Thermo Scientific Dionex Aquion Manual

Thermo Scientific
Preventive Maintenance
Procedure
Dionex Aquion
Dionex ICS-1000
Dionex ICS-1100
Dionex ICS-1500
Dionex ICS-1600
Dionex ICS-2000
Dionex ICS-2100
031928 Revision 07 March 25, 2016

© 2016 Thermo Fisher Scientific Inc. All rights reserved.
All other trademarks are the property of Thermo Fisher Scientific Inc. and its subsidiaries.
Thermo Fisher Scientific Inc. provides this document to its customers with a product purchase to use in the
product operation. This document is copyright protected and any reproduction of the whole or any part of this
document is strictly prohibited, except with the written authorization of Thermo Fisher Scientific Inc.
The contents of this document are subject to change without notice. All technical information in this
document is for reference purposes only. System configurations and specifications in this document supersede
all previous information received by the purchaser.
This document is not part of any sales contract between Thermo Fisher Scientific Inc. and a purchaser. This
document shall in no way govern or modify any Terms and Conditions of Sale, which Terms and Conditions of
Sale shall govern all conflicting information between the two documents.
Revision history: Revision 01 released February 2003
Revision 02 released March 2003
Revision 03 released October 2006
Revision 04 released September 2009
Revision 05 released October 2012; new part numbers assigned
Revision 06 released August 2013; new part numbers assigned
Revision 07 released March 2016; support for Dionex Aquion added, checklist removed
Software version: Chromeleon 7.2 SR4 and later required for Dionex Aquion support
For Research Use Only. Not for use in diagnostic procedures.

© 2016 Thermo Fisher Scientific Inc.
All rights reserved.
This manual describes a preventive maintenance procedure for the Thermo Scientific™ Dionex™ Aquion,
ICS-1000, ICS-1100, ICS-1500, ICS-1600, ICS-2000, and ICS-2100 Ion Chromatography Systems.
The procedure consists of:
• Rebuilding the high-pressure injection valve
• Rebuilding the auxiliary valve (optional)
• Replacing the pump check valve cartridges
• Replacing the pump seals
• Replacing the waste valve and priming valve O-rings
• Replacing the end-line filter
Thermo Fisher Scientific recommends performing this procedure annually, as well as before scheduled
Performance Qualification tests.
Time
Required
30 to 45 minutes
Parts
Required
Before starting the preventive maintenance procedure, verify that all parts listed in this section are at hand.
Included Parts
In addition to this manual, the Preventive Maintenance Kit (P/N 057954) includes the following items:
Preventive Maintenance Procedure
Dionex Aquion and ICS-1000/1100/1500/1600/2000/2100
IMPORTANT Substituting non-Dionex/Thermo Scientific parts may impair system performance,
thereby voiding the product warranty. Refer to the warranty statement in the Dionex Terms and
Conditions for more information.
Part Number Item Quantity
014895 O-ring for pump spacer 2
045987 End-line filter 1
045994 Check valve cartridge 2
048722 Pump rinse seal 2
055752 O-ring for waste and priming valves 2
055870 Piston seal 2
059283 O-ring for pump piston rinse seal 2
062823 NEXT DUE DATE label 1
075973 Injection Valve Rebuild Kit, 6-port 1
Revision 07 031928

2
Items Provided in the System Ship Kit
The following items are provided in each system Ship Kit:
• 1/4 x 5/16-in open-end wrench (P/N 014605)
• 10 cc syringe (P/N 079803)
Additional Items Required
The following items must be provided by the user:
• ASTM filtered, Type I (18 megohm-cm) deionized water
• Squirt bottle (optional)
• Standard disposable laboratory gloves (must be powder-free, oil-free, and particle-free)
• 0.2 micron filtered, Class 10, isopropyl alcohol (IPA) (optional)
• 1/2-in wrench (P/N 062336)
• Two 10-32 fitting plugs (P/N 042772)
Figure 1. Split-cone ferrule
Rebuilding
the High-
Pressure
Injection
Valve
To rebuild the high-pressure injection valve
1. Turn off the pump.
2. Open the front door of the system.
3. Disconnect all liquid lines to the pump head.
4. Disconnect each liquid line connected to the injection valve.
5. Follow the instructions provided in the Injection Valve Rebuild Kit, 6-port (P/N 075973) to
replace the rotor seal and stator face seal.
System Ship Kit Part Number
Dionex Aquion, ICS-1000, ICS-1100, ICS-1500, or ICS-1600 057905
Dionex ICS-2000 or ICS-2100 064375
IMPORTANT DO NOT OVERTIGHTEN FITTINGS. Overtightening a fitting can restrict the
tubing ID, which can cause damage to the system. The split-cone ferrules are especially sensitive to
overtightening (see Figure 1). Use a wrench to tighten the fittings. Tighten them slightly more only if
they leak.

