Chemyx Fusion Series User manual

CHEMYX
Fusion Series User Manual
Chemyx Inc.
10905 Cash Road
Stafford, TX 77477 USA
www.chemyx.com
Updated: 2016-11-08
Intellectual Property
All Intellectual Properties, as defined below, owned by or which is otherwise the property of
Chemyx Inc. or its suppliers relating to the Chemyx syringe pumps, including but not limited to,
accessories, parts or software relating thereto (Chemyx Syringe Pumps), are proprietary to
federal and state laws, and international treaty provisions. Intellectual Property includes but is
not limited to, inventions (patentable or unpatentable), patents, trade secrets, copyrights,
software, firmware, computer programs, and related documentation and other works of
authorship. Moreover, you agree that you will not, and will not attempt to, modify, prepare
derivative works of, reverse engineer, disassemble the Chemyx syringe pumps, decompile or
otherwise attempt to create source code from the related software/firmware. No title to or
ownership in Intellectual Property is transferred to you. All applicable rights of the Intellectual
Property shall remain with Chemyx and its suppliers.

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Chemyx, Inc.
Fusion Series User Manual
EU Declaration of Conformity (DoC)
The PDF version of the latest DoC can be downloaded at www.chemyx.com/support.

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Chemyx, Inc.
Fusion Series User Manual
INTELLECTUAL PROPERTY 1
EU DECLARATION OF CONFORMITY (DOC) 2
MANUAL DESCRIPTION 6
GENERAL INFORMATION 6
SAFETY INFORMATION 6
WARRANTY AND REPAIR INFORMATION 7
LIMITED WARRANTY 7
REPAIR FACILITIES AND PARTS 8
DEAD PIXEL POLICY 8
SERIAL NUMBERS 8
CALIBRATIONS 8
PRODUCT OVERVIEW 9
THE FUSION SERIES SYRINGE PUMPS 9
PRINCIPLE OF OPERATION 9
FEATURES 11
PUMP 11
CONTROLS 13
POWER AND DATA CONNECTORS 14
AUDIBLE ALERTS 14
STALL DETECTION 14
SPECIFICATIONS 15
PUMP SETUP 16
POWERING ON/OFF THE PUMP 16
LOADING A SYRINGE 17
FUSION 100 17
FUSION 200 18
FUSION 400 19
ADJUSTING THE SAFETY COLLAR 19
FUSION 100 AND 200 20
FUSION 400 20
PUMP OPERATION 21
SELECTING ITEMS 21
NAVIGATING BETWEEN SCREENS 22

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Chemyx, Inc.
Fusion Series User Manual
ENTERING VALUES 22
ENTERING NUMBERS 22
ENTERING LETTERS 23
MODE SELECTION SCREEN 23
BASIC MODE 24
SYRINGE SELECTION 24
TARGET TRANSFER VOLUME 26
INFUSION/WITHDRAWAL (FUSION 200 ONLY) 26
FLOW RATE 26
START-TIME DELAY 27
OPTIONS 28
Flow-Rate Units 28
Saving Run Parameters 28
Priming/Bolus Rate 29
Enable Volume Lock 29
MULTI-STEP MODE 30
SETUP 30
Syringe Selection 30
Total Steps 31
Loop All 31
Sub-Loops 31
Flow-Rate Units 32
STEP PARAMETERS 32
32
Target Transfer Volume 32
Infusion/Withdrawal (Fusion 200 only) 33
Flow Rate 33
Static Flow Rate 34
Variable Flow Rate 34
Start-Time Delay 34
Step Loop 35
RUNNING THE PUMP 36
BASIC MODE SYSTEM STATUS 37
MULTI-STEP MODE SYSTEM STATUS 38
LOAD RUN 40
SYSTEM SETTINGS 41
TOUCHSCREEN TOGGLE 41
BAUD RATE 41
POWER SETTINGS 42
MOTOR POWER 42
LCD POWER-OFF TIME 43

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Chemyx, Inc.
Fusion Series User Manual
PUMP CONTROL BY COMPUTER 44
CABLE REQUIREMENTS 44
CONNECTING 45
SETTINGS 45
PUMP COMMANDS 45
CHEMYX PUMP CONTROLLER PROGRAMS 51
PUMP MAINTENANCE 52
LUBRICATING THE PUMP 52
REPLACING THE FUSE 53
PUMP ACCESSORIES 54
FOOT SWITCH 54
CONNECTING THE FOOT SWITCH 54
USING THE FOOT SWITCH 54
10-CHANNEL SYRINGE RACK (FUSION 200 ONLY) 55
ATTACHING THE RACK 56
LOADING SYRINGES 58
APPENDICES 59
APPENDIX A: SYRINGE VOLUME/DIAMETER REFERENCE TABLE 59
APPENDIX B: AVAILABLE PARTS 67
Fusion Series Syringe Pumps 67
Options and Accessories 67
Stainless-Steel Syringes 67
APPENDIX C: CONTACT INFORMATION 68

