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Table of Contents
Related Manuals for Jasco PU-1580
Summary of Contents for Jasco PU-1580
- Page 1 MODEL PU-1580 INTELLIGENT HPLC PUMP MAINTENANCE MANUAL P/N 0302-0390B...
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Page 2: Safety Considerations
Safety Considerations To ensure operation safety, this instrument must be operated correctly and maintained regularly according to schedule. Carefully read to fully understand all safety precautions in this manual before operating the instrument. This manual denotes precautions against actions that can result in hazardous situations or equipment damage by using the signal words WARNING, CAUTION, and Note. - Page 3 If a warning label peels off the instrument or becomes illegible, contact your local JASCO distributor (See list on the back cover of this manual) for a replacement label. Be sure to indicate the part number (P/N) on the label.
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Page 4: Preface
When not using the instrument, keep this manual stored in a safe place. Should this instruction manual be lost, order a replacement from your local JASCO distributor. The manuals for this instrument consist of an operations manual and a maintenance... -
Page 5: Installation Conditions
Installation Conditions To ensure safe operation, the following recommendations should be observed: Do not operate the instrument under voltage fluctuations exceeding 10% of the recommended line voltage. Large fluctuations may cause the instrument to fail. Use a three-pronged electrical outlet with a ground. When only a two- pronged socket is available, use an adapter and be sure to connect the ground wire of the adapter. -
Page 6: Maintenance
Copying of software or related materials for purposes other than backup is prohibited. Transfer or authorization of the use of Jasco software to or by a third party is prohibited. Disclosure of confidential information related to Jasco software is prohibited. -
Page 7: Warranty
This product is warranted for a period of one year from the date of delivery. If any defects should occur in the product during this period of warranty, JASCO will repair or replace the defective part(s) or product free of charge. -
Page 8: Table Of Contents
Table of Contents Page Safety Considerations ................i Preface....................iii Installation Conditions ................iv Maintenance ..................v Warranty ....................vi Table of Contents................vii Error Messages ................1 1.1 Errors during the self-diagnostic test when power is turned on....1 1.1.1 ROM, RAM, and DC power errors ............1 1.1.2 Back-up errors .................. - Page 9 2.4.6 Inlet tube fitting leaks................16 Pump Inspection and Calibration ..........17 3.1 Pressure tests (pressure ramp and holding tests) ........17 3.1.1 Preparation ..................... 17 3.1.2 Pressure Test 1 (pressure ramp test) ............. 17 3.1.3 Pressure Test 2 (pressure holding test)..........18 3.2 Adjustment of Zero Pressure..............
- Page 10 5.5 Replacement of the plunger washing mechanism diaphragm ....43 5.5.1 Preparations for diaphragm replacement ..........43 5.5.2 Exposing the diaphragm ................. 44 5.5.3 Diaphragm replacement ................. 45 5.5.4 Assembly of the head mount flange and other units....... 45 5.5.5 Post-replacement verification ..............46 5.6 Purge valve needle and purge valve packing replacement......
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Page 11: Error Messages
1 Error Messages 1.1 Errors during the self-diagnostic test when power is turned on The PU-1580 automatically checks the following items when the power is turned on: ROM (Memory) RAM (Memory) C-MOS RAM (Memory backed up by battery) DC power (Direct current power supply) -
Page 12: Pump Sensor Errors
JASCO distributor. 1.2 Errors during operation Table 1 lists the problems that can be detected by the PU-1580 during operation. When a problem is detected, a message will appear on the LCD. Press [CLEAR] to return to the monitor screen. -
Page 13: Errors Due To Exceedingly High Pressure
1.2.1 Errors due to exceedingly high pressure If the operating pressure exceeds the maximum pressure (P.MAX) setting, a TROUBLE OVER PRESS error message will appear on the display. If the operating pressure is within an appropriate range, increase the maximum pressure (P.MAX) setting. -
Page 14: Troubleshooting
This chapter describes likely causes for problems that might occur while using the PU-1580. Refer to Fig. 2.1 for a list of part names used in this chapter. The descriptions presented in this chapter are primarily concerned with pump problems and how to deal with these problems. -
