220-240 Serv

VARIAN
Instrument Group/Walnut Creek Division

2700 MiklleU Drive, Walnut Creek, CA 94598/USA/Phone (925) 939-1400
VARIAN
ProStar 220/230/240
STAR 9002/9012
Solvent Delivery Module
Field Reference Manual
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chromatography systems
2700 mitchell drive/Walnut creeklca 94598-1675/u.s.a.tphone (51 0) 939-2400
~~ 9001
R E G I S T E R E D
9012/9002 Pump
Operator's Manual
Varian Associates, Inc. 1994 Printed in U.S.A. 03-914436-40:3

Varian Analytical Instrument
Warranty
Hardware Products
All analytical instruments sold by Varian are warranted to Repair or replacement under warranty claims shall be
be free from defects in material and workmanship for the made in Varian's sole discretion either by sending a
periods specified and in accordance with the terms on Customer Support Representative to the site or by
the face of Varian's quotation or as otherwise agreed authorizing the Customer to return the defective
upon in writing between Varian and the Customer. The accessory or instrument to Varian or to send it to a
warranty period begins on the date of shipment from designated service facility. The Customer shall be
Varian to the original Customer. However, where responsible for loss or damage in transit and shall
installation is paid for by the Customer or included in the prepay shipping cost. Varian will return the accessory or
purchase price, the warranty period begins upon instrument to the Customer prepaid and insured. Claims
completion of installation. If the Customer schedules for loss or damage in transit shall be filed by the
Installation to start later than 30 days after delivery or if Customer. To correct software operation anomalies,
such delay is caused through the Customer's inability to Varian will issue software revisions where such revisions
provide adequate facilities or utilities or through failure to exist and where, in Varian's opinion, this is the most
comply with Varian's reasonable pre-installation efficient remedy.
instructions or through other omissions by Customer,
then the warranty period starts on the 31st day from date
of shipment. Moreover Varian will charge the Customer Limitation of Warranty
for labor and other expenses involved in making multiple This warranty does not cover software supplied by
or follow-up installation service calls. the Customer, equipment and software warranted by
another manufacturer or replacement of expendable
items and those of limited life, such as but not limited to:
Software Products Filters, glassware, instrument status lamps, source
Where software is provided within the frame of a license lamps, septa, columns, fuses, chart paper and ink,
agreement concluded between the Customer and nebulizers, flow cells, pistons, seals, fittings, valves,
Varian, any warranty shall be strictly in accordance with burners, sample tubes, probe inserts, print heads, glass
the terms of such agreement. lined tubing, pipe and tube fittings, variable temperature
In the absence of a license agreement and unless an dewars, transfer lines, flexible discs, magnetic tape
alternate warranty period is agreed upon in writing cassettes, electron multipliers, filaments, vacuum
between Varian and the Customer, the warranty period is gaskets, seats and all parts exposed to samples and
as specified on the face of Varian's quotation. Varian mobile phases.
warrants such software products, if used with and This warranty shall be void in the event of accident,
properly installed on Varian hardware or other hardware abuse, alteration, misuse, neglect, breakage, improper
as specified by Varian to perform as described in the operation or maintenance, unauthorized or improper
accompanying Operator's Manual and to be substantially modifications or tampering, use in an unsuitable physical
free of those defects which cause failure to execute environment, use with a marginal power supply or use
respective programming instructions; however, Varian with other inadequate facilities or utilities. Reasonable
does not warrant uninterrupted or error-free operation. care must be used to avoid hazards.
This warranty Is expressly In lieu of and excludes
all other express or Implied warranties, Including
Remedies but not limited to warranties of merchantability
The sole and exclusive remedy under hardware warranty and of fitness for particular purpose, use or
shall be repair of instrument malfunctions which in application, and all other obligations or liabilities
Varian's opinion are due or traceable to defects in on the part of Varian, unless such other warranties,
original materials or workmanship or. at Varian's option, obligations or liabilities are expressly agreed to In
replacement of the respective defective parts, provided writing by Varian.
that Varian may as an alternative elect to refund an
equitable portion of the purchase price of the instrument
or accessory. Limitation of Remedies and Liability
Repair or replacement under warranty does not extend The remedies provided herein are the sole and
the original warranty period. exclusive remedies of the Customer. In no case
will Varian be liable for Incidental or consequential
damages, loss of use, loss of production or any
other loss Incurred.
03-914412-00:1 1 of 1
Operating Instructions
This instruction manual is provided to help you establish operating conditions which will permit safe and efficient use of
your equipment. Special considerations and precautions are also described in the manual, but appear in the form of
NOlES, CAUTIONS, and WARNINGS as described below. It is important that you operate your equipment in accordance with
this instruction manual and any additional information which may be provided by Varian. Address any questions regarding
the safe and peeper use of your equipment to the National Sales and Service Center below.
NOTE: Information to aid you in obtaining optimal performance
from your instrument.
&CAUTION: Alerts you to situations that may cause moderate
injury and/or equipment damage, and how to avoid these situ-
ations.
&WARNING: Alerts you to potentially hazardous situations that
could result in serious injury, and how to avoid these situations.
Spare Parts Availability

It is the policy of Varian to provide operational spare parts for any instrument and major accessory for a period of five {5)
years after shipment of the final production run of that instrument. Spare parts will be available after this five {5) year
period but on an "as available" basis. Operational spare parts are defined as those individual electrical or mechanical
parts that are susceptible to failure during their normal operation. Examples include resistors, inductors, capacitors,
semi-conductor devices of all kinds, relays, lamps, temperature probes, detector elements, motors, etc. Sheet metal
parts, structural members or assemblies and castings, printed circuit boards, and functional modules are normally
capable of being rebuilt to like-new condition throughout their useful life and therefore will be supplied on an as available"
basis only after the final production run of the instrument.
Service Availability
Varian provides a variety of services to support its customers after warranty expiration. Repair service can be provided
by attractively priced service contracts or on a time and material basis. Technical support and training can be provided
by qualified chemists on both contractual or as-needed basis.
U.S. Sales and Service Information

For Sales or Service Assistance
and To Order Parts & Supplies ...
CALL THE NA710NAL SALES
AND SERVICE CENTER!
1-800.926-3000
Send Orders, Bids and Correspondence to:

Varian Analytical Instruments
National Sales and Service Center
505 Julie Rivers Road, Suite 150
Sugar Land, Texas 77478
03-914399-00:5
varian
Australia
Main International Sales Offices
Varian Australia PTY, Ltd.
679 Springvale Road
Great Britain
Varian U.K. Limited
28 Manor Road, Walton-On-Thames
Spain
Varianlberica,S.L.
Avenida Pedro Diez, 25

Mulgrave, Victoria Surrey KT12 20F, England 3rd Floor
3170 Australia Tel. (44) (932) 243-741/Telex 928070 E-28019 Madrid, Spain
Tel. (61) (3) 560-7133/Telex AA31229 Fax (44) (932) 228-769 Tel. (34) (1) 472-7612
Fax (61) (3) 560-7950 Fax (34) (1) 472-5001
Italy
Belgium Varian SpA Sweden
Varian Belgium N.VJS.A. Via Brescia 47 VarianAB
Excelsiorlaan 21, Bus 1 Cernusco SIN (Milano) Huvudstagatan 1 I P.O. Box 1099
B-1930 Zaventem Haly S-17122 Solna, Sweden
Belgium Tel. 0039-02 921351/Telex 310099 Tel. (46) (8) 820-030/Telex 10403
Tel. (32) (2) 721-4850/Telex 24361 Fax 0039 02 92135250 Fax(46)(8)827~7
Fax (32) (2) 720-7596
Japan SWitzerland
Brazil Varian Instruments Limited Varian International AG
Varian Industria e Comercio Ltda. 3rd Matsuda Building Zweigniederlassung Basel
Avenida Dr. Cardoso de Mello, 1.644 2-2-6 Ohkubo-Shinjuku GOeterstrase 86/ Postfach 385
CEP 04548-005 Tokyo, 169, Japan CH-4008 Basel, Switzerland
Sao Paulo, Brazil Tel. {81) (3) 3204-1200/Telex 26471 Tel. (41) (61) 271-3737
Tel. (55) (11) 820-0444/Telex 24314 Fax(81)(3)3204-1782 Fax (41) (61) 271-3103
Fax (55) (11) 820-9350
Mexico United States
canada Varian SA Varian Associates

Varian canada, Inc. Liverpool 96, Colonia Juarez National Sales and Service Center
6705 Millcreek Drive, Unit #5 Mexico, D.F. 06600 505 Julie Rivers Road, Suite 150
Mississauga, Ontario Tel. (52) (5) 533-5985/Telex 1n4410 Sugar Land, Texas n478
Canada L5N 5R9 Fax (52) (5) 514-5383 Tel. (713) 240-7330
Tel. (416) 819-8181 Fax (713) 240-6752
Fax(416)819-8348 Netherlands
Varian Nederland B. V. Other Countries in Africa,
Eastem European Office DeMolen2 Near and Middle East
Varian Ges.M.B.H. 3994 DB Houten Varian Associates
Eisgrubengasse 2/Postfach 14 The Netherlands 607 Hansen Way
A-2334 Vosendorf Bei Wien Tel. (31) (3403) 50909/Telex 40645 Palo Alto, California 94304-1 015
Austria Fax (31) (3403) 51116 Tel. (415) 493-4000
Tel. (43) (1) 695-545/Telex 36701 Fax (415) 855-7201
Fax (43) (1) 694-018 Norway
VarianAB
France PB 71/ N-1405 Langhus
Varian SA Oslo, Norway
7 Avenue des Tropiques Tel. (09) 86 74 70
Z.A. Courtaboeuf, B.P. 12 Fax (09) 86 76 30
91941 Les Ulis Cedex, France
Tel. (33) (1) 6986-3838/Telex 602435 Southeast Asia
Fax (33) (1) 6928-2308 Varian Pacific, Inc.
Mandarin Plaza, Room 1018-20
Germany Tower A, 14 Science Museum Road
Varian GmbH Tsimshatsui East, Kowloon
Alsfelder Strasse 6 Hong Kong
Postfach 11 14 35 Tel. (852) (3) 724-2836/Telex 35626
D-61 00 Darmstadt, Germany Fax(852)(3)694-280
Tel. (49) (6151) 7030/Telex 419429
Fax (49) (6151) 703-237
varian

03-914399-00:5

Hazard Hazard Getahr Warning Pellgro
Symbol Warnings Warnungen Avertlssement Advertenc/as
Electric Shock: Elektrlscher Schlag: Electrocution: Des Choques Electrlcos:
~
Hazardous voltages are Gefllhrliche Hochspannung voltages dangereux son! Altos voltajes existen
present inside instrument. in diesem Gehause. presents a l'interieur de adentro de las cubiertas.
Disconnect from main Netzstecker ziehen, bevor l'appareil. Debrancher Desconecte Ia
power before removing angeschraubte Deckel l'appareil avant tout electricidad antes de
screw-attached panels. entfernt warden. demontage. quitar cualquier cubierta
atornillada.
...j~
Chemical: Hazardous
chemicals may be present
in the instrument. Avoid
contact, especially when
replenishing reservoirs.
Chemlsche Gefahr:
Dieses Gerat kann
gefllhrliche Chemikalien
enthalten. Vermeiden Sie
direkten Kontakt und
lnhalierung der Dampfe,
besonders beim AuffOIIen
Prodults Chlmlques: Des
produits chimiques
dangereux peuvent se
trouver dans !'instrument.
Eviter tout contact,
particulierement pendant le
remplissage des reservoirs.
Sustanclas Qulmlcas:
Sustancias quimicas
peligrosas pueden existir
adentro del instrumento.
Evite el contacto con
estas, especialmente al
reponer elliquido del
der Behalter. depOsito.
s{ Heat: Very hot surfaces

may be exposed. Use
caution to avoid severe skin
damage.
Yerbrennungsgefahr:
Sehr heisse nicht isolierte
Aachen oder Teile. Vorsicht
nicht berOhren.
BrOiures: Attention aux
elements brOiants qui
peuvent se trouver a
l'interieur; prendre toutes
Altas Temperatures:
Ciertas superficies del
instrumento alcanzan
temperatures muy altas.
les precautions pour eviter Use precauci6n para
un contact direct. evitar quemaduras
severas.
Eye Hazard: Eye damage Augenverletzungen: Blessures aux Yeux: Des Pellgro para los Ojos:
~
could occur either from Ultraviolette Strahlung, projections ou des rayons Dai'lo a los ojos puede
flying particles or UV herumfliegende Partikel ultra-violets peuvent causer ser ocasionado por
radiation. Wear safety oder FIOssigkeiten kOnnen des domages aux yeux. Le impactos de particulas
glasses when servicing Augenschlldigungen port de lunettes de securite voladoras 0 por Ia
instrument. hervorrufen. Tragen Sie est recommande durant Ia radiaci6n ultravioleta.

eine Schutzbrille wahrend maintenance de l'appareil. Use anteojos de
der Arbeit am Gerat. seguridad cada vez que
trabaje con el
instrumento .
Fire: The potential for fire

may be present. Follow
manual instructions to
ensure safe operation.
Feuer: Es besteht eine
mogliche Feuergefahr.
Beachten Sie die
Vorschriften im Handbuch
um eine gefahrlose
Bedienung des Gerates zu
gewahrleisten.
lncendle: Suivre les
instructions du manuel
pour minimiser les risques
d'incendie et assurer Ia
securite des usagers.
lncendlo: Para evitar
incendios y asegurar una
operaci6n segura, siga
las instrucciones
detalladas en el manual
de operaciones.
~
Explosion: The potential Explosion: Es besteht eine Explosion: Certains gaz ExplosiOn: Ciertos
for explosion may exist mogliche Explosionsgefahr ou liquides utilises peuvent gases y liquidos tienen Ia
because of type of gas or bedingt durch die im Gerat presenter des risques capacidad para explotar.
liquid used. Follow manual eingesetzten Chemikalien d'explosion. Suivre avec En el manejo de estas
instructions carefully. (Gase und FIOssigkeiten). soin les instructions du sustancias siga muy
Beachten Sie die manuel. cuidadosamente las
Vorschriften im Handbuch. instrucciones detalladas
en el manual de
operaciones.

a
Radiation: Ionizing
radiation source is
contained inside. Follow
operators manual
instructions for proper use
Radloaktlvltlt:
Radioaktive Substanzen
innerhalb dieses Gerates.
Bitte befolgen Sie die
Vorschriften im Handbuch
Radloactlvlte: L'appareil
contient une source de
radiations ionisantes. Se
referer au manuel pour les
precautions d'emploi et
Material Radloactlvo:
La fuente intema
contiene material
radioactive. Siga las
instrucciones contenidas
and disposal. fOr den korrekten pour I'elimination des en el manual para
Gebrauch, Unterhalt sowie sources perimees. operadores para el uso y
zur Entsorgung . desecho de este material.
When safe procedure is in doubt, contact

your local Varian office before proceeding.
03-914408-00:3
varians
1 of2

Safety Practices
General GC Safety Practices
The following safety practices are intended to
insure the safe operation of the equipment. Exhaust System
F~es and heat emana~ng from GC detectors is minimal. Except when
Electrical Hazards testmg ~zardous chemicals, no special exhaust dueling is required in a
1. Removal of some panels expose potentially well ventilated room. If ducting is installed, observe the following guidelines.
dangerous voltages. Such panels will bear a 1. Use only fireproof ducting.
warning label noting the hazard. Disconnect the
instrument from all power sources before 2. Install blower at duct outlet.
removing protective panels. 3. Locate duct intake far enough from the detector to avoid any vibration or
2. When power cord plugs must be changed to air current effect on detector performance.
conform to on-site power receptacles, be sure to 4. Check duct suction periodically.
adhere to color coding and polarity described in
the manual.
Radiation Safety (Radioactive Source Detectors)
3. Replace blown fuses with size and rating
stipulated on the fuse panel or holder, and in the 1. Note and comply with all NOTES. CAUTIONS and WARNINGS appearing
manual where listed. in the Ni63 ECD manual section.
4. Replace or repair faulty or frayed insulation on 2. Perform scheduled test for removable radioactive contamination as
power cords. prescribed in the above publication.
5. Check actual line voltage to confirm it is the value 3. NOTE: It is the responsibility of the user to be sure that leak test
for which the instrument is wired. Be sure power schedules and procedures are complied with.
cords are plugged to correct voltage sources.
Burn Hazard
Compressed Gas Cylinders Heated zones of gas chromatographs can remain hot for a considerable
time after the instrument power has been turned off. To prevent painful bums
1. Compressed gases should be stored and handled resulting from contact with hot surfaces (injector nuts, columns, etc.) be sure

strictly in accordance with relevant safety codes. that all heated areas have cooled to room temperature, or wear adequate
2. Fasten all cylinders securely to an immovable hand protection.
structure or permanent wall.
3. Store or move cylinders only in a vertical position.
Do not move or transport cylinders with regulators LC Safety Practices
attached.
4. Store cylinders in a well ventilated area away from High Pressure Hazard
heat or ignition sources. The pump employed in Varian Liquid Chromatographs can generate high
pressures. Liquid at such high pressures is potentially hazardous. There is
5. Mark all cylinders clearly so there can be no doubt always the danger associated with a high velocity stream of volatile and/or
as to contents. toxi? liquid in the event of a line rupture, a relief device opening, or a valve
6. Use only approved regulators and tubing accidentally opened under pressure.
connections. While personal hazard from such incidents is minimized by the low volumes
involved, complete protection is afforded by wearing face protection (safety
7. Connect cylinders to instrument only with clean
gl~ses, face shields, etc.) when injecting samples or performing routine
tubing whose pressure rating is significantly
mamtenance.
greater than highest outlet pressure from
regulator. Reservoirs which operate under 50-60 psi of nitrogen should only be of the
shatter-proof type provided with the instrument. The reservoir enclosure
should be kept closed when reservoirs are under pressure.
General Precautions
Read and adhere to all NOTES, CAUTIONS, and WARNINGS appearing in
1. Perform periodic leak checks on supply lines and
the manual.
pneumatic plumbing.
2. Arrange gas lines so they cannot become kinked. Ultraviolet Radiation
punctured, or otherwise damaged, and will not
interfere with foot traffic. Liquid chromatographic detectors employing a UV light source must have
adequate shielding to prevent any radiation exposure to personnel.
3. Store organic solvents in fireproof, vented, clearly
labeled cabinets identifying toxic and/or flammable 1. Ensure that protective lamp covers of variable and fixed wavelength
materials. detectors are always in place during operation.
4. Do not allow flammable and/or toxic solvent

2. Do not look directly into detector fluid cells or at the UV light source. When

viewing or inspecting the light source or cell, use protective eye covering
wastes to accumulate. Follow a regulated, approved
such as afforded by borosilicate glass, polystyrene, or most pocket
waste disposal program. Never dispose of such
magnifiers.
products through the municipal sewage system.
2of2 03-914408-00:3

The following is a Federal Communications Commission advisory:
WARNING: This equipment generates, uses, and can radiate

radio frequency energy and if not installed and used in
accordance with the instruction manual may cause interference
to radio communications. It has been tested and found to comply
with the limits for a Class A computing device pursuant to Subpart
J of Part 15 of FCC rules, which are designed to provide
reasonable protection against such interference when operated
in a commercial environment. Operation of this equipment in a
residential area is likely to cause interference in which case the

user at his own expense will be required to take whatever
measures may be required to correct the interference.
03-914409-00:2 1 of 1
Index to Useful Information
for Multiple-Purpose ln~Vitro Diagnostic Instruments
The Food and Drug Administration has determined that Varian Associates, Inc. can market
this instrument as a medical device subject to the provisions of the Federal Food, Drug,
and Cosmetics Act.
Name and Model No. of Product: Star 901219002 Solvent Delivery System
Intended Use: To provide unattended automatic solvent delivery selection
and blending for liquid chromatography applications.
1 . Installation Procedures and Special Requirements

Section 2
2 . Principles of Operation
Section 4
3 . Performance Characteristics and Specifications
Section 1
4 . Operating Instructions
Section 4, Appendix
s . Calibration Procedures
None
6 . Operational Precautions and Limitations
Section 2, Section 3, Section 4, Section 6, Appendix A, Appendix B, Appendix C
7. Hazards
See Warnings throughout the manual.
a . Service and Maintenance Information
Section 6, Section 7, Appendix D, Appendix E
9. Manufacturer
Varian Chromatography Systems
2700 Mitchell Drive, Walnut Creek, California 94598-1675
10. Manual (labeling) I Revision Date

Publication Number 03-914436-00 I January 1994
03-914436-41 :2 Page 1 of 1
Section 1
Introduction/Specifications
Table of Contents
1. 1 General . . . . . . . . . 1-1
1.2 How to Use The Manual 1-1
1.3 Specifications . . . . 1-3
1.3.1 General . . . 1-3
1.3.2 Performance 1-3
1.3.3 Physical . . 1-3
Section 2
Installation
2.1 General . . . . . . . . . . . . . . . 2-1
2.2 Receiving Inspection . . . . . . . . 2-1
2.3 Unpacking . . . . . . . . . . . . . 2-1
2.4 Location of Solvent Delivery Module 2-2
2.5 Site Preparation . . . . . . . . . . . 2-2
2.5.1 Power . . . . . . . . . . . . . . . . . 2-2
2.5.2 Voltage and Fuse Rating Check . . . . . . . . 2-2
2.6 Signal Cable Connections (Rear Panel) . . . . . . . . 2-4
2.6.1 J1 Main Power Switch, Power Receptacle, Power Fuse, and Voltage Selection 2-4
2.6.2 J2 PRESSURE 5 atm/mV . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6.3 J3-J8 RELAY 1 through RELAY 6 . . . . . . . . . . . . . . . 2-5
2.6.4 J9 and J10 Synchronization Signal Ports . . . . . 2-5
2.6.5 S201, DEVICE ADDRESS Switch, J201, GPIB Port . . . . . . . . 2-6
2.7 Solvent Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2. 7.1 Damper Outlet to Mixer/Filter . . . . . . . . . . . . . . . . . . . 2-6
2.7.2 Reservoir(s) to Proportioning Valve Line(s) (Star 9012 SDS) . 2-6
2.7.3 Reservoir to Pump Inlet Port (Star 9002 SDS) 2-8
2.8 Mounting Peripheral Components . . . . . . . 2-8
2.9 Pneumatic Requirements (Compressed Gas) 2-8
2.10 Post Installation Leak Check . . 2-8
2.11 Powered Events Module (PEM) . 2-9
2.12 Serial Printer Installation 2-9
Section 3
System Description
3.1 General . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Pump Hardware . . . . . . . . . . . . . . . . 3-1
3.2.1 Piston Stroke Control . . . . . . . . . . 3-1
3.2.2 Solvent Proportioning (Star 9012 SDS) 3-1
3.2.3 !socratic Solvent Delivery (Star 9002 SDS) 3-3
3.3 Front Panel Display . 3-3
3.4 Front Panel Keys .. 3-3
3.4.1 START . . . 3-3

3.4.2 STOP . . . . 3-3
03-914436-42:2
Table of Contents

3.4.3 STATUS. 3-3
3.4.4 RESET . 3-3
3.4.5 PURGE. 3-3
3.4.6 PRIME . 3-3
3.4.7 PUMP . 3-4
3.4.8 CURSOR. 3-4
3.4.9 PREVIOUS LINE 3-4
3.4.10 NEXT LINE .. 3-4
3.4.11 SELECT .. . 3-4
3.4.12 CLEAR . . . . . 3-4
3.4.13 INSERT LINE . . 3-4
3.4.14 DELETE LINE . 3-4
3.4.15 INCREASE/DECREASE 3-5
3.4.16 SHIFT . . . . . . . . . . 3-5
3.4.17 AUTOMATION MENU . 3-5
3.4.18 AUTOMATION ACTIVATE . . 3-5
3.4.19 %ABCFLOW . . . . . . . . 3-5
3.4.20 RELAYS . . . . . . . . . . . 3-5
3.4.21 CONFIGURE MENU (Configuration Menu) 3-5
3.4.22 SET CONDITIONS . . . . . . . . . . . . . . . . . 3-5
3.4.23 METHOD ACTIONS (Method Actions Menu and Selections) . 3-5
3.4.24 LOCAL . . . . . 3-6
3.5 Rear Panel Connectors . 3-6
3.5.1 J1 3-6
3.5.2 F1 . 3-6
3.5.3 J2 .. 3-6

3.5.4 J3-J8 3-6
3.5.5 J9 .. 3-7
3.5.6 J10 . 3-7
3.5.7 J201 GPIB IEEE 488 PORT 3-7
3.5.8 TeleDiagnostics Serial Connector 3-7
3.6 Synchronization Signals at J9 and J10 . 3-7
Section 4
Operation
4.1 General . . . . . . . 4-1
4.2 Starting Up . . . . . 4-2
4.2.1 Warm Start . 4-2
4.2.2 Cold Start 4-2
4.3 Starting the Pump . 4-3
4.4 Priming the Pump . 4-3
4.4.1 9012 SDS 4-3
4.4.2 9002 SDS 4-3
4.5 Purging the System . 4-4
4.5.1 9012 SDS . 4-4
4.5.2 9002 SDS . 4-4
4.6 The Status Displays . 4-4
4. 7 Table Selections . . 4-5
4. 7.1 % ABC FLOW (Flow and Composition) (9012 SDS) .. 4-5
4.7.2 Set Conditions . . . . . . . . . . . . . . . . . . . . . 4-7

4.7.3 Configure Menu . . . . . . . . . . . . . . . . . . . . 4-8
4.7.4 METHOD ACTIONS (Method Actions Menu and Selections) . 4-9
li 03-914436-42:2
Table of Contents
4. 7.5 RELAYS . . . . . . . . . . . . 4-11

4.7.6 Automation Menu . . . . . . . 4-11
4.8 Proportioning Mode Selection (9012 SDS) 4-12
Section 5
Applications
5.1 General 5-1
Section 6
Maintenance/Service
6. 1 General . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Solvent Recommendations . . . . . . . . . . . 6-1
6.2.1 Quality and General Considerations . 6-1
6.2.2 Preparation . . . . . . . . . . . . 6-1
6.2.3 Miscibility . . . . . . . . . . . . 6-1
6.2.4 Solvent and Pump Compatibility . 6-2
6.2.5 Viscosity . . . . . . . . 6-2
6.2.6 Spectral Characteristics 6-2
6.2.7 Aqueous Buffers . . . . 6-2
6.3 Preventive Maintenance . . . . 6-3
6.3.1 Recommended Spares 6-3
6.3.2 Recommended Preventive Maintenance Schedule 6-4
6.3.3 Log Sheets . . . . . . . . . . . . . . . . 6-6
6.4 Troubleshooting Procedures . . . . . . . . . . . 6-7

6.4.1 The Importance of Good Documentation 6-7
6.4.2 The Systematic Approach . . . . . . . . 6-7
6.4.3 Hydraulic Component Tests . . . . . . . . 6-7
6.4.4 General System Troubleshooting Techniques 6-9
6.5 Diagnosing the Problem . . . . . . . . . . . . . . 6-10
6.5.1 Electronic Faults/Cold Start Diagnostics . . 6-10
6.5.2 Performance Parameters . . . . . . . 6-10
6.5.3 Unexpected Chromatographic Results . . 6-13
Section 7
Inert 9012
7.1 General . . . . . . . . . . . . . . . . . . . 7-1
7.2 Component Identification and Construction 7-2
7.2.1 Identification of Inert Components . 7-3
7.3 Pump Seal Replacement and Mixer Riter Replacement . 7-5
7.4 Solvent and Pump Compatibility . . . . . 7-5
7.4.1 Solvent and Pump Compatibility . 7-5
7.4.2 Aqueous Buffers . . . . . . . . . 7-5
Section 8
Regulatory Compliance
8.1 Scope and Purpose . . 8-1
03-914436-42:2 Ill
Table of Contents
Appendix A
Extended Diagnostics
A.1 General . . . . . . . . . . . . .
Appendix B
. . . . . . . . . . . . . . . . . . . . . . . . A-1

Fault Table
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Appendix C
Advisory Displays
C.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D
Maintenance Reference Material
0.1 General . . . . . . . . . . . . . . . . . . D-1
Appendix E
Injector Valve Reference Material
E.1 .General . . . . . . . . . . . . . . . . . .... --~
E-1
Index

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03-914436-42:2

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Section 1
1.1 General
The Star 9012 and Star 9002 Solvent Delivery Systems are stand-alone modular units that feature
a reciprocating single piston pump. This manual describes the 9012 and the 9002 in stand-alone
service, and provides installation and operating instructions for this mode only. The module can,
however, be integrated into an HPLC system controlled remotely by the LC Star Workstation.
Integrated system operation is described in the LC Star Workstation Operator's Manual.
The single piston pump, coupled with efficient pulse damping hardware, delivers flow in a linear
dynamic range of 10 J.IL/min to 10 mLJmin. Proportioned delivery of up to three solvents can be
achieved by the 9012 pump. The 9002 is designed for isocratic (single solvent) applications only.
All controls for setting pump operating conditions and building methods are located on the front
panel below a 2-line, 40-character display. Signal cable and power line connections are made on
the rear panel.
All pump and method building parameters are pre-defined and stored in memory. Values and
options for each field are selected with the INCREASE and DECREASE keys and become a part of
the method when the cursor leaves the field. This mode of selection applies to all fields. The range
of values or options for each field are given in Section 3, System Description. Under this system of
field entry, no illegal entries are possible. You can enter an inappropriate value, but not an illegal
one.
1.2 How to Use The Manual
NOTE: The initials SDS are used throughout this manual and
stand for Solvent Delivery System. When not preceded by 9012
or 9002, either or both systems are referred to.
This manual comprises six sections, each tabbed for quick reference in the following order: Section
1 INTRODUCTION, Section 2 INSTALLATION, Section 3 SYSTEM DESCRIPTION, Section 4
OPERATION, Section 5 APPLICATIONS, and Section 6 MAINTENANCE AND SERVICE.
Section 2 Installation
Section 2 provides initial installation and set-up directions. This section specifies power and
operating gas requirements. Fuse replacement and power selection procedures are described.
Signal cable connection diagrams provide directions for signal interfacing with other instruments.
The Powered Events Module (PEM) is described and procedures for a post installation leak test are
included.
Section 3 System Description