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Chemyx, Inc.
Fusion Series User Manual
Manual Description
This manual covers the basic operational elements and usage of Chemyx Fusion Touch Series
Syringe Pumps using firmware version 1.7.6c.
This manual does not include all aspects of usage or OEM / custom-designed systems that are
fabricated by Chemyx for other companies. Chemyx does not directly support OEM systems
unless otherwise specified.
Additional support material may be found at the Chemyx website: www.chemyx.com/support
General Information
Safety Information
Please read the following safety precautions to ensure personal safety and operational longevity
of the Chemyx syringe pump. Chemyx is not responsible for the equipment if used in a manner
not specified by the manufacturer; warranty coverage provided by the equipment may be
dropped as a result.
CHEMYX PRODUCTS ARE NOT APPROVED FOR CLINICAL USE ON HUMANS.
USE PROPER POWER SUPPLY
Chemyx is not responsible for the use of power supplies outside the stated electrical
specifications or failure to switch the power converter from 220V to 110 V while in the 220V
environment or vice versa.
GROUND PRODUCT
The product should be properly grounded.
DO NOT OPEN THE PUMP
Warranty coverage will be lost if the pump is opened without authorization from Chemyx. Do not
touch any electrical connectors on or in the product.
DO NOT OPERATE WITH SUSPECTED FAILURES
Even though the pump can operate at extremely fast speeds, the user must determine the
proper flow rate for any given application. For instances, pumping at 90 mL/min using a 20-
gauge needle will cause stalls and/or potential bursting of the syringe. Chemyx is not
responsible for any damage that might result from situations similar to the example above.

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Chemyx, Inc.
Fusion Series User Manual
PINCH HAZARD
Do not place fingers between the pusher block and the end block while the pump is running.
OBSERVE ALL WARNING LABELS ON PRODUCT
Read all labels on the product to ensure proper usage.
CHEMYX IS NOT RESPONSIBLE FOR SYRINGE DAMAGE
The user is responsible for wetting ground glass syringes and setting/tightening the safety
collar/bar appropriately.
Warranty and Repair Information
Limited Warranty
Chemyx provides a two-year warranty from the shipment date for its pumps against defects in
materials and workmanship. Chemyx will repair any product that proves defective during its
stated warranty period.
The foregoing warranty will not apply to damage resulting from:
●Improper or inadequate maintenance or operation
●Unauthorized modification or misuse of the product
●Operation outside the electrical specifications for the product
●Operation outside the temperature specifications for the product
●User-induced internal and external contaminations of the instrument
●Failure to use proper surge protection
●Improper product return, packaging, and shipping
●Removing serial number from syringe pump
You must contact Chemyx (call [phone] or visit www.chemyx.com/contact-us) before
returning a product. Chemyx will issue a Return Authorization (RA) number to you.
Return products to:
Chemyx Inc.
10905 Cash Road
Stafford, TX 77477 USA
For more information about the warranty policy, please visit the Chemyx website.

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Chemyx, Inc.
Fusion Series User Manual
Repair Facilities and Parts
Chemyx can repair any syringe pump without major damage. You must contact Chemyx (call
[phone] or visit www.chemyx.com/contact-us) before shipping a product for repair.
Chemyx will issue a Return Authorization (RA) number to you.
Return products to:
Chemyx Returns
10905 Cash Road
Stafford, TX 77477 USA
Dead Pixel Policy
During the LCD Monitor manufacturing process, it is not uncommon for one or more pixels to
become fixed in an unchanging state. The visible result is a fixed pixel that appears as an
extremely tiny, dark or bright dot. In almost every case, these fixed pixels are hard to see and
do not detract from display quality or usability. A display with three to seven bright or dark dots
is considered normal and within industry standards. If your screen displays more than seven
dead pixels during the warranty period, your system will qualify for warranty replacement.
Please see the Limited Warranty section for details on how to activate a warranty claim.
Serial Numbers
The serial number is located on the back, top left corner or center of the pump under a small
barcode. Removal of the serial number label will void the warranty.
Calibrations
Chemyx pumps are pre-calibrated upon arrival to your site. All calibrated parameters are within
stated accuracy and precision specifications of the pump. Although the pump is highly accurate,
syringes of different materials can attribute significant volume errors. Typically, these errors can
range from 1% for glass syringes to 5% for plastic syringes. Chemyx is not responsible for
errors generated from syringes.

