Thermo Scientific Dionex Integrion HPIC Manual

Thermo Scientific
Dionex Integrion HPIC
System
Preventive Maintenance Procedure
22153-97004 Revision A March 22, 2016

© 2016 Thermo Fisher Scientific Inc. All rights reserved.
The following are registered trademarks in the United States and possibly other countries: KIMWIPES is a
registered trademark of Kimberly-Clark Corporation.
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 A released March 2016; initial release of Preventive Maintenance Kit
Software version: Chromeleon 7.2 SR4 and later
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™
Integrion™ HPIC System. This procedure consists of:
• Rebuilding the injection valve
• Rebuilding the auxiliary valve (optional)
• Replacing the pump check valve cartridges
•Replacingpumpseals
• Replacing the pump priming valve knob
• Replacing the end-line filter
Time
Required
45 to 60 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 Dionex Integrion Preventive Maintenance Kit (P/N 22153-62041)
includes the following items:
Dionex Integrion Preventive Maintenance
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
040695 O-ring 2
045987 End-line filter 1
045994 Pump check valve cartridge 2
062823 NEXT DUE DATE label 1
063382 Priming valve seal/seal wash seal 3
075768 Main seal 2
075973 High-pressure valve rebuild kit, 6-port 1
AAA-062056 Priming valve knob 1
Revision A 22153-97004

2
Items Provided in the Dionex Integrion Ship Kit
The following items are provided in the Ship Kit (RFIC, P/N 22153-62003; non-RFIC,
P/N 22153-62002):
• 1/4 x 5/16-in open-end wrench (P/N 014605)
• Seal insertion tool (P/N 60-078499)
• Syringe, 10 mL (P/N 079803)
Additional Items Required
The following items must be provided by the user:
• ASTM Type I (18 megohm-cm) filtered and deionized water (for specifications, refer to the Dionex
Integrion operator’s manual)
• Clean work surface
• Large flat-blade screwdriver
• Lint-free paper towels (KIMWIPES™ or equivalent)
•Smallbeaker
• Standard disposable laboratory gloves (must be powder-free, oil-free, and particle-free)
• Two 10-32 fitting plugs (P/N 042772)
• 0.2 micron filtered, Class 10, isopropyl alcohol (IPA)
• 1/2-in wrench (P/N 062336)
• 3-mm hex key (P/N 062338)
Rebuilding
the High-
Pressure
Injection
Valve
To rebuild the high-pressure injection valve
1. Turn off the pump.
2. Open the column compartment door.
3. Disconnect each liquid line connected to the valve.
4. Follow the instructions provided in the High-Pressure Valve Rebuild Kit, 6-port (P/N 075973) to
rebuild the valve.
5. Reconnect all liquid lines to the injection valve.
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 4-port auxiliary valve, use a High-Pressure Valve Rebuild Kit (P/N 074698).
• For the 6-port auxiliary valve, use a High-Pressure Valve Rebuild Kit (P/N 075973).
• For the 10-port auxiliary valve, use a High-Pressure Valve Rebuild Kit (P/N 079054).

3
Replacing the
Pump Check
Valve
Cartridges
To remove the pump check valve cartridges
1. Flip the power switch on the rear panel to turn off the system power.
2. Disconnect the power cord from both its source and from the rear panel (to ensure that you do not
unintentionally start the system).
3. Open the pump compartment door.
4. 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.
5. Disconnect the tubing connections from the inlet and outlet check valves (see Figure 1).
Figure 1. Pump components
6. Using a 1/2-in wrench (P/N 062336), loosen both check valve assemblies and remove them from the
pump head.
Figure 2. Inlet and outlet check valve assemblies
7. 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 2).
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.
Primary pump head
Inlet check valve
Outlet check 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

