Knauer BlueShadow V6 User manual

BlueShadow
HPLC
Valves V6-V16
Service manual
V7696A

3Tableofcontents
Table of contents
Safety for service technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembling the housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removing the device hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removing the sides of device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overview of open device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacing the fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removing the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing and removing the valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removing the gearbox and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removing the gearbox and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installing the gearbox and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installing the motor and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjusting position 1 of the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjusting position 1 of the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mounting of the valve on the valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Screw the adapter plate to the back side of the valve. . . . . . . . . . . . . . . . . . 17
Screw the valve onto the valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mounting plate for valves and column holder . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connecting capillary with valve and seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inserting the needle seal in the syringe connection . . . . . . . . . . . . . . . . . . . . . 20
Multifunction module ‘Assistant’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connection of the pump with other devices . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control of the pump with chromatography software . . . . . . . . . . . . . . . . . 22
Local area network and automatic configuration . . . . . . . . . . . . . . . . . . . . . 22
Interfaces for data transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remote terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BIN 0–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Binary code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacing EEPROM or motherboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Overview of motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replacing the EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Possible problems and rectifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Valves and valve drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
V6-V16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
V7696A

4 Safety for service technicians
Safety for service technicians
Checking intended use Only use the device for applications that fall within the range
of the intended use. Otherwise, the protective and safety
equipment of the device could fail.
The installation manual is an addition to the existing device
manual; it includes all work that requires the installation of 
certain components or the opening of a device's housing.
Who may perform
repairs?
These instructions apply to the following professional groups
If you do not belong to one of these professional groups, under
no circumstances may you perform the work described in this
manual.
What must be taken into
account?
Observe the following:
All safety instructions in the maintenance manual
All safety instructions in the device manual
The environmental, installation and connection specifications
Only use spare parts, tools and cleaning agents recommen-
ded or prescribed by the manufacturer
Do not perform repairs
on the motherboard
Observe the ROHS conformity for motherboards! Never perform
maintenance on the motherboards independently.
Always replace the motherboards and return the defective
boards to the manufacturer technical support.
Professional group Authorized
Service technician Service technicians from manufac-
turer
Service technicians authorized by
the manufacturer with a certificate

5 Disassembling the housing
Protective measures
The following applies for all repairs on the device:
Disassembling the housing
Disassembly of the device hood and side panels is necessary
when carrying out certain repairs inside the device.
Removing the device hood
The device hood is attached to the rear panel of the device
by two hexagon socket screws.
Procedure The following steps are recommended for opening the housing:
1. Switch off the device and pull the power plug
2. Remove the hexagon socket screws of the device hood
3. Push back the device hood and lift off
Tools Hex socket screwdriver size 2
Duration Approx. 3 min
Level of difficulty Level 2 (from 1 to 7, very easy to very difficult)
Hazard symbol Warning instructions
DANGER! Danger due to toxic, caustic
or radioactive substances due to con-
tamination of the device.
The customer must ensure that the
device has been thoroughly deconta-
minated before repairs are performed.
Caution! Micro-electronic device com-
ponents that could be damaged by
electro-static discharge (ESD) when
touched.
Take precautions against electrostatic
discharge.

6 Disassembling the housing
Result The device hood has been opened.
Removing the device
hood
Process Figure
Legend
A Hexagon screws
1. Remove the two
hexagon screws on
the rear side of the
device.
Fig. 1 Unscrew the device hood
Legend
A Device hood
2. Push back the device
hood approx. 2 cm;
using both hands,
lift to remove.
Fig. 2 Tilting up the device hood
A
A

7 Disassembling the housing
Removing the sides of device
The two side panels are inserted into the front side of the
housing.
Prerequisite The device hood is open.
Procedure Lift the side up and tilt out
Duration Approx. 3 min
Level of difficulty Level 2 (from 1 to 7, very easy to very difficult)
Result The sides of the device are now open. Those repairs which,
according to the instructions in the manual, are to be carried
out inside the device, can be performed.
Overview of open device
Fig. 4 View of open device
Removing the sides
of device
Process Figure
Legend
A Side panel
1. Lift the side panel
approx. 1 cm
upwards.
2. Tilt out the side
panel and remove.
3. For the second side
panel, follow the
same procedure.
Fig. 3 Removing the side
of the device
A
Legend
A Board for the display
B Gearbox-motor sub-
assembly
C Motherboard
D Board for the photo-
electric sensor
E Slotted disk for
alignment
BC
D
E
A

