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Knauer Smartline 1050 Maintenance Manual

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Pump 1050
Maintenance
V7611A

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Summary of Contents for Knauer Smartline 1050

  • Page 1 Pump 1050 Maintenance V7611A...
  • Page 2 Table of contents Note: For your own safety, read the manual and always observe the warnings and safety information on the device and in the manual! Intended use ..........Pump type .
  • Page 3 Replace motherboard ......... . . Motherboard types and configuration of the plug connectors .
  • Page 4 Intended use Intended use HPLC High Performance Liquid Chromatography (HPLC) is a method for separating substance mixtures and their determining their qualitative and quantitative makeup. Smartline Pump 1050 The pump is a conveying system for analytical and semi- preparative applications. Pump head inlays made of different materials cover all needs of the user.
  • Page 5 Explosion hazard! Never use the device in potentially explosive atmospheres without appropriate protective equipment and approval by a notified body! Inform the technical support of KNAUER. Safety The installation manual is an addition to the existing system manual that includes all work that requires the installation of certain components or the opening of a device's housing.
  • Page 6 Safety Laboratory regulations  Adherence to labora- Observe national and international regulations pertaining tory regulations to laboratory work!  Good Laboratory Practice (GLP) of the American Food & Drug Administration  For development of methods and validation of devices: Protocol for the Adoption of Analytical Methods in the Clinical Chemistry Laboratory, American Journal of Medical Technology, 44, 1, pages 30–37 (1978) ...
  • Page 7 Safety Solvent The following solvents are suitable to only a limited extent only suitable to a limited for use in the device: extent  Methylene chloride  Tetrahydrofuran (THF)  Dimethyl sulfoxide (DMSO)  Slightly volatile solvents Unsuitable The following solvents can attack the components of the device solvents and are therefore not suitable: ...
  • Page 8 Safety Protective measures The following applies for all repairs on the device: Hazard symbol Warning instructions DANGER! Danger of electric shock! Switch off power supply! Pull the power plug! DANGER! Danger due to toxic, caustic or radioactive substances due to contamination of the device. The customer must ensure that the device has been thoroughly decontaminated before repairs...
  • Page 9 Safety Symbols and labels Explanations of the symbols and labels Markings Symbol Explanation Flow direction symbol for piston backflushing: inlet to flush pump Flow direction symbol for piston backflushing: outlet to pump head Symbol indicating flow direction through a column CE (Conformité...
  • Page 10 Safety Hazard symbols Symbol Explanation For your own safety, read the operating instructions and always observe the warnings and safety information on the device and in the operating instructions! Caution! Micro-electronic device components that could be damaged by electro-static discharge (ESD) when touched.
  • Page 11 What is maintained or repaired? Mandatory sign Take precautions against electrostatic discharge. To disconnect the device from the mains power, disconnect the power plug. Wear safety gloves when handling corrosive or toxic chemicals. Carefully screw capillaries to avoid leaks. What is maintained or repaired? Measures Hours in operation ...
  • Page 12 Pump head repair Pump head repair WARNING! Aggressive or toxic solvent residue can irritate the skin! Wear protective gloves! In case of a malfunction or as part of routine maintenance, the pump head can be disassembled into individual parts. During this procedure, seals, guide discs, springs or pistons can be replaced.
  • Page 13 Pump head repair Removing the pump head 1. Remove the tubes from the inlet and outlet of the piston backflushing (A). 2. Remove all tubes from the solvent bottles. 3. Unscrew the eluent line (D). 4. Unscrew the outlet fitting 2 (E) and the inlet fitting of the pressure sensor (F) to remove the capillary.
  • Page 14 Pump head repair Removal of Pump Head CAUTION! Avoid breaking the piston rods! Before disas- sembly, first remove the two piston rods. Deposit the two piston rods in the correct orien- tation to ensure correct orientation when put- ting them back in. Overview of the pump Figure head parts...
  • Page 15 Pump head repair Overview of the pump Component Comment head parts Check valve Ball valve with flow in one direction; Made of sapphire/ ruby w/direction of flow indicator Seal Modified Teflon seal Outlet fitting Outlet fitting, side of pump head Capillary connection kit Ø...
  • Page 16 Pump head repair Complete disassembly of Procedure Figure the pump head A Piston backflushing 1. Flush the pump head with water or B RFID-Chip isopropanol if the C Piston rod pump head is to be stored. D Piston guide 2. Remove the pump E Feed block head (see manual).
