ASHSV Manual

qVisc 4320 AX Autosampled Viscometer
qVisc 4320 AX
Autosampled High Speed Viscometer Service Manual
Page 1 of 196 June 14 /2006 V1.0

Cautions and Warnings:

Used as directed, your qVisc 4320 AX is designed to provide safe, trouble free operation. To ensure safe
and reliable operation read and follow all safety and usage instructions. This instrument uses heptane or
toluene solvent for automatic cleaning. Vapors can become explosive if allowed to build up and are very
flammable.
•Follow the procedure in this manual carefully. Use safe handling practices and use proper personal
protection equipment to protect yourself and your instrument. Ensure that the vent/exhaust tubing from
the vacuum system is routed to an outside location as directly as possible. The vacuum system vent
will contain high levels of vapor and may also have small amounts of liquid solvent. The exit points of
this vent must NOT be located near any ignition source, such as a furnace, HVAC, exhaust fan, etc.
This is not a complete list, if you are unsure, consult with someone who is familiar with your suggested
exhaust location.
•The qVisc 4320 AX does not need to have a fume hood or any special ventilation besides the above.
Under normal operation very little solvent vapor escapes the instrument. However, the qVisc 4320 AX
should be located in an air space with adequate air exchange to prevent the small amount of vapor from
building up.
•Never use anything but an inert gas to pressurize the vacuum system during emptying. Failure to do
so may cause a fire or explosion.
•Never use the instrument if you see solvent has leaked or suspect a solvent leak or you can smell or
suspect high levels of solvent vapor near the instrument. Investigate immediately.
•To prevent the vacuum waste trap tank from overflowing, always empty the waste tank when the
solvent is filled. If you are not using the vacuum system designed for your qVisc 4320 AX, your waste
tank should be larger than the solvent container.
•The qVisc 4320 AX has over temperature cutout safety switches and will automatically turn off the
heating system(s) in the event of an over temperature. However, if you are going to leave the
instrument unattended for longer than 2 days, we recommend you turn the instrument off.
• Unless otherwise indicated, the instrument can left on for many tasks. If you chose to do so, or the
instrument has not been turned off for at least 8 hours, be careful as parts in and around any bath
set to 100°C will be hot and parts in and around any bath set to 40°C will be noticeably warm.
• When reattaching parts, always start all fasteners loosely and only tighten when all are in place.
•When you need to slide the instrument out from under the autosampler for easier access, you must first
exit the software and then disconnect all inject lines from the autosampler.
Page 2 of 196 June 14 /2006 V1.0

Table of Contents
Table of Contents..............................................................................................................................................3
Instrument Setup............................................................................................................................................... 7
Stand assembly..............................................................................................................................................7
Stand height adjustment..............................................................................................................................11
Unpacking.......................................................................................................................................................11
Autosampler................................................................................................................................................11
Instrument................................................................................................................................................... 14
Instrument setup..............................................................................................................................................16
Glass install.................................................................................................................................................16
Instrument Prep.......................................................................................................................................16
Tube installation..................................................................................................................................... 19
Tube solvent line connections.................................................................................................................26
Tube inject line connections................................................................................................................... 28
Instrument reassembly............................................................................................................................ 29
Fill...........................................................................................................................................................29
Pc connections........................................................................................................................................ 31
Power up................................................................................................................................................. 32
Autosampler setup...................................................................................................................................... 32
Probe tip..................................................................................................................................................32
Drain line................................................................................................................................................ 37
Solvent / waste containers.......................................................................................................................38
Pc connections........................................................................................................................................ 40
Vacuum setup............................................................................................................................................. 41
Exhaust....................................................................................................................................................41
Instrument connections........................................................................................................................... 42
Auxiliary Vacuum line............................................................................................................................42
Waste spout.............................................................................................................................................43
Nitrogen.................................................................................................................................................. 43
Software ..................................................................................................................................................... 43
Install...................................................................................................................................................... 43
Com / basic settings................................................................................................................................ 44
Tray setup............................................................................................................................................... 44
Deck mapping......................................................................................................................................... 45
General................................................................................................................................................45
Trays................................................................................................................................................... 46
Samples...............................................................................................................................................48
Waste and Cleaning Ports................................................................................................................... 49
Inject Ports..........................................................................................................................................49
Calibration.................................................................................................................................................. 50
Temperature Adjustments.......................................................................................................................50
Autosampler Connections.......................................................................................................................52
Cut-out Adjustments............................................................................................................................... 53
Volume Adjustments.............................................................................................................................. 54
Instrument test.........................................................................................................................................56
Calibration.............................................................................................................................................. 59
Verification............................................................................................................................................. 60
Removal & Installation Of Parts.....................................................................................................................60
Case.............................................................................................................................................................60
Front Access Door.................................................................................................................................. 60
Side Access Doors.................................................................................................................................. 61
Case front................................................................................................................................................61
Case sides................................................................................................................................................63
Page 3 of 196 June 14 /2006 V1.0
Case Skirt................................................................................................................................................64
Case top front..........................................................................................................................................65
Case top rear........................................................................................................................................... 65
Case rear................................................................................................................................................. 67
Utility panel............................................................................................................................................ 70
............................................................................................................................................................... 72
Tanks...........................................................................................................................................................72
Tank cover top........................................................................................................................................ 72
Tank cover.............................................................................................................................................. 72
Heater assembly......................................................................................................................................74
Tank........................................................................................................................................................ 76
Tubes.......................................................................................................................................................... 78
Tubes...................................................................................................................................................... 78
Tube Inject Line......................................................................................................................................80
Tube Solvent Line...................................................................................................................................82
Valves......................................................................................................................................................... 83
Connecting Tube.....................................................................................................................................83
Lower Solenoid Valve Assembly........................................................................................................... 84
Replace Coils (Lower Valves)................................................................................................................86
Replace Coils (Solvent Valves).............................................................................................................. 88
Valve Rebuild Kit (Lower Valves)......................................................................................................... 88
Valve Rebuild Kit (Tube Vent/Solvent Valves)..................................................................................... 90
Inject valves............................................................................................................................................ 92
Top Vent / Solvent Valves Assembly..................................................................................................... 93
Vent Tubes..............................................................................................................................................94
Electronics.................................................................................................................................................. 96
Cpu board............................................................................................................................................... 96
Solenoid board........................................................................................................................................97
Power supply...........................................................................................................................................98
Bath Temperature Controller..................................................................................................................99
Eprom................................................................................................................................................... 100
Fan (bottom rear).................................................................................................................................. 100
Fan (top)............................................................................................................................................... 101
Motor Run Cap..................................................................................................................................... 101
Replacement Temp Sensor................................................................................................................... 103
SSR....................................................................................................................................................... 104
Timing Sensor.......................................................................................................................................105
Wiring....................................................................................................................................................... 109
Instrument to PC serial cable................................................................................................................ 109
Motor Run Cap Wiring Harness........................................................................................................... 110
Optic Sensor Harness............................................................................................................................110
Power Receptacle Harness....................................................................................................................111
Power Switch........................................................................................................................................ 112
Power Switch Harness.......................................................................................................................... 114
Serial port harness.................................................................................................................................114
Solenoid board ribbon cable................................................................................................................. 114
SSR Wiring Harness............................................................................................................................. 115
Switch Supply Harness......................................................................................................................... 116
Plumbing...................................................................................................................................................117
Instrument Solvent feed Lines.............................................................................................................. 117
Internal Vacuum Plumbing................................................................................................................... 118
Replacement Vacuum Gauge................................................................................................................119
Vacuum Block...................................................................................................................................... 121
Vacuum Block Distribution Lines........................................................................................................ 123
Vacuum Pump Rebuild Kit...................................................................................................................124
Mounting...................................................................................................................................................125
Page 4 of 196 June 14 /2006 V1.0
Cpu mount.............................................................................................................................................125
Inject Valve Mount............................................................................................................................... 126
Top vent valve mount........................................................................................................................... 127
Solenoid board mount...........................................................................................................................128
Lower valve mount............................................................................................................................... 128
Autosampler Parts.....................................................................................................................................129
Syringe.................................................................................................................................................. 129
Syringe Seal.......................................................................................................................................... 131
3 Port Valve Head.................................................................................................................................131
Pump Drive 3 Port................................................................................................................................ 132
Pump Drive 8+ Port..............................................................................................................................135
8+ Port Valve Head.............................................................................................................................. 137
Probe Line Tube Support......................................................................................................................138
Smart Valve Head.................................................................................................................................139
Z-Rack.................................................................................................................................................. 140
Autosampler Plumbing............................................................................................................................. 141
Clean Lines........................................................................................................................................... 141
Inject Lines........................................................................................................................................... 142
Smart Valve Lines.................................................................................................................................143
Solvent Feed Lines................................................................................................................................144
Autosampler Drain Line....................................................................................................................... 145
Inject Block...........................................................................................................................................146
Inject Ports............................................................................................................................................148
Insulation Block....................................................................................................................................150
Probe & Line.........................................................................................................................................151
Inject Block Drain Line........................................................................................................................ 154
............................................................................................................................................................. 155
Procedures.................................................................................................................................................... 155
Tubes........................................................................................................................................................ 155
Setting the Height................................................................................................................................. 155
Setting Oil Volume............................................................................................................................... 156
Tanks.........................................................................................................................................................158
Filling....................................................................................................................................................158
Draining................................................................................................................................................ 160
Optic Sensors............................................................................................................................................ 161
Adjusting...............................................................................................................................................161
Testing.................................................................................................................................................. 163
Autosampler..............................................................................................................................................164
Deck Mapping...................................................................................................................................... 164
General..............................................................................................................................................164
Trays................................................................................................................................................. 165
Samples.............................................................................................................................................167
Waste and Cleaning Ports................................................................................................................. 168
Inject Ports........................................................................................................................................168
Instrument................................................................................................................................................. 169
Temperature Calibration.......................................................................................................................169
Over Temperature Cutout Adjustment..................................................................................................171
Inject Volume Adjustments.................................................................................................................. 172
Repeatability Testing............................................................................................................................ 174
Instrument Testing................................................................................................................................ 177
Calibration............................................................................................................................................ 178
Vacuum Sensor Adjustment..................................................................................................................179
Sliding Out for Access..........................................................................................................................180
Draining Solvent................................................................................................................................... 181
Vacuum System........................................................................................................................................ 181
Startup...................................................................................................................................................181
Page 5 of 196 June 14 /2006 V1.0
Shutdown.............................................................................................................................................. 181
Draining................................................................................................................................................ 181
Maintenance..................................................................................................................................................181
Recommended Schedule...........................................................................................................................181
Tubes........................................................................................................................................................ 181
Glass Cleaning...................................................................................................................................... 181
Back Flushing....................................................................................................................................... 182
Removing a Blockage with Cleaning Wire...........................................................................................184
Lower Valves............................................................................................................................................185
Cleaning................................................................................................................................................ 185
Operational Testing.............................................................................................................................. 187
Top Vent/Solvent Valves..........................................................................................................................189
Cleaning................................................................................................................................................ 189
Operational Testing.............................................................................................................................. 190
Autosampler..............................................................................................................................................191
Drive Lubrication..................................................................................................................................191
Troubleshooting............................................................................................................................................191
Symptom................................................................................................................................................... 192
Recommended Course of Action.............................................................................................................. 192
Page 6 of 196 June 14 /2006 V1.0

Instrument Setup
Stand assembly
• Place the top of the stand on the floor with the slot to the right side and facing up so the bottom is
visible. The top will be easy to tip over so have someone hold it in place or lean it against a wall.
• Prepare a screw with a lock washer. All stand bolts require a lock washer. Start all bolts only until
instructed to tighten.
• Place one of the sides next to the top with the bolt holes for the rear brace at the bottom, and
loosely bolt together with four bolts as shown.
• Place the rear brace and loosely bolt together with two bolts as shown.
• Place the other side next to the top and loosely bolt together with four bolts.
• Loosely bolt the rear brace to the new side with two bolts.
Page 7 of 196 June 14 /2006 V1.0

• Tighten all bolts until the lock washer is flattened using a 7/16 wrench.
• Tip the stand to the vertical position from the back.
• Place stand in its final location.

• Place the drawer in front of the stand and lean it up on the top or bottom edge, with the bottom side
facing you. Do not place top face down as this may scratch the surface.
Page 8 of 196 June 14 /2006 V1.0

• Bolt one of the four legs with casters on near the top. Note that there are two left and two right
legs. Each one requires four bolts. Loosely start all bolts, then tighten.
• Bolt the leg on the other side as above.

• Turn the deck over and attach the remaining two legs.
• Place the deck on the casters in front of the stand.
Page 9 of 196 June 14 /2006 V1.0

• Note that the deck has a front and back. The back of the deck does not have an obstruction on the
slide.
• Extend the slide from the stand. As the leveling feet are fully in for shipping you may need to raise
the stand to align the slide.
• Extend the slide over the corresponding slide on the deck. Duplicate on the other side.
• Slide the deck fully into the stand. As the stand has not been adjusted and has no weight on it, the
stand may slide backwards. To prevent this place the stand against the wall or simply hold onto
the stand while pushing the deck in. The deck slide will be stiff as you are sliding against the ball
bearing action, ensure the castors are unlocked.
Page 10 of 196 June 14 /2006 V1.0

Stand height adjustment.

• To adjust the stand, raise or lower the adjustable feet on the stand.
• You should be able to rotate each castor with noticeable drag/slide on the floor.
• Adjust each foot until all castors have the same noticeable drag. This provides the best weight
spread between the stand and the deck when loaded.
Unpacking
Autosampler
Note: the autosampler box contains the fragile glass capillary tubes and accessories, handle with care.
• Remove the top of the autosampler box.
Page 11 of 196 June 14 /2006 V1.0

• Remove the accessories from the rear two slots.

• Remove the top piece of foam.
• Lift the cardboard sides off of the box.
Page 12 of 196 June 14 /2006 V1.0

• Remove the front two pieces of foam.

• Remove and place the box containing the glass capillary tubes aside in a safe location.
• Lift the autosampler off of the box and place on the top of the stand. The autosampler is heavy and
awkward, two people are required.
• Position the autosampler so that the right edge is aligned with the slot in the top of the stand as
shown.
Page 13 of 196 June 14 /2006 V1.0

• Position the autosampler so that the inject block on the deck is centered on the slot from front to
back as shown.
• Remove the Velcro straps and foam from the arm.
Instrument
• Open the top of the instrument box.
• Remove the top wood cover.
• Remove the top pieces of foam.
• Slide the box off the top.
Page 14 of 196 June 14 /2006 V1.0

• Extend the lower deck of the stand fully out.

• Place the instrument on the deck. The instrument is heavy and awkward, two people are
required.
• Slide the deck fully back in.

