Knauer BlueShadow 80P Operating instructions

Pump 80P
Service Instructions
Document Number: V6700
Document No. V7681A
HPLCHPLC
BlueShadow

Note: For your own safety, read the instructions and observe the
warnings and safety information on the device and in the instructions.
Keep the instructions for future reference.
Telefon: [phone] (9-17h, Central European Time)
Fax: [phone]
E-Mail: [e-mail]
Languages: German, English
KNAUER Wissenschaftliche Geräte GmbH
Hegauer Weg 38
14163 Berlin
Telefon: [phone]
Fax: [phone]
Internet: www.knauer.net
E-Mail: [e-mail]
Document number: V7681A
Version number: 2.1
Release date: 2021/02/19
Original edition
The information in this document is subject
to change without prior notice.
For the latest version of the service instruction, visit the
partner area on our website (login required):
www.knauer.net/Service-instructions
This document contains confidential information and may not be
reproduced without written consent of KNAUER Wissenschaftliche
Geräte GmbH.
© KNAUER Wissenschaftliche Geräte GmbH 2021
All rights reserved.
BlueShadow® is a registered trademark of
KNAUER Wissenschaftliche Geräte GmbH.
Customer
Support:
Publisher:
Version information:
Copyright:

BlueShadow Pump 80P Service Instructions V7681A
Table of contents
1. General ..............................................................................1
1.1 About these service instructions ...................................................1
1.2 Signal words ....................................................................1
1.3 Additional typographical conventions ..............................................2
1.4 Legal information ................................................................2
1.4.1 Liability limitation......................................................2
1.4.2 Warranty conditions ...................................................2
1.4.3 Warranty seal .........................................................2
1.4.4 Declaration of conformity...............................................2
2. Safety instructions for service technicians ................................................3
2.1 Qualification of the service technician ..............................................3
2.2 Service request form and decontamination report ...................................4
3. What is maintained or repaired? ........................................................5
4. Pump head repair and maintenance .....................................................6
4.1 Removing the pump head ........................................................6
5. Disassembling the housing .............................................................7
5.1 Removing the device hood .......................................................7
5.1.1 Spare parts ...........................................................8
6. Overview of the device ................................................................9
7. Replacing the LC display ..............................................................10
7.1 Removing the display unit .......................................................10
7.1.1 Display spare parts ...................................................11
8. Replacing the keypad .................................................................12
8.1 Removing the keypad ...........................................................12
8.2 Installing a new keypad..........................................................13
8.2.1 Keypad spare parts ...................................................13
9. Replacing the fans ...................................................................14
9.1 Replacing the device fan ........................................................14
9.1.1 Spare parts ..........................................................15
9.2 Replacing the fan of the power board .............................................16
9.2.1 Spare parts ..........................................................17

BlueShadow Pump 80P Service Instructions V7681A
Table of contents
10. Replacing the piston backflushing pump ................................................18
10.1 Removing the piston backflushing pump ..........................................18
10.1.1 Spare parts ..........................................................19
11. Replacing the pressure sensor .........................................................20
11.1 Removing the pressure sensor ...................................................21
11.2 Installing a new pressure sensor ..................................................22
11.2.1 Spare parts ..........................................................22
12. Repairing the pump drive .............................................................23
12.1 Replacing the carbon brushes on the motor........................................23
12.1.1 Spare parts ..........................................................24
12.2 Replacing the motor ............................................................24
12.2.1 Spare parts ..........................................................25
12.3 Replacing the timing belts .......................................................25
12.3.1 Removing the timing belts .............................................25
12.3.2 Tightening the timing belts on the pump drive ...........................28
12.3.3 Spare parts and equipment ............................................33
12.4 Replacing the hall sensor ........................................................33
12.5 Spare parts ....................................................................33
13. Replacing the fuses that protect the boards..............................................34
13.1 Spare parts ....................................................................35
14. Replacing the power board............................................................36
14.1 Spare parts ....................................................................36
15. Replacing the main board .............................................................37
15.1 Loosening plug connections of the main board.....................................38
15.2 Removing the main board .......................................................39
15.2.1 Spare parts ..........................................................40
15.3 Replacing RFID printed circuit board ..............................................41
15.3.1 Spare parts ..........................................................41
16. Replacing the power supply ...........................................................42
16.1 Removing the power supply .....................................................42
16.1.1 Spare parts ..........................................................43
17. Tightening torque for screws ..........................................................44
17.1 Screws in materials made of metal ................................................44
17.2 Screws in materials made of plastic ...............................................45