  • Page 17 Pump head repair Removing the parts of Procedure Figure the piston guide A Low-pressure seal 1. Remove the parts and securely deposit B Washer them in the proper C Compression spring sequence and in the correct orientation. D Bushing E Piston guide F Piston rod Fig.
  • Page 18 Pump head repair Replacing seals on the Procedure Figure inner side of the feed block A Special tool for removal 1. Screw the special seal tool into the Bal Seal® seal and B Feed block remove from the feed block. Fig. 6 Special tool for Bal Seal®...
  • Page 19 Pump head repair Replacing the seals on Procedure Figure the inner side of the  piston backflushing A O-Ringe 1. Replace O-rings of the piston backflush- B Low-pressure seal ing. 2. Screw the special tool into the low- pressure seal and remove from the feed block.
  • Page 20 Pump head repair Pre-forming the seal Procedure Figure from Bal Seal® with the special tool A Special tool for pressing 1. Set the high-pres- in the seal sure seal with the metal washer spring B High-pressure seal pointing out onto the special tool and pre-form the seal.
  • Page 21 Pump head repair Inserting the spacer Procedure Figure A Adaptor ring 1. Insert sapphire ring into adaptor ring and place on seal- ing tool. 2. Using the sealing tool, insert the adap- Fig. 13 Sapphire ring in adaptor tor ring, together ring with the sapphire ring, into the feed...
  • Page 22 Pump head repair Pressing the low-pres- Procedure Figure sure seal from Bal Seal® into the piston back- flushing A Low-pressure seal 1. Position the low- pressure seal on the B Special tool special tool. 2. Press fitting seal using special tool. Fig.
  • Page 23 Pump head repair Positioning the washers Procedure Figure flat and fitting the com- pression springs and bushings A Washers The springs for the pis- ton guide can be posi- B Bushing tioned on the feed C Compression spring block and piston back- flushing, which have been put together.
  • Page 24 Pump head repair Screwing the pump head Procedure Figure together A Piston guide 1. Position piston guide. B Screw 2. Insert screws with C Compression spring Allen wrench. 3. Manually press the piston guide down against the compres- sion springs. 4.
  • Page 25 Replacing the check valves Dirty check valves may not open and close correctly. The entire check valve is replaced. For replacement of the check valves, KNAUER recommends removing the pump head. Prerequisites • Pump has been flushed with water and isopropanol.
  • Page 26 Disassembling the device Disassembling the device  Disassembly of the device hood, suitable for certain maintenance and repair work on the inside of a device. Danger of electric shock!  WARNING! Switch off the power supply! Pull the power plug! Remove the device hood upward The device hood is secured with a total of 6 cross-head screws, three on each side.
  • Page 27 Disassembling the device Replacing the device door Prerequisite The housing has been opened and the device hood has been removed. Procedure Always remove the door with on the device.  Tools Cross-head screwdriver size 1  Duration Approx. 5 min. ...
  • Page 28 Replacing the fan Spare parts Component Comment Order number Device door complete with G1616 control panel, display, magnet lock Replacing the fan Note the following when repairing the fan:  The fan is fastened on the rear panel of the device with fan mountings made of EPDM rubber ...
  • Page 29 Replacing the fan  Tools Combination pliers or bent needle-nose pliers  Scissors or knife  Duration Approx. 15 min.  Level of difficulty Level 2 (from 1 to 7, very easy to very difficult) Pulling out the fan 1. Remove the fan power cable from the PIN connector (C). 2.
  • Page 30 Replacing the fan Inserting a new fan Note Pay attention to the direction of the fan printed on the fan. One arrow indicates the direction of rotation of the fan, the other indicates the direction in which the air is pulled. Legend A Power supply B Fan with the power...
  • Page 31 Removal of piston backflushing pump Removal of piston backflushing pump Prerequisite Side parts and cover of the housing have been removed. Fig. 27 Overview: Piston backflushing pump (A) Piston backflushing The piston backflush pump (A) is attached to the inside of the pump front panel.
  • Page 32 Functional principle The pressure sensor is adjusted to the mechanical and electrical properties of the pump with a calibration procedure. The calibration requires a test station from KNAUER and the service software. For better results, the calibration is repeated once.
  • Page 33 Replacing the pressure sensor Removing the pressure sensor The pressure sensor is secured with two screws on the inside of the housing of the pump. Removing the pressure Process Figure sensor 1. Close bleed Exterior view  screw (B) (order number: P2719XA).
  • Page 34 M1368 Replacing the motor Note Replacing the motor of the pump on the inside of the housing is to be performed exclusively by the KNAUER technical service department or a company authorized by KNAUER. Danger of electric shock!  WARNING! Switch off the power supply!...
