standoffs on the 15-pin D-connector.
Section 3 - Installation
®
Black service port connector located behind D-connector
15-pin D-connecto
D-connecto standoffs
Center cover screw
3-3
Section 3 - Installation
Brooks Service ToolTM for QUANTIM
5. Assemble the RS-232 serial cable, communications interface adapter, and Service Tool 3-wire communications cable.
6. Connect the RS-232 serial cable to a serial port on your computer.
If the distance is short enough, you can connect the communications interface adapter directly to the PC’s serial port, as shown below, and do not need the RS-232 serial cable.
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7. Connect the 3-wire communications cable to the device’s service port, the black connector located behind the D-connector. Align the communications cable’s 5-pin connector with the black wire towards the center of the device (towards the LEDs).
The QUANTIM QMA model’s service port has a 6-pin connector. To attach the communications cable’s 5-pin connector to the 6-pin service port, make the connection so that the unused pin is the innermost pin (the pin closest to the center or LEDs), as shown in the following illustration.
Section 3 - Installation
Brooks Service ToolTM for QUANTIM
®
Service port connector attached (viewed from rear of device)
Unused 6th pin on QUANTIM QMA
8. Reconnect the standard cable to the device’ s D-connector.
This connection is used to apply power and the analog setpoint to the device while using the Service Tool.
9. Turn on power to the device.
10.Verify that the device initializes properly, as indicated by the Status LED being solid green.
You are now ready to use the Service Tool.
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Section 3 - Installation
Brooks Service ToolTM for QUANTIM
3.2.3 Disconnecting the PC from the Device
When you are done using the Service Tool, you should disconnect the PC from the device and reinstall the device’s cover.
To disconnect the PC from the device’s service port:
1. Exit from the Service Tool.
2. Turn off power to the device.
3. Disconnect the standard cable and the 3-wire communications cable from the device.
4. Disconnect the RS-232 serial cable (or interface adapter) from your PC.
5. Place the cover onto the device, and reattach it using the screw at the center of the top cover and the two 3/16-in. standoffs on the 15-pin D-connector.
Installation and Operation Manual
X-BST-Qm-eng
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Part Number: 541B026AAA
July , 2004
6. Reconnect the standard cable to the device’ s 15-pin D-connector. You can now reapply power to the device and begin using it in its process
application.
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3.3 Device D-Connector Pin-Outs
The QUANTIM device pin-outs are listed below .
Section 3 - Installation
Brooks Service ToolTM for QUANTIM
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1
9
Pin No. Function
1 Setpoint Return 2 0 to 5 Vdc Flow Signal Output 3 Not used 4 4 to 20 mA Flow Signal Output 5 +13- to +30-Vdc Power Supply 6 Not used 7 4 to 20 mA Setpoint Input 8 0 to 5 Vdc Setpoint Input
9 Power Supply Common 10 Signal Output Return 11 +5 V Reference Output 12 Valve Override Input
8
15
13 4 to 20 mA Density or Temperature 14 Not used 15 Not used
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Section 3 - Installation
Brooks Service ToolTM for QUANTIM
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4 Basic Operations
This section describes the Service Tool’s basic operations, including:
Starting the tool and opening a new session
Setting the options to determine what variables will be displayed in the main window and how they will be displayed
Putting the tool into Indicator or Control mode, which determines whether the tool can initiate changes in setpoint values
Controlling different aspects of how the trending graphs are displayed in the main window
Capturing the current st ate of the trend graph to the clipboard or a file, and/or by printing it to a hard copy
Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
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Closing the session and exiting the tool
4-1
Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
4.1 Starting the Service Tool and Opening a New Session
To start the Service Tool and open a new session:
1. Select the Brooks Service Tool from your Start menu, or double-click its application file. The main window displays, with no session open.
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2. To open a new session, open the File menu and select New Session. The Open Session dialog box displays.
Installation and Operation Manual
X-BST-Qm-eng Part Number: 541B026AAA July , 2004
3. From the Select Communications Port drop-down list, select the
Comm port to which the Service Tool cable is connected, then click OK.
Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
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The Trend Graph and Status indicators begin showing the data that is being read from the device.
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Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
4.2 Main Window Elements
Figure 4-1 indicates the major elements of the main window.