Section 3 contains information for the new user. This section describes the physical layout of the
front and rear panels. Keys are grouped in functional clusters with clear identification. The physical
characteristics and function of each front panel key are given in detail.
The location and application of the switches and connectors on the rear panel are described.
03-914436-01:1 1-1

Read through this section to familiarize yourself with the identification, location, and function of each
key and connector before connecting to power and starting up.
Section 4 Operation
Section 4 will be the section most often referred to. This section contains detailed method building
procedures with graphic presentations of display responses to key selections executed by the
operator.
Pre-run preparation, such as priming and purging operations are included in this section.
Cold and warm starts are defined and compared and Cold Start Diagnostics and Extended
Diagnostics and how they interrelate are explained.
Section 5 Applications
This section of the manual is provided as a repository for any applicable information you may wish
to save for convenient reference.
Section 6 Maintenance and Service

This section contains a list of repair and replacement kits available. The repair and replacement
procedures included in this section are also included in the repair kit.
Appendix A Extended Diagnostics
A listing of the Extended Diagnostics Menu and how to access it is included in Appendix A.
Appendix B Fault Table

This table lists the Fault#, a brief message identifying the location where the fault occurred, and
suggested user action.
Appendix C Advisory Displays

Appendix C is a listing of advisory messages that alert the user to actions that are not acceptable.
A brief explanation of each message is given along with possible corrective actions that may be
taken.
Appendix D Maintenance Reference Material

Appendix D includes copies of installation instructions supplied with field replacement kits required

when replacing the Mixer Filter, Check Valve, Inlet Valve and Piston Seal, for eitehr the standard
9012 pump or the Inert 9012 pump.
Appendix E Injector Valve Reference Material

Appendix E consists of a number of vendor supplied data sheets which may be of use to the
customer when choosing various valving options.
1-2 03-914436-01 :1

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Section 2
Installation
2.1 General
These installation instructions apply to the Star 9012 and 9002 Solvent Delivery Systems used as
stand alone solvent delivery systems to unspecified LC column and injector arrangements. Basic
installation requires connecting the pump to power, any time programmed accessories through
relay outputs, and solvent lines from reservoirs to 9012 proportioning valves or 9002 pump head
inlet port, and from the damper outlet to the LC column.
All power and signal cable connections are located on the rear panel of the module. All hydraulic
connections are made outside of the covered area of the module and do not require the removal of
any protective panels.
Solvent reservoirs may be positioned anywhere convenient to available bench space, but preferably
as close to the pump as possible.
NOTE: An optional solvent reservoir holder designed to hold three

1 liter bottles is available from Varian as PIN 03-919252-00. This
holder provides compact storage of solvents and helps prevent
accidental tipping and spillage.
2.2 Receiving Inspection

Inspection and unpacking instructions have been provided in the Pre-Installation Instructions you
received prior to delivery. It is repeated here for future reference.
The 9012 or 9002 Solvent Delivery System Module will arrive at your site in a single shipping carton.
Before opening the carton, carefully examine it for any evidence of shipping damage, i.e., crushed
corners, forklift punctures, tears or cuts, and water stains. If such evidence is present, do not open
the carton, but report your findings to the carrier, and to:

2700 Mitchell Drive
Walnut Creek, California 94598-1675
Attention: Manager of Customer Service
Phone(510)939-2400
or, your local Sales/Service Center
2.3 Unpacking
Your Pre-Installation Instructions, sent prior to delivery, provided instructions for unpacking this
instrument in greater detail. Continue with unpacking your instrument as follows:
a. Remove the top tray containing the Standard Accessory Kit, cables included in the order,
and this manual.
b. Lift the outer shell of the shipping carton straight up and out of the bottom base tray.
03-914436-Q2:1 2-1
Installation

c. Lift the inner shell straight up. Remove the front panel protective cover. Position your
instrument as instructed in paragraph 2.4.
After you have removed the shipping carton from the instrument, check to be sure you have the
following items:
1 Model 9012 or 9002 Solvent Delivery System Module
1 Standard Accessory Kit, P/N 03-919074-90 (9012), or P/N 03-919074-91 (9002)
NOTE: The contents of the Standard Accessory Kit are itemized

in a list enclosed in the kit package. Report any missing items as
instructed in paragraph 2.2.
2.4 Location of Solvent Delivery Module

There are no stringent requirements for the location of the SDS module other than providing a sturdy,
vibration tree bench, and sufficient space (at least 6 inches) in back to permit easy access to the
rear panel services, and unobstructed ventilation.
Allow enough space adjacent to the module tor up to three, one liter or one gallon solvent reservoirs.
As noted earlier, an optional solvent reservoir holder (PIN 03-919252-00) is available. The rack is
designed to hold up to three, one liter bottles and provides tor the orderly and compact arrangement
of solvent reservoirs. A recommended arrangement is shown in Figure 2-1.

2.5 Site Preparation
Site preparation is limited to providing adequate bench space for the pump and its associated
components, and assuring that required power and compatible receptacles are available.
2.5.1 Power
Power receptacles matching the parallel blade three prong power plug shown in Figure 2-2 (U.S.
and Canada), and the two prong design for international service must be available.
If it is necessary to change the power cord plug to make it compatible with existing power outlet
configurations, be sure that the polarity shown in Figure 2-3 is followed.
2.5.2 Voltage and Fuse Rating Check

For single phase power, the 9012 and 9002 are protected by a single, slow blow fuse rated at 3
Amp, 250V, for 120 volts, and a 1.5 Amp, slow blow fuse for 220 volts. Instruments wired for two
phase power are protected by two fuses rated at 2.5 Amp, 250 volts. The fuse holder is located on
the rear panel in the power receptacle assembly (J1). Refer to Figure 2-4. Fuse ratings and part
numbers are listed in Table 2-1.
Table 2-1 Voltage Selection Option Kit
Qty Ap~lication Specification Varian PIN
1 ea. 120V, Single Phase 3.0 ASB, 250V, 3 AG 67-135430-00
1 ea. 220V, Single Phase 1.5 ASB, 250V, 3 AG 67-135415-00
or
*1 ea. 220V, Single Phase 2.5A, Type T, 250V, 3 AG N/A
2ea. 220V, Split Phase 2.5A, Type T, 250V, Metric 55-500344-00
2-2
*Available in Europe only.
03-914436-02:1

Installation
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-- ---
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Figure 2-1 9012 Module and Solvent Reservoirs
Neutral Hot Neutral Hot

(Une) (Une)
Ground
Ground Pin
da 1KJtioJ 101 Service
15Amps 220 Vac Nominal
120 Vac Nominal 50Hz
60Hz
Ground (green/yellow or green)
Neutral
(ll blue or white)
US.A. and CCI'1CJda Hot (brown or black)
Figure 2-2 Power Cord Plugs for Figure 2-3 Power Receptacle Polarity
120 ancl220 Vac Service
2.5.2. 1 Checking _the Voftage Selection

The 9012 and 9002 Solvent Delivery Systems may be wired for either 120V, 50/60 Hz single phase,
220V, 50/60 Hz single phase, or 220V, 50/60 Hz two phase (phase/phase) operating voltage.
Generally, units manufactured for USA/Canada users are wired for 120V and units scheduled for
non-domestic markets are wired for 220V service. Some European areas use two phase power.
Instruments shipped to those sites are protected by two fuses as shown in Figure 2-4(A). A label
stating the operating power rating of your instrument (as wired in the factory) is affixed to the rear
panel adjacent to the power receptacle and voltage selection assembly (J1) .
03-914436-02:1 2-3
Installation

North Amlcan Fusing A"anpment
(B)
Figure 2-4 Main Power Fuse ReplacementNoltage Selection

Before connecting the unit to power, check the operating voltage selection to be sure it matches
your power service. To determine this, check the row of voltage rating holes on the fuse cover and
ensure that the selector pin appears at the appropriate position.
A WARNING
DANGEROUS VOLTAGES EXPOSED WHEN COVER IS REMOVED.
UNPLUG POWER CORD
2.5.2.2 Checking and/or Changing Power Fuses (F1 J

The fuse rating and operating voltage is printed on the rear panel next to the power receptacle.
If your instrument fails to power up when the power switch is turned on, check that the power cord
is properly connected. Check for power at the wall receptacle, then check the main power fuse
(F1 ). Instructions for changing fuses are detailed in paragraph 2.5.2.1, above.
2.6 Signal Cable Connections (Rear Panel)

2.6.1 J1 Main Power SwHch, Power Receptacle, Power Fuse, and Voltage Selection
These combined services comprise the Power Entry Module.
2.6.2 J2 PRESSURE 5 atmlmV
The pressure transducer output can be connected to a strip chart recorder for continuous monitoring
and for troubleshooting when required. Use signal cable PIN 02-001954-00, terminated at one end
with a three pin Molex connector and with spade lugs at the other end.
2-4 03-914436-02:1

Installation
2.6.3 J3-J8 RELAY 1 through RELAY 6

Six contact closure relay outputs for time programming optional external events are also used in
conjunction with the Powered Events Module (PEM). For added information on the Powered Events
Module, see paragraph 2.11.
J3 through J8 are three pin male connectors requiring a matching Molex connector. If the PEM unit
is used for programming a 120V power outlet, the required signal cable will be terminated on both
ends with three pin female Molex connectors (cable P/N 03-908348-02).
NOTE: The three pin Molex connectors are not keyed to insure
proper mating. The design of the interconnecting bodies does
reduce, but does not eliminate mismatching. Follow the orientation
shown in Figure 2-5 below.
Figure 2-5 Correct Matching of Molex Connectors
2.6.4 J9 and J1 0 Synchronization Signal Ports

Bidirectional synchronization signals are used in the absence of the GPIB Workstation interface.
Synchronization cables are available in two configurations: General purpose cables and Dedicated
cables.
The general purpose cables have a "D" shell connector on one end to connect to the instrument
and a switchcraft connector on the other end for each individual synchronization signal. These are
extremely flexible and allow the connection of any configuration of Varian and non-Varian modules.
The dedicated cables are designed for specific configurations of Varian modules and have a "D"
shell connector on each end.
General Purpose Gables

There are many system configurations incorporating all of the LC Star System Modules. Each
configuration has unique cable arrangements. Schematic diagrams of several common
configurations are presented in the Synchronization Cable Manual, PIN 03-914262-00 for the
general purpose cables. These diagrams provide cable connection points between modules in
addition to cable and cable kit part numbers. Refer to the specific diagram in the manual that
conforms to your system configuration.
These ports require the synchronization cables included in cable kit PIN 03-919910-90. J9 is a nine
pin male "D" shell connector that requires a cable terminated with a matching female connector.
J10 is a nine pin female "D" shell connector requiring its matching cable connector.
03-914436-02:1 2-5
Installation

Each 9000 Series instrument requires a specific cable kit. The 9000 Series instrument and its
specified cable kit is listed in the table below:
Cable PIN 03-919900-00, for J9, and cable PIN 03-919902-00, for J10, are in kit P/N 03-919910-90.
Instrument Cable Kit Part Number
Star 9012/9002 Solvent Delivery System 03-919910-90
Star 9050 UVNIS Detector 03-919910-90
Star 9100/9095 AutoSampler 03-919911-90
Polychrom 9065 Diode Array Detector 03-919912-90
AASP 03-919913-90
A cable adapter kit that converts the general purpose cable configuration to spade lug terminators
for connecting to unspecified or non-Varian instruments is available as cable kit PIN 03-919914-90.
Dedicated Csbles
Instruments Cable Kit Part Number
Star 9010/9012/9001/9002/9050 to Star 9100/9095 AutoSampler 03-919949-90
Star 9010/9012/9001/9002 SDS to Star 9050 Detector 03-919948-90
Star 9010/901219001/9002/9050 to Rheodyne Position Sensing Switch 03-919947-90
Star 9010/9012/9001/9002/9050 to Star Workstation ADC 03-919950-90
Synchronization cables and pin designations of J9 and J10 are described in greater detail in Section
3 (System Description) paragraph 3.6.
2.6.5 S201, DEVICE ADDRESS Switch, J201, GPIB Port
This switch and port are present when the GPIB Board has been installed and the 9012 is interfaced
with the LC Star Workstation.
2.7 Solvent Line Connections

The 9012 pump requires up to three solvent inlet lines connected to the three proportioning valves.
The 9002 isocratic pump requires a single solvent inlet line connected to the inlet port of the pump
head.
2.7.1 Damper Outlet to Mixer/Filter
Use 1/16" OD stainless steel tubing with 1/16" stainless steel nuts and ferrules for making the
connection between the damper outlet port and the Mixer/Filter. See Figures 2-6 and 2-7. For most
applications, use 0.020" ID tubing for all connections up to the injector and 0.01 0" or smaller ID
tubing for all connections downstream of the injector.
2.7.2 Reservoir(&) to Proportioning Valve Une(s) (Star 9012 SDS)
Use 1/8" 00 PTFE tubing and a 1/8" PTFE ferrule with stainless steel nut for making the connection
to the proportioning valve(s). The reservoir ends of these solvent lines are terminated with 10 micron
porous metal filters.
From one to three reservoirs are required depending upon your mode of operation, i.e., isocratic
(single solvent composition), binary, or ternary. All of the necessary hardware for assembling and
connecting the reservoirs is included in the Standard Accessory Kit (PIN 03-919074-90) that
accompanies your instrument. The plastic screw caps included in the kit will fit either the four liter
reagent bottle, or the graduated clear glass reservoir. Each cap assembly is pre-drilled with two
holes, and includes about four feet of 1/8" 00 PTFE tubing. Also included are three porous metal
(10 micron) filters that should be installed on the reservoir end of each line.
2-6 03-914436-02:1
Installation
~~-------,------------------,
Pressure
Tranaducer
I
~Damper Outlet
to Mixer/Filter
9002
Figure 2-6 Hydraulic System Plumbing
NOTE: It is important that you install these filtars. They prevent

particulates from entering the pump and causing damage to seals
and sealing surfaces.
Connect the other end of the reservoir line to the fitting on each proportioning valve using the 1/8"
PTFE ferrules and 1/8" stainless steel nuts provided in the Standard Accessory Kit. Tighten the nuts
finger tight, then just enough of an additional turn with a wrench to prevent leaking.
Proportioning valve positions are labeled A, 8, and C. Be sure that solvent reservoirs (which also
should be labeled A, 8, and C) are connected to the matching proportioning valve .
NOTE: It is critical to your chromatographic results that the correct

solvents are plumbed to the appropriate proportioning valve.
Reservoir Acontaining Solvent Amust be drawn into proportioning
valve A installed in pump head position A as stamped on the pump
head. See Figure 2-7 for the correct plumbing of the hydraulic
system.
o-
o-
-
o-
Purge Valve
@
-
o-
o-
Mixer/Filter
Figure 27 Solvent Delivery System with a Valve Mounting Assembly Attached
03-914436-02:1 2-7
Installation

2.7.3 Reservoir to Pump Inlet Port (Star 9002 SDS)
Install the 1/8' TEFZEL nut and ferrule on the pump end of the 1/8' OD reservoir tubing as shown
in Figure 2-8. Important: Install the ferrule in the reversed position as shown in the illustration.
Thread the nut and solvent line into the pump head port finger tight only. Before tightening the nut
be sure the solvent line is inserted as far as it will go into the pump head port.
~Nut
Figure 2-8 Reservoir To Pump Head Fitting Assembly
2.8 Mounting Peripheral Components

Columns, purge valves, and loop valve injectors may be mounted in varied configurations.
Depending upon the make-up of the system, such peripherals may be mounted on other modules.
For example, the Star 9100/9095 AutoSampler will usually have the loop valve injector mounted on
it. Where these mounting facilities are inconvenient, a field installable kit is available that contains
all of the hardware, frames, panels, purge valve, and interconnecting tubing needed for mounting
on the 9002 or 9012. A typical installation is shown in Figure 2-7.
Complete installation instructions are included in the kit (PIN 03-919256-90).
2.9 Pneumatic Requirements (Compressed Gas)

If a pressure-actuated injector is used, a 55 to 75 psig compressed air source is required. If the
9100/9095 AutoSampler is a component of your Star LC System, helium should be available since
that is the gas of choice for wash solvent sparging. Refer to the 9100/9095 AutoSampler Operator's
Manual for a more detailed discussion on this particular requirement.

If the air-actuated loop injector valve is driven from the relay outputs on the 9002 or 9012, a Powered
Events Module (PEM), PIN 03-919009-90 (120V) or PIN 03-919009-91 (220V), is a convenient and
compact unit that enables time-programmed events to be driven by the SDS Method.
2.10 Post Installation Leak Check

A general leak check of the system is advised after installation is complete, and before running
analyses. The purpose of the leak check is to detect and correct any leaks before operation. Of
particular interest will be the connections you just made in the installation. Look for leaks around
compression fittings. Check inlet and outlet fittings on the pump head, fittings in and out of the static
mixer, pulse damper, injector valve, and column.
See Section 6, paragraph 6.4.3.6 for instructions on running a leak test. If a leak is found, tighten
the fitting just enough to correct the leak. DO NOT OVERTIGHTEN.
Leaks appearing, or dripping from the pump head usually indicate internal leaks that require seal
replacement. Instructions for pump seal replacement are included in the Piston Seal Replacement
Kit and in Appendix D of this manual.
2-8 03-914436-02:1

Installation
2.11 Powered Events Module (PEM)

The Powered Events Module (PEM) is al') easily installed, compact unit that enables you to control
powered, and air-actuated accessories with the time programmed relays in the 9012 and 9002
Solvent Delivery Systems. The Powered Events Module Kit, P/N 03-919009-90, is ordered as an
optional accessory and includes Installation Instructions.
2.12 Serial Printer Installation

A serial printer allows the printing of methods, run logs, and automation sequence tables. The serial
printer can only be used on a stand-alone, non-GP/8 equipped pump. You must install the Serial
1/0 Kit (03-919080-90) before a printer can be connected. This kit provides a rear panel RS-232C
connector for the pump. Installation instructions are provided in the kit. With the rear panel connector
installed, you will need a printer. Varian provides a printer and cable kit (03-907517-90/91} for use
with the pump. Alternatively, you may use your own printer if it supports the configurations listed in
Table 2-2 below.
The printer is connected to the pump by a shielded cable terminated at both ends by standard
RS232C, 25-pin connectors. Correct installation is ensured by the design of the connector hood
and the offset alignment of the pins. It makes no difference which way the cable is installed. Be sure
the printer cable is connected to J201 on the rear panel and not to the Diagnostics port.
If you are using the HP ThinkJet printer, be sure "MODE" and "RS232C" switches on the back of
the printer are set as shown in Figure 2-9. If you are not using the HP ThinkJet printer, your printer
must have following RS232C configurations:
Table 22 RS232C Configurations for the 9012 Serial Printer
Parameter Setting
Baud Rate 9600
Parity None
Stop Bits None
XON/XOFF Supported
DTR Handshake Supported
Printer:
HPThinkJet
03-914436-02:1
Figure 2-9 HP ThlnkJet Mode/RS232C Switch Settings
29
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Section 3
System Description
3.1 General
The Star 9012 and Star 9002 Solvent Delivery Systems are stand-alone units with the mechanical
and electronic hardware enclosed in a single module. All operator inputs are entered at the front
key panel. Operating and method parameters are displayed on the two line, forty character Liquid
Crystal Display (LCD) of the front panel.
Operating switches, cable connectors, fuses, and the power input receptacle are located on the
rear panel.
Hydraulic connections to the pump inlet and proportioning valves are external to the module cover,
making it unnecessary to remove panels when making tubing connections.
The stand alone modular approach enables you to arrange your system in a layout most compatible
with the available laboratory bench space.
An optional kit is available containing brackets for mounting manually or pneumatically driven loop
valve injectors, columns, and a purge valve on either the right or left side of the Module. See Section
2, paragraph 2.8, and Figure 2-7, of this manual.
3.2 Pump Hardware

Solvent is delivered by a single piston, reciprocating pump. Piston design and electronically
controlled stroke provide a nearly pulseless flow. Incorporation of a pulse damper further reduces
any pump pulses inherent in the system. A mixing chamber assures adequate mixing of solvents
prior to sample injection, and finally, a pressure transducer converts the pressure in the system to
an electrical output that is digitally displayed on the front panel.
3.2.1 Piston Stroke Control

The piston stroke is controlled by the rotation of the piston cam. A full pump cycle consists of a fill
stroke in which the piston is traveling in a reverse (out of the pump head) direction, and a pump
stroke in which the piston is traveling in a forward direction (into the pump head). During the pump
stroke solvent is discharged through the outlet check valve.
The rotation of the piston cam is determined by a software-controlled stepper motor. See Rgure 3-1.
Pump head and valving details are shown in the cut-away photograph (Figure 3-2).
3.2.2 Solvent Proportioning (Star 9012 SDS)

The pump head is ported to accommodate three proportioning valves. Solvent delivery may be
selected from any combination of the three.
The proportioning valves admit solvents from the specified reservoirs during the fill stroke. Three
reservoirs are used for ternary gradient analyses, one or two reservoirs for isocratic or binary
applications. Each valve is opened by an electrically driven magnetic coil energized by the circuit
logic according to the programmed solvent composition entered in the % ABC FLOW table. A
cross-sectional diagram of the proportioning valve and the solvent path through it are shown in
Figure 3-3 .
03-914436-03:1 3-1
System Description
Spring Ho~sing
s&darl
Outlet Check
/Valva

'
Inlet Valva Ca Inlet Valve SUder
F'~gure 3-1 Pump Components

F'~gure 3-2 Pump Head Valving, Cut-Away VIew
3-2
Figure 3-3 Proportioning Valve Solvent Path
03-914436-03:1

System Description
3.2.3 lsocratic Solvent Delivery (Star 9002 SDS)

A single solvent line from a single solvent reservoir is connected directly to the inlet port of the pump
head.
3.3 Front Panel Display

Communication from the 9012 or the 9002 to the operator is by way of the two line, forty character
Liquid Crystal Display (LCD). All entries are displayed in fields. Use the INCREASE and DECREASE
keys to select options and values in each selected field.
The cursor is identified as a flashing dash underlining a character. Its home, or initial position when
bringing up a display is the last character in the first programmable field. Move the cursor
horizontally along a line with the right and left arrow keys, and from line to line with the PREVIOUS
LINE or NEXT LINE keys.
A display contrast control that rotates clockwise to increase screen and character intensity and
counterclockwise to decrease intensity is located under and at midpoint of the display.
3.4 Front Panel Keys

All operator inputs are generated by front panel key selections. In addition to the keys are Light
Emitting Diode (LED) indicators that keep the operator alerted as to instrument and method states.
Input keys are conveniently grouped according to specific function, i.e., instrument operation,
method editing, and table selection.
Following are brief descriptions of the response of each key when pressed:
Keys located in the OPERATION section of the front panel

3.4.1 START
Pressing this key starts the method clock when the method is STOPPED or READY.
3.4.2STOP
Pressing this key stops the method clock and pump.
3.4.3 STATUS
Pressing this key puts Status Une 1 on the display. Use PREVIOUS LINE and NEXT LINE keys to
selectively view the other three status lines.
3.4.4 RESET
Pressing this key resets the method to time=O conditions.
3.4.5 PURGE
Pressing this key will start the pump running at 10 mLJmin at the composition specified by the Flow
and Composition Table.
Since the Flow and Composition Table is not applicable to the isocratic 9002 SDS, the system is
purged with the connected solvent.
The PURGE indicator will be lit during the purge action.
3.4.6PRIME
Pressing PRIME A pumps 100% solvent A at 10 mLJmin. The PRIME indicator lights when the pump
is in the priming mode. PRIME B and PRIME C function in the same way. The display shows which
of the three solvents is being pumped to prime the system .
03-914436-Q3:1
System Description

In the Star 9002 SDS, the PRIME A, 8, and C keys function identically to the PURGE key. Pressing
any one of these keys will cause the SDS to pump at 10 mLJmin. and only the isocratic flow rate will
be displayed. No %A, 8, C shows on the display.
3.4.7 PUMP
The pump does not start when the module main power is turned on. After power has been turned
on, press the PUMP key to start the pump. Press the STOP key to stop the pump.
Keys located in the EDrr section of the front panel
3.4.8 CURSOR
Left and right arrow keys move the cursor, field-by-field, in the selected direction. The cursor
(underline). will rest under the last character in the field. When the cursor rests in the last field,
pressing the right cursor key will cause the cursor to "wrap-around" to the first field of the sequence.
This feature saves time and key strokes since you do not have to back track field-by-field to move
from the last to the first field.
3.4.9 PREVIOUS UNE
Pressing this key moves the previous line into the display.
3.4.10 NEXT UNE
Pressing this key moves the next line into the display.
3.4.11 SELECT
Press this key to select a menu item, or to select a method to activate, delete, or copy.
3.4.12 CLEAR
Pressing this key clears a field value on the flow/composition line only tO allow the entry of
independent flow and/or composition values. This key function is inoperative if applied to any other
line. The flow and composition may not both be cleared on the same line. See paragraph 4.7.1,
step 11, for a more detailed description of the CLEAR key.
3.4.13 INSERT UNE
Pressing this key adds a new line and increases the line number of all existing following lines by
one. This key also increases the time to the next whole minute and copies all of the field values of
the line showing when the key is pressed.
3.4.14 DELETE LINE
Pressing this key deletes the displayed line from a method table. Depending upon the line deleted,
the following actions prevail:
a If the last line of the table is deleted, the previous line is displayed with the cursor resting
in the left most entry field, or,
b. If a line follows the deleted line, the line following will be displayed when the specified line
is deleted.
NOTE: The delete key is ignored if an attempt is made to delete

a lime=O.OO line.
03-914436-03:1

System Description
3.4.15 INCREASE/DECREASE
Pressing these keys cause the value of the field at which the cursor rests to increase or decrease
if numeric, or, change if the field is alphabetic.
NOTE: The INC/DEC selection process allows you to select

predetermined values stored in memory.
3.4.16 SHIFT
The SHIFT key is used to increase the size of incremental changes when applied to fields of
numbers. For example: the normal incremental change for all time values is 0.01 minute. When the
r::HIFT key is pressed and active, incremental steps for time are 1.0 minute for values less than 100
minutes, and 5.0 minutes for values greater than 100 minutes. The SHIFT indicator is lit during all
periods when the SHIFT feature is in effect. Press the key to activate, press again to deactivate the
SHIFT mode.
3.4.17 AUTOMATION MENU

Pressing this key displays the Automation Menu with the cursor in the first, or farthest left field of
the display.
3.4.18 AUTOMATION ACTIVATE

Pressing this key starts the automation sequence, and the AUTOMATION LED lights. Pressing the
key when automation is active stops the automation sequence and the current method continues
to run.
Keys located in the TABLE SELECT section of the front panel
3.4.19 %ABC FLOW

Pressing this key displays the heading line and the first line of the Flow and Composition Table. The
first line is displayed with default, or preset values until changed by the user.
When the %ABC FLOW key is pressed on the 9002 SDS, an isocratic flow table is displayed. %ABC
headings do not appear.
3.4.20 RELAYS
Displays the heading and first line of the Relay Table with the cursor resting in the farthest left field.
Each relay is treated as a field since each can be set independently.
3.4.21 CONFIGURE MENU {Configuration Menu)

Pressing this key displays the basic set-up menu, and allows you to enable or disable the keyboard
"beeper".
3.4.22 SET CONDmONS

Press this key to display the Set Conditions Table. The column heading line and the current values
for Endtime, Endtime Action, Pmin and Pmax, and Equilibration Time are displayed with the cursor
resting in the first, or farthest left field.
3.4.23 METHOD ACTIONS {Method Actions Menu and Selections)

Press this key to display the Method Actions Menu. The cursor rests at selection (1) Method Select
field. Section 4, paragraph 4.7.4, describes the other menu choices.
Key located in the CONTROL section of the front panel
03-914436-03:1 3-5
System Description

3.4.24 LOCAL
If the 9012 or 9002 is under remote (Workstation) control, the REMOTE indicator will be on. To use
other functions from the keypad, such as PURGE or PRIME keys, press the REMOTE key and wait
for the REMOTE LED to turn off.
-
PRESSURE
o: DIAGNOSTICS
P<liiT
o-
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REUY1
o:
REUY2
o:
REUY3
o:
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AlTENTION
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120VAC
REUY4
RElAYS
o:
o:
REUYI
o:.. GPI8
EEE
~~:m~ AEADYour
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o-
-
1::J ENAa.Eour
STARrlt
FAULT II
SYNC SIGNALS
IEADYII
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Figure 3-4 Rear Panel Connectors
3.5 Rear Panel Connectors

