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Dionex Integral Systems Operator’s Manual

Doc. 065250-06 03/2020

3 • SP Sample Preparer Description

. . . . . . . . . . . . . . . . . .19

3.1

SP Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.2

SP Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.3

SP Power and Computer Connections . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.4

SP Liquid Leak Sensor and Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3.5

SP Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3.5.1

Metering Valve (Rotary Valve) . . . . . . . . . . . . . . . . . . . . . . . . .24

3.5.2

Dilution Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

3.5.3

Dilution Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3.5.4

Loading Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3.5.5

Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

3.5.6

Vial Cooler (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

3.6

SP Panel Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

3.6.1

SP1 for Concentration or Direct Injection . . . . . . . . . . . . . . . . .29

3.6.2

SP2 for Dilution or Direct Injection . . . . . . . . . . . . . . . . . . . . .33

3.6.3

Flow Paths and Valve Positions Used During Analyses . . . . . .38

3.6.4

SP Gas and Liquid Input and Output Lines . . . . . . . . . . . . . . . .44

3.7

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

3.8

SP TTL and Relay Control (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . .48

3.8.1

Relay Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

3.8.2

TTL Input Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

3.9

Liquid Level Sensor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

3.10 Flow Sensor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

3.11 Pressure Sensor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Summary of Contents for Dionex

Page 1: ...Dionex Integral Process Analytical Systems Operator s Manual Document No 065250 Revision 06 March 2020...

Page 2: ...as is The contents of this manual are subject to being changed without notice in future revisions Thermo Fisher Scientific Inc makes no representations that this document is complete accurate or error...

Page 3: ...Documentation 8 1 4 Safety Information 9 1 4 1 Safety Messages and Notes 9 1 4 2 Safety Symbols 11 1 5 Regulatory Compliance 11 1 5 1 Notice on Lifting and Handling of Thermo Scientific Instruments 12...

Page 4: ...Pump 26 3 5 4 Loading Pumps 27 3 5 5 Solenoid Valves 28 3 5 6 Vial Cooler Option 29 3 6 SP Panel Configurations 29 3 6 1 SP1 for Concentration or Direct Injection 29 3 6 2 SP2 for Dilution or Direct...

Page 5: ...and Liquid Drain 66 5 AE Analyzer Enclosure Description 67 5 1 AE Overview 67 5 2 AE Exterior Features 68 5 3 AE Interior Features 70 5 3 1 Shelves 70 5 3 2 Power Outlet Strip 71 5 3 3 Drip Tray and...

Page 6: ...1 Prepare the Site and Facilities 85 7 1 2 Connect the Facilities 85 7 1 3 Connect the Communications Cables 86 7 1 4 Connect the Sample Inlet Line 86 7 2 Initial Startup 86 7 2 1 Turn On the Power 8...

Page 7: ...ntenance 98 9 Troubleshooting 99 9 1 Troubleshooting Strategies 99 9 2 Audit Trail Error Messages 100 9 3 Liquid Leaks Leak Alarm 118 9 4 Air and Gas Leaks 120 9 5 System or System Component Does Not...

Page 8: ...onents 140 10 11 Changing the SP or SS Main Power Fuses 140 A Specifications 143 A 1 Environmental All Analyzer Components 143 A 2 AE Analyzer Enclosure and LE Liquids Enclosure 143 A 2 1 Electrical 1...

Page 9: ...talling the TTL and Relay Breakout Boards 160 C 3 1 Overview 160 C 3 2 TTL and Relay Breakout Board Installation Procedure 161 C 4 Installing the AE Tower Light Kit 169 C 4 1 Overview 169 C 4 2 AE Tow...

Page 10: ...Configuring the Pump in Chromeleon 7 189 F Liquid Level Sensor Installation Instructions 191 F 1 Overview 191 F 2 Liquid Level Sensor Installation Procedure 191 F 2 1 Installing the Liquid Level Senso...

Page 11: ...Heated Dilution Vessel 199 G 3 1 Overview 199 G 3 2 Heated Dilution Vessel Installation Procedure 200 H Lockout Instructions for the AE SP or SS 203 H 1 Lockout Device Installation Procedure 203 H 1...

Page 12: ...Dionex Integral Systems Operator s Manual x Doc 065250 06 03 2020...

Page 13: ...contains an analytical pump a detector and an SP Sample Preparer A Dionex Integral analyzer consists of from one to four systems combined to operate in parallel The analyzer is configured to sequenti...

Page 14: ...e 1 1 Example Dionex Integral System Dionex ICS 6000 Detector Chromatography Module Dionex ICS 6000 Eluent Generator Chromeleon 7 Process Analyzer Computer SP Sample Preparer Dionex ICS 6000 Dual Pump...

Page 15: ...iate support structure LE Liquids Enclosure The LE provides an enclosure for housing standard and reagent bottles as well as NOWPak containers for eluents and solvents The LE includes a gas supply con...

Page 16: ...ientific Dionex Chromeleon 7 Chromatography Data System Chromeleon 7 PA integrates Chromeleon 7 with a client program called Analyzer This adds several process monitoring functions including stream se...

Page 17: ...1 Introduction Doc 065250 06 03 2020 5 Figure 1 2 Example Analyzer Configuration...

Page 18: ...stem components the software required for operation and the user manuals Chapter 2 System Configurations Provides an illustration of a typical Dionex Integral system configuration Chapter 3 SP Sample...

Page 19: ...x Integral system Appendix C TTL and Relay Installation Instructions Provides instructions for installing TTL and relay control functions in the SP and AE Appendix D AE Purge Kit Installation Instruct...

Page 20: ...CD and ED Document No 22181 97002 Dionex UltiMate 3000 RS and SD series module manuals Consumable Product Documentation For information about Dionex columns suppressors EluGen cartridges and other co...

Page 21: ...1 4 1 Safety Messages and Notes This manual contains warnings and precautionary statements that can prevent personal injury and or damage to the Dionex Integral system when properly followed Safety me...