Installation and Operation Manual
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Part Number: 541B026AAA
July , 2004
Maximum flow for which the device was calibrated
Trend Graph controls
Setpoint slider
(used in Control
mode)
Current Setpoint
value
Setpoint
Indicator/Control
switch
Status bar
Figure 4-1 Main Window Elements
Trend Graph
Trend lines of selected variable data, indicated by color
Variable data
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Installation and Operation Manual
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4.3 Setting the Main Window Options
To set the main window options, open the File menu and select Options. The Options window displays. From this window, you can
perform the functions described in Table 4-1.
Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
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Table 4-1 Options Window Functions
Function Description
Modify the current settings You can modify the options settings on any of the
three tabs. The options on the three tabs, and which elements on the main window they control, are illustrated in Figures 4-2 through 4-4.
Save current settings as defaults Changes that you make to the option settings are
in effect only for the current session. However, you can save the current settings so that they are used as the default values the next time a session is opened. To do this, select the Save Selections as Defaults option at the bottom of the Options
window. Cancel your setting changes Click the Cancel button. Save your setting changes Click OK.
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Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
Installation and Operation Manual
X-BST-Qm-eng
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Part Number: 541B026AAA
July , 2004
NOTE: Range values here affect only the trend graph; they do not change the representation of the variable on an analog output.
Figure 4-2 Process Variables Options
Range values determine
variable data values
at 0% and 100% scale
Graph options determine which variable data is trend graphed
Assignment options determine Setpoint type and what variable data is displayed
Select unit of measure
for each variable data type
Select this option to save current settings as default values next time a session is opened
Figure 4-3 Units of Measure Options
Enter precision of measurement data
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Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
X-Axis Scroll Method determines how trend graph will advance over time:
Smooth (continuously), or
Page (in time window increments; for example, every 30 seconds)
®
Y-Axis Scale values
determine upper and lower
percentage values
along the Y-axis
Figure 4-4 Trend Graph Options
X-Axis Window determines the time window displayed along the X-axis
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Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
4.4 Putting the Service T ool in Indicator or Control Mode
By default, a session opens with the Service Tool in Indicator mode. In this mode, the setpoint is being controlled by the standard setpoint input source. The setpoint data in the Service Tool’s main window “indicates” what the device is currently reporting as its setpoint.
However, you can control the setpoint directly from the Service Tool by moving the Setpoint Switch to Control, then using the slider to set the setpoint or entering a value in the field below the slider. Figure 4-5 shows the Setpoint controls and trend graph in Control mode.
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Installation and Operation Manual
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Part Number: 541B026AAA
July , 2004
Indicates when Setpoint slider was moved to current position
In Control mode,
use slider to choose setpoint
or
Enter setpoint value here,
then press the Enter key
Setpoint switch in Control mode, setpoint at 51.82 gr/hr
Figure 4-5 Setpoint Switch in Control Mode
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4.5 Trend Graph Functions
The following topics cover the functions that you can perform on the trend graph.
4.5.1 Trend Graph Element s
Figure 4-6 shows the Trend Graph’s main element s. Table 4-2 summarizes the Trend Graph’ s toolbar functions.
The data graphs are coordinated by color to the variable data to which they correspond. Note that the selection of what variable data to graph is determined by settings in the main window’s options; refer to “4.3 Setting the Main Window Options” on p. 4-5.
Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
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Trend Graph toolbar
Y-axis, indicating percent
of variable data relative
to upper/lower range settings,
as defined in the main window options
Figure 4-6 Trend Graph Main Elements
Mass Setpoint graph
Valve Drive graph
Mass Flow graph
Current variable data readings
X-axis, indicating elapsed time window since start of session
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Section 4 - Basic Operations
Brooks Service ToolTM for QUANTIM
Table 4-2 Summary of Trend Graph Toolbar Functions
Function Description
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Starts variable data trending, if it has been stopped.
Stops variable data trending.
Scroll up and down the Y-axis, or back and forth across the X-axis.
Zoom in and out of a selected axis.
Zoom in and out of both axes simultaneously.
Part Number: 541B026AAA
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Zoom in on a region of the trend graph.
View the X- and Y-axes values at a given point in time the trend graph.
Copy the trend graph to the clipboard.
Save the trend graph as a file.
Print the trend graph.
The following topics provide more detail about each of the Trend Graph toolbar functions.
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