BlueShadow Pump 80P Service Instructions V7681A
Table of contents
18. Troubleshooting......................................................................46
18.1 Error list .......................................................................46
18.2 Possible problems and rectifications ..............................................49
19. Spare parts ..........................................................................51
19.1 Pump heads ...................................................................51
19.2 Housing .......................................................................51
19.3 Display and keypad .............................................................51
19.4 Fan ...........................................................................52
19.5 Piston backflushing pump .......................................................53
19.6 Pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
19.7 Pump drive ....................................................................54
19.8 Boards and fuses ...............................................................55
19.9 Power supply ..................................................................56

1
BlueShadow Pump 80P Service Instructions V7681A
1. General
1.1 About these service instructions
This document is an addition to the user instruction of the device. It inclu-
des all work that requires the opening of the device, installation of certain
components and maintenance work.
The service instructions enable the safe and ecient operation of the
device. The service technician must have carefully read and understood
this service instructions before starting any work.
The basic prerequisite for safe operation is compliance with all safety
instructions (see chapter „Safety instructions for service technicians“ auf
Seite 3). In addition to the safety and warning instructions in these
service instructions, the local accident prevention regulations and the
national industrial safety regulations apply.
Observe the following:
All safety instructions in the service instructions
All safety instructions in the user instructions
The environmental, installation and connection specifications in the
user instructions
Only use spare parts, tools and cleaning agents recommended or
prescribed by KNAUER.
Observe the RoHS conformity for mainboards! Never perform mainte-
nance on the mainboards independently. Always replace the mainboards
and return the defective boards to KNAUER technical support, otherwise
he warranty will lapse.
1.2 Signal words
Possible dangers related to the device are distinguished in personal and
material damages.
Symbol Meaning
DANGER (red) indicates a highly hazardous situa-
tion. If not avoided, it will result in death or serious
injury.
WARNING (orange) indicates a hazardous situa-
tion. If not avoided, it could result in death or
serious injury.
CAUTION (yellow) indicates a moderate hazardous
situation. If not avoided, it could result in minor or
moderate injury.
NOTICE (blue) is used to address issues which are
not related to physical injury.
What must be taken
into account?
Do not perform repairs
on the mainboard

2
BlueShadow Pump 80P Service Instructions V7681A
1.3 Additional typographical conventions
General equal treatment: When persons are described, this document
uses the male grammar form to keep the text easy to read. The form
has a neutral sense and speaks to people of any gender in the same
way.
Note: Specific information are prefixed with the word “Note” and an
information icon.
Note: This is an example.
1.4 Legal information
1.4.1 Liability limitation
The manufacturer is not liable for the following issues:
Non-compliance of these instructions
Non-observance of necessary safety precautions
Improper use
Operation of the device by unqualified personnel (see chapter
„Qualification of the service technician“ auf Seite 3)
Use of non-approved spare parts
Technical changes by the service technician such as unauthorized
modifications
Violations of General Terms and Conditions (GTC)
1.4.2 Warranty conditions
For information on warranty please refer to our general terms and condi-
tions on the website: https://www.knauer.net/terms
1.4.3 Warranty seal
The warranty seal is a security label which indicates if
any opening on instrument has occurred. Most KNAUER
products are sold with the blue seal on the rear side to
confirm that KNAUER was the last who took care of the
instrument.
An authorized service technician must order and ax
the orange warranty seal after opening the instrument
(order no. V0602) in the same place. If unauthorised per-
sons tamper with the device or if the seal is damaged,
the warranty will lapse.
1.4.4 Declaration of conformity
The declaration of conformity is enclosed as a separate document with
the product and can be obtained online:
www.knauer.net/en/Support/Declarations-of-conformity.

3
BlueShadow Pump 80P Service Instructions V7681A
2. Safety instructions for service technicians
The device has been developed and constructed in such a way that
hazards arising from its intended use are largely excluded. Nevertheless,
the following safety instructions must be observed in addition to the
basic safety instructions in the user instructions in order to avoid residual
hazards.
The following applies for all repairs on the device:
Electric shock
Danger of electric shock from voltage-carrying parts inside the
device. The housing serves as a protective cover against voltages
inside the device.
Switch the device o before opening the device.
Pull the power plug.
2.1 Qualification of the service technician
These service instructions are intended for the following professional
groups:
Task Authorized
Maintenance KNAUER service technicians
Service technicians authorized by KNAUER
who have completed a service training
Level 2
Repair KNAUER service technicians
Service technicians authorized by KNAUER
who have completed a service training
Level 3
If you do not belong to one of these professional groups, you must under
no circumstances carry out the work described in this instruction.
The service technician is qualified to handle the device if all of the
following points apply:
Fluent English to be able to use the English-language service software
and online help.
Knowledge about the properties of the used solvents and their health
risks.
Protective measures
against any dangers
Electronic defect
Electrostatic discharge can destroy the electronics.
Wear a protective bracelet against electrostatic discharge and ground.
Who may perform
repairs?