3
6. Reconnect all liquid lines to the injection valve (see Figure 2 or Figure 3).
Figure 2. Dionex Aquion or ICS-1000/1100/1500/1600 injection valve plumbing
Figure 3. Dionex ICS-2000/2100 injection valve plumbing
Rebuilding
the Auxiliary
Valve
(Optional)
If an auxiliary valve is installed and has been used enough to require maintenance, rebuild the valve by
following the basic procedure described in “Rebuilding the High- Pressure Injection Valve” on page 2. Use
the appropriate Rebuild Kit and refer to the instructions included with the kit:
• For the 6-port auxiliary valve, use the Injection Valve Rebuild Kit (P/N 075973).
• For the 10-port auxiliary valve, use the 10-port Valve Rebuild Kit (P/N 079054).
Replacing the
Pump Check
Valve
Cartridges
To remove the pump check valve cartridges
1. Rinse the pump flow path with ASTM filtered, Type I (18 megohm-cm) deionized water. Direct
the flow to waste by opening the waste valve on the secondary pump head (see Figure 4). To open
the valve, turn the knob one-quarter to one-half turn counterclockwise.
2. After rinsing, turn off the pump and close the waste valve.
Note A backpressure coil may be installed between port Pand the line labeled
TO INJECT VALVE - P.

4
3. To prevent contamination of pump parts, put on standard disposable laboratory gloves (must be
powder-free, oil-free, and particle-free) before disassembling the pump head.
4. Disconnect the tube fittings from the inlet and outlet check valve assemblies on the primary
pump head (see Figure 4).
Figure 4. Pump heads (Dionex Aquion and ICS-1100/1600/2100 pump shown)
5. Using a 1/2-in wrench (P/N 062336), loosen both check valve assemblies and remove them from
the pump head.
Figure 5. Inlet and outlet check valve assemblies
6. Remove the cartridges from the housings.
Note Never disassemble the pump head with bare hands. Even minute particles of dust, dirt, skin
cells, etc., on the check valves or piston can contaminate the inside of the pump head and result in
poor pump performance.
Note The inlet check valve assembly housing has a 1/4-28 port. The outlet check valve assembly
housing has a 10-32 (smaller) port (see Figure 5).
IMPORTANT The pump will not operate properly and may be damaged unless the check valve
cartridges are installed in their respective housings in the correct orientation. Liquid enters
through the check valve in the large single hole and exits through the small double holes.
Secondary
pump head
Outlet check valve
Primary pump head
Acorn nuts (2)
Inlet check valve
Waste valve
Inlet check valve
1/4-28 port
Flow
Inlet check valve
cartridge (double-hole
end visible)
Outlet check valve
10-32 port
Outlet check valve
cartridge (single-hole
end visible)
Flow