Page 15: Large Variations In Operating Pressure
Table 2.2 Dealing with TROUBLE UNDER PRESS errors Cause Confirmation What to Do Method Pump head contains air Open the purge valve and bubbles remove the air bubbles (See Section 4.1) Inlet filter is clogged (use of Check for Replace the inlet filter buffer solutions often leads clogging to clogging) - Page 16 Table 2.3 Dealing with Large Pressure Variations Cause Confirmation What to Do Method Pump head contains Open the purge valve and remove air bubbles the air bubbles (See Section 4.1) Inlet filter is clogged See Section 5.3.1 Replace the inlet filter if clogged (use of buffer solutions often leads to clogging)
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Page 17: Baseline Problems
Inlet tube Check valve assembly (OUT) Head mount flange Drain pipe Pump heads Inlet filter Left side: Delivery head Right side: Modifier head Solvent selection valve knob Purge valve knob Outlet port (line filter inside) (or "knob") Check valve assembly (IN) Head mount flange Pump head Outlet port... -
Page 18: High Baseline Noise
2.2.1 High baseline noise Table 2.4 lists potential causes, confirmation methods, and methods for solving problems that may arise due to high baseline noise. Table 2.4 Dealing with High Baseline Noise Cause Confirmation What to Do Method Variations in pump pressure Stop solvent delivery. -
Page 19: Large Baseline Drift
2.2.3 Large baseline drift Table 2.6 lists potential causes, confirmation methods, and methods for dealing with large baseline drift. Table 2.6 Dealing with Large Baseline Drift Cause Confirmation Method What to Do Insufficient solvent Does the drift level decrease with Wait (increase the replacement time? -
Page 20: Appearance Of Ghost Peaks
Table 2.7 Dealing with Periodic Baseline Drift Cause Confirmation Method What to Do Variations in ambient Is a breeze from the air Protect the column temperature conditioner striking a using thermal column or detector? insulation or a windbreak 2.2.5 Appearance of ghost peaks Table 2.8 lists potential causes, confirmation methods, and methods for dealing with ghost peaks. -
Page 21: Poor Reproducibility For Retention Time
Table 2.10 lists potential causes, confirmation methods, and methods for dealing with shortening retention times. Table 2.10 Dealing with Shortening Retention Times Cause Confirmation Method What to Do Column deterioration Replace the column Variation in ambient Is a breeze from the air Protect the column temperature conditioner striking the... -
Page 22: Plunger Seal Leaks
Note: A careful daily check for leaks in the pump section, autosampler, detector, and other system components is recommended, even if the operating pressure and chromatograms appear normal. Early discovery and remedy of leaks minimizes the time and cost of maintenance and reduces the damage to the instrument. -
Page 23: Check Valve Assembly Leaks
first, remove the solvent selection valve and the purge valve, and then tighten the pump head. Evenly tighten the two screws used to secure the pump head so that an even gap is maintained between the pump head and the head mount flange (See Fig. 5.11). If the screws have not been tightened evenly, loosen them and then re-tighten them properly. -
Page 24: Purge Valve Leaks
tightness the screws securing the pump head (in other words, over-loosen the screws and then tighten them to their previous tightness). (2) When turning the wrench, be sure to hold the pump so that it doesn’t move. (3) Do not use a wrench having a handle longer than 20 cm, as doing so may cause excessive torque to be applied to the check valve assembly, causing the threads to become stripped. -
Page 25: Outlet Port (Line Filter) Leaks
Table 2.12 Dealing with Purge Valve Leaks Type of Leak What to Do Leak from the drain pipe Firmly tighten the purge valve knob when the purge valve is If the leak persists, replace the purge valve needle closed (See Section 5.6.1) Leak from the base of the Check for drain tube clogging purge valve knob when the... -
Page 26: Bottom Panel Drain Port Leaks
Note: Since loosening the tubing connected to the outlet port may inadvertently loosen the line filter, when disconnecting the tubing to the outlet port, use a wrench to stop the outlet port from turning. 2.4.5 Bottom panel drain port leaks Table 2.13 lists potential causes and methods for dealing with leaks from the bottom panel drain port. -
Page 27: Pump Inspection And Calibration
3 Pump Inspection and Calibration 3.1 Pressure tests (pressure ramp and holding tests) Although the final test of pump operations involves checking the chromatogram (baseline) when the injector, column, detector, and other units are connected, the tests described in this section are simple and can be performed using the only pump. Be sure to perform the tests described in this section after replacing pump parts (for example, the plunger seal or purge valve needle). -
