Thermo Scientific Dionex ICS-1000 User manual

Preventive Maintenance Procedure for
Dionex ICS-1000, ICS-1100, ICS-1500,
ICS-1600, ICS-2000, and ICS-2100
Ion Chromatography Systems
Document No. 031928
Revision 05
October 2012

© 2012 Thermo Fisher Scientific Inc. All rights reserved.
Chromeleon is a registered trademark of Thermo Fisher Scientific Inc. in the United
States.
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.
Thermo Fisher Scientific Inc. makes no representations that this document is
complete, accurate, or error-free and assumes no responsibility and will not be liable
for any errors, omissions, damage, or loss that might result from any use of this
document, even if the information in the document is followed properly.
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
For Research Use Only. Not for use in diagnostic procedures.

Doc. 031928-05 10/12 1
Preventive Maintenance Instructions
These instructions describe a preventive maintenance procedure for the Thermo
Fisher Scientific Dionex™ICS-1000, ICS-1100, ICS-1500, ICS-1600, ICS-2000,
and ICS-2100 Ion Chromatography Systems. Thermo Fisher Scientific
recommends performing this procedure annually, as well as before scheduled
Performance Qualification tests.
The preventive maintenance procedure consists of the following steps:
•Rebuilding the injection valve
•(Optional) Rebuilding the auxiliary valve
•Replacing the pump check valves
•Replacing the pump piston rinse seals and piston seals
•Replacing the waste valve and priming valve O-rings
•Replacing the end-line filter
Included Parts
In addition to these instructions, the Preventive Maintenance Kit (P/N 057954)
includes the following items:
Part Number Item Quantity
057896 Injection Valve Rebuild Kit 1
045994 Pump check valve cartridge 2
048722 Pump piston rinse seal 2
055870 Pump piston seal 2
059283 O-ring for pump piston rinse seal 2
014895 O-ring for pump spacer 2
055752 O-ring for waste and priming valve 2
045987 End-line filter 1
062823 NEXT DUE DATE label 1

Preventive Maintenance Instructions
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Additional Items Required
The following items are provided in the Ship Kit for each system:
•1/4 x 5/16-inch open-end wrench (P/N 014605)
•10 cc syringe (P/N 079803)
The following items must be provided by the user:
•ASTM filtered, Type I (18 megohm-cm) deionized water
•Cleanroom gloves (lint-free, particle-free, and oil-free)
•1/2-inch wrench (P/N 062336)
•Two 10-32 fitting plugs (P/N 042772)
Preventive Maintenance Checklist
For your convenience, a Preventive Maintenance Checklist is provided in
Section 8. While performing preventive maintenance, record information on the
checklist whenever instructed to do so. When you finish, save the checklist. The
completed checklist verifies that the maintenance is performed at regularly
scheduled intervals.
Time Required
30 to 45 minutes
Substitution of non-Thermo Scientific/Dionex parts may impair
system performance and void the product warranty. For details, see
the warranty statement in the Dionex Terms and Conditions.
System Ship Kit Part Number
Dionex ICS-1000 or ICS-1100 057905
Dionex ICS-1500 or ICS-1600 067110
Dionex ICS-2000 or ICS-2100 064375

Dionex ICS-1000, ICS-1100, ICS-1500, ICS-1600, ICS-2000, and ICS-2100
Doc. 031928-05 10/12 3
1. Rebuilding the Injection Valve
1. Turn off the pump.
2. Open the front door of the system.
3. Disconnect each liquid line connected to the injection valve.
4. Follow the instructions provided in the Rebuild Kit (P/N 057896) to replace
the rotor seal, isolation seal, and stator face.
5. Reconnect all liquid lines to the injection valve (see Figure 1 for the Dionex
ICS-1000/1100/1500/1600 or Figure 2 for the Dionex ICS-2000/2100).
DO NOT OVERTIGHTEN FITTINGS. Overtightening a fitting can
restrict the tubing ID, which can cause damage to the system.
The split-cone ferrules shown
here are especially sensitive to
overtightening. Tighten these
fittings fingertight only and
then tighten them slightly more
only if they leak.
Figure 1. Dionex ICS-1000, ICS-1100, ICS-1500, and ICS-1600
Injection Valve Plumbing

Preventive Maintenance Instructions
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NOTE A backpressure coil may be installed between port P and
the line labeled TO INJECT VALVE - P.
6. Close the door.
7. Turn on the pump.
Record the completed steps on the Preventive Maintenance Checklist.
2. (Optional) Rebuilding the Auxiliary Valve
If an auxiliary valve is installed and has been used enough to require maintenance,
rebuild the valve by following the basic procedure described for rebuilding the
injection valve (see Section 1). Use the appropriate Rebuild Kit and refer to the
instructions included with the kit.
•For the 6-port auxiliary valve, use an Injection Valve Rebuild Kit
(P/N 057896).
•For the 10-port auxiliary valve, use a 10-port Valve Rebuild Kit (P/N AAA-
061759).
Record the completed steps on the Preventive Maintenance Checklist.
Figure 2. Dionex ICS-2000 and ICS-2100 Injection Valve Plumbing