5
To install the new check valve cartridges
1. For the inlet check valve: Place a new cartridge (P/N 045994), with the double-hole end of the
cartridge visible, in the housing.
For the outlet check valve: Place a new cartridge, with the single-hole end visible, in the housing.
2. For the inlet check valve assembly: Install the check valve assembly on the bottom of the primary
pump head.
For the outlet check valve assembly: Install the check valve assembly on the top of the pump head.
3. Tighten the check valves fingertight, and then use the 1/2-in wrench (P/N 062336) to tighten an
additional one-quarter to one-half turn.
Replacing the
Pump Seals
Note about replacing a pump piston
Pump piston replacement is not part of the preventive maintenance procedure. However, if replacement is
required (for example, because the piston is dirty, scratched, or broken), order the piston separately
(P/N 052840) and follow the instructions in this section to remove the old piston and replace it with the
new one.
To remove the pump head and piston
1. Disconnect all tubing connections to the pump head.
2. Using the 1/4 x 5/16-in wrench (P/N 014605), remove the two acorn nuts from the pump head
(see Figure 4).
3. Slowly pull the head and allow it to separate from the housing. Carefully disengage the head from
the piston by pulling the head straight off and away from its mounting studs.
Note The opening for the outlet check valve assembly is slightly closer to the back of the pump
head than the opening for the inlet check valve assembly.
IMPORTANT Overtightening may damage the pump head and check valve housing and crush the
check valve seats.
Note Complete the following steps for each pump head in turn.
CAUTION Lateral motion while disengaging the pump head from the piston may
break the piston.
CAUTION Un mouvement latéral pendant la séparation de la tête et du piston peut
casser le piston.
CAUTION Vermeiden Sie Seitwärtsbewegungen, wenn Sie den Kopf vom Kolben
lösen. Andernfalls kann der Kolben brechen.

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4. Place the head (front end down) on a clean work surface and lift off the spacer to expose the
piston seal (see Figure 6 for the primary pump head; see Figure 7 for the secondary pump head).
Figure 6. Primary pump head
Figure 7. Secondary pump head
Piston
(P/N 052840)
O-Ring
(P/N 055752)
Piston Seal
(P/N 055870)
Primary Pump Head
(P/N 055711)
Seal Guide
(P/N 058032)
Spacer with Drain
(P/N 057913)
Priming Valve Knob
(P/N 055709)
Inlet Check
Valve Assembly
(P/N 045722)
Outlet Check
Valve Assembly
(P/N 045721)
O-Ring
(P/N 059283)
Piston Rinse Seal
(P/N 048722) O-Ring
(P/N 014895)
Piston
(P/N 052840)
Seal Guide
(P/N 058032)
O-Ring
(P/N 055752)
Piston Seal
(P/N 055870)
Secondary
Pump Head
(P/N 055712)
Spacer with Drain
(P/N 057913)
Waste Valve Knob
(P/N 055710)
O-Ring
(P/N 059283)
Piston Rinse Seal
(P/N 048722) O-Ring
(P/N 014895)

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5. The piston does not come off as part of the pump head assembly because it is captured by a
magnetic retention system. To remove the piston after removing the pump head:
a. Hold the shaft of the piston (near the base).
b. Tilt the piston slightly.
c. Pull the piston away from the pump.
To install the new piston rinse seal
1. Remove the seal guide from the spacer to expose the piston rinse seal and O-ring.
2. Remove the O-ring.
3. Remove the old piston rinse seal from the seal guide:
a. Hold the seal guide with the flat side facing up.
b. To dislodge the piston rinse seal, gently insert the shaft of the piston through the small hole in the
center of the seal guide (see Figure 8).
Figure 8. Removing the piston rinse seal
c. Pull the seal off the end of the piston shaft and remove the piston from the seal guide.
4. Hold the new piston rinse seal (P/N 048722) with the grooved side facing up.
5. Using your fingertip, gently press the piston rinse seal into the seal guide until the edge of the seal
is below the surface of the seal guide.
6. Place the new O-ring (P/N 059283) into the groove in the seal guide.
7. Remove the O-ring from the groove in the flat side of the spacer and replace it with the new
O-ring (P/N 014895).
8. In one hand, hold the guide with the O-ring and piston rinse seal facing up (this prevents the
O-ring from falling out). In the other hand, hold the spacer with the cavity facing down.
9. Gently press the seal guide into the cavity in the spacer until it is fully seated.
To remove the piston seal from the pump head
1. For the primary pump head: Install a 10-32 fitting plug (P/N 042772) on the outlet check valve.
Tighten the plug.
For the secondary pump head: Install a 10-32 fitting plug (P/N 042772) in both the inlet and
outlet ports. Tighten the plugs.
IMPORTANT The piston rinse seal is made of soft plastic. Do not press on the seal with anything
hard or sharp, including your fingernail. If the seal is nicked or gouged, it will not seal properly and
may result in leaks.