• Position the instrument so that the slot in the top that reveals the inject valves is centered
under the slot in the top of the stand as shown.
Page 15 of 196 June 14 /2006 V1.0

Vacuum system
Instrument setup
Glass install
Instrument Prep
• Slide the instrument deck fully out.
• Remove the top of the instrument by pulling up on in (it pops off).
• Unscrew the two screws holding the front panel access door and remove the door.
Page 16 of 196 June 14 /2006 V1.0

• Unscrew the six screws (three on each side) holding the front panel on.
• Remove the front panel by pulling the bottom out until it is past the front of the deck. You may
need to slide the instrument slightly forward. Be careful not to slide the front leveling feet off of
the deck.
Page 17 of 196 June 14 /2006 V1.0

• Unscrew and remove, the top of the tank cover (6 screws).
• Disconnect the four optic sensors from the cpu board. Place the loose connectors into the top of
the tank cover.
Page 18 of 196 June 14 /2006 V1.0

• Remove the tank cover (10 screws). Do not remove the screw holding the cpu board mounting
bracket (marked with an X).
• Repeat for the other side.
Tube installation
• Carefully open the box containing the glass capillary tubes.
Page 19 of 196 June 14 /2006 V1.0
• The tubes are packaged in two layers and are labeled with their tube number (1-8). The tube
positions in the instrument go from left to right and then rear to front (see table below).
1 2
3 4
5 6
7 8
• Remove the tube to be installed from the packaging, start each bath with the rear-most tube (1 or
2). Locate the correctly numbered tube inject line and tube solvent line with fittings from the
accessories.
• Remove the cardboard from the top of the tube.

• Slide the three o-rings down the tube until they are just above and touching the black line on the
tube.
Page 20 of 196 June 14 /2006 V1.0

• Verify the correct placement of the o-rings with the optic heighting tool. The bubble joining the
two different sizes of capillary should be just below (not visible) the hole for optic two (shown by
the arrow).
• Unscrew the nut from the tube inject line fitting. The inject line can be identified by the white
compression fitting on the other end.
• Slide the nut and then the three o-rings over the inject tube of the glass as shown. The inject tube
is the glass tube that connects to the horizontal section from below, it also has the smaller inside
diameter.
Page 21 of 196 June 14 /2006 V1.0

• Using a slight amount of pressure, hold the fitting on the end of the glass and screw the nut on as
tightly as comfortable with your fingers. Do not tighten with a wrench or the tube will crack
when heated.
• Attach the solvent line to the other top glass tube in the same manner.
• Open the side door of the instrument.
• Slide the lower valves down by loosening the two wing nuts at the back of the valves.
• Loosen the vertical vent tube so it points down to the left.
• Unscrew the black and brass connecting tubes and place aside.
• Loosen the nut for the tube at the bottom of the tank.
Page 22 of 196 June 14 /2006 V1.0

• Insert the tube from the top of the instrument into the hole in the top of the optical sensor as
shown.
• Gently slide the tube down and through the nut at the bottom. You may have to remove the nut
and manually slide the two o-rings over the glass and retread the nut. Do not place any horizontal
force on the glass as it will break.
Page 23 of 196 June 14 /2006 V1.0

• Slide the tube down slowly, until the three o-rings positioned earlier just touch the top of the
optical sensor. If you slide the tube down too far and shift the o-rings, you we need to remove the
tube and re-height it.
• Orient the first tube with the fittings towards the front as shown below.
• Finger tighten the nut at the bottom of the tank while holding the top of the tube to prevent it from
turning and moving vertically.
• Replace the tank top (without the tank top cover). Do not screw into place at this time.
• Reconnect the four optical sensors to the cpu board. Verify that the wires are not crossed and are
connected to the correct jack.
Page 24 of 196 June 14 /2006 V1.0

• Continue with the remaining tubes in the same fashion.

• Orient the tubes as shown below. The two tubes nearest the back of the instrument have their
fittings towards the front. The third is towards the outside of the instrument and the front tubes are
towards the rear. Failure to orient the tubes correctly may interfere with connecting the lines in the
next steps. The tubes and their fittings should not be in contact with each other or the sides of the
tank top. Gently wiggle the tank top to check.
Page 25 of 196 June 14 /2006 V1.0

• Using a ½ inch wrench tighten the nuts holding the tubes in place at the bottom of the tank by
another half turn. Hold the tubes from the top to prevent them from rotating or moving vertically.
Tube solvent line connections

• Start with the tube closest to the front of the instrument.
• Be careful with these lines as they are now connected to the glass tubes, excessive tugging or
pulling of these lines may break the glass tube.
• Connect the tube solvent line (the one without the white compression fitting), to the correct
connection of the top vent/solvent solenoid block. Pass the line behind the aluminum top vent
valve block, and ensure that these lines do not get in the way of connecting the inject lines.
Page 26 of 196 June 14 /2006 V1.0

• The tube solvent lines connect to the steel tube protruding from the bottom of the block at the rear
by simply sliding over it. The numbers are indicated on the solenoid control board just below the
block. For reference they are numbered 1, 3, 5, 7 – 8, 6, 4, 2 from left to right.
• Connect all eight solvent lines.
Page 27 of 196 June 14 /2006 V1.0

Tube inject line connections

• Connect each tube inject line to the bottom of the corresponding inject valve (located over the
center of the cpu board. The inject valves are numbered from 1 to 8 going from back to front. Be
careful not to cross thread the plastic fittings. You may unmount the inject valve if required to
more easily thread the connections.
• Tighten finger tight. Using one index finger from each hand makes this easier.
• Repeat for each tube.
Page 28 of 196 June 14 /2006 V1.0

Instrument reassembly
• Verify that none of the tubes or their fittings are in contact with each other or the sides of the tank
top.
• Reattach the tank top.
• Reattach the black and brass connecting tubes top the lower valves.
• Slide the lower valves back up, ensure the black connecting tube slides over the protruding glass
tube. Slide the lower valves gently up until you meet resistance of the rubber stop inside the
connecting tube, be careful not to move the glass itself up (if this happens, lower the tube back
down to the 3 o-rings that set the height are correctly positioned on the optical sensor. Tighen the
two wing nuts at the back of the valves.
• Position the vertical vent tube so it points up.
• Orient the optical wires and lines neatly through the slots provided.
• Reinstall the front panel and access door in the reverse order of removal.
• Reinstallation of the tank top cover and instrument top are not done until the baths are filled.
Fill
• Verify that the drain valve is closed and has the drain plug tight.
Page 29 of 196 June 14 /2006 V1.0

• Verify that all tubes are inserted or plugged and that that all tube fittings are tight.
• Place rags around the tank cover to catch any accidental spills.
• Position another person so they can see the top bolts holding the tank window on, or pour slowly
and check periodically for correct fill level (check frequently near the correct level).
• Pour the silicon bath oil into the tank through the tank cover slowly being careful not to spill. A
container with an air hole prevents the oil from glugging, if one is not available, pour with the
spout at the top of the container to allow the air to get in easier.
Page 30 of 196 June 14 /2006 V1.0

• The correct fill levels are half way across the screws for the 40°C side and just under them for the
100°C side (the oil will expand slightly when heated).
• Reinstall the tank cover tops.
Pc connections
• Connect the instrument RS-232 jack to one of the computers com ports (default is com2) using the
cable provided.
Page 31 of 196 June 14 /2006 V1.0

Power up
• Plug the instrument in.
• Turn on the instrument.
• The bath controllers will self test and then display the target and actual temperature.
• Check that all three cooling fans are running by simply placing your hand behind each one.
• Check that the bath circulator motors are running by the movement of the bubbles in the oil baths.
• Use the time needed to warm the baths up to continue with the rest of the setup.
Autosampler setup
Probe tip
• Your probe tip, line, z-rack, tube support and insulation block come as one assembly.
• To install, disconnect the fitting from the end of the largest line.
Page 32 of 196 June 14 /2006 V1.0

• Remove the tube support from the line.

• Pass the end of the line through the z-rack hole on the autosampler.
• Orient the z-rack with the threads on the left and insert into the hole from below.
Page 33 of 196 June 14 /2006 V1.0

• Position the z-rack so that the bottom is almost into the z-rack hole.
• Slide the tube through the z-rack until the insulation block and probe are correctly mounted. The
z-rack has a flat spot on the left side, the set screw of the insulation block should be over this flat
spot.
• Tighten the set screw ½ turn past finger tight.
Page 34 of 196 June 14 /2006 V1.0

• Slide the line back through the tube support into the long end.
• When the tube is visible in the access slot near the end of the tube support, use a small screwdriver
to pull the end out of the slot and continue sliding the tube through until enough slack is through to
allow the line to reach the entire deck but not to sag.
Page 35 of 196 June 14 /2006 V1.0

• Pass the line through the large hole in the tube support bracket on the right side of the autosampler,
insert the tube support into the small hole.
• Reconnect the fitting to the end of the line.

• Pass the fitting end through the tube access hole on the right side of the autosampler.
Page 36 of 196 June 14 /2006 V1.0

• Connect the fitting to the pump drive.
Drain line
• Insert the drain line into the drain hole on the autosampler deck.
• Push and rotate the drain line until you can grab it and pull it out from under the autosampler.
Page 37 of 196 June 14 /2006 V1.0

• Pull the drain line through the hole, and slide the end over the drain fitting on the inject block.
• Work the drain line up onto the drain fitting.
• Pass the other end of the drain line over the back of the stand.
Solvent / waste containers

• Position the waste container on the drawer of the stand near the back.
• Place the drain line into the waste container.
Page 38 of 196 June 14 /2006 V1.0

• For heptane, place the solvent container on the stand next to the autosampler on the right.
• For toluene, place the solvent container in front of the waste container.
Page 39 of 196 June 14 /2006 V1.0

• Place the autosampler and instrument solvent feed lines into the solvent container until they reach
the bottom of the container. The instrument solvent lines should exit the instrument through the
top. Pass the lines from the front access door to the top just behind the front panel.
Pc connections
• Connect the autosampler to one of the computers serial ports (default com1) using the supplied
cable.
Page 40 of 196 June 14 /2006 V1.0
• Plug the autosampler in and turn it on.
Vacuum setup
Exhaust
• Connect the ½ inch nylon line to the exhaust vent connection.
• When using compression fittings, always check that you have both parts of the ferrule and nut over
the line before tightening. Tighten the fitting 1 turn past finger tight.
Page 41 of 196 June 14 /2006 V1.0

•Route the line to an outside location. Ensure that the vent/exhaust tubing from the vacuum system is
routed to an outside location as directly as possible. The vacuum system vent will contain high levels
of vapor and may also have small amounts of liquid solvent. The exit points of this vent must NOT be
located near any ignition source, such as a furnace, HVAC, exhaust fan, etc. This is not a complete list,
if you are unsure, consult with someone who is familiar with your suggested exhaust location.
• Alternately, you can route the exhaust line to a fume hood provided you place the line in a
container to catch any liquid solvent and ensure that the fume hood is always on when the vacuum
system is running. This should be checked whenever someone uses the vacuum system and
periodically while running to prevent solvent vapor build up if the fume hood fan fails.
Instrument connections
• Connect the 3/8 nylon line from the ‘viscometer’ connection on the vacuum system to the
instrument vacuum fitting. The shorter this run, the better.
Auxiliary Vacuum line

• Connect the clear flexible ¼ inch line with the copper spud to the auxiliary vacuum fitting, this line
is used for maintenance and any other additional vacuum needs.
Page 42 of 196 June 14 /2006 V1.0

Waste spout
• Connect the copper waste spout to the drain fitting, orient the spout facing down.
Nitrogen
• Connect the ¼ nylon line from a 10 PSI nitrogen (or other inert gas) to the nitrogen fitting. This is
not required to run the instrument, but will be needed to periodically drain the vacuum trap.
Software
Install
• Insert the cd into the cd drive. The installer should start automatically, if not, open the cd and run
setup.exe.
• Follow the on screen instructions to install the software.
Page 43 of 196 June 14 /2006 V1.0

• Once the software is installed, remove the cd from drive.

• The minimum permissions required for a restricted user to run the software are full control to the
HSV_DATA and logs folders in the program install directory (normally c:\hsv\).
• Run the software.
• If your instrument is on the default com ports, the software will find and and ask you to insert the
instrument setup floppy. Do so now, the setup floppy contains tube volume and optics offset
information from the factory testing. If the instrument could not be found, follow the instructions
in the next section to adjust the com ports and use the floppy when asked later.
Com / basic settings

• Select ‘setup->instruments’ from the menu.
• In the general tab of the instrument setup window, set the autosampler and instrument com ports to
match where the cables were plugged in.
• Set the two bath temperatures correctly.

• Select the correct tube paring mode. The instrument can be operated in the three modes described.
• Select the ‘Floor Model’ and correct solvent configuration.
• Go to the Tube Types tab.
• Select the correct tube configuration installed in the instrument.
• Click Ok to save the changes.
• If you have changed the com ports, select rescan for instruments from the file menu.
Tray setup
• Place the racks on the deck as needed for the rack configuration selected by the customer (a typical
rack configuration is shown below).
Page 44 of 196 June 14 /2006 V1.0

• The software can have many rack configurations and allows the users to switch between them.
You need to map the deck for each configuration (you can cut and paste the inject block mapping
to all maps).
Deck mapping
• Setup the configuration to be mapped.
General
• Select Diagnostics from the setup menu.
• Go to the Arm Control tab.
• From here you can see the current layout, move and measure the current arm position.
• The arrow keys on the keyboard move the probe in the x and y directions. The page up and down
keys move the probe up and down. Tapping the keys once moves the arm exactly one count.
Page 45 of 196 June 14 /2006 V1.0

Holding the keys down causes the arm to continue moving in the direction request with slowly
increasing speed.
• Open the default deck configuration file (asdeck.asdc) in the HSV_DATA sub directory in
notepad. As objects on the deck are located this file will be updated with that information. The
software will allow the user to select from any *.asdc file in the HSV_DATA directory as a deck
layout.
• Use the keys to move the probe least ½ inch above the highest object on the deck.
• Read the current Z position and enter this as ZTravel, ZDispense, and ZStart in the general section.
Be careful not to accidentally read the coordinates in the ‘Move To’ editable boxes below the
current position data.
[General]
Trays = 2
Samples = 1
ZTravel = 500
ZDispense = 500
ZStart = 500
ZMax = 1615
InjectDia = 12.5
XRange = 1745
YRange = 2150
ZRange = 1670
• You can define sample positions in two ways, tray and samples. Samples define one position. A
tray defines any number of sample positions in rows and columns with only two corners setup.
The example deck shown above will have 2 trays (one for the small round racks and one for the
larger square ones, and 1 sample position for the large plastic container.
• To allow optimal sample pickup the software will only submerge the probe as far under the surface
as needed. To allow this to work the software needs information on the volume of the containers
used as well as the top and bottom levels. The simplest way to get volumes is to tare the container
on a balance and fill to the low side of the expected fill level and weigh the water, the weight in
grams is the same as the volume in ml’s. The number entered into the software should be slightly
smaller then the measured value in case some samples are short on volume. If you find that the
software submerges correctly near the top of the container but not as the container empties, then
your volume is too high. This feature can be turned off entirely or skipped in the deck layout by
simply entering 0 as the volume.
Trays
• Enter the number of trays you are defining in the general section.
• For each tray, place a container in the upper left position.
Page 46 of 196 June 14 /2006 V1.0

• Move the probe to just above the maximum liquid level and centered over the container.
• Find the section for the tray number you are defining. The tray section will be [Tray#] where # is
the tray number (eg ‘[Tray1] is tray number 1).
• If there is no section for the tray, create one.
• Enter the current x position as StartX.
• Enter the current y position as StartY.
• Enter the current z position as ZStart.
• Move the probe to just above the bottom of the container. Moving the container up to touch the
probe as the probe is moved slowly down in steps will allow you to check the space remaining on a
container you can’t see through.
• Enter the current z position as ZMax.
• Move the probe up and move the container to the lower right position.
• Move probe to just above the container and centered over the container.
Page 47 of 196 June 14 /2006 V1.0

• Enter the currect x position as EndX

• Enter the current y position as EndY
• Enter the number of columns as Columns.
• Enter the number of rows as Rows.
• Enter the container volume in ml’s as Vol
• If the container is round, enter the diameter in mm as Dia. This is only used to present a
representative display of the deck and does not need to be accurate.
• If the container is rectangular, enter the width in mm as SizeX and the depth as SizeY. This is only
used to present a representative display of the deck and does not need to be accurate.
• An example of a round container tray is shown below.
[Tray1]
ZStart = 710
ZMax = 1535
Rows = 16
Columns = 8
StartX = 35
StartY = 55
Dia = 16
Vol = 10
EndX = 818
EndY = 2030
Samples
• Enter the number of samples you are defining in the general section. Do not include sample
positions defined in trays.
• For each sample, place a container the correct position.
• Find the section for the sample number you are defining. The sample section will [Sample#]
where # is the sample number (eg ‘[Sample1] is sample number 1).
• If there is no section for the sample, create one.
• Enter the current x position as x.
• Enter the current y position as y.
• Enter the current z position as z.
Page 48 of 196 June 14 /2006 V1.0

• An example of a round container sample is shown below.
[Sample1]
ZStart = 550
z = 1615
x = 1231
y = 309
Dia = 40
Vol = 220
Waste and Cleaning Ports

• Move the probe tip over the clean position of the inject block (the small hole at the very back) and
center it over the hole.
• Lower the probe slowly into the hole until you hear the probe bottom out.
• Move the prove ¼ inch back up.
• Enter the current x, y, z position in the [Clean] section.