8Replacingthefan
Replacing the fan
WARNING! Danger of electric shock! 
Switch off the power supply!
Pull the power plug!
Fig. 5 Fan
Removing the fan
Prerequisite The device hood has been removed.
The right side of the device has been removed.
Procedure Remove the PIN connector
Open cable holder
Unscrew the fan
Tools Cross-head screwdriver size 1
5.5 mm wrench
Duration Approx. 5 min
Level of difficulty Level 2 (from 1 to 7, very easy to very difficult)
Legend
A PIN connector
B Fan with
power cable
A B

9Replacingthefan
Result The fan has been removed from the device.
Installing the fan
Prerequisite The device hood has been removed.
The right side of the device has been removed.
Procedure Set the fan in place and grip securely
Insert both screws and tighten
Press the cable into the cable holder
Plug the PIN connector into the motherboard
Tools Cross-head screwdriver size 1
5.5 mm wrench
Duration Approx. 5 min
Level of difficulty Level 2 (from 1 to 7, very easy to very difficult)
Removing the fan Process Figure
1. Remove the fan power
supply cable from the
PIN connector (A)
on the main board.
2. Open the cable
holder (B).
3. Use the wrench to hold
the nuts inside the
device in place (E).
4. While gripping the fan
securely (D), loosen the
four Phillips-head
screws on the rear side
of the device.
5. Remove the fan and
cable from the housing.
Fig. 6 Removing the fan
AB C DE

10 Replacing the fan
Result A new fan has been inserted and connected to the main board
via a PIN connector.
Installing the fan Process Figure
1. Insert the four rubber
dampers (D) into the
rear panel of the
device.
2. Set the fan (A) onto
the rear panel of the
device, so that the
arrow on the fan indi-
cating the direction of
air suction corresponds
with the arrow in the
drawing.
3. Insert the Phillips-head
screws with washers (C)
through the rubber
dampers in the rear
panel of the device.
4. Position the toothed
washers and the
nuts (B).
5. While using the wrench
to grip the nuts from
behind the panel, tigh-
ten the Phillips-head
screws from the front.
6. Use four screws to fas-
ten the fan to the rear
panel of the device.
7. Lay the power cable
into the cable holder.
8. Plug the PIN connector
into the motherboard.
Fig. 7 Installing the fan
ABC

11 Installing and removing the valve drive
Installing and removing the valve drive
The valve drive is composed of the following subassemblies
Note: Together, the gearbox and the motor form a single subas-
sembly. For this reason, always replace the gearbox and motor
together.
When is it necessary to
replace the gearbox and
motor?
If the valve position is not achieved and an error message
is displayed
If the valve position is not achieved in the specified time
If the axle can no longer be turned by hand
Removing the gearbox and motor
The valve drive is attached by circlips to the mounting, in order
to leave the valve drive with sufficient play.
Prerequisites The valve has been unscrewed
The device hood has been removed
The cable from the gearbox and motor has been discon-
nected from the motherboard
The cable from the board of the photoelectronic sensor
has been disconnected from the motherboard
The correct spare parts are on hand:
134:1 gear ratio of the gearbox for the 13P/1C and 
17P/1C multiposition valves
66:1 gear ratio of the gearbox for the 6P/3C injection
valves
Procedure The following steps are recommended for removing the valve
drive:
1. Switch off the device and remove the external power supply
2. Remove both circlips
3. Disassemble the slotted disk
4. Unscrew the mounting as well as the board with the photo-
electric sensor
5. Remove the gearbox, motor and axle by lifting inward
Legend
Slotted disk (A)
photoelectronic
sensor (B) gearbox
and motor (C)
Fig. 8 Valve drive
ABC

12 Installing and removing the valve drive
Tools 3.0 mm and 2.5 mm Allen wrenches
Cross-head screwdriver size 1
Oscilloscope
Soldering iron
Duration Approx. 15 min
Level of difficulty Level 3 (from 1 to 7, very easy to very difficult)
Removing the gearbox and motor
Process Figure
1. Use pliers to loosen
both circlips (A,B)
on the the gearbox
mounting inside the
device; use a screw-
driver to lift them
off.
Fig. 9 The drive is fastened down
by circlips
2. Pull the drive and
motor together with
the slotted disk and
photoelectric sensor
away from the
mounting to
remove.
Fig. 10 Slotted disk (A), photoelec-
tric sensor (B), gearbox (C),
and motor (D)
B
A
ABCD

