Flom 300 Series User manual

CORPORATION
Instruction Manual
INTELLIGENT PUMP
Model 300 Series

INTELLIGENT PUMP
Model 300 Series
Instruction Manual
Contents:
1. Introduction………………………………………………………………….
1.1 How IP300 Works………………………………………………....1
1.2 Technical Specifications………………………………………...
2. Installation………………………………………………………………….....3
2.1 Unpacking and Inspection………………………………………..3
2.2 Tubing…………………………………………………………….
2.3 Priming the Pump………………………………………………....4
3. Operation…………………..………………………………………………..
3.1 Layout of Front and Rear Panels………………………………..5
3.2 Functions of Parts and Keys……………………………………..7
3.3 Selecting Flow Rate, Flow Pressure and Pressure Limit……..9
3.4 Purging……………………………………………………………..9
4. Maintenance………………………………………………………………...
4.1 Cleaning the Piston……………………………………………...10
4.2 Replacing the Piston Seal………………………………………
4.3 Pump Head Configuration………………………………………11
4.4 Cleaning Check Valves………………………………………….11
4.5 Check Valve Configuration……………………………………...12
5. Troubleshooting……….………………………………………….………...
5.1 Description of Error Signals…………………………………….13
5.2 Problem Solving………………………………………………….13
5.3 List of Replacement Parts………………………………………14
6. Safety Instructions………………………………………………………….
6.1 While Using IP300……………………………………………….15
7. Warranty Information……………………………………………………….17
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1. Introduction
This instruction manual is designed to provide the user the necessary information for
installation, safe operation, and maintenance of the Intelligent Pump Series 300 (IP300).
Please read carefully and thoroughly before the operation.
1. 1 How IP 300 Works
The Intelligent Pump Series 300 is designed to reduce the pulsation problem that is
common to all the High Performance Liquid Chromatography pumps. Controlled by a
microprocessor circuit, the motor continually adjusts its speed to achieve a steady flow of
solvent that is crucial to precision analysis and data reliability.
Most of today’s HPLC pumps share similar technology such as a rapid-refill cam design,
speed-adjusting motors, pulse damper, and preprogrammed pulse-reduction patterns.
What distinguishes IP300 is its Automatic Pulse Reduction System which virtually eliminates
pulsation without use of dampers, and achieves a highly stabilized solvent flow that is not
easily reproducible by other HPLC pumps. At the initial stage of solvent flow, the
microprocessor circuit analyzes pulsation pattern, and then gradually reduces pulsation by
continually adjusting the motor speed. Unlike other HPLC pumps, IP300 dose not apply
preprogrammed patterns that do not reduce pulsation adequately. Instead, the circuit
studies the pulse pattern, and then applies the best motor speed for the pulsation that is
unique and particular to each solvent. The circuit continuously adjusts the motor speed
until the pulsation is reduced to insignificance. The result is an amazing flow stability that
meets the increasing demand for technological sophistication in today’s chromatography
(See Figure 1).
Figure 1: Pulse Reduction Chart
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1. 2 Technical Specifications
Model 301M 301 302
Max. Pressure (PEEK) 20 20 5
Max. Pressure
(Stainless Steel 316)
30 30 5
Flow Rates (ml/min) 0.001 ~ 0.999 0.01 ~ 9.99 0.1 ~ 50
Flow Accuracy (%) ±2
Flowrate Precision (%) ±0.3 RSD
Delivery System Dual Piston Pump
Wetted Materials PEEK, Sapphire, Ruby, PCTFE
Features Automatic Pulse Elimination System
Prime Purge System
Adjustable Pressure Limit (0 ~ 35Mpa)
LED Display
Remote Input RS-232C (x2)
Remote Output Remote Control Output
Dimensions (mm) 79W x 285D x 144H
Weight (kg) 5.0 4.5 5.0
Power Voltage AC100 ~ 240V 2A
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2. Installation
2.1 Unpacking and Inspection
Upon unpacking, make sure that all the accessories listed below are included in the box. If
the package appears dented and twisted, contact the carrier immediately to report
mishandling and inspect the contents for damage. Save the packing materials in case you
need to return the pump for repair service.