• Move the probe tip over the waste position of the inject block (the small hole at the very back) and
• Enter the current x and y position in the [Waste] section. Set the z to the same as the clean section
z.
Inject Ports
• Move the probe over the inject port to be mapped and center it.
• Move the probe down until it’s approximately 1 inch over the white inject port at the bottom of the
hole.
Page 49 of 196 June 14 /2006 V1.0
• Using a stool, look down on the port from above. As the probe is in the way, look from both
forward of the z-rack and behind. You should see light coming from the center part of the inject
port. Move the probe up or down until the crescent shape of the inject port is seen.
• Based on the shape of the crescent(s), adjust the probe position as shown below until the crescents
are equal and centered as shown with the check mark. This will center the probe over the inject
port.
• Slowly move the probe down until you hear or see that it has made contact with the inject port.
Verify the probe is centered by carefully moving the probe slightly to the right and left, if the
probe was not centered it should fall into the inject port. Adjust the x or y position as required to
re-center the probe over its new position.
• Using the exercise x 1 button, listen to the sound of the contact with the inject port. Increase the
depth by small steps until the sound becomes noticeably louder. If a ‘z-axis error’ occurs, the
probe has been moved down too far, re-initialize the autosampler and start again.
• View the probe from the front and exercise the probe, watch that the probe does not shift to the left
or right as it makes contact with the port, adjust the x axis until this no longer occurs.
• Perform the same with the y axis by looking from the side.
• Enter the current x, y, and z position in the correct inject section of the deck file, the inject ports
are numbered from back to front.
Calibration
Temperature Adjustments
• It is highly recommended to calibrate the temperature controllers, if you are using heptane, you
must calibrate at least the 100°C side to prevent the solvent from boiling over. As long as the bath
Page 50 of 196 June 14 /2006 V1.0
temperatures are close to the required set points the error will be calibrated out by the calibration
samples. Calibration also allows you to reset the controllers to adjust for the temperature sensors
drifting with time instead of recalibrating the entire instrument.
• If required, wait for the bath temperature to stabilize, it should read the same as the set point.
• Slide the instrument out.
• Insert an ASTM thermometer into the access port at the back of the tank cover. The ASTM
thermometer are required to get the correct accuracy (they only cover +/- 1 degree around the
target set point).
• Slide the thermometer down the access port until the bulb(s) are submerged. You can place a
grommet on the thermometer to allow you to release it.
• Wait for the temperature reading to stabilize.

• Read the thermometer from the side of the instrument or through the tank window.
Page 51 of 196 June 14 /2006 V1.0

• To correct the temperature controller, press the button to access the menu system.
• The controller will display ‘Ac,Cd’ in the lower half of the display alternating with the menu
number. Use the up and down arrow keys to select menu 4.
• Press the button until ‘CAL,L’ is displayed.
• If the temperature reading on the thermometer is high, press the down arrow ( ) until the
temperature reading on the controller reads the same as the thermometer.
• If the temperature reading on the thermometer is low, press the up arrow ( ) until the
• Press the button to exit.

• Wait 15 minutes for the bath to re-stabilize at the new setting, check the temperature again.
Autosampler Connections
• Slide the instrument fully back on the stand.
• Connect the eight inject lines from the autosampler to the tops of the inject valves. Note that the
lines are numbered from back to front.
• Pass the inject block drain line through the instrument to exit through the top.
Page 52 of 196 June 14 /2006 V1.0

• Connect the inject block drain line to the inject block.
Cut-out Adjustments
• Turn the over temperature cut outs down slowly, one at a time, until the cut out trips. This will
turn off the heater system and the temperature controller. You may not be able to cause baths set
for 40°C to trip, in that case simply leave the dial turned all the way down and skip the next step
for that cut out only.
Page 53 of 196 June 14 /2006 V1.0

• Turn the dial back up 1/8 of a turn and press the red reset button to turn the heater system back on.
Volume Adjustments
• You are now ready to start testing the instrument, startup the vacuum system.
• Flush the probe tip three times to prime the pump by pressing the flush button in the manual
control window.
• Quick clean all tubes. Observe the cleaning cycle to ensure correct operation.
• Have a quantity of new oil poured into one of the calibration containers. 100 – 200ml works well.
The new oil should be around an ISO100 hydraulic oil or a 5W30 or 10W30 engine oil. This oil
will be used instead of calibration fluid to adjust the instrument setup and test the instrument
before calibration.
• If you are running in Dual Temperature Mode, create four samples. Otherwise create eight
samples.
• Create the samples in the 'sample info' window of the software shown below.
• Select the correct autosampler location. Click on the drop down button , or press F4 to see the
graphical location selection window where you can verify the correct location, or select one by
clicking on it. Set all samples from the same location.
• Enter the typical viscosity for your test oil for all samples. As you are using a new oil, a number
from the spec book, or a typical value for the oil will be fine.
• Go to the Auto Analysis window:
Page 54 of 196 June 14 /2006 V1.0

• Ensure the 'Samples Filled on Start' option is selected.

• Check off the 'Quick Clean all Tubes on Start' option.
• Check that there is enough solvent for the samples in the solvent remaining indicator, fill solvent if
required.
• Press the start button.
• Watch the amount of oil that enters the each tube as it is injected. Look at the position of the top
meniscus of the oil as the oil flows into the sensor to start timing 1 and the position of the top
meniscus when the cleaning cycle starts (the oil will be sucked out of the tube at the start of the
cleaning cycle).
• Using the chart below, check that the volume level is not too much nor too little. For the 40°C
tubes, it is ok to have the volume set to slightly too much if required to meet the too little
requirement due to the larger volume required for the 40°C tubes.
Start of
Timing 1
Correct Too Much
Page 55 of 196 June 14 /2006 V1.0

Start of
Cleaning
Correct Too Little

• Adjust the volume in the Tube Types tab of the instrument setup window. The volume offsets are
in ul, and 100ul will move the top meniscus approximately ¼ inch.
• Start again until all volumes are correct.
Instrument test
• Once all of the volumes look correct, refill the test oil container.
• Enter the oil as a calibration oil in the calibration oils window (from the setup menu).
• To define a calibration oil you need to enter two lines on this window, one for the 40°C
measurement and one for the 100°C measurement.
Page 56 of 196 June 14 /2006 V1.0

• Ensure you enter the correct viscosities in the correct columns. The column labeled simply
viscosity is the viscosity of the oil at the temp in the next column. The column labeled ‘Visc @
40C’ is always the viscosity of the oil at 40°C, regardless of the temperature in the previous
column.
• Select the correct location for the oil.
• Click ok to save your changes.
• Select Calibration Curve from the setup menu.
• Set the minimum number of samples to 10 and the maximum RSD to 9999. This will cause the
system to run 10 samples and stop when calibrating.
• Click OK, and go to the Manual Control window.
Page 57 of 196 June 14 /2006 V1.0

• Click the quick clean all button.

• Flush the probe tip.
• When the tubes have returned to idle, select calibrate all tubes from the tube menu. The system
will now run 10 samples into each tube.
• When the samples are complete, cut and paste the results from the results window into excel or
openoffice.
• Sort the results by tube and format the results will several blank rows between tubes.
• Compute the average, and stdev of each timing measurement (in calibration mode the results show
raw counts).
• Compute the rsd as average divided by stdev and format as a percentage. Your sheet should look
similar to:
1886 1176 1L 1898 1141 2L 1961 1247 3L 1879 1177 4L
1890 1175 1L 1886 1139 2L 1928 1233 3L 1875 1175 4L
1862 1176 1L 1878 1134 2L 1940 1237 3L 1878 1173 4L
1871 1174 1L 1869 1134 2L 1939 1229 3L 1876 1175 4L
1877 1177 1L 1878 1141 2L 1947 1232 3L 1871 1170 4L
1875 1177 1L 1873 1136 2L 1936 1231 3L 1870 1171 4L
1874 1176 1L 1874 1134 2L 1937 1231 3L 1870 1172 4L
1874 1176 1L 1863 1127 2L 1940 1232 3L 1868 1169 4L
1876.125 1175.875 1877.375 1135.75 1941 1234 1873.375 1172.75

8.675705 0.991031 10.74294 4.652188 9.651055 5.732115 4.138236 2.764572
0.46% 0.08% 0.57% 0.41% 0.50% 0.46% 0.22% 0.24%
869 522 1R 882 540 2R 878 540 3R 907 511 4R

860 518 1R 860 527 2R 876 537 3R 896 507 4R
854 513 1R 863 526 2R 869 534 3R 893 507 4R
858 516 1R 865 528 2R 872 534 3R 895 508 4R
856 516 1R 866 530 2R 874 536 3R 898 507 4R
863 517 1R 865 528 2R 869 535 3R 895 506 4R
862 518 1R 855 529 2R 872 535 3R 893 507 4R
862 517 1R 874 530 2R 875 536 3R 892 507 4R
Page 58 of 196 June 14 /2006 V1.0

860.5 517.125 866.25 529.75 873.125 535.875 896.125 507.5

4.659859 2.531939 8.34523 4.367085 3.226564 1.95941 4.793969 1.511858
0.54% 0.49% 0.96% 0.82% 0.37% 0.37% 0.53% 0.30%
• If all of the percentages are below 1.00%, you can continue and calibrate the instrument.
Otherwise you should follow the instrument test procedure (in the procedures section) to bring the
respeatabilities down before calibrating.
Calibration
• Go to the calibration oils window.
• Delete the test oil from the list.

• Create two lines for every calibration fluid used (N10, N35, N100, N350, N1000 are
recommended).
• Ensure you correctly enter the viscosities of the oils at the correct temperature. Most fluid bottles
will list multiple temperatures on the label.
• It is good practice to also enter the batch or expiry date of the oil in the description field for future
reference.
• Set the location for each oil to the location you plan to use for the oils. Label the containers and
fill with the oils. If you have more oils than large quantity locations, you can reuse a location, but
you must remember to only select oils that do not share locations and run multiple calibrations to
build up the curve.
• Verify all oils are entered correctly, and the containers on the deck are filled.
• Click ok to save.
• Go to the calibration curve window.
• Set the minimum number of samples to 3 and the maximum RSD to 1.2. This will cause the
system to run 3 samples and stop when calibrating if the repeatability is good.
• Go to the manual control window.
• Quick clean all tubes.
• Flush the probe.
Page 59 of 196 June 14 /2006 V1.0
• When all tubes have returned to idle, select calibrate all. Select all oils if no oils share locations,
otherwise select the ones placed on the deck.
• The instrument will now run at least three samples of each oil and generate a calibration curve.
• If you need multiple batches due to oils that share locations, run the additional oils after the system
finishes the first set in the same manner.
Verification
• Go to sample information window.
• Enter one sample for each tube or tube pair of one of the calibration fluids (or a qc oil with a
known viscosity).
• Go to the automated analysis window
• Clear the 'Quick Clean all Tubes on Start' option.
• Press start.
• Verify that the measured results match the known value to within +/- 2-3%.
• The instrument is now ready to run.
Removal & Installation Of Parts
Notes:
• Unless otherwise indicated, the instrument can be left on for many tasks. If you chose to do so, or
the instrument has not been turned off for at least 8 hours, be careful as parts in and around any
bath set to 100°C will be hot and parts in and around any bath set to 40°C will be noticeably warm.
• When reattaching parts, always start all fasteners loosely and only tighten when all are in place.
• When you need to slide the instrument out from under the autosampler for easier access, you must
first exit the software and then disconnect all inject lines from the autosampler, disconnect the
inject block drain, and remove the waste line from the waste container (place a rag to catch any
drips from the waste line).
• When handling electronic parts, ensure you are grounded or using a grounded wrist strap.
Case
Front Access Door
Removal:
• Unscrew the two screws holding the front panel access door and remove the door.
Page 60 of 196 June 14 /2006 V1.0

Installation:
• Reattach the door using the screws, washers and lock washers removed.
• Loosen the screws and adjust the door left to right and front to back to maintain even seems with
the front panel.
Side Access Doors

Removal:
• Unscrew the three screws holding the side panel access door and remove the door.
Installation:
• Reattach the door using the screws, washers and lock washers removed.
• Loosen the screws and adjust the door left to right and front to back to maintain even seems with
the side panel.
Case front
Removal:
• Remove the front access door.
• Unscrew the six screws (three on each side) holding the front panel on. If you have removed the
three screws at the back of the side panel, the side panel will come off. Either reattach at least the
top screw in the back of the side panel to hold it in place, or remove the side panel first.
Page 61 of 196 June 14 /2006 V1.0

• Remove the front panel by pulling the bottom out until it is past the front of the deck. You may
need to slide the instrument slightly forward. Be careful not to slide the front leveling feet off of
the deck.
Page 62 of 196 June 14 /2006 V1.0

