Thermo Scientific

Dionex ICS-5000+/ICS-6000
Dual Pump and
Dionex ICS-5000+/ICS-6000
Single Pump
Preventive Maintenance Procedure

60-065483 Revision C February 2018

© 2018 Thermo Fisher Scientific Inc. All rights reserved.

Chromeleon is a registered trademark of Thermo Fisher Scientific Inc. in the United States.

KIMWIPES is a trademark of Kimberly-Clark Worldwide, Inc. PharMed and Tygon are registered trademarks
of Saint-Gobain Performance Plastics.

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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 November 2012; initial release of Dionex ICS-5000+
Revision B released August 2016; part number changes, checklist removed
Revision C released February 2018; initial release of Dionex ICS-6000

For Research Use Only. Not for use in diagnostic procedures.

 Dionex ICS-5000+/ICS-6000 DP/SP
Preventive Maintenance
Overview This manual describes a preventive maintenance procedure for the following products:
• Thermo Scientific™ Dionex™ ICS-5000+ Dual Pump (DP)
• Thermo Scientific™ Dionex™ ICS-5000+ Single Pump (SP)
• Thermo Scientific™ Dionex™ ICS-6000 Dual Pump (DP)
• Thermo Scientific™ Dionex™ ICS-6000 Single Pump (SP)
During this procedure, the following parts in each pump are replaced:
• Main piston seals
• Piston seal wash body O-rings
• Piston seal wash seals
• Inlet and outlet check valves (primary pump head only)
• Priming valve seal (secondary pump head only)
• Piston seal wash system tubing
Thermo Fisher Scientific recommends performing preventive maintenance every 18 months for capillary
pumps and annually for analytical pumps.

Note If you have a DP, Thermo Fisher Scientific recommends finishing the preventive maintenance
procedure for pump 1 before going on to pump 2.

Time 60 minutes per pump

Required

Parts Before starting the preventive maintenance procedure, verify that all parts listed in this section are at hand.
Required
IMPORTANT Substituting non-Dionex/Thermo Scientific parts may impair pump performance,
thereby voiding the product warranty. Refer to the warranty statement in the Dionex Terms and
Conditions for more information.

Included Parts
The Preventive Maintenance Kit is available in two versions:
• Dionex ICS-5000+/ICS-6000 Capillary Pump Preventive Maintenance Kit (P/N 075039)
• Dionex ICS-5000+/ICS-6000 Analytical Pump Preventive Maintenance Kit (P/N 075970)
In addition to this procedure, each kit contains all of the parts that need to be replaced for one pump.
When performing preventive maintenance on a DP, two kits are required.

Revision C 60-065483
© 2018 Thermo Fisher Scientific Inc.
All rights reserved.
Table 1. Dionex ICS-5000+/ICS-6000 Capillary Pump Preventive Maintenance Kit contents
Part Number Item Quantity in Kit
040695 O-ring 2
044540 Outlet check valve assembly 1
044541 Inlet check valve assembly 1
062823 NEXT DUE DATE label 1
063268 PharMed tubing, 0.159 cm (0.0625 in) ID 30 cm (12 in)
063382 Piston seal wash seal/priming valve seal 1
064079 Tygon 2075 tubing, 0.15 cm (0.06 in) ID 51 cm (20 in)
068628 Piston seal wash seal 2
075493 Main piston seal 2

Table 2. Dionex ICS-5000+/ICS-6000 Analytical Pump Preventive Maintenance Kit contents

Part Number Item Quantity in Kit
040695 O-ring 2
045721 Outlet check valve assembly 1
045722 Inlet check valve assembly 1
062823 NEXT DUE DATE label 1
063268 PharMed™ tubing, 0.159 cm (0.0625 in) ID 30 cm (12 in)
063382 Piston seal wash seal/priming valve seal 3
064079 Tygon™ 2075 tubing, 0.15 cm (0.060 in) ID 51 cm (20 in)
075768 Main piston seal 2

Note Do not be concerned about minor design differences between parts in the Preventive
Maintenance Kit and parts currently installed in your pump. As part of our ongoing quality
improvement program, Thermo Fisher Scientific reserves the right to introduce new pump parts
periodically.