Page 28: Pressure Test 2 (Pressure Holding Test)
Male plug Figure 3.1 Pressure Test 3.1.3 Pressure Test 2 (pressure holding test) (1) Screw a male plug into the outlet port and tighten firmly using a wrench. (2) Tighten the purge valve firmly. (3) Set the flow rate to 0.5 ml/min and the maximum pressure to 50.0 MPa. (4) Begin solvent delivery. -
Page 29: Flow Rate Calibration
PRESS ZERO ADJ trimmer, refer to Fig. 3.2 and follow the procedure described in Fig. 3.3. RS‑232C "PRESS. ZERO ADJ." trimmer PRESS. ZERO ADJ. FUSE 100‑120V T2.5A EVENT 220‑240V T1.6A FUSE 警告 U S E U S E VALVE 火災の危険に対する 保護のため、定格の ヒューズを使用すること。... -
Page 30: Input Method For The Flow Rate Calibration Value
(2) The flow rates of multiple pumps must be accurately matched. (3) The flow rate calibration value is unknown. For example, when a BACK UP ERROR occurs due to depletion of the backup battery. 3.3.2 Input method for the flow rate calibration value The input method for the flow rate calibration value is described below. -
Page 31: Flow Rate Calibration: Step 2 (With Back Pressure)
Refer to Fig. 3.4 Enter the temporary flow rate calibration values Note: Enter temporary values for the settings when the flow rate compensation value is unknown. Measure the flow rate Use a volumetric flask (having a capacity equal to the amount of solvent delivered in five minutes or longer) and a stopwatch. - Page 32 Flow rate calibration without back pressure completed Flow rate calibration Step 1 completed [SHIFT] [EVEN/3] Flow rate compensation screen Setting a temporary flow rate compensation value FLOW COMP: FLOW COMP = Value obtained in flow rate calibration Step 1 PRESS COMP = 4.7, a temporary value PRESS COMP: Use a volumetric flask (having a capacity equal to the amount Measure the flow rate...
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Page 33: Maintenance
4 Maintenance 4.1 Air bubble removal Remove air bubbles by following the procedure described below. Note: Before air bubbles removal, check for clogs in the purge valve and drain tube. First, turn the purge valve in the counterclockwise direction to open the valve. -
Page 34: Pump Solvent Replacement
Syringe Syringe needle with fitting Drain tube Syringe needle Removed drain tube Drain port Figure 4.2 Removing Air Bubbles via Syringe 4.2 Pump solvent replacement This section explains how to quickly replace the solvent in the pump. The procedures described in this section can also be used to replace the solvent in the equipment upstream from the pump (for example, a degasser, 6 solvent selection valve or low pressure gradient unit). -
Page 35: Replacing The Solvent With Water
Note: First, set the pressure to 3.0 MPa. Depending on the extent of filter clogging and dimensional (internal diameter and length) variation in the tube connected to the pump outlet port, the OVER PRESS message may appear on the display. If this happens, increase the maximum pressure setting. (3) Sufficiently degas the water to be used during replacement. -
Page 36: Replacing The Water With Methanol
(6) Stop the pump, lift the inlet tube out of the container, and use water to wash off any buffer adhering to the outside of the tube. (7) Insert the inlet tube into a container filled with water (use a different container than that used in Step 2 above) and restart the pump. -
Page 37: Cleaning Using An Acid Or Alkaline Solution
Aqueous solvents Buffer solutions, Salt solutions Water Ethanol, Organic solvents IPA, (or acetone) Acetonitrile, Methanol Chloroform, Ethyl acetate n-hexane, Isooctane Figure 4.4 Solvent Solubility 4.3 Cleaning using an acid or alkaline solution 4.3.1 Conditions under which cleaning is required Cleaning using an acid or alkaline solution is necessary when a problem has been traced to pump head deterioration or contamination within the pump. -
Page 38: Cleaning Procedure
When cleaning other components (for example, the injector, the autosampler, or detector cells) in addition to the pump, use acid when an alkaline solution has been determined to be more effective, except. The acid (nitric acid) and alkaline solution (sodium hydroxide) concentrations described above are also used in cleaning other components. - Page 39 Replace with water See Section 4.2 See Sections 3.1.2 and 3.1.3 Pressure Test 1 A maximum pressure of 10.0 MPa is sufficient. (The purpose here is to verify that there are no leaks, and not to check pump performance.) Pressure Test 2 CAUTION: The acid or alkaline solution used to clean the pump will not corrode the components...