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Chemyx, Inc.
Fusion Series User Manual
Product Overview
The Fusion Series Syringe Pumps
Chemyx Fusion Series syringe pumps are designed to handle every type of high-precision
dosing application. The units’ flexibility with syringe types and sizes and an advanced software
interface allow this line of high-precision syringe pumps to be integrated into any operation or
laboratory work flow. Thoroughly durable both inside and out, the Chemyx Fusion syringe
pumps are designed to provide years of constant and reliable service.
Principle of Operation
A syringe pump is a small, positive-displacement pump used to gradually transfer precise
volumes of fluid. All Chemyx Fusion-series syringe pumps are driven via a stepper motor. This
stepper motor precisely turns a lead screw that is threaded through a pusher block, which
causes the pusher block to move. When the pump is in infusion mode, the pusher block pushes
against the plunger of a secured syringe, causing the fluid to be ejected at an accurate and
precise rate.
Fusion 100
Fusion 200
Fusion 400

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Chemyx, Inc.
Fusion Series User Manual
If the pump is capable of withdrawal, the plunger of the syringe is held by brackets on the
pusher block. When the stepper motor turns in the opposite direction, the pusher block moves
such that the syringe plunger is pulled, thus drawing fluid into the syringe.
For the Fusion Series syringe pumps, the pusher block moves to the right for infusion and to the
left for withdrawal.

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Chemyx, Inc.
Fusion Series User Manual
Features
Pump
Fusion 100 pump components
All Fusion Series pumps have a single lead screw through which the pusher block is threaded.
The pusher block moves when the lead screw turns. The two guide rods keep the pusher block
horizontal and perfectly perpendicular to the lead screw. The block-release button disengages
the pusher block from the lead screw, which allows the pusher block to be easily moved to a
new position as long as the button is held. Releasing the button will lock the pusher block back
in place.
Syringes are placed on the syringe-holder block in the v-shaped grooves, or channels, and held
securely using syringe clamps. The Fusion 100 and 200 both have two syringe channels, while
the Fusion 400 has four smaller syringe channels.
The safety collar of the Fusion 100 and 200 helps protect the integrity of syringes by keeping
the pusher block from pushing on a completely depressed syringe.

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Chemyx, Inc.
Fusion Series User Manual
In addition to having all of the same features and components of the Fusion 100, the Fusion 200
is capable of both infusion and withdrawal. Because of this difference, the Fusion 200 uses
adjustable retaining brackets on the pusher block and the syringe-holder block that keep the
syringe in place during both infusion and withdrawal.
Fusion 400-specific pump components
Fusion 200-specific pump components

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Chemyx, Inc.
Fusion Series User Manual
The Fusion 400 has all of the same functions and components as the Fusion 100, except that it
has four channels for syringes and uses screw clamps to secure the syringes. Additionally,
instead of a safety collar, the Fusion 400 have a safety bar to protect the syringes.
Controls
Front panel of pump
The Fusion Series uses a bright, 4.25”, resistive, LCD touchscreen with an intuitive graphical
user interface (GUI) for setting up detailed pump run methods. Buttons and entry fields within
the GUI are all selectable using the touchscreen. As a resistive, LCD touchscreen, the interface
can be operated with any object, not just the touch of a fingertip. Selecting elements by touch
only requires a small amount of pressure; however, please do not use sharp objects as they
may damage the screen.
The Fusion series also includes physical navigation controls, allowing users to manually
maneuver between selectable GUI elements without touching the screen. Inputting numbers
and letters within the GUI is done using the physical numeric keypad. The physical pump control
keys are used to start, pause, and stop pump activity.
The power LED and pump-control LEDs allow users to easily discern whether the pump is on
and whether it is currently running, paused, or stopped.

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Chemyx, Inc.
Fusion Series User Manual
Power and Data Connectors
Back of pump
The Fusion Series is compatible with 110V and 220V power sources and is easily switched
between the two. Additionally, all Fusion Series syringe pumps have two serial connectors
(USB-B and DB9) that allow for remote control of the pump through a computer (See Pump
Control by Computer). An optional Chemyx Foot Switch accessory that connects to the pump’s
TTL port is also available, which provides easy control of the pump.
Audible Alerts
The Fusion series pumps have an audible beep that sounds when the pump powers on and
when any of the pump control keys are pressed.
A longer beep will sound if the pump has stalled.
Stall Detection
Stall detection on the Fusion series pumps occurs when the optical detector that is used to
verify the expected movement of the motor detects jamming or excessive pressure. Stalling
occurs when the pusher block can no longer move, such as when the pusher block hits the
safety collar or when the fluid in the syringe is too viscous for the set flow rate.
Severe stalls can occur from corroded guide rods. In the case of a severe stall, the block-
release button will decouple and unlock the pusher block.