Refer to Figure 3-4 in the following descriptions.
3.5.1 J1
J1 is a power input assembly that includes a rocker type main power switch, a three prong main
power connector, fuse holder, and voltage selection assembly. J1 is located in the upper left corner
of the rear panel (when viewed from the rear of the instrument).
3.5.2 F1
F1 is located in the main power assembly J1. Fuse changing procedures are described in detail in
Section 2 of this manual. Refer to Table 2-1 for fuse requirements.
3.5.3 J2
J2 is the Pressure 5 atm/mV Connector. The output voltage signal of the pressure transducer is
accessed at this port for connection to an external recording device, e.g., a strip chart recorder.
3.5.4J3-J8
J3-J8 are the connectors for Relays 1 through 6. The open or closed modes for these relays are
time programmed in the Relays Table. Up to six external events may be controlled from these ports .
03-914436-Q3:1

System Description
3.5.5 J9
J9 is a nine pin "D" shell connector used with synchronization signal cables. Refer to the
Synchronization Cable Manual for detailed application and installation information.
3.5.6 J10
J1 0 is a nine pin "D" shell connector used with synchronization cables. Refer to the Synchronization
Cable Manual for detailed application and installation information.
3.5.7 J201 GPIB IEEE 488 PORT
A connector is present at this location on the rear panel if an optional GPIB (General Purpose
Interface Bus) has been installed, enabling remote operation from a central Workstation.
3.5.8 TeleDiagnostics Serial Connector

Actively using this feature requires the installation of a modem, Kit No. 03-919555-90. The Modem
enables a Varian Customer Support Representative at a remote service center to view and diagnose
the Extended Diagnostic menu on his terminal via the telephone. Complete installation instructions
are included with the modem kit.
3.6 Synchronization Signals at J9 and J1 0

These signals are used to synchronize the actions of a group of instruments that are not interfaced
with a Star Workstation by GPIB Boards and cables.
An input is activated or said to be present when its two signal wires are connected together, quite
often done by a relay contact closure. If the inputs are driven from another instrument with optical
isolators, or other polarized devices, then attention must be paid to the polarity of the signal wire
connections. The positive(+) output signal must connect to the positive(+) input signal, and the
negative (-) output to the negative (-) input.
The outputs are optical isolators and simulate a relay contact closure when they are activated.
Enable In: This polarized input signal enables the Ready In input signal.
When Enable In is not present, the Ready In signal is ignored and is equivalent to a constantly
present Ready ln.
When Enable In is present, the SDS requires a Ready In signal before it can go to the READY state.
Enable Out: This is a non-polarized, constantly active output (a short). It can be used to activate
Enable In on the next instrument in the system.
Ready In: When Enable In is present, this polarized input signal must be present before the
SDS will go to the READY state.
Specifically, activating Ready In will cause the SDS to go from the "Not Ready-Method Waiting-Pump
Running" state (equilibration complete) to the READY state. It must stay active until the SDS starts.
Ready In will be ignored in all other states.
Ready Out: This polarized output signal indicates that the SDS is in the READY state and is
ready to start a time program.
Start In: This polarized edge-triggered input signal will start the SDS active method if it is in the
READY state.
Start Out: This polarized output signal will be activated for 600 milliseconds when the SDS starts
a time program .
03-914436-03:1 3-7
System Description

Fault In: This polarized edge-triggered input signal informs the SDS that a fault condition exists
in another instrument. The SDS will stop the pump, halt the time program, and send a Fault Out
signal. If the SDS also has a fault, a Fault Out signal will not be sent.
Fault Out: This polarized output signal will activate for 600 milliseconds when one or the other
of the following events occurs:
a. The SDS detects an internal fault condition that warrants stopping the pump, or,
b. The SDS receives a Fault In signal and has no internal fault condition itself.
Refer to Figure 3-5 for J9 and J1 0 pin designations of the synchronization signals described above.
J10
5 V(+) 6 6 Start Out(+)

Fault Out() 1
!nable Out (+) 7 7 Enable In (+)
Faull Out(+) 2
Enable Out () 8 8 Enable In ()
Ready In() 3
Start,~ (+) 9 9 SV(+)
Fsultln (+) Ready In(+) 4
Start Out() 5

Figure 3-5 Pin Designation for J9 and J10
See Figures 3-6 and 3-7 for typical installations using general purpose and dedicated
synchronization cables.
03-914436-03:1

System Description
9012Pump 9100/9095 AutDSampler 9050 Detector
F'~gure 3-6 Typical Configuration with General Purpose Synchronization cables
..
lrn
lrn
J1Q
9012Pump 910019095 AutoSampler 9050 Detec:ror
F'~gure
03-914436-Q3:1
3-7 TYPical Configuration with Dedicated Synchronization cables
Section 4
Operation
4.1 General
The parameters that control the pump are grouped together to form a method. There is always one
active method, either one with preset values, or one with your entered parameters. Only the method
that is currently active can be edited.
The pump is controlled locally using the front panel
TABLE SELECT
keypad. Four tables that control solvent delivery
conditions may be accessed and changed. Access
to the method editing tables is gained by pressing
any of the keys in the TABLE SELECT section of the
front panel. The following operating instructions - -
o/oABC FLOW RELAYS
- -
assume that you are using the Star 9012 or 9002 CONFIGURE SET
Solvent Delivery System in the "local" mode. Under MENU CONDITIONS
this condition the REMOTE indicator in the lower
right corner will be off. See Figure 4-1 for key
-
locations in the TABLE SELECT section of the front METHOD
panel. ACTIONS
You have five tables from which to select the method
parameters. All five of these tables are accessed by

the keys grouped at the right side of the front panel
under the heading TABLE SELECT. There is no fixed
order for selecting the pump conditions. The order
we have selected to present in the following
discussions does not dictate a mandatory order for
-
CONTROL
LOCAL REMOTE
0
building your pump method. It is assumed that all of Figure 4-1 TABLE SELECT
the necessary installation procedures for "stand
alone" operation have been completed.
NOTE: 9002 SDS users disregard references to setting

composition.
03-914436-04:1 4-1
Operation

4.2 Starting Up
The assumption is made that all installation procedures have been completed. Only the operation
of the Star 9012 or 9002 Solvent Delivery System in a stand alone mode is covered in this manual.
4.2.1 Warm Start
Turn on the main power switch (J1) on the rear panel. "Self Test" will appear on the display. During
Self Test, a brief (about 30 seconds) diagnostic routine is being performed to check the integrity of
the electronics and hardware. If no faults are detected during this Self Test period, a warm start
occurs and "Methods Saved" appears as shown in the display below:
VARIAN 9012 Solvent Delivery System

Rev. A 1.3, Methods Saved
or

Rev. A 1.3, Methods Saved
4.2.2 Cold Start

A cold start is initiated by turning on the main power while simultaneously pressing, and holding
down the RESET key until the first audible double beep is heard. With a cold start, all fields are
restored to preset values, and the display informs you that method presets are loaded.

Rev. A 1.3, Method Presets Loaded
or

Rev. A 1.3, Method Presets Loaded
A cold start is a convenient way to replace all of your entered values and selections with the preset
parameters. All methods will be set to preset values and the proportioning mode will be set to one
stroke.
When first starting up, it will be necessary to prime the pump then purge the hydraulics of the entire
pumping system. Special function keys in the OPERATION section of the keypad enable you to
perform these operations directly.
03-914436-04:1

Operation
4.3 Starting the Pump

The pump does not start pumping when instrument power is turned on. To start the pump press the
PUMP key on the front panel. The PUMP key will not turn the pump off. To stop the pump, press
STOP.
4.4 Priming the Pump

4.4.1 9012 SDS
PRIME is branched to three separate keys labeled A, B, and C. When any one of these keys is
pressed, the selected solvent will be pumped through the system at a preset rate of 10 mLJmin from
its reservoir bottle.
Before pressing the PRIME key, open the Prime valve (see Figure 4-2) by turning the valve handle
counterclockwise about one turn. Hold a small beaker or other waste receiver under the drain line
during the priming process.
Press PRIME A. The pump will start, the PRIME indicator will go on, and liquid will be discharged
through the drain line. Continue priming until the liquid flow is regular and free of bubbles.
Repeat the procedure for PRIME Band C if reservoirs for them are in place. After priming is complete
rotate the prime valve handle clockwise to close it.
NOTE: No changes are required in the Aow and Composition

Table for the priming process.
4.4.2 9002 SDS

The PRIME keys function the same as the PURGE key.
Before pressing the PURGE or PRIME keys, open the Prime valve (see Figure 4-2) by turning the
valve handle counterclockwise about one turn. Hold a small beaker or other waste receiver under
the drain line during the priming process.
Prime Valve
~Drain
Figure 4-2 Prime Valve and Drain
03-914436-04:1
Operation
4.5 Purging the System

4.5.1 9012 SDS
NOTE: Before you can purge the system using a specified mixture
of solvents, you must make changes in the Row and Composition

Table. For a detailed discussion on procedures for modifying this
table refer to paragraph 4.7.1.
The purpose of the purge operation is to pump solvents from the reservoirs selected in the Flow
and Composition Table at the specified composition. The first time the instrument is turned on, the
Flow and Composition Table is preset to 100% A. Until this table is changed to a different solvent
composition, the system will be purged with solvent A only.
The purge operation must be carried out before the column is installed in your system because at
the purge flow rate of 10 mLJmin pressure would exceed the maximum pressure of 410 atmospheres
and shut off the pump.
With the PRIME valve closed, pump your selected solvent composition through the entire system.
Observe the flow from the detector discharge line, and continue pumping until the flow is constant
and free of bubbles.
The system is now ready for table modifications and the development of methods for your specific
applications.
4.5.2 9002 SDS
Since the 9002 is an isocratic pump and has only one solvent, either the PURGE or PRIME key will
result in the same pump action.
4.6 The Status Displays

Four status displays are provided to give status information for the current pump conditions. Status
information includes the active method number, method state, run time, pump state, flow

composition, flow rate, pressure, relay states, pressure minimum/maximum, automation status, and
the number of pump strokes since the last piston seal replacement.
The Status displays are read only and cannot be edited.
When you press the STATUS key, the first of four Status lines is displayed. You can view any of the
four lines by pressing the NEXT LINE and PREVIOUS LINE keys.
The following are typical layouts of the four Status displays.
Meth %A %B %C Flow Pres Relays Time

1 100 0 0 0.00 0 ------ 0.00
or for 9002 SDS
I~ethod Flow
0.00
Pres
0
Relays
------
Time
0.00
03-914436-04:1

Operation
The three following displays are common to both 9012 and 9002 Solvent Delivery Systems.
Line Method 1 Pump Runtime Endtime

2 Not Ready Stopped 0.00 20.00
Line Automation Line Method Run Loop

3 Off 1 1 1/ 1 1/ 1
Pump Strokes
4321
NOTE: Entries cannot be made in these displays; they are

informational only. Status displays may be called up at any time.
The Status displays solvent composition to 1%; however, in a

gradient run the composition changes in increments of 0.1%.
4.7 Table Selections

All of the operating conditions of the pump and method are assigned in the five tables whose access
keys are grouped on the right side of the front panel keypad under TABLE SELECT. Tables are
randomly accessed. There is no set order required when building your method.
Probably the easiest and quickest way to familiarize yourself with the contents of each table is to
select a table, press the appropriate key, and view the front panel display, keeping in mind that the
top line of the display is always the heading line. The top line cannot be altered or added to, and
you will note that the cursor is never positioned there.
Press the %ABC FLOW key. Note the two lines that appear on the display. The top line displays the
headings and the second line will contain some values (presets if this is the first time the pump has
been powered up} that you may want to change unless they are appropriate for your application.
The cursor (a flashing character width underscore} appears beneath the last character of the value
for %A on the second line, ~d will move right or left, field-by-field, when you press the CURSOR
left or right arrow keys. The cursor comes to rest beneath the last character of the field. This is the
general procedure for all of the tables. In the following paragraphs each table is described, including
a simulated reproduction of the display and notes.
4.7.1 % ABC FLOW (Flow and Composition) (9012 SDS)
Press the %ABC FLOW key and the following display appears:
Method Line Time %A %B %C Flow

1 1 0. 00 10.Q. 0 0 1.0
Notes on the o/oABC FLOW Table

1. Solvent compositions are settable to 1%. During a gradient run the solvent composition actually
changes by increments of 0.1 %.
2. When the Flow and Composition Table is initially displayed by pressing the %ABC FLOW key,
the cursor rests in the %A field since LINE 1 and TIME 0.00 cannot be changed. Changes can
be made only in the Composition and Flow fields. To add lines, press the INSERT LINE key. Line
1 will advance to Line 2 and you may now position the cursor in the Time field and build your
03-914436-04:1
Operation

table. The current lines are displayed by pressing the NEXT LINE or PREVIOUS LINE keys. The
Method number (1 to 5) is selected in the Method Actions menu.
3. The total number of lines for all events in any given method table is between 37 and 72,
depending upon which tables are used. When all events have been used, any attempt to insert
another line with the INSERT LINE key will result in the message TABLE FULL appearing in the
Line and Time fields. Moving the cursor out of the last field of the last line into lowered numbered
lines, or pressing other function keys will eliminate the TABLE FULL message.
4. Changing values with the INCREASE and DECREASE keys will change values only in the field
in which the cursor rests, with one exception. Since the total% of A, B, and C must always equal
100, any change in %A will cause a compensating change in %B. Likewise, a change in %B
will cause a change in %C such that the total will equal100%. A change in %C will cause %A
to change. An attempt to change %8 when %A equals 100 will result in the advisory message
"DECREASE %A COMPOSITION". To return to the %ABC FLOW display, press one of the
CURSOR arrow keys.
5. Changes to the Flow and Composition Table are executed as follows:
a. With the method not running, and the run time=O, any change to the Time=O line will take
place immediately with an equilibration step carried out if included in the method. Note:
Values or selections entered in a field do not take effect until the cursor leaves that field.
b. With the method running, if a change is made to a line with a Time greater than the current
run time, the change will take effect when the run time equals the new time change.
c. With the method running, if a change is made to a line with a Time less than the current run
time, no change will take effect until the next time the method is run.
6. DUP Message. If the Time field value of one line is changed to equal the Time field value of
another existing line, the message DUP is displayed at the right side of the Time field. This
indicates to you that somewhere in the existing lines there is another line with the same
(duplicate) time value. If the cursor is moved from the Time field, the line containing the DUP
message is retained. If the time is changed in the DUP line, the line that was duplicated is
retained.

7. To create a new line, use the INSERT LINE key. The Time of the inserted line is increased to the
next whole minute. The NEXT LINE key is used for displaying existing lines only.
Example: If Line 4 had a Time of 2.25 minutes then your newly created Line 5 (by pressing the
INSERT LINE key} will have a Time value of 3.00.
8. Data entered in a field is activated when the cursor leaves that field. All field values are selected
by the INCREASE and DECREASE keys.
9. The INSERT LINE key is ignored if the Time field value of 1440.00 (upper time limit) is displayed.
10. The number of digits displayed for the flow rate value will depend upon the flow rate setting.
From 0.01 to 0.99 ml/min flow rates will be displayed to 0.01 ml/min. Above 1.0 mLJmin flow
rates will be displayed to 0.1 ml/min.
03-914436-04:1

Operation
NOTE: The SHIFT key may be used when setting times or flow
rates to increase the size of the incremental change when a broad
range change is to be made. Example: For the Time field, with the
SHIFT active (SHIFT indicator light on) the normal incremental
change of 0.01 (unshifted) is increased a hundredfold to 1.0 in the
0-1 00 range and 5.0 above 100. See Section 3, paragraph 3.4.1.6
for a broader description of the SHIFT key operation.
11. CLEAR key. This key enables you to clear either (not both simultaneously} the composition fields
or the flow rate field. Since composition and flow rate are two independent variables that are
displayed on a single line, you may want to vary one over a specified time without varying the
other.
Certain conditions apply to the CLEAR key:
a The CLEAR key only affects the composition and flow fields.
b. The CLEAR key cannot be used on the 0.00 Time line since this line must contain valid
values in all fields.
c. When the composition fields are cleared, pressing the INCREASE or DECREASE keys will
enter 100% in the composition field the cursor is in.
NOTE: When the %ABC FLOW key is pressed on the 9002 SDS, _
only the flow rate may be changed. The display will not show
composition values, i.e., o/o A, B, or C headings or values are not

displayed.
4.7.2 Set Conditions

When you press the SET CONDITIONS key, the following table is displayed:
Meth Endtirne Action Prnin/Prnax Equil time

1 20.00 Stop 6/400 atrn 10.00
In this table you set the Endtime, the Endtime Action you have selected to take place at the end of
the run, minimum and maximum pressures (Pmin/Pmax}, and Equilibration Time.
Notes on the Set Conditions Table
1. The Endti!"lle defines when the Endtime Action takes place.
2. Equil (in the Endtime Action column) causes the Method to go to READY after performing an
equilibration step. When you select Equil as an Endtime Action, an equilibration period of the
time entered in the last field of the Set Conditions Table is performed before a method moves
to the READY state. During this equilibration period a gradient change from the current solvent
composition and flow rate to the Time=O composition and flow rate occurs. The gradient
composition change takes 10% of the equilibration time, with the new conditions being held for
the remaining 90% of the time. This programmed equilibration is intended to cause a smooth
changeover in solvent composition in automated applications, and is executed when a new
method with a different flow rate or composition is activated. Equilibration is not done if the
current conditions are the same as the T=0 conditions or the Equilibration value is set to 0. An
equilibration can be forced at Time=O by changing the equilibration time. An equilibration in

progress can be terminated by pressing the RESET key.
03-914436-()4:1 4-7
Operation

3. HOLD (Endtime Action column) stops the method clock and holds the last specified conditions
with the pump running.
4. STOP (Endtime Action column) stops the pump and the method clock at the Endtime.
NOTE: The End Action selected is valid for manual operation only. When Automation is active,
equilibration is always done regardless of the choice entered in the Set Conditions Table.
5. Pmin is always less than Pmax. The range for Pmin is 0-409 (Pmax -1) atmospheres; therefore,
the range for Pmax must be Pmin plus 1 to 410 atmospheres. Pmin and Pmax are independent
variables and resetting the value of one does not affect the other.
6. Again, in this table, the SHIFT key may be used to increase the size of incremental steps where
large range changes are required. For example, the standard increment for Pmin and Pmax is
1 atmosphere. The shifted increment for both fields is 10 atmospheres. Also, shifted increments
for time values of .01-99.99 minutes is 1 minute. Shifted increments for time values of greater
than 100 minutes is 5.00 minutes.
4.7.3 Configure Menu

The options in this table allow you to enable or disable a keyboard beeper that gives audible
indication of positive keystrokes or to set the proportioning mode to be used by the pump.
Press the CONFIGURE MENU key. The following display appears.
IKeyboard
Beeper
Proportioning
Mode

Make your choice from the menu with the cursor arrow keys and press SELECT. If you choose
Keyboard Beeper, the following is displayed.
~Keyboard beeper state: Enabled
Use the INCREASE/DECREASE keys to make your selection. Upon leaving this display, any change
to the beeper state will take effect.
The beeper also calls attention to system faults. However, it cannot be disabled for this function.
The choice you make does not affect operation.
If you choose Proportioning Mode, the following is displayed: (9012SDS)
See manual section 4.8 before changing

Proportioning Mode: One-Stroke
Use the increase/decrease keys to choose one-stroke, two-stroke, or four-stroke proportioning

mode. Upon leaving this display, any change to the proportioning mode will take effect.
NOTE: Selection of the two-stroke or four-stroke proportioning

mode requires the installation of a larger volume mixer. Please
read section 4.8 for a complete desaiption.
03-914436-04:1

Operation
4.7.4 METHOD ACTIONS (Method Actions Menu and Selections)

When the METHOD ACTIONS key is pressed the Method Actions Menu is displayed.
Method Error Method Method Run Table

Select Log Copy Delete Log Print
Make your choice from the menu with the cursor arrow keys, and press SELECT.
If you chose Method Select the following is displayed:
\Select Meth~d- Press Select
When you enter the desired Method number (1 to 5) and press SELECT, your selection is verified
as shown below.
\Method 1 Selected
To make another selection from the above headings, press the METHOD ACTIONS key.
When you select Error Log you obtain a record of any errors detected during the run. Time,
description, and the codes of the detected error(s) are presented in the following format:
!Time Error Description Error Code
The NEXT LINE key may be used to look for more than one error.
NOTE: This is a read-out display only. No changes can be made

to the fields of this table.
When you select Method Copy the display below appears:
\Copy Method Fr~m To - Press Select

3
Enter the Method number you want to copy, and the Method number it is to be copied to, press
SELECT, and the copy action is verified as shown in the following display:
!Method 1 Copied to 2
Move the cursor to Method Delete and press SELECT. The following is displayed:
Delete Method - Use Inc/Dec to Choose,

2 Then Press Select
Enter the Method number to be deleted with the INCREASE/DECREASE keys and press SELECT.
The verification of the deleted method is displayed as shown below:
03-914436-04:1 4-9
Operation
'Method 2 Deleted
Note: When a Method is "deleted" by this command, it is not erased. It is restored to preset
values.
The Run Log provides a quick way to review the conditions of the run just completed. The table lists

Time, Event, and Value of run parameters in the following format.
ITime Event Value
Events listed in the table are: o/oA, o/oB, o/oC, Flow, Relays On, Pmin, Pmax, and Proportioning Mode.
Values appearing in the Value column will be those entered and executed in the last run completed.
The contents of the table are viewed by scanning with the NEXT LINE and PREVIOUS LINE keys.
NOTE: The contents of this display can only be viewed. No

changes can be made to the fields in this table.
Table Print Selection

NOTE: The RS-232 Kit (PIN 03-919080-90) must be installed, and a compatible serial printer (e.g.,
Hewlett-Packard ThinkJe~) are required to use this feature.
Move the cursor to Table Print and press select to access the menu displayed below:
Print
Method
Print
Run Log
Print
Auto Table
Position the cursor at Print Method and press SELECT. Enter the Method number of your choice
with the INCREASE/DECREASE keys and press SELECT for the display below:

'Print Method 1 - Press Select
After you have selected the Method to be printed, move the cursor to either of the two tables and
press SELECT. A message, "Printer Started", will be displayed and the printer will print the selected
table, unless the printer is currently busy or has not been connected. If the printer is printing out a
report, or if a printer has not been connected, the following message is displayed:
'Printer Busy or Not Connected
Notes on the Method Actions Menu

1. Error Log and Run Log displays may be viewed only, not changed.
2. There are cases when certain actions are not allowed and are described in Exception Displays.
3. The Error Log will contain an error code and a description of the fault that has occurred. The
Pmin and Pmax errors occur when the pressure either drops below Pmin or exceeds the Pmax
values specified in the Set Conditions menu. For a complete list of faults see Appendix B.
4-10 03-914436-()4:1

Operation
4. All pump errors are "fatal", that is, the pump goes to the STOPPED state, and the method goes
to NOT READY or STOPPED. Also, all background diagnostic errors (faults) are reported in the
Error Log.
5. All tables will be printed out in tabular form. The #8 position on switch S5 can be set to allow
or inhibit form feeds between print operations. Set switch #8 to the up position if no page
separation between print operations is wanted, and down for page form feeding. The 9012 is
shipped with switch #8 in the down position. Switch SS is located in the upper right corner of
the SBC Board.
4.7.5 RELAYS
This table provides you open and closed contact control of six external event relays. Relays may
be time programmed to open and close to control a series of external events.
A closed relay appears in the display as its numeric identity. An open relay is represented by a dash
(-).For example, the following display would indicate that Relays 1, 3, and 6 are closed and the
other three open.
NOTE: When a fault is detected, all relays open. Any peripheral

equipment in relay control will shut down.
When you press the RELAYS key the following display appears.
Time Relays On
0.00 1-3--6
Relays are activated by moving the cursor to any one of the dashes and pressing the INCREASE
key. If the cursor is under the first dash pressing the INCREASE key will cause the numeral1 , which
represents Relay 1 (pins 1 and 2 of J3 on the rear panel} to be displayed. Conversely, to turn the
relay off, position the cursor under the selected numeral and press the INCREASE key.
4.7.6 Automation Menu
The Automation Menu is a scheduler that enables you to program a series of methods in a prescribed
order. A sequence table is displayed that lists the methods you select to be run in the order you
want them run when the ACTIVATE key is pressed.
Press AUTOMATION MENU and the following display is presented:
Automation Automation Setup

Table Parameters
Position the cursor under Table and press SELECT to see the display below:
Method Runs
1 2
Position the cursor under Parameters and press SELECT to see the display below.
* Loops1 Self Start

No
Completion Action
Keep Pump Running
1. Up to five lines can be entered in the Automation Table with the INSERT LINE key. If you attempt
the insert more than five lines you will get a TABLE FULL message .
03-914436-04:1 4-11
Operation
2.
3.
4.
Use the NEXT LINE key to move from one line to another, if you have more than one line. If only
one line exists, pressing the NEXT LINE key will result in the message: TO ADD LINE PRESS
INSERT LINE KEY.
Under Line and Method, select 1 to 5. Under Runs, select 1 to 99.
In the Automation Setup Parameters fields you select 1-99 for #Loops, Yes or No for Self Start,

and Keep Pump Running or Stop Pump in the Completion Action Field. Self Start is useful when
the pump controls the filling of the sample loop. When set to Yes, the automation sequence will
start when the pump goes to the READY state.
Generally, if an autosampler is used in the system, it will provide the start signal and the Self
Start parameter will be set to No.
5. The value you enter in the #Loops field determines the number of times a complete Automation
Table will repeat itself.
6. Completion Action (action to be taken at the end of the automation sequence): The pump may
be left running, or may be stopped after the last method has been run to completion. This allows
an automation sequence to be run which will terminate in an orderly fashion in the absence of
an attending operator.
4.8 Proportioning Mode Selection (9012 SDS)

The 9012 SDS has the capability to select among one-, two-, and four-stroke proportioning modes.
The one-stroke mode is preferred for most isocratic work and gradient work at flow rates of 1 ml)min
and below because the lower delay volume may save analysis and column equilibration time. The

four-stroke mode is useful for applications where the highest retention time reproducibility or the
lowest presst.Jre pulsations are required. When the four-stroke mode is selected, a larger volume
mixer must be added to the system (e.g. PIN 00-997876-00). The rest of this section describes the
different proportioning modes in more detail.
What are one-, two-, and four-stroke proportioning modes?

The metering of different solvents into the pump is done according to a one-, two-, or four-stroke
cycle. As an example, a proportioned isocratic solvent mixture of 90%A and 10%8 would be
metered as follows:
Stroke#1 Stroke#2 Stroke#3 Stroke#4

Mode AmountofB
A B A B A B A B
90% 10% 90% 10% 90% 10% 90% 10%
One-stroke

-
III II II II II II I I II I III II II II III II II II 10%/1 10%
Two-stroke
Four-stroke
80%
III II II I
60%
I I I I I I
20% 100% 0% 80%
II II II II II I III IIII I
40% 100% 0% 100%
20% 100%
-
0% 100%
OOk
III II II II II
00/o
II II II I I II I I I I II II II I I I I I II II II II
200/o/2 10%
40% I 4= 100/o
In the one-stroke mode, the complete solvent composition is proportioned on each fill stroke- i.e.
each fill stroke contains 10% B. In the two-stroke mode, the complete solvent composition is divided
over two fill strokes, with twice as much 8 solvent metered on one fill stroke and then none on the
next stroke- i.e. alternating fill strokes of 20% 8 and 0%8, which average out to 10%8. In the
four-stroke mode, the complete solvent composition is proportioned over four fill strokes, with four
times as much 8 solvent metered on one fill stroke and then none on the next three strokes- i.e. one
stroke of 40%8, followed by three strokes of 0%8, which average out to 10%8. In all cases, the
average concentration of solvent is the same- 10%8. Only the metering sequence has been
4-12 03-914436-04:1
Operation
changed. This proportioning across one, two, or four strokes is done for both isocratic proportioned
compositions and gradient formation when using two or three solvents.
What Parameters are optimized with the 1-, 2-, or 4-Stroke Proportioning Modes?
Optinized Parameter Best Mode to Use Next Best Mode Next Best Mode
Delay & Flushout 1 2 4
Mixing Noise 1 2 4
Pressure Pulsations 2,4 1
Gradient Unearity 4 2 1
Step Accuracy and Precision 4 2 1
What are the advantages of each proportioning mode?