Dionex ICS-1000, ICS-1100, ICS-1500, ICS-1600, ICS-2000, and ICS-2100
Doc. 031928-05 10/12 5
3. Replacing the Pump Check Valves
Preparation
1. Rinse the pump flow path with deionized water. Direct the flow to waste by
opening the waste valve on the secondary pump head (see Figure 3). To open
the valve, turn the knob one-quarter to one-half turn counterclockwise.
2. After rinsing, close the waste valve and turn off the pump.
3. Close the eluent valve from the system Control panel in the Thermo Scientific
Dionex Chromeleon™Chromatography Data System or select Eluent Valve
Closed on the touch screen PUMP page.
4. Turn off the main power switch and disconnect the power cord, to ensure that
you do not unintentionally start the system.
Replacing Check Valves
1. To prevent contamination of pump parts, wear cleanroom gloves when
disassembling the pump head.
2. Disconnect the tube fittings from the inlet and outlet check valve assemblies
on the primary pump head (see Figure 3).
3. Use a 1/2-inch wrench (P/N 062336) to loosen both check valve assemblies.
Remove the check valve assemblies from the pump head.
Figure 3. Pump Heads (Dionex ICS-1100/1600/2100 Pump Shown)
Secondary
Pump Head
Primary
Pump Head
Outlet Check
Valve
Inlet Check
Valve
Acorn Nuts

Preventive Maintenance Instructions
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NOTE The inlet check valve assembly housing has a 1/4-28
port. The outlet check valve assembly housing has a 10-
32 port (see Figure 4).
4. Place a new cartridge (P/N 045994) in
the inlet check valve housing with the
double-hole end of the cartridge visible.
Place a new cartridge in the outlet
housing with the single-hole end visible
(see Figure 4).
NOTE The pump will not operate
properly unless the cartridge is
installed in the housing in the
correct orientation. Liquid
enters through the check valve in
the large single hole and exits
through the small double holes.
Figure 4. Inlet and Outlet Check Valve Housings
5. Install the inlet check valve assembly (P/N 045722) on the bottom of the
primary pump head. Install the outlet check valve assembly (P/N 045721) on
the top of the head. Tighten the check valves fingertight, and then use the
1/2-inch wrench to tighten an additional one-quarter to one-half turn.
Record the completed steps on the Preventive Maintenance Checklist.
Overtightening may damage the pump head and check valve housing
and crush the check valve seats.
Single-hole
Flow
Flow
Inlet Check Valve Outlet Check Valve
1/4-28 Port 10-32 Port
Double-hole

Dionex ICS-1000, ICS-1100, ICS-1500, ICS-1600, ICS-2000, and ICS-2100
Doc. 031928-05 10/12 7
4. Replacing Pump Piston Rinse Seals and Piston 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.
NOTE Complete the following steps for each pump head.
Removing the Head and Piston
1. To prevent contamination of pump parts, wear cleanroom gloves while
disassembling the pump head.
2. Disconnect all tubing connections to the pump head.
3. Use the 1/4 x 5/16-inch wrench (P/N 014605) to remove the two acorn nuts
(see Figure 3) from the pump head.
4. 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.
5. Place the head (front end down) on a clean work surface and lift off the spacer
to expose the piston seal (see Figure 5 or Figure 6).
Lateral motion while disengaging the pump head from the piston may
break the piston.

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Figure 5. Primary Pump Head
Figure 6. 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)

Dionex ICS-1000, ICS-1100, ICS-1500, ICS-1600, ICS-2000, and ICS-2100
Doc. 031928-05 10/12 9
6. 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: hold the shaft of the piston (near the base), tilt the piston
slightly, and pull the piston away from the pump.
Installing the New Piston Rinse Seal
1. Remove the guide from the spacer to expose the piston rinse seal and O-ring.
Remove the O-ring.
2. Remove the old piston rinse seal from the guide as follows:
a. Hold the 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 guide (see Figure 7).
c. Pull the seal off the end of the
piston shaft and remove the piston
from the guide.
Figure 7. Removing the Piston Rinse Seal
3. Hold the new piston rinse seal (P/N 048722) with the grooved side facing up.
4. Using your fingertip, gently press the piston rinse seal into the guide until the
edge of the seal is below the surface of the guide.
5. Place the new O-ring (P/N 059283) into the groove in the guide.
6. 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).
7. 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.
8. Gently press the guide into the cavity in the spacer until it is fully seated.
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.