Additional Items Required

The following items are provided in the pump Ship Kit:
Part Number Item Quantity in Kit
042772 10-32 fitting plugs 3
079803 10 cc syringe 1
062338 3 mm hex key 1
063675 Seal insertion tool 1

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 The following items must be provided by the user:
• ASTM Type I (18 megohm-cm) filtered and deionized water

Note Deionized water must meet the specifications listed in Dionex ICS-5000+ Ion
Chromatography System Operator’s Manual (Document No. 065446) or Dionex ICS-6000 Ion
Chromatography System Operator’s Manual (Document No. 22181-97002).

• Large flat-blade screwdriver

• Lint-free paper towels (KIMWIPES™ or equivalent)
• Methanol (optional)
• Small beaker
• 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)
• 1/2-inch wrench (P/N 062336)

Replacing the Piston seals are installed in both the primary and secondary pump heads. Check valves are installed in the
Piston Seals primary pump head only.
and Check  To remove the pump head and piston
Valves
1. Turn off the pump flow.
2. Open the DP/SP door to access the mechanical components.
3. Open the priming valve on the secondary pump head by turning it one-half turn
counterclockwise.
4. For the Thermo Scientific™ Dionex™ Chromeleon™ 7 Chromatography Data System, begin
monitoring the Current Pressure reading on the pump ePanel. When the system pressure reaches
zero, click Connect to disconnect the pump from the software.
For the Thermo Scientific™ Dionex™ Chromeleon™ 6.8 Chromatography Data System, begin
monitoring the Current Pressure reading on the pump panel on the panel tabset. When the
system pressure reaches zero, clear Connected to disconnect the pump from the software.
5. Press the POWER button on the front of the DP/SP for 2 seconds to place the pump in standby
mode.
6. 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.

IMPORTANT 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.

7. Disconnect all tubing connections to the pump head.

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8. The primary and secondary pump head components are not identical. When disassembling a
pump head, see Figure 1 for a primary pump head or Figure 2 on page 5 for a secondary pump
head.
Figure 1. Primary pump head assembly for capillary and analytical pumps
2
1
1 Piston
P/N 068646 (Capillary)
P/N 079857 (Analytical)
2 Seal Retainer
P/N 068627 (Capillary)
P/N 062092 (Analytical)
3 Piston Seal Wash Seal
P/N 068628 (Capillary)
P/N 063382 (Analytical)
8 cartridge (C).
7
6
4
3
4 Seal Wash Body
P/N 074446 (Capillary)
P/N 075767 (Analytical)
5 8 Primary Pump Head
6 Backup Ring
P/N 074371 (Capillary)
P/N 074370 (Analytical)
7 Main Piston Seal
P/N 075493 (Capillary)
P/N 075768 (Analytical)
4
Note: Each check
9 valve assembly
B includes a valve
body (B) and a
C
C
10 B
P/N 60-082602 (Capillary)
P/N 075047 (Analytical)
9 Outlet Check Valve Assembly
P/N 044540 (Capillary)
P/N 045721 (Analytical)
10 Inlet Check Valve Assembly
P/N 044541 (Capillary)
P/N 045722 (Analytical)
 Figure 2. Secondary pump head assembly for capillary and analytical pumps

9. Use a 3 mm hex key (P/N 062338) to loosen the two Allen screws on the pump head. Remove
the Allen screws, and then carefully remove the head and place it on a clean surface.
10. Remove the seal wash body from the pump head.
–or–
If the seal wash body was not removed with the pump head in Step 9, pull it straight out of the
pump mechanism now.
11. The piston is fragile. Carefully pull the piston straight out of the pump mechanism.