The one-stroke mode was optimized for low delay and flushout volume and has the advantage of
low fluctuations in the average composition of the mobile phase coming out of the pump head. This
requires a very low mixing volume and is particularly useful when a low delay and flushout volume
are desired, as when operating with 2 mm i.d. columns. (Delay volume is the volume between the
pump head and the sample injector valve that a change in solvent composition must pass through
in order to reach the column. It may also be referred to by the term delay time, as long as the flow
rate is specified.) The constant metering used by the one-stroke mode also leads to lower
fluctuations on the detector baseline caused by inhomogeneity in the mobile phase, especially if
one of the solvents has an appreciable detector response. However, operation with this low delay
volume requires that the refill time of the pump be made longer, leading to larger fluctuations in the
column pressure. These pressure fluctuations are not a problem for the Star 9050 UV-VIS detector,
but may be significant when operating with detectors which are more flow sensitive, such as
refractive index or electrochemical detectors.
The two- and four-stroke modes both have a shorter refill time and, therefore, lower pressure
pulsations. However, since the solvents are metered over a multiple refill stroke sequence, a larger
mixing volume is required to achieve adequate mixing of the mobile phase. The entire fill stroke
sequence must be mixed in order to arrive at the desired composition. Because multiple solvents
are only metered every second or fourth refill stroke, these modes offer the highest degree of
proportioning accuracy and precision. For compounds with a very high sensitivity of k' to changes
in solvent composition, these modes may give better retention time precision.
What hardware changes are required when changing proportioning modes?
System
Proportioning Mixer
Mixer Part Number Delay
Mode Volume
Volume
one-stroke low volume 03-919468-00 02ml 1 ml
two-stroke static open tube 03-905985-90 1.2ml 2ml
four-stroke dynamic OD-997876-00 12ml 2ml*
or high performance static
* While the delay volume is the same for both two- and four-stroke modes, solvent changes will take
longer to reach their equilibrium value with four-stroke mode due to slower flushout of the dynamic and
high performance static mixers.
03-914436-04:1 4-13
Operation

For the two-stroke mode, a mixer volume of approximately 1-1.5 ml is sufficient to produce a
homogeneous mobile phase, adding only about 1 minute to the gradient delay time for a flow rate
of 1 mL/min on a 4 mm i.d. column. An empty stainless steel tube (4.6mm i.d. by 85mm long) will
provide adequate mixing for most solvents when using the two-stroke mode. Therefore, the
two-stroke mode represents a good compromise between pressure pulsations and mixing noise.
The four-stroke mode also requires a mixer volume of approximately 1-1.5 ml. Either a dynamic
mixer or a high performance static mixer may be used. A mixer with higher performance than an
empty tube is needed for best solvent mixing. With a flow rate of 1 mL/min on a 4 mm i.d. column,
the delay time is about two minutes.
NOTE: Operation of the 9012 in two- or four-stroke proportioning

mode with a mixer which is too small may result in sinusoidal
fluctuations on the detector baseline due to incompletely mixed
mobile phase.
How are the different proportioning modes selected?

The different proportioning modes are selected from the Configure Menu. See paragraph 4. 7.3. The
proportioning mode will be saved in battery backed-up memory, even when the power is turned
off. Once selected, a specific proportioning mode is used for all methods until it is either changed
by the user or the value is returned to preset in the battery backed-up memory due to a) battery
failure, b) a user-performed "cold start" (see paragraph 4.2.2), or c) any time the message:
"Methods Lost" is displayed. When any of these events occur, the mode will automatically return to

one-stroke proportioning.
What fill time is used with each proportioning mode?
Conligu'8lian Men.! FlcM Rale Rar9

Seleclian 0.01 - 0.09 nt.Jrrin 0.1 - 5.0 ntJrrin 5.1 - 10 rrilrrin
One 1-stroke (400 ms) 1-stroke (400 ms) 2-stroke (200 ms)
Two 2-stroke (400 ms) 2-stroke (200 ms) 2-stroke (200 ms)
Four 4-stroke (400 ms) 4-stroke (200 ms) 4-stroke (200 ms)
Note that when the one-stroke proportioning mode is selected at flow rates above 5 ml/min, the
two-stroke mode is automatically used. This change is necessary because of the reduced time
available for refilling the pump at the higher flow rates. When one-stroke proportioning mode is
selected and only one solvent reservoir is used, the fill time is 200 ms.
4-14 03-914436-04:1

Section 5
Applications
5.1 General
This tabbed section has been included to provide you with an open section of your manual that will
serve as a repository for any data or publications relating to the Star 9012 and Star 9002 Solvent
Delivery System applications you may wish to preserve .
03-914436-05:2 5-1
Applications
LC 1
LC 2
LC 3
The Determination of N-methylcarbamate Pesticides in Water by HPLC
Amino Tag Precolumn Amino 'Acid Analysis
ChiraJ Separation and Detection Enhancement of Propanolol Using

Automated Pre-column Derivatization

LC 4 The Analysis of Milk Sugars with a Modem Refractive Index Detector
and a Carbohydrate Column
LC 5 Enhancement of Detection Sensitivity of Tobramycin Using Pre-Column Derivatization
LC 6 Enhancement of Selectivity in Sample Cleanup for Tobramycin in Serum

Using Derivatization before Solid Phase Extraction
LC 7 HPLC Detector Options for the Determination of Polynuclear Aromatic Hydrocarbons
LC 8 Identification of Polynuclear Aromatic Hydrocarbons in a Complex Matrix with

Diode Array Detection
LC 9 Identification and Quantitation of Herbicides and Pesticides in Water by LC

and Diode Array Detector
LC 10 Application of Multicomponent Analysis of HPLC Diode AlTay Detection for

Quantitation of Completely Unresolved Components
LC 11 Application of Multicomponent Analysis of HPLC Diode AlTay Detection for the

Quantitation of Partically Resolved Peaks
LC 12 Analysis of Basic Drugs in Postmortem Blood by HPLC with Diode Array Detection
5-2 03-914436-05:2

The Determination of
e N-methy/carbamate Pesticides
in Water by HPLC Varian Application Note
LC
Number 1
John J. Sullivan, Jan Tschida and Steve Aamodt
Keywords: Carbamate Pesticides, Post Column Reaction System, Fluorescence, o-Phthalaldehyde, Derivatization,
Reagent Stability
As a class, the N-methylcarbamates are some of the most widely used insecticides in agriculture. Recent concerns
over the appearance of carbamate residues in water and foods have prompted increased awareness and testing for
these compounds. Since the carbamates are somewhat polar and thermally unstable, analysis by the more traditional
gas chromatographic methods used for most pesticide residues is difficult. Consequently, the method of choice for
the analysis of carbamate residues in both food and water has become the HPLC procedure utilizing a Post Column
Reaction System (PCRS).
The HPLC procedure is based on a reversed phase separation of the carbamates with derivatization by
o-Phthalaldehyde (OPA) followed by fluorescence detection. The PCRS uses a two step reaction in which, first, a
strong base is used to cleave off methylamine from the carbamate compound, and then the methylamine is reacted
with the OPA and 2-mercaptoethanol. The resulting fluorophore has excitation and emission maximums of
approximately 330 nm and 450 nm, respectively.
The Varian carbamate System
Varian has combined the latest in HPLC instrumentation with the most respected name in Post Column Reaction
Systems to bring you a Carbamate Analysis System that is unmatched in performance and reliability. The combination
of Varian's PC based LC Star System and the Pickering Carbamate PCRS provides state-of-the-art performance with all
of the service and support advantages of a single vendor. All components in the system have been tested and
optimized for long-term stability
and reliability in automated
analysis situations. Among the
features of the system:
Fully automated PC based HPLC

system, with single point control of
pump, autosampler and data
system
HPLC Column tested and certified
to provide efficient separation of
the carbamate pesticides
Tested supply of all reagents.
needed for the PCRS
Industry standard PCRS pump
with a long history of reliable
operation
Helium blanketed OPA delivery
system for maximum long-term
stability
Advanced safety features
tELIUM
including a safety interlock to SUPPlY
varian
protect the analytical column and
pressure relief valve to prevent
over-pressurization of the PCRS. F'.gure 1. Flow diagram for the Varian carbamate System.
All post column reagents, supplies and HPLC column are provided.
Analysis Conditions
Column: Pickering C18, 4.6 X 150 mm, 5 J.Lm
Mobile Phases: Methanoi+Water; Binary Gradient
Injection Volume: 200-400 J.LL water
PCRS:
1
2
4
9
Reagent 1: 0.05M NaOH Solution @ 0.3 mUmin 3
(Hydrolysis for 20 sec. @ 100C) 5
Reagent 2: CPA Solution in 0.05M Borate buffer@ 6
0.3 mUmin (reaction for 8 sec.) "2
Ill
"C
c:
Detector: Fluorichrom II, Ex.-350 nm Bandpass Riter, Ill
Em.-420 nm Cutoff Riter 10 CiS

iii
E
~
l
5 10 15 20 25
Minutes
Figure 2. Separation of the carbamate pesticides in Reagent Water at the 50 ppb level (400 pl. injection).
See Table 1 for the peak assignments.
System Performance Table 1 Comparison of the EPA

and Varian carbamate Methods
To meet the water testing requirements, the HPLC Peak EPA Method Varian Method

system must provide efficient separation of the common # Analyte RSD{%) EDL (ppb) RSD (%) EDL {ppb}
carbamate pesticide residues with detection limits at or 1 A. Sulfoxide 5.0 2.0 1.4 0.54
below 1 ppb. Method 5 and Draft Method 531.1 of the
2 A. Sulfone 4.0 2.0 2.2 0.56
EPA define the requirements for suitability of the HPLC
3 Oxamyl 4.0 2.0 2.4 0.62
system for this type of testing. Shown in Figure 2 is a
chromatogram of the separation of the carbamates in 4 Methomyl 4.0 0.5 2.1 0.~
the Varian Carbamate Analysis System. As can be 5 3-0H Carbofuran 4.0 2.0 1.7 0.77
seen, all of the compounds are well resolved within 30 6 Aldicarb 3.0 1.0 2.4 0.65
minutes. Table 1 lists the performance of the system 7 Baygon 3.0 1.0 2.0 0.86
compared to the EPA Method 531.1. The data represent 8 Carbofuran 5.0 1.5 1.8 0.95
the periodic analysis of a spiked water sample at the 10 9 Carbaryl 6.0 2.0 1.2 0.87
ppb level (400 J.LL injection) over 12 hours (n=16). For 10 Methiocarb 2.0 4.0 2.5 1.30
all of the carbamates, the system performance meets or
exceeds that of the EPA method. Superior performance EPA Method: 531.1 (4/15/88)
coupled with the long-term stability of the Varian EDL: Estm. Detection Umit; calculated by multiplying the SD by the
Carbamate Analysis System provides an excellent tool student's t value (99%, n-1 ), or 5 times the noise, whichever is
for the monitoring of carbamate pesticide residues in greatest.
water.
Ordering Information
Item Part Number Item Part Number

HPLC Pump, Model9010 03-919001HX> Carbamates Column (included above) 03-912058-52
AutoSampler, Model9100 03-909100-10 Column Heater (included above) 88-310210-00
Large Volume LC Option 03-906708-90 Hydrolysis Reagent {1 cs) 00-997798-02
Fluorichrom II Detector OQ-43()()20-02 CPA Diluent (1 cs) 00-997798-01
Garbamates Pesticide Analysis System
varian
88-3102C&OO o-Phthalaldehyde (5 gm)
These data represent typical results.

For further information, contact your local Varian Sales Office.
03-915074-00

LC1:0591
e AminoTag Precolumn. LC
Varian Application Note
Amino Acid Analysis
Number 2
Anton G. Mayer and Fran Lai

Keywords
Amino Acids, FMOC, AminoTag, AutoMix, Precolumn Derivatization, Fluorescence
Introduction
Amino acid analysis covers a wide range of different research and development areas such as biochemistry,
biotechnology, and pharmacology and is also used in the quality control of food, beverage and feed samples. This
diversity of samples requires that the chosen precolumn chemistry be rugged, sensitive and flexible.
FMOC (Fiuorenylmethyl-chloroforrnate) is a highly reactive reagent that has been used as an amino-protecting group in
peptide SYf!thesis. Precolumn derivatization with FMOC is suitable for analyzing amino acids in protein hydrolysates as
well as in pnysiological fluids1.
AminoTag: FMOC Precolumn Derivatization
AminoTag is Varian's automated implementation of FMOC amino acid derivatization. After years of development and
peptide core facility evaluation2, AminoTag has been proven to be a reliable and accepted methodology. The reaction is
complete in minutes. is carried out at room temperature, and provides a hundred-fold increase in sensitivity over
colorimetry. Furthermore, the derivatives can be separated with excellent efficiency and selectivity using
reversed-phase chromatography.
Through the micro-robotic features of the Varian Star 9100 AutoSampler, sample preparation schemes can be fully
automated3. In the case of AminoTag, the entire derivatization, extraction and injection scheme is performed by the
9100. This level of automation frees the analyst from mundane sample prep protocols, while giving unsurpassed
precision and accuracy for micro determinations of amino acids.
~ ~
CHro-C-CI + CHa-o-c-N-c-coo- +H+ a-
II n 1
0 0 R
FMOC Dadvallwt
FMOC + HOH ...
CHa
I
OH
Hydrolysis Product
varians
fM.(IH
F'agure 1. FMOC Chemistry
LC2:1/4
Fluorescence or uv Detection
AminoTag offers flexibility of either fluorescence or UV absorbance detection modes. The sensitivity and selectivity of
fluorescence detection (excitation 265 nm/emission 345 nm) makes the analysis of low pmole levels fairly routine.
During high sensitivity analysis, fluorescence detection offers stable, flat baselines due to its selective response to
fluorescent products only. Even though UV based chemistries may offer pmole sensitivities, detector response to a
gradient baseline makes the UV absorbance analysis much more difficult. With rigorous cleanup of all reagents and
mobile phase to eliminate background amino acids and other amines, quantities as low as 400 fmole (on column} have
been measured at a signal-to-noise ratio of 4 (Rgure 2). At quantities ~100 pmole, UV detection at 265 nm offers a
convenient alternative.
7
16
1.ARG 10. MET
2.SER 11. VAL
3.ASP 12. PHE
4.GLU 13.1LE
5.THR 14.LEU
6.GLY 15. HIS
7.F~H 16. LYS 12.13.14
-8.ALA 17. TYR 2 34 6
9.PRO 5 8 n 17
9 I)
(AminoTag ODS 4.6 mm x 15
15 an column)
Fagure 2. 400 fmole of each AA on column

The Chromatography
Separations must be able to resolve more than just the 17 protein hydrolysate amino acids. Collagen, beverages and
pharmaceuticals usually include additional amino acids that are equally important. AminoTag derivatives separate well
on the AminoTag optimized, reversed-phase column using aqueous buffer-organic gradient elution (Rgure 3). Eluting
peaks have been positively identified by standard additions controlled by the 9100 AutoSampler. One of two qualified
internal standards, beta-thienyl alanine or norvaline, may be used to monitor the entire process.
1. Phosphoserine 14. Proline

2. Phosphothreonine 15. Methionine
3:CysteicAcid 16. Vali ne
4. Arginine 17. Norvaline 25
23
5. Methionine SuHoxide 18. S1atine (4-Amino-3-hydroxy-
6. Hydroxypro6ne 6-melhylhydroxy-heptanoic acid) 26
7. Serine 19.Phenylalanine
8. Aspartic Acid
9. Glutamic Acid
20.1soleucine
21.Leucine 2 ...~
:::IE
1B
o.
1 Threonine 22.Cystine
11. Carboxymethyl cystine 23. Hydroxylysine 20
12. Glycine 24.Histidine ~ 7
8
.,p f9J21
12
13.Aianine 25. LYSIne
26. Tyros~ne
1 3
5 6 910, 13
'15
14
a
I
ll.
Figure 3. 200 pmole AminoTag Chromatogram

'
:::IE
l A T u. l

Optimal Reproducibility
Volumetric transfers, reaction time and column equilibration time are all crucial for good precision. On the Star LC
System, FMOC derivatives (at 200 pmoles each on column) have an area precision of less than 3% RSD and a retention
time precision of less than 0.7% RSD. Based on internal standard corrections, quantitative precision can be improved to
less than 1.5% RSD for all peaks (typically better than 1%).
Table1
AminoTag Amino Acid Precision
Internal
Area Standard Retention
o/oRSD Corrected lime
Peak Name (n=8)* o/o RSD o/oRSD
Phosphothreonine 2.5 0.8 0.6

Methionine Sulfoxide 2.5 0.8 0.7
Aspartic Acid 2.5 0.6 0.4
Carboxymethyl cystine 2.4 0.6 0.4
Proline 2.1 0.4 0.3
Norvaline 2.2 INT. STD. 0.4
Isoleucine 2.2 0.3 0.2
Lysine 2.1 1.5 0.2
Tyrosine 2.9 1.5 0.2
*Eight separate sample, derivatization, extraction, and injection steps.
Star AminoTag Perfonnance

To determine whether a new method is giving correct values requires comparisons to be made with a proven
benchmark. The classical benchmark for amino acid analysis is ion exchange separation and post-column reaction with
ninhydrin, such as described by Spackman, Moore and Stein in 1958.
The quality of correlations between AminoTag and post-column ninhydrin analysis validates the accuracy of the
precolumn AminoTag (Table 2). AminoTag's sensitivity is demonstrated by the fact that ninhydrin samples were diluted
by a factor of 100 before being analyzed by AminoTag.
Table2
Amino Acid Composition Detennined Using AminoTag and Ninhydrin Methods
Molar Ratios Molar Ratios
LYSOZVME EXPECTED AminoTag NINHYDRIN BRADYKININ EXPECTED AminoTag NINHYDRIN
SER 10 9.3 8.8 ARG 2 1.7 2.3
ASX 21 19.6 20.3 SER 1 1.0 1.0
GLX 5 6.4 6.3 GLY 1 1.0 1.0
ARG 11 10.1 9.2 PRO 3 3.4 3.2
THR 7 6.3 6.1 PHE 2 1.7 2.1
ALA 12 11.7 12.0
TYR 3 2.6 2.8
GLY 12 11.3 11.0 SUBSTANCEP
PRO 2 2.1 2.0 ARG 1 1.0 1.0
MET 2 1.4 1.3 GLU 2 2.0 2.1
VAL 6 5.8 6.4 GLY 1 1.0 1.0

PHE 3 3.0 3.3 PRO 2 2.0 1.9
ILE 6 5.2 5.6 MET 1 0.9 1.0
LEU 8 8.2 8.1 PHE 2 2.0 2.0
HIS 1 1.0 0.9 LEU 1 0.9 1.0
LYS 6 6.0 5.7 LYS 1 1.0 1.0
LC2:a'4
Summary
The modular construction of the Star AminoTag system provides an analytical system that offers a simple and optimal
approach to amino acid analysis. Each component can be run individually or centrally controlled from the Star
Workstation, enabling the user to adapt the system to the latest developments in research technology.
References
1. Einarsson, S., B. Josefsson, and S. Largerkvist, J. Chromatography 282:609 (1983)
2. Smith, Alan J., Presley, Jack M., and Mcintire, William, Techniques in Protein Chemistry; Hugli, Tony E., Ed.;
Academic Press, Inc.: London, 1989; p 255
3. Cunico, R., Mayer, A.G., Wehr, C.T., and Sheehan, T., BioChrornatography 1, 6-14 (1986)
HardWare List for AmlnoTag
9010 Solvent Delivery System

9010 GPIB Kit
9100 AutoSampler (with Valco or Rheodyne)
9100 GPIB Kit
9010 Purge Valve
03-90912.WO 9070 Ruorescence Detector
Star Workstation Host Computer
Star Workstation Software Kit (AT Bus)
03-907789-90 Star ADC Board Kit
03-912023-52 MicroPak AminoTag Column
00-997~ Guard Column (3 Pk.)
88-310052-00 Guard Column Cartridge Holder
88-301176-00 AminoTag (FMOC) Derivatization Reagent
88-310168-00 Amino Acid Calibration Standard
88-310206-00 LC Column Oven
varian8 These data represent typical results.

LC2l4U 0392

Chiral Separation and
e Detection Enhancement of
Propranolol Using Automated Varian Application Note
LC
Pre-column Derivatization Number 3
Fran Lai
Keywords
Pharmaceuticals, Propranolol, FLEC, AutoMix, Chiral, 2. Using chiral mobile phase.
Enantiomers, Diastereomers, Racemic mixtures,
Detection enhancement, Fluorescence, Pre-column 3. Using chiral stationary phase.
derivatization. Of the three methods, the first one offers multiple
advantages:
Introduction
Drugs with chiral centers exist naturally in racemic 1. No special column or mobile phase required.
mixtures, that is, a mixture of nearly equal proportions of 2. Micro-scale derivatization keeps cost low.
the enantiomers such that the mixture is optically
inactive. Since enantiomers of drugs can have different 3. Additional benefit of detection enhancement.
therapeutic characteristics and effectiveness, the The derivatization process is easily automated using the
determination of enantiomeric purity has become saf11)1e preparation features on the Star 91 00
increasingly important in the pharmaceutical industry. AutoSampler.
Currently there are three different LC methods for chiral Methodology

separations:
In this apptication, Propranolol, existing in racemic form,
1. Converting enantiomers to diastereomers by is analyzed by pre-column derivatization with
pre-column derivatization with optically active (+)-1-(9-FiuorenyQethyl chloroformate (FLEC), a pure
reagents. enantiomer, which is fluorescent (Figure 1).
() Propanolol (enantiOmers)
C* = Ct*al cenler
varians Figure 1. Analysis of () Propranolol Using Pre-Column Derivatization (FLEC)

Three areas of accomplishment are: Linearity
Range: 0 - 400 pmoles
1. Chiral separation.

2. Enhancement of detection sensitivity. Correlation coefficient for Derivative 1 =0.99960
3. Enhancement of detection select!vity. Correlation Coefficient for Derivative 2 = 0.99998
9100 AutoSampler Procedure Reproducibility of 6 Runs at 200 picomoles

1. Transfer and mix FLEC with Propranolol sample. Derivative 1 Derivative 2
2. Wait for programmed reaction time (2-5 minutes). Average 189.2 pmoles 191.2 pmoles
3. Inject. Std. Deviation 1.9 pmoles 2.3 pmoles
Rei. Std. Deviation 1.1~ 1.8~
HPLC Conditions
References
Column: MicroPak SP C8 4 mm x 15 em
1. FLEC APPLICATIONS: Resolution of Beta-blockers,
Mobile Phase: 30:70::Acetate:Acetonitrile, 2 mUmin. Eka Nobel AB, 8-44501 Surte, Sweden. Telefax
+4631-981954
Detection: Auorescence, Ex. 265 nm, Em. 345 nm 2. S. Einarsson, B. Josefsson, P. Moeller, D. Sanchez,
Separation of amino acid enantiomers and chira/
Results amines using precolumn derivatization with (+)-1-(9-
1. The enantiorners are weD separated with no F/uoreny/) ethyl ch/orofonnate and reversed-phase
interference from the blank, as shown in Figure 2. liquid chromatography, Anal. Chem., 1987, Vol. 59,
No.8, P.1191-5.
2. Using fluorescence, the response is at least 10 times
that of UV absorbance. See Figure 3. 3. D. Sanchez, P. Meeler, S. Einarsson, B. Josefsson,
FLEC, a new development in chiral separation and the
3. Auorescence detection eliminates the interference determination of amino acids, amines and alcohols,
detected by uv absorbance. s~ Figure 3. JanssenChimicaActa, ~988, Vo1.6, No.1, P.1G-14.

4. Souter, R.W., Chromatographic separation of
stereoisomers, CRC Press, 1985.
.
~ Derivative 1
.. Derivallve 2
Derivallve 2
+ lnlelference
Excess
FLEC
...I
Excess
.......

Fl..EC

:: Excess
FLEC
I I I I I I I I I I I I
0 2 4 6 8 10 12 0 2 4 6 8 10 12 0 2 4 6 8 10 12 14
tA'Iutes Minutes Minutes
Chromatogram ol Fl..EC Cllromalogram ol FlE~er FLEC.Derivalized () Prapranolol FLEc-Delivallzed () Propranolol
() Propanolol, 200 pmoleS (Blank) (100 pmoles) Using UV at254 nm (100 pmoles) Using RJorescence
Ex. 265 nm, Em. 345 nm
Detection= Fluon!SCanCe: Ex. 265 nm, Em. 345 nm
Mobile Phase : 30:70::Acetale:Acelonltrle Del Limit= 10 prnoles DeL Uml =1 pmole
F~gure 2. FLEC-Derivatization of () Propranolol Figure 3. Detection Enhancement
varian@ These data represent typical results.

Using Fluorescence vs. UV

l.C-3:0583
The Analysis of Milk Sugars
with a Modern Refractive Index

Detector and a Carbohydrate
LC
Column Number 4
Maureen Joseph .
Varian, Chromatography Systems
KeyWords
Sugars, refractive index detection, lactose, glucose,
galactose, carbohydrate column
Sugar analysis is a common i!ldustrial ~alytical . Experimental:

requirement. It is particularly Important 1n the_ analys1s_of This application note describes the analysis of milk
food products such as milk. Though _lactose 1s the ma1n sugars in whole milk and lactose reduced milk u~ing a
carbohydrate in milk (1) and was typically th~ only su_gar carbohydrate column and the Rl-4 refractive index
of concern, recently interest has expanded tn an~Jyz1!lg detector. This requires the separation of three sugars:
milk products with reduced lactose. The lactose 1n mtlk lactose, glucose, and galactose. The glucose and
can be reduced by hydrolyzing lactose into two other galactose are produced as a result of the hydrolysis of
sugars, glucose and galactose, with an enzyme. The lactose (2). The samples were prepared by precipitating
result is a product with reduced lactose that can more the milk proteins with isopropanol and water and
easily be consumed by large percentage of the world's centrifuging the samples. The supernatant was filtered
population that are lactose intolerant (2J.
through a 0.45 J.UTl filter, and the samples _were dil~ed

with water. This separation with commerctally available
There are two major HPLC approaches to the analysis of lactose-reduced milk is shown in Figure 1.
milk sugars. One method is to us~ _a specific resin b~ed
carbohydrate column with a sensitiVe, modern, refractiVe
index detector. This is an excellent approach as these
columns have the ability to separate sugars within a Flow Rate: 0.5 mi./min
Mobile Phase: 100% Water
group (i.e., C5 and C6 sugars), the corresponding su~ar Temperalure: 80"C
alcohols, and some larger sugars. The standard mob1le Detection: Rl4
phase for such a column is 1 CJ?% w~!er. A second.
approach uses an amine modified sthca column With
either a refractive index detector or a UV detector at a
low wavelength. These amine columns have been used
extensively. Currently, there are distinct advantages to
using resin type carbohydrate columns for sugar
analysis. Resin columns have pro~en to be mo~e stable
since amine columns can be modified by certa1n
samples and therefore demonstrate~~~ stability(3>. ~ilica
based amine columns require acetonitrile/water mob1le
phases at flow rates of 1.5 - 2.0 mUmin produ.c:ing
substantial amounts of hazardous waste. Additionally,
these factors allow a cost analysis to be made:
Carbohydrate Column Amine Column

Solvent Water: $90.00/case ACN: $140.00/case
Water: $90.00/case
Disposal no yes
Row Rate 0.50 mLJmin 1.5 mLJmin
240mllday 720mllday
$6.47/day Figure 1. Separation of Lactose Reduced Milk (1 :10 dilution)
varian
Cost $1.35/day
Whole milk can be analyzed using the same method with Results:
lactose as the only sugar of concern (Rgure 2).
The average recovery of the lactose was 104% (n=6). The
quantitation was done using an external standard method
(range 0.014 mg/mL to 0.68 mg/mL) with a linear
calibration curve (R=0.99998) (Rgure 3). The baseline
stability and retention time reproducibility (Rgure 4) was
excellent for both samples (6.68 min 0.42%, n=20) and
standards (6.68 min 0.18%, n=21 ). The acidophilus
(lactose reduced) milk samples showed a reduction in
lactose of over 50%, as expected.
Flow Rale: 0.5 mUmin
Mabie Phase: 100% Water
Temperature: 80"C
Dateclion: Rl-4 2~----------------------------~
R=0.99998
0~--~--~--~--~----~--~--~
Figure 2. Separation of Whole Milk (1 :25 dilution) 0.00. 0.1 0 0.20 0.30 0.40 0.50 0.60 0.70
rnwra
Figure 3. calibration CUrve for Lactose
The chromatographic system consisted of a Varian
Star 9010 pump, SPH99 column oven, a MicroPak
carbohydrate column, Rl-4 detector, and 4400

Integrator. The column was heated to SOOC and the Conclusions
detector to SOOC. Sugar analysis on an ion exchange carbohydrate column
with an aqueous mobile phase is a simple, sensitive
Flow Rate: 0.5 mL/min method. Additionally the cost of mixing and disposal of
Mobile Phase: 100% Watsr solvents is eliminated, making this a cost effective method
Temperature: IIO"C of analyzing sugars.
Detection: Rl-4
References
1. Richmond, M.L; Harte, B.A.; Gray, J.l.; Stine, C.M.; J.
Dairy Sci. 70 (1987) 1140-1147.
2. Aim, L J. Dairy Sci. 65(3) (1982) 346-352.
Figure 4. Lactose Standard@ O.G14 mg/mL
3. Patrick, D.W~; Kracht. W.R. J. Chromatogr. 318 (1985)
269-278.