13 Installing and removing the valve drive
Result The gearbox and motor have been removed.
3. Unscrew both of the
inner 2.5 mm hexa-
gon socket screws
(A,B) in order to lift
off the slotted disk.
Fig. 11 Unfastening the 6P or 
16P slotted disk
4. Using a cross-head
screwdriver, loosen
the three Phillips-
head screws hold-
ing down the
mounting plate
and the board of
the photoelectric
sensor.
Fig. 12 The gearbox and motor
mounting and the board
for the photoelectric sensor
5. Remove the gear-
box-motor subas-
sembly
Fig. 13 Gearbox-motor 
subassembly
Process Figure
A
B
A

14 Installing and removing the valve drive
Installing the gearbox and motor
Note The gearbox and motor are always installed with a clearance
of 0.25–0.5 mm so that these have sufficient play during
operation
Always leave 0.2 mm clearance from the drive mounting
when installing the slotted disk
Take note of the direction of rotation of the gearbox and
motor! The red cable needs to be connected to the plus ter-
minal; the red and black cable needs to be soldered to the
negative terminal. Otherwise, the drive and motor will turn
in opposite directions
If there is reason to believe that the photoelectric sensor is
registering too much reflected light, use a matte black felt
pen to make a 1 cm marking on the inside of the front panel,
at the height of the perforated disk.
Prerequisites The correct spare parts are on hand:
134:1 gear ratio of the gearbox for 6 and 12 port valves
64:1 gear ratio of the gearbox for all other valves
The cable has been soldered to the gearbox-motor subassem-
bly (see instructions)
Procedure When installing the gearbox and motor, it is recommended
that the installation sequence be carried out in reverse order,
with the following steps:
1. Join the slotted disk, photoelectronic sensor with holder
and the gearbox and motor
2. Turn the slotted disk upward, in front of the photoelectric
sensor
3. Install the assembled slotted disk, photoelectric sensor,
holder, and the gearbox and motor in such a way that
the setup marking on the axis and the hole in the slotted
disk are pointing up
4. Attach both circlips
5. Connect the cable to the motherboard
6. Mount the valve with the setup marking pointing up
Tools 2.5 mm Allen wrench
Soldering iron
Duration Approx. 10 min
Level of difficulty Level 3 (from 1 to 7, very easy to very difficult)

15 Installing and removing the valve drive
Installing the motor and gearbox
Result The gearbox and motor have been installed.
Adjusting position 1 of the valve
Note:
Always use the alignment tool to realign position 1 of the valve
When is adjusting
necessary?
After installing a new motherboard
Process Figure
1. Installing the subas-
sembly
Fig. 14 Slotted disk (A), photoelec-
tric sensor (B), gearbox (C),
and motor (D)
2. Rotate the drive axle
with setup marking
(B) and the slotted
disk with adjustment
opening (A)
upwards for
position 1
(home position)
Fig. 15 Slotted disk
3. Function test of
the photoelectric
sensor, prior to
installation
Note:
If there is reason to believe that the
photoelectric sensor is not focusing
properly, use a matte black felt pen
to make a 1 cm wide marking
on the inside of the front panel,
at the height of the perforated disk
ABCD
A
B

16 Installing and removing the valve drive
Adjusting position 1 of the valve
Note: Only loosen the setting screw on the sensor board
when installing a new motherboard.
Process Illustration/description
1. Position the
alignment tool
(A) and secure in
place with the
hexagon socket
screws
Fig. 16 Alignment tool
2. The setup mark-
ing (B) needs to
be centered in
the alignment
tool
3. Disconnect the
motor cable from
the motherboard
Note:
As long as the motor is connected
with the motherboard, the motor
impedes the proper adjustment of
the zero point.
4. Use the oscillo-
scope to correct
the adjustment
Note:
Tighten the setting screw on the signal
board when the signal is at the maxi-
mum height.
5. Use safety paint
to mark the set-
ting screw (C) on
the sensor board
6. Position the valve in the correct direction, so that both
adjustment points of the drive and the valve are
pointing up
A
B
C