Product Name Description Quantity Note
Power cord 7A 125V 1
3P adapter 15A 125V 1
Fuse 2A 2
Open-end Wrench 8 x 10 1
Hex Wrench 2.5mm 1
PEEK Tube 1/16” x 0.5 x 1m
1/16 x 0.75 x 1m
1 301 Analytical
302 Semi-prep.
EASY FITT PEEK 2 For PEEK tube and syringe
STOP FITT PEEK 1
Syringe 1
Teflon Tube 3φx 2φx 1m 1 Two tubes for 302 semi-prep
Tee Joint 1 M8 tee joint / For 301
analytical only
TefzelⓇTube for Tee
Joint
1/16” x 1φx 9cm 2 For 302 semi-prep only. (four
EASY FITT 10φincluded)
Tee Joint Holder Stainless Steel 1
Suction Filter 1
M8 Flat-Seal Fitting 1 Two for 302 semi-prep
Double-Lock Ferrule 1 Two for 302 semi-prep
Note: STOP FITT, tee joint, Tefzel tube for tee joint and tee joint holder can be located on the
front panel of IP300. Do not use tools to tighten non-metal tee joints, nuts and plugs or it
may damage the connections. If you find any of the listed accessories defective, please
notify FLOM Corporation immediately. The warranty does not cover the cost of repair if the
damage was caused by the use of non-FLOM products.
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2.2 Tubing
Connect the inlet tube to the flow inlet. Connect the outlet tube to the flow outlet. For
tubing, use the PTFE tube included in the package.
2.3 Priming the Pump
Activate the pump and set the flow rate at 1ml/min. Connect a syringe connector to the
drain outlet and turn the drain valve about 90 degrees counterclockwise. Connect the
syringe to the syringe connector and draw air, until the solvent fills the inlet tube and reaches
the syringe. Turn the drain knob clockwise to shut the drain.
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3. Operation
3.1 Layout of Front and Rear Panels
1. LED Display
2. Flow Volume LED
3. Flow Pressure LED
4. Pressure Limit LED
5. Mode Selection Key
6. Pump LED
7. Pump Start / Stop Key
8. Down Key
9. Up Key
10. Flow Outlet
11. Drain Outlet
12. Drain Valve
13. Outlet Check Valves
14. Dual Pumphead
15. Cleaning Ports
16. Inlet Check Valves
17. Flow Inlet
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18. RS1 Port
19. RS2 Port
20. Remote Control Connection
21. Cooling Fan
22. Main Power Switch
23. Power Supply Inlet
24. Ground Connection
25. Fuse Box
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3.2 Functions of Parts and Keys
1. LED DISPLAY Shows flow volume, flow pressure, or pressure limit. Press the
mode selection key to switch from one mode to another.
2. Flow Volume LED The LED Display will show flow volume when this LED is lit. By
pressing UP or DOWN key (8 and 9), the user can adjust the
flow volume.
3. Flow Pressure LED The LED Display will show flow pressure when this LED is lit.
By pressing UP or DOWN key (8 and 9), the user can adjust the
flow pressure.
4. Pressure Limit LED The LED Display will show pressure limit when this LED is lit.
By pressing UP or DOWN key (8 and 9), the user can adjust the
pressure limit. The pump will buzz when the flow pressure
exceeds the pressure limit set by the user.
5. Mode Selection Key By pressing SET key (Mode Selection Key), the user can select
the desired mode (flow volume, flow pressure or pressure limit)
to show on the LED Display and make necessary changes with
the UP and DOWN keys.
6. Pump LED This LED lights up when the pump is activated. It will blink
during the purging process.
7. Pump Start/Stop Key This key activates and stops the pump. To activate the
emergency stop, press the key twice. It will blink when the
purge mode is activated.
8. Down Key It decreases the number shown in the LED Display. The
number decreases faster when the key is pressed down.
9. Up Key It increases the number shown in the LED Display. The number
increases faster when the key is pressed down.
10. Flow Outlet The solvent flows out from this outlet. This outlet should be
connected with a tube to a column or detector.
11. Drain Outlet This outlet is used to draw the solvent into the pump heads with
a syringe.
16. Flow Inlet The solvent flows in from this outlet. This inlet should be
connected with a tube to a solvent container or a degasser.
17. RS1 Port (In) It connects with any one of FLOM Gradient Controller 300 Series.
(Port type: RS-232C Inlet)
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18. RS2 Port (Out) It connects with any one of the FLOM pressure pumps.