Page 22: ...s mortelles Signale une situation de danger potentiel qui si elle n est pas vit e pourrait entra ner des blessures graves mortelles Signale une situation de danger potentiel qui si elle n est pas vit...

Page 23: ...nclude replacing a part or adding components options or peripherals not specifically authorized and qualified by Thermo Fisher Scientific To ensure continued compliance with EMC and safety standards r...

Page 24: ...5 1 Notice on Lifting and Handling of Thermo Scientific Instruments For your safety and in compliance with international regulations the physical handling of this Thermo Scientific instrument requires...

Page 25: ...cordance with local and state requirements Conformit DEEE Ce produit est conforme avec la directive europ enne 2012 19 EU des D chets d Equipements Electriques et Electroniques DEEE Il est marqu par l...

Page 26: ...low a regulated approved waste disposal program Never dispose of wastes containing organic solvents through the municipal sewage system Neutralize all acidic and caustic wastes before disposal Compres...

Page 27: ...n drive mechanism with moving parts Before servicing the pump turn off the main power switch and unplug the power cable Stepper motor pumps include the dilution pump and one type of sample loading pum...

Page 28: ...Dionex Integral Systems Operator s Manual 16 Doc 065250 06 03 2020...

Page 29: ...ental requirements This chapter describes two of the most common configurations of analytical system modules sampling modules and enclosures that make up a Dionex Integral system 2 1 Example Configura...

Page 30: ...Dionex Integral Systems Operator s Manual 18 Doc 065250 06 03 2020 Figure 2 2 Example Dionex Integral System Configuration UltiMate 3000 System AE and Internal SP...

Page 31: ...rect injection The generic SP can be customized with pumps valves and other components as required for HPLC applications or for IC applications that use other sample preparation techniques for example...

Page 32: ...openings are exposed to the environment When the external SP enclosure is mounted on the side of an AE it meets NEMA 4X requirements because the ventilation openings are inside the AE and are not exp...

Page 33: ...eceptacle The fuse cartridge contains two fast blow IEC 127 fuses rated 3 15 A P N 954745 For instructions on how to change the fuses see Section 10 11 The power cord plugs into the IEC 320 three pron...

Page 34: ...a shock hazard may result Do not operate or connect to AC power mains without earthed ground connections The power supply cord is used as the main disconnect device Make sure the socket outlet is loc...

Page 35: ...Drain A leak sensor is located inside the SP enclosure in the bottom front of the enclosure If the leak sensor becomes wet it reports the leak to Chromeleon 7 and an error message is displayed in the...

Page 36: ...valve that measures sample or standard for delivery to a dilution vessel The valve is available in two models PEEK P N 068556 and stainless steel P N 068557 Both models are electrically activated two...

Page 37: ...e pressure reaches 340 kPa 50 psi a pressure relief valve opens Dilution Vessel Mixer Both dilution vessels are equipped with a mixer and a PTFE polytetrafluoroethylene stir bar Specify the default mi...

Page 38: ...vessel can be set to between 15 C and 40 C Specify the temperature in the Chromeleon 7 Instrument Configuration Manager on the Temperature page or in the Chromeleon 7 instrument method 3 5 3 Dilution...

Page 39: ...an be set to between 0 0 mL min and 3 0 mL min the default is 3 0 mL min Use a flow rate appropriate for delivering sample to a concentrator column You can change the flow rate in the Chromeleon 7 Ins...

Page 40: ...enoid valves see Figure 3 8 that direct liquid flow throughout the SP flow path For valve locations and functions for the SP1 see Section 3 6 1 for the SP2 see Section 3 6 2 For custom SP configuratio...

Page 41: ...tion vial in the vial cooler If you are using the vial cooler to cool a standard set the standard vial in the cooler and direct the line from the ST valve see Figure 3 11 to the vial 3 6 SP Panel Conf...

Page 42: ...on valve ST SV1 NC C NO Metering Valve 1 2 3 5 7 9 4 6 8 10 To waste Plug To waste Plug NC C NO DI water in Plug NC C NO To wasten DI SV2 CS SV3 SM SV4 SS SV5 DV SV6 Dilution Pump Plug To waste Loadin...

Page 43: ...Directs sample to loading pump Dilution Vessel Valve DV SV6 3 way solenoid valve On Directs calibration standard to SS valve Off Purges dilution vessel to waste Metering Valve ME 10 port 2 position v...

Page 44: ...shows the layout of the SP1 components when they are installed in the horizontal orientation Figure 3 12 SP1 Component Layout Vertical Orientation plug plug plug 1 2 5 7 9 4 6 8 10 3 standard i n wast...

Page 45: ...the sample loop before chromatographic analysis A system configured for dilution is often used when assaying process samples for major constituents Dilution factors up to 1 25 000 can be achieved Fig...

Page 46: ...injection valve ST SV1 NC C NO Metering Valve 1 2 3 5 7 9 4 6 8 10 To waste Plug To waste Plug NC C NO DI water in Plug NC C NO To wasten To waste DI SV2 CS SV3 SM SV4 SS SV5 DV SV6 Dilution Pump GAS...

Page 47: ...Off Directs undiluted sample or check standard to loading pump Dilution Vessel Valve DV SV6 3 way solenoid valve On Directs diluted sample standard to SS valve Off Purges dilution vessel to waste Mete...

Page 48: ...3 16 shows the layout of the SP2 components when they are installed in the horizontal orientation Figure 3 15 SP2 Component Layout Vertical Orientation plug plug 1 2 5 7 9 4 6 8 10 3 standard i n was...

Page 49: ...gure 3 16 SP2 Component Layout Horizontal Orientation Loading Pump Dilution Pump Dilution Vessel Gas Pressure Regulator Knob DV SV6 SM SV4 ST SV1 SS SV5 DI SV2 CS SV3 plug plug 1 2 5 7 9 4 6 8 10 3 Me...