L.C-4:1090
Enhancement of Detection
Sensitivity of Tobramycin Using

Pre-column Derivatization
LC
Fran Lai
Varian Chromatography Systems Number 5
Keywords
Pharmaceuticals, Tobrarnycin, OPA,

AutoMix, Detection Enhancement,
Fluorescence, Pre-column Derivatization,
Varian 9100 AutoSarnpler
Reversed Phase HPLC and UV detection

are very popular methods for the analysis
of pharmaceutical compounds. This
works well for nonpolar and UV-absorbent
compounds, but for compounds that are
rather polar and lack UV-absorptivity, the
analysis becomes a major challenge.
Tobrarnycin, an aminoglycoside
antibiotic, is a good example of a polar

pharmaceutical compound with low
UV-absorptivity. To overcome these
problems, a method has been
developed using pre-column
derivatization with orthophthalaldehyde
(OPA).
Figure 1. Analysis of Tobrarnycin
Procedure Using Pre-column Derivatization (OPA)
The derivatization process is easily
automated using the sample preparation
features on the 9100 AutoSampler.
Results
1. Prepare Tobrarnycin sample in 1. Two derivatives are obtained. Due to multiple primary
acetonitrile:water/60:40. amino sites on the compound, multiple derivatives
may be expected. The ratio of Derivative 2/Derivative 1
2. Prepare OPA reagent: increases with reaction time and with increase in
OPA5mg/ml acetonitrile in the sample solvent
2-rnercaptoethanol (2-ME) 1% v/V The optimum reaction time is 30 minutes, and the
in borate buffer pH 10.4, 0.4M optimum solvent composition is 60% acetonitrile.
There is no interference from the blank. (Figure 2)
Derivatization Using Varian 9100 AutoSampler
2. Using fluorescence, the detection limit is about 400
1. Transfer and mix OPA reagent with Tobramycin times better than when using UV absorbance.
sample (1:1 v/V) (Figure 1). (Figure 3)
2. Wait for programmed reaction time. 3. Unearity was tested up to 1.2 nrnoles and found to
be linear with a correlation coefficient of 0.998.
3. Inject onto the HPLC.
varians
Derivative 1
..,
N
.
Gl
Derivative 2
..,r-
..."'
Gl
--A-J~----------------
I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
0 4 8 12 0 4 8 12
Minutes Minutes
OPA-Derivatized Tobramycin (1.6 nmol) OPA-Derivatized Blank
Figure 2. OPA-Derivatization of Tobramycin

Column: M"aoPak SP C8 4 mm x 15 em
Mobile Phase: 0.02M Phosphate pH 6.5:Acelooilrile/52:48, 2 mLJmin
Detection: Ruorescence
Ex. 340 nm (Bandpass filter CS-7-54, CS-7~)
Em. 450 nm (Bandpass filter CS-4-76, Cutclf filter CS-3-73)
Derivalive 1
N
In
&
.
Derivative 1

...
&
111111111111 II I I I I I I I I I I I I I I
0 4 8 0 4 8 12
Minutes Minutes
OPA-Derivatized Tobrarnycin (1.6 nmol) OPA-Oerivalized Tobramycin (1.6 nmol)
Using UV at 254 nrn Using Fklolesceuce, Ex. 340 nm, Em. 450 nm
Detection Limit 400 pmol Deteclion Until 1 pmol
Figure 3. Detection Enhancement Using Ruorescence vs. UV Absorbance
References
1. Sten-Erik Back, Chemical Assay, Involving Uquid Chromatography, for Aminoglycoside Antibiotics in Serum,
Clinical Chemistry, Vol25, No.7, p. 1222-1225, 1979.
2. Robert Cunico, Automatic Precolumn Derivatization of Amino Acids with Orthophthalaldehyde,
Varian LC at Work #161, 1985.
varian These data represent typical results.

LC5:0991

Enhancement of Selectivity
in Sample Cleanup to~

Tobramycin in Serum Using Varian Application Note
LC
Derivatization before Number 6
Solid Phase Extraction

Fran Lai
Keywords Procedure
Pharmaceuticals, Tobramycin, OPA, Detection 1. Prepare OPA reagent:
Enhancement, Selectivity Enhancement, Solid Phase
Extraction, Sample Cleanup, Derivatization, Bond Elut OPASmg/mL
2-mercaptoethanol (2-ME) 1% v/v in borate buffer
pH 10.4, 0.4M
Solid Phase Extraction (SPE) using reversed phase
sorbent has proven very successful for the cleanup of 2. Deproteinate serum sample using 10% (w/v)
nonpolar compounds from biological samples. Polar sulfosalicylic acid .

compounds, however, would have low selectivity and Vortex and centrifuge.
poor recovery.
3. Mix OPA reagent with Tobramycin sample (1 :1 v/v)
Tobramycin, an aminoglycoside antibiotic, (Rgure 1).
is a good example of a polar pharmaceuti-
cal compound. To improve its cleanup from
a biological matrix, a method has been
developed using pre-SPE derivatization
HSCH:zCH~
with orthophthalaldehyde (OPA). This
method has a secondary advantage of
enhanced detection sensitivity by means of
fluorescence detection of the derivative
formed .
varian Using
Figure 1. Analysis of Tobramycin
Pre-column Derivatization (OPA)
Solid Phase Extraction 2. Peak heights and standard concentrations from 13 to
128 J.LM (40-400 pmoles on column) were linearly
1. Condition Bond Elut C1s with acetonitrile, followed by

related with a correlation coefficient of 0.998.
acetonitrile/phosphate buffer pH 8 (10:90 v/v).
3. Reproducibility of 6 runs of a 96 1-1M standard (300
2. Load derivatized sample in acetonitrile/phosphate pmoles on column) had a relative standard deviation
buffer. of 1.1%.
3. Wash with acetonitrile/phosphate buffer. 4. Peak heights and spiked serum concentrations from
32 to 128 1-1M were linearly related with a correlation
4. Elute with acetonitrile/water (90:10 v/v}. coefficient of 0.995.
5. Inject onto HPLC. 5. Recoveries of spiked serum at 128 J.LM averaged 98%
Results with a relative standard deviation of 3.6%.
References
1. Two derivatives are obtained. Due to multiple primary
amino sites on the compound, multiple derivatives
1. Sten-Erik Back, Chemical Assay, Involving Uquid
may be expected. Following SPE, Derivative 2 is the
Chromatography, for Aminoglycoside Antibiotics in
prominent peak, probably due to a stabilization effect
Serum,
of the SPE. There is no interference from the blank. Clinical Chemistry, Vol25, No.7, p. 1222-1225, 1979.
The advantage of this method is shown by a
comparison study where SPE was followed by 2. Robert Cunico, Automatic Precolumn Derivatization of
derivatization. This latter method had a poor recovery Amino Acids with Orthophthalaldehyde,
of 2% (Figure 2). Varian LC at Work #161 , 1985.

Derivatization before SPE SPE before Derivatization
....

...
II I t I I I I I I I I I I I II I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
0 4 8 12 0 4 8 12 0 4 8 12
Ma1utes M"IIUtes Minutes
60 J,d. of 1281&M Sample 100 !d- of 480 11M Sample

(200 pmol of Derivalive Injected) (300 pmol of Derivalive Expected)
Figure 2. Chromatograms of Tobrarnycin-Spikec:l Serum

Column: MicroPak SP Cs, 4 mm x 15 an
Mobile Phase: 0.02M Phosphate pH S.S:Acetonitrile/50:50, 2 mUmin
Detection: Auorescence
Ex. 340 nm (Bandpass filter CS-7-54, CS-7-60)
Em. 450 nm (Bandpass filter CS-4-76, Cutoff filter CS-3-73)

For tuither information, contact your local Varian Sales Office.

LC6:0991
HPLC Detector Options for
the Determination of
Polynuclear Aromatic
LC
Hydrocarbons
Number 7
Maureen Joseph
Key Words: Polynuclear Aromatic Hydrocarbons, PAHs, PNAs, UV, fluorescence, EPA 61 0, wavelength optimization
The presence of polynuclear aromatic hydrocarbons Fluorescence detectors can be monochromator based
(PAHs) is a common environmental concern. Some of the allowing for wavelength programming to achieve
PAHs have been found to be carcinogenic and optimum sensitivity. The appropriate choice of detector(s)
mutagenic. These compounds are typically introduced depends upon the actual method being used and the
into the environment by both naturally occurring detection limits required for the samples being studied.
combustion processes, such as forest fires, and In general, methods for the analysis of samples with few
industrial combustion processes, such as the burning of matrix components, other than drinking water, may be
fossil fuels. The PAHs then are carried into rivers, lakes, analyzed by UV absorbance at 254 nm. More complex
and other water sources. 1 Therefore waste water and samples such as soil, may require fluorescence
other water sources are commonly tested for their detection for added selectivity. Drinking water samples
presence. EPA method 610 for the determination of PAHs require the added sensitivity of fluorescence detection.
in municipal discharges is a commonly used method
requiring the determination of the 16 priority pollutant

PAHs that may be present in water. The European Experimental
Community (EC) member states require the This application note shows the analysis of PAH samples
determination of six of the PAHs in drinking water. Some with two different detector options, UV and fluorescence.
countries and states have additional recommendations The Varian Star 9050 UVNis absorbance detector is used
and these may include the 16 PAHs in the EPA method at 254 nm and with wavelength programming to enhance
and some additional PAHs. The list of frequently sensitivity and selectivity. The second detector used is
determined PAHs in Table 1 includes the 16 from EPA the Varian 9070 dual monochromator fluorescence
610 and perylene. detector. An excitation and emission wavelength
program is used with this detector to achieve the best
Table 1. Commonly Determined PAHs sensitivity. The first column is a Vydac 201TP54, 250 mm
Acenaphthene Dibenzo(a,h)anthracene x 4.6 mm, 5 !J1Tl particles. The separation of all 16 PAHs
Acenaphthylene Auoranthene* requires a gradient program. The conditions are:
Anthracene Auorene
Benzo(a)anthracene lndeno(1,2,3-cd)pyrene* Time (min) Conditions Row
Benzo(a)pyrene* Naphthalene
Perylene 0 50% CHsCN, 50% H20 1.5mUmin
Benzo(b )fluoranthene* 1.5mUmin
Benzo(g,h,i)perylene* Phenanthrene 7.0 50% CHaCN, 50% H20
Pyrene 20.0 80% CHsCN, 20% H20 1.5mUmin
Benzo(k)fluoranthene* 1.5mUmin
Chrysene 25.0 80% CHsCN, 20% H20
30.0 95% CHsCN, 5% H20 1.5mUmin
*PAHs regulated by the EC member states for drinking water.
The second column is a Shandon Hypersil Green PAH
A common method for PAHs uses HPLC with UV column (PIN 01-900017-00), 100 mm x 4.6 mm, 5 J.lrTl
detection at 254 nm because these canpounds can be particles. This column is designed for the separation of
determined with good sensitivity under these conditions. these PAHs and others. This separation is also a gradient
This is easily done with a UVMs detector such as the program. The conditions are:
Varian Star 9050. A second very popular option is
Time (min) Conditions Row
varian@
fluorescence detection for some of the PAHs, as many of
these compounds have a high natural fluorescence. 0 50% CH3CN, 50% H20 2.0mUmin
5.0 50% CHaCN, 50% H20 2.0mUmin
25.0 100%CHsCN 2.0mUmin
All samples are 20 JJ.L injections.
LC7:1/4
The NIST standard 1647 PAH mix is used to determine Results
the optimum conditions and for spiking into water
samples. The EC guidelines state requires that the total A sample chromatogram of the separation of 16 PAHs
using the 9050 absorbance detector at 254 nm is shown

concentration of the 6 PAHs in drinking water not exceed
0.2 J,Lg/L and benzo(a)pyrene may not exceed 0.01 J.Lg/L. in Figure 1. There is no wavelength programming for this
This requires approximate maximum concentrations of run. This is the simplest way to operate the detector and
0.03 J.Lg/L for the remaining five PAHs. achieve satisfactory detection limits (Table 2). These
detection limits are based on extraction from a 1L water
sample with concentration of the extract to 1 ml. The
compounds are listed in elution order.
10 Amount on
Compound wr Column
1. Naphthalene 5.96 450ng
2. Acenaphthylene 7.16 382ng
5 11 3. Acenaphthene 9.37 420ng
4. Fluorene 10.06 98ng
9 13 5. Phenanthrene 11.95 101 ng
1
6. Anthracene 13.41 65ng
7. Auoranthene 1525 202ng
1a 12 16 8. Pyrene 16.18 197ng
6 9. Benzo(a)anthracene 19.n 101 ng
4 10. Chrysene 20.24 93ng
11. Benzo(b)fluoranthene 23.00 102 ng
2 12. Benzo(k)fluoranthene 24.10 101 ng
13. Benzo(a)pyrene 25.18 106ng
1.5 14. Dibenzo(a,h)anthracene 29.09 74ng
I. 1 1
Ai -
15.
16.
Benzo(g,h,i)perylene
lndeno(1 ,2,3-c,d)pyrene
28.24
30.03
82ng
82ng

Rgure 1. UV 254 nm Chromatogram, Vydac Column
Table 2. UV and Fluorescence Detection Umits
UV254nm Ruorescence EPA610 EPA550.1

Compound (J1g/L) (J1g/L) (Jlgtl) (J1g/L)
1. Naphthalene 0.27 ** 1.8 2.20
2. Acenaphthylene
3. Acenaphthalene
4. Auorene
0.27
0.31
0.020
-
**
**
2.3
1.8
0.21
1.41
2.04
0.126
5. Phenanthrene 0.0062 0.003 0.64 0.150
6. Anthracene 0.0083 0.0012 0.66 0.140
7. Ruoranthene* 0.010 0.010 0.21 0.009
8. Pyrene 0.010 0.0083 0.27 0.126
9. Benzo(a)anthracene 0.0062 0.0011 0.013 0.004
10. Chrysene 0.0042 0.0021 0.15 0.160
11. Benzo(b)fluoranthene* 0.0045 0.00075 0.018 0.006
12. Benzo(k)fluoranthene* 0.0056 0.00012 0.017 0.003
13. Benzo(a)pyrene* 0.0050 0.00079 0.023 0.016
14. Dibenzo(a,h)anthracene 0.016 0.00094 0.030 0.035
15. Benzo(g,h,i)perylene* 0.012 0.0016 0.076 0.020
16. lndeno( 1,2,3-cd)pyrene* 0.0093 0.0018 0.043 0.036
*Indicates the EC 6, with detection limits estimated based on total of 0.2 J.L9}L

-Not normally determined by fluorescence
LC7:2/4
Figure 2 shows the PAHs extracted from a spiked water Fluorescence detection was also optimized with
sample. In this case wavelength programming of the wavelength programming of both the excitation and
9050 was used to optimize sensitivity and selectivity. By emission wavelengths. The chromatogram in Figure 3
wavelength programming it is possible to reduce the shows the PAHs detected with the Varian 9070
number of matrix components that are visible in the fluorescence detector following the wavelength program
chromatogram. The wavelength program used is listed in in Table 3. Acenaphthylene has the weakest fluorescence
Table 3. Sensitivity is enhanced by wavelength and must be determined by UV absorbance.
programming at appropriate absorbance maximas. This Naphthalene, acenaphthene, and fluorene have a
can also enhance selectivity where these wavelengths sufficiently strong UV absorbance to use this method of
discriminate against matrix components. detection. Therefore, some PAH methods recommend
placing the UV and the fluorescence detectors in series.
3
Compound R/T
1. Naphthalene 6.13
2. Acenaphthylene 7.36
2 3. Acenaphthene 9.63
4. Auorene 10.32
5. Phenanthrene 12.25
6. Anthracene 13.70
6 7. Auoranthene 15.49
8 8. Pyrene 16.40
9. Benzo(a)anthracene 19.91
10. Chrysene 20.37
7 11. Benzo(b)fluoranthene 23.05
5 12. Benzo(k)fluoranthene 24.08
13. Benzo(a)pyrene 25.08
14. Dibenzo(a,h)anthracene 27.98
15. Benzo(g,h,i)perylene 28.89
16. lndeno(1,2,3-c,d)pyrene 29.85
Figure 2. Water Sample Spiked with Low Level Standard, Vydac Column
Table 3. Wavelength Programs for UV Absorbance and Ruorescence Detection
Sensitivity
uv Enhancement Auorescence
Compound Wavelength Factor Excitation (nm) Emission (nm)
1. Naphthalene 227 25.0 224 330
2. Acenaphthylene 227 8.5 not detected
3. Acenaphthalene 227 35.0 234 320
4. Auorene 227 1.0 224 320
5. Phenanthrene 250 1.2 252 370
6. Anthracene 250 1.7 252 402
7. Auoranthene 235 1.6 252 402
8. Pyrene 235 1.0 238 398
9. Benzo(a)anthracene 280 1.0 238 398
10. Chrysene 280 1.8 238 398
11. Benzo(b)fluoranthene 297 1.0 268 398
12. Benzo(k)fluoranthene 297 1.2 268 398
13. Benzo(a)pyrene 297 1.1 268 398
14. Dibenzo(a,h)anthracene 297 12.0 234 420
15. Benzo(g,h,i)perylene 297 2.5 234 420
16. lndeno(1,2,3-cd)pyrene 297 1.0 300 466
Excitation and Emission Detector Bandwidth = 8 nm for 9070 fluorescence detector
LC7:314
This allows even greater sensitivity and selectivity than such as USEPA 61 0. But more sensitivity and selectivity
with the UV detector alone. The detection limits achieved can be achieved with fluorescence detectors when using
with the 9070 are listed in Table 2. The chromatogram in wavelength programming. A fluorescence detector in
Figure 4 is the same spiked water sample as the one series with a UV detector will provide the best sensitivity
analyzed with the UV detector. This chromatogram shows and selectivity. Very few compounds naturally fluoresce
all of the fluorescent PAHs and shows fewer matrix so it is easy to discriminate against matrix components
peaks. This simplification of the chromatogram is an with a fluorescence detector. Wavelength programming
excellent reason for adding the fluorescence detector in of the fluorescence detector can be done with a
series with the UV detector, even when the UV detector monochromator based fluorescence detector to result in
has adequate sensitivity for the PAHs. the lowest detection limits possible. UV detection at
254 nm is both simple and sensitive, with enhanced
selectivity when the UV detector is also wavelength
Conclusions programmed.
Both UV and fluorescence detectors can be used for the
determination of PAHs. UV detectors are often used at
254 nm with no wavelength programming. This provides Reference
adequate sensitivity for the PAHs as defined by methods 1. Furata, N.; Otsuki, A., Anal. Chern. 1983, 55,2407-2413.
Amount on
Compound Rrr Column
4 6 12 1. Naphthalene 3.97 16.0 ng
3 2. Acenaphthylene N.D. 32.0ng
3. Acenaphthene 6.87 16.0 ng
11 4. Ruorene 7.34 3.2 ng
5. Phenanthrene 8.53 1.6ng
5 6. Anthracene 9.70 1.6ng
7. Ruoranthene 10.85 3.2 ng
8. Pyrene 11.63 1.6ng
9. Benzo(a)anthracene 14.76 1.6ng
10. Chrysene 15.42 1.6 ng
8 11. Benzo(b)fluoranthene 17.98 3.2 ng

9 12. Benzo(k)fluoranthene 19.31 1.6ng
13. Benzo(a)pyrene 20.19 1.6ng
10 13 14. Dibenzo(a.h)anlhracene 22.17 3.2 ng
15. Benzo(g,h,i)perylene 22.83 3.2ng
16. lndeno(1,2,~.d)pyrene 23.64 1.6 ng
N.D.::Not Detected
Figure 3. Chromatogram of PAHs with Fluorescence Detection, Shandon Hypersil Green PAH Column
12
3
Compound Rrr
1. Naphthalene 6.23
3. Acenaphthene 9.78
4. Ruorene 10.53
5. Phenanthrene 12.39
6. Anthracene 13.83
7. Ruoranthene 15.63
8. Pyrene 16.55
9 9. Benzo(a)anthracene 20.03
10. Chrysene 20.50
10 11. Benzo(b)fluoranthene 23.17
12. Benzo(k)fluoranthene 24.20
13. Benzo(a)pyrene 25.22
14. Dibenzo(a.h)anthracene 29.04
15. Benzo(g,h,Qperylene 28.13
16. lndeno( 1,2,3-c,d)pyrene 29.99
Figure 4. Fluorescence Chromatogram of Water Spiked Sample, Vydac Column
varian These data represent typical resuns.

LC7l414 1291

Identification of Polynuclear
e Aromatic Hydrocarbons in a
Complex Matrix with Diode
LC
Array Detection
Number 8
Maureen Joseph
Key Words: Polynuclear Aromatic Hydrocarbons, PAHs {PNAs}, diode array detectors, compound identity, EPA 610,
waste water, PolyView, Polychrom
Introduction Table 1. Commonly Determined PAHs

The analysis of polynuclear aromatic hydrocarbons Acenaphthene Dibenzo{a, h)anthracene
{PAHs} is a typical environmental requirement. The HPLC Acenaphthylene Auoranthene*
methods used to analyze these compounds have several Anthracene Fluorene
Benzo(a)anthracene lndeno{ 1,2,3-cd}pyrene*
things in common. First, they require UV absorbance Benzo(a)pyrene* Naphthalene
detection at 254 nm with a fluorescence detector added Benzo{b)fluoranthene* Perylene
to achieve greater sensitivity. Second, an additional Benzo{g,h,i)perylene* Phenanthrene
method of analysis, such as GC/MS, is usually Benzo{k)fluoranthene* Pyrene
recommended when the compounds cannot easily be Chrysene
identified by the HPLC methods. One of the limitations to
single wavelength UV absorbance and fluorescence *PAHs regulated by the EC states for drinking water.
detectors is the lack of qualitative information, other than
retention time. A diode array detector can simultaneously
provide qualitative and quantitative information, such that
Experimental
a second method of analysis may not be required. Two specialty PAH columns were compared to a Varian
Spectral libraries are quickly built from standards, MicroPak SP-C18-5 column. The physical characteristics
reflecting actual run conditions and accurately confirming of the three columns are listed in Table 2. Standard
compound identity. samples were analyzed on each column using a
Polychrom diode array detector at 254 nm. An apex
To make the rapid, accurate analysis of PAHs possible, spectrum from each PAH was used to build the spectral
the selectivity of some HPLC columns has been optimized library. A different library was built for each column,
for this analysis. These columns usually guarantee the allowing retention time comparison in the library search.
separation of the PAHs monitored in drinking water in the Wavelength conditions for peak detection {PolyView peak
European Community and the U.S. {Table 1). The rapid sensing) were optimized for accurate library searches.
separation of all 16 compounds requires gradient HPLC
conditions, which are provided by the column Table 2. Column Descriptions
manufacturer. The six PAHs listed in the EC guidelines Shandon Hypersil Green PAH: 100 mm x 4.6 mm
can be separated using an isocratic HPLC method. (PIN 01-900017-00) 5 JJ.fn, 120A
Combining these specialty PAH columns with the diode Carbon loading (13.0-14.0%}
array detector provides the best equipment for a reliable Surface Area {175 m2/g}
separation and confirm compound identity in one quick Spherical
analysis.
Vydac 201TP5415: 150 mm x 4.6 mm
5 JJ.fn, 300A
Carbon loading (8-9%)
Surface area (90 m2/g}
Spheroidal
Varian MicroPak SP-C18-5: 150 mm x 4.0 mm
varian@
(PIN 03-912042-42) 4.5 J.Lm, aoA
Carbon loading (12.5-13.5%)
Surface area 200 m2/g
Spherical
LC8:114
Once the best standard conditions were obtained, a coal large peaks in the front and much smaller ones later in the
tar extract containing 11 of the 16 PAHs was analyzed. chromatogram. This makes SIN peak sense programming
This sample tested the capability of the diode array

a valuable aid in integrating all of the small peaks. This is
detector to identify PAHs in a complex matrix. combined in the peak sense program in Figure 3. The
library search was applied to a time window in which PAHs
are expected to elute (Data File Time Range, Figure 4).
Results Relative retention time ranges were also narrowed to allow
The diode array detector can only be an acceptable specific identification of the PAHs. Only the wavelengths
substitute for the UV detector at 254 nm if the detection at which the PAHs absorb were included in the search
limits required by the method are still obtainable. Table 3 wavelength range. All of this information is determined
shows the detection limits obtained with UV, fluorescence, from the standard runs from which the library was built.
and the diode array detector (DAD) in comparison to the
requirements of the EPA waste water method 610. The
DAD compares well to the UV detector and meets the
required detection limits for almost every compound. Shandon Hypersil Green PAH Column
Therefore, it was worth pursuing the use of the diode
array detector for compound identification.
Table 3. Detection Limits Comparison

uv DAD Fluo1 EPA610
Compound (JJ.Q/L) (JJ.g/L) (JJ.QIL) (JJ.g/L)
1. Naphthalene 0.27 0.80 1.8
2. Acenaphthylene 0.27 0.81 2.3
3. Acenaphthalene 0.31 0.76 1.8
4. Fluorene 0.020 0.040 0.21
5. Phenanthrene 0.0062 0.008 0.003 0.64
6. Anthracene 0.0083 0.027 0.0012 0.66
7. Fluoranthene 0.010 0.028 0.01 0.21
8. Pyrena 0.010 0.040 0.0083 0.27
0.0062 O.Q15 0.0011 0.013
;15 ,zo
9. Benzo(a)anthracene
10. Chrysene 0.0042 0.014 0.0021 0.15

11. Benzo(b)fluoranthene 0.0045 0.017 0.00075 O.Q18
12. Benzo(k)fluoranthene 0.0056 O.Q11 0.00012 0.017 !111M.
13. Benzo(a)pyrene 0.0050 0.020 0.00079 0.023 ! Vydac 201lP5415 Column [1
14. Dibenzo(a,h)anthracene
15. Benzo(g,h,i)perylene
0.016
0.012
0.040
0.040
0.00094
0.0016
0.030
0.076
j2oi
16. lndeno(1,2,3-cd)pyrene 0.0093 0.020 0.0018 0.043 ! 6 10
lm I j
~
Not determined by fluorescence, SIN=3. fi
!
..Acenaphthylene is present, but does not fluoresce.
i 1il l
I I
1 See LC Application Note #7 1
1.
- 2
i l I 1 sl~ l 131
II. n ~~ . ~~I~ lilh2 ~
Figure 1 shows the standard resolved on the three different
columns. In each chromatogram the elution order is from
Table 3. While the MicroPak SP-C18-5 column was able to
lSi
!
i
I
,
1
1
i
nl
_ij
1
111
!i il
/lu lul Jl
II r I
il I!! I
11
P.l
1 i']
11
;
11
8
l
1~1.1 !ll'f: 14 U
I
:1
1
1 :,
'tf i"'l
: ,n 1~ df
I
15 16
u :1
j -+-"-----'J'_]~.__;!J't.,J' LU.,~ :~ .. uw~..JV\----1

resolve the small impurity eluting after Pyrene, it could not
resolve several of the pairs of the PAHs, including i: !Z.5 15.0 17.5 1111.11 112.5
acenaphthalene and fluorene and benzo(a)anthracene

and chrysene. These pairs could be well resolved on
either of the Specialty columns. With each specialty
l
!
IIIAlJ Yarian MicroPak SP-C1H Column 9,11 n
column the separation was obtained using the
recommended conditions. This makes it easy for the im I
chromatographer to start operating successfully with no i 6 l
methods development.
!-m
;
iIa s1
1
iI
1 1
The coal tar extract chromatogram is shown in Figure 2. : I '4 I I J12
Ill ; ~
i
There are many small matrix components which are not !1M i ,i,.l i
larger than the PAH components. Therefore, the peak :
1
II I l 7 il ~ !13
detection (PolyView peak sensing) is optimized when
wavelength ranges characteristic of the strongest UV
absorbance bands of the PAHs are used, as in Figure 3.
1.
!
-51 p Il!
:1
1\
H
'I' .,! ::
\,p! ~
II !! I~ hll1
~ 8 ::
p 1:
51
" 6
1i ),
c
PolyView's flexibility to program either a range of

l; i!;l I! ld\''u : JU. !'------;
1\i] .jl,rr:
: -~-------~'-'-"ij
1, , .. W;.....;v
wavelengths or a single wavelength allows more accurate !
i 15.0 17.5 118.8 112.5
I
peak detection. The chromatogram also contains very :
Figure 1. Comparison Separation of PAH Standards

on3Columns
LC8:2/4
The results of PolyView's automated library search are Conclusions
shown in Figure 4. The accuracy of the match is
demonstrated by the very high similarity values (0.993 or This combination allows the requirements of many
greater) and the very low dissimilarity values (0.12 or methods for PAH analysis to be met, including USEPA
below). An example of the spectral match from 610, with a minimum of effort. The diode array detector
fluoranthene to the library is shown in Rgure 5 (next provides confirmation of peak identity for the PAHs
page). In addition to the PAHs accurately and correctly separated in a complex matrix. When combined with a
identified, none of the other peaks were incorrectly specialty PAH column the separation is easy to achieve.
identified as these PAHs. One advantage of using the
diode array detector was the accurate identification of
both benzo(b)fluoranthene and benzo(k)fluoranthene.
These isomers are not distinguished by a benchtop mass
spectrometer.
II Pesksense Time Program 1:1

Threshold OptionaNalue
SIN Threshold 110 HI
0.00 SIN Threshold 15

4.63 Peaksense 244-287 . . 4 sec
8.66 Peaksense 234-306 .,. 4 sec
8 66 SIN Threshold 1 0
Figure 2. Chromatogram of Coal Tar Extract

(NIST Reference Materia/1547)
Scan Rate: 10.851 Hz Bunch: 4 Data Rate: 2.713 Hz

Figure 3. Peak Detection Program
Search Parameters: PuP Interval: 2.00 nm, Wavelength Range: 220-339