Preventive Maintenance Instructions
10 Doc. 031928-05 10/12
Removing the Piston Seal from the Head
1. If this is the primary pump head, install a 10-32 fitting plug (P/N 042772) on
the outlet check valve. Tighten the plug.
2. If this is the secondary pump head, install a 10-32 fitting plug (P/N 042772)
in both the inlet and outlet ports. Tighten the plugs.
3. Fill the head cavity with deionized water by injecting the liquid through the
piston opening.
4. Reinsert the piston approximately 3 mm (0.125 inch) into the seal.
5. Push the piston into the head. (This should hydraulically unseat the seal from
the head.) Remove the piston and pull off the seal.
NOTE If the piston seal is not removed, ensure that the 10-32
fitting plug(s) are tight and add more water. Verify that
the head contains no air bubbles, and then repeat Step 4
and Step 5.
6. Remove the 10-32 fitting plug(s).
Installing 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 then 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
isopropyl alcohol to facilitate insertion.
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.

Dionex ICS-1000, ICS-1100, ICS-1500, ICS-1600, ICS-2000, and ICS-2100
Doc. 031928-05 10/12 11
Reinstalling the 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 inch) 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).
Record the completed steps on the Preventive Maintenance Checklist.
5. Replacing the Waste Valve and Priming Valve O-Rings
NOTE Complete these steps for each valve O-ring.
1. To remove the waste valve or priming valve from the pump head (see
Figure 8), turn the knob counterclockwise until it is loose, and then pull the
knob straight out of the cavity in the pump head.
Figure 8. Waste and Priming Valves (Dionex ICS-1100/1600/2100 Pump Shown)
Waste Valve
Priming Valve

Preventive Maintenance Instructions
12 Doc. 031928-05 10/12
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 9). 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. Do not scratch the
cavity.
3. Slide a new O-ring (P/N 055752) over the end of the valve.
4. Reinstall the valve containing the new O-ring into the pump head, turn the
knob clockwise and tighten fingertight.
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.
Record the completed steps on the Preventive Maintenance Checklist.
Scratches in the cavity will cause leaks around the base of the knob
while the pump is being primed.
Figure 9. Waste Valve or Priming Valve O-Ring Replacement
Valve Knob
O-Ring
(P/N 055752)

Dionex ICS-1000, ICS-1100, ICS-1500, ICS-1600, ICS-2000, and ICS-2100
Doc. 031928-05 10/12 13
6. Replacing the End-Line Filter
Install the new end-line filter (P/N 045987) on the end of the eluent or deionized
water line, inside the reservoir. 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.
Record the completed step on the Preventive Maintenance Checklist.
NOTE If the system is in continuous operation, change the end-
line filter weekly, or whenever it becomes discolored.
Replace the filter more often if bacterial buildup is
visible or if the eluent does not contain solvent.
7. Completing the Preventive Maintenance Procedure
1. Reconnect all liquid lines to the pump head.
2. Reconnect the power cord.
3. Turn on the system main power.
4. Open the eluent valve from the System Control panel in Chromeleon or select
Eluent Valve Open on the touch screen PUMP page.
5. Prime the pump.
6. When the system is at operating pressure, check for leaks from the check
valves. Tighten a check valve a little more only if it leaks.
7. Check for leaks from fittings and tighten as needed.
8. Record the date for the next preventive maintenance on the NEXT DUE DATE
label (P/N 062823). Apply the label to a convenient place on the exterior of
the system.
9. Complete the Preventive Maintenance Checklist.

Preventive Maintenance Instructions
14 Doc. 031928-05 10/12
8. Preventive Maintenance Checklist
Preventive maintenance completed by: _______________________________________
(signature)
Date: __________________
Dionex Product Serviced:
ICS-1000 ICS-1100 ICS-1500 ICS-1600 ICS-2000 ICS-2100
1. Injection valve rebuild (see Section 1)5. Waste valve and priming valve O-ring
replacement (see Section 5)
Rebuilt injection valve
Reconnected liquid lines to the valve
Installed new O-ring in waste valve
Installed new O-ring in priming valve
2. (Optional) Auxiliary valve rebuild (see
Section 2)6. End-line filter replacement (see Section 6)
Rebuilt auxiliary valve
Reconnected liquid lines to the valve
Installed new end-line filter
3. Check valve replacement (see
Section 3)7. Preventive maintenance completion (see Section 7)
Installed new inlet and outlet check
valve cartridges in the housings
Verified correct flow orientation of
each cartridge
Reinstalled inlet check valve assembly
on bottom of primary pump head
Reinstalled outlet check valve
assembly on top of primary pump
head
Reconnected liquid lines to pump
heads
Primed pump
Checked for leaks; tightened check
valves and fittings as needed
Recorded date for next maintenance
and applied the label to the system
4. Pump piston rinse seal and piston
seal replacement (see Section 4)Comments:
Installed new piston rinse seal in
primary pump head
Installed new piston seal in primary
pump head
Installed new piston rinse seal in
secondary pump head
Installed new piston seal in secondary
pump head