fann MACS II User manual

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

MACS II User Manual
101796668 Revision E ii
Multiple Analysis Cement System (MACS II) User Manual
©2015 Fann Instrument Company
Houston, Texas, USA
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construction, and appearance of our products without prior notice.
FANN®and the FANN®logo are registered trademarks of Fann Instrument Company
in the United States and/or other countries.

MACS II User Manual
101796668 Revision E iii
Document Conventions
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Contains additional information for the reader that is not safety
related.
Describes a situation or practice that if ignored, will result in
equipment damage or loss of data.
Describes an unsafe condition or practice that, if not
corrected, will result in personal injury, possibly death.

MACS II User Manual
101796668 Revision E iv
Contact FANN®
Phone
TELEPHONE: [phone]
TOLL FREE: 800-347-0450
FAX: [phone]
Mail
Fann Instrument Company
P.O. Box 4350
Houston, Texas, 77210 USA
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14851 Milner Road, Gate 5
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Online
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[email protected]

MACS II User Manual
101796668 Revision E v
Table of Contents
OVERVIEW..........................................................................................................................................................1
1.1. MULTIPLE ANALYSIS CEMENT SYSTEM II....................................................................................................... 2
1.1.1. Thickening Time ....................................................................................................................................5
1.1.2. Transition Time......................................................................................................................................5
1.2. SPECIAL CONSIDERATIONS.............................................................................................................................. 5
SAFETY.................................................................................................................................................................7
2.1. MACHINE HAZARD ..........................................................................................................................................9
2.1.1. Pressure.................................................................................................................................................9
2.1.2. Temperature...........................................................................................................................................9
2.1.3. Electrical ...............................................................................................................................................9
2.1.4. Pinch Points.........................................................................................................................................10
2.2. ERGONOMIC CONSIDERATIONS ..................................................................................................................... 10
2.3. ENVIRONMENTAL CONSIDERATIONS.............................................................................................................10
FEATURES AND SPECIFICATIONS.............................................................................................................11
3.1. MACS II INSTALLATION PREPARATION........................................................................................................ 13
3.2. PHYSICAL REQUIREMENTS............................................................................................................................13
3.3. OPERATIONAL CONSIDERATIONS .................................................................................................................. 13
3.4. COMPUTER SPECIFICATIONS ......................................................................................................................... 14
INSTALLATION................................................................................................................................................ 15
4.1. PRE-INSTALLATION CONSIDERATIONS..........................................................................................................17
4.2. HARDWARE (MECHANICAL)INSTALLATION ................................................................................................. 17
4.2.1. Water, Air, and Coolant Connections.................................................................................................. 17
4.2.2. Electric Power Connection.................................................................................................................. 19
4.2.3. Power Up MACS II Unit...................................................................................................................... 19
4.2.4. Initial Verification of Alignment..........................................................................................................19
4.2.5. Water Test............................................................................................................................................22
4.3. SOFTWARE INSTALLATION ............................................................................................................................22
4.3.1. Software Quick Install ......................................................................................................................... 23
4.3.2. MACS II SGS Software Installation..................................................................................................... 23
4.3.3. USB Connection Configuration........................................................................................................... 24
4.3.4. Software Updates................................................................................................................................. 28
4.4. POST-INSTALLATION VERIFICATIONS............................................................................................................ 28
MACS II SOFTWARE....................................................................................................................................... 31
5.1. SOFTWARE BASICS........................................................................................................................................33
5.2. INTERFACE ELEMENTS .................................................................................................................................. 33
5.2.1. Menu Bar............................................................................................................................................. 34
5.2.2. Variable Indicators.............................................................................................................................. 34
5.2.3. Status Indicator....................................................................................................................................35
5.2.4. Start/Stop Test Button..........................................................................................................................35
5.2.5. Results Graph ...................................................................................................................................... 36
5.3. FILE MENU.................................................................................................................................................... 37
5.3.1. Connect Command...............................................................................................................................37
5.3.2. Disconnect Command.......................................................................................................................... 37
5.3.3. Save Data Command ........................................................................................................................... 37
5.3.4. Exit....................................................................................................................................................... 38
5.4. EDIT MENU ...................................................................................................................................................38
5.4.1. Machine Settings..................................................................................................................................38
5.4.2. Profile Editor....................................................................................................................................... 45
5.5. CALIBRATION MENU..................................................................................................................................... 46