4
BlueShadow Pump 80P Service Instructions V7681A
Due to technical training and experience, the service technician can
understand and carry out all the work described in the service instruc-
tions and recognize and avoid possible dangers independently.
The ability of the technician to react is not impaired by the consump-
tion of drugs, alcohol or medication
2.2 Service request form and decontamination
report
We advise you not to repair devices which are not accompanied by the
completed document “Service request form and decontamination report”
(www.knauer.net/decontamination-report).

5
BlueShadow Pump 80P Service Instructions V7681A
3. What is maintained or repaired?
Check the number of operating hours in the KNAUER Service Tool
software.
Hours in operation Measures
1.000 Check the torque of the screw fittings
Clean the pistons
Check check valves
5.000 Check the drive
Check the tension of the timing belt
Check motor and axial tolerance
Replace all seals
Clean the check valves
10.000 Clean pump drive and grease again
(if necessary)
Replace timing belt
Check carbon brushes and replace if
necessary
Overhaul pump head, replace all wear parts
Check motor and axial tolerance
Check the adjustment of all parameters with
the service tool
Replace check valves
Check
operating hours

6
BlueShadow Pump 80P Service Instructions V7681A
4. Pump head repair and maintenance
Possible skin damage
Aggressive or toxic solvent residue can irritate the skin!
Wear protective gloves.
Flush the pump head before exchanging it.
In case of a malfunction or as part of routine maintenance, the pump
head can be disassembled into individual parts and cleaned.
During this procedure, seals, backing rings, springs or pistons can be
replaced. It is not necessary to disassemble the pump head to replace the
check valves.
Please refer to the pump head service instructions (VSM-001) in the part-
ner area on the KNAUER website for detailed instructions.
4.1 Removing the pump head
1. To remove the capillaries, loosen the capillary screw fittings (A) at the
pump head outlet and pressure sensor inlet.
2. Disconnect the tubing of the piston backflushing (B) from the inlet
and outlet of the flush pump and from the pump head.
3. Remove the eluent lines (D) from the eluent inlets.
4. Using an Allen key, loosen the opposite pairs of fastening screws (C)
at the pump head evenly and alternately to prevent the pump pistons
on the inside from jamming.
5. Hold the pump head by hand, and consecutively pull out all fastening
screws.
6. Remove the pump head.
Legend:
A Capillary screw fittings
B Tubing of the piston
backflushing
C Fastening screw
D Eluent lines
Fig. 1: Removing
C
D
A
B
the pump head

7
BlueShadow Pump 80P Service Instructions V7681A
5. Disassembling the housing
It is necessary to open the housing for certain maintenance and repair
work.
Electric shock
Danger of electric shock from voltage-carrying parts inside the
device. The housing serves as a protective cover against voltages
inside the device.
Switch the device o before opening the device.
Pull the power plug.
5.1 Removing the device hood
The device hood is secured with six 3.0mm inner diameter Torx screws:
The following steps are recommended for opening the housing:
1. Switch o the device and pull the power plug.
2. Remove the screws of the device hood on the rear of the device.
3. Push the housing hood back and then remove it upward.
Torx screwdriver, T10
Approx. 5min.
Level 2 (from 1 to 7, very easy to very dicult)
Process Figure
1. Unscrew the 6 Torx screws (A)
and washers with the screwdri-
ver and store them safely.
Fig. 2: Removing
A
screws of
device hood
Procedure
Tools
Duration
Level of diculty

BlueShadow Pump 80P Service Instructions V7681A
Disassembling the housing 8
Process Figure
2. Push device hood (B) back.
3. Lift the device hood up with
both hands.
Fig. 3: Removing device hood
The device has been opened.
5.1.1 Spare parts
Component Comment Order number
Device hood P5163A
Result
B

9
BlueShadow Pump 80P Service Instructions V7681A
6. Overview of the device
Legend:
A LC Display
B Ventilation screw
pressure sensor
C Pump head
D Timing belt
E Pump drive
F Fan of power board
G Power board
H Device fan
I Main board
Fig. 4: Top view of the open device
Legend:
A Motor
B Piston backflushing
pump
C Carbon brushes of the
motor
D Pressure sensor
Fig. 5: View from left side of the open device
I
C
BD A
H
G
G
C
B
A
DEF

BlueShadow Pump 80P Service Instructions V7681A
Replacing the LC display 10
Legend:
A RFID printed circuit
board
B Power board
C Main board
D Power supply
E Hall sensor
Fig. 6: View from upper right side of the open device
7. Replacing the LC display
The device is switched o.
The power plug has been pulled.
The device hood has been removed (see chap. 5 on page 7).
The following steps are recommended for replacing the display:
1. Remove cable connections.
2. Remove screws and washers.
3. Remove display component.
4. Install new display component or parts of it.
Torx screwdriver, T6
Approx. 5min.
Level 2 (from 1 to 7, very easy to very dicult)
7.1 Removing the display unit
Note: The display unit, consisting of LC display and display board must
be replaced as a component.
E
Prerequisite
Procedure
Tools
Duration
Level of diculty
Electronic defect
Electrostatic discharge can destroy the electronics.
Wear a protective bracelet against electrostatic discharge and ground.
C
B
A
D