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 pull it out of the pump mechanism.

 To clean the piston

1. Place the piston in a small beaker containing ASTM Type I (18 megohm-cm) filtered and
deionized water (or methanol) and sonicate for several minutes.
2. After cleaning, rinse the piston thoroughly with ASTM Type I (18 megohm-cm) filtered and
deionized water and dry it with a lint-free paper towel.

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 3. Inspect the piston carefully; if the piston is dirty or scratched, it should be replaced before you
resume operation.

IMPORTANT Even minute scratches or 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.

Because piston replacement is rarely required during annual preventive maintenance, new pistons
are not provided in the Preventive Maintenance Kit and must be ordered separately (capillary
pump: P/N 068646; analytical pump: P/N 60-062082).
 To remove the main piston seal

1. For the primary pump head: Insert a 10-32 fitting plug (P/N 042772) into the 10-32 outlet hole
of the check valve nut.
For the secondary pump head: Insert a 10-32 fitting plug (P/N 042772) into both the 10-32 inlet
and outlet holes.
2. Close the priming valve.
3. Using a squirt bottle or a plastic syringe, fill the pump head cavity with deionized water through
the piston opening (see Figure 3).
Figure 3. Filling the pump head cavity with deionized water

Plastic syringe

4. Reinsert the piston into the seal, and then push the piston into the head (see Figure 4). The seal
should hydraulically pop out from the head.
Figure 4. Removing the main piston seal

Piston
Main piston seal

Pump head

IMPORTANT Do not use a sharp tool (such as tweezers) to remove the piston seal. This will scratch
the inside of the pump housing; these scratches will prevent a proper seal and cause leakage.

5. Remove the piston and pull off the seal.

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 6. If the piston 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 deionized water and check for bubbles.
c. If there are no bubbles, repeat Step 4.
 To remove the piston seal wash seal

1. Remove the O-ring (P/N 040695) and backup ring (capillary pump: P/N 074371; analytical
pump: P/N 074370) from the seal wash body.

Note Save the backup ring. You will reinstall it later.

2. Remove the piston seal wash seal (capillary pump: P/N 068628; analytical pump: P/N 063382)
from the seal wash body:
a. Use a large flat-blade screwdriver to remove the retainer (capillary pump: P/N 068627; analytical
pump: P/N 062092) for the seal wash seal 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.

IMPORTANT Do not use a sharp tool (such as tweezers) to remove the piston seal wash seal. This
may scratch the seal and the inside of the pump housing; scratches may prevent a proper seal and
cause leakage.

 To install the new piston seal wash seal

1. Place the seal wash body on a clean work surface.

2. Remove the 10-32 fitting plugs from the pump head.
3. Slide the new piston seal wash seal (capillary pump: P/N 068628; analytical pump:
P/N 063382), with the open side of the seal facing upward, onto the seal insertion tool
(P/N 063675) (see Figure 5).
Figure 5. Piston seal wash seal and seal insertion tool
Piston seal wash seal
P/N 068628 (capillary)
P/N 063382 (analytical)

Seal insertion tool

(P/N 063675)

4. 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.
5. Remove the seal insertion tool from the seal wash body.
6. The piston 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.
7. Place the new O-ring (P/N 040695) on the seal wash body.

Note When replacing a seal, always replace the O-ring, also. This will prevent leaks.

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 8. Place the backup ring (capillary pump: P/N 074371; analytical pump: P/N 074370) removed in
Step 1 of “To remove the piston seal wash seal” on page 7 on the seal wash body.
 To install the new main piston seal

1. Rinse the new main piston seal (capillary pump: P/N 075493; analytical pump: P/N 075768)
with IPA (isopropyl alcohol) 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 piston seal,
being careful not to deform the seal.
3. Make sure the new piston seal is centered.

IMPORTANT If the piston seal is not centered now, applying pressure to it in Step 6 will damage
the seal and make it unusable.