Installation is in reverse order of removal.
Case sides
Removal:
• Remove the side access door.
• If you are removing both side panels, remove the front panel first, otherwise the other side panel
screws will hold the front panel in place for you.
• Unscrew the three screws at the front of the side panel if not already removed.
Page 63 of 196 June 14 /2006 V1.0

• Unscrew the three rear screws holding the side panel on and remove the side panel. Be prepared to
support the side panel.
Case Skirt
Removal:
• Turn the instrument off.
• Remove the case top front panel.
• Remove the case top rear panel.
Page 64 of 196 June 14 /2006 V1.0

• Unscrew the eight ball studs and six nuts holding the skirt pieces to the frame. Do not remove the
screws, or the nuts and washers underneath the skirt (these have lock-tight on them to make
accidental removal difficult).
Case top front

Removal:
• Remove the top of the instrument by pulling up on in (it pops off).
Case top rear

Removal:
• Remove the top front panel.
• Pop the top rear of the instrument by pulling up on in (it pops off). There are several wires
connecting the rear top to the instrument, do not move the top rear such that these wires are pulled
on. Do not touch the stirrer motors or any parts on the cpu board as they may be hot.
Page 65 of 196 June 14 /2006 V1.0

• Disconnect the temperature sensor wire harnesses (2).
• Disconnect the temperature controller harness from the cpu board.
• Disconnect the top rear case fan harnesses (2) from the cpu board.
Page 66 of 196 June 14 /2006 V1.0

• Disconnect the main power harness.
• Place the top rear in a safe location.
Case rear
Removal:
• Place an index mark for the current location of both over temperature cutout dials.
Page 67 of 196 June 14 /2006 V1.0

• Remove both over temperature cutout dials by unscrewing the small flat head screw in the dial.
• Remove the six screws in the rear of both side panels. If you have removed the front screws in the
side panels either replace the screws, or fully remove both side panels.
• Unscrew the four screws holding the rear panel on. Be prepared to hold the rear panel in place.
Do not let the rear panel rest on or move the over temperature cutout dial posts or reset button as
they may break off.
Page 68 of 196 June 14 /2006 V1.0

• Tilt the back panel out at the bottom and slide down to remove.
• Place the back panel a short distance away from the rear of the instrument and disconnect the rear
fan harness.
Page 69 of 196 June 14 /2006 V1.0


• When installing the rear panel, locate the panel to make sure the over temperature cutout dial posts
and reset button are free to move and then tighten the four rear screws.
• Restore the dials to the indexed location after reassembly. As the dials will move slightly inward
when turned, leave a small amount of space between the rear case and the dial.
Utility panel
Removal:
• Dry all tubes 4 times to remove all liquids from the internal vacuum lines.
• Turn instrument off.
• Turn off the vacuum system.
• Remove rear case panel.
• Remove over temperature cutout switch by unscrewing the two screws holding it in place. Move
the switch out of the way.
• Remove the motor run caps.

• Remove the ssr’s.
• Disconnect the serial port harness from the cpu board.
Page 70 of 196 June 14 /2006 V1.0

• Disconnect the internal vacuum line from the bulkhead fitting by reaching down from the top.
• Unscrew the four screws holding the utility panel on.
• Disconnect the three power wires from the receptacle.
Page 71 of 196 June 14 /2006 V1.0

Tanks
Tank cover top
Removal:
• Remove the case top front.
• Unscrew and remove, the top of the tank cover (6 screws).
Tank cover
Removal:
• Remove the case top front.
• Follow the instructions to disconnect the inject and solvent lines from the instrument to the glass
capillary tubes (ensure that you leave the lines connected to the tubes themselves).
• Disconnect the four optics harnesses from the cpu board.
Page 72 of 196 June 14 /2006 V1.0

• Remove the tank cover (10 screws). Do not remove the screw holding the cpu board mounting
bracket.
Page 73 of 196 June 14 /2006 V1.0

Heater assembly
Removal:
• Wait for at least 10 minutes to allow the heaters to cool. Note, the 100°C side will still be hot.
• Remove the top rear case panel.
• Remove the rear case panel.
• Disconnect the motor harness, the heater harness, and the over temperature cutout harness.
• Unscrew the two screws holding the over temperature cutout
• Unscrew the six screws holding the heater assembly to the tank.
Page 74 of 196 June 14 /2006 V1.0

• Gently remove the heater assembly by sliding it straight up. Be careful not to touch the
temperature sensor located on the front of the stainless steel baffle plate.
• As you pull up you may need to guide the over temperature cutout switch past the rear of the
instrument frame.
Page 75 of 196 June 14 /2006 V1.0

Tank
Removal:
• Drain the tank.
• Remove the top front and top rear case panels.
• Remove all tubes from the tank.
• Remove the front, side, and rear case panels.
• Remove the tank cover.
• Remove the heater assembly.
• Remove the cpu board mount.
• Unbolt the four bolts holding the tank on from below. You can also do this by loosening the four
screws shown.
Page 76 of 196 June 14 /2006 V1.0

• Unscrew the side support screw from the tank.
• Lift the tank out vertically.

• When installing the tank, ensure the rubber vibration mount is correctly positioned over all four
bolt holes.
Page 77 of 196 June 14 /2006 V1.0
• Before tightening the tank bolts and screws, loosely reattach the cpu mount tank connecting rails.
Tubes
Tubes
Removal:
• With care you can remove and replace a tube while the instrument is full of bath oil. You may
drain the instrument if you wish. If the instrument has been running recently, the tubes will be hot,
use work gloves.
• Remove the case front panel.
• Remove the tank cover top.
• If you are removing tubes 1 or 2, remove the tank cover.
• Remove the solvent feed lines from the solvent container. Place into a pail on the floor to catch
outflow.
• Quick clean all tubes twice to drain the lines of any solvent.
• Exit the instrument software, and turn the instrument off.
• Locate and disconnect the top vent / solvent line from the top vent / solvent valve block. The
numbers are indicated on the solenoid control board just below the block. For reference they are
numbered 1, 3, 5, 7 – 8, 6, 4, 2 from left to right.
• Locate and disconnect the inject line from the inject valve. The inject valves are numbered from 1
to 8 going from back to front. You may unmount the inject valve if required to more easily access
the connections.
Page 78 of 196 June 14 /2006 V1.0

• Open the side access door.

•Loosen the two wing nuts holding the solenoid valve to the black bracket and carefully slide the valve
down so the black rubber tube slides off the glass capillary tube.
•Unscrew the brass nut to remove the black rubber tube.

• Have a tube plug ready.
• Loosen the nut holding the tube in place at the bottom of the tank. Hold the tube from the top to
prevent it from rotating. Loosen only enough to allow the tube to slide, not enough for oil to flow
out. Caution, these parts may be hot, use gloves if required.
Page 79 of 196 June 14 /2006 V1.0

• Carefully slide the tube up until the bottom of the tube is close to the retaining nut.
• Use the tube plug to push the tube up by aligning the plug with the glass. You may need to gently
rotate the tube plug slightly back and forth or loosen the nut slightly to allow the plug to replace
the tube in the seal.
• Once the tube is free, remove it from the top of the instrument and set in a safe place.
• Tighten the retaining nut to prevent any bath oil from leaking.
Installation is in resevse order of removal.

• When replacing a tube, follow the instrument setup instructions to set the tube at the correct height.
• If the replacement tube is new or a different tube it will need to be re-calibrated after installation.
Tube Inject Line

Removal:
• Remove the tube from the instrument if required.
• Loosen the brass fitting on the inject line of the tube.
Page 80 of 196 June 14 /2006 V1.0

• Slide off the three o-rings and nut.
Installation:
is the glass tube that connects to the horizontal section from below; it also has the smaller inside
diameter.
Page 81 of 196 June 14 /2006 V1.0

when heated.
Tube Solvent Line

Removal:
• Remove the tube from the instrument if required.
• Loosen the brass fitting on the inject line of the tube.
• Slide off the three o-rings and nut.
Page 82 of 196 June 14 /2006 V1.0

Installation:
is the glass tube that connects to the horizontal section from below; it also has the smaller inside
diameter.
when heated.
Valves
Connecting Tube
Removal:
• If the instrument software is running, wait for the tube to be idle and then disable the tube.
Page 83 of 196 June 14 /2006 V1.0

•Unscrew the brass nut to remove the black rubber connecting tube.
Lower Solenoid Valve Assembly

Removal:
• If the instrument software is running, wait for the tube to be idle and then disable the tube.
Page 84 of 196 June 14 /2006 V1.0

•Unscrew the brass nut to remove the black rubber tube
•Unscrew and remove the clear vertical vent tube.

•Unscrew and remove the two black nuts that retain the solenoid coils.
Page 85 of 196 June 14 /2006 V1.0

•This step removes the vacuum hose. You will either need to shut off your vacuum system or have an
object to plug the 1/8” ID of the tubing. Slide off the black rubber vacuum tubing and brass ring
located at the bottom of the solenoid valve.
•Fully remove the two wing nuts at the back of the solenoid valve and remove the whole assembly.
Installation is in the reverse order of removal.

• When reinstalling the solenoid coils, the one with the blue dot sticker, or blue dot on the face of
the coil (where the nut goes) must be placed on the upper valve.
Replace Coils (Lower Valves)

Removal:
• Exit the instrument software.
Page 86 of 196 June 14 /2006 V1.0

•Unscrew and remove the clear vertical vent tube.

•Unscrew and remove the two black nuts that retain the solenoid coils.
• Disconnect the solenoid coil harness from the solenoid control board.

Page 87 of 196 June 14 /2006 V1.0
• When reinstalling the solenoid coils, the one with the blue dot sticker, or blue dot on the face of
the coil (where the nut goes) must be placed on the upper valve.
Replace Coils (Solvent Valves)

Removal:
•Unscrew and remove the two black nuts that retain the solenoid coils for the tube required.
• Disconnect the solenoid coil harness from the solenoid control board.

• When reinstalling the solenoid coils, the one with the longer wiring must be placed on the upper
valve.
Valve Rebuild Kit (Lower Valves)

Removal:
• Note: a 3-way kit is required for the upper solenoid (where the vent tube is attached) in the lower
valve, and a 2-way kit for the lower solenoid in the lower valve.
• Note: there may be some solvent and/or oil present in the valves. Use appropriate personal
protection.
• Remove the lower valve assembly.
• Unscrew the two armature screws holding the retaining plate on for the upper or lower solenoid.
Page 88 of 196 June 14 /2006 V1.0

• Carefully remove the armature by wiggling it gently back and forth. There is an o-ring seal at the
bottom of the armature that can be easily damaged.
• Remove the poppit from the armature.
• At this point the internals of the valve block should be cleaned with Q-tips and solvent.
• Clean the armature and poppit if new parts are not being used in reassembly.

• Check that the poppit moves freely in the armature. Binding may cause the valves to jam. Do not
use binding parts.
• When reinstalling the armature into the valve block, place a thin coat of new oil on the o-ring seal
to help insert it without cutting/pinching the o-ring. Gently rock the armature while applying a
small amount of pressure to reseat the seal.
Page 89 of 196 June 14 /2006 V1.0

• After assembly adjust the orientation of the vent tube if required by loosening the two armature
plate screws and attaching the vent tube. Rotate the vent so that it points up and slightly to the left
when tightened by pushing on the tube about 1 to 1.5 inches from the fitting, do not over tighten or
you will damage the seal. Tighten the screws when finished.
Valve Rebuild Kit (Tube Vent/Solvent Valves)

Removal:
• Note: the tube vent/solvent valve only use a 2-way kit.
protection.
outflow.
• Remove the coils from the correct solenoid valves (see Replace Coils Solvent Valves).
Page 90 of 196 June 14 /2006 V1.0
• Clean the armature and poppit if new parts are not being used in reassembly.

use binding parts.
Page 91 of 196 June 14 /2006 V1.0

Inject valves
Removal:
• Turn off the instrument.
• Remove the case top front panel, and case front panel.
• Locate and disconnect the tube inject line from the bottom of the correct inject valve. The inject
valves are numbered 1 to 8 from back to front.
• Disconnect the inject valve harness from the solenoid control board.
Page 92 of 196 June 14 /2006 V1.0

• Unscrew the two screws holding the inject valve to the mounting bracket. There are two washers
on each screw, do not loose the washers as the screws will prevent the valve from operating if they
are missing.
Top Vent / Solvent Valves Assembly

Removal:
• Remove the solvent feed lines from the solvent container.
• Quick clean all tubes twice to dry out the lines.
• Remove all instrument solvent feed lines.
• Disconnect all tube solvent lines from the valve assembly.
Page 93 of 196 June 14 /2006 V1.0

• Remove all solvent valve coils and disconnect from the solenoid control board.
• Unscrew the two screws holding the solvent valve assembly to the mounting bracket.
Vent Tubes
Removal:
• Disable the tube you wish to work on.
• Locate the vent tube you wish to remove.
• Unscrew the vent tube counter clockwise.
Page 94 of 196 June 14 /2006 V1.0

Installation:
• Fold the vent tube in half to make starting the threads easier.
• Loosely attach the vent tube until the seal starts to grab. The threads on the vent tube are plastic,
be careful not to cross thread.
• Tighten by pushing on the tube about 1 to 1.5 inches from the fitting. The vent tube should point
up (slightly to the right or left is ok). If not, adjust the orientation of the vent tube by removing the
solenoid coils and loosening the two armature plate screws. Then rotate the vent so that it points
up and slightly to the left when tightened by pushing on the tube about 1 to 1.5 inches from the
fitting. Tighten the screws.
Page 95 of 196 June 14 /2006 V1.0

Electronics
Cpu board
Removal:
• Remove the case front top panel.
• Remove the case rear top panel.
• Remove the inject valve mount and place the valves on one of the tank covers.
• Remove the plastic protection sheet.
• Disconnect all harnesses from the cpu board.
• Disconnect the vacuum sensor line from cpu board.
• Unscrew the 8 nuts and two standoffs holding the cpu board to the mounting bracket.
Page 96 of 196 June 14 /2006 V1.0

• Slide the cpu forward for easiest removal.
Solenoid board
Removal:
• Disconnect all harnesses from the solenoid board.
• Remove the six bolts holding the solenoid board in place.
Page 97 of 196 June 14 /2006 V1.0

• Slide the solenoid board out to the side past the solvent feed lines (not shown).
Power supply
Removal:
• Wait 15 minutes to allow all capacitors to discharge.
• Remove the case rear panel.
• Disconnect the power harnesses, and switching supply harness from the power supply.
• Rotate the instrument so the back is towards the front of the stand.
• Carefully move one foot of the instrument off the front of the stand so you have access to of the
four screws holding the power supply on (on the same side). Be careful to fully support the
instrument as it may wish to tip toward the foot you have slid off.
• Remove the two screws from below.
Page 98 of 196 June 14 /2006 V1.0

• Repeat for the other two screws.

• Note, ensure that you do not change the spacers on the screws holding the power supply on. The
power supply thread depth is very shallow and screws that go in too far could short the supply out.
The screws have a hex nut, a split lock washer and a flat washer on them in that order.
Bath Temperature Controller

Removal:
• Place the case rear top panel on a clean surface upside down, be careful not to scratch the powder
coating.
• Write down the current locations of the wire connections.
• Using a small flat screwdriver, pop the retaining clip up while applying slight pressure to the
controller outwards. Continue trying each clip until the clips are past the ratchet area. This can
take a little time.
• Loosen the screws to remove both harnesses from the controller.
Page 99 of 196 June 14 /2006 V1.0

• Slide the controller out of the front of the case rear top.

