Jasco PU-1580 User manual

P/N 0302-0390B
MODEL PU-1580
INTELLIGENT HPLC PUMP
MAINTENANCE MANUAL

i
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.
(1) Safety symbols
Instruction manual symbol. If the product is marked with this symbol,
refer to the instrument manuals to protect the instrument against
damage.
WARNING A WARNING indicates an potentially hazardous situation which, if not
avoided, could result in death or serious injury
.
CAUTION A CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used
to alert against unsafe practices.
Do not proceed beyond a WARNING or CAUTION notice until you
understand the hazardous conditions and have taken the appropriate
steps.
Note A Note provides additional information to aid the operator in obtaining
optimal instrument performance.
Pressurized, hazardous solvents are used in high-performance liquid
chromatography. Always follow the proper laboratory procedures to ensure operator
safety. Always wear goggles, gloves and protective clothing when operating the
instrument, especially when injecting sample and opening valves.

ii
(2) Warning Labels
Warning labels are attached at several locations on this instrument. Do not remove,
deface or damage the warning labels. 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.
(1) Fuse Warning Label (P/N: 0822-0120A)
Fuse ratings are indicated in the maintenance
manual.
(2) Electric Shock Warning Label (P/N: 0822-0125A)
Electric shock may occur if the instrument is not
properly grounded.
Since water pipes are often constructed of non-
metallic materials (e.g., polyvinyl chloride), do not
use these pipes for grounding purposes.
For safety reasons, do not use gas pipes for
grounding purposes.
FUSE
PUSH
FUSE
PUSH
T1.6A
T2.5A
100‑120V
220‑240V
FUSE
1
2
3
4
5
6
7
PRESS.ZERO
ADJ.
EVENT
VALVE
GRAD.
LOWPRESS.
8
ACINPUT
GND
FUSE
RS‑232C
R
R
(2) Electrical shock
warning label
(1) Fuse warning label
ONLY WITH FUSE OF THE SPECIFIED
AGAINST RISK OF FIRE, REPLACE
FOR CONTINUED PROTECTION
TYPE AND CURRENT RATINGS.
WARNING
Figure 1 Rear View of the UV-1580
ONLY WITH FUSE OF THE SPECIFIED
AGAINST RISK OF FIRE, REPLACE
FOR CONTINUED PROTECTION
TYPE AND CURRENT RATINGS.
WARNING
WARNING
MAINS PLUG GROUND PIN
OR GROUND TERMINAL
MUST BE CONNECTED
TO GROUND.

iii
Preface
This instruction manual serves as your guidebook for using this instrument. It is
intended to instruct first-time users on how to properly use the instrument, and to
serve as a reference for experienced users.
Before using the instrument, please read this instruction manual carefully, and make
sure that the contents are fully understood. This manual should be easily accessible to
the operator at all times during instrument operation. 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
manual. This is the operations manual.

iv
Installation Conditions
To ensure safe operation, the following recommendations should be observed:
(1) Do not operate the instrument under voltage fluctuations exceeding 10%
of the recommended line voltage. Large fluctuations may cause the
instrument to fail.
(2) 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.
(3) Operate the instrument under a temperature range of 10 ∼30°C.
(4) Operate the instrument under a humidity range of 35 ∼85% (RH). If
ambient humidity exceeds 85% (RH), water vapor may deteriorate optical
components. If possible, install the instrument in a location having a
humidity of 60% or lower.
(5) Operate the instrument under an atmospheric pressure of 750 ∼1060 hPa.
(6) Avoid strong magnetic fields and sources of high-frequency waves. The
instrument may not function properly when near strong magnetic fields or
high-frequency wave sources.
(7) Avoid vibrations caused by vacuum pumps, electric motors, processing
equipment and machine tools.
(8) Avoid dust and corrosive gas. Do not install the instrument in a location
where it may be exposed to dust, especially in locations exposed to
outside air or ventilation outlets that discharge dust particles.
(9) Do not install the instrument in a location where it may be exposed to
direct sunlight.
(10) Do not install the instrument in a location where it may be directly exposed
to the air current from an air conditioner or heater, as such a location may
inhibit stable measurement.
Note: The above conditions do not ensure optimal performance of this instrument.

v
Maintenance
Consult your local JASCO distributor, listed at the back of this manual, regarding
maintenance. In addition, contact your local JASCO distributor representative when
transporting the instrument.
Replacement parts can be ordered according to part number from local JASCO
distributor. When the part number is not known, inform parts name,instrucment
model name and it’s serial number.
Notices
(1) Jasco shall not be held liable, either directly or indirectly, for any consequential
damage incurred as a result of the use of this product.
(2) Software prohibitions:
yCopying of software or related materials for purposes other than backup is
prohibited.
yTransfer or authorization of the use of Jasco software to or by a third party
is prohibited.
yDisclosure of confidential information related to Jasco software is prohibited.
yChanges or revisions to Jasco software are prohibited.
yUse of Jasco software on multiple workstations or terminals, through a
network or through any other means, is strictly prohibited. (This does not
apply to entities with the network license contract)
(3) The content of this manual is subject to change without notice in accordance
with product improvements.
(4) Unauthorized copying of this manual is prohibited.
(5) This manual shall not be used to guarantee or copyright industrial rights or other
rights.
(6) Company and product names listed herein are trademarks or registered
trademarks of various companies.