Data File Time Range: 3.800 - 10.600 min
Ubrary Relative Time Range: 0.950 - 1.050
Minimum Peak Height: 10.000
Target Apex
{min) Best Possible Match Sim Dissim tR{min) Ub Entry#
4.123 Naphthalene 0.99995 0.00995 4.190 B 16
6.949 Phenanthrene 0.99990 0.01396 6.930 B 4
7.452 Anthracene 0.99986 0.01656 7.416 B 5
8.067 Auoranthene 0.99986 0.01702 8.005 B 6
8.429 Pyrene 0.99993 0.01218 8.356 B 7
9.664 Benzo(a)anthracene 0.99999 0.00375 9.554 B 8
9.898 Chrysene 0.99846 0.05545 9.n5 B 9
Search Parameters: PuP Interval: 1 0.00 nm, Wavelength Range: 210-335 nm

Data File Time Range: 10.800 - 15.000 min
I.Jbrary Relative Time Range: 0.000 - 2.000
Minimum Peak Height: O.OOOmAU
10.905 Benzo(b)fluoranthene 0.99327 0.11580 10.764 B 10

11.305 Benzo(k)fluoranthene 0.99726 0.07400 11.151 B 11
11.661 Benzo(a)pyrene 0.99925 0.03872 11.514 B 12

12.742 .Benzo(g,h,i)perylene 0.99503 0.09958 12.552 B 14
13.043 lndeno(1 ,2,:H:,d)pyrene 0.99705 0.07670 12.810 B 15
Figure 4. Coal Tar Extract- Ubrary Search Report
LC8:S(4
NORII
Coal Tar Extract Fluoranthene Spectrum

Fluoranthene Ubrary Spectrum
Purity Parameters
249.48 nm
249.74 nm

225 250 275 325 350
W.WienQIIIInml
Rgure 5. Ruoranthene Spectral OVerlay
mAU IIIAU
40
30
20

mAU
400
300


LC8l414 1291
Identification and Quantitation
of Herbicides and Pesticides
LC
in Water by LC and Diode
Number 9
Array Detector
Jean-Michel Huen
Varian S.A., Orsay, France
Key Words: Pesticides, Herbicides, Triazines, Phenylurea Herbicides, Diode Array Detector, Library Search,
Purity Parameters, HPLC, Empore ~ Solid Phase Extraction, Environmental
Introduction
In 1992 a new regulation will be effective in France and The methodology consists of:
some other European countries for the determination of
herbicides in water. The guidelines in DIN (Deutsche Sample preparation by Solid Phase Extraction
Industria Norm) 38-407, Teil12, cover 17 common using Empore Disk technology
herbicides. The following method was developed not only
for the separation and detection of those 17 herbicides Separation by HPLC
but also 19 additional herbicides and pesticides of
possible interest. All 36 compounds are listed on the Peak identification by Spectral Ubrary Search
chromatogram in Figure 1. using a Diode Array Detector
0
-a!<:! 34
&DID
D II
a;.,. 1 Atrazine, deisopropyl 19 Metobromuron
"'u 2 Metamitron 20 Metazachlor
Bi= 3 Dichlorprop 21 Sebutylazine
e~
~:E 4 Atrazine, 2-hydroxy 22 Propazine
5 Atrazine, clesethyl 23 Terbutylazine
6 Crimic:ine 24 Linuron
7 Me1Dxuron 25 Chlorbromuron
8 Hexazinone 26 Anilazine
9 Bromacil 27 Chlorpropham
28
10 Simazine 28 Metolachlor
32 11 Cyanazine 29 Barban
8 33 12 Atraton 30 Dipropetryne
14 13 Melhabenzthiazuron 31 Neburon
14 Chlor1Diuron 32 Diazinon
17 30 15 Atrazine 33 Tetracflfon
6
4 27 35 16 Monormuron 34 Bioallethrin
16
13
22 9 17 lsoproturon 35 Trifluralin
10 8t9 31
1112 5 18 Diuron 36 Fenpropathrin
36
I I
85 95
lllnutes
Figure 1. Separation of a mixture of herbicide
varian
and pesticide standards in water (5 mg/L). Detection: 239 nm
Procedure Detection:
Varian Polychrom 9065 Diode Array Detector at 239 nm

1. Sample Preparation or reprocess at three different selective wavelengths for
maximum response:
1. Condition C1s Empore disk with dichloromethane/ethyl
acetate (50:50), followed by methanol and 220 nm (Compounds 5,1 0,11, 15,20,21 ,23,28)
organic-free water. 244 nm (Compounds 7,8, 14, 16, 17, 18,19,24)
230 nm (Compound 13)
2. Apply 1L of water sample.
3. Elute with ethylacetate, followed by dichloromethane
and finally ethylacetate/dichloromethane (50:50). IH. Peak ldentNicatlon
4. Combine eluates and evaporate to dryness. Peak identities were confirmed with an automated
5. Reconstitute with 0.5 mL methanol. PolyView library search routine. The search parameters
include retention time windows and Purity Parameter
(PuP) range with final ranking based upon
II.' HPLC Conditions: similarity"/"Dissimilarity" fit.
Column: Varian TSK ODS 80TM, 5 J.l!Tl, 25 em x 4.6 mm

Column temperature: 4QO C ResultS
Mobile Phase: Rgure 1 shows the chromatogram of the separation of 36

herbicides and pesticides, each of which is identified by
A: Ammonium acetate/2% acetonitrile/2% methanol the Ubrary Search routine. Rgure 2 shows the identifica-
B: Acetonitrile/2% ammonium acetatef20k methanol tion of Atrazine by matching the PuP, similarity" and
oissimilarity" values with those of the standard. While the
'3radient from 100% A to 80% B run time is 105 minutes for all36 compounds, it can be
shortened to 80 minutes or less if only the 17 DIN
compounds are of interest. Recoveries of the DIN-required
compounds are shown in Table 1.
at~
010
..- I
~
Peak Apex,
Alrazine
Note:
Similarity
IR: 48.192 min, PuP: 222.n4 rm
Peak Height 5.433 mAU at 224 run
PosSible Malch: (library: A, 15)
Dissimilarity PuP(rm) 1R(min)

Table 1. % Recoveries
(from Empore disk)
for the 17 DIN Compounds
0.5 JJQIL each (N:S)

a;~
'-... 0.99987 0.01639 222.675 47.946
&l!= Desethylatrazine 55
o-
e.s
~:E
:
.. Metoxuron
Hexazinone
Simazine
72
68
73
c
e....
....~
0
lit ..a ...
....
"' ...=
Cyanazine
Methabenzthiazuron
78
81
.... o ... 0
. Chlortoluron 76
......
cc..-
c
I I
......
.."' z Atrazine
Monolinuron
79
67
.g~
"'E
21=
!-o
-c
<W
................,

...
~
....
: I. Jsoproturon
Diuron
Metobromuron
75
73
78
Metazachlor 93
.Sc
~E Sebutylazine 75
uO Terbutylazine 78
N8 I I I I CD I I I I I
Cl!ari
o..- 15 25 35 45 .5 55 65 75 85 95 Unuron 78
a 1 N Metolachlor 83
""0
CD~
t'!! Minutes
!.e
~~=
<
.!!

c.> en Figure 2. Chromatogram of Local Water
(1 L Extracted with Empore Disk). Detection: 239 nm.
varian8 These data represent typical results.

L.C-9:0392
Application of Multicomponent
e Analysis to HPLC Diode Array
Detection for Quantitation of Varian Application Note
LC
Completely Unresolved Number 10
Components
Maureen Joseph
Keywords: Multicomponent Analysis, Quantitation, Diode Array Detection, PolyViewTM,

Chromatographic Resolution, Sunscreens
Introduction Table 1 Coelution Conditions for Sunscreen Agents

Baseline resolution (2.0 +) for all peaks in a
chromatogram cannot always be achieved or is not Mobile Phase: 100% Methanol
always desired. Accurate quantitation when the Flow Rate: 1 mUmin
compounds are not completely resolved is difficult with
conventional data processing. Multicomponent Analysis Column: Shandon Hypersil Green PAH,
(MCA) allows accurate quantitation of diode array data 10 em x 4.6 mm, 5 fJil1
when the compounds of interest are not resolved or only oAD@306nm
Detection:
partially resolved. MCA is a spectral analysis process
that provides accurate identification and quantitation of
an unknown mixture based upon a known set of spectra. Results
This means that quantitative information can be extracted
from diode array data along with qualitative results. The chromatogram of these four compounds is shown in
Rgure 1. The integration area was defined from 1.3
A complete quantitative analysis is done by first minutes to 2.2 minutes to include both peaks. For three of
constructing a library of known compounds with the four sunscreens there is no resolution, as is shown in
quantitative information. This is obtained by integrating a the plot analysis of the integration region (Table 2).
peak across all wavelengths. The result is an area
spectrum containing quantitative information defined by Absorbance at 30& nm - SUSI4006.RUN
the flow rate, amount, and detector conditions which is mAU
used for later comparison with unknown peaks. Similarity
and dissimilarity coefficients are included in the 200
automations report to indicate the quality of the match. MA.OMC.OS
.,/
150
Experimental
Four sunscreen agents were analyzed. Under certain 100

conditions (Table 1) three of these sunscreen agents
completely coeluted. Two of these, cetyl methoxy-
cinnamate (OMC) and cetyl salicylate (OS). are 50
oxv~
popular UV absorbing agents in sunscreen preparations.
With four sunscreen agents present, oxybenzone (OXY),
"'
01~----------------~~~~~~--~----~~
menthyl-o-aminobenzoate (MA), OMC, and OS,
oxybenzone will elute first and the other three will coelute o.s 1.0 1.5
minldi:S
under the conditions used. MCA was used to determine
varian
various levels of these compounds . Figure 1 Chromatogram of Sunscreen Components
with Coelution
The plot analysis (Rgure 2) clearly shows that three
components are present in the second peak. These are
identified and quantitated as OMC, OS, and MA by the

spectral analysis (Rgure 3 and Table 3). The results even
account for the tailing of the oxybenzone into the second
peak in the chromatogram. The accuracy and precision
of the results is listed in Table 4.
Table2 Plot Analysis at 306 nm

- Targetand
Ubrary tR Height Width Reconstructed
Index (min) mAU (sec) Resolution Chromatogram 200
#2 1.352 5.39 4.9

150
#3 1.659 173.67 4.6 2.28
#4 1.659 49.44 4.6 0.00 100
#1 1.671 9.59 6.9 0.08
so
Table3 Spectrum Analysis over 259-367 nm
Ubrary Index Name Amount Injected
1.50 2.00
minutas
#4 OS 0.415 J.Lg
MA
Figure 2 Plot Analysis at 306 nm
#1 0.301 J.Lg
#3 OMC 0.299 J.Lg
#2 OX'f 0.033J.Lg

Table 4 Accuracy and Precision of UCA
Quantitation from Coeluting Sunscreens* 259 367 AU.s
-Target and
Compound Accuracy Precision Reconstructed
Speclrum 1.00
OX'f 98.2"k 0.20%
MA 102% 0.85% 0.75
OMC 101% 0.21%

o.so
OS 97.4% 0.53%
0.2S
*Accuracy is determined as % Recovery for n=9
Conclusions
Multi component Analysis as applied to HPLC diode Figure 3 Spectrum Analysis over 259-367 nm
array detection can accurately quantitate compounds
with poor or zero resolution. This can be an advantage in
situations where no quantitative results have ever been
achieved due to the lack of an adequate separation.
When the quantitative results are calculated the
compounds are identified and all results are confirmed.
These results are generated automatically by the system
at the end of a run. Since MCA has no resolution
limitations, it can also be used to reduce the amount of
time spent developing methods by reducing the need for
a complete separation. When applied to routine analyses,

more samples can be analyzed with shorter run times.

LC10:0492
e Application of Multicomponent
Analysis to HPLC Diode Array Varian Application Note
LC
Detection for the Quantitation Number 11
of Partially Resolved Peaks
Maureen Joseph
Keywords: Multicomponent Analysis, Quantitation, Diode Array Detection, Chromatographic Resolution,

Paraquat, Diquat, Po/yView"": U.S. EPA Method 549
Introduction Experimental
Using a diode array detector allows the qualitative The determination of two herbicides, paraquat and
identification of compounds even when they are not diquat, is usually done by ion-pair HPLC in a single
completely resolved, but peak quantitation under these analysis in which they are only partially resolved
conditions is more difficult. Using multicomponent (Figure 1). A typical quantitation procedure requires that
analysis (MCA), a technique that provides accurate data be extracted and reprocessed at two separate
quantitation and identification of unknown components wavelengths (Table 1). Jhere is a large potential for peak
based on known reference spectra, quantitation of diode area assignment problems with these two compounds
array data is easily achieved under partial or zero

resolution conditions.
Multicomponent Analysis evaluates a peak from start to

end. This is necessary for accurate quantitation but has
the added advantage of more thoroughly testing a peak
for homogeneity than many other purity assessment
based on both spectral and experimental considerations.
Though the spectra for paraquat and diquat are very

different (Figure 2), there is still some absorbance from
each of the compounds at the recommended
wavelengths for quantitation. When the two compounds
are both present in a sample at very different levels,
techniques, which are applied only between the upslope traditional peak integration and quantitation can be
and downslope inflection points (peSk heart region). The difficult. Non-MCA peak integration can result in only one
individual peak profiles are determined by MCA over the detected peak at each quantitation wavelength with both
complete wavelength range. Small peaks fused to a Paraquat and Diquat contributing to the peak area. This
major peak are easily quantitated even when they are not will result in significant quantitation errors unless MCA is
visually detected, or integrated separately. This used. This makes quantitation very difficult.
quantitation is done without the need to select different
optimum wavelengths to distinguish the compounds. MCA is the best method to accurately determine the
amount of each compound present in the peak under
these types of conditions.
varian@ LC11:1/4
Table 1 HPLC Conditions for Results
Paraquat/Diquat Analysis
Column Conditions: A Plot Analysis of this sample separation at very different
levels is shown in Rgure 3. Paraquat is at its optimum
Column: Hamilton PRP-1 5 Jl, 4.1 mm x 150 mm wavelength and present at 1Ox the concentration level of
Column Temperature: 35.0C Diquat. This figure is part of the standard MCA report
Flow Rate: 2.0 mUmin which includes a plot analysis (top) and a corresponding
Mobile Phase: !on-Pair Mobile Phase consisting of error analysis (bottom). Rgure 4 shows an MCA Plot
a-phosphoric acid, diethylamine, and Analysis of the same sample at the optimum wavelength
1-hexane sulfonic acid dissolved in water for Diquat. At these wavelengths the smaller component
Separation: !socratic causes quantitation errors in the major component. Since
there is nothing that exceeds the noise threshold (Figure
Detector Conditions:
3), the peak contains only the Paraquat and Diquat.
Wavelength Range: 210 - 367 nm
Sample Rate: 1.4 Hz Plot Analysis at 259 nm
(Data Rate = 11 Hz, Bunch = 8)
Run Time: 5.0 min Library tR Height Width
Index (min) mAU (sec) Resolution
Quantitation Wavelengths:
#2 2.015 1.84 8.8
Paraqat: 259 nm Diquat: 316 nm #1 2.286 118.40 12.3 0.90
mAU
100
75
~ :11259 .... -PGIII.RIJN
50
30
25
25
0

za 2.5 3.0 3.5
uAJJ
15 Noisi Threshold
50
1D
30
v 10
s
) Figure 3 Plot Analysis of Paraquat and Diquat
z 3 @ 259 nm Paraquat Concentration 10X Diquat
With No Significant Error
Figure 1 Separation of Diquat and Paraquat Plot Analysis at 316 nm
Library tR Height Width
Index (min) mAU (sec) Resolution
- #2
#1
2.015
2.286
13.26
0.53
8.8
12.3 0.90
a&tr
10.0
7.5
5.0
2.5
LC11:Z'4
Figure 2 Diquat and Paraquat Spectra ainut.es
3.0
Figure 4 Plot Analysis of Paraquat and Diquat

@ 316 nm Paraquat Concentration 10X Diquat
3.5
0.0

A significant error, such as an unexpected impurity, would Spectrum Analysis over 215-367 nm, except 335-367
result in a peak exceeding the noise threshold in the error
Library
analysis plot (Figure 5). The plot error analysis is not

limited to the single wavelength of the reconstructed Index Name Amount
chromatogram plot. The error analysis is done as a #1 Paraquat 9.95 J.Lg
comparison of the spectrum at each point in the
chromatogram to the reconstructed spectrum from the #2 Diquat 0.945 J.Lg
MCA spectral analysis. This allows all wavelengths of Similarity: 1.00000 Dissimilarity: 0.00150
interest to be evaluated and all impurities to be detected.
367 !U.s
MCA's spectrum analysis (Figure 6) contains quantitative
information and additional error analysis. The Similarity 1.50
and Dissimilarity coefficients would differ significantly 1.25
from 1.0 and 0.0 respectively, if there was a large error in Paraquat 1.00
the results. The results will automatically indicate a bad
match if it applies (Figure 7). In addition, the spectrum 0.75
difference portion of the plot compares the current area 0.50
spectrum (AUs) to the reconstructed spectral sum based
0.25
on the library spectra and presents this magnified
difference (mAUs). The difference spectrum is magnified
and autoscaled to make the small differences between
the target and reconstructed spectrum as visible as
possible. :aAU .s
1
H-~----~---+--~~--~L----#~0
-1
mAU -2
60
Figure 6 Spectrum Analysis of Paraquat and Diquat
50
No Significant Spectral Difference
40
30
20
10 Spectrum Analysis over 220-367 nm, except 335-367
0 Library
Index Name Amount
#2 Diquat 12.32 J.Lg
Similarity: 0.90226 Bad Match
Noise Threshold Dissimilarity: 0.43119 0.00000024 (expected value)
l
Figure 5 Plot Analysis (top) and
Error Analysis (bottom) at 259 nm
W"lth an Unexpected Impurity
Peak>Noise Threshold
During the MCA spectral decomposition, the wavelength

range 335-367 nm is excluded since it contains no
significant absorbance. This increases the accuracy of
the results .
Target Spectn.m =Area Spectn.rn over Integration Region
Component Spectrum= MrA Decoll1)0Sition limited to Diquat only
Figure 7 Spectrum Analysis over 220-367 nm,

except 335-367 nm
LC11:314
The quantitative information is the same at both plot With these herbicides the presence of both in one
wavelengths (259 nm and 316 nm). These MCA results analysis could be easily missed if diode array data were
are compared to quantitative results from single not properly evaluated. Typical diode array tests for purity
wavelength multipoint calibrations, as shown in Table 2. could miss the small peak fused to the main peak, as
they are often applied only to the peak heart region. MCA
For the Paraquat and Diquat example, acceptable can also be used for assessing peak homogeneity by
standard quantitation will be the result when one comparing an average spectrum to the spectrum at each
component is present at a high level and the other at a point in the time range. This generates a Purity Report
low level and quantitation is done at the optimum and the results would be the same as a plot analysis with
wavelength of the most concentrated analyte. the error analysis segment indicating where the impurities
Unacceptable quantitation will be the result when the low are found. Both types of results are produced as
level compound is quantitated in the presence of the high automations reports.
level compound even at its optimum wavelength. MCA
will provide accurate quantitative results in both cases.
Conclusions
Multicomponent Analysis is a very powerful technique
which provides accurate quantitative results from partially
resolved peaks. The MCA process is fast and more
accurate than conventional single channel integration
techniques. In addition the purity assessment feature of
MCA provides greater confirmation of peak identity and
homogeneity than many other diode array purity
evaluation techniques.

For further infonnation, contact your local Varian Sales Office.

LC11:414 0592
Analysis of Basic Drugs in
Postmortem Blood by HPLC Varian Application Note
LC
with Diode Array Detectiont Number 12
Ilona Davies, Varian Chromatography Systems, Walnut Creek, CA 94598, USA

Eva Koves, Toxicology Section, Center of Forensic Sciences, Toronto, M7A 2G8, Canada
Key Words: toxicology, drug identification, HPLC, diode array detector, blood, purity parameter, PuP, forensic
Introduction Extraction Method: 2.0 ml of blood sample was placed

Forensic toxicologists are routinely confronted with the in a 15-ml glass culture tube and extracted following the
difficult problem of detecting and quantitating a wide procedure outlined in Figure 1.
range of drugs in postmortem blood. Gas chromatography/
mass spectrometry (GCIMS) may be used for the Analysis: For quantitative calibration, drugs were added
analysis of many basic drugs, but there are some highly to drug-free blood in the range corresponding to their
polar drugs, such as temazepam, verapamil, or therapeutic concentrations. Standard curves were
trazodone, which are ~ot suited to this technique. For constructed from duplicate samples at each
such compounds, high performance liquid concentration. Spectral libraries were created which
chromatography (HPLC) together with diode array contained compound names, Purity Parameters (PuP),
detection is an excellent alternative. retention times, and spectra of 119 drugs.
Experimental Validation Studies: Studies were performed to determine

Instrumentation: A Varian LC Star System was used: the linearity, recovery, accuracy, precision, and
Model 901 0 ternary gradient pump; Model 9095 reproducibility of this analysis [refer to Reference (1 )].
AutoSampler; Polychrorm> 9065 Diode Array Detector; All validation studies were satisfactory.
Star HPLC Workstation with software for system control
and quantitative reports; and PolyViewTM spectral Results
processing software for automated post run spectral To increase the level of confidence in quantitative
evaluation. Chromatography was carried out isocratically analysis, an HPLC retention index database with a UV
at ambient temperature on one of two reversed-phase spectral database was established on two different
columns using different filtered, degassed mobile phases. columns using different mobile phases. Table 1 lists this
data for 15 drugs. Retention times were reproducible,
Column 1: 5 J.UTI, APEX ODS 25 em x 4.6 mm ID producing a median variation coefficient of 1.37% (0.1 ~k
to 3.67% range) in a total of 126 measurements for 18
Mobile phase (Column 1): 0.8 mUmin flow rate; drugs on column I (14 on column II) and extended over a
acetonitrile/0.025% H3P04 (v/v)ltriethylamine buffer year. The double-back acid extraction technique
(1% v/v in water) at pH 3.4 (25:1 0:5 v/v/v). described in Figure 1 produced virtually interference free
chromatograms for both fractions, while increasing the
Column II: 5 J.UTI, J.L-Phenyl, 15 em x 3.9 mm ID specificity of the analytical method itself. Figure 2 shows
chromatograms obtained from (A) sulfuric acid extracts
Mobile phase (Column II): Acetonitrile/0.025% and (B) hydrochloric acid extracts from two spiked blOod
varian@
H3P04 (v/v) (50:50 v/v) at 0.6 mUmin. samples, using column I.
1Abstracted from Reference (1) with pennission.

Table 1. HPLC retention time and UV SP.,:.ectral purity
parameters for some drugs2
Using this technique, chromatographic peaks can be

~ Pupb Rf identified and their purity can be confirmed with a high
Alprazolam 4.62 224.43 5.08
level of confidence. A sample of postmortem blood was
carbamazepine 425 233.59 2.82
Codeine 3.98 216.07 11.10
extracted using the method described in Figure 1, and the
Diazepam 6.92 229.86 9.71
two fractions were analyzed by HPLC using column I.
Ethylclazepam 825 229.62 10.47 Figure 3 is the chromatogram of the sulfuric acid extract,
Haloperidol 7.8 228.65 c:he and Figure 4 is the chromatogram of the hydrochloric acid
Lorazepam 4.51 225.94 3.07 extract. Note that diazepam and propranolol eluted at
Metcprolol 4.91 220.92 c:tte similar retention times and would have co-eluted had they
No !diazepam 5.43 228.56 8.69 not been separated into two different fractions during the
Pimozide 10.19 21529 c:he extraction procedure. Co-elution of diazepam would have
Prazepam 10.31 229.38 14.14 resulted in an error in quantitation and would have yielded
Propranolol 6.78 221.30 c:tte UV spectrum consisting of both propranolol and diazapam
Temazepam 5.41 230.38 3.99 spectra (Figure 5). The drugs in this blood sample were
'Trazodone 5.79 222.61 c:he identified by automatic spectral library search and
Verapaml 8.93 229.12 c:he multicomponent analysis (MCA). For some samples, the
aColumnl J.1Phenyl column was. also required to avoid potential drug
bBroad range purity parameter (PuP). 210 ID 367 nm on colll'lln I
c Colll'lln II or metabolite interference with the APEX column.
dne =did not elute from this column wiltin 15 rrin
=
At retention time in rriootes
The identity of a chromatographic peak was only
considered definite when both its retention time and its
2.0 IlL Blood, 7.0 mL Toluene and 0.1 ml cone. NH.tOH
spectral purity parameter (P~P) matched that of a
RaT'ATE for 20 minutes reference COfll)OUnd in the library file. Figure 6 shows the
... PuP statistics report for propranolol. The seven spectra
CENTRIRJGE (Discard Blood)
... represent pure standards, spiked blood standards, and
VORTEX Toluene with 2.0 ml 0.2N H2S04 evidentiary blood samples collected over a six month
... period. Concentrations ranged from 0.25-16 J.1glml. The
AQUEOUS Acid ...,_ TOWENE l.aJer PuP mean and standard deviation, as well as the
ADD 1 dr Indicator and male VORTEX with 2.0 mi.. 6N HCI
alcaline with 2.5 NaOH
... ...
CENTRIRJGE (Discard Aqueous)
similarity and dissimilarity values for all seven spectra
were well within the established limits (PuP 0.5 nm;
VORI'EX with 3.0 IlL Toluene
... COOL Add
... Layer in FI88Zel'
similarity 1.ooo-0.998; dissimilarity o.oo-0.06) .
CENTRIRJGE (I)IscaRt Aqueous)
Wllllh Toluene with 0.5 mL water ADD
...
CENTRIRJGE
... (I)IscaRt Aqueous)
1nc1cator
1 dr
...
and ma1Ge
alcaline wltii5N NaOH
The within-day reproducibility and recovery results for
selected drugs are listed in Table 2. With the exception of
...
Evapanda Toluene
REDISSOLVE in 300 Jll mobile phase

...
VORTEX with 3.0 IlL Toluene
CENTRIRJGE (Discard Aqueous)

alprazolam, the recovery percentages varied from
58.7-90.7<'-k and the coefficient of variation was less than
Ylash Toluene with 0.5 mL water
lr1eet 25 Jll on HPLC
...
FRAC110N A
...
CENTfiRJGE (Discard Aqueous)
5.1% for low and 4.4% for high concentrations. A 16-fold
linearity of response was achieved for basic drugs in
REDISSOLVE
... Jll
Evlpalaa Toluene
in 300 mobile phase

blood using th.is methoct The detection limit, determined
at a signal-to-noise of 5, varied from drug to drug. In pure
...
ll1eGt Jll on
25
FRACTION B
HPLC
solutions, it was approximately 2.5 ng/25 J.1L injection for
most of the drugs studied, while in blood, the detection
level was 50 nglml using a final residue volume of
Figure 1. Flow diagram of the method for basic drug
extraction from bloocP ' 300 Jll. For better sensitivity, the final residue may be

dissolved in 100 J.1L of mobUe phase.
2Abstraded from Table 1 in Reference (1) where this data is ~ fOr 121 drugs.
3copyrigtt ASTM. Reprinted with pennission. LC12:2'4
4
AI A2
3 5 9
2
10
B2
7
II
12
2 Bl
0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14
minutes minutes
Figure 2. Chromatograms obtained from extracts of two spiked blood samples: (A1) and (A2), diluted sulfuric acid fractions;
(81) and (82); 6N HCI fractions. Peaks: (1) coc:leine, (2) alprazolam, (3) trazodone, (4) propranolol, (5) haloperidol,
(6) verapamil, (7) pimozide, (8) lorazepam, (9) temazepam, (10) diazepam, (11) ethyldiazepam, and (12) prazeparn3
4
5
2
1
0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14
minutes minutes
Figure 3. Chromatogram obtained from an extract of Ftgure 4. Chromatogram obtained from an extract of a
forensic blood sample; diluted sulfuric acid fraction: forensic case blood sample (the same blood as in F~gure 3);
(1) carbamazepine, (2) metoprolol, (3) nordiazepam, 6N HCI acid fraction: (1) carbamazepine, (3) nordiazepam,
and (4) propranoloP and (5) diazepam3
3Copyright ASTM. Reprinted with pennission.