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Page 40: Part Replacement And Operations Check
5 Part Replacement and Operations Check 5.1 Plunger seal replacement 5.1.1 Plunger seal replacement preparations Replace the solvent inside the pump with one of the following solvents (See Section 4.2): Methanol Water Since this operation involves the disassembly of the pump, solvent or liquid remaining inside the pump will unavoidably come into contact with fingers and hands. -
Page 41: Plunger Seal Removal
5.1.2 Plunger seal removal Remove the tubing See Fig. 5.2 around the pump head See Fig. 5.3 Remove the solvent 1) Use a 1.5 mm Allen wrench and remove the knob from selection valve the solvent selection valve. 2) Remove the tubing between the solvent selection valve and the pump head. - Page 42 Pump head Inlet tube Tubing (1) Figure 5.2 Pump Head Tubing Attachment/Removal Solvent selection valve Pump head Head mount flange (delivery) Knob Plunger Pump head (modifier) Allen bolt (Bolt used to secure the pump head) Allen wrench Purge valve knob Figure 5.3 Pump Head Attachment/Removal...
- Page 43 Pull straight out Delivery head Figure 5.4 Diagram of Delivery Head Removal Plunger seal Small flathead screwdriver Figure 5.5 Plunger Seal Removal...
- Page 44 Cross section Figure 5.6 Plunger Seal Attachment Hole...
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Page 45: Plunger Seal Installation
5.1.3 Plunger seal installation See Fig. 5.8 Pre-form a new Press a new, unformed plunger seal into the seal pre-forming plunger seal tool. Wait for two minutes, press on the push-up pole to extract the seal, and install the seal immediately. Note: If the plunger seal cannot be smoothly inserted into the pump head seal attachment hole, pre-form the plunger... -
Page 46: Pump Head, Solvent Selection Valve, And Purge Valve Attachment
Plunger seal Pump head Figure 5.9 Plunger Seal Installation 5.1.4 Pump head, solvent selection valve, and purge valve attachment Mount the pump See Fig. 5.3 head Moisten the inside of the plunger seal with methanol to make mounting easier. Note: Remember the following when mounting the pump head onto the head mount flange. -
Page 47: Post-Replacement Verification
Head mount flange Even space Pump head Allen wrench Figure 5.11 Tightening the Pump Head 5.1.5 Post-replacement verification Refer to sections 3.1.2 and 3.1.3 and perform the pressure test. Verify that there are no leaks from the plunger seal (See Fig. 2.2). If the test reveals a leak, see Section 2.4.1, which describes procedures for dealing with leaks from the plunger seal. -
Page 48: Line Filter Replacement Procedure
5.2.2 Line filter replacement procedure See Fig. 5.13 Remove the filter Note: When loosening the filter retainer screw, use a wrench retainer screw to hold the filter holder so that the entire pump unit does not move. Clean the filter Remove any gasket material or other contaminants remaining holder in the filter holder. -
Page 49: Post-Replacement Verification
5.2.3 Post-replacement verification Refer to Section 3.1.3 and perform the pressure test. Verify that there are no leaks from the line filter (See Fig. 2.2). If the test reveals a leak, see Section 2.4.4, which describes procedures for dealing with leaks from the line filter. 5.3 Inlet filter replacement 5.3.1 How to check for inlet filter clogs Use a siphon to observe the flow of solvent in the inlet tube. -
Page 50: Pump Head Check Valve Assembly Replacement
5.4 Pump head check valve assembly replacement 5.4.1 Preparations for check valve assembly replacement Replace the solvent inside the pump with one of the following solvents (See Section 4.2): Methanol Water Since this operation involves the disassembly of the pump, solvent or liquid remaining inside the pump will unavoidably come into contact with fingers and hands. -
Page 51: Check Valve Assembly Replacement Procedure
5.4.2 Check valve assembly replacement procedure Remove the tubing See Fig. 5.2 around the pump head See ① in Fig. 5.16 Remove the tubing on top of the pump head Remove the check in Fig. 5.16 ② valve assembly Note: Remember the following when removing and attaching the check valve assembly: Tighten sufficiently the bolts securing pump head... - Page 52 Tubing Check valve assembly (OUT) Check valve assembly (IN) is not drawn Check valve assembly (IN) Figure 5.16 Check Valve Assembly Removal and Attachment If replacement of the check valve assembly is difficult while the pump head is attached, refer to Figs. 5.2 ~ 5.4 and remove the pump head before replacing the check valve assembly.