• Note: the power harness has three brown wires. The two brown wires that are next to each other
on the cpu harness end are the output, the other brown with the blue are the line input.
Eprom
Removal:
• Slide the protective plastic sheet out of the way.
• Using a small flat screwdriver, gently pry the eprom loose by alternately prying from both sides.
Installation:
• Line up the eprom with the pin one indicator on the lower left.
• Ensure all pins are correctly aligned, then push the eprom down.
Fan (bottom rear)

Removal:
• Remove the rear case panel.
Page 100 of 196 June 14 /2006 V1.0

• Unscrew the four screws and nuts holding the fan and finger guard to the case rear panel. Be
careful not to loose the nuts and washers from the other side.
Fan (top)
Removal:
• Unscrew the four screws and nuts holding the fan and finger guard to the case rear panel. Be
careful not to loose the nuts and washers from the other side.
Motor Run Cap

Removal:
• Unscrew the two screws holding the motor run cap to the utility panel.
Page 101 of 196 June 14 /2006 V1.0

• Disconnect the motor run harness from the cpu board.
• Disconnect the motor harness.
Page 102 of 196 June 14 /2006 V1.0

• Locate and disconnect the ground wire that comes from the motor harness from the frame star
ground.
Installation is in reverse order of disassembly.

Replacement Temp Sensor
Removal:
• Remove the heater assembly for the same side as the temperature sensor you are removing.
• Undo the two wire retainers holding the sensor to the baffle plate.
Page 103 of 196 June 14 /2006 V1.0


• When reinstalling the sensor, place the sensor as shown to avoid contact with the baffle plate
which will cause temperature stability problems.
• Do not over tighten the wire retainers as they could cut into the wiring.
SSR
Removal:
• Unscrew the two screws holding the ssr to the utility panel.
Page 104 of 196 June 14 /2006 V1.0
• Disconnect the ssr harness from the cpu board.
Timing Sensor
Removal:
• Remove the tank cover top.
• Prepare a clean rag to wipe the sensor and another to place the sensor on after removal.
• Use gloves as the sensor and tools used will become hot.
• Remove the capillary tube for the timing sensor you are removing.
• Disconnect the timing sensor harness from the cpu board.
Page 105 of 196 June 14 /2006 V1.0

• Using a 5/8 socket on an extension handle, reach down and unscrew the timing sensor. Hold onto
the wiring harness and allow it to spiral around the extension handle.
Page 106 of 196 June 14 /2006 V1.0

• Once the timing sensor has been unscrewed, use the extension handle and wiring harness to pull
the timing sensor out of the oil bath.

• Note that the sensor normally has one plastic spacer on the bottom, when replacing a timing
sensor, ensure there is one and only one spacer between the sensor and the bottom of the tank. If
the spacer stays in the tank, remove the one on the sensor before installing.
Page 107 of 196 June 14 /2006 V1.0

• Use the wiring harness to hold the sensor to the extension handle while installing the sensor as
shown.
Page 108 of 196 June 14 /2006 V1.0

Wiring
Instrument to PC serial cable
Removal:
• Disconnect the cable from both the instrument and the computer.
Page 109 of 196 June 14 /2006 V1.0

Motor Run Cap Wiring Harness

Removal:
• Remove the motor run cap.
• Slide the connector boot off the top of the cap.
• Disconnect the four harness wires from the cap. Note the correct grouping of the wires by color.

• Note, ensure boot is fully installed on cap before reassembly.
Optic Sensor Harness

Removal:
• Remove the timing sensor (optic sensor).
• Remove the harness from the sensor.
Page 110 of 196 June 14 /2006 V1.0

Power Receptacle Harness

Removal:
• Remove the case rear.
• Disconnect the harness from the power receptacle.
• Disconnect the harness from the cpu board.
Page 111 of 196 June 14 /2006 V1.0

• Disconnect the harness from the switching power supply.
• Disconnect the two ground wires from the star ground post.
Power Switch
Removal:
Page 112 of 196 June 14 /2006 V1.0

• Place the case rear top panel on a clean surface upside down, be careful not to scratch the powder
coating.
• Pinch the plastic catches on both the top and bottom of the power switch to release it.
• Slide the switch and harness through the hole.
• Remove any electrical tape from the switch.

• Disconnect the harness from the switch. Note correct wiring for reassembly.
Page 113 of 196 June 14 /2006 V1.0


• Note, when reinstalling, the side of the switch with the wires indicates the ON position.
Power Switch Harness

See power switch.
Serial port harness

Removal:
• Disconnect the serial port harness from the cpu board.
• Unscrew the two screws that hold the harness to the utility panel. Be careful not to loose the nuts
and washers on the other side.
Solenoid board ribbon cable

Removal:
Page 114 of 196 June 14 /2006 V1.0


• Disconnect the ribbon cable from cpu board.
• Disconnect the ribbon cable from the solenoid board.
SSR Wiring Harness

Removal:
• Remove the SSR.
• Note the correct wiring of the SSR.
• Remove the four wires. Note, ROHS versions of the instrument may have a plastic connector
guard that is not shown, you will need to remove this first.
Page 115 of 196 June 14 /2006 V1.0

Switch Supply Harness

Removal:
• Remove case front top panel.
• Remove case top rear panel.
• Remove case front and rear panel.
• Disconnect the switch supply harnesses from the power supply.
• Disconnect the switch supply harnesses from the cpu board.
Page 116 of 196 June 14 /2006 V1.0

• Disconnect the switch supply harness from the solenoid board.\
• Remove the power harness wiring from the instrument.
Plumbing
Instrument Solvent feed Lines
Removal:
• Exit the software.
Page 117 of 196 June 14 /2006 V1.0


outflow.
• Disconnect the solvent feed line from the top vent/solvent solenoid block by sliding the line down.
Have a rag at hand to catch any outflow from the block.
Internal Vacuum Plumbing

Removal:
• Exit instrument software.
• Remove case top front panel.
• Remove case top rear panel.
• Disconnect the main vacuum line from the vacuum block.
• Disconnect vacuum line from cpu board vacuum sensor.
Page 118 of 196 June 14 /2006 V1.0

• Disconnect the internal vacuum line from the bulkhead fitting on the utility panel by reaching
down from the top.
• Remove vacuum plumbing through the front access door. You will need to flex the plastic line.
Replacement Vacuum Gauge

Removal:
• Shut down the vacuum system.
• Disconnect the vacuum line from the back of the gauge.
Page 119 of 196 June 14 /2006 V1.0

• Remove the orange lock pin from the top seal of the gauge by sliding it out.
• Using a small flat head screw driver, remove the top seal.
Page 120 of 196 June 14 /2006 V1.0

• Push the gauge out as far as possible by hand.

• Using a large flat head screw driver, pry the gauge out by gently prying at many points around the
gauge. Continue prying all around until the gauge is out.
• Replace the top seal in the gauge.
Vacuum Block
Removal:
• Note: you can perform this task through the front and side access doors. Pictures were taken with
one of the tanks removed for clarity.
• Remove the inject block drain line from the vacuum block.
Page 121 of 196 June 14 /2006 V1.0

• Disconnect the main vacuum line from the vacuum block.
• Disconnect the vacuum block distribution lines from the vacuum block.
• Unscrew the two screws holding the vacuum block to the frame.
Page 122 of 196 June 14 /2006 V1.0
Vacuum Block Distribution Lines

Removal:
• Note: you can perform this task through the front and side access doors. Pictures were taken with
one of the tanks removed for clarity.
• Disconnect all eight distribution lines from the vacuum block.
• Disconnect the distributions lines from the lower valve assemblies.
Page 123 of 196 June 14 /2006 V1.0

Vacuum Pump Rebuild Kit

• Shutdown the vacuum system.
• Unscrew the six nuts on the pump input, output and transfer tubes.
• Disconnect the input and output lines.
Page 124 of 196 June 14 /2006 V1.0

• Gently bend the transfer tubes just enough to remove them.
• You can now follow the vacuum pump rebuild kit instructions to rebuild the pump in place.
• Reconnect all lines after installing the rebuilt kit in the reverse order of removal.
Mounting
Cpu mount
Removal:
• Remove the case top rear panel.
• Remove the inject valve mount.
• Remove the cpu board.
• Unscrew the four screws holding the cpu mount plastic to the tank connecting rails.
Page 125 of 196 June 14 /2006 V1.0

• Unscrew the four screws holding the tank connecting rails to the tank. These screws have spacers
on the bottom, be careful not to drop the spacers.
Inject Valve Mount

Removal:
Page 126 of 196 June 14 /2006 V1.0


• Disconnect all eight tube inject lines from the bottom of the inject valves.
• Unscrew the two nuts holding the inject valve mount.
• Place the inject valves and mount on one of the tank cover tops.
Top vent valve mount

Removal:
• Remove both top vent/solvent solenoid assemblies.
• Unscrew the two screws (one on each side) holding the mount to the frame.
Page 127 of 196 June 14 /2006 V1.0

Solenoid board mount

Removal:
• Remove the solenoid control board.
• Unscrew the four screws holding the mount to the frame.
Lower valve mount

Removal:
• Take the tube you are working on offline, or exit the software.
• Remove the lower solenoid valve assembly.
• Unscrew the two screws holding the lower valve mount in place.
Page 128 of 196 June 14 /2006 V1.0

• Remove the lower valve mount from the instrument.
Autosampler Parts
Syringe
Removal:
•Wait until all tubes are idle.
•As the syringes contain solvent use proper protection equipment.
•Select Diagnostic Tools from the setup menu.
•Go to the maintenance tab and click the change syringe button.
•Select the syringe you wish to replace and click ok.
•The software will instruct you to remove the solvent line, this is the line that goes to the solvent
container.
Pump 1 Pump2
•The software will next lower the syringe and tell you to change it now (do not click ok).
•Unscrew the nut holding the bottom of the syringe to the drive.
Page 129 of 196 June 14 /2006 V1.0

•Unscrew the small Phillips screw on the black syringe clamp near the top of the syringe.
• Unscrew the syringe itself to remove it.
Installation:
•Install the syringe by reversing the previous steps.
•Press Ok, the syringe will be moved back up.
•Reattach the solvent line.
Page 130 of 196 June 14 /2006 V1.0

Syringe Seal
Removal:
•Remove the syringe.
•Remove the plunger from the syringe.
•Using pliers, gently remove the white syringe seal, do not scratch the plunger.
•Remove and replace the o-ring under the seal and press a new seal onto the plunger.
Installation:
•Install the syringe by reversing the previous steps.
•Press Ok, the syringe will be moved back up.
•Reattach the solvent line.
3 Port Valve Head

Removal:
• Remove the syringe.
• Disconnect the probe tip line.
Page 131 of 196 June 14 /2006 V1.0

• Unscrew the two screws holding the valve head on.

• Note, when installing the valve head, ensure you position the head onto the drive shaft in the
correctly keyed position.
Pump Drive 3 Port

Removal:
• Turn off the autosampler.
• Disconnect the probe tip line.
Page 132 of 196 June 14 /2006 V1.0

• Remove the back autosampler panel by unscrewing the 12 screws.
• Unscrew and disconnect the pump drive harness.
Page 133 of 196 June 14 /2006 V1.0

• Unscrew the four screws holding the pump drive to the autosampler. Remove the drive by sliding
it out the front.
Page 134 of 196 June 14 /2006 V1.0


• Note, ensure new pump is set to pump number 0 on the pump drive board selector.
Pump Drive 8+ Port

Removal:
• Disconnect the clean lines and smart valve line from the valve head.
• Remove the back autosampler panel by unscrewing the 12 screws.
Page 135 of 196 June 14 /2006 V1.0

• Unscrew and disconnect the pump drive harness.
• Unscrew the four screws holding the pump drive to the autosampler. Remove the drive by sliding
it out the front.
Page 136 of 196 June 14 /2006 V1.0


• Note, ensure new pump is set to pump number 1 on the pump drive board selector.
8+ Port Valve Head

Removal:
Page 137 of 196 June 14 /2006 V1.0
• Disconnect the clean lines and smart valve line from the valve head.

Probe Line Tube Support

Removal:
• Remove the probe tip line, but to not remove the probe tip or insulation block.
• Slide the tube support out of the holder vertically.
Page 138 of 196 June 14 /2006 V1.0

Smart Valve Head

Removal:
• Remove the smart valve lines.
• Remove the two clean lines from the smart valve.
Page 139 of 196 June 14 /2006 V1.0


Z-Rack
Removal:
• Remove the probe and line.
• Slide the z-rack vertically out of the top of the autosampler.

• Note, you will need to re-map the deck.
Page 140 of 196 June 14 /2006 V1.0

Autosampler Plumbing
Clean Lines
Removal:
• Remove the autosampler solvent feed lines from the solvent.
• Quick clean all tubes to remove most of the solvent from the lines.
• The clean lines will still have some solvent in them, use appropriate personal protection.
• Disconnect the clean lines from the inject block, note the ordering of the numbers on the lines.
• Disconnect the clean lines from the valves, note the ordering of the numbers on the lines.
• Feed the lines through the exit hole on the right side of the autosampler.
Page 141 of 196 June 14 /2006 V1.0


• Ensure clean lines are installed on the valves numbered left to right, and on the inject block from
back to front.
Inject Lines
Removal:
• Disconnect the eight inject lines from the bottom of the inject block.

• Disconnect the inject lines from the top of the inject valves.
Page 142 of 196 June 14 /2006 V1.0


• Note, ensure inject lines are numbered from back to front when reinstalling.
Smart Valve Lines

Removal:
• Disconnect the smart valve transfer line.
• Disconnect the smart valve dead end line.
Page 143 of 196 June 14 /2006 V1.0

Solvent Feed Lines

Removal:
• Remove the solvent feed lines and place in a container on the floor to catch outflow.
• Disconnect the solvent feed lines from the pump drive valves.
• Feed the lines through the exit hole on the right side of the autosampler.
Page 144 of 196 June 14 /2006 V1.0

Autosampler Drain Line

Removal:
• Disconnect the inject lines from the inject block.
• Unmount the inject block by loosening the two fittings clamping it down, and slide the block
vertically up.
Page 145 of 196 June 14 /2006 V1.0

• Disconnect the autosampler drain line from the inject block.
• Slide the drain line out the bottom of the autosampler.

• Note, as the inject block will have shifted, you will need to remap the inject block.
Inject Block
Removal:
• Disconnect the clean lines from the inject block.
Page 146 of 196 June 14 /2006 V1.0

• Disconnect the inject lines from the inject block.
• Disconnect the inject block drain line from the inject block.
• Unmount the inject block by loosening the two fittings clamping it down, and slide the block
vertically up.
Page 147 of 196 June 14 /2006 V1.0

• Disconnect the autosampler drain line.

