Binary Solvent Delivery Module Dual Series-III Pumps with Serial PC and Voltage Control Operator's Manual 90-2581 rev B Scientific Systems, Inc. 349 N.
1. INTRODUCTION This operator's manual contains information needed to install, operate, and perform minor maintenance on the Binary Solvent Delivery Module. The figures below are for reference of items described in the manual. Power Switch “T” With Outlet Left Drawer Right Drawer Control Keypads Prime Purge Valves Outlet Filters Cooling Fan Power Entry RS-232 Serial Ports Auxiliary I/O Voltage Control, etc.
1.1 Description of the Binary Solvent Delivery Module The system consists of two Series III high performance metering pumps, in a compact package with pulse dampener and an off-line pressure transducer. The pumps use a drawer system for easy access to internal components for troubleshooting & service.
Flow adjustment in 0.01 ml increments, from 0.01 to 10.00 ml/min with a precision of 0.2% RSD (10mL/min heads) • Microprocessor advanced control • Digital stepper motor design to prevent flow rate drift over time and temperature • Back panel RS232 serial communications port for complete control and status monitoring • Remote analog inputs (e.g. voltage) to control flow rate 1.1.2 Wetted Pump Materials Pump heads, check valve bodies, and tubing are made out Stainless Steel or PEEK™.
1.1.4 Self-Flush and Seal Life It is recommended that the Self Flush feature be used to improve seal life in a number of applications. In particular, (as stated above) if pumping Buffers, Acids/Bases or any inorganic solution near saturation, the pump should utilize the Self Flush feature. With every piston stroke, an extremely thin film of solution is pulled back past the seal.
1.2 Specifications for the Binary Solvent Delivery Modules Flow Rates ............ 0.000 to 5.000 mL/min for 5mL/min heads 0.00 to 10.00 mL/min for 10mL/min heads Pressure ................ 0 to 6,000 p.s.i. for SS pump heads, 0 to 5,000 p.s.i. for PEEK™ heads, Pressure Accuracy… .± 1% of full-scale pressure Pressure Zero Offset. .± 2 p.s.i. Flow Accuracy ........ ± 2% for a flow rate of 0.20 mL/min and above. Flow Precision ....... 0.2% RSD Dimensions ............ 9" high x 10.5" wide x 18.5" deep Weight .
2. INSTALLATION 2.1 Unpacking and Inspection Prior to opening the shipping container, inspect it for damage or evidence of mishandling. If it has been damaged or mishandled, notify the carrier before opening the container. Once the container is opened, inspect the contents for damage. Any damage should be reported to the carrier immediately. Save the shipping container. Check the contents against the packing list. 2.
SELF-FLUSH PUMP Connect wash solution inlet and outlet tubing (opaque) to the flush housing as shown. Make sure ferrule is in the correct position. Connect pump inlet tubing as shown. Make sure ferrule is in the correct position. Screw syringe on luer fitting. Insert wash outlet tubing end into clear adapter. Ensure inlet line filter is submersed into solvent. Attach syringe to Prime-Purge valve. Open Prime-Purge valve by turning knob counterclockwise two turns. Draw syringe back to prime.
2.4 Electrical Connection The system utilizes Universal Switching Power Supply, and will accept voltages from 90 – 260 VAC, 50-60 Hz. WARNING: Do not bypass the safety ground connection as a serious shock hazard could result. 2.5 Solvent Preparation Proper solvent preparation will prevent a great number of pumping problems. The most common problem is bubble formation, which may affect the flow rate consistency.
2.5.2 Cavitation Cavitation occurs when inlet conditions restrict the flow of solvent and vapor bubbles are formed during the inlet stroke. The key to preventing cavitation is to reduce inlet restrictions. The most common causes of inlet restrictions are crimped inlet lines and plugged inlet filters. Inlet lines with tubing longer than 48" (120 cm) or with tubing of less than 0.085" (2 mm) ID may also cause cavitation. Placing the solvent reservoirs below the pump level also promotes cavitation.
2.6.2 Self-Flush Solution Self-flush heads require 250-500 mL of flushing solution. See section 1.1.4 for self-flush solution recommendations. A pH indicator that will indicate the concentration of salts in the solution is recommended as a reminder to change the solution. This flush solution should be replaced with a fresh solution weekly to avoid frequent pump maintenance. 2.6.3 Inlet Tubing and Filters The table below shows the inlet tubing and filter used in the Binary Solvent Delivery Module.
2.7 Preparation for Storage or Shipping 2.7.1 Isopropanol Flush Disconnect the outlet tubing from the pump. Place the inlet filter in isopropanol. Use a syringe to draw a minimum of 50 ml through the pump. Pump a minimum of 5 ml of isopropanol to exit. Leave the inlet tubing connected to the pump. Place the inlet filter in a small plastic bag and attach it to the tubing with a rubber band.