Page 50: ...ee Figure 3 17 Step 2 Sending the loop contents and deionized water the diluent to the dilution vessel see Figure 3 18 Step 3 Purging the diluted standard from the dilution vessel and loading it to th...

Page 51: ...lve ST SV1 NC C NO Metering Valve 1 2 3 5 7 9 4 6 8 10 To waste Plug To waste Plug NC C NO DI water in Plug To wasten DI SV2 DV SV6 NO C NC GAS SV8 Gas in Regulator Gauge Pressure Relief Valve To wast...

Page 52: ...s Dilution Vessel NC C NO NC C NO To loading pump and injection valve From ME valve To wasten SS SV5 SS SV5 DV SV6 To SM valve NO C NC GAS SV8 Gas in Regulator Gauge Pressure Relief Valve To waste Val...

Page 53: ...SM SV4 SS SV5 SS SV5 DV SV6 To waste Loading Pump From dilution vessel Valve Positions for Check Standard Analyses ST SV1 Off DI SV2 Off CS SV3 On SM SV4 On SS SV5 Off DV SV6 Off GAS SV8 Off ME 1 2 Ch...

Page 54: ...ten CS SV3 SM SV4 SS SV5 SS SV5 DV SV6 To waste Loading Pump From dilution vessel Valve Positions for Sample Stream Analyses ST SV1 Off DI SV2 Off CS SV3 Off SM SV4 On SS SV5 Off DV SV6 Off GAS SV8 Of...

Page 55: ...sample from the dilution vessel and loading it to the injection valve This step is also performed when the calibration standard is analyzed see Figure 3 19 Figure 3 24 Analyzing Sample Streams SP2 Dil...

Page 56: ...in the flow path see Figure 3 11 for the SP1 or Figure 3 14 for the SP2 Figure 3 25 SP1 and SP2 I O Lines and Port Assignments I O Port Assignments Gas In Gas Valve Waste Not Connected Not Connected L...

Page 57: ...ditional cables separately The input voltage range for each input is 0 to 10 V maximum The sampling rate is 3 Hz and the resolution is 24 bits To connect the analog input 1 Turn off the SP power 2 Dis...

Page 58: ...free ends of the wires to the appropriate connector pins on the device 8 Close and secure the SP service door 9 If you removed the SP from the AE rear panel a Lift up the SP align the four hooks on th...

Page 59: ...s 2 and 3 See Figure 3 28 for the function assigned to each jumper position Figure 3 27 Analog Input 4 Jumper Default Position 5 To change the position of the jumper slide the jumper up and off the pi...

Page 60: ...s installed on an external SP enclosure the TTL and relay connectors are installed on the side of the enclosure see Figure 3 29 When the SP is installed inside an AE or mounted on the side of an AE tw...

Page 61: ...n the Script Editor view in the Chromeleon 7 Instrument Method Editor Notes If a relay output is configured to change states with an alarm event see Section 3 8 2 do not program the relay output to co...

Page 62: ...ent method see page 49 Include the command in all methods that are used with the system 3 9 Liquid Level Sensor Option The optional Liquid Level Sensor Kit P N 068563 provides a sensor that signals wh...

Page 63: ...p to two flow sensors can be installed in the SP High and low limits for the flow rate are entered in the Chromeleon 7 Instrument Configuration Manager If the flow rate is outside the specified range...

Page 64: ...n enter and leave the flow sensor from either side 8 Close and secure the SP service door 9 If you removed the SP from the AE rear panel a Lift up the SP align the four hooks on the rear of the SP wit...

Page 65: ...point The pressure reading is displayed in the Chromeleon 7 Command window under the SP device and on the SP ePanel in Chromeleon 7 NOTE Pressure transducers for other pressure ranges are also availa...

Page 66: ...low the instructions in Section 10 7 to access the main SP electronics board 6 Locate the connector labeled Pressure in the lower left corner of the main SP electronics board see Figure 3 34 Figure 3...

Page 67: ...align the four hooks on the rear of the SP with the mounting rails on the AE rear panel and hang the SP on the rails b Replace any modules that were removed from the lower shelf of the AE c Replace th...

Page 68: ...oltage on and off on the SP ePanel in Chromeleon 7 or by adding commands to the Chromeleon 7 instrument method To connect a device to the DC voltage control option 1 Turn off the SP power 2 Disconnect...

Page 69: ...and turn on the power 11 Open the Chromeleon 7 Instrument Configuration Manager and open the SP Properties dialog box The DC Voltage Control check box is enabled on the Pumps Motors page Enter the def...

Page 70: ...ically used to control the dilution vessel mixer to turn the power output on and off and control the amount of power delivered to the device from 0 to 100 of maximum These commands are available in th...

Page 71: ...of the wires to the appropriate connector pins on the device 8 Close and secure the SP service door 9 If you removed the SP from the AE rear panel a Lift up the SP align the four hooks on the rear of...

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Page 73: ...d to up to seven sample streams This allows sampling from one of 7 14 or 21 streams depending on the number of valves installed in the SS 4 2 Stream Selection SS stream selection valves are 17 port 8...

Page 74: ...4 for the SP2 flow path If a stream from valve B or C is selected the selected stream is cascaded to the common sample outlet line on valve A Streams that are not selected flow continuously out of the...

Page 75: ...l it meets NEMA 12 requirements because the ventilation openings are exposed to the environment When the external SS enclosure is mounted on the side of an AE it meets NEMA 4X requirements because the...

Page 76: ...inside an AE connect the power cord to the power outlet strip inside the AE see Section 5 3 2 The AE power outlet strip is a grounded receptacle When the SS is mounted on the side of the AE or instal...

Page 77: ...16 ft long DANGER D LECTROCUTION Pour viter toute lectrocution il faut utiliser une prise de courant avec prise de terre Ne l utilisez pas et ne le branchez pas au secteur C A sans utiliser de branche...