17 Installation and connection
Installation and connection
Mounting of the valve on the
valve drive
Delivery ex works All valve drives are delivered with a ready-mounted injection or
multiposition valve. For repeat orders, the electrical valves are
delivered with included adapter plate.
Screw the adapter plate to the back side of the valve.
1. Attach the adapter plate the right way around. The openings
for the countersunk screws point to the front.
2. Fasten the adapter plate with two Phillips-head screws (M3).
Tighten the Phillips-head screw firmly.
Fig. 17 Back side of the electrical valve – adapter plate
for mounting
Legend
A. Back side of an elec-
trical valve
B. Markings for the
mounting
C. Opening for the
drive axle of the
valve drive
D. Adapter plate for 
the mounting
E. Opening for coun-
tersunk screws
F. Phillips-head screws
A
B
C
D
E
F

18 Installation and connection
Screw the valve onto the valve drive
Caution! Risk of mix-up! Always mount the switch or injection
valve onto the matching valve drive. An operation of
the valve with the wrong valve drive can block the
eluent flow. Damage to the device or the system
might be the consequence. Observe the operating
modes!
Fig. 18 Mounting of the valve on the valve drive
1. Check the positions of the DIP switches on the bottom of the
device to make sure that the electrical control of the valve
drive has been set correctly.
2. Switch on the valve drive. The initialization of the valve drive
causes the markings on the drive axle to be on top.
3. Port 1 of the injection valve has to point up! Plug the injec-
tion valve on the drive axle on the valve drive.
4. Screw the injection valve to the adapter plate with Allen
screws M3.
Legend
A. Valve drive
B. Markings for the
true-sided mount-
ing on the drive axle
C. Injection valve
D. Position 1 top to the
true-sided mount-
ing on the drive axle
E. Allen screws (M3)
F. Sample loop, 20 μl
A
B
C
D
E
F

19 Installation and connection
Mounting plate for valves and column
holder
Valves can be attached on the side of housings of pumps, detec-
tors, valves, or multifunction modules (assistant) with a mount-
ing plate (order number G6725) and 4 screws.
Fig. 19 Mounting plate for valves and column holder
Connecting capillary with valve
and seal
Biconical seal
or Dynaseal
You can use two seal types to connect the steel or PEEK capillary
with the valves – biconical – or Dynaseal.
Note: For pressures ≥50 bar you should always use
a Dynaseal.
Legend
A. Valve drive
B. Mounting plate
C. Electrical injection or
multiposition valve
D. Side holder for
valves
E. Column holder
A
B
C
D
E
A. Biconical seal
B. Cutting ring
C. Seal ring
Fig. 20 Biconical seal and Dynaseal
B
AC

20 Installation and connection
Prerequisite The capillary end was cut off cleanly and at a right angle to the
capillary axis with a tube cutter (order number A0569).
UNF seal Steel capillaries are fastened with UNF seals at pressure of over
300 bar. The screw fittings of the seal are retightened with a
hexagonal spanner.
Note: All screw fittings are available as a short or long head
version. Short-as-possible capillaries with small inner
diameters allow for a low dead volume.
Inserting the needle seal in the
syringe connection
The needle seal for the syringe connection is available as PTFE
or Teflon tube. The sample loop is filled with a syringe or a feed
pump. It is necessary for this to insert a needle seal in the syringe
connection and to fixate it with a biconical seal.
1. Insert the needle seal in the syringe connection and put a
biconical seal on the tip to seal off the needle seal.
2. Screw on the syringe connection with installed needle seal on
connection 1 of the valve.
Connecting the capillar-
ies
Steps Figure
1. Place the biconical
seal (C) on the nee-
dle seal (B).
2. Push the capillary all
the way into the
valve connection.
3. Screw the screw fit-
ting hand-tight to
the seal.
Fig. 21 Biconical seal, capillary and
screw fitting as example of
the syringe connection (A)
C
B
A

21 Installation and connection
The injection valve is prepared for the injection of sample solu-
tions in the sample loop via a glass syringe with luer lock:
Fig. 22 Injection of a sample with glass syringe and
metal cannula
Multifunction module ‘Assistant’
The valve can be a component of a multifunction module in
which all necessary devices are already permanently assembled
in the factory. This multifunction module carries as an order
name the product name ‘Assistant’.
Note: Explanations on the mechanism and handling of the
multifunction module (‘Assistant’) are described in a
separate information sheet and added to the devices.
Legend
A. Injection valve
B. Syringe connection
C. Needle seal
D. Sample loop
E. Metal cannula with
luer lock
F. Glass syringe
A
B
C
D
F
E
Legend
A. Fraction collection
valve
B. Injection valve
C. Pump
Fig. 23 Example of a multifunction module (‘Assistant’)
ACB