4
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
Replace the pump seals in both pump heads.
To remove the pump head and piston
1. Disconnect all tubing connections to the pump head.
2. Using a 3-mm hex key (P/N 062338), alternately loosen both screws on the pump head
one-eighth turn at a time. Remove the screws, and then carefully remove the head and place it on
a clean surface.
3. When disassembling the pump heads, see Figure 3 and Figure 4.
Figure 3. Primary pump head assembly
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.
Piston
(P/N 079857)
Seal retainer
(P/N 062092)
Seal wash seal
(P/N 063382)
Seal wash body
(P/N 075767)
O-ring
(P/N 040695)
Backup ring
(P/N 074370)
Primary pump head
(P/N 083477)
Outlet check valve
assembly (P/N 045721)
(includes valve housing
and cartridge)
Inlet check valve
assembly
(P/N 045722)
(includes valve
housing and cartridge)
Main seal
(P/N 075768)
Housing (outlet)
Housing (inlet)
Cartridge
(P/N 045994)

5
Figure 4. Secondary pump head assembly
4. Remove the seal wash body (if present) from the pump head. If the seal wash body remained in the
pump mechanism when you removed the pump head, pull it straight off of the pump mechanism
now.
5. The piston is fragile. Carefully pull the piston straight out of the pump mechanism.
To clean the piston (optional)
1. Place the piston in a beaker containing either ASTM Type I (18 megohm-cm) filtered and deionized
water. Sonicate for several minutes.
2. After cleaning, rinse the piston thoroughly with ASTM Type I (18 megohm-cm) filtered and
deionized water. Dry it with a lint-free paper towel.
3. Inspect the piston carefully. If the piston is dirty, scratched, or scored, replace it.
Because piston replacement is not usually required during annual preventive maintenance, new
pistons (P/N 068646) are not provided in the Preventive Maintenance Kit; they must be ordered
separately.
For piston replacement instructions, see “To reinstall the piston and pump head” on page 7.
To remove the main seal
1. For the primary pump head: Insert a 10-32 fitting plug (P/N 042772) into the outlet check valve, and
then tighten fingertight. Use a 1/4 x 5/16-in open-end wrench (P/N 014605) to turn an additional
one-quarter turn.
For the secondary pump head: Insert a 10-32 fitting plug (P/N 042772) into both the inlet and outlet
holes, and then tighten fingertight. Use a 1/4 x 5/16-in open-end wrench (P/N 014605) to turn an
additional one-quarter turn.
Note A magnet secures the piston in place. If the magnetic force makes the piston difficult to
remove, tilt the piston to one side and then gently pull it out of the pump mechanism.
IMPORTANT Even slight scratches or particles of dust, dirt, etc., on the check valves or piston can
contaminate the inside of the pump head and result in poor pump performance.
Piston
(P/N 079857)
Seal retainer
(P/N 062092)
Seal wash seal
(P/N 063382)
Seal wash body
(P/N 075767)
O-ring
(P/N 040695)
Backup ring
(P/N 074370) Secondary pump
head (P/N 083482)
Main seal
(P/N 075768)
Priming valve
(P/N 063968)
Priming valve seal
(P/N 063382)

6
2. Using a 10 mL syringe (P/N 079803), inject a few drops of ASTM Type I (18 megohm-cm) filtered
and deionized water through the main seal and into the piston cavity in the pump head.
3. Reinsert the piston approximately 3 mm (0.125 in) into the seal and press gently. The seal should pop
out of the head and onto the piston.
4. If the main seal was not removed in Step 3, follow these steps:
a. Verify that the 10-32 fitting plugs 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 3.
To remove the seal wash seal
1. Remove the O-ring (P/N 040695) and the backup ring (P/N 074370) from the seal wash body.
2. Follow these steps to remove the seal wash seal from the seal wash body:
a. Using a large flat-blade screwdriver, remove the seal retainer (P/N 062092) from the seal wash
body.
b. Insert the piston into the seal wash body from the O-ring side and gently push the seal out of the
retainer.
To install the seals and O-ring
1. Place the seal wash body on a clean work surface.
2. Slide the new seal wash seal (P/N 063382), with the open side of the seal facing upward, onto the seal
insertion tool (P/N 60-078499) (see Figure 5).
Figure 5. Seal wash seal and seal insertion tool
3. Insert this end of the tool partway into the seal wash body. Make sure the tool is centered and does
not rock back and forth. Then, press firmly on the tool and the seal wash body until they snap
together.
4. Remove the seal insertion tool from the seal wash body.
IMPORTANT Do not use a sharp tool (such as tweezers or a seal removal tool) to remove the main
seal. This may scratch the inside of the pump housing; these scratches will prevent a proper seal
and cause leakage.
IMPORTANT Do not use a sharp tool (such as tweezers) to remove the seal wash seal. This may
scratch the seal and the inside of the pump housing; these scratches will prevent a proper seal
and cause leakage.
Seal wash seal
(P/N 063382)
Seal insertion tool
(P/N 60-078499)