Page 78: ...enclosure see Figure 4 4 If the sensor becomes wet it reports a leak to Chromeleon 7 and an error message is displayed in the audit trail Any liquid that collects in the bottom of the SS exits through...

Page 79: ...es the following levels of NEMA environments When the AE is equipped with a blower it meets NEMA 12 requirements because it has ventilation openings that are exposed to the environment When the AE is...

Page 80: ...omponents connected to the power outlets inside the AE see Section 5 3 2 Figure 5 2 AE Front Exterior If an emergency occurs turn off the power by pushing the knob on the Emergency Off switch complete...

Page 81: ...Follow all appropriate hazardous materials and safety guidelines for chemicals when operating the Dionex Integral system DANGER D LECTROCUTION Un danger d lectrocution existe dans l enceinte lorsque...

Page 82: ...needed to accommodate a variety of module sizes and combinations The shelves slide forward about 10 cm 4 in to allow easier access to the modules installed on the shelves To pull a shelf forward use...

Page 83: ...drain lines from all modules installed inside the AE can be routed to the AE drip tray The drip tray collects any liquid that drains from these lines as well as any liquid that drains from other compo...

Page 84: ...rovided in the AE Ship Kit P N 069066 from this connector to a grounded single phase power source The power cord is configured with a NEMA L5 20P plug 125 Vac 20 A twist lock see Figure 5 5 for connec...

Page 85: ...e enclosure and is easily accessible DANGER D LECTROCUTION Pour viter toute lectrocution il faut utiliser une prise de courant avec prise de terre Ne l utilisez pas et ne le branchez pas au secteur C...

Page 86: ...on the main power switch before initial operation and leave the switch on unless instructed to turn it off for example before performing a service procedure Computer Connections The top of every AE i...

Page 87: ...ectors are provided on the top of the AE see Figure 5 7 These connectors are functional only if the AE TTL and Relay Kit P N AAA 068548 and the SP TTL and Relay Kit P N 068573 are installed For detail...

Page 88: ...al Systems Document No 070186 for mounting and connection instructions When the air conditioner heater is installed a control box is located inside the AE on the upper wall To operate the air conditio...

Page 89: ...gas compressed air or nitrogen to maintain a positive pressure inside the enclosure The purge system consists of the following features see Figure 5 8 A control unit with pressure regulator and alarm...

Page 90: ...73 The SP relays are used to turn the lights on and off Each tower light color is controlled by a different relay output Lights can be configured to turn on whenever a particular error occurs Use the...

Page 91: ...example have the yellow light turn on if the retention time of the chloride peak exceeds 3 225 In Chromeleon 7 control the relays in the instrument method Enter commands for controlling the relays in...

Page 92: ...Dionex Integral Systems Operator s Manual 80 Doc 065250 06 03 2020...

Page 93: ...is shipped with 2 liter bottles P N 044129 If necessary 1 liter bottles P N 044128 can be ordered separately NOWPak containers for the mobile phase eluent or solvent Either 20 liter NOWPak Bag in a Bo...

Page 94: ...anel The knobs provide on off control of gas pressure to the reservoirs and NOWPak containers To apply pressure turn the knob to the PRESSURE position To turn off the gas turn the knob to the VENT pos...

Page 95: ...matic Requirements All reagent and standard reservoirs and NOWPak mobile phase containers require a pressurized supply of nitrogen or helium regulated to between 20 and 34 kPa 3 to 5 psi The gas purit...

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Page 97: ...ion requirements document Also refer to this document for appropriate voltages currents pressures and flow rates 7 1 2 Connect the Facilities 1 Connect electrical power to the Dionex Integral system c...

Page 98: ...each remaining system 2 Connect the sample line from the analyzer systems to the SS or sample source Refer to the installation requirements document for correct pressures and flow rates 3 If an SS is...

Page 99: ...the NOWPak Bag in a Bottle containers P N AAA 068551 for filling instructions Open water supplies to each system 5 Manually actuate the SP valves to flush the lines with water diluent sample and stand...

Page 100: ...he procedure to be performed for example click Dilution Pump Calibration to calibrate the dilution pump A window appears 3 Follow the instructions in the window to complete the calibration NOTE The pe...

Page 101: ...d length Be very careful to cut the end square to the axis of the tubing with no angle Tubing that is poorly cut will cause fittings to leak 2 Install a 10 32 PEEK bolt P N 043275 and a PEEK ferrule f...

Page 102: ...10 Subtract the weight of the empty loop Step 3 from the weight of the filled loop Step 9 the difference is the weight of the water in the standard loop 11 Repeat Step 9 and Step 10 until four to five...

Page 103: ...nalytical pump if required Refer to the pump manual for instructions Detector Calibration Calibrate the detector if required Refer to the detector manual for instructions 7 2 6 Set Up the Dionex Integ...

Page 104: ...e the Dionex Integral analyzers instruments and streams Refer to the Chromeleon 7 PA Help for detailed instructions 7 3 Routine Startup and Operation Routine operation consists of first confirming tha...

Page 105: ...has been started use the following checklist to monitor operation 1 Check for alarms and errors If necessary see Chapter 9 for troubleshooting assistance 2 Check for any liquid or gas leaks Isolate an...

Page 106: ...than two weeks 1 In Chromeleon 7 PA select the analyzer to be shut down 2 Place the selected analyzer in the standby state 3 Exit Chromeleon 7 PA 4 Shut down the computer 5 Empty and rinse the mobile...

Page 107: ...rocedure is performed Besides ensuring that these procedures are accomplished a maintenance log is very helpful when troubleshooting the system 8 1 Daily Maintenance Completion time 10 15 min for a du...

Page 108: ...for piston seal leaks replace defective seals Conductivity detector Record the total conductivity readings at the beginning of a run Suppressor EGC Check for leaks If the suppressor is operating in A...

Page 109: ...in the load position SS valves Check for leaks Gas and drain connections Check all connections including the drain manifold and the fluid connection panels Check for accumulated liquid on the inside b...