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5.5.1. Zero Drive............................................................................................................................................ 46
5.5.2. Calibrate Pressure............................................................................................................................... 47
5.5.3. Calibrate SGS...................................................................................................................................... 53
5.5.4. Test Repeatability ................................................................................................................................ 54
5.6. OPERATE MENU ............................................................................................................................................ 58
5.6.1. Cell Operations.................................................................................................................................... 58
5.6.2. Valve Operations................................................................................................................................. 60
5.6.3. Manual Operation ............................................................................................................................... 61
5.6.4. Release Pressure.................................................................................................................................. 62
5.7. HELP MENU .................................................................................................................................................. 62
5.7.1. Online Help.......................................................................................................................................... 62
5.7.2. Check for Updates ...............................................................................................................................62
5.7.3. About....................................................................................................................................................62
5.8. START TEST WIZARD .................................................................................................................................... 62
5.8.1. Step One...............................................................................................................................................63
5.8.2. Step Two ..............................................................................................................................................65
5.8.3. Step Three............................................................................................................................................ 66
5.8.4. Step Four............................................................................................................................................. 66
5.8.5. Step Five.............................................................................................................................................. 67
5.9. TEST RUN...................................................................................................................................................... 69
5.10. STOP TEST..................................................................................................................................................... 69
INSTRUMENT OPERATIONS ........................................................................................................................71
6.1. START TEST WIZARD MODULE ..................................................................................................................... 73
6.2. PHYSICAL EQUIPMENT ACTIVITY.................................................................................................................. 73
6.3. CEMENT TEST ...............................................................................................................................................76
RESULTS ANALYSIS .......................................................................................................................................77
7.1. MACS II SOFTWARE..................................................................................................................................... 79
7.1.1. Show Cursor ........................................................................................................................................79
7.1.2. Show Torque........................................................................................................................................79
7.1.3. Autoscale X.......................................................................................................................................... 79
7.1.4. Autoscale Y..........................................................................................................................................79
7.2. DATA MANAGER SOFTWARE ...................................................................................................................... 795
7.3. DATA INTERPRETATION ................................................................................................................................ 80
MAINTENANCE AND TROUBLESHOOTING ............................................................................................81
8.1. PREVENTIVE MAINTENANCE.........................................................................................................................83
8.1.1. Pneumatic Maintenance ...................................................................................................................... 83
8.1.2. Hydraulic Maintenance.......................................................................................................................83
8.1.3. Mechanical Maintenance.....................................................................................................................94
8.2. TROUBLESHOOTING ...................................................................................................................................... 94
ACCESSORIES AND SCHEMATICS .............................................................................................................98
9.1. MACS II TOOL KIT..................................................................................................................................... 100
9.2. MACS II ACCESSORY PARTS KIT ............................................................................................................... 100
9.3. MACS II CALIBRATION KIT........................................................................................................................102
9.4. MACS II SCHEMATICS................................................................................................................................ 102
PARTS LIST.................................................................................................................................................111
10.1. MASTER ASSEMBLY 101677665.................................................................................................................113
10.2. ELECTRICAL BOX ASSEMBLY 101676548................................................................................................... 115
10.3. MECHANICAL ASSEMBLY 101595348......................................................................................................... 121
10.4. TOP PLATE AND PRESSURE CELL BODY 101723011 ...................................................................................128
10.5. TURN TABLE ASSEMBLY 101723010.......................................................................................................... 135

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10.6. FRAME DRAWER,MECHANICAL ASSEMBLY 101723012.............................................................................138
10.7. SGS TEST CUP ASSEMBLY 101636768....................................................................................................... 147
10.8. SLURRY CUP ASSEMBLY 100072017 .......................................................................................................... 149
10.9. PADDLE ASSEMBLY,SGS 101636441......................................................................................................... 151
WARRANTY AND RETURN..................................................................................................................................155