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Page 53: Post-Replacement Verification
5.4.3 Post-replacement verification Refer to sections 3.1.2 and 3.1.3 and perform the pressure test. Verify that there are no leaks from the check valve assembly (See Fig. 2.2). If the test reveals a leak, see Section 2.4.2, which describes procedures for dealing with leaks from the check valve assembly. -
Page 54: Exposing The Diaphragm
5.5.2 Exposing the diaphragm Remove the tubing See Fig. 5.2 (Refer to Section 5.1.2) around the pump head Remove the solvent See Fig. 5.3 (Refer to Section 5.1.2) selection valve Remove the purge See Fig. 5.3 (Refer to Section 5.1.2) valve Remove the pump See Figs. -
Page 55: Diaphragm Replacement
Plunger guide Plunger Spacer (2) Diaphragm Plunger guide Head mount flange Note: Be careful not to confuse the front and rear sides of the spacer during ② attachment. Figure 5.19 Head Mount Flange Attachment/Removal 5.5.3 Diaphragm replacement (1) Pull the diaphragm out from the plunger. It may be easier to remove the diaphragm along with the spacer ②... -
Page 56: Post-Replacement Verification
See Fig. 5.19 Attach the head Note: Remember the following during assembly: mount flange Do not strike any of the plungers when turning the Allen wrench. Since the rim of the diaphragm will be squeezed between the head mount flange and the spacer , some resistance is to be expected when ②... -
Page 57: Purge Valve Needle Replacement
5.6.1 Purge valve needle replacement Note: Before removing the needle, either remove the inlet tube or place the solvent reservoir in a lower position than the pump in order to prevent spilling or leakage of the solvent. Refer to Fig. 5.22 and replace the needle. After the needle has been replaced, perform the pressure test described in Section 3.1.3 and check the purge valve for leaks (See Fig. -
Page 58: Plunger Replacement
Needle Packing Guide Figure 5.23 Purge Valve Packing Replacement 5.7 Plunger replacement 5.7.1 Plunger replacement preparations Replace the solvent inside the pump with one of the following solvents (See Section 4.2): Methanol Water Since this operation involves the disassembly of the pump, solvent or liquid remaining inside the pump will unavoidably come into contact with fingers and hands. -
Page 59: Plunger Replacement
This procedure is identical to that for exposing the diaphragm of the plunger washing mechanism (See Section 5.5.2). Remove the diaphragm and the spacer on the side of the worn out plunger. 5.7.3 Plunger replacement Run the pump so that the plunger to be replaced is extended to the point farthest from the main unit. - Page 60 Plunger guide Plunger Box wrench Slider rod Disk Lock screw Figure 5.25 Plunger Replacement Figure 5.26 Check After Plunger Attachment...
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Page 61: Assembly Of Head Mount Flange And Other Parts
5.7.4 Assembly of head mount flange and other parts This procedure is identical to that for assembling the plunger washing mechanism (See Section 5.5.4) 5.7.5 Post-replacement verification Since the pump head is removed when the plunger is replaced, the plunger seal must be checked for leaks. -
Page 62: List Of Consumable Parts
Knob Pump head Tubing Screw Figure 5.28 Solvent selection Valve Removel/Attachment Stator Disk Ring Coned disc springs Valve axis Screw Thrust bearing Bearing holder Knob Figure 5.29 Solvent Selection Valve Disassembly Diagram Valve axis Disk Groove Figure 5.30 Reverse View of Disk 5.9 List of consumable parts... - Page 63 Table 5.1 lists the major consumable parts of the pump. Table 5.1 Consumable Parts List Part Name Order Reference unit diagram Inlet tube assembly 1 set Fig. 5.14 Replacement plate filter Fig. 5.14 Plunger seal (black) Fig. 5.9 Line filter kit 2 sets Fig.
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