• Note, as the inject block will have shifted, you will need to re-map the inject block.
Inject Ports
Removal:
• Disconnect the inject line from the bottom of the inject block for the port you are removing.
Page 148 of 196 June 14 /2006 V1.0

• Using a 5/16 socket on an extension, unscrew the inject port through the top as shown.
• When the inject port is loose, tilt the socket and pull the inject port out vertically. If the inject port
falls into the hole, use the thick cleaning wire to extract the port by passing the wire through the
center of the port.
Page 149 of 196 June 14 /2006 V1.0


• Note, you will need to re-map this inject port location.
Insulation Block
Removal:
• Unscrew the set screw holding the insulation block to the z-rack.
• Slide the probe line and insulation block down.

• Disconnect the tubing from the insulation block.
• Unscrew the probe locking screw.
Page 150 of 196 June 14 /2006 V1.0

• Remove any remaining tubing from the insulation block (there is a short piece of tubing that goes
from the thick probe line to the probe itself).
• Slide the probe out of the bottom on the block (it will be tight).
• Disconnect the insulation block harness.

Probe & Line

Removal:
• Remove the insulation block.
• Disconnect the probe line from the pump drive.
Page 151 of 196 June 14 /2006 V1.0

• Disconnect the thickest line from the fitting.
• Slide the probe line out of the hole in the right of the autosampler.
Page 152 of 196 June 14 /2006 V1.0

• Slide the probe line out of the tube support.
• Slide the probe line out of the top of the z-rack.
Page 153 of 196 June 14 /2006 V1.0


Inject Block Drain Line

Removal:
• Disconnect inject block drain line from vacuum block.
Page 154 of 196 June 14 /2006 V1.0

• Disconnect inject block drain line from inject block by sliding it off the metal tube.
Procedures
Tubes
Setting the Height
• Remove the tube from the instrument.
• Slide the three o-rings down the tube until they are just above the black line on the tube. If the
black line is missing or you wish to reset the height from scratch, move the o-rings down close to
the transition to the smaller capillary tube.
• Verify the correct placement of the o-rings with the optic heighting tool. The bubble joining the
two different sizes of capillary should be just below (not visible in) the hole for optic two (shown
by the arrow).
Page 155 of 196 June 14 /2006 V1.0

• Reinstall the tube.
Setting Oil Volume

before calibration.
samples. If you only wish to test one tube, create one sample and disable the other tubes from the
manual control window.
Page 156 of 196 June 14 /2006 V1.0


required.
cleaning cycle).
Page 157 of 196 June 14 /2006 V1.0

Start of
Timing 1
Correct Too Much
Start of
Cleaning
Correct Too Little

Tanks
Filling
• Remove the tank cover tops.
• Verify that the drain valve is closed and has the drain plug tight.
Page 158 of 196 June 14 /2006 V1.0

• Verify that all tubes are inserted or plugged and that that all tube fittings are tight.
• Place rags around the tank cover to catch any accidental spills.
• Position another person so they can see the top bolts holding the tank window on, or pour slowly
and check periodically for correct fill level (check frequently near the correct level).
• Pour the silicon bath oil into the tank through the tank cover slowly being careful not to spill. A
container with an air hole prevents the oil from glugging, if one is not available, pour with the
spout at the top of the container to allow the air to get in easier.
Page 159 of 196 June 14 /2006 V1.0

• The correct fill levels are half way across the screws for the 40°C side and just under them for the
100°C side (the oil will expand slightly when heated).
• Reinstall the tank cover tops.
• Reinstall the case top front panel.
Draining
• Ensure the drain handle is closed and remove the drain cover plug.
Page 160 of 196 June 14 /2006 V1.0

• Connect the 3/8 nylon drain line to the drain port. Careful, metal parts will be hot.
• Place the other end in a container to catch the oil. The oil is expensive and can be reused if it is
kept clean.
• Open the drain valve. Warning: the oil will be hot, be careful. It is best to drain the oil while hot
to speed up the process.
• When the drain is complete, close the drain valve.
• Remove the drain line and re-plug the drain port.
• Close the side access door.
Optic Sensors
Adjusting
• Perform the instrument test procedure first.
• Using the information form the instrument test, adjustments can be made to improve the
repeatability as well as diagnose several instrument problems.
• Do not adjust optics unless indicated from the instrument test section, ensure tubes are clean,
flowing with no blockages and solvent clean correctly first.
• Note: the optics sensors have been adjusted at the factory and the settings included on the
instrument disk. You may need to perform an adjustment if tubes are placed in the wrong
positions, an optic sensor is replaced, or things have changed during shipping.
• The instrument performs two independent measurements of the oil flowing calling timings. In
each sensor housing there are four pairs of detectors (numbered 1 to 4 from top to bottom). Each
pair consists of a transmitter and receiver. When the oil redirects the light from the transmitter, the
drop in intensity triggers the receiver. The four detectors are used as stop and start marks for the
timings as shown below.
Page 161 of 196 June 14 /2006 V1.0
Oil
Large Glass
Capillary Tube
Optic 1
Timing 1 is the time

elapsed from
triggering optic 1 to
optic 2.
Optic 2
Optic 3
Timing 2 is the time

elapsed from
triggering optic 3 to
optic 4.
Optic 4
Small Glass
Capillary Tube
• Normally, the optics start as slightly too sensitive (with offset 0) and will sometimes pick up the
leading edge of the liquid meniscus. As the meniscus shape is not constant from run to run this
will introduce variability in the timings.
• The purpose of adjusting the optics is to set the sensitivity so that the detectors trigger on the
middle of the meniscus and give the most repeatable results.
• If the start optics (1 and 3) are too sensitive and trigger early, the timing they start will be long.
• If the stop optics (2 and 4) are too sensitive and trigger early, the timing they stop will be short.
• You can adjust the optics by selecting instruments from the setup menu. Then go to the optics
offset tab. The window below will be displayed.
• If you see that one of the timings from the instrument test has 1-3 high outliers that do not
correspond to high outliers in the other timing, adjust the start optic offset by adding 1. Repeat the
test, if you run out of range, or the results get noticeably worse after 3 tries, consider adjusting the
stop optics by subtracting 1. It is unusual for optics to have sensitivities set below –1.
• If you see that one of the timings from the instrument test has 1-3 low outliers that do not
correspond to low outliers in the other timing, adjust the stop optic offset by adding 1. Repeat the
Page 162 of 196 June 14 /2006 V1.0

test, if you run out of range, or the results get noticeably worse after 3 tries, consider adjusting the
start optics by subtracting 1. It is unusual for optics to have sensitivities set below –1.
Testing
• Tests are only valid on a clean tube, tubes that have fluid in them will not read correctly.
• Select the diagnostics option from the setup menu.
• Go to the Maintenance tab.
• Select optics test. The follow window will be displayed:
• To test an optic simply select the optic in the ‘select a cell’ box.
• The instrument will then continually probe the optic and report back all intensities received in the
lower white section of the window.
• The results are displayed as five numbers. The first is an error code, a code of zero means no
error. A code of 8x indicates an error and the second digit indicates which optic(s) set the error
code (one bit is set for each sensor).
• The next four numbers indicate the amount of light needed to send light through the tube from 0-
255. Normally these numbers are in the 90-150 range for clean glass tubes, and 120-200 for tubes
darkened by used oils. A sensor with 0 or 255 has indicated an error.
• A 255 means that the system cannot generate enough light. This can be caused by fluid in the tube,
a dirty tube, or a optics, optics harness failure, or cpu board failure. Verify the tube is clean, then
swap the harness on the cpu board with the adjacent working optic, if the failure is gone, the optic
or harness has failed, replace them.
• A 0 means that the system could generate enough light, but that the optic is false triggering. This
could be because the sensitivity has been adjusted too high, turn down the sensitivity by placing a
7 in the optics offset and retest, if the problem does not go away the optic is bad, replace it.
Otherwise, increase the original offset by 1 until the problem goes away.
Page 163 of 196 June 14 /2006 V1.0
Autosampler
Deck Mapping
• Setup the configuration to be mapped.
General
• Select Diagnostics from the setup menu.
• Go to the Arm Control tab.
• From here you can see the current layout, move and measure the current arm position.
• The arrow keys on the keyboard move the probe in the x and y directions. The page up and down
keys move the probe up and down. Tapping the keys once moves the arm exactly one count.
Holding the keys down causes the arm to continue moving in the direction request with slowly
increasing speed.
• Open the default deck configuration file (asdeck.asdc) in the HSV_DATA sub directory in
notepad. As objects on the deck are located this file will be updated with that information. The
software will allow the user to select from any *.asdc file in the HSV_DATA directory as a deck
layout.
• Use the keys to move the probe least ½ inch above the highest object on the deck.
Page 164 of 196 June 14 /2006 V1.0

• Read the current Z position and enter this as ZTravel, ZDispense, and ZStart in the general section.
Be careful not to accidentally read the coordinates in the ‘Move To’ editable boxes below the
current position data.
[General]
Trays = 2
Samples = 1
ZTravel = 500
ZDispense = 500
ZStart = 500
ZMax = 1615
InjectDia = 12.5
XRange = 1745
YRange = 2150
ZRange = 1670
• You can define sample positions in two ways, tray and samples. Samples define one position. A
tray defines any number of sample positions in rows and columns with only two corners setup.
The example deck shown above will have 2 trays (one for the small round racks and one for the
larger square ones, and 1 sample position for the large plastic container.
• To allow optimal sample pickup the software will only submerge the probe as far under the surface
as needed. To allow this to work the software needs information on the volume of the containers
used as well as the top and bottom levels. The simplest way to get volumes is to tare the container
on a balance and fill to the low side of the expected fill level and weigh the water, the weight in
grams is the same as the volume in ml’s. The number entered into the software should be slightly
smaller then the measured value in case some samples are short on volume. If you find that the
software submerges correctly near the top of the container but not as the container empties, then
your volume is too high. This feature can be turned off entirely or skipped in the deck layout by
simply entering 0 as the volume.
Trays
• Enter the number of trays you are defining in the general section.
• For each tray, place a container in the upper left position.
Page 165 of 196 June 14 /2006 V1.0

• Find the section for the tray number you are defining. The tray section will be [Tray#] where # is
the tray number (eg ‘[Tray1] is tray number 1).
• If there is no section for the tray, create one.
• Enter the current x position as StartX.
• Enter the current y position as StartY.
• Enter the current z position as ZMax.
• Move the probe up and move the container to the lower right position.
• Move probe to just above the container and centered over the container.
Page 166 of 196 June 14 /2006 V1.0

• Enter the currect x position as EndX

• Enter the current y position as EndY
• Enter the number of columns as Columns.
• Enter the number of rows as Rows.
• An example of a round container tray is shown below.
[Tray1]
ZStart = 710
ZMax = 1535
Rows = 16
Columns = 8
StartX = 35
StartY = 55
Dia = 16
Vol = 10
EndX = 818
EndY = 2030
Samples
• Enter the number of samples you are defining in the general section. Do not include sample
positions defined in trays.
• For each sample, place a container the correct position.
• Find the section for the sample number you are defining. The sample section will [Sample#]
where # is the sample number (eg ‘[Sample1] is sample number 1).
• If there is no section for the sample, create one.
• Enter the current x position as x.
• Enter the current y position as y.
• Enter the current z position as z.
Page 167 of 196 June 14 /2006 V1.0

• An example of a round container sample is shown below.
[Sample1]
ZStart = 550
z = 1615
x = 1231
y = 309
Dia = 40
Vol = 220
Waste and Cleaning Ports

• Move the probe tip over the clean position of the inject block (the small hole at the very back) and
• Lower the probe slowly into the hole until you hear the probe bottom out.
• Move the prove ¼ inch back up.
• Enter the current x, y, z position in the [Clean] section.

• Move the probe tip over the waste position of the inject block (the small hole at the very back) and
• Enter the current x and y position in the [Waste] section. Set the z to the same as the clean section
z.
Inject Ports
• Move the probe over the inject port to be mapped and center it.
• Move the probe down until it’s approximately 1 inch over the while inject port at the bottom of the
hole.
Page 168 of 196 June 14 /2006 V1.0
• Using a stool, look down on the port from above. As the probe is in the way, look from both
forward of the z-rack and behind. You should see light coming from the center part of the inject
port. Move the probe up or down until the crescent shape of the inject port is seen.
• Based on the shape of the crescent(s), adjust the probe position as shown below until the crescents
are equal and centered as shown with the check mark. This will center the probe over the inject
port.
• Slowly move the probe down until you hear or see that it has made contact with the inject port.
Verify the probe is centered by carefully moving the probe slightly to the right and left, if the
probe was not centered it should fall into the inject port. Adjust the x or y position as required to
re-center the probe over its new position.
• Using the exercise x 1 button, listen to the sound of the contact with the inject port. Increase the
depth by small steps until the sound becomes noticeably louder.
• View the probe from the front and exercise the probe, watch that the probe does not shift to the left
or right as it makes contact with the port, adjust the x axis until this no longer occurs.
• Perform the same with the y axis by looking from the side.
• Enter the current x, y, and z position in the correct inject section of the deck file, the inject ports
are numbered from back to front.
Instrument
Temperature Calibration
• It is highly recommended to calibrate the temperature controllers, if you are using heptane, you
must calibrate at least the 100°C side to prevent the solvent from boiling over. As long as the bath
temperatures are close to the required set points the error will be calibrated out by the calibration
Page 169 of 196 June 14 /2006 V1.0
samples. Calibration also allows you to reset the controllers to adjust for the temperature sensors
drifting with time instead of recalibrating the entire instrument.
• If required, wait for the bath temperature to stabilize, it should read the same as the set point.
• Insert an ASTM thermometer into the access port at the back of the tank cover. The ASTM
thermometer are required to get the correct accuracy (they only cover +/- 1 degree around the
target set point).
• Slide the thermometer down the access port until the bulb(s) are submerged. You can place a
grommet on the thermometer to allow you to release it.
• Wait for the temperature reading to stabilize.

• Read the thermometer from the side of the instrument or through the tank window.
Page 170 of 196 June 14 /2006 V1.0

• To correct the temperature controller, press the button to access the menu system.
• The controller will display ‘Ac,Cd’ in the lower half of the display alternating with the menu
number. Use the up and down arrow keys to select menu 4.
• Press the button until ‘CAL,L’ is displayed.
• If the temperature reading on the thermometer is high, press the down arrow ( ) until the
• If the temperature reading on the thermometer is low, press the up arrow ( ) until the
• Press the button to exit.