vi
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.
This warranty does not apply to defects as a result of the following:
(1) USE FOLLOWING IMPROPER OR INADEQUATE INSTALLATION.
(2) IMPROPER OPERATION.
(3) MOVEMENT, MODIFICATION, OR REPAIR BY PERSONS OTHER THAN
AUTHORIZED JASCO PERSONNEL.
(4) USE OF PARTS OTHER THAN THOSE THAT ARE AUTHORIZED BY
JASCO.
(5) INORDINATELY RAPID DETERIORATION DUE TO THE USE OF
CORROSIVE SOLVENTS OR SAMPLES.
(6) NATURAL DISASTERS SUCH AS FIRES, WATER DAMAGE, OR
EARTHQUAKES.
In addition, this warranty does not cover:
CONSUMABLE PARTS OR PARTS THAT HAVE A SEPARATE WARRANTY OR A
WARRANTY PERIOD THAT IS DIFFERENT THAN THAT SPECIFIED ABOVE.
The warranty period for all parts and repairs supplied under this warranty expires
with the warranty period of the original product.
Jasco Corporation, 1998

vii
Table of Contents
Page
Safety Considerations .......................................................................... i
Preface................................................................................................. iii
Installation Conditions ........................................................................iv
Maintenance ..........................................................................................v
Warranty ...............................................................................................vi
Table of Contents................................................................................vii
1 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 .......................................................................................... 1
1.1.3 Pump sensor errors .................................................................................. 2
1.2 Errors during operation................................................................................. 2
1.2.1 Errors due to exceedingly high pressure .................................................. 3
1.2.2 Errors due to exceedingly low pressure.................................................... 3
1.2.3 External device errors............................................................................... 3
2 Troubleshooting..............................................................................4
2.1 Abnormal operating pressure....................................................................... 4
2.1.1 TROUBLE OVER PRESS errors .............................................................. 4
2.1.2 TROUBLE UNDER PRESS errors............................................................ 4
2.1.3 Large variations in operating pressure...................................................... 5
2.2 Baseline problems......................................................................................... 7
2.2.1 High baseline noise .................................................................................. 8
2.2.2 Spike-shaped baseline noise.................................................................... 8
2.2.3 Large baseline drift ................................................................................... 9
2.2.4 Periodic drift.............................................................................................. 9
2.2.5 Appearance of ghost peaks.................................................................... 10
2.3 Chromatogram problems ............................................................................ 10
2.3.1 Lengthening retention time ..................................................................... 10
2.3.2 Shortening retention time........................................................................ 10
2.3.3 Poor reproducibility for retention time ..................................................... 11
2.3.4 Poor reproducibility for peak areas or peak heights
(reproducibility for retention times is good)............................................. 11
2.3.5 Peak waveform problems (peak broadening, peak splitting) .................. 11
2.4 Pump section leaks ..................................................................................... 11
2.4.1 Plunger seal leaks .................................................................................. 12
2.4.2 Check valve assembly leaks................................................................... 13
2.4.3 Purge valve leaks ................................................................................... 14
2.4.4 Outlet port (line filter) leaks..................................................................... 15
2.4.5 Bottom panel drain port leaks................................................................. 16

viii
2.4.6 Inlet tube fitting leaks.............................................................................. 16
3 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...................................................................... 18
3.2.1 Conditions under which adjustment is required ...................................... 18
3.2.2 Adjustment using the PRESS ZERO ADJ trimmer ................................. 18
3.3 Flow rate calibration.................................................................................... 19
3.3.1 Conditions under which the flow rate must be adjusted ......................... 19
3.3.2 Input method for the flow rate calibration value...................................... 20
3.3.3 Flow rate calibration: Step 1 (without back pressure)............................ 20
3.3.4 Flow rate calibration: Step 2 (with back pressure) ................................. 21
4 Maintenance ..................................................................................23
4.1 Air bubble removal ...................................................................................... 23
4.2 Pump solvent replacement ......................................................................... 24
4.2.1 Solvent replacement preparations.......................................................... 24
4.2.2 Replacing the solvent with water ............................................................ 25
4.2.3 Replacing the water with methanol......................................................... 26
4.2.4 Notes on solvent replacement ................................................................ 26
4.3 Cleaning using an acid or alkaline solution ............................................. 27
4.3.1 Conditions under which cleaning is required .......................................... 27
4.3.2 Acid and alkaline solution concentrations............................................... 27
4.3.3 Cleaning procedure ................................................................................ 28
5 Part Replacement and Operations Check ...................................30
5.1 Plunger seal replacement ........................................................................... 30
5.1.1 Plunger seal replacement preparations .................................................. 30
5.1.2 Plunger seal removal .............................................................................. 31
5.1.3 Plunger seal installation.......................................................................... 35
5.1.4 Pump head, solvent selection valve, and purge valve attachment ......... 36
5.1.5 Post-replacement verification ................................................................. 37
5.2 Line filter replacement................................................................................. 37
5.2.1 Check for line filter clogs......................................................................... 37
5.2.2 Line filter replacement procedure ........................................................... 38
5.2.3 Post-replacement verification ................................................................. 39
5.3 Inlet filter replacement................................................................................. 39
5.3.1 How to check for inlet filter clogs ............................................................ 39
5.3.2 Inlet filter replacement procedure ........................................................... 39
5.4 Pump head check valve assembly replacement ....................................... 40
5.4.1 Preparations for check valve assembly replacement.............................. 40
5.4.2 Check valve assembly replacement procedure ...................................... 41
5.4.3 Post-replacement verification ................................................................. 43

ix
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...................... 46
5.6.1 Purge valve needle replacement ............................................................ 47
5.6.2 Purge valve packing replacement........................................................... 47
5.7 Plunger replacement ................................................................................... 48
5.7.1 Plunger replacement preparations.......................................................... 48
5.7.2 Exposing the plunger .............................................................................. 48
5.7.3 Plunger replacement............................................................................... 49
5.7.4 Assembly of head mount flange and other parts .................................... 51
5.7.5 Post-replacement verification ................................................................. 51
5.8 Solvent selection valve disk replacement ................................................. 51
5.9 List of consumable parts ............................................................................ 52