3. OPERATION 3.1 Pump Front Panel Controls and Indicators 3.1.1 Control Panel 3.1.1.1 Digital Display The 3-digit display shows the pump flow rate (mL/min), system pressure (psi), or the set upper or lower pressure limit (psi) when operating. Choice of display is selected with the MODE key. 3.1.1.2 Digital Display Pump Keypad ∆ When pressed, this button increases the flow rate. ∇ When pressed, this button decreases the flow rate.
3.1.1.3 Status LEDs Q ml/min When lit, the digital display shows flow rate in mL/min. Q PSI When lit, the digital display shows system pressure in psi. Q HI PR When lit, the display shows the user-set upper pressure limit in psi. Q LO PR When lit, the display shows the user-set lower pressure limit in psi. Q RUN Lights to indicate that the pump is running. Q FAULT Lights when a fault occurs and stops the pump. 3.1.1.
Align Refill Switch Mode: The signal that initiates the refill phase can be displayed during power-up by pressing and holding the PRIME and the UP-ARROW buttons when the power is switched on. Release the buttons when the display displays "rFL". When the slotted disk allows the light beam to pass from the emitter to the detector on the slotted optical switch a pulse will be generated which signals the beginning of refill.
4. THEORY OF OPERATION 4.1 Pump Mechanical Operation 4.1.1 Liquid System Flow Path The flow path of the Binary Solvent Delivery Module starts at the inlet reservoir filter passes through the inlet check valve, then through the pump head, and finally exits through the outlet check valve. 4.1.2 Pump Cycle The pump cycle consists of two phases, the pumping phase, when fluid is metered out of the pump at high pressure, and the refill phase, when fluid is rapidly drawn into the pump.
4.2 Electronic Control 4.2.1 Microprocessor Control The pump is controlled by hybrid microprocessor circuitry which (1) provides control signals to the motor drive circuitry, (2) interfaces with the keyboard/display, (3) receives signals from the refill flag, and (4) provides external input/output (RS-232) interfacing. Firmware programming is stored in an EPROM. An eccentric cam provides refill in a fraction of the full cam cycle.
Motor Stall Detector press the DOWN-ARROW button and the display will display "OFF". To exit this mode and store the current setting in non-volatile memory, press the RUN/STOP button. The Motor Stall Detector uses a timer to determine if the camshaft has stopped turning or if the refill switch is defective. The timer begins timing after the pump accelerates or decelerates to its set point flow rate.
5. MAINTENANCE Cleaning and minor repairs of the Binary pump can be performed as outlined below. NOTE: Lower than normal pressure, pressure variations, or leaks in the pumping system can all indicate possible problems with the piston seal, piston, or check valves. Piston seal replacement could be necessary after 1,000 hours of running time. See Section 5.2.3. 5.1 Filter Replacement 5.1.1 Inlet Filters Inlet filters should be checked periodically to ensure that they are clean and not restricting flow.
CAUTION: Check that the Allen nuts at the front of the pump head are secure before removing any tubing from the pump head. 3. Remove the inlet line from the inlet check valve. 4. Remove the outlet line from the outlet check valve. 5. Remove inlet and outlet self-flush check valves. 6. Momentarily turn ON the Binary pump and quickly turn OFF the power upon hearing the refill stroke. This reduces the extension of the piston and decreases the possibility of piston breakage. 7. Unplug the power cord. 8.
OUTLET FLUSHING CHECK VALVE OUTLET CHECK VALVE O-RING PISTON SEAL BACKUP PLATE SELF-FLUSH SEAL PUMP HEAD SELF-FLUSH HOUSING INLET FLUSHING CHECK VALVE SEAL BACKUP WASHER SEAL INLET CHECK VALVE Figure 5-1. Stainless Steel Self-Flushing Pump Head Assembly HOLE PLUG OUTLET CHECK VALVE PISTON SEAL BACKUP PLATE NON-FLUSH GUIDE BUSHING PUMP HEAD SELF-FLUSH HOUSING O-RING SEAL BACKUP WASHER SEAL INLET CHECK VALVE Figure 5-2.
OUTLET FLUSHING CHECK VALVE OUTLET CHECK VALVE O-RING PISTON SEAL BACKUP PLATE PUMP HEAD SELF-FLUSH SEAL SELF FLUSH HOUSING INLET FLUSHING CHECK VALVE SEAL BACKUP WASHER SEAL INLET CHECK VALVE Figure 5-3. Bioclean (PEEK™) Self-Flushing Pump Head Assembly HOLE PLUG OUTLET CHECK VALVE PISTON SEAL BACKUP PLATE NON-FLUSH GUIDE BUSHING PUMP HEAD SELF-FLUSH HOUSING O-RING SEAL BACKUP WASHER SEAL INLET CHECK VALVE Figure 5-4.
