Knauer BlueShadow 10P User manual

BlueShadow
HPLC
Pump 10P/20P
Service
V7635A

3Tableofcontents
Table of contents
Note: For your own safety, read the manual and always
observe the warnings and safety information on the
device and in the manual!
Safety for service technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power supply and mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What is maintained or repaired? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump head repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removing the pump head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembling the pump head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembling the pump head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing the ball valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exchanging the ball valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassembling the housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removing the housing hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removing the side panels of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overview of the open device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removing and maintaining the pump drive. . . . . . . . . . . . . . . . . . . . . . . . 26
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Replacing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tightening the timing belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Replacing the fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removing the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installing the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replacing the Hall sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacing the LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacing the keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removing the keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Gluing on the keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Replacing the motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacing the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
V7635A

4Tableofcontents
Tightening torque for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Screws in materials made of metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Screws in materials made of plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Possible problems and rectifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pump head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10 ml Stainless steel head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pump head 10 ml titanium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
50 ml Pump head, stainless steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
50 ml Pump head, titanium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5 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 equip-
ment 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?
This manual is intended for 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
in the device manual
Only use spare parts, tools and cleaning agents recommended
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.
Conformity The Declaration of conformity for this device is located in the
device manual.
Professional group Title
Service technician Service technicians from
manufacturer
Service technicians authorized by
the manufacturer with a certificate

6 Safety for service technicians
Protective measures
The following applies for all repairs on the device:
Hazard symbol Title
DANGER!
Danger of electric shock!
Switch off power supply!
Pull the power plug!
DANGER!
Danger due to toxic, caustic, or
radioactive substances due to conta-
mination of the device.
The customer must ensure that the
device has been thoroughly decon-
taminated before repairs are perfor-
med.
CAUTION!
Micro-electronic device components
that could be damaged by electro-
static discharge (ESD) when tou-
ched.
Take precautions against electrostatic
discharge.
Electrostatic Discharge

7 Safety for service technicians
Power supply and mains connection
The device is intended for use with AC power networks of 100-
240 V.
The supplied power cable is to be used in connection with the
external power supply to connect the device to the mains sup-
ply.
CAUTION!
If the power supply is switched on, then the firmware may be
damaged by switching the mains on and off.
Switch off power supply beforehand!
Ground
The ground connection for the pump has a designated hole with
a thread M3 on the back of the device.
If the supplied power supply is used, then the ground connec-
tion remains unused.
Please contact the technical service department of the manu-
facturer, if the pump along with other devices should be con-
nected to the power supply with a 6-prong power supply.
CAUTION! Contact the technical customer service of the
manufacturer if the pump should be connected with a multi-
ple power supply of another manufacturer to the power sup-
ply. There is a risk of damaging the electronics.

8 What is maintained or repaired?
What is maintained or repaired?
Check operating hours Check the number of operating hours on the display.
Lubrication schedule
Check the moving parts inside the pump drive every 10000 ope-
rating hours for wear and sufficient lubrication.
Hours in operation Measures
1000 Check the torque of the screw
fittings
Clean the pistons
Check ball valves
5000 Check the drive
Check the tension of the timing belt
Check motor and axial tolerance
Replace all seals
Clean the ball valves
10000 Clean drive and grease again (if
necessary)
Replace timing belt
Overhaul pump head, replace all
wear parts
Check motor and axial tolerance
Check the adjustment of all
parameters with the service tool
Replace ball valves
Compo-
nent
Comment Lubricating
grease
Slider All surfaces of the slider that
have contact with the drive
housing
Molykote
bearing
grease, MOS2
Ball bear-
ings of the
slides
Surfaces of the outer bearing
ring
Molykote
grease paste
Cam plates for the surfaces of the cam
plates
Molykote
grease paste

9 Pump head repair
Pump head repair
WARNING!
Aggressive or toxic solvent residue can irritate the skin! Wear
protective gloves!
In case of a malfunction or as part of routine maintenance, the
pump head can be disassembled into individual parts and clea-
ned.
During this procedure, seals, guide discs, springs or pistons can
be replaced. It is not necessary to disassemble the pump head to
replace the ball valves.
Prerequisites Access to the list of spare parts (online or manual)
OQ test has been performed
Large, clean work surface
The pump head has been flushed with suitable solvent.
Special tool Torque wrench: X0219
Plug tool: X0221; X0222; X0223
Plug-in hexagon socket 4 mm: X0236
Adapter for hexagon socket: X0234
Special tool KIT for pressing in the seals for a 10 ml pump
head: W0200
Special tool KIT for pressing in the seals for a 50 ml pump
head: W0206
Allen wrench set: X0217
Duration About 30 minutes
Level of difficulty Level 7 (1 = very easy to 7 = very difficult)