• Wait 15 minutes for the bath to re-stabilize at the new setting, check the temperature again.
Over Temperature Cutout Adjustment

• Turn the over temperature cut outs down slowly, one at a time, until the cut out trips. This will
turn off the heater system and the temperature controller. You may not be able to cause baths set
for 40°C to trip, in that case simply leave the dial turned all the way down and skip the next step
for that cut out only.
Page 171 of 196 June 14 /2006 V1.0

• Turn the dial back up 1/8 of a turn and press the red reset button to turn the heater system back on.
Inject Volume Adjustments

• Flush the probe by pressing the flush button in the manual control window.
• Quick clean all tubes. Observe the cleaning cycle to ensure correct operation.
before calibration.
samples.
Page 172 of 196 June 14 /2006 V1.0


required.
cleaning cycle).
Page 173 of 196 June 14 /2006 V1.0

Start of
Timing 1
Correct Too Much
Start of
Cleaning
Correct Too Little

Repeatability Testing
• Enter the test oil as a calibration oil in the calibration oils window (from the setup menu).
• To define a calibration oil you need to enter two lines on this window, one for the 40°C
measurement and one for the 100°C measurement.
Page 174 of 196 June 14 /2006 V1.0

• Ensure you enter the correct viscosities in the correct columns. The column labeled simply
viscosity is the viscosity of the oil at the temp in the next column. The column labeled ‘Visc @
40C’ is always the viscosity of the oil at 40°C, even if the temperature in the previous is 40.
• Select the correct location for the oil.
• Click ok to save your changes.
• Select Calibration Curve from the setup menu.
• Set the minimum number of samples to 10 and the maximum RSD to 1000. This will cause the
system to run 10 samples and stop when calibrating.
• Click OK, and go to the Manual Control window.
Page 175 of 196 June 14 /2006 V1.0

• Click the quick clean all button.

• When the tubes have returned to idle, select calibrate all tubes from the tube menu. The system
will now run 10 samples into each tube.
• When the samples are complete, cut and paste the results from the results window into excel or
openoffice.
• Sort the results by tube and format the results will several blank rows between tubes.
• Compute the average, and stdev of each timing measurement (in calibration mode the results show
raw counts).
• Compute the rsd as average divided by stdev and format as a percentage. Your sheet should look
similar to:
1886 1176 1L 1898 1141 2L 1961 1247 3L 1879 1177 4L
1890 1175 1L 1886 1139 2L 1928 1233 3L 1875 1175 4L
1862 1176 1L 1878 1134 2L 1940 1237 3L 1878 1173 4L
1871 1174 1L 1869 1134 2L 1939 1229 3L 1876 1175 4L
1877 1177 1L 1878 1141 2L 1947 1232 3L 1871 1170 4L
1875 1177 1L 1873 1136 2L 1936 1231 3L 1870 1171 4L
1874 1176 1L 1874 1134 2L 1937 1231 3L 1870 1172 4L
1874 1176 1L 1863 1127 2L 1940 1232 3L 1868 1169 4L
1876.125 1175.875 1877.375 1135.75 1941 1234 1873.375 1172.75

8.675705 0.991031 10.74294 4.652188 9.651055 5.732115 4.138236 2.764572
0.46% 0.08% 0.57% 0.41% 0.50% 0.46% 0.22% 0.24%
869 522 1R 882 540 2R 878 540 3R 907 511 4R

860 518 1R 860 527 2R 876 537 3R 896 507 4R
854 513 1R 863 526 2R 869 534 3R 893 507 4R
858 516 1R 865 528 2R 872 534 3R 895 508 4R
856 516 1R 866 530 2R 874 536 3R 898 507 4R
863 517 1R 865 528 2R 869 535 3R 895 506 4R
862 518 1R 855 529 2R 872 535 3R 893 507 4R
862 517 1R 874 530 2R 875 536 3R 892 507 4R
860.5 517.125 866.25 529.75 873.125 535.875 896.125 507.5
Page 176 of 196 June 14 /2006 V1.0

4.659859 2.531939 8.34523 4.367085 3.226564 1.95941 4.793969 1.511858

0.54% 0.49% 0.96% 0.82% 0.37% 0.37% 0.53% 0.30%
• If all of the percentages are below 1.00%, you can continue and calibrate the instrument.
Otherwise you should follow the instrument test section to bring the respectabilities down before
calibrating.
Instrument Testing
• Perform or have available the results of a repeatability test.
• If all percentages are below 1.00%, the instrument is functioning correctly, otherwise continue.
• For each timing that is not below 1.00%, move the outlier farthest from the mean to the side.
Continue until the rsd is below 1.00%.
• Consult the chart of examples below to decide what action to take.
Timing 1 Timing 2 Timing 1 Timing 2

897 534 898 520
899 536 909 521
895 536 904 521
943 534 904 521
890 534 908 540
905 538 909 522
906 539 909 522
904 540 909 522
904.875 536.375 906.25 523.625

16.34833 2.386719 3.991061 6.653409
1.81% 0.44% 0.44% 1.27%
Action: Action:
Single high outlier timing 1, Single high outlier timing 2,
adjust optic 1 by +1. adjust optic 3 by +1.

1957 1151 911 523
1924 1124 909 523
1937 1145 912 525
1933 1142 910 524
1871 1091 911 478
1740 994 914 528
1682 852 911 527
1554 801 910 527
1824.75 1037.5 911.1429 518.2857

148.6431 140.376 1.573592 17.86724
8.15% 13.53% 0.17% 3.45%
Action: Action:
Increasingly lower timings, Single low outlier timing 2,
check for solvent in inject port. adjust optic 4 by +1.
Page 177 of 196 June 14 /2006 V1.0


891 622 1958 1161
893 588 1965 1151
886 589 1966 1156
891 619 1959 1199
890 628 1957 1157
888 621 1854 1155
883 576 1961 1155
887 579 1970 1187
888.625 602.75 1948.75 1165.125

3.248626 21.68442 38.54404 17.71551
0.37% 3.60% 1.98% 1.52%
Action: Action:
First timing good, second timing Single low outlier timing 1,
noisy, backflush and remove adjust optic 2 by + 1. Two high
any stuck particles, adjust the outliers timing 2, adjust optic 3
tube height. by +1.

2022 1181 938 561
2029 1201 905 548
1981 1168 892 565
2035 1196 916 547
2040 1203 904 553
2000 1178 906 518
1942 1148 905 551
2029 1191 942 558
2009.75 1183.25 913.5 550.125

33.71202 18.65284 17.61493 14.42654
1.68% 1.58% 1.93% 2.62%
Action: Action:
Random low measurements in Random high and low
both timings simultaneously, measurements, check for good
check for good drying, low oil flow and correct oil volume.
vacuum, solvent in inject block.
• Take the suggested action and then perform the repeatability test again.
Calibration
• Go to the calibration oils window.
Page 178 of 196 June 14 /2006 V1.0

• Delete the test oil from the list.

• Create two lines for every calibration fluid used (N10, N35, N100, N350, N1000 are
recommended).
• Ensure you correctly enter the viscosities of the oils at the correct temperature. Most fluid bottles
will list multiple temperatures on the label.
• It is good practice to also enter the batch or expiry date of the oil in the description field for future
reference.
• Set the location for each oil to the location you plan to use for the oils. Label the containers and
fill with the oils. If you have more oils than large quantity locations, you can reuse a location, but
you must remember to only select oils that do not share locations and run multiple calibrations to
build up the curve.
• Verify all oils are entered correctly, and the containers on the deck are filled.
• Click ok to save.
• Go to the calibration curve window.
• Set the minimum number of samples to 3 and the maximum RSD to 1.2. This will cause the
system to run 3 samples and stop when calibrating if the repeatability is good.
• Go to the manual control window.
• Quick clean all tubes.
• Flush the probe.
• When all tubes have returned to idle, select calibrated all. Select all oils if no oils share locations,
otherwise select the ones placed on the deck.
• The instrument will now run at least three samples of each oil and generate a calibration curve.
• If you need multiple batches due to oils that share locations, run the additional oils after the system
finishes the first set in the same manner.
Vacuum Sensor Adjustment

• Ensure the vacuum system is on and the all tubes are idle (the software must be running).
Page 179 of 196 June 14 /2006 V1.0
• Turn the pot on the cpu labeled vac set (just above the vacuum sensor) down slowly until the
software displays ‘Low Vacuum’ in red on the status bar.
• Turn the pot 1/8 of a turn back up. The software should indicate ‘Vacuum Ok’.
Sliding Out for Access

• Disconnect the inject block drain line from the inject block.
• Disconnect the eight inject lines from the autosampler to the tops of the inject valves.
Page 180 of 196 June 14 /2006 V1.0

Draining Solvent
outflow.
• Quick clean all tubes twice to drain solvent from the solvent feed lines.
• Flush the probe tip four times to remove solvent from the autosampler pump and probe line.
Vacuum System
Startup
• Check trap level; follow the instructions on the system to empty if required.
• Check autosampler waste container and empty if required.
• Check that all valves are closed.
• Turn on vacuum pump using switch on bottom of pump (located on the right of the system).
• Open both blue valves (labeled tank and instrument vacuum).
• Wait approximately one minute for vacuum level to build.
Shutdown
• Wait for all measurements and cleaning to finish and tubes to read 'Idle'.
• Turn off vacuum pump.
• Close both blue valves.
• Slowly open the AUX Vacuum valve and wait until the tank pressure reads zero.
• Slowly open the tank drain valve to let the oil flow back into the trap tank.
• The liquid level in the trap tank can now be seen on in drain line.
Draining
• Follow the shut down instructions above.
• Follow the drain instructions on the vacuum system (upper left).
Maintenance
Recommended Schedule
Maintenance Frequency
Glass Cleaning Once a week, or every 1000 samples.
Clean Lower Valves Once every six weeks, or every 7500 samples.
Back Flushing As required
Drive Lubrication Once every 3 months, or every 25000 samples.
Tubes
Glass Cleaning
• Wait until all tubes are Idle.
• Turn down the 100°C temperature to 90°C, by pressing the down arrow button until 90 is
displayed.
• Fill container with a 50/50 mixture of FL70 (available from Fisher) glass cleaner and distilled
water, place on designated location (marked on the autosampler deck).
• Fill another container with distilled water and place on designated location.
• Fill the IPA container on the autosampler deck.
• Wait until temperature has reached 91°C or lower.
• Select the 'Clean Glass' command from the tube menu to display the glass cleaning window:
Page 181 of 196 June 14 /2006 V1.0

• Select the tubes to be cleaned by clicking on them, or press 'Select All' to quickly select all tubes.
• Press the Start button.
• Cleaning tubes takes around one to one and half hours.
• Close the window when cleaning is complete, all tubes will be cleaned with solvent automatically.
• Return the 100°C side to 100 degrees by pressing the up arrow until 100 is displayed.
• Wait until the 100°C side is stable before running samples.
Back Flushing
•Quick clean the tube.
•Take the tube offline by pressing the disable button in the manual control window.
•Prepare by filling a 50ml beaker with solvent, use appropriate personal protection.
•Locate the solenoid valve for the tube. Loosen the two wing nuts holding the solenoid valve to the
black bracket and carefully slide the valve down so the black rubber tube slide off the glass capillary
tube.
Page 182 of 196 June 14 /2006 V1.0

•Unscrew the brass nut to remove the black rubber tube.

•Remove the top panel of the instrument by pulling up (it pops off).
•Unscrew the inject line from the top of the inject valve for the tube that is blocked. The inject line
goes from the autosampler to the instrument.
•Screw in the included adapter tube to the inject valve.

•Connect the auxiliary vacuum line to the adapter tube.
Page 183 of 196 June 14 /2006 V1.0

•Place the beaker under the glass tube at the bottom of the instrument and allow the vacuum to draw up
multiple short shots of solvent from the beaker.
•To return to normal operation, reassemble the instrument by reversing the above steps.
•Run a quick-clean cycle on the tube before testing to see it the blockage has been removed.
• If this will not dislodge the object, some pieces of fine wire are included with the instrument for
this purpose. See the section below.
Removing a Blockage with Cleaning Wire
• Note: there is a thicker wire for the larger tubes and a thin wire for the narrow ones. Ensure there
are no kinks in the wire that could cause it to bind in the capillary tube.
•Follow the steps above for back flushing up to and including connecting the auxiliary vacuum line to
the adapter tube.
•Very carefully slide the wire up until you can see it inside the glass, above the timing sensors (never
allow the wire to reach the bends in the glass as this will scratch the tube). NEVER force the wire as
this can cause the tube to break. If you reach an obstruction that you cannot simply push through,
apply gentle pressure and rotate the wire, this will slowly dig through the object.
Page 184 of 196 June 14 /2006 V1.0

•Slowly remove the wire, which will have dislodged the debris.
•Place the beaker under the glass tube at the bottom of the instrument and allow the vacuum to draw up
multiple short shots of solvent from the beaker.
•To return to normal operation, reassemble the instrument by reversing the above steps.
•Run a quick-clean cycle on the tube before testing to see it the blockage has been removed.
Lower Valves
Cleaning
protection.
• Remove the lower valve assembly.
Page 185 of 196 June 14 /2006 V1.0

• The internals of the valve block should be cleaned with Q-tips and solvent.
• Clean the armature and poppit with Q-tips and solvent.

use binding parts.
Page 186 of 196 June 14 /2006 V1.0

• After assembly adjust the orientation of the vent tube if required by loosening the two armature
plate screws and attaching the vent tube. Rotate the vent so that it points up and slightly to the left
when tightened by pushing on the tube about 1 to 1.5 inches from the fitting. Tighten the screws
when finished.
Operational Testing
• Ensure that the tube is idle and the vacuum system is on.
• Lower the valve but do not unscrew the connecting tube or vent tube.
• Go to the diagnostics window from the setup menu.
• Select the valve control tab.
Page 187 of 196 June 14 /2006 V1.0

• Click on the tube button to turn on the tube valve (the upper of the two).
• Verify that you can hear or feel the vacuum on the connecting tube.
• Close the tube valve and open the vent valve.
• Verify that you can hear or feel the vacuum on the connecting tube and the vent tube.
• Close the vent valve.
• Place a vacuum gauge on the vent tube and block the connecting tube with a rubber stopper.
• Wait 1 minute, the gauge should not move, if the gauge moves, the valve is leaking vacuum and
will cause measurement problems. Clean the valve and or replace or rebuild if required.
• Open the tube valve.
• Remove and replace the rubber stopper.
• The gauge should take longer then 15 seconds to reach 10 inHg. If the valve fails this test, the
instrument may have trouble cleaning out thick oils. Clean the valve and or replace or rebuild if
required.
• Close the tube valve.
• Return the valve to the raised position.
Page 188 of 196 June 14 /2006 V1.0

Top Vent/Solvent Valves

Cleaning
protection.
outflow.
• Remove the coils from the correct solenoid valves (see Replace Coils Solvent Valves).
Page 189 of 196 June 14 /2006 V1.0

• Clean the armature and poppit.

use binding parts.
Operational Testing
outflow.
• Ensure that the tube is idle and the vacuum system is on.
• Go to the diagnostics window from the setup menu.
• Select the valve control tab.
Page 190 of 196 June 14 /2006 V1.0