(Port type: RS-232C Outlet)
19. Remote Control The Remote Control Port transmits following signals:
1. Pressure level (at 0.1V per 10Mpa).
2. Pump Start
3. Pump Stop
4. Program End (for Gradient Controller 300 Series)
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3.3 Selecting Flow Rate, Flow Pressure and Pressure Limit
First, press SET key to select from three choices: flow rate, flow pressure and pressure limit.
A different LED indicator (FLOW, PRES, and P. LIM.) will light up each time you press the
SET key, and the LED Display will show the value of each selection. Use UP and DOWN
keys to change the value shown on the LED Display.
To set the flow rate, press SET key repeatedly until the green LED indicator located
under the word “FLOW” lights up. The current flow rate will appear on the LED Display.
Then, change the flow rate shown on the LED Display by pressing UP or DOWN key.
Press PUMP key to start the pump. It will activate the automatic pulse reduction system to
reduce pulsation to a minimum.
To set the pressure limit, press SET key repeatedly until the green LED indicator
located under the word “P. LIM.” lights up. You can adjust the pressure limit with the UP
and DOWN keys. When the pressure level goes over the set limit, the alarm will go off and
the pump will shut down automatically with the error signal “Er 1” shown on the LED Display.
Press any key to shut off the alarm and return to normal. To reactivate the pump, press
PUMP key.
To set the pressure level, press SET key repeatedly until the green LED indicator
located under the word “PRES” lights up. The current pressure level will appear on the
LED Display. Then, change the value with the UP and DOWN keys.
3.4 Purging
To remove unwanted air bubbles inside the pump heads, press PUMP while pressing down
SET. The red LED indicator under the SET key will brink and the pump will be activated.
Increase the flow rate for faster and more efficient purging. Make sure that the increased
flow rate will not damage any equipment connected to the flow outlet. We recommend the
opening of drain valve to redirect the increased pressure to the drain outlet. To stop
purging, press PUMP once and the pump will slow down to a gradual stop. Press PUMP
twice to stop the pump immediately.
When air is left in the pump heads, the automatic pulse reduction system will fail to
reduce flow pulsation and the error signal “Er 3” will appear on the LED Display. When this
happens, run the purge mode at the flow rate of 10 MPa to eliminate all the bubbles inside.
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4. Maintenance
4.1 Cleaning the Piston
Often, the pump seal is damaged by crystals left on the piston by dried solutions. To
prevent crystallization, connect tubes to the cleaning ports as shown on the picture below
and flush out the deposited crystal from the pump head with distilled water.
4.2 Replacing the Piston Seal
The piston seal needs to be replaced periodically to prevent solvent leakage. To replace
the piston seal, remove tubing from both inlet and outlet check valves. Use a hex wrench
to unscrew and pull out the pump head. Plug the inlet check valve with a STOP FITT and
connect the syringe connector to the outlet check valve. By using a syringe, fill the pump
head with distilled water. Insert the Seal Insertion Tool1as shown below, and pull the
piston seal and O-ring gently out of the pump head. Insert a new piston seal and the O-ring
to the short end of the seal insertion tool. Make sure to have the O-ring facing outward.
Then insert the seal and O-ring into the pump head slowly. Re-attach the pump head to the
front panel and use a hex wrench to tighten the screws.
1Seal Insertion Tool is sold separately and not included in the original package.
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4.3 Pump Head Configuration
The picture below shows components of the IP300 pump head. Use this as a reference for
parts replacement.
1. Pump Head
2. Piston Seal and small O-Ring
3. Seal Backup Washer
4. Large O-Ring
5. Piston Housing
6. Flush Seal
7. Seal Backup Plate
8. Metal Spring
9. Piston Adapter
10. Piston
11. Bearing
12. Spacers
4.4 Cleaning Check Valves
Check valves need periodic cleaning to avoid clogging up of solvents. When left unwashed,
dried solutions may leave crystallized deposits inside the check valves. One way to clean
check valves is to pump laboratory-grade detergent by using prime purge mode and then
flush out the detergent with distilled water. If this method does not work, remove the tubing
from both the inlet and outlet check valves and use a wrench to unscrew the check valves
from the pump heads. Place the check valves in a beaker filled with alcohol or distilled
water and give them an ultrasonic bath for 10 to 20 minutes. Make sure to place the inlet
check valves to the inlets and the outlet check valves to the outlets. Tighten them firmly
with your own hands and use a wrench to provide extra tightening (turn the wrench about 60
to 90 degrees more). DO NOT OVER-TIGHTEN THE CHECK VALVES! The most
common damage to check valves is the crashing of seat holder, caused by excessive
tightening. “Firm feeling” is sufficient for tightening check valves.