10 Pump head repair
Removing the pump head
Procedure 1. Remove tubing from the connections of the piston backflus-
hing (A).
2. Remove all connections from the solvent bottles.
3. Unscrew the eluent line (D).
4. Unscrew the outlet fitting 2 (E) and the inlet fitting pressure
sensor (F) so as to remove the capillary.
5. Loosen the opposite pairs of fastening screws (B) on the pump
head evenly and alternately.
6. Hold the pump head by hand, and consecutively pull out all
fastening screws.
7. Remove the pump head.
.
Fig. 1 Pump head
Legend
A Fastening screw
B Inlet screw fitting
C Connection for eluent
line
D Outlet screw fitting
E Inlet fitting of the pres-
sure sensor
B
B
ED
C
A

11 Pump head repair
Disassembling the pump head
CAUTION!
Avoid breaking the piston rods! Before disassembly, first
remove the two piston rods.
Deposit the two piston rods in the correct orientation to
ensure correct orientation when putting them back in.
A Capillary screw fitting
B Seal ring
C Capillary connection kit
D Inlet screw fitting
E Ball valve
F Seal
G Outlet screw fitting
H Capillary connection kit
I Feed block
J High-pressure seal
K Sapphire ring
L Adaptor ring
M Support ring
N O-ring
O Piston backflushing
P Low-pressure seal
Q Washer
R Compression spring
S Bushing
T Piston guide
U Screw
V Piston rod
Fig. 2 Rear view of a complete pump head
H
G
F
E
I J K L MN O P Q R S T U V
D
B
A
C
Flussrichtung

12 Pump head repair
Removing and
inspecting the piston
1. Deposit the pump head onto a soft surface.
2. Remove the piston rod by hand, making sure it does not tilt
and is pulled out straight.
3. Deposit the piston rod in the correct orientation.
4. Check both piston rods for visual wear tracks.
Complete disassembly
of the pump head
Process Figure
1. Flush the pump head
with water or isopro-
panol if the pump
head is to be stored.
2. Remove the pump
head (see manual).
3. Remove and inspect
the piston rods (A) of
the removed pump
head, e.g. for wear
tracks.
4. Unscrew the piston
guide (B).
5. Put the individual
parts of the piston
guide back onto the
piston in the correct
orientation to make
the subsequent
assembly easier.
6. Remove flushing
block (C).
Fig. 3 Back of the device, the sub-
assemblies are visible.
A
B
C
Removing the piston
guide
Process Figure
1. Clamp the pump
head in a vice if pos-
sible.
2. Unfasten screws (A)
using Allen wrench
“size 4” while pres-
sing down on piston
guide (B) to protect
against pressure.
3. Remove piston guide
from the pump head
and lay it to the side.
Fig. 4 Piston guide
B
A

13 Pump head repair
Practical tip Use new seal.
Removing the piston
guide
Process Figure
A Remove the parts
and securely deposit
them in the proper
sequence and in the
correct orientation.
A Low-pressure seal
B Washer
C Compression spring
D Bushing
E Piston guide
F Piston rod
Fig. 5 Parts of the piston guide
AB C D E F
Legend
A High-pressure seal
from with metal wire
mesh to the feed
block
B Sapphire ring
C Adaptor ring for sap-
phire ring with guide
to the outside
D Piston
Fig. 6 Principle of the internal structure of the piston guide
ABC D
Replacing seals on the
inner side of the feed
block
Process Figure
A Special tool for
dismantling the seals
B Feed block
1. Screw the special
tool into the seal and
pull from the feed
block.
Fig. 7 Special tool with feed block
A
B

14 Pump head repair
Replacing the seals of
piston backflushing
Process Figure
1. Replace
O-rings (A) of
the piston
backflushing.
Fig. 8 O-ring of the piston backflushing
2. Screw the spe-
cial tool into
the low-pres-
sure seal (B)
and pull from
the flushing
block.
Fig. 9 Low-pressure seals of the piston
backflushing
A
B

15 Pump head repair
Assembling the pump head
Order of operation
for assembly
The pump head is assembled in this sequence:
• The pump head is assembled.
• Peripherals are attached to the pump head.
• Pump head is installed into the pump.
Assembly begins with inserting the new seals on the feed and
flushing blocks. The blocks are then laid onto each other in the
correct orientation.
Pre-forming the high-
pressure seal
Process Figure
1. Set the high-pressure
seal (A) with the
metal washer spring
pointing outwards
onto the special tool
(B) and pre-form the
seal.
Fig. 10 Special tool for pressing in
the high-pressure seal
B
A
Press in the high-pres-
sure seal with the spe-
cial tool
Process Figure
1. Press the high-pres-
sure seal into the
feed block using the
special tool (A).
Fig. 11 Special tool in the feed
block
A