Page 110: ...f the pressure does not return to near the original for this column replace the guard column Air filter Clean with warm water whenever a fine layer of dust or lint is visible Establish a cleaning sche...

Page 111: ...a specific system component or to an aspect of the analysis Once this has been done corrective action can be taken This manual cannot address every possible symptom and failure however the techniques...

Page 112: ...ail Each error message is preceded by an icon that identifies the seriousness of the underlying problem see the table below Icon Severity Level Description Warning A message is displayed in the audit...

Page 113: ...104 DelaySP command must occur within BeginSPSamplePrep EndSPSamplePrep command block Error page 105 Dilution pump driver is over current Abort page 105 Dilution pump home sensor not detected Abort pa...

Page 114: ...offset calibration value is out of range User analog input 4 offset calibration value is out of range Abort page 114 User analog input 1 slope calibration value is out of range User analog input 2 sl...

Page 115: ...strument method that includes an EndSPSamplePrep command does not also include a BeginSPSamplePrep command or If BeginSPSamplePrep is not the first command in the sample preparation command block See...

Page 116: ...p command See Notes on page 92 for more information To troubleshoot 1 Open the instrument method 2 In the Script Editor view add the BeginSPSamplePrep command before the first sample preparation comma...

Page 117: ...roubleshoot Move the command inside the sample preparation command block or Delete the sample preparation command from the method This error may indicate a problem in the dilution pump electronics To...

Page 118: ...SP power again and restart the pump flow 5 If the problem persists contact Technical Support for Dionex products for assistance This is a warning message only The pump continues to function and no act...

Page 119: ...cript Editor view add the BeginSPSamplePrep command before the first sample preparation command This message occurs if the flow rate of the sample stream being monitored by the flow sensor exceeds the...

Page 120: ...for Dionex products for assistance 3 If the problem persists contact Technical Support for Dionex products for assistance This error occurs if the offset value is out of the expected range when the f...

Page 121: ...r 2 wet error occurs when liquid accumulates in the drip tray in the bottom of the AE To troubleshoot 1 Locate the source of the leak by visually inspecting tubing fittings and components in the SP or...

Page 122: ...is not dry it will remain activated and will continue to report a leak to the audit trail 4 If no leak is found check the leak sensor s electrical connection on the main SP electronics board Follow t...

Page 123: ...etect when the pump reaches the home position This can be caused by high pressure in the flow path To troubleshoot 1 Check for a blockage in the pump outlet tubing or in tubing downstream from the pum...

Page 124: ...ly by pressing the SP power switch 4 Turn on the SP power again and restart the pump flow 5 If the problem persists contact Technical Support for Dionex products for assistance The Mixer Stir Bar Auto...

Page 125: ...calibration see Section 10 10 2 If the problem persists contact Technical Support for Dionex products for assistance This error occurs if the instrument method includes a command that specifies a volu...

Page 126: ...ontrol on the ePanel 5 If the problem persists contact Technical Support for Dionex products for assistance This error occurs if the offset value is out of the expected range when the analog input is...

Page 127: ...hnical Support for Dionex products for assistance This error occurs if the dilution vessel heater temperature is above the maximum allowed 120 C To troubleshoot This error may indicate a problem with...

Page 128: ...ce between the two calibration temperature set points is not at least 5 C when calibrating the vessel heater To troubleshoot Make sure the set points are at least 5 C apart and then rerun the calibrat...

Page 129: ...If the problem persists contact Technical Support for Dionex products for assistance This error occurs if the difference between the two calibration temperature set points is not at least 5 C when cal...

Page 130: ...the leak Tighten or if necessary replace the liquid line connection Broken or damaged liquid line Cut the tubing at the break and install a new fitting or If cutting the tubing would make it too short...

Page 131: ...hat the DV SV6 valve is off b Turn on the GAS SV8 valve for 1 to 3 minutes 3 The pressure applied to the dilution vessel may be insufficient to empty it Make sure the high purity gas supply is regulat...

Page 132: ...ure gauge for a drop in pressure Repeat as often as necessary until the leak is found NOTE Do not use Snoop or other dilute soap solutions for leak detection This will contaminate the tubing Water may...

Page 133: ...e power strip inside the AE see Figure 5 3 provides AC outlets for components installed inside an AE or mounted on the side of an AE System component power switch is off Make sure the component s powe...

Page 134: ...entation lectrique et contactez Thermo Fisher Scientific pour obtenir de l aide Wenn der Unterbrecherschalter kontinuierlich ausl st kann es sein da die Schaltung kurzgeschlossen oder berlastet ist En...

Page 135: ...n the fluid system for example crimped tubing can cause excessive system backpressure This in turn may cause leaks or irreparable damage to system components 1 Begin pumping mobile phase through the s...

Page 136: ...idges If new cartridges are not available clean the cartridges currently installed see page 126 To replace the check valve cartridges 1 Turn off the SP power 2 Disconnect the power cord 3 To prevent c...

Page 137: ...pump cannot operate properly unless the check valve cartridges are installed in the housings in the correct orientation Liquid enters the check valve through the large single hole and exits through t...

Page 138: ...ges in a beaker with methanol Sonicate or agitate the parts for several minutes 3 Rinse each check valve housing and cartridge thoroughly with filtered and deionized water 4 Follow Step 7 through Step...

Page 139: ...contamination of pump parts put on a pair of powder free gloves before disassembling the pump head Refer to Figure 10 4 when disassembling and reassembling the pump head To remove the pump head and p...

Page 140: ...spacer off the pump head 2 Remove the backup washer from the spacer using one of the following methods With the backup washer facing up cup the spacer in your hand and blow clean laboratory air at the...

Page 141: ...e new backup seal P N 066163 with the grooved side facing away from the washer Then insert the shaft of the piston through the seal c Insert the piston into the center hole in the spacer d Push the pi...