7
5. The seal wash seal is now partially installed. To complete the seal installation, place the retainer in the
seal wash body and use the large flat-blade screwdriver to tighten the retainer.
6. Place the new O-ring (P/N 040695) on the seal wash body.
7. Place the new backup ring (P/N 074370) on the seal wash body.
To install the main seal
1. Rinse the new main seal (P/N 075768) with 0.2 micron filtered, Class 10, isopropyl alcohol (IPA) or
dip it into a container of IPA. (The seal is easier to install when it is lubricated.)
2. Insert the piston through the seal wash assembly, and then through the new main seal, being careful
not to deform the seal.
3. Make sure the main seal is centered.
4. Remove the 10-32 fitting plugs from the pump head.
5. Place the front of the pump head, flat side down, on a clean work surface. Make sure the open side of
the main seal faces away from the retainer for the seal wash seal (see Figure 6).
Figure 6. Open side of the main seal
6. Wet the inside of the pump head cavity where the main seal will be installed with IPA.
7. Place the components on the pump head and gently but firmly press the housing until the main seal
snaps into place. Make sure the pressure is uniform on all sides.
When pressing the seal in place, ensure that the piston is free to move out. This will relieve the
pressure in the pump head during seal installation.
To reinstall the piston and pump head
1. Slide the piston partway into the pump head; approximately 6 mm (1/4 in) of the sapphire part of the
piston should extend from the head.
2. Place the pump head back on the pump.
3. Reinstall the screws in the pump head. Using a 3-mm hex key (P/N 062338), tighten the screws just
until they come into contact with the pump head. Then, alternately tighten the screws another
one-quarter to one-half turn, one-eighth of a turn at a time.
Note When replacing a seal, always replace the O-ring, also. This will prevent leaks.
IMPORTANT If the main seal is not centered, applying pressure to it in Step 7 will damage the seal
and make it unusable.
IMPORTANT Do not use a sharp tool (such as tweezers) to install the main seal. This will scratch
the seal and the inside of the pump housing; these scratches will prevent a proper seal and cause
leakage.
Open side of the main seal
(P/N 075768)

8
4. Reconnect all tubing connections to the pump head. Tighten connections fingertight, and then
tighten an additional one-quarter turn only.
Replacing the
Pump Priming
Valve Knob
To replace the pump priming valve knob
1. The priming valve knob is located on the secondary pump head (see Figure 7). To remove the knob,
turn it counterclockwise all the way and then pull it straight off.
Figure 7. Priming valve knob on secondary pump head
2. Hold the new seal (P/N 063382) with the groove in the priming valve seal facing away from the new
priming valve knob (P/N AAA-062056) (see Figure 8). Carefully slide the seal onto the knob; avoid
scratching or nicking the sides.
Figure 8. Priming valve and seal
3. Insert the new knob into the transducer housing, 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 the power cord.
2. Flip the power switch on the rear panel to turn on the system power.
3. Prime the pump.
4. Enter the flow rate required for your application and turn on the pump flow.
5. Begin monitoring the pressure reading to verify that the pressure remains stable. When the pump is at
operating pressure, check for leaks from valve and pump fittings and from the check valves. Tighten
fittings if needed. Tighten a check valve one-eighth of a turn at a time only if it leaks.
Priming valve knob
Priming valve seal
(insert with groove
facing away from
the knob)

9
6. Close the pump and column compartment doors.
7. 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.