16 Pump head repair
Inserting the spacer Process Figure
1. Insert sapphire ring
into adaptor ring (A)
and place on sealing
tool.
2. Using the special
tool, insert the adap-
tor ring, together
with the sapphire
ring, into the feed
block.
Fig. 12 Sapphire ring in the adaptor
ring
A
Inserting the guide
disc and the O-ring
into the piston back-
flushing
Process Figure
1. Insert guide discs (A)
into the flushing
block.
2. Insert O-rings (B).
3. Put the feed block
and piston backflus-
hing together in the
correct orientation.
Fig. 13 Piston backflushing with
O-ring
AB

17 Pump head repair
Press in the low-pres-
sure seal into the pis-
ton backflushing
Process Figure
1. Place the low-
pressure seal
(A) onto the
special tool
(B).
2. Press in the
seal with the
special tool.
Fig. 14 Special tool and low-pressure seal
Fig. 15 Feed block with piston backflus-
hing and low-pressure seals
AB

18 Pump head repair
CAUTION!
It is important that the washers are positioned flat, as any til-
ting will shorten the pump head service life.
Intermediate result The pump head is ready to be screwed together.
Positioning the
washers flat, compres-
sion springs, bushings
Process Figure
The springs for the pis-
ton guide can be positi-
oned on the feed block
and piston backflus-
hing, which have been
put together.
1. Positioning the
washers (A) flat
2. Position compres-
sion springs (B).
3. Position the bus-
hings (C) in the cor-
rect orientation. Fig. 16 Piston backflushing with
washers
Fig. 17 Compression springs with
bushing
A
A
B

19 Pump head repair
CAUTION! It is important that the pistons are not pushed in
tilted at an angle, as this will reduce the service life of the
pump head.
Result The pump head was repaired and reassembled.
Screwing the pump
head together
Process Figure
1. Position piston guide
(A).
2. Insert screws with
Allen wrench (B).
3. Manually press the
piston guide (C)
down against the
compression springs.
4. Alternately screw in
the screws with a size
4 Allen wrench to 3
Nm, making sure
that no tilting or jam-
ming occurs.
Fig. 18 Mounting the piston guide
A
B
C
Inserting the piston
rod
Process Figure
1. Carefully insert the
piston rods (A) indi-
vidually one after the
other by hand.
Fig. 19 Assembled pump head wit-
hout peripherals
A

20 Pump head repair
Replacing the ball valves
Dirty ball valves may not open and close correctly. The entire ball
valve is replaced. For replacement of the ball valves, the manu-
facturer recommends removing the pump head.
Prerequisite • Pump has been flushed with water and isopropanol.
• Pump has been switched off.
Duration About 10 minutes
Level of difficulty Level 2 (1 = very easy to 7 = very difficult)
Process Title
1. Loosen the capillary
connections (C, D) bet-
ween the two feed
chambers of the pump
with a wrench, alterna-
ting sides every revolu-
tion to avoid jamming
(due to tilting).
2. Loosen screw fitting of
the outlet and inlet side
(A).
3. Check seals (F) made of
advanced Teflon® and
replace if necessary.
4. Replace ball valve (G,
H), paying attention to
its alignment. Marking
ring in the ball valve
indicates the direction
of flow (see illustration).
The marking on the
ball valve has to be on
the bottom, as the flow
of eluent will otherwise
be blocked.
Fig. 20 Ball valves with marking
ring for the direction of
flow

21 Pump head repair
Torques
Exchanging the ball valves
Note: The ball and position of the valves have been harmo-
nized to each other. Insert the valves in the direction of
flow!
Fig. 21 Functional principle of the ball valve
Dirty ball valves do not open and close properly. They cause pres-
sure fluctuations and irregular flow.
Purge the pump head before changing the ball valve.
Removing the ball valves Note: Loosen the screw fittings of the capillary connections
alternately, to prevent the capillaries from bending.
1. Unscrew the inlet fitting 2 (A) and capillary fitting (B).
2. Unscrew outlet fitting 1 (C).
3. Remove the ball valve.
4. Unscrew inlet fitting 1 (E).
5. Remove the ball valve.
No. Torque Wrench
C, K 7.5 Nm Size 10
D5Nm 1/4"
E, J 15 Nm Size 13
Legend
A Ball valve
B Ball (dotted line)
C Flow direction
(arrow)
B
A
C