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Chemyx, Inc.
Fusion Series User Manual
Specifications
Specification
Fusion 100
Fusion 200
Fusion 400
Available Movement
Modes
Infusion
Infusion / Withdrawal
Infusion
Syringe Sizes
(Min/Max)
0.5 μL / 60 mL
0.5 μL / 60 mL
0.5 μL / 10 mL
Flow Rate Range
(Smallest Syringe)
0.0001 - 1.5679 μL/min
0.0001 - 1.5679 μL/min
2 - 10.536 pL/min
Flow Rate Range
(Largest Syringe)
0.0002 mL/min - 128
mL/min
0.0002 mL/min - 128
mL/min
4.83 pL/min - 2.1
mL/min
Drive Mechanism
1.8° stepper motor with
1/32 microstepping
1.8° stepper motor with
1/32 microstepping
1.8° stepper motor with
1/32 microstepping
Step Resolution
0.098 μm / μstep
0.046 μm / μstep
0.016 μm / μstep
Nominal Linear Force
16 kg (35 lbs)
23 kg (50 lbs)
23 kg (50 lbs)
Accuracy
± < 0.04% error (99.96%)
± < 0.04% error (99.96%)
± < 0.04% error (99.96%)
Reproducibility
± < 0.05% deviation
(99.95%)
± < 0.05% deviation
(99.95%)
± < 0.05% deviation
(99.95%)
Operation Temp
4°C to 40°C
(40°F to 104°F)
4°C to 40°C
(40°F to 104°F)
4°C to 40°C
(40°F to 104°F)
Storage Temp
-10°C to 70°C
(14°F to 158°F)
-10°C to 70°C
(14°F to 158°F)
-10°C to 70°C
(14°F to 158°F)
Relative Humidity
20% - 80%
20% - 80%
20% - 80%
Data Ports
RS-232 (DB9 and USB-
B), TTL (USB-B)
RS-232 (DB9 and USB-
B), TTL (USB-B)
RS-232 (DB9 and USB-
B), TTL (USB-B)
Height
11 cm (4.4 in.)
12 cm (4.7 in.)
13 cm (5.1 in.)
Width (Length)
24 cm (9.5 in.)
24 cm (9.5 in.)
24 cm (9.5 in.)
Depth
17 cm (6.8 in.)
17 cm (6.8 in.)
17 cm (6.8 in.)
Weight
3 kg (7 lb)
3 kg (7 lb)
3 kg (7 lb)
Screen
4.25" diagonal
3.7" X 2.1"
4.25" diagonal
3.7" X 2.1"
4.25" diagonal
3.7" X 2.1"

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Chemyx, Inc.
Fusion Series User Manual
Pump Setup
Powering On/Off the Pump
To provide power to the pump, an IEC 60320 C13 cable should be plugged into the power
socket on the back of the pump. The cable should be plugged into an appropriate power source
(110V or 220V) with proper grounding. Adjust the voltage-converter switch on the back of the
pump such that the value displayed on the switch corresponds with the voltage of the power
supply.
The power switch for the pump is located on the back, above the power socket. Upon flipping
the switch to the “on” position, the blue LED power light on the front of the pump will
immediately turn on, along with the red LED light on the Stop key. In a few seconds, a beep will
sound, and the LCD screen will display an initial startup screen.
The startup screen displays the
version of the firmware currently
installed on the pump at the top
of the screen. The startup
screen will display for
approximately five seconds as
indicated by the countdown on
the right of the startup screen.
After the startup screen, the
LCD screen will display the last
mode the pump was in.
Startup screen

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Chemyx, Inc.
Fusion Series User Manual
Loading a Syringe
The Fusion series can accommodate up to two syringes in the Fusion 100 and 200 models,
while the Fusion 400 can house up to four syringes. The Fusion 200 can be expanded to 10
channels using the 10-Channel Syringe Rack accessory. The volume of the syringes can vary
from a minimum of 0.5 μL up to a maximum of 60 mL (10 mL maximum for the Fusion 400).
Syringes of any material (e.g., glass, plastic, stainless steel) can be used; however, the
accuracy of the dispensed volume and the durability of the syringe under higher flow rates will
certainly be affected by the type of material used. For more information about syringe or tubing
selection or to see tutorial videos of syringe loading, please visit www.chemyx.com/support.
Fusion 100
1. If necessary, move and tighten the infusion safety collar (see Adjusting the Safety
Collar).
2. While pressing in the block-release button, slide the pusher block all the way to the left.
3. Pull up on the spring-loaded syringe clamp and place the syringe in one of the channels
of the holder block. Ensure that the flange of the syringe barrel is flush against the edge
of the holder block. Slowly lower the syringe clamp to secure the syringe in place.
4. Press the block release button and slide the pusher block to the right until it is flush
against the syringe plunger.