LC12:314
Table 2. Within-day precision for selected basic drugs in
blood (values show the mean SO; n=4)3

Low High
Recovery
10
Drug Concentration Concentration
~ CV% 11AlmL CV% :5%a
Alprazolam 0.2350.012 5.06 2.190.02 0.75 34.1
Codeile 0.420 0.010 2.29 4.400.06 1.43 78.7
Diazepam 0.1170.003 2.21 1.63 0.(11 4.31 83.7
Proprenolol
Haloperidol 0.4140.010 2.48 4.490.06 1.36 79.5
P U P ( 210 317 IIIII ) : 221.32 ...,
Nordiazepam 0.1170.005 3.96 1.670.01 0.73 89.6
MIXTURE ot Diezepem Pimozide 0.345 0.012 3.39 3.640.09 2.EO 58.7
nd Proprnolol
P UP ( 210 317 IIIII ) "' 222-" ...,
Propranolol 0.207 0.007 3.40 2.170.05 2.15 82.8
Temazepam 0.056+0.002 2.70 0.84+0.02 1.88 SIJ.7
Trazodcne 0.4100.018 4.46 4.34+0.05 1.09 81.1
Verapaml 0.394 0.015 3.73 4.090.10 2.54 E0.3
a Average of 8 detenninations, based on the low and high concentration
=
SO standard deviation
=
CV% coefficient of variation
Conclusions
An automated HPLC system with diode array detection
has been descriled for the determination of several basic
drugs in postmortem blood. The sirJl)le isocratic mobile
Figure 5. Co-elution of propranolol and diazepam3 phase produced a stable and reliable HPLC system for
qualitative and quantitative ~rk. The ability of the system
to separate individual drugs is not as efficient as that of
gradient elution, but it is suitable for the detection of over
100 drugs in 15 minutes. It was demonstrated that the
back-extraction procedure resulted in clean extracts, so
that the spectra obtained by photo diode array detection
can be used for identification. The extraction

charaderistics of a drug together with its library search,
..n Con.IAUM
wns. coneJ.aU
Z ... J
1 ...
:U.t
Ia
'"'"'
l.tHUl
Daaaa.t e.eezne
l&eaaa 1.1171 allows more confidence in determining the identity of each
.a..z.,. .., ::n..s:7 s~ De&eca.ea 1. ,
drug.
PROPRANOLOL
N =7 Reference
PuP (Z10317Nn)
Avg. P u P = 221.33 Nn (1) E.M. Koves and J. Wells, J. of Forensic Sciences,
STD = 0.08Nn
JFSCA, Vol. 37, No. 1 (1992) 42-60.
-
Figure 6. Spectral overlay and purity parameter (PuP)
statistics for propranolol in methanol and in blood at 3Copyright ASTM. Reprintec:l with pennission.

different concentrations3

LC1~4 0793
a:
i
I
C'J
..n
~
CD
c
CD
Section 6
Maintenance/Service
6.1 General
This section covers maintenance and repair procedures that are easily performed by the user.
Several kits are available that contain all of the necessary parts for a given repair or replacement
procedure. These kits are listed in Table 6-1. Included in this section are recommended procedures
and time schedules for preventive maintenance procedures, and a section on diagnosing problems
with an HPLC system, with special attention given to problems that might occur with the 9012 and/or
9002 pumps.
6.2 Solvent Recommendations

6.2.1 Quality and General Considerations
Use only HPLC grade solvents. The time saved from not having to diagnose unpredictable results
caused by other grades of solvents will more than offset the higher cost of good solvents.
Check the column manufacturer's recommendations for any limitations on the allowable solvents
for that particular column.
Easily oxidized solvents such as dioxane and THF (tetrahydrofuran) require either the use of an
anti-oxidant such as BHT (butylated hydroxytoluene), or continuous sparging with nitrogen or helium
to prevent the build-up of peroxides. For detector operation at low UV wavelengths, sparging is
preferred over the use of solvents containing anti-oxidants.
Freshly prepared HPLC grade water must be used to obtain the maximum performance and lifetime
of an HPLC system, especially for high-sensitivity gradient work. Never store water in plastic carboys
or other containers that may release plasticizers or other contaminants. Sterile techniques should
always be used and water checked daily for bacterial growth.
Water can be checked for HPLC suitability by pumping 20-30 mL of water through a C1s column,
followed by a gradient up to 100% of the organic solvent used. Peaks indicate impurities in the
water which may be concentrated in differing amounts at the beginning of each gradient run.
6.2.2 Preparation
HPLC grade solvents may be used directly from the bottle without further preparation (unless
degassing or sparging is required by the application).
All buffers should be filtered after preparation. HPLC grade water produced by an in-house
purification system should have as its final step passage over an activated carbon column followed
by filtration.
6.2.3 Miscibility
Care must be taken to not introduce solvents into the pump which are not miscible with each other.
For example, when switching from hexane to water, a mutually miscible solvent such as isopropanol
must first be flushed through the hydraulic system. In some cases more than one intermediate
solvent will be required. Sufficient time must be allowed for the hydraulics to be completely flushed
with each solvent.
Solvent manufacturers' literature contains data on solvent miscibility. For example, American
Burdick & Jackson publishes a High Purity Solvent Guide.
03-914436-Q6:1 6-1
Maintenance/Service
6.2.4 Solvent and Pump Compatibility

The wetted materials in the 9012 and 9002 pumps are passivated 316 stainless steel, sapphire,
ruby, and inert polymers, fluoropolymers, and perfluoroelastomers. Any solvents used must be
compatible with these materials.
Avoid using solvents which corrode stainless steel. These include:
Halide-containing buffers or acids (F, cr, Bf, r) at a concentration exceeding 2M or at a
pH less than 2
Solvents that can form HCI, such as carbon tetrachloride or chloroform
The following solvents may decrease the lifetime of the damper. Avoid using them for extended
periods:
Fully halogenated solvents (e.g., Freons) and acids (e.g.,trifl.uoroacetic acid)
Buffers at a pH greater than 10
6.2.5 Viscosity
Solvents vary in viscosity (resistance to flow). This means that the pressure will change when the
solvent is changed. During gradients the pressure will often be higher than it is for either pure
solvent. This is especially true for gradients between water and organic solvents such as methanol,
isopropanol, or acetonitrile.
6.2.6 Spectral Characteristics
Purity of solvents is important in order to take advantage of high sensitivity HPLC detectors. Consult
the solvent manufacturer's data sheets for appropriate wavelength ranges. Dissolved oxygen can
increase the absorbance in the low UV ( nm). [See, for example, S.E. Walker, R.A. Mowery, and R.K.
Bade, J. Chrom. Sci, 18, 639 (1980).] Sparging may be necessary to achieve the highest sensitivities
in this region. Oxygen absorption will cause both short-term and long-term drift and will be very
temperature dependent. This effect may be accentuated when the solvent is vacuum degassed
and then used in contact with the atmosphere. The oxygen concentration will then vary from an
extremely low level immediately after degassing to the equilibrium level for that temperature and
solvent. [This effect is described by J.N. Brown, M. Hewins, J.H.M. van der Linden, and R.J. Lynch
in J. Chrom. 204,115 (1981).]
len-pairing salts such as tetramethylammonium salts (TMA) may contain UV-absorbing impurities.
Use only the highest purity available.
6.2.7 Aqueous Buffers
Preparation: After preparing an aqueous buffer, filter it through a 0.2 micron filter to remove any
undissolved particulates. Adding 0.002% sodium azide or a small amount of isopropanol, methanol,
or acetonitrile at a level known to inhibit bacterial or fungal growth is recommended. Use sterile
reservoirs, solvent filters, and plumbing.
Special precautions (solubility and precipitation): The solubility of the buffer salt in the mobile phase
decreases rapidly as the percentage of the organic solvent increases. In most organic/buffer solvent
systems, there will be a concentration of the organic solvent above which the buffer will actually
precipitate. Should this occur in the pump, hydraulics, or column, the pressure will rapidly increase
as the tubing or column plugs up. Care must be taken to keep the concentration of the organic
solvent below this point at all times. The maximum allowable concentration of organic solvent can
be easily measured by mixing buffer and solvent in a beaker and visually checking for the formation
of precipitate. A goal of using a concentration of organic no higher than 90% of the precipitation
point is recommended.
6-2 03-914436-Q6:1

Maintenance/Service
Analyses where buffers are proportioned may be made more troublefree by premixing the buffered
mobile phase into the organic mobile phase at the maximum concentration (determined as
described above). This way, gradients can still be run between the pure buffer and the organic/buffer
reservoirs, but the concentration of organic solvent in the system can never exceed that which will
cause precipitation.
Daily flushing: At the end of each operating period, preferably daily, flush the LC system with water
followed by a miscible organic solvent such as acetonitrile or methanol. To start the system back
up, use the reverse procedure. Storing the pump and column in organic solvent will greatly reduce
the amount of bacterial growth. Buffers should be made fresh periodically and discarded whenever
evidence of bacterial growth is seen.
6.3 Preventive Maintenance

Follow the procedures in this section to maintain your instrument.
6.3.1 Recommended Spares

Refer to Table 6-1 for the recommended spares and their kit part numbers. The recommended
interval of change is also listed.
Table 6-1 Recommended Spares
Replacement Number of Kits Recommended
Component Kit or Kit PIN Recommended Change Interval
0.5 JUT1 Riter, for mixer 03-919491-90 1 3-6 months, depending
on solvent used
Piston Seal Repair Kit 03-919101-90 3 6months
10 JUT1 Reservoir Riter
Mixer/Filter Assembly
Check Valve Filter
Replacement Kit
27-180387-00
03-919468-00
03-919594-90
5
1
1
3-12 months, depending
on solvent used
After 5-10 filter replacements
NOTE: For latest version
valves only.
See Appendix D for
identifying which valve
you have.
The following components will only need infrequent replacement

or repair. These kits may also be kept on hand as spares.
Spare Outlet Check Valve 03-919465-90 1

Spare Inlet Valve 03-919085-90 1
Spare Damper 03-919544-90 1
Proportioning Valve 03-919496-90 1
Repair Kit
Purge/Prime Valve 27-189153-00 1
Repair Kit
Spare Piston Kit 03-919102-90 1
03-914436-Q6:1
Maintenance/Service

6.3.2 Recommended Preventive Maintenance SChedule
Daily: For a set of conditions which are used for a routine analysis:
Check and record the column pressure at the standard conditions.
Observe and record the overall shape of the pressure trace on a recorder at a fairly slow chart
speed (0.5-2 em/min). A pressure trace with a uniform envelope indicates that the system is
functioning properly, while a trace that has an erratic envelope or varying pressure indicates a
filter or frit in the high pressure hydraulic path which is becoming plugged and needs to be
replaced.
Record the detector noise level on the recorder or data system at the same standard conditions.
Replace the detector lamp when the noise level becomes unacceptably high. Refer to the
detector operator's manual for details on this procedure. The 9050 detector status displays the
number of hours on the deuterium lamp. Generally these lamps should be replaced every I 000
hours for best results.
Inject a blank sample. Check for spurious peaks.
Inject a standard mixture at the standard conditions. Calculate the k' and peak heights/areas
of the components.
At the end of the day, set up a program to flush the system with water and then with acetonitrile
or methanol and leave the system in this organic solvent. If the instrument is in use 24-hours
per day, this wash procedure needs to be performed less often.
Weekly: Rush any proportioning valves that have been used with buffer solutions. Pump water first
followed by acetonitrile or methanol.
If buffers are in use, flush the back of the piston seal using a wash bottle of water. The inlet for
the flushing port is in the top of the pump head toward the rear, just to the left of the outlet check
valve. The flush liquid will then drain off of the dark brown plastic skirt beneath the pump head.
See Figure 6-1. Check the reservoir filters for free flow according to the procedure in 6.5.2.1.
Flushing Port