Page 142: ...eck valve is plugged tightly when inserting the piston If you want install a 10 32 fitting plug P N 042772 on the outlet check valve Add more water make sure the head contains no air bubbles and repea...

Page 143: ...the magnetic follower inside the pump housing 1 Pull the piston partially out of the spacer so that about 1 2 cm 1 4 in of the shaft is exposed This ensures that the magnetic follower picks up the pis...

Page 144: ...ton seal P N 069006 in the dilution pump or the stepper motor loading pump P N 068561 both pumps When replacing a piston always replace the piston seal also 10 6 Replacing the Waste Valve Seal A damag...

Page 145: ...oved side away from the valve Then slide the seal over the end of the valve 6 Insert the valve with the new seal into the pump head opening Turn the knob clockwise and then tighten finger tight 7 Plug...

Page 146: ...access to the main SP electronics board The instructions vary slightly depending on the type of SP enclosure If the SP is an external enclosure 1 Turn off the SP power 2 Disconnect the power cord 3 U...

Page 147: ...The following step requires lifting the SP which weighs 21 kg 46 lb 5 Grasp the SP with both hands and lift it up enough to remove it from the mounting rails on the AE rear panel Then pull the SP str...

Page 148: ...connect each liquid line on the valve to be replaced see Figure 10 10 and remove any fitting plugs installed in the valve ports Figure 10 10 Solenoid Valve SS Valve Shown as an Example 4 Follow the in...

Page 149: ...anel 9 Carefully pull the cable out through the front of the SP 10 Thread the cable from the new solenoid valve P N 068554 through the opening on the SP panel and route the cable to the main SP electr...

Page 150: ...ectors typically SV9 on the main SP electronics board is assigned to control the peristaltic pump rather than a solenoid valve A cable from the peristaltic pump plugs into the main SP electronics boar...

Page 151: ...p the SP align the four hooks on the rear of the SP with the mounting rails on the AE rear panel and hang the SP onto the rails b Replace any modules that were removed from the lower shelf of the AE c...

Page 152: ...speed of the pump delivers the required flow rate see Section 10 9 10 11 Changing the SP or SS Main Power Fuses 1 Turn off the SP or SS power switch 2 Disconnect the power cord 3 If the SP or SS is m...

Page 153: ...e the fuse drawer 5 Pull the fuse drawer out of the rear panel and remove the old fuses 6 Replace the two fuses with new fast blow IEC 127 fuses rated 3 15 A P N 954745 Thermo Fisher Scientific recomm...

Page 154: ...Dionex Integral Systems Operator s Manual 142 Doc 065250 06 03 2020...

Page 155: ...ty 5 to 95 relative humidity noncondensing AE Main Power 100 to 240 Vac 50 60 Hz Auto sensing power supply no manual voltage or frequency adjustment required Typical input power 10 W AE only without o...

Page 156: ...25 in 97 cm 38 in with the LE extension Depth 66 cm 26 in Weight AE Weight 70 kg 155 lbs empty LE Weight 75 kg 166 lbs empty Main Power 100 to 240 Vac 50 60 Hz Auto sensing power supply no manual vol...

Page 157: ...e 15 0 mL min maximum Type Stepper motor Operating Pressure 0 28 to 17 MPa 40 to 2500 psi Flow Rate 3 0 mL min maximum Type Peristaltic Operating Pressure 0 34 MPa 50 psi Flow Rate Dependent on tubing...

Page 158: ...tuated valve Operating Pressure 5 5 MPa 800 psi maximum Capacity 250 mL Operating Pressure 170 to 240 kPa 25 to 35 psi Pressure Relief Valve Opens at 340 kPa 50 psi Capacity 50 mL Operating Temperatur...

Page 159: ...A Specifications Doc 065250 06 03 2020 147 A 4 2 Physical Dimensions Height 53 cm 21 in Width 30 5 cm 12 in Depth 32 cm 12 5 in Weight 34 kg 76 lbs...

Page 160: ...Dionex Integral Systems Operator s Manual 148 Doc 065250 06 03 2020...

Page 161: ...er 069094 Computer Control Installation Kit 068546 Purge Kit AE 068549 Tower Light Kit AE AAA 068548 TTL and Relay Kit AE 068544 Ventilation fan SP SS 070171 Cable analog input 070181 Cable DC voltage...

Page 162: ...p outlet check valve assembly stepper motor 066110 Pump piston stepper motor 069006 Pump seal stepper motor 068572 Thermal Control Board Kit 068573 TTL and Relay Kit SP 069608 USB Extension Kit SS 068...

Page 163: ...068573 SP TTL and Relay Kit Provides a controller board connectors and cables for adding TTL and relay control to the SP AAA 068548 AE TTL and Relay Kit Provides connectors cables and protective hoods...

Page 164: ...Attaching the TTL Relay controller board to the main SP electronics board For a stand alone SP only Installing the TTL Relay panel on the SP and connecting the cables Attach the TTL Relay Controller...

Page 165: ...th the component side facing up and the notched corner on the lower right hand side see Figure C 2 7 Align the two connectors on the back of the TTL Relay controller board with the connectors labeled...

Page 166: ...d to the main SP electronics board If you are installing a stand alone SP go on to the next section To install the AE TTL and Relay Kit go on to Section C 2 To install the AE Tower Light Kit go on to...

Page 167: ...one SP 1 Remove the cover plate from the side of the SP see Figure C 3 2 Orient the TTL Relay panel with the TTL and relay connectors at the bottom of the panel and then install the panel where the co...

Page 168: ...he relay cable into the male connector on the TTL Relay controller board 5 Plug one end of the female to female TTL cable into the female connector on the rear of the TTL Relay panel 6 Plug the other...

Page 169: ...2 2 AE TTL and Relay Kit Installation Procedure These are the main steps in the installation procedure Installing the 25 pin D sub connector inserts female and male in the TTL and relay openings on t...

Page 170: ...the screws that attach the cap to the AE and remove the cap 3 Install either the female relay or male TTL 25 pin D sub connector insert into the empty TTL and relay opening and secure the insert with...