5.2.2 Cleaning the Pump Head Assembly NOTE: If you choose to remove the piston seal or self-flush seals, you should have a new set on hand to install after cleaning. It is not recommended that you reinstall used piston or self-flush seals since they are likely to be scratched and damaged during removal and would not provide a reliable seal if reused.
3. If the check valves have been removed, tighten the check valves on stainless steel pumps to 75 inch-pounds or enough to seal at maximum pressure. Do not exceed maximum torque. For Bioclean (PEEK™) pumps, tighten each check valve firmly by hand. Do not go ¼ turn past finger tight. NOTE: The inlet check valve has a larger opening (1/4"-28, flat-bottom seat) for the 1/8" inlet tubing; the outlet check valve has a smaller opening (#10-32, cone seat) for the 1/16" outlet tubing.
RING SINGLE INLET HOLE OW FL OW FL INLET CHECK VALVE (SS) INLET CHECK VALVE (PEEK) MULTIPLE OUTLET HOLES OW FL OW FL RING OUTLET CHECK VALVE (PEEK) OUTLET CHECK VALVE (SS) OW FL OUTLET SELF-FLUSH CHECK VALVE TRANSPARENT WASHER OW FL INLET SELF-FLUSH CHECK VALVE CROSS BALL RETAINER Figure 5-5. Check Valves 5.2.3 Replacing Piston Seals Lower than normal pressure, pressure variations, and leaks in the pumping system can all indicate possible problems with the piston seal.
5.2.3.1 Removing the Seals 1. Remove the pump head as described in Section 5.2.1. Use caution so as not to damage the sapphire piston. 2. Insert the flanged end of the seal insertion/removal tool into the seal cavity on the pump head. Tilt it slightly so that flange is under the seal and pull out the seal. CAUTION: Using any other “tool” will scratch the finish. 3. Repeat the procedure for the low-pressure seal in the flush housing. 4.
2. Place a self-flush replacement seal on the seal insertion/removal tool so that the spring in the seal is visible when the seal is on the tool. As in the previous step, insert the tool and seal into the seal cavity on the flushing housing, taking care to line up the seal with the cavity, and then withdraw the tool. When the seal is fully inserted only the polymer part of the seal will be visible in the seal cavity. 3. Place seal back-up washer over the high-pressure seal.
5.2.5 Replacing the Pump Head CAUTION: The sapphire piston is fragile. Twisting the pump head during replacement can cause the piston to break. Closely follow instructions during head removal and replacement to avoid breakage. 1. Make sure that the inlet valve is on the bottom and the outlet valve is on the top. Carefully align the self-flush housing and gently slide it into place on the pump. If misalignment with the piston occurs, gently push up on the piston holder. 2.
5.4 Check Valve Cleaning and Replacement Many check valve problems are the result of small particles interfering with the operation of the check valve. As a result, most problems can be solved by pumping a strong solution of liquid, laboratory grade detergent through the check valves at a rate of 1 mL/min for one hour. After washing with detergent, pump distilled water through the pump for fifteen minutes. Always direct the output directly to a waste beaker during cleaning.
rebuilt. Do not attempt to refill or refurbish the pulse damper until you have a refurbishing kit. Instructions are furnished with the kit. 5.5.3 Pulse Damper Installation 1. Position the pulse damper, aligning it with the four mounting holes in the bottom of the cabinet. The pressure transducer should be pointed toward the rear of the cabinet. 2. From the underside of the pump cabinet, tighten the four screws to hold the pulse damper in place. 3.
10. If storing the pump for more than 12 hours fill each pump head with 100% isopropanol then seal the inlets and outlet with the supplied plugs. 5.7 Lubrication The Binary pump has modest lubrication requirements. The bearings in the pump housing and piston carrier are permanently lubricated and require no maintenance. A small dab of light grease such as Lubriplate 630-AA on the cam is the only recommended lubrication.
The Pump mechanism, Control Boards, & Pulse Dampener (with Pressure Transducer) are accessible by removing pump drawer.
5.9 Fuse Replacement Three fuses protect the Binary Solvent Delivery Module. Two of the fuses are located in the power entry module at the rear of the cabinet and are in series with the AC input line. The other fuse is located on the circuit board and is in series with the 24 VDC supply. Troubleshooting the fuses is straightforward. If the power cord is plugged in and the on/off power entry switch is on and the display does not light, check the two fuses in the power entry module.
5.10 Battery Replacement (If applicable) See attached photo for battery option. Depending on the version of drive board assembly installed, the board may not have a battery. If the printed circuit board does not have a battery, it is designed with circuitry that does not require a battery backup and you should disregard the following instructions. The battery provides power for the memory that holds the current pump configuration.