  • Page 35 Replacing the motor Removing the motor of the pump Removal of the motor Process Figure 1. Disconnect all elec- trical connections of the motor, for instance the control unit for the pulse per revolution (encoder) and the DC power connec- tion.
  • Page 36 Replacing the motor Removal of the motor Process Figure 3. Only loosen the two screws of the motor mount (C) with a screwdriver (cross- head), do not unscrew them com- pletely. This removes the  tension from the V- belt (D). 4.
  • Page 37 Replacing the motor Tensioning the V-belt Process Figure 1. Turn the drive shaft (C) together with the V-belt to a posi- tion where the upper retaining screw of the motor becomes visible through one of the openings (B) of the drive shaft 2.
  • Page 38 Replacement of the motherboard Replacement of the motherboard Practical tip Not all plug connections on the motherboard are designed confusion-proof. Mark the cable before removing it. Legend A Power supply B Motherboard C Piston backflushing pump D Pump E Motor F Fan ...
  • Page 39 Replacement of the motherboard Replace motherboard Danger of electric shock!  WARNING! Switch off the power supply! Pull the power plug! Caution! Electrostatic discharge can destroy the electronics!  Wear protective bracelet against electrostatic discharge and ground. Fig. 36 Edge connector with snap lock ...
  • Page 40 Replacement of the motherboard Motherboard types and configuration of the plug connectors Pump A Rear wall of device B Fan, possibly  doubled C Power supply D Pressure sensor E Display F RFID G Motor DC connection H Hall sensor I Flush pump J Manager connection Fig.
  • Page 41 Replacement of the motherboard Spare parts Component Comment Order number Fuses M2099 62 mA M0734 250 mA M0731 S1050 motherboard G1156XB Removing the power plug Prerequisite The housing has been opened. Procedure Procedure for removing the power supply:  Disconnect all electrical power supply connections ...
  • Page 42 Replacement of the motherboard Removing the power Process Figure plug A Cross-head screws 1. Remove the 5 cross-head screws (A) on the back of B Rear view of the device the device. 2. Fold down the back of the device (B). Fig.
  • Page 43 Tightening torque for screws Tightening torque for screws Practical tip The use of a dynamometric screwdriver for the tightening torques is highly recommended. Screws in materials made of metal The following materials are considered metal:  Aluminum  Steel, stainless and other ...
  • Page 44 Troubleshooting Screws in materials made of plastic The following materials are considered plastic:  PEEK  PETP   PMMA  PTFE Size Tightening torque (in Nm) Troubleshooting Error list In the following list, the error numbers with the associated indexes are listed that appear on the display if an error occurs.
  • Page 45 Troubleshooting Error number Index Error_22 12C Init failed Error_23 Cannot read RTC Error_24 12C operation failed Error_25 Cannot write data on FRAM Error_26 Cannot read data from FRAM Error_27 Instrument remote controlled Error_28 Error input activated Error_29 Time already exists Error_30 Too many lines in program Error_31...
  • Page 46 Troubleshooting Error number Index Error_53 Cannot start time table Error_54 Time table is not active Error_55 Time table is not loaded Error_56 No gradient is available in isocratic mode Non-existing component is set to  Error_57 non-0 value Error_58 Sum of components is not 100. Error_59 Maximum pressure! System stopped Error_60...
  • Page 47 Troubleshooting Possible problems and rectifications In the following table, approximately 90% of the problems that occur in practical use are listed with possible solutions. Problem Cause Solution   Instable Malfunction Clean the ball pressure, of ball valve valves instable flow ...
  • Page 48 Troubleshooting Problem Cause Solution   Pump can only Keyboard, Replace door with be controlled display or control panel using the touchscreen computer, not from the device control panel   Managers The supply Replace cannot be voltage with connection cable controlled even 24 V is not of manager pump...
  • Page 49 Table of figures Table of figures Fig. 1: Rear view of a complete UHPLC pump head ....15 With the pump head removed at the back of the device,  Fig.
  • Page 50 Table of figures V-belt (C) and position  Fig. 34: of the drive shaft (D) to remove tension from the V-belt ..37 Motor (A), drive shaft (C) and openings in the gear (B)  Fig.
  • Page 51 © Wissenschaftliche Gerätebau Dr. Ing. Herbert Knauer GmbH All rights reserved. The information in this document is subject to change without prior notice. Translation of the original German edition of this manual. 2011-07-26 Printed in Germany. ® ChromGate and ClarityChrom are registered trademarks of Wissenschaftlicher Gerätebau...