Page 171: ...free end of the relay cable into the male connector insert inside the AE 4 Repeat Step 1 through Step 3 for the female cable and connector 5 Close and secure the SP service door 6 If you previously r...

Page 172: ...Assigning TTL input control types Additional items needed Phillips screwdriver Multiconductor cables see the specifications below or individual 24 AWG or 22 AWG 0 51 mm or 0 65 mm wires NOTE Multicon...

Page 173: ...r installation For example TTL input 1 requires pins 13 and 25 on the TTL connector Relay output 1 requires pins 1 and 14 on the relay connector See Table C 1 for the TTL connector see Table C 2 for t...

Page 174: ...to the board you can connect wires to all of the positions if you want 5 Use a screwdriver to tighten the locking screws on the connectors Function Pin Function Pin Relay 1 NO 1 Relay 1 COM 14 Relay...

Page 175: ...C TTL and Relay Installation Instructions Doc 065250 06 03 2020 163 Figure C 9 TTL Breakout Board Figure C 10 Relay Breakout Board...

Page 176: ...al SP a Plug the breakout boards into their corresponding connectors on the side of the SP see Figure C 12 b Connect the free ends of the wires to the appropriate connector pins on other devices For c...

Page 177: ...as the pin number to which it is connected You will need this information when connecting the cable to other devices b Thread the unconnected end of the cable through the rectangular opening in the A...

Page 178: ...pty cap and tighten the nut i Plug the assembled connector hood into the corresponding TTL or relay connector on the top of the AE see Figure C 15 j Connect the wires from the free end of the cable to...

Page 179: ...iguration Manager 2 Double click the SP icon under the instrument name The Properties dialog box appears 3 Click the TTL Inputs tab 4 Select the name of the input and press the F2 key The Device Confi...

Page 180: ...ion Normal Pulse In normal pulse operation the negative falling edge of the TTL signal is the active edge and the positive rising edge is ignored A pulse width of 50 ms or more is guaranteed to be det...

Page 181: ...f the AE enclosure The kit includes the following parts Additional item needed Phillips screwdriver C 4 2 AE Tower Light Kit Installation Procedure These are the main steps in the installation procedu...

Page 182: ...opening in the front left corner of the AE see Figure C 16 3 On the inside of the AE slide the ring back onto the tower light and tighten the ring to secure the tower light to the top of the AE see F...

Page 183: ...ee Section 10 7 4 Plug the other end of the extension cable into the relay connector on the TTL Relay controller board on the SP service door see Figure C 18 5 Close and secure the SP service door 6 I...

Page 184: ...065250 06 03 2020 b Replace any modules that were removed from the lower shelf of the AE c Replace the two access panels on the exterior of the AE 7 Plug in the power cord and turn on the power For AE...

Page 185: ...f gas regulated to between 0 41 MPa and 0 79 MPa 60 psi and 115 psi The gas purity should be appropriate for the application Tubing and fittings for the gas connection Use tubing with the following mi...

Page 186: ...nclosures D 2 1 Installing the Purge Control Unit 1 Turn off the power 2 Disconnect the power cord 3 On the top of the AE remove the cover plate on the left front corner 4 With the alarm indicator bal...

Page 187: ...the fitting see Figure D 2 8 On the inside of the AE thread the red and black wires of the purge control cable through the gray fitting nut see Figure D 3 and out to the top of the AE Figure D 2 AE In...

Page 188: ...lack box by removing two Phillips screws see Figure D 4 10 Thread the purge control cable through the fitting on the cover of the black box see Figure D 5 Figure D 4 Remove Cover on Purge Control Unit...

Page 189: ...ctors on the black box Plug the black wire into the middle connector and the red wire into the outside connector see Figure D 6 12 Reinstall the cover on the purge control unit black box see Figure D...

Page 190: ...r from the left see Figure D 8 To do so squeeze the front of the jumper and pull down Figure D 8 AE Interior Remove Jumper NOTE Save the jumper it must be reinstalled if the purge control cable is not...

Page 191: ...e to its mounting panel see Figure D 10 View B 4 Remove the cover plates from any two small rectangular openings on the AE LE or SP enclosure The available locations depend on the configuration of enc...

Page 192: ...0 Figure D 11 the purge orifice spark arrestor and relief valve are installed on the right side of an LE Figure D 11 Purge Orifice Spark Arrestor and Relief Valve Installed on Right Side of LE Example...

Page 193: ...the AE Purge Kit Install the included gaskets to ensure airtight seals On the top of the AE install screws with seals in the open screw holes see Figure D 12 and install a gray fitting in the larger r...

Page 194: ...If an SP is installed insert a plug in the drain inside the SP see Figure D 13 If the AE is mounted on the wall install a plug in the drain under the AE see Figure D 14 Figure D 13 Plug in SP Drain F...

Page 195: ...ation Procedure These are the main steps in the installation procedure Installing the pump on the SP panel Connecting the pump cable Assembling the peristaltic tubing and fittings Installing the peris...

Page 196: ...de the body of the pump through the opening on the SP panel Attach the pump mounting panel to the SP panel as shown in Figure E 1 E 2 2 Connecting the Pump Cable 1 Plug the pump cable into the connect...

Page 197: ...See Figure E 2 and Figure E 3 for the locations of SV10 and SV09 Figure E 2 SP Vertical Enclosure Service Door Open Figure E 3 SP Horizontal Enclosure Service Door Open Position SV10 Use for second p...

Page 198: ...inside diameter that is closest in size to the outside diameter of the tubing 2 Push the point of the adapter body into the tubing until the tubing is flush with the adapter body see Figure E 4 3 Sli...

Page 199: ...7 Wrap the tubing loosely around the pump head rollers see Figure E 5 allowing the ends to extend approximately equally from the pump 8 Push down on the top tubing clip to open it insert the tubing in...