4. Place the front of the pump head, flat side down, on a clean work surface. Make sure the open
side of the piston seal faces away from the retainer for the seal wash seal (see Figure 6).
Figure 6. Open side of the main piston seal

Open side of the main piston seal

P/N 075493 (capillary)
P/N 075768 (analytical)

5. Rinse the inside of the pump head cavity (where the seal will be installed) with IPA. Inspect the
area for any particulate matter. If necessary, rinse again until the inside of the cavity is clean.
6. Place the components on the pump head and gently but firmly apply uniform pressure to all sides
of the housing until the piston seal snaps into place.
While pressing the seal into place, make sure the piston is free to move out. This relieves the
pressure in the pump head during seal installation.

IMPORTANT Do not use a sharp tool (such as tweezers) to install the main piston seal. This will
scratch the inside of the pump housing; these scratches will prevent a proper seal and cause
leakage.

7. For the primary pump head: Go to “To remove the check valves” on page 8 and “To install the
new check valves” on page 9. When you finish, go to “To reinstall the piston and pump head” on
page 10.
For the secondary pump head: Go to “To reinstall the piston and pump head” on page 10 to place
the pump head back on the pump.
 To remove the check valves

1. Using a 1/2-in wrench (P/N 062336), loosen both check valve assemblies and remove them from
the pump head (see Figure 7).

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 7).

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 Figure 7. Inlet and outlet check valve assemblies

Inlet check valve Outlet check valve

1/4-28 port 10-32 port

Inlet check valve Outlet check valve

cartridge (double-hole cartridge (single-hole
end visible) end visible)
Flow Flow

 To install the new check valves

1. For the new inlet check valve assembly (capillary pump: P/N 044541; analytical pump:
P/N 045722): Verify that the double-hole end of the cartridge is visible.
If the double-hole end is not visible, remove the cartridge from the housing and install it correctly.
2. For the new outlet check valve assembly (capillary pump: P/N 044540; analytical pump:
P/N 045721): Verify that the single-hole end of the cartridge is visible.
If the single-hole end is not visible, remove the cartridge from the housing and install it correctly.

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 cartridge through the large single hole and exits through the small double
holes.

3. Before installing the check valves, rinse the bottom of the check valve ports in the pump head
with IPA and air dry them. Inspect the bottom of each port for any particulate matter. If
necessary, rinse and dry the ports again.

IMPORTANT The next two steps involve tightening check valves into the primary pump head.
Overtightening the check valves may damage the pump head and check valve housing and crush
the check valve seats.

4. Screw the inlet check valve assembly into the port on the bottom of the primary pump head until
contact is made. Tighten the check valve fingertight, and then use the 1/2-in wrench
(P/N 062336) to tighten an additional one-quarter to one-half turn.
5. Screw the outlet check valve assembly into the port on the top of the primary pump head until
contact is made. Tighten the check valve fingertight, and then use the 1/2-in wrench
(P/N 062336) to tighten an additional one-quarter to one-half turn.

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. Improper orientation will adversely
impact pump performance.

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  To reinstall the piston and pump head

1. Slide the piston partway into the pump head, until about 6 mm (1/4 in) of the sapphire part of
the piston extends from the head (see Figure 8).
Figure 8. Reinstalling the piston

Sapphire part of the piston

Pump head

2. Place the pump head back on the pump.

3. Reinstall the two Allen screws in the pump head. Use the 3 mm hex key (P/N 062338) to 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.
4. Reconnect the tubing to the inlet check valve nut and the outlet check valve nut.

Replacing the  To replace the priming valve seal

Priming Valve 1. The priming valve is located on the secondary pump head (see Figure 9). To remove the valve,
Seal turn it counterclockwise all the way and then pull it straight off the pump head.
Figure 9. Priming valve location

Priming valve

Secondary pump head

2. Pull the old seal off the end of the priming valve knob.

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 3. Hold the new priming valve seal (P/N 063382) with the groove facing away from the knob (see
Figure 10). Gently slide the seal onto the knob, being careful not to scratch or nick the sides.