MACS II User Manual
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Table of Figures
Figure 1-1 MACS II Front View (Shown with Customer Laptop) ............................. 2
Figure 1-2 MACS II with Door Open................................................................... 3
Figure 1-3 Turn Table Assembly And Pressure Cell............................................... 4
Figure 4-1 MACS II Hydraulic and Pneumatic Ports .............................................18
Figure 4-2 X Direction Adjustment....................................................................19
Figure 4-3 Y Direction Adjustment....................................................................20
Figure 4-4 Z Direction Adjustment....................................................................20
Figure 4-5 R Direction Adjustment....................................................................21
Figure 4-6 MACS II Limit Switches....................................................................21
Figure 4-7 Found New Hardware Wizard............................................................26
Figure 4-8 Unable to Import Configuration Settings Dialog Box ............................27
Figure 4-9 Software Updates Dialog Box............................................................28
Figure 5-1 MACS II SGS Software Main Screen ..................................................33
Figure 5-2 XY Graph .......................................................................................36
Figure 5-3 General Tab Screen.........................................................................39
Figure 5-4 Test Header Tab Screen...................................................................41
Figure 5-5 Slurry Cup Paddle Motion Tab Screen ................................................42
Figure 5-6 Constants Tab Screen......................................................................43
Figure 5-7 PID Tab Screen...............................................................................44
Figure 5-8 Profile Editor Screen........................................................................45
Figure 5-9 Zero Drive Adjusting Drive Mechanism Message..................................46
Figure 5-10 Reference Position Dialog Box.........................................................47
Figure 5-11 Calibrate Screen Old Calibration (Top) Portion ..................................47
Figure 5-12 Calibrate Screen New Calibration (Bottom) Portion............................48
Figure 5-13 Calibrate SGS Screen.....................................................................53
Figure 5-14 Test Repeatability Step One Dialog Box............................................55
Figure 5-15 Test Repeatability Step Two Dialog Box............................................55
Figure 5-16 Test Repeatability Step Three Dialog Box .........................................56
Figure 5-17 Test Repeatability Results Screen....................................................57
Figure 5-18 Cell Operations Dialog Box .............................................................58
Figure 5-19 Valve Operations Screen ................................................................60
Figure 5-20 Operate Manually Dialog Box..........................................................61
Figure 5-21 Test Information Screen.................................................................63
Figure 5-22 Mandatory Text Boxes ...................................................................64
Figure 5-23 Temperature Reference Screen.......................................................65
Figure 5-24 Cement Sample Cell Dialog Box ......................................................67
Figure 5-25 Wizard Complete Screen ................................................................68
Figure 6-1 Complete Slurry Cup and Paddle Assembly (Eng. Drawing #101636768)74
Figure 6-2 Slurry Cup and Paddle (Eng. Drawing #101636768)............................75
Figure 8-1 High Pressure Valve Location............................................................85
Figure 8-2 Items to Disconnect ........................................................................86
Figure 8-3 Wrenches on Valve..........................................................................87
Figure 8-4 Removing Air Actuator Assembly.......................................................87
Figure 8-5 Internal Sensor Assembly Location....................................................88
Figure 8-6 Internal Sensor Assembly Removal ...................................................88
Figure 8-7 Seat Retainer .................................................................................89

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Figure 8-8 - Lubrication of Threads...................................................................89
Figure 8-9 Torque Sensor Tool.........................................................................90
Figure 8-10 Vise with Soft Jaws........................................................................90
Figure 8-11 Spring Pad ...................................................................................91
Figure 8-12 Valve Parts...................................................................................91
Figure 8-13 Stem and Spring...........................................................................92
Figure 8-14 O-ring and Backup Ring .................................................................92
Figure 8-15 Loctite Application.........................................................................93
Figure 8-16 Reassembled Sensor......................................................................93

MACS II User Manual
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Overview
Table of Contents
OVERVIEW..........................................................................................................................................................1
1.1. MULTIPLE ANALYSIS CEMENT SYSTEM II....................................................................................................... 2
1.1.1. Thickening Time ....................................................................................................................................5
1.1.2. Transition Time......................................................................................................................................5
1.2. SPECIAL CONSIDERATIONS..................................................................................................................................5