Page 200: ...ing clamp by pushing it to the left until the tabs lock into place see Figure E 7 11 Close the pump door making sure that both tabs are outside the door see Figure E 8 12 Connect plumbing lines to the...

Page 201: ...r of the AE 14 Plug in the power cord and turn on the power E 2 4 Configuring the Pump in Chromeleon 7 1 Start the Chromeleon 7 Instrument Configuration Manager 2 Double click the SP icon under the in...

Page 202: ...Dionex Integral Systems Operator s Manual 190 Doc 065250 06 03 2020...

Page 203: ...vel Sensor Installation Procedure These are the main steps in the installation procedure Attaching the liquid level sensor to the reservoir or NOWPak Bag in a Bottle container Plugging the liquid leve...

Page 204: ...abel was removed see Figure F 2 Figure F 2 Sensor with Dual Lock Tape 3 Wrap the appropriate cinch strap around the reservoir or NOWPak Bag in a Bottle container and loosely secure it Then slide the c...

Page 205: ...the reservoir or NOWPak Bag in a Bottle container Figure F 4 Sensor Installed on Reservoir F 2 2 Plugging the Liquid Level Sensor Cable into the Main SP Electronics Board 1 Turn off the SP power 2 Dis...

Page 206: ...rom the lower shelf of the AE c Replace the two access panels on the exterior of the AE 9 Plug in the power cord and turn on the power 10 Open the Chromeleon 7 Instrument Configuration Manager and ope...

Page 207: ...068572 provides the parts necessary for adding a thermal control board to the main SP electronics board The kit includes the following parts Part Number Option Description 068572 Thermal Control Boar...

Page 208: ...l control board with the component side facing up 6 Align the connector on the back of the thermal control board with the corresponding connector near the lower right corner of the main SP electronics...

Page 209: ...thermal control board see Figure G 3 Figure G 2 Main SP Electronics Board Thermal Control Board Installed Vertical SP Enclosure Shown Figure G 3 Main SP Electronics Board Thermal Control Power Supply...

Page 210: ...cedure install the Thermal Control Board Kit see Section G 1 G 2 1 Overview These are the main steps in the installation procedure for the vial cooler P N 068566 Installing the vial cooler on the SP p...

Page 211: ...nnector on the thermal control board G 3 Installing the Heated Dilution Vessel NOTE Before starting this procedure install the Thermal Control Board Kit see Section G 1 G 3 1 Overview These are the ma...

Page 212: ...ed dilution vessel assembly onto the holder see Figure G 6 Figure G 5 Heated Dilution Vessel 4 Plug the cable from the heated dilution vessel assembly into the connector on the SP panel 5 Connect the...

Page 213: ...G Thermal Options Installation Instructions Doc 065250 06 03 2020 201 6 Connect the liquid line from the DV valve to the bottom of the heated dilution vessel...

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Page 215: ...r Hubbell HLD2 lockout device For more information refer to the Hubbell website H 1 Lockout Device Installation Procedure H 1 1 Getting Ready 1 Notify all affected persons of the intended lockout 2 Tu...

Page 216: ...Dionex Integral Systems Operator s Manual 204 Doc 065250 06 03 2020 Figure H 2 SP SS Power Switch Figure H 3 AE Power Switch Power Switch Power Switch...

Page 217: ...or into the device see Figure H 4 2 Close the lockout device and slide the cover so that the padlock holes are lined up between the cover and the base see Figure H 5 View A 3 Insert a padlock see Figu...

Page 218: ...gure H 6 Lock the padlock and remove the keys H 1 3 Re energizing a Module 1 Unlock the padlock on the lockout device and remove the padlock 2 Open the lockout device and remove the power connector 3...

Page 219: ...cess panels 135 Shelves 70 Tower Light Kit 169 Tower lights 78 TTL and relay connectors 75 AE Relay and TTL Kit 48 Installation instructions 157 159 Air conditioner AE 76 Specifications 146 Air consum...

Page 220: ...lacement procedure 124 126 Check valves Replacement procedure 126 Chromatography systems supported 4 Chromeleon 7 Process Analyzer software 1 4 Audit trail error messages 100 109 111 113 117 Configuri...

Page 221: ...83 Liquid level sensor 50 Pressure requirements 82 PTFE liner 149 PTFE liner replacement 81 EMC compliance 12 Emergency Off switch 68 Environmental specifications Gas pressure 143 Humidity 143 Operat...

Page 222: ...cooler temperature 29 Instrument methods 26 Sample preparation commands 92 Integral Process Analytical Systems Calibration at initial startup 88 CE mark 12 Chromatography systems supported 4 Componen...

Page 223: ...e 24 Calibrating the loop 88 Flow schematic 24 Functions 25 31 35 PEEK valve 24 Stainless steel valve 24 Types 24 Mixer for dilution vessel 25 Mixer Stir Bar Auto Recovery option 26 112 Mobile phase c...

Page 224: ...valve Seal replacement procedure 132 Pumps Check valve cartridge replacement procedure 124 126 Check valve replacement procedure 124 Dilution pump 26 Leaking 120 Loading pumps 27 Piston replacement p...

Page 225: ...er program 91 Chromeleon 7 Processs Analyzer 91 Shutdown long term 94 Shutdown short term 93 Site requirements 85 Snoop leak detector solution 120 Solenoid valves 28 Flow schematic 28 Functions perfor...

Page 226: ...utine 92 Stepper motor pump See Dilution pump See Loading pump stepper motor type Stir bar 25 Stream selection valve 61 PEEK valve 61 150 Port connections 61 62 Stainless steel valve 61 150 Suppressor...

Page 227: ...ves See Gas valve See Metering rotary valve See Solenoid valve See Stream selection valve Vessel heater 26 Installation instructions 199 200 Vial cooler 29 Installation instructions 198 199 Volume Dil...

Page 228: ...Dionex Integral Systems Operator s Manual Index 10 Doc 065250 06 03 2020...

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