BlueShadow Pump 80P Service Instructions V7681A
Replacing the LC display 11
Process Figure
1. Remove the keypad ribbon
cable (A) and the display cable
(B) from the LC display board
(C).
Fig. 7: Cable on display board
2. Loosen the 2 Torx screws and
washers (D) from the display
board.
3. Carefully remove the display
from the device.
Fig. 8: Screws on display board
The LC display has been removed.
1. Install a new display component in reverse order.
2. Switch on the device and check if the display, standby function and
standby light work properly.
7.1.1 Display spare parts
Component Comment Order number
Display assembly complete G1957A
Display board G1813XA
BC
D
Result
Next steps
A

BlueShadow Pump 80P Service Instructions V7681A
Replacing the keypad 12
8. Replacing the keypad
The keypad is adhesive. The adhesive surface is covered by a protective
film.
The device is switched o.
The power plug has been pulled.
The device hood has been removed (see chap. 5 on page 7).
The following steps are recommended for replacing the keypad:
1. Remove cable.
2. Remove keypad.
3. Install new keypad.
Slotted screwdriver
Approx. 20min.
Level 4 (from 1 to 7, very easy to very dicult)
8.1 Removing the keypad
Process Figure
1. Remove the keypad ribbon
cable (A) from the display
board (B).
Fig. 9: Keypad cable
connection
2. Remove the keypad (C) by
sliding the slotted screwdriver
under the keypad in one cor-
ner and lifting it up.
3. Lift up the keypad and pull it
from the device.
4. Carefully remove residues of
glue from the front plate.
5. Using a cloth and isopropanol,
degrease the surface.
Fig. 10: Keypad
Procedure
Tools
Duration
Level of diculty
A
C
B

BlueShadow Pump 80P Service Instructions V7681A
Replacing the keypad 13
The keypad has been removed.
Install a new keypad.
8.2 Installing a new keypad
Process Figure
1. Bend the ribbon cable (A)
away from the keypad.
2. Remove the protective film (B)
from the adhesive surface.
Pay attention that the ribbon
cable does not touch the
adhesive surface.
Fig. 11: Keypad
3. Guide the ribbon cable
through the slot (C) in the front
plate.
4. Stick the keyboard to the front
panel.
Fig. 12: Slot for keypad cable
5. Connect the ribbon cable (A)
to the display board.
Fig. 13: Keypad cable connector
The keypad has been replaced.
8.2.1 Keypad spare parts
Component Comment Order number
Keypad Complete M3220E
Result
Next steps
A
B
C
Result
A

14
BlueShadow Pump 80P Service Instructions V7681A
9. Replacing the fans
There are two kinds of fans inside the device:
Legend:
A Device fan
B Fan of the power board
Fig. 14: Fans inside the device
9.1 Replacing the device fan
Note the following when replacing the device fan:
The device fan can be removed from the inside of the device without
using tools.
Always replace the fan and the fan sleeve together.
The device is switched o.
The power plug has been pulled.
The device hood has been removed (see chap. 5 on page 7).
Procedure for removing the device fan:
1. Remove the device fan power supply cable from the PIN connector
on the main board.
2. Remove the device fan completely from the inside of the device by
hand.
3. Insert a new fan.
4. Insert the fan power supply cable into the PIN connector on the
mainboard.
Approx. 10min.
Level 2 (from 1 to 7, very easy to very dicult)
Airflow direction
A
B
Prerequisites
Procedure
Duration
Level of diculty

BlueShadow Pump 80P Service Instructions V7681A
Replacing the fans 15
Process Figure
Legend:
A PIN connector
on the main board
B Fan
C Fan sleeve
D Fan knobs
1. Remove the fan power cable
from the PIN connector (A).
Fig. 15: Device fan
2. By hand, remove the entire fan
with the sleeve out of the rear
panel of the device by turning
it clockwise until the knobs (D)
align with the bigger holes.
Fig. 16: Fan knobs
The device fan has been removed.
Insert a new in reverse order.
Note: Pay attention to the air path of the fan which is marked with an
arrow on the fan. The air path leads out of the device.
Note: There are two PIN connectors on the main board which are loca-
ted next to each other which are designed for the fan (see „Fig.51: Assi-
gnment of the plug connections on the main board“ on page 38).
9.1.1 Spare parts
Component Comment Order number
Fan Complete G5029
Fan sleeve M2431
C
BA
D
Result
Next step