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Chemyx, Inc.
Fusion Series User Manual
Fusion 200
1. If necessary, move and tighten the infusion safety collar (see Adjusting the Safety
Collar).
2. While pressing in the block release button, slide the pusher block all the way to the left.
3. Loosen the screw knobs for the flange retaining bracket and adjust the bracket such that
the flange of the syringe barrel will fit in between. Do not tighten the bracket, yet.
4. Pull up on the spring-loaded syringe clamp and place the syringe in one of the channels
of the holder block. Ensure that the flange of the syringe barrel is flush against the edge
of the holder block. Slowly lower the syringe clamp to secure the syringe in place.
5. Loosen the bracket clamp knob for the plunger retaining bracket and adjust the gap such
that the plunger cap of the syringe may fit.
6. Press the block release button and slide the pusher block to the right until it is flush
against the syringe plunger. The plunger cap for the syringe should fit in the gap
between the bracket and the pusher block.
7. Tighten the bracket clamp knob for the plunger retaining bracket to secure the syringe
plunger in place.
8. Move the flange retaining bracket flush against the flange of the syringe barrel and
tighten the bracket clamp knobs to secure the syringe barrel flange in place.

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Chemyx, Inc.
Fusion Series User Manual
Fusion 400
1. If necessary, move and tighten the infusion safety bar (see Adjusting the Safety Collar).
2. While pressing in the block release button, slide the pusher block all the way to the left.
3. Unscrew the clamp screw knob to raise the syringe clamp and place the syringe in one
of the channels of the holder block. Ensure that the flange of the syringe barrel is flush
against the edge of the holder block. Lower the syringe clamp by tightening the screw
knob until the syringe is secured.
4. Press the block release button and slide the pusher block to the right until it is flush
against the syringe plunger.
Adjusting the Safety Collar
The Fusion series of pumps can generate a significant amount of linear force. While this is
extremely useful for dispensing viscous fluids at higher flow rates, the higher linear force of the
Fusion series can also potentially damage the syringes in use. One source of potential damage
of a syringe may occur when the plunger of the syringe is complete depressed, and the pusher
block is still pushing against the syringe. Depending on the material of the syringe (i.e., glass or
plastic) and the thickness of the plunger, the pressure from the pusher block could bend, distort,
or just break the syringe.
To protect against this potential problem, Fusion syringe pumps use safety collars (Fusion 100
and 200) and safety bars (Fusion 400) to physically stop the pusher block before it can
completely depress the syringe plunger. When a pusher block hits the safety mechanism and
can no longer move forward, the pump will stop running, emit a long beep, and enter pump-
stalled mode.
For an example tutorial video of adjusting the safety collar/bar, please visit
www.chemyx.com/support.

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Chemyx, Inc.
Fusion Series User Manual
Fusion 100 and 200
Adjusting the safety collar requires
the use of the hex key, which is
conveniently stored on the back left
of the pump, right above the power
switch. Loosening the hex screw on
the safety collar allows for the collar
to be slid freely along the guide rod
and then securely tightened at the
desired position. The position of the
safety collar should be set slightly
further from the syringe-block holder
than the top of syringe plunger when
fully depressed.
Caution
On the Fusion 200, during withdrawal, a syringe plunger can potentially be pulled out from the
syringe, which could cause the contents of the syringe to leak out. Users should be especially
aware of the length of the plunger and the point where the withdrawing pusher block will
exceed that length. There are no safety collars on the Fusion 200 to prevent too much
withdrawal.
Fusion 400
The Fusion 400 uses a safety bar
instead of a collar to limit the
distance the pusher block may
travel. By loosening the safety bar
clamp knob on top of the pusher
block, the safety bar can be slid left
or right. The safety bar should be set
such that the length of the bar
exposed on the right side of the
pusher block is longer than the
distance from the top of a fully
depressed syringe plunger to the
edge of the syringe-holder block.
Once the safety bar has been set to
the proper length, tightening the
Safety collar adjustment
Safety bar adjustment