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4.5 Check Valve Configuration
Check valve internals are shown on the picture below. Use this as a reference when you
assemble and disassemble check valves for cleaning purpose.
1. 1/16 Valve Cartridge
2. 1/16 Valve Cartridge
3. 1/8 Valve Cartridge
4. Seal*
5. Sphere and Seat*
6. Seat Holder
7. End Seal*
8. Connection Seal
9. T-Seal
* Important Notes:
1. When you place the seat (5) to the seat holder (6), make sure that the gloss side
faces inward (toward the sphere). Use light to identify the gloss finish. The flat
side faces outward, not touching the sphere.
2. To distinguish the end seal (7) from the regular seal (4), compare the thickness of
each. The seal that is thicker than the other is the end seal.
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5. Troubleshooting
5.1 Descriptions of Error Signals
Error Signal Descriptions
Er 1 Flow pressure exceeded the pressure limit set by the user. Check the
tubing and the column to see no unnecessary pressure is being applied.
Also make sure that the pressure limit is set at the reasonable level.
Er 3 The solvent does not flow through check valves. Use the prime purge
mode to remove any accumulated dirt or air inside the check valves. Clean
the check valves with an ultrasonic bath for more effective cleaning if
necessary.
Er 4 Pump motor was shut down because of high flow pressure / irregular
motor spinning. The most frequent cause of this error is not the
malfunction of the motor itself, but the presence of air bubbles destabilizing
the flow pressure. Run the prime purge mode to remove the air from the
pump heads and check valves. If the error still persists, clean the check
valves with an ultrasonic bath. Contact FLOM Corporation if these solutions
fail to solve the problem.
Er 5 Battery for memory chip has run out. Contact FLOM Corporation for
battery replacement. (The average lifespan of battery is 5 years.)
5.2 More Problem Solving
1. No power when the pump turned on.
 Check the power plugs and make sure they are inserted fully.
 Check the fuses in the fuse box to see if they require replacement.
 Check the voltage from power supply. If the voltage exceeds 250V, it
may damage the internal power adaptor.
2. Pump makes a clanging/slapping noise.
 Keep the pump reasonably away from other electronic devises.
 Keep the pump heads and cooling fan away from columns.
 Remove any objects covering ventilations on the casing.
3. Flow rate fluctuates
 Check the power supply. If the voltage is under 90V, the pump motor fails
to provide stable piston movement.
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5.3 List of Replacement Parts
P/N Product Name Description Quan Model
2100 1/16 Outlet Check Valve Kit No.10-32UNF 1 301/302
2101 1/16 Inlet Check Valve Kit No.10-32UNF 1 301
2102 1/8 Inlet Check Valve Kit M8 1 302
2204 Piston Seal ID3.2mm (water solution) 2 301
2206 Piston Seal ID3.2mm (buffer) 2 301
2227 Piston Seal ID3.2mm (organic solution) 2 301
2205 Flush Seal ID3.2mm 2 301
2207 Piston Seal ID 7mm (water solution) 2 302
2227 Piston Seal ID 7mm (buffer) 2 302
2208 Piston Seal ID 7mm (organic solution) 2 302
2226 Flush Seal ID 7mm 2 302
2209 Piston Seal Replacement Tool ID3.2mm 1 301
2228 Piston Seal Replacement Tool ID 7mm 1 302
2315 Cleaning Kit Tube and Syringe Connector 1 301/302
2561 Remote Connection Cable 1m cable (Pump On/Off) 1 301/302
How to Order:
Contact FLOM Corporation at the address shown below and provide part number and
product name. The parts listed above are only a fraction of products offered by FLOM
Corporation. If you cannot find the parts in the list, contact FLOM Corporation and
provide a detailed description of what you need. We will be glad to send you a detailed
list of parts.
FLOM Corporation
3-4-28 Imai
Ome-shi, Tokyo 198-0023
JAPAN
Phone: [phone]
Fax: [phone]
Email: [email protected]
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6. Safety Instructions
6.1 While Using IP300
 Do not pour or splash any liquid on the IP300. If the solvent is splashed on any part of
the pump by accident, turn off the main power switch immediately and pull the plug off
the power outlet before wiping off the solvent. Do not turn on the power switch until
the solvent on the pump has dried out completely, or it may cause fire, electric shock, or
malfunction of the pump. If the solvent wetted inside the pump, contact FLOM
Corporation immediately.