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2. Close the priming valve.
3. Using a squirt bottle or a plastic syringe, fill the head cavity with deionized water through the
piston opening (see Figure 9).
Figure 9. Filling the head cavity with deionized water (plastic syringe shown)
4. Reinsert the piston into the seal, and then push the piston into the head (see Figure 10). The seal
should hydraulically pop out from the head.
Figure 10. Seal popping out from the head
5. Remove the piston and pull off the seal.
6. If the main seal was not removed in Step 4, follow these steps:
a. Verify that the 10-32 fitting plugs in the inlet and outlet holes are tightened enough to prevent
any leaks from the pump head.
b. Fill the piston cavity with water and check for bubbles.
c. If there are no bubbles, repeat Step 4.
7. Remove the 10-32 fitting plug(s).
To install the new piston seal
1. Open the priming valve knob (primary pump head) or waste valve knob (secondary pump head)
by turning the knob one-quarter to one-half turn counterclockwise.
2. Push the piston through the spacer and through the new seal (P/N 055870). Insert the piston and
seal into the pump head until the seal makes contact with the bottom of the counterbore.
Note If necessary, lubricate the seal with a small amount of 0.2 micron filtered, Class 10, isopropyl
alcohol (IPA) to facilitate insertion.
Piston
Pump head
Seal

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3. To seat the seal, push down on the spacer until it is flush with the head. A clicking sound
indicates that the seal is correctly seated.
4. Close the priming valve knob or waste valve knob.
To reinstall the pump head and piston
Thermo Fisher Scientific recommends reinstalling the head and piston as a single assembly, so that the
piston centers itself onto the magnetic follower.
1. Hold the assembled spacer and guide with the drain tubes aligned vertically and press the spacer
into the head until it is flush with the indented surface of the head.
2. Insert the piston so that 6 mm (1/4 in) of the shaft is exposed. This ensures that the magnet in
the follower picks up the piston. (The follower is the cylinder that holds the piston in place as it
moves in and out of the pump head assembly.)
3. Reinstall the head and piston assembly. Use a wrench to tighten the nuts evenly (12 in-lb torque).
Replacing the
Waste Valve
and Priming
Valve
O-Rings
To replace the waste valve and priming valve O-rings
1. To remove the waste valve or priming valve from the pump head, turn the knob counterclockwise
until it is loose, and pull the knob straight out of the cavity in the pump head (see Figure 11).
Figure 11. Waste and priming valves (Dionex Aquion and ICS-1100/1600/2100 pump shown)
2. If the O-ring is removed with the valve knob in Step 1, pull the O-ring off the end of the knob
(see Figure 12).
If the O-ring is not removed with the valve knob, insert a thin object (for example, the bent end
of a paper clip) into the cavity in the pump head and carefully extract the O-ring.
IMPORTANT Do not scratch the cavity. Scratches in the cavity will cause leaks around the base of
the knob while the pump is being primed.
Waste valve Priming valve

10
Figure 12. Waste valve or priming valve O-ring replacement
3. Slide a new O-ring (P/N 055752) over the end of the valve.
4. Reinstall the valve knob containing the new O-ring into the pump head, turn the knob
clockwise, and tighten fingertight.
Replacing the
End-Line
Filter
To replace the end-line filter
1. Install the new end-line filter (P/N 045987) on the end of the eluent or deionized water line,
inside the reservoir.
2. Verify that the end of the filter extends to the bottom of the reservoir and that the filter is
submerged in liquid. This prevents air from being drawn through the lines.
Completing
the
Procedure
To complete the preventive maintenance procedure
1. Reconnect all liquid lines to the pump head.
2. Prime the pump.
3. When the system is at operating pressure, check for leaks from the check valves. Tighten a check
valve one-eighth of a turn at a time only if it leaks.
4. Check for leaks from fittings and tighten as needed.
5. Close the front door of the system.
6. Enter the date one year from today on the NEXT DUE DATE label (P/N 062823). Attach the label
to a convenient place on the exterior of the system.
Note It is normal to encounter resistance after several rotations of the knob. The O-ring is being
pushed into the cavity of the pump head.
Valve Knob
O-Ring
(P/N 055752)