IMPORTANT Do not use a sharp tool to install the priming valve seal. This may scratch the seal
and the surface of the priming valve knob; these scratches will prevent a proper seal and cause
leakage.
Figure 10. Replacing the priming valve seal

Priming valve seal Insert the seal with the groove

(P/N 063382) facing away from the knob.

4. Insert the priming valve into the secondary pump head, turn the knob clockwise, and tighten
fingertight.

DP After completing preventive maintenance for pump 1 of the DP, perform the following procedures for
Maintenance pump 2:
• “Replacing the Piston Seals and Check Valves” on page 3
• “Replacing the Priming Valve Seal” on page 10

Replacing the  To remove the old piston seal wash tubing

Piston Seal 1. Remove the PharMed tubing from the peristaltic pump (see Figure 11):
Wash Tubing
a. Lift the lever up and to the right, and hold it in that position with one hand.
b. Using your other hand, pull the PharMed tubing away from the rotor and out of the lower notch
on the left side of the mounting plate.
c. Release the lever.
d. Pull on the fitting slightly to remove the PharMed tubing from the upper notch on the pump
mounting plate.
Figure 11. Peristaltic pump for the seal wash system

PharMed tubing Mounting plate

(P/N 063268)

Fitting
Rotor
Tygon 2075 tubing
(P/N 064079) Lever

2. Pull the PharMed and Tygon 2075 tubing off the fitting.

Note Save the fitting; you will reinstall it later.

11
 3. Pull all seal wash tubing off the seal wash reservoir and the pump heads.
 To install the new piston seal wash tubing

1. Cut three new pieces of 0.15 cm (0.060 in) ID Tygon 2075 tubing (P/N 064079) and one piece
of 0.159 cm (0.0625 in) ID PharMed tubing (P/N 063268) to the same lengths as the tubing
just removed.
2. Connect the new tubing pieces to the seal wash reservoir and pump heads (see Figure 12).
Figure 12. Piston seal wash tubing connections

PharMed
Tubing

Tygon 2075
Tubing

Seal
Wash
Reservoir

Secondary Primary
Head Head

3. Push the tubing onto the fitting that was removed in Step 2 of “To remove the old piston seal
wash tubing” on page 11.
4. Connect the PharMed tubing to the peristaltic pump:
a. Push the tubing into the lower notch on the pump mounting plate.
b. Lift the lever to the right, and hold it in that position with one hand.
c. Using your other hand, wind the tubing around the rotor.
d. Release the lever.
e. Pull on the fitting slightly to slide the tubing into the upper notch.
f. Verify that there is no slack in the tubing. If necessary, lift the lever again, adjust the tubing around
the rotor and through the lower notch to remove any slack, and release the lever.

Completing  To complete the preventive maintenance procedure

the 1. Reconnect all tubing connections to the pump. If this is a DP, reconnect all tubing connections to
Procedure both pumps. Tighten connections fingertight, and then tighten an additional one-quarter turn
only.
2. Press the POWER button on the front of the DP/SP to turn on the pump.

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3. Complete the following steps for an SP or for each pump of a DP:
a. For Chromeleon 7: Click Connect on the pump ePanel to reconnect the pump to the software.
For Chromeleon 6.8: Select Connected on the pump panel to reconnect the pump to the software.
b. Turn on the pump flow.
c. Prime the pump.
d. Begin monitoring the Current Pressure reading to verify that the pressure remains stable. When
the pump is at operating pressure, check for leaks from the check valves. Tighten a check valve
one-eighth turn only if it leaks.
e. On the NEXT DUE DATE label (P/N 062823), enter the following date:
• 18 months from today (for a capillary pump)
• 12 months from today (for an analytical pump)
f. Attach the label to the pump.

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