6. PROBLEM SOLVING Quick Guide to Problem Solving You Notice This May Mean Possible Cause You Should 1. Uneven pressure trace. 2. Pressure drops. 3. No flow out the outlet check valve. 1. Bubble in check valve. 2. Leaks in system. 3. Dirty check valve. 4. Bad check valve. 1. Solvent not properly degassed. 2. Fittings are not tight. 3. Mobile phase not properly filtered. 4. Particles from worn piston seal caught in check valve. 5. Plugged inlet filter. 1.
7.
BINARY, PEEK 880201 880202 880203 880204 880408 880721 880652 880353 880354 880414 880511 880124 880806 Seal Kit, Aqueous, 5mL Seal Kit, Organic, 5mL Seal Kit, Aqueous, 10mL Seal Kit, Organic, 10mL Check Valve Kit - PEEK Replacement Inlet Filter Elements (Package of 2) Prime Purge Valve Rebuild Kit - PEEK Series II-IV, Binary Piston, 5mL Series II-IV, Binary Piston, 10mL Self-Flush Check Valve Kit Binary Drive Assembly Front Panel Assembly Fuse, 2 Amp, 5x20 mm (10 pack) Specific to Left Hand Pump Drawer
APPENDIX A A.1 Rear Panel Serial Communications Port - Pump An RS-232C modular jack is provided on the back panel. A computer, with appropriate software, can be used as a remote controlling device for pump operation via this connection. A.1.1 Hardware Implementation The REMOTE INPUT serial communications port is configured for 9600 baud, 8 data bits, 1 stop bit, and no parity. The connector is a standard RJ-11 modular telephone type jack.
output is at a low logic level. A low logic level is -3.0 to -15 volts and a high logic level is 3.0 to 15 volts. A.1.3 Command Interpreter The pump’s high-level command interpreter receives and responds to command packets. The pump will not send a message except when prompted, and it will send a response to every valid command as described below. The response to an invalid command is “Er/”. Each command is characterized by a unique two-letter command code, and only one command can be issued per line.
CS OK,x.xx,y,z,PSI,w,v,u/ (x.xxx, xx.xx, or xxx.x) (y, yy, yyy, or yyyy) (z, zz, zzz, or zzzz) ID UPxxxx OK,vx.xx SR3O firmware/ OK/ LPxxxx OK/ SF OK/ RF OK,x,y,z/ KD OK/ KE PCxx OK/ OK/ RC HTx OK,x/ (x or xx) OK/ RH OK,x/ Reads the current pump setup, where: x.xxx, xx.xx, or xxx.
PI OK,a.aa,b,c,d,e,f,g,h,i,j,k,l, m,n,o,p,q/ (a.aaa, a.aa, aa.aa, or aa.a) (c or cc) RE A.2 OK/ Reads the current pump setup, where: a.aaa, a.aa, aa.aa, or aa.
the EVENT 1 terminal and the EVENT 2 and EVENT 3 terminals is affected. EVENT 2 is Normally Closed (connected to EVENT 1) until a fault occurs and then opens. EVENT 3 is Normally Open (not connected to EVENT 1) until a fault occurs and then closes. A.2.1.1 Upper and Lower Pressure Limit Range (pump A only) The pressure sensing transducer provides accurate, wide range pressure monitoring. Because of the sensitivity of the transducer, the zero reading may shift up to 0.
Pin 10 9 8 7 6 5 4 3 2 1 Function VOLTAGE COM VOLTAGE IN FREQ IN ENABLE IN PUMP-RUN PUMP-STOP No connection No connection No connection COM A.2.3 General Information on Run, Stop, and Enable Inputs The PUMP-RUN, PUMP-STOP, and ENABLE IN inputs operate from an internal 5 VDC source and each one draws approximately 0.008 amps when connected to COM. To activate either the PUMPRUN, PUMP-STOP, or ENABLE IN input connect it to COM. Any device capable of switching 0.
A.2.4 Enable Input When activated (ENABLE IN is at a low logic level), the ENABLE IN input disables flowrate control on the front panel and enables flowrate control on the back panel. A.2.5 General Information on Voltage and Frequency Inputs Special programming and circuitry allows this pump to be operated remotely with the flowrate controlled by voltage or frequency inputs. To select the remote mode of operation: a.
APPENDIX B EZ GRIP FITTING GUIDE A-8
Scientific Systems Inc. Warranty Statement Scientific Systems, Inc. (SSI) warrants that instruments or equipment manufactured by it for a period thirty-six (36) months from date of shipment to customer, against defects in materials and workmanship under normal installation, use and maintenance. Expendable items and physical damage caused by improper handling or damage caused by spillage or exposure to any corrosive environment are excluded from this warranty.
IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