 Do not stick any sharp materials or pour any type of liquid through the ventilation
openings located on the sides of metal casing. It may damage the pump inside.
 When you move the IP300, make sure to turn off the main power switch and pull the
plug off the outlet. Touch neither the main power switch nor the plug when your hands
are wet.
 Do not place the IP300 where it could easily fall, such as near the edge of the table. If
the outlet is too far for the power cord to reach, use an extension cord with a
grounding-type plug.
 Protect the power cord from being walked on. Do not pinch the power cord. Insert
the plug firmly into the outlet to avoid the exposure of prongs.
 DO NOT DISASSEMBLE THE IP300 AND ATTEMPT TO FIX OR MODIFY IT
YOURSELF! If you desire to modify the IP300, or to fix IP300 that is malfunctioning,
contact FLOM Corporation and let our qualified engineers repair the IP300 or make
necessary changes. Under no circumstance remove the metal casing. Any
malfunctions caused by modifications by any person other than authorized FLOM
engineers will not be covered by the warranty. FLOM Corporation takes no
responsibility for any personal injuries or mechanical damages caused by unauthorized
modifications.
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 Do not use the IP300 in an outdoor environment.
 Do not place the IP300 other than the standing position. Do not lay it on its side or
stand on its front or rear panel.
 Keep the IP300 away from corrosive gases.
 Do not place the IP300 nearby high-voltage electronic devises. It may degrade the
performance of CPU board inside.
 Do not operate the IP300 under direct sunlight.
 Do not operate the IP300 in the environment where temperature fluctuates rapidly.
The room temperature must be within the range of 10C and 40C.
 The acceptable voltage for the IP300 ranges from AC 100V to 240V (50/60Hz). Do not
deviate from this voltage range or it may cause fire or electric shock.
 When you notice abnormality during the operation, turn off the main power switch
immediately and check the tube connections and the power cord. If no visible
problems are detected and the abnormality continues, contact FLOM Corporation
immediately.
 Do not bent, step on, or stack heavy materials on the power cord. Do not bundle
power cords.
 Do not place the IP300 nearby any heat sources. It may damage the IP300 or cause
fire.
 Make sure to remove all the remaining solvents inside the IP300 by flushing the tubes
with laboratory-grade detergent and distilled water before storing.
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7. Warranty Information
FLOM Statement of Limited Warranty
All of us at FLOM Corporation thank you for purchasing FLOM Intelligent Pump 300 Series
(IP300). We provide a 1-year warranty, and it is subject to the following limitations:
1. This warranty herein applies only to FLOM Intelligent Pump 300 Series and its
accessories packaged by FLOM Corporation and its authorized manufacturers.
2. The liability of FLOM Corporation shall be limited to:
a. Replacement of the defective Intelligent Pump 300 Series and its
accessories listed on the List of Accessories.
b. The cost of repairing the defective Intelligent Pump 300 Series and its
accessories including labor and replacement parts.
3. The warranty does not cover malfunctions caused by the following reasons:
a. The user failed to operate the IP300 according to the safety precautions
and safety instructions explained in the instruction manual.
b. The user operated the IP300 with another equipment that was defective.
c. The IP300 was mechanically modified by the owner or other users without
a written authorization from FLOM Corporation.
d. The user failed to follow the proper installation and operation procedure
explained in the instruction manual.
e. Degradation of the parts quality resulting from normal wear.
f. The user failed to notify FLOM Corporation of the problem within 30 days
from the date of occurrence.
g. The claimant failed to provide sufficient information regarding how the
failure occurred.
h. The claimant failed to return the parts to FLOM Corporation that he/she
claimed defective.
This warranty is written solely by FLOM Corporation. Neither party is responsible for
incidental or consequential damages arising from this warranty such as a decrease in profits,
loss of research data, and damage to other equipments. Limitations allowed on the
warranty vary from country to country, so certain limitations may not apply to you. This
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warranty gives you specific rights but you may have other rights according to laws of the
country in which you reside. If you have any questions regarding this warranty, contact
FLOM Corporation at the address below:
FLOM Corporation
3-4-28 Imai
Ome-shi, Tokyo 198-0023
JAPAN
Phone: [phone]
Fax: [phone]
Email: [email protected]
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