• Click on the Solv button to turn on the solvent valve (the lower of the two).
• Verify that you can hear the valve click as is opens
• Close the solvent valve and open the top vent valve.
• Verify that you can hear the valve click as is opens
• Close the vent valve.
• Exit the diagnostics window.
• Return the lines to the solvent container.
• Quick clean the tube.
Autosampler
Drive Lubrication
• Periodically you need to lubricate the drive screw.
• Using the syringe of silicon grease supplied, apply a thin bead of grease to the entire length of the
driver screw (accessible through the from of the pump drive).
• Normal usage will blend the new grease in.
Troubleshooting
This section will describe common problems encountered, and techniques for troubleshooting them. It is
highly recommended that the customer routinely run an oil of known viscosity to check the system is
working correctly. Diagnosing problems is easier and problems are discovered sooner, which makes the
maintenance or repair also easier. A calibration oil is not needed for these QC samples, a container of bulk
oil that has been checked using another instrument or averaged over all tubes bracketed by calibration
checks will save costs. The recommended frequency is before and after each tray (if trays are run back to
back, you can start the first tray with a manual QC check and have the software include the end of tray
check to eliminate back to back QC samples). If QC checks are not being routinely run, you may need to
run three samples of a known viscosity to get the data needed for troubleshooting.
A list of symptoms and suggested actions are provided below. Find the symptom description that best
matches the instruments symptoms and follow the recommend actions until the problem is resolved.
Page 191 of 196 June 14 /2006 V1.0

Symptom Recommended Course of Action Notes

Tube is OFFLINE 1. Make sure the injection and the volume look
because it is ‘Failing good for the injected sample.
RSD’ 2. Back-flush the tube.
3. Glass clean.
4. Perform the instrument test procedure on the
tube. If repeatability is good, recalibrate or
quick calibrate the tube.
Tube is OFFLINE 1. Run a worst case cleaning cycle.
because both timings are 2. Make sure the injection and the volume look
out good for the injected sample.
3. Back-flush the tube.
4. Glass clean.
5. Clean the lower valve body.
Tube is OFFLINE due to 1. See procedure above for multiple tubes which
a ‘Time Out’ are OFFLINE due to a ‘Time Out’.
Multiple tubes are 1. Make sure QC oil is filled to the proper level. If the system has run low on solvent
OFFLINE due to a 2. Make sure that there is enough solvent. then the pump will be an excess of air
‘Time Out’ 3. Check to see if there is air in the syringe in the system line and therefore the
when aspirating a sample. volume of the sample injection will
4. Replace syringe seal and/or syringe if be way too low.
necessary.
5. Re-initialize autosampler and use the
diagnostic tools to check the alignment of the
inject block.
6. Re-map inject block if necessary.
Multiple tubes are 1. Check to see if there is sufficient vacuum to If there is a blockage in the inject
OFFLINE because their the system. block drain, then solvent will build
timings are extremely 2. Check to see if there is sufficient vacuum to up in the inject block and mix with
low and are ‘Failing the inject block drain. the injected samples and yield low
RSD’ or are failing ‘< timings or fail rsd or below cal.
CAL’
Tube is OFFLINE 1. Make sure the injection and the volume look
because QC is good for the injected sample.
continually failing 2. Glass clean.
‘Outside Range’ 3. Make sure the timings are consistent (over a
QC run of 3 or more) and that the value
which is ‘Outside Range’ is relatively close to
the expected QC value. If so, perform a
quick calibration.
QC is failing high on 1. Make sure the injection and the volume look
one timing good for the injected sample.
3. Glass clean.
4. Make sure the timings are consistent (over a
Page 192 of 196 June 14 /2006 V1.0
quick calibration.
QC fails high on both 1. Make sure the injection and the volume look Refer to maintenance schedule for
timings good for the injected sample. recommended intervals of running the
2. Back-flush the tube. Glass Clean
3. Glass clean.
4. Make sure the timings are consistent (over a
quick calibration.
Tube continually fails 1. Do a clean on the tube (not a quick clean).
RSD 2. Run at least 3 QC injections on the tube.
3. Make sure the injection and the volume look
good for the injected sample.
4. Proceed to diagnose the problem based on the
timings from step 2.
6. Glass clean.
Timings for injections 1. Check bath temperature with ASTM This will happen if the bath
on all tubes are thermometer. temperature is significantly lower
extremely high and are 2. Correct if possible with the temperature than the set point
failing rsd , outside controller’s calibration.
range, or > CAL 3. Check to see if stirrer motor is operating and Replacing the RTD sensor and/or
the bath liquid is indeed moving. motor assembly should be a last
(Or all 4 Tubes in the 4. Verify temperature controller settings. resort if the other steps have failed
same bath) 5. Verify temperature controller wiring (make
sure the connections are secure).
6. Replace RTD sensor.
7. Replace the motor assembly.
The sample/QC injection 1. Do a clean on the tube (not a quick clean). It is important to adhere to the
is stuck in the tube and 2. Clean out the lower valve body. maintenance schedule for the lower
does not flow down 3. Back-flush the tube. valve bodies
4. Clean out the upper valve body.
Oil is stuttering when 1. Do a clean on the tube (not a quick clean).
flowing down the tube 2. Make sure the injection and the volume look
good for the injected sample.
4. Glass clean.
5. Clean the lower valve body.
6. Clean the upper valve body.
Page 193 of 196 June 14 /2006 V1.0

Injection does not back 1. The top vent may be blocked. In #3, it is possible that the solvent
up in the tube at all, it 2. Test the top vent valves with the valve and/or top vent valves become
just flows straight down diagnostics in the software. physically inoperable if soap (i.e. the
the tube 3. Clean out top vent valve and poppets. glass clean procedure) is run at 100
4. Check for a lower valve vacuum leak. degrees Celsius. This is why it is
important to drop the bath
temperature to 90 degrees before
running the Glass Clean procedure.
Injection is being sucked 1. Check for vacuum leak on the lower valve Possible vacuum leak on the tube
down the tube – results body. poppet in the lower valve body
in RSD failure and/or ‘< 2. Clean lower valve body.
CAL’ 3. Replace poppets and/or valve body if It is important to adhere to the
necessary. maintenance schedule for the lower
valve bodies.
Low volume in the tube 1. Make sure QC oil/samples are filled to the
proper level.
2. Make sure probe line is properly flushed to
eliminate any air in the line.
3. Make sure the probe is making good contact
with the inject port – re-map inject block if
necessary.
4. Check probe line for leaks.
5. Check to see if there is air in the syringe
when aspirating a sample - Replace syringe
seal and/or syringe if necessary.
6. Check for blockages in the tube – piano-wire
and back-flush as necessary.
7. Clean out lower valve body.
8. Adjust volume offset.
Injection volume of QC 1. Adjust the volume offset. Adjust the volume offset if the
is too high volume is too high
Otherwise, if to low, refer to the ‘low
volume’ procedure above.
Tube stuck on ‘Waiting’ 1. Check to see if the oil has flowed down the For #1, if there hasn’t been enough
tube or not. volume injected to flow down the
2. Back-Flush. tube, the tube will be ’stuck’ on
3. Glass clean. waiting until it times out.
4. Adjust the optics intensities.
Optics adjustment are extremely rare
and should only be done as a last
resort
Tube stuck on ‘Optic 1’ 1. Back-Flush. Optics adjustment are extremely rare
2. Glass clean. and should only be done as a last
3. Adjust the optics intensities. resort
Tube stuck on ‘Timing 1. Back-Flush. Optics adjustment are extremely rare
1’ 2. Glass clean. and should only be done as a last
Tube stuck on ‘Optic 3’ 1. Back-Flush. Optics adjustment are extremely rare
2. Glass clean. and should only be done as a last
Tube is ‘< CAL’ with 1. Back-Flush. Optics adjustment are extremely rare
timings of 0 and/or 1 2. Glass clean. and should only be done as a last
Optic reads ‘ERROR’ 1. Follow the Optics Test Procedure.
Page 194 of 196 June 14 /2006 V1.0

Error message: Step-loss 1. Re-initialize autosampler and use the Occurs when probe tip had descended
on Z-axis diagnostic tools to check the alignment of the to somewhere it shouldn’t have and
inject block. hits something with force
2. Re-map inject block if necessary.
Heptane is coming out 1. Check the 100 degree bath temperature with In #3, it is possible that the solvent
of the top vent an ASTM thermometer and calibrate the and/or top vent valves become
controller if necessary. physically inoperable if soap (i.e. the
2. Check the boiling point of the heptane itself, glass clean procedure) is run at 100
this is to make sure the heptane is not degrees Celsius. This is why it is
contaminated with another solvent which important to drop the bath
could lower the boiling point significantly. temperature to 90 degrees before
3. Check and make sure the solvent and top vent running the Glass Clean procedure.
valves are operating properly (electrically
using the diagnostic valve controls).
4. Clean upper valves.
Software is frozen 1. Exit the Software – (by force if required).
2. Turn off instrument.
3. Turn off Autosampler.
4. Wait 5 minutes.
5. Re-start in reverse order.
Watchdog on instrument 1. Exit the Software – (by force if required). The watchdog indicator light is
is lit up 2. Turn off instrument. located under the case top front panel
3. Turn off Autosampler. on the cpu board near the vacuum
4. Wait 5 minutes. sensor.
5. Re-start in reverse order.
Temperature reading is 1. Check to see if stirrer motor is operating and Replacing the RTD sensor and/or
erratic the bath liquid is indeed moving. motor assembly should be a last
2. Verify temperature controller settings. resort if the other steps have failed
3. Try adjusting the temperature controller’s
calibration to match that of an ASTM
thermometer.
4. Verify temperature controller wiring (make
5. Replace RTD sensor.
Temperature controller 1. Verify temperature controller settings. Replacing the RTD sensor and/or
is outputting a error 2. Check to see if stirrer motor is operating and motor assembly should be a last
message the bath liquid is indeed moving. resort if the other steps have failed
3. Verify temperature controller wiring (make
4. Try adjusting the temperature controller’s
calibration to match that of an ASTM
thermometer.
5. Replace the RTD sensor.
Temperature controller 1. Adjust the over temperature cutout reset.
is shut off
Temperature cutout reset 1. Check the bath temperature with a
keeps triggering thermometer and calibrate the controller
accordingly.
2. Make sure the bath oil is moving and is at a
proper level.
3. Adjust temperature cutout.
Page 195 of 196 June 14 /2006 V1.0

Pump error when 1. Re-initialize autosampler.

flushing the probe tip or 2. Go through shutdown procedure.
when injecting 3. Change pump syringe seal and/or pump
syringe.
There is solvent below 1. Replace syringe seal.
the syringe seal 2. Replace syringe.
There is air in the 1. Replace syringe seal. A few air bubbles in the syringe is
syringe when the pump 2. Replace syringe. normal, however if there is a few mm
is aspirating a sample or of air or more in the syringe then
QC there will be problems
Tube is not cleaning and 1. Make sure solvent levels are good. It is important to adhere to the
drying properly 2. Make sure vacuum levels are ok. maintenance schedule for the lower
3. Using the valve diagnostics, check the valve bodies
operation of the lower valve.
4. Clean out the lower valve body if necessary. In #5, it is possible that the solvent
5. If solvent is not getting into the tube, and the and/or top vent valves become
lower valve body and the inject valve are physically inoperable if soap (i.e. the
operating, then the solvent valve body might glass clean procedure) is run at 100
need to be cleaned. degrees Celsius. This is why it is
important to drop the bath
temperature to 90 degrees before
running the Glass Clean procedure.
Solvent remains in the 1. Clean lower valve body. It is important to adhere to the
lower vent tube (doesn’t 2. Replace poppets and/or valve body if maintenance schedule for the lower
get vacuumed out during necessary. valve bodies
cleaning), and/or solvent
overflows from lower
vent tube
Vacuum level on the 1. Check to make sure there is sufficient
software screen is vacuum in the system.
reading ‘Vacuum Low’ 2. Make sure there are no vacuum leaks in the
system.
3. Adjust the vacuum sensor.
Vacuum level on the 1. Make sure there are no vacuum leaks in the
software screen is system.
toggling between 2. Make sure there is sufficient vacuum on the
‘Vacuum Low’ and system.
‘Vacuum OK’ 3. Adjust the vacuum sensor.
Cleaning cycles are 1. Make sure there are no vacuum leaks in the
extremely slow system.
2. Make sure there is sufficient vacuum on the
system.
3. Adjust the vacuum sensor.
Page 196 of 196 June 14 /2006 V1.0

ASHSV Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ASHSV Manual

Uploaded by

Copyright:

Available Formats

qVisc 4320 AX Autosampled Viscometer

Page 1 of 196 June 14 /2006 V1.0

Cautions and Warnings:

Page 2 of 196 June 14 /2006 V1.0

Page 6 of 196 June 14 /2006 V1.0

Page 7 of 196 June 14 /2006 V1.0

• Place stand in its final location.

Page 8 of 196 June 14 /2006 V1.0

• Bolt the leg on the other side as above.

• Place the deck on the casters in front of the stand.

Page 9 of 196 June 14 /2006 V1.0

Page 10 of 196 June 14 /2006 V1.0

Stand height adjustment.

• Remove the top of the autosampler box.

Page 11 of 196 June 14 /2006 V1.0

• Remove the accessories from the rear two slots.

• Lift the cardboard sides off of the box.

Page 12 of 196 June 14 /2006 V1.0

• Remove the front two pieces of foam.

Page 13 of 196 June 14 /2006 V1.0

• Remove the Velcro straps and foam from the arm.

Page 14 of 196 June 14 /2006 V1.0

• Extend the lower deck of the stand fully out.

• Slide the deck fully back in.

Page 15 of 196 June 14 /2006 V1.0

Page 16 of 196 June 14 /2006 V1.0

Page 17 of 196 June 14 /2006 V1.0

• Unscrew and remove, the top of the tank cover (6 screws).

Page 18 of 196 June 14 /2006 V1.0

• Repeat for the other side.

• Remove the cardboard from the top of the tube.

Page 20 of 196 June 14 /2006 V1.0

Page 21 of 196 June 14 /2006 V1.0

Page 22 of 196 June 14 /2006 V1.0

Page 23 of 196 June 14 /2006 V1.0

Page 24 of 196 June 14 /2006 V1.0

• Continue with the remaining tubes in the same fashion.

Page 25 of 196 June 14 /2006 V1.0

Tube solvent line connections

Page 26 of 196 June 14 /2006 V1.0

• Connect all eight solvent lines.

Page 27 of 196 June 14 /2006 V1.0

Tube inject line connections

Page 28 of 196 June 14 /2006 V1.0

Page 29 of 196 June 14 /2006 V1.0

Page 30 of 196 June 14 /2006 V1.0

Page 31 of 196 June 14 /2006 V1.0

Page 32 of 196 June 14 /2006 V1.0

• Remove the tube support from the line.

Page 33 of 196 June 14 /2006 V1.0

Page 34 of 196 June 14 /2006 V1.0

Page 35 of 196 June 14 /2006 V1.0

• Reconnect the fitting to the end of the line.

Page 36 of 196 June 14 /2006 V1.0

• Connect the fitting to the pump drive.

Page 37 of 196 June 14 /2006 V1.0

Solvent / waste containers

Page 38 of 196 June 14 /2006 V1.0

Page 39 of 196 June 14 /2006 V1.0

• Plug the autosampler in and turn it on.

Page 41 of 196 June 14 /2006 V1.0

Auxiliary Vacuum line

Page 42 of 196 June 14 /2006 V1.0