6-4
Figure 6-1 Pump Components
03-914436-06:1

Maintenance/Service
Monthly: Clean the reservoir filters in an ultrasonic bath, then backflush with distilled water and
clean air.
Rinse detector flow cell with dilute phosphoric acid. Refer to the procedure in the detector
manual.
Check the priming capability of the pump to test for an obstructed outlet check valve filter.
Follow the procedure in paragraph 6.4.3.4. Replace if the filter is plugged.
Every 6 months: Replace piston seal, mixer filter and check valve filter screen (latest version only).
See Appendix 0 to determine which version check valve you have.
Every 12 months:
A.WARNING
UNPLUG POWER CORD
Inject lubricating oil (P/N 88-299423-00) into the ports of both the piston slider, and the inlet valve
slider (see Figure 6-2) with the 1 cc syringe and blunt needle provided in the Accessory Kit. To do
this, fill the syringe with approximately 350 ~of oil and inject this amount into each port. This will
overfill the reservoir, but it will ensure an adequate amount of oil is contained within.
The pump must be on bottom dead center (SOC) to line up the lubricating port on the spring housing
and the piston slider. Bottom dead center is the normal stopped position of the piston slider with
the power off. If these holes are not aligned, make certain the pump is on the BDC by manually
rotating the pump stepper motor until the holes line up visually.
Piston Slider Port
03-914436-06:1
Figure 6-2 Slider Lubricating Ports
Maintenance/SeNice
~~~
The pump has a stroke counter, which, along with the date, is a convenient way to keep track of
how much use each replaceable component has on it. This stroke counter may be viewed through
the fourth line of the Status display. (Paragraph 3.4.3 describes use of the Status display.) See Table

6-2 for a sample maintenance log sheet.
Table 6-2 Sample Maintenance Log Sheet
Starting Stroke Ending Stroke

Counter Reading Counter Reading Difference Date
Piston Seal
Mixer Filter
Inlet Valve

OUtlet Check Valve
03-914436-Q6:1

Maintenance/Service
6.4 Troubleshooting Procedures
This troubleshooting guide is written in outline form. For a more

complete discussion of troubleshooting HPLC problems, see, for
example, Maintenance and Troubleshooting HPLC Systems by
Dennis Runser.
6.4.1 The Importance of Good Documentation

Good documentation will help to avoid many potential problems and will allow the user to spot
trends that may be developing before they become full-fledged problems. This includes such things
as writing down the instrument settings, including detector wavelength, attenuation, and time
constant, recorder settings, the solvent composition and flow rate, the injection volume, and any
other parameter set by the user. It also includes operational variables such as the column pressure
recorded on a daily basis.
6.4.2 The Systematic Approach
Whenever a problem is encountered, the fastest way to reach a resolution is to approach the problem
systematically. This means changing only one variable at a time. Often the easiest way to show
whether or not a component is functioning properly is to swap it for a known good component. If
the swap does not solve the problem, then something else is probably the cause.
6.4.3 Hydraulic Component Tests
6.4.3.1 10 Micron Reservoir Filter Test
Test the reservoir filter for free flow by disconnecting the primed 1/8" OD Teflon tube from the pump
and holding this end of the tube up. Measure the time required for the liquid to flow back into the
reservoir bottle. If it takes more than 15 seconds for the solvent in the line to reach the level of the
solvent in the bottle, then the filter needs to be replaced. As a short-term solution, the filter may also
be cleaned by either sonicating or by back flushing with air or solvent at high flow rate. Otherwise
the filter needs to be replaced. Clogged filters generally occur more often in pure water or buffer
reservoirs than they do in organic solvents due to bacterial growth in the aqueous mobile phases.
6.4.3.2 Mixer Filter Flow Resistance Test

Disconnect the 1/16" OD tubing from the outlet of the mixer. With a container to catch the solvent
held below the outlet, start the pump at 5 ml/min. If the pressure reading on the display is more
than 30 atmospheres, it is time to replace the filter cartridge in the mixer.
6.4.3.3 Damper Test

Disconnect the 1/16" OD tubing from the outlet of the damper. Start the pump at 1 ml/min. The
pressure reading on the display should read less than 20 atmospheres. If it reads more than 20
atmospheres, stop the pump. If the pressure drops to zero, the damper is still functional and should
be tested periodically. If the pressure does not decrease, loosen the fitting at the entrance to the
damper. If the pressure drops, the damper is plugged and needs to be replaced. If the pressure
stays high, continue loosening fittings one at a time, working back toward the pressure transducer
until the plugged fitting is located.
6.4.3.4 Outlet Check Valve Filter Test

Disconnect the 1/8" OD Teflon line at the A proportioning valve. Raise it up so the liquid flows back
into the reservoir bottle. Reconnect the line to the proportioning valve. Open the prime valve 1 full
turn. Press prime A. If the pump does not prime in 2 minutes, the filter located in the outlet check
valve is plugged and either the check valve assembly must be replaced or the replaceable filter
screen must be replaced depending on the version of the check valve. As a short-term fix for earlier
version check valves which have non-removable filters, the surface of the filter may be rinsed with
a wash bottle. See Appendix D to determine which version check valve you have.
03-914436-Q6:1 6-7
Maintenance/Service
6.4.3.5 Locating a Plugged Component

Starting at the detector, with the pump running, loosen fittings one at a time, observing the pressure
on the pump display. When the plugged component is removed from the flow path, the pressure
will drop dramatically.
6.4.3.6 System Leak Test

A system leak test is available through the Extended Diagnostics (see Appendix A for details on

other tests). It can operate in either of two modes: constant pressure or pressure decay.
In the constant pressure mode, the pump operates to maintain the set pressure. The reported leak
rate (in microliters per minute) is the flow rate required to maintain the set pressure. It is suggested
that the constant pressure mode leak test be run first.
In the pressure decay mode, the pump pressurizes the hydraulics to the set pressure and then
stops. The decay of the pressure is then monitored as a function of time. The pressure decay mode
is useful for further diagnosis if the system fails the constant pressure mode test.
Either leak test may be performed on the entire high pressure flow path (from the inlet valve to the
outlet of the column) or only on the SDS itself (from the inlet valve to the outlet of the damper).
Because most detector flow cells are not designed to operate at high pressure, when testing the
entire system, the plug must be placed upstream from the detector.
F--.. .AWARNING
.....J.... I--H:-:-AZA-:::-:--::R-::-DO-::-:-:-US::-C7:H:::E:::;M~I~CAL~S~U~N;.:;D~E-::-R-::-P-::-RE::-:S:-::S:-:-U=R-::E-.--1
~ USE PROPER EYE AND SKIN PROTECTION.
To run the leak test in either constant pressure mode or pressure decay mode:
1.
2.
Carefully inspect the system for leaks (drips or salt crystals). Any obvious leaks must be
corrected before continuing. Locations to check include the piston seal drain, the prime/purge
valve, and all nuts and ferrules.
Connect the solvent to be used for the leak test to the A proportioning valve. Prime the pump
and purge solvent through the entire system to remove any air. Any solvent may be used for

the leak test.
3. Remove the fitting from the outlet side of the farthest downstream component to be tested and
replace it with the plug (PIN 28-211489-00) found in the Accessory Kit.
CAUTION: The hydraulic path must be plugged in such a way that

the pressure transducer is always induded in the dosed system.
Operation of the leak test without the pressure transducer in line
could result in damage to the pump.
4. Turn off the main power switch. Press and hold the SELECT key while simultaneously turning
on the power. This will display the Extended Diagnostics Menu.
5. Scroll to the Leak Test using the NEXT LINE key. Press START.
6. Select either Constant Pressure or Pressure Decay mode using the increment/decrement keys.
Press NEXT LINE.
7. Set the pressure for the leak test. The pressure may be set from 10 to 410 atm. A good test
pressure would be slightly higher than the expected operating pressure. Typically 200 atm is
used. Press NEXT LINE.
03-914436-06:1
Maintenance/Service
8. Close the Prime valve (if it is open.). Press START. After the pressure has stabilized, determine
if a leak exists. If so, look for visible signs of solvent leaking at one of the fittings. If a leak is
found, tighten the fitting just enough to correct the leak. DO NOT OVERTIGHTEN.
9. When the leak test has been completed, press STOP. Slowly release the pressure by carefully
opening the prime valve. After the pressure has dropped to zero, remove the plug and reconnect
the solvent line. Turn off the power switch and then turn it back on to restore normal operation
of the SDS.
Interpreting leak test results:
The constant pressure leak test displays the leak rate directly in J.LL/min. Because of the extreme
sensitivity of this test, care must be taken in interpreting the reported leak rate. By relating the leak
rate to the operational flow rate, a decision can be made about the significance of a reported value.
For example, a leak rate of less than 1 J1LJmin will be unimportant at a flow rate of 1 mLJmin.
The pressure decay mode displays a pressure drop and an elapsed time. If the standard damper
is included as part of the hydraulics being tested, the leak rate in fll.Jmin may be estimated by
multiplying the pressure drop (in atmospheres) by 1 J.lllatm and dividing by the elapsed time.
Both test modes are sensitive to fluctuations in ambient temperature which may lead to thermal
expansion or contraction of the liquid in a closed system. This may cause small fluctuations in the
pressure or leak rate readings, but if there is truly a leak, it should become apparent after the system
has been under pressure for 5 or 10 minutes. As a rule of thumb, a drop of water is approximately
50 .. For organic solvents or mixtures of organic and water, a drop is typically smaller than 50 ..
Therefore, with a leak rate exceeding 25 fll.Jmin, liquid should be visible at one o~ the fittings after
several minutes of test. Lower leak rates with a high percentage of organic solvent may not allow a
visible amount of solvent to accumulate because of evaporation. If no visible leak is seen, then the
pump head may be leaking internally (piston seal or inlet valve) or, if included in the test, the injector
valve may be leaking internally.
If the constant pressure leak test produces a higher leak rate than is tolerable after running it for 10
minutes and no visible leaks can be found, run the pressure decay leak test. If the results of this
test are acceptable, then the fittings between the outlet check valve and the plug are leak tight and
an internal leak in the pump head is indicated. Check carefully around the drain passage at the
bottom of the pump head. If no leakage is seen here, then the inlet valve may be leaking, since
leaks here can not be seen externally. If the results of the tests are not conclusive, the leak tests
should be repeated before changing any of.the hardware in the pump head.
6.4.4 General System Troubleshooting Techniques
6.4.4. 1 Baseline Run
Run the pump and data system through a gradient without turning on the injector. This will test the
effect of changing the solvent on the baseline and test for spurious peaks coming from the solvents.
6.4.4.2 Blank Injection .

Inject a blank sample (sample prepared by the usual method but without sample in it). This will test
. for artifacts added during sample preparation.
6.4.4.3 Carryover Test

All the sample loop with the initial mobile phase and inject. This tests the carryover of the injector.
6.4.4.4 Correlation of Effects with Row Rate

Change the flow rate on the pump to see if the character of the problem also changes. This is
particularly useful for diagnosing detector noise.
03-914436-06:1 6-9
Adaintenance!Service
6.5 Diagnosing the Problem

6.5.1 Electronic Faults/Cold Start Diagnostics
Each time the instrument is turned on, the system performs a Self Test to check the functionality of
the SDS electronics. If any faults are detected during the self test, the fault LED will flash and the
audible beeper will sound periodically. The faults detected will be entered in the Error Log, along
with its unique code number. The detected faults may be displayed by pressing the METHOD

ACTIONS key, moving the cursor to Error Log, and pressing SELECT. If more than one fault has
been detected, the last one detected is displayed. Pressing NEXT LINE or PREVIOUS LINE will
display any additional faults. All faults are listed in Appendix B.
If the instrument will not power up:
Check to be sure power cord is connected
Check wall outlet for power
Check fuse F1
6.5.2 Performance Parameters
6.5.2. 1 Pressure Too High
Indicated by one of the following:
Pressure reading is higher than it should be or
Pmax shutdown of pump (fault code 66} or
Hardware overpressure shutdown of pump (fault code 72} or

Pump stalls repeatedly once it reaches pressure
Possible Causes
Plugged 0.5 IJl11 filter in mixer- test for restriction (see paragraph 6.4.3.2}, replace as
necessary.
Plugged column frit or pre-column frit- backflush or replace frit. Filter solvents and sample.
Inappropriate flow rate- check column ID and solvent program.
Higher viscosity solvent - a different, higher viscosity solvent may be in use from when
the method was developed.
Pressure maximum during gradient- mixtures of water and many organic solvents exhibit
higher viscosities than either pure solvent.
Plugged tubing- isolate problem by working from detector back toward pump.
Failed damper- measure restriction (see paragraph 6.4.3.3}. Replace damper if
necessary.
6.5.2.2 Pressure Too Low

Indicated by one of the following:
Pressure reading lower than it should be or
Pmin shutdown of pump (fault code 67}
Possible Causes
Leak in system- check visually for leaks at fittings;

Pump not primed - check for bubbles in inlet lines.
Purge or prime valve open.
6-10 03-914436-06:1
Maintenance/Service
Low viscosity solvent.

Piston seal leak- check for extert:~alleakage behind pump head- usually seen as solvent
dripping from plastic skirt.
Outlet check valve failure- exchange with new valve.
Inlet valve failure- exchange with new valve.
Proportioning valve plugged -lack of a clicking sound on each fill stroke indicates a stuck
poppet- clean by sonicating in water or replace if required.
Solvent level too low in one reservoir- check for air bubbles in inlet lines; refill reservoirs.
Reservoir filter plugged -test according to paragraph 6.4.3.1, then clean or replace.
Pump loses prime- clean or replace reservoir filter.
6.5.2.3 Can't Prime Pump

Possible Causes
Prime valve not opened.
Outlet check valve filter plugged - clean filter by rinsing with a wash bottle or replace check
valve, or in the case of the latest design valve; replace the filter. See Appendix D for additional
information.
Reservoir filter plugged- test according to paragraph 6.4.3.1, then clean or replace.
Outlet check valve failed - replace check valve.
6.5.2.4 Pump Frequently Loses Prime
Possible Causes
Reservoir filter plugged -test according to paragraph 6.4.3. 1, then clean or replace.
Bubbles visible in solvent line- degas mobile phase.
6.5.2.5 Pressure Pulsations Too Large

Possible Causes
Pressure too low to get good damping for a specific application ( < 50 atm at 1 ml/min)- add
a restrictor coil or column between the mixer and the injector. If pulsations are still too large,
add another damper between the mixer and the injector.
High flow rate- Higher flow rates may require additional dampers to reduce pressure pulsations.
Failed outlet check valve - replace check valve if measured flow rate is lower than set flow
rate.
6.5.2.6 External Leaks

Possible Causes
Leak at a fitting -tighten fitting only until leak stops. If leak cannot be stopped with moderate
tightening, then the fitting must be replaced.
Leak out of a proportioning valve- if the proportioning valve continues to leak after it is properly
t~ghtened into the head, it indicates that the inlet valve is leaking and should be replaced.
Leak out of the inlet valve- replace inlet valve.
Leak from behind pump head (usually drips off plastic skirt)- replace piston seal.
Leak out of injector - increase tension on rotor or replace rotor.
03-914436-06:1 6-11
Maintenance/Service

6.5.2. 7 Clacking Noises (sharp, clacking sound on each fill stroke)
Possible Cause
Failed outlet check valve - replace check valve.
Sticking piston- if noise does not occur when solvent is switched to IPA, change the piston
seal. If noise continues with IPA at low pressure, call a Varian Customer Support Representative.
6.5.2.8 Excessive Detector Baseline Noise

Random noise
Possible Causes
Incorrect time constant setting on detector.
Aging detector lamp - may show up as increased high frequency noise or as actual low
frequency steps in detector output.
Improper detector hook-up- may indicate a ground loop.
High background level caused by operating at a wavelength below the solvent cutoff.
Dirty flowcell (contamination). Flush with dilute nitric or phosphoric acid according to the
detector manual.
Two immiscible solvents in system. Flush the system with a solvent that is miscible with both
solvents.
Periodic noise (correlates to pump strokes)

Possible Causes
Two- or four-stroke proportioning mode selected with low volume mixer installed. Install a larger
volume mixer or use one-stroke proportioning.
Bubble(s) in the flow cell. Check the backpressure restrictor on the outlet of the detector flow
cell for proper operation.
Mixing noise caused by strong absorbance of one solvent. Change solvents or detection
wavelength or add a larger mixing volume before the injector.
Column resistance too low. Add a restrictor column or coil between the mixer and injector to

increase the pressure at the same flow rate.
Two immiscible solvents in the system. Flush system with a solvent that is miscible with both
solvents.
6-12 03-914436-06:1

Maintenance/Service
Baseline Spikes
Possible Causes
Bubbles in flow cell -check back pressure terminator
Two immiscible solvents in system - flush system with a solvent which is miscible with both
solvents.
6.5.2.9 Excessive Baseline Drift

Cyclical drift
Possible Causes
Repeats with each gradient run - is due to absorbance and/or refractive index changes
between the two solvents.
Correlates with laboratory air conditioner/heater cycles.
Unidirectional drift
Possible Causes
Oxygen absorption by solvent - either let solvent sit for a longer period between degassing
and use or continuously sparge with helium.
Detector warm-up- use lamp timer on 9050 to turn lamp on earlier each day.
Leak in detector flow cell - consult detector manual.
Evaporation of pre-mixed solvent (absorbance change).
Temperature sensitivity of detector.
6.5.3 Unexpected Chromatographic Results
6.5.3. 1 Retention Times

Longer than expected
Possible Causes
Leak(s)- see paragraph 6.5.2.2.
Different solvent composition.
Flow rate changed.
Column temperature decreased.
Incorrect gradient program.
Degradation of LC column stationary phase.
Shorter than expected

Possible Causes
Different solvent composition.
Flow rate changed.
Insufficient regeneration time after gradient elution.
Column temperature increased.
Degradation of LC column stationary phase .
03-914436-06:1 6-13
AAaintenance!Service

6.5.3.2 Reduced Peak Areas or Heights- Retention Times the Same
All peaks change
Possible Causes
Sample: Evaporation of solvent and sample.
Degradation of sample during storage.
Injection: Wrong syringe volume/ wrong loop volume.
Unintended partial filling of loop.
Internal valve leak.
Sample siphoning out of loop.
Incorrect syringe needle gauge.
Column: Loss of efficiency (peak height reduced, but area remains constant)- may be caused
by a void or plugged inlet frit.
Detector: Leak in flow cell.
Wrong range or attenuation setting.
Only some peaks change
Possible Causes
Sample: Chemical decomposition (decomposition by-products may become obvious in the
chromatogram).
Column: Sample adsorption.
Detector: Wrong wavelength.
6.5.3.3 Resolution Decreased

Possible Causes
Increased flow rate.
Sample overload.

Loss of column efficiency.
6.5.3.4 Selectivity Changed

Possible Causes
Wrong solvents.
Column not equilibrated.
Sample decomposed.
pH of mobile phase changed- use a buffered mobile phase.
Secondary separation mechanism operating - add ion-pairing reagent.
Degradation of LC column stationary phase.
6.5.3.5 Poor Peak Shape

Possible Causes
Column is overloaded. Decrease sample concentration.
Column is physically degrading (void at top of column). Top off column with more packing or
replace column.

Inappropriate pH. Check to see if a buffer is required.
6-14 03-914436-Q6:1
Maintenance/Service
Tubing ID is too large. Use 0.010' or smaller ID tubing for all connections downstream of the
injector.
Secondary separation mechanism operating. Add ion-pairing reagent.
Sample dissolved in strong organic solvent. Dissolve in mobile phase.
6.5.3.6 Spurious Peaks

Possible Causes
System contamination.
Contaminated solvents. Run a blank gradient.
Injection carryover. Run carryover test.
Peaks added during sample work-up. Inject a sample blank.
Rl peaks caused by solvent front. Dissolve sample in mobile phase .
03-914436-Q6:1 6-15
Section 7
Inert 9012
7.1 General
The Inert Star 9012 Solvent Delivery System (SDS) features the same high performance and quality
of construction that make the Star 9012 the best analytical scale SDS available. The Inert 9012
differs only in that inert flowpath components have been substituted for stainless steel wherever
possible. The result is a SDS made as inert as possible without compromising the unequalled flow
accuracy and precision of the 9012 SDS.
Refer to Sections 1 through 6 of this manual for general specifications and instructions for operation
and maintenance applicable to both the standard and Inert 9012 Solvent Delivery Systems.
Section 7 details the key differences that make the Inert 9012 useful in specific applications. Specific
component changes and solvent compatibility of PEEK (polyetheretherketone) components are the
main topics of this section .
03-914436-07:1 7-1
Inert 9012
7.2 Component Identification and Construction

(9) places
Damper Outlet
to Mixer/Filter
NOTE: Titanium Tubing is Identified by a Yellow Band

I!!) PIN 03-919619-00
~ PIN 03-919621-{)0
j PIN 03-919620-{)0
~ PIN 03-919614-00

Figure 7-1 Pump Hydraulics
Component Construction Pan Number
~ Solvent Reservoir Filter Construction is sintered commercially pure titanium PIN 28-211524-00
101J. (3) places with PEEK fitting body
!I] Pump head Commercially pure titanium PIN 03-919607-00
0 Inlet Valve Titanium solvent manifold PIN 03-919604-90

@] Outlet Check Valve Titanium body and filter element PIN 03-919600-90
[!:] High Pressure Tubing Titanium See Note Above
OJ Prime/Purge Valve PEEK body with Kei-F parts PIN 03-919612-00
[gJ Mixer/Filter Assembly PEEK body with aluminum retaining body PIN 03-919622-00
and end caps
lliJ Fittings Upchurch LiteTouch Fittings: PEEK Ferrules

Nut {1/16" SSD
PIN 28-211523-00
PIN 15-001410-00
OJ
7-2
Pump Seal Ruoroloy G seal material with gold plated spring PIN 03-919609-00
03-914436-07:1

Inert 9012
7 .2.1 Identification of Inert Components
Threaded PEEK fitting body

[!] Reservoir Filter (gray in color)
The Titanium head is identified by a small dimple

between check valve and front face of head
[]Head
Identified by gold colored

solvent manifold
[] Inlet Valve
Identified by yellow Kei-F

sealing ring
@] Outlet Check Valve .
. /'";
,. .,_~
Ti tubing is identified by a yellow band
'
. .
..:..::...._w
.,,w,, ..,._ .
-
~ ... 1 . ..
---v,-,~--:-~
' .
[!] High Pressure Tubing (4 pieces)
03-914436-Q7:1 7-3
Inert 9012
- - - - ldentified.by PEEK body (gray in color)

ITJ Prime/Purge Valve
This end does not have frit
~ Mixer/Filter Assembly
Replaceable Filter
(211 Titanium Filter)
PIN 88-310216-00

Stainless Steel Nut
PIN 15-00141()-()0
Identified by Gold Plated

Seal Spring
- T h e flattened end of the ring
faces toward the nut
The narrow end of the ferrule Yellow Colored

fits inside the ring. Fluoroloy G
_Hold the tubing to the bottom of

the fitting while tightening the nut
lliJ Fittings (Upchurch 2 Piece Design) J, Pump Seal
7-4 03-914436-07:1
Inert 9012
7.3 Pump Seal Replacement and Mixer Filter Replacement

Refer to Appendix D for replacement procedure.
7.4 Solvent and Pump Compatibility

7.4.1 Solvent and Pump Compatibility
Greater than 99.99% of the wetted surface of the Inert 9012 is inert to most mobile phases. Frits
contribute over 99% of the wetted surface area. The Inert 9012 features commercially pure Titanium
frits throughout. Other materials contacted by mobile phase and sample include sapphire, ruby,
gold, inert polymers and a small amount of stainless steel.
Avoid using halide-containing buffers or acids (F, Cl-, 8(, r) at a concentration exceeding 2M or
at a pH less than 2.
The following solvents may decrease the lifetime of the damper. Avoid using them for extended
periods:
Fully halogenated solvents (e.g., Freons) and acids (e.g., trifluoroacetic acid)
Buffers at a pH greater than 10
7.4.2 Aqueous Buffers

Preparation: After preparing an aqueous buffer, filter it through a 0.2f.1 filter to remove any
undissolved particulates. Adding 0.002% sodium azide or a small amount of isopropanol, methanol,
or acetonitrile at a level known to inhibit bacterial or fungal growth is recommended. Use sterile
reservoirs, solvent filters, and plumbing.
Special precautions (solubility and precipitation): The solubility of the buffer salt in the mobile phase
decreases rapidly as the percentage of the organic solvent increases. In most organic/buffer solvent
systems, there will be a concentration of the organic solvent above which the buffer will actually
precipitate. Should this occur in the pump, hydraulics, or column, the pressure will rapidly increase
as the tubing or column plugs up. Care must be taken to keep the concentration of the organic
solvent below this point at all times. The maximum allowable concentration of organic solvent can
be easily measured by mixing buffer and solvent in a beaker and visually checking for the formation
of precipitate. A goal of using a concentration of organic no higher than 90% of the precipitation
point is recommended.
Analyses where buffers are proportioned may be made more troublefree by premixing the buffered
mobile phase into the organic mobile phase at the maximum concentration (determined as
described above). This way, gradients can still be run between the pure buffer and the organic/buffer
reservoirs. but the concentration of organic solvent in the system can never exceed that which will
cause precipitation.
Daily flushing: At the end of each operating period, preferably daily, flush the LC system with water
followed by a miscible organic solvent such as acetonitrile or methanol. To start the system back
up, use the reverse procedure. Storing the pump and column in organic solvent will greatly reduce
the amount of bacterial growth. Buffers should be made fresh periodically and discarded whenever
evidence of bacterial growth is seen.
~. '~ ~------~~--------------~
.AWARNING
HAZARDOUS CHEMICALS UNDER PRESSURE
...._.,. USE PROPER EYE AND SKIN PROTECTION.
The burst pressure of PEEK tubing may be lowered when pumping
some solvents, especially THF or Methylene Chloride.
03-914436-07:1 7-5
8.1 Scope and Purpose
Section 8
Regulatory Compliance
The purpose of this section of the manual is to help the user comply with regulations such as
GLP, GALP, and ISO 9000 among others. This section provides information and documentation
that can be used to demonstrate that the 9012 pump and its embedded software were
designed, developed, and tested using commonly accepted high quality engineering practices
including life cycle software design. The section documents that the instrument was
manufactured and tested to commonly accepted high quality manufacturing practices including
Statistical Process Control (SPC). Our ISO 9001 certification assures that the procedures and
practices described here are carefully followed.
Also contained in this section are suggested procedures that you can use to validate and
recertify the performance of your 9012 pump. These procedures can be modified by you and
incorporated into your own documentation. Where available, Varian or your local Varian
representative can be contracted to perform these recertification services as well as providing
training and certification of the operator of this instrument in its proper operation.
All hardware and software design and test procedures along with source code and test results
are available for customer review here at Varian Chromatography Systems in Walnut Creek,
California, U.S.A.
This information is available for review by an instrument user or an agent of a user. Regulatory
agencies may also confirm that an instrument was designed, 9eveloped, manufactured, and
tested in accordance with procedures described in this document.
The software source code and documentation for this product are stored away from
Chromatography Systems to assure that the code will be accessible in the event of natural
disaster or business failure.
Varian cannot guarantee your compliance with either GLP, ISO 9000 or any other regulations.
This is strictly the responsibility of the instrument user. The information in this section is intended
only to help you comply with these regulations.
8.2 Outline of Design Procedures for the 9012 Pump

The 9012 pump was designed using our standard PROS (Product Research and Development
System) product design procedures. These are compliant with the life cycle design philosophy
for hardware and software products. An outline of this procedure is given below .
03-914436-08:1 8-1
8.2.1 The PROS System
The PROS system consists of six phases. Each phase includes many steps involving all of the
departments of Varian Chromatography Systems. The relevant steps of each phase relating to
the design, testing and release of the product using standard engineering practices are listed
below. During each phase, the relevant documentation is developed, approved, used for
subsequent phases and archived so that a complete record of the project is preserved.

1. Phase 1 includes product research and product definition.
2. Phase 2 includes high level requirements analysis, system functional requirements,

engineering plans strategy, research and engineering, manufacturing and technical
assurance plans and product qualification plans.
3. Phase 3 includes the development of engineering product specifications, bread boarding

and testing, design review, prototype production and testing, development review and
pilot run production. For software only products, prototype production is replaced by a
series of prototype software release and testing steps. A change control committee
monitors the product testing and manages hardware and software discrepancies (bugs).
4. Phase 4 includes the release of product documentation, manufacturing reliability

qualification and the training of Customer Support Representatives.
5. Phase 5 includes the release of the product for shipment. All product documentation
including internal documents relating to product design and testing and external
documents such as operator's manuals are in place.
6. Phase 6 includes product support. During this phase, product quality is continuously
monitored through product testing in manufacturing, customer service and sales input, and
the tracking of warranty and installation times and product failure rates. Any problems are
dealt with either through an engineering issues committee or a specific corrective action
team.
During all stages, all drawings and source code are subject to revision control. Any changes
made to the 9012 pump are made according to the revision control system described in the
PROS documentation and our ISO procedures.
When the 9012 was finished, the New Product Checklist shown in Figure 8-2 was completed.
8.2.2 Test Plan and Results for the 9012 Pump Design
The outline of the plan that tested the performance, capability, safety and conformance to
regulations of the 9012 pump when it was originally designed is given in Figure 8-1. These tests
were done prior to signing off the New Product Checklist.
8-2 03-914436-08:1

Figure 8-1
9002/9012 SDS Chrom R&D Evaluation Plan
Table of Contents
Page
I. Editing ...................................................................................................................................................................1
A. Cursor position and movement on a line
C. Adding/removing lines to a table
E. Changing parameter values with inc and doc
F. Completion of entries
G. Parameter changes at time zero
II. Keyboard Operation ..............................................................................................................................................2
A. Pump control keys
B. Method control keys
Ill. Menus ....................................................................................................................................................................2
A. Configuration menu
B. Automation menu
C. Method actions menu
IV Tables...................................................................................................................................................................2
B. Set conditions table
C. Pump parameters table
D. Relays table
E. Auto schedule table
F. Auto setup parameters table
V. Information Displays ..............................................................................................................................................4
A. Status display
B. Method log
C. Errorlog
D. LEOs
VI. Pump Performance ..............................................................................................................................................5
A. Functional specifications
B. Pump errors
C. Extended gradient testing
D. Performance of correction algorithms
E. Pump hardware extended testing
F. Proportioning algorithm selection as a function of flow rate
G. Priming/purging and flow rate steps
VII. Method Execution .............................................................................................................................................6
A. Running a method .
B. Running automation
C. Real-time updates
D. Instrument loading conditions
E. Sync signals
F. Reset at end of run
G. Faults
H. Automatic equilibration
VIII Special Functions .................................................................................................................................................S
A. Remote/local operation
B. Printer option
C. Single-solvent option
D. Warm start
E. Front panel cold start
F. Extended diagnostics
G. Exception messages
H. Pressure output
I. Stroke counter
Appendix I. Method Default Values ...........................................................................................................................9
03-914436-08:1 8-3
Figure 8-2
New Product Checklist

Completion of this checklist and sign-off by each department manager and the General Manager
is required before first customer shipment of any new product.

Product: 90 lljCJoo 2. SdveuT :D.. l,v~..t sf.S.
Research & Engineering 1J_ COG targets established

JfJ COG targets deemed achievable
~ 1-
Jl Prcdud Specifications approved- all combinations
~ Product Specifications achieved- aD combinations
J!!..f'rototype review held- all departments accept design
; )~d-L-.... .$ DooJmentation released to Manufacturing

Drawings
~ Assemb6es
Kits - ufG. ..k "~ ll~-"""- ,,..sTRwr-..0!$ "< -rl.r-. 'r sj(u
Product Strudure
Options/combinations
11\ ATP inputs to Manufacturing
Basic instrument
AD options/combinations
a Maruals approved, printed. and in stock ..
Pre-lnstalation lnstruc:tions''IN ~..&.~ '/IIJ!f5
Operator's Manual
Other wogte. S'J"AnDN 4poi'MlUM - J.y .A'! fP

Q Addenda fd needed) inserted for shipments
1J. Software suitable for customer use
Basic instrument
As part of a multi-instrument system
~ Software DoaJmentation Approved
j!il Training completed

Assemblers
Test and Bum-In Techniques
Planners
Jl. Service spares available
Key parts and assemblies
PC Boards
Software sets complete
ATP's released to Final Test
0 Pilot Run Review completed
I( OemoiCustomer Units Shipment Schedule estab6shed
0 lnterc:onned cables tested and in stock
ll!(, Cost of Goods established- first produdion run
0 COG reduc:lion plan estabished
~ Inspection pla!Vdetails released ( ~ ~)
r:t Training of Inspectors completed ( Sl.{ ~)
0 100"/o Inspection of R&E identified Proto-Pilot Critical Parts
Finance . 0 CMIS ProdUd Codes Established
~-J/'L Finance Manager
~J&J
Date
03-914436-08:1

Quality Engineering JD Produd QualifiCation Test Plan (POTP) completed
,Ci Produd Safety Evaluation & Checklist completed
-~
/t1.L
~
Q Shipping box approved
ljil Regulatory requirements satisfied
FDA- 51 O(K) letter on file
;l{t
FCC- test range report on file ~-.. 7f> lti>tuy.'}
3-<:03 EC Compfiance Test/Certification :.1d.
~
UUCSA/Other - decision to test
Date
Iii OE Trial (first unit to ship): passed tiM_
~
..!II Installation Audit Plan estab&shed
}fi Sugar Land computer axles estab6shed
Technical Support ,.. Service strategy approved and released (TA & P&S)
North America
Europe/Other International
pl. Se!Vice partS inventoly plan implemented (TA & P&S)
North America
EuropeiOther International
Kits in Sunnyvale
:J-17-'r :J ;a:.Pre-lnstaDalion Instructions reviewed
Date ;a Installation Checkist approved
Jllnstrument installation time established
~Special test equipment construded and distributed
Jt Customer maintenance instructions reviewed.
Jill. Customer Service Rep. Training Plan completeftraining underway 1/at~
f' US Installation & Warranty accounts established
i'l Sugar Land Service Techrical Coordinators trained '3/A.~
Jif European Technical~ staff trained ;/~

!lif Capability to service demo units established
~Service Engineers trained-wor1clwide -J{?.i!a
Training plan prepared
Adequate coverage by regiontcounuy
Service mansats avaiable
Marketing/Sales i"Price list approved

Marketing Manager
Lr
ControBer
CSB General Manager .1:/
~~ Usts printed and dslributed ~c. rc~ll
Marketing Manager e"'"Product margin goals satisfied r,111l .f..l~
.ejertormance specificalions approved }I' JS
..1/n/f~ ll!f ~ lileraiUre printed - ,.~,,.,.J)d (Jao~a~~-)
Date .a"AjPcations information printed- ready for customers
..a"&der forecast appRM!d
a6s Order Processing stall trained
-i("s_ygar Land Order Processing staff trained
riuropean Order Processing staff trained
e1iJeS and Field Support Chemist training completed
-ef"B!la test sites- Positive results
a1ntroduction Plans approved
03-914436-08:1 8-5
8.2.3 History of the 9012 Pump Design and Revisions
The 9012 pump was originally designed as a 9010 HPLC pump and the initial release to
manufacturing of hardware and software was on 11/24/88. Since then the 9012 pump has
undergone several revisions. All of these revisions have been and are made using the revision
control system described above. The major revisions of the 9012 pump are listed below.

Product designation, Part Users
Date of number and software Type of change to the directly
release revision number., instrument Bugs fixed'f notified3
11/24/88 9010 gradient pump (First development and NA NA
PN 03-919000-00/01 release)
Software released as Rev A 1.1
5/25/89 9010 Gradient pump PN 03- Change ROMs on SBC Correct Pump No.
919000-00/01 board stall at 1.2 Service
mL/min notified to
Software release as Rev. 8.1.1
replace
any unit
showing
problem
free.
Service
Bulletin
89015

1/12/90 9001 isocratic pump (option) Removed proportioning No No
PN 03-919571-00/01 valves and modified
software to produce an
Software revised to Rev A 1.2
isocratic pump.
6/24/92 Inert 9010 pump (option) Stainless steel hydraulic No No
PN 03-919571-00/01 components replaced
with Titanium or other inert
No Software revision
components.
3/25/93 9012/9002; Inert 9012 pump. Added flow to 10 mLJmin No No
9012:03-919643-00/01 and optional 2 and 4
Inert 9012: 03-919643-02/03 stroke proportioning.
9002:03-91~00/01 9010,9001 and Inert 9010
discontinued.
Software revised to Rev A 1.3
for all products
'The part number for the 9012 pump can be found on the label on the rear of the instrument. The model
number for the instrument can be found on the front label of the instrument. The software revision number
can be found by powering up the 9012 pump and reading the number on the two-line display. The OX/OY
part of the part number signify the part number for the 11 OV and 220V versions of the pump respectively.
2 Were there any known bugs fixed in this revision of the software? If there were, they will be listed in a
separate list below.
3lnstrument users are directly notified of this change to the instrument. In general, if there are fixes of
known bugs, all users of this instrument will be directly notified by Varian and given the opportunity to
upgrade their systems.
03-914436-08:1
8.3 Manufacturing and Product Testing
All Varian 9000 series pumps are manufactured using validated procedures controlled by
Statistical Process Control (SPC). All procedures are documented and under revision control.
Use of these procedures is monitored and assured by ISO 9001 certification.
All 9000 series pumps are tested to assure that have been made no errors in the production of
these pumps. The test procedures are documented in Varian's Acceptance Testing Procedures
(ATPs) for the product. These documents are under revision control. The purpose of these tests
is to make sure that the instrument was manufactured correctly and not necessarily to test the
instrument to its published specifications. Therefore, some specifications are not addressed in
these tests and other tests are not reflected in our published specifications.
8.3.1 Signed Off Documentation for the Testing of this 9012 Pump
Included with your instrument is the signed-off Certificate of Test Compliance. This assures you
that the product was tested using our final test procedures and was passed. You should handle
this certificate as your own procedures require but we recommend that either the original or a
copy of the certificate be kept in the Operator's Manual or the Instrument Log Book. An example
of the Certificate of Test Compliance is shown in Figure 8-3. A Test Record Sheet is shown in
Figure 8-4.
8.3.2 The manufacturing tests cover the following:

1. The software revision is checked on all units to make sure that the proper software is
installed.
2. The built in diagnostics are run to make sure that all of the electronic functions of the
system are performing properly.
3. The "gap on the mechanical inlet valve is checked and adjusted if needed so that it falls
within tolerance. This assures that the solvent has a direct flow into the pump head~
4. The optical switch and proportioning adjustments assure that the solvents are
proportioned correctly.
5. The volumetric flow efficiency tests check the flow rate at 0.99 mL/min. Adjustments can be
made. The flow is then tested at 2 mL/min to make sure that it is correct.
03-914436-08:1 8-7
Figure 8-3. Certificate of Compliance for the 9012 pump.
varian

2700 mitchell drive I walnut creek I ca 94598-16751u.s.a.l phone (510) 939-2400
Certificate of Test Compliance
System Type:
SeriD.l Number:
Varian certifies the equipment listed above has been successfully tested per established and
approved Acceptance Test Procedures. The instruments used to collect test results have been
routinely cahbrated to assure <:onect test readings.
A reconi of test results is maintained by the factory Quality Engineering Department. Proof of
calibration for all test mstn.u:nents is kept by the Fabrication Department.

Sincerely,
VARIAN OIROMATOGRAPHY SYSTEMS
Final Test Technician Date
03-914436-08:1

Figure 8-4. Sample Test Record Sheet for the 9012 Pump
RECORD SHEET
Model 9012 ~ 9012 INERT
Serial/FIN Number__~~~~l?.~Y~------- Tested by __

--~t?o ___________
(Circle one)
Date IM/~.J
INSTRUMENT PRETEST AND CALIBRATION

Self Test, Software Revision Level ,/-~ ~-
~)
PUMP PRECONDITIONING
~heck
~
Hydraulics Run Check
~ck
Inlet Gap Adjustment .046 .001

Optical Switch Adjustment 0-5%~ 10% 20% - 25% Step
0-1% __LZ,?. 20% of 20 - 25%
Step 50% nominal
value
Reference 20 - 25% Step from most Linear Operating Region ~~
Proportioning A & B 48- 49% ~49- 50% ~50- 51%~~~

Proportioning A & c 48- 49% ~49- 50%~50 -~~~
Proportioning Step Adjustment ~3 _4 _5 _6 ~witches On
~~9ml/min
PERFORMANCE TESTS
Volumetric Efficiency _4 .985 to .995
2.0ml/min 1.99 to 2.01 ~
Initialize Maintenance Log /~~?~No. of Strokes ~eck
03-914436-08:1 8-9
8.3.3 Installation Test and Check Out
If your instrument is installed by Varian, you will be provided with documentation of the
procedures performed. Varian recommends placing a copy of the documentation in your
Operator's Manual or Instrument Log Book.

8.4 Procedures for Validation or Recertification of 9012 Pump Operation
The following are procedures which Varian recommends be used to test the HPLC pump to
prove that it is functioning properly. You may follow these tests directly or modify them. If you
modify these tests, you may have to modify the acceptance criteria. These tests are not
designed to measure the specifications of the system. Instead, they are designed to validate
that your system is performing properly. NOTE: In some cases these tests will measure your
system specifications.
Along with the recommended tests, there are several optional tests. These tests take advantage
of some of the unique self diagnostic capabilities of the Varian 9012 pump. They will tell you if
the electronics of the pump is working correctly.
Only personnel qualified to run the Varian Star 9012 HPLC Pump should perform these tests. In
some locations, a Varian Customer Support Representative can be contracted to perform these
tests on a routine basis.
These tests should be performed on a scheduled periodic basis and after any major repairs to
the instrument. The recommended frequency of testing depends on how often you use the
pump for HPLC. If you are in a regulated industry, your regulator will normally have a test
frequency with which they will feel most comfortable. In the absence of any other information,
testing on a yearly basis would be appropriate.
8.4.1 Recommended Test Procedures
8.4. 1. 1 The materials needed for the recommended test procedures for the 9012 pump include
the following:
Isopropyl Alcohol, HPLC Grade
Water, HPLC grade
Acetone
Calibrated volumetric flask, 10 ml
Calibrated stop watch or other time measuring device
Restrictor coil giving about 150- 200 ATM backpressure at 1 mLJmin flow rate with
Isopropyl alcohol.
Restrictor coil giving about 150- 200 ATM backpressure at 5 mLJmin flow rate with
water.
UV detector with a 4 to 10 mm flow cell. The detector should be linear to at least 1.5 AU.
Chart recorder or data system capable of recording the output of the detector
Approved waste container attached to the waste lines
8-10 03-914436-08:1

8.4.1.2 Pump flow rate accuracy test (This test is run on the 9012 and 9002 pump)
SAFETY NOTE: Make sure that the waste lines from the prime valve are routed into a proper
waste bottle.
1.
2.
Place HPLC grade Isopropanol (Isopropyl alcohql) in the A reservoir.
Prime the pump and purge the solvent transfer lines by opening the prime valve and
pressing the PRIME A button on the front panel of the 9012 keyboard.
3. Prime 9012 for 3 minutes or until the Isopropanol has completely filled the solvent reservoir
lines and comes all of the way through the pump. If there are any problems priming the
pump, see Section 4, paragraph 4.4 in the Operator's Manual. Once the pump is fully
primed, stop the pump and close the prime valve.
4. Attach the restrictor coil described above to the outlet of the mixer.
5. Make sure all other connections of the HPLC system are leak tight.
6. Program the 9012 pump as follows:
a. Press the METHOD ACTION key on the 9012 keypad.
b. Press SELECT to activate the Method Select item.
c. If anything other than 1 appears, press the INCREASE key as many times as needed
until a 1 appears under the select method entry. NOTE: Any of the 5 methods may be
e.
used for this test.
d. Press the SELECT key to select method 1.
Press the %ABC FLOW key. The flashing cursor should be under the numeric value for
%A.
f. Adjust the %A to 100% using the INCREASE or DECREASE keys as needed.
g. Read the value under flow. If it is 1.0, go to step 7.
h. If it is not 1.0, push the right CURSOR key three times. The cursor should be positioned
under the entry below Flow.
i. Adjust the Flow rate to 1.0 mLJmin using the INCREASE or DECREASE keys.
7. Have available a small beaker for waste, the calibrated volumetric flask and a calibrated
stop watch or other timing device.
8. With the end of the restrictor over the waste beaker, press the PUMP key to start the pump.
9. Press the STATUS button to read the pump status .
03-914436-08:1 8-11
10. When the pump has been pumping for 4 minutes, the pressure has stabilized between 150
and 200 ATM and there are no bubbles visible in the solvent lines, put the 10 ml
volumetric flask under the restrictor outlet and immediately start the stop watch. (If the
pressure does not stabilize between 150 and 200 ATM, allow the pump 5 min more to
stabilize.) If it still has not, troubleshoot the problems or call your local Varian Service
representative for assistance.
11. When the meniscus in the volumetric flask just reaches the mark on the flask, stop the stop
watch.
12. Stop the pump by pushing the STOP button.
13. Calculate the flow rate by dividing the time on the stop watch in hundredths of a minute by
10. The result is the flow rate in mlJmin. The flow rate should be between 0.97 mlJmin and
1.03 mlJmin.
Date Volume Time Flow Pass (YIN) Action taken Sign off Sign off
(ml) (min) Rate
Date
Volume (ml)
Time (min)
Date test was performed.
Volume that was collected.
Length of time needed to collect the above volume.

Flow Rate The flow rate in mlJmin calculated by dividing the volume by the time.
Pass (Y/N) If the calculated flow rate is between the values listed on line 22, then the
pump passes. Therefore enter Yes. If the rate is outside this range, enter
No.
Action taken If the pump didn't pass, what action was taken?
Sign off These are the places for the person who actually did the test and the
supervisor responsible for the testing to sign, assuring that everything
was done correctly.
8-12 03-914436-08:1

8.4.1.3 Proportioning precision and accuracy (This test is only run on the 9012 pump)
SAFETY NOTE: Make sure that the line from the purge valve and the line from the outlet of the
detector are secured in a waste container.
1. Make up two solvents. Solvent 1 should contain 98% water and 2% Isopropyl alcohol (by
volume). Solvent 2 should contain 97.5% water, 2% Isopropyl alcohol and 0.5% acetone by
volume. Mix thoroughly and degas the solvents with He before using. (While the 9012
pump does not require He sparging to operate correctly, it will be easier to compare the
results of this and subsequent tests if the mobile phase is thoroughly degassed.)
2. Put solvent 1 into the A reservoir.
3. Put solvent 2 into the Band C reservoir.
4. Attach the restrictor to the outlet of the mixer and the inlet of the UV detector.
5. Set the UV detector to 265 nm. Attach either a recorder, integrator, workstation or data
system to the detector. Set the output of the detector to 1 AUFS if a recorder is used. If an
integrator or workstation is used, set it up so that data up to 1 AUFS can be collected.
NOTE: THE LINEAR RANGE OF THE DETECTOR MUST BE GREATER THAN 1 AU.
6. Prime the pump and purge the solvent transfer lines from the B reservoir by opening the
prime valve and pressing the PRIME B key on the front of the instrument. Allow the pump
to prime and purge the transfer lines for at least 3 minutes or until the transfer line is
completely purged of previous solvent.
7.
8.
9.
Repeat the above procedure for the C and A reservoirs respectively .
Close the prime valve finger tight.
Program the 9012 pump as follows:
a. Press the METHOD ACTION key on the 9012 key pad
b. Press SELECT to activate the Method Select item
used for this test.
e. Press the %ABC FLOW key. The flashing cursor should be under the numeric value for
%A.
g. Adjust the Flow rate to 5.0 ml/min using the INCREASE or DECREASE keys as needed .
03-914436-08:1 8-13
10. Press the INSERT LINE key and program the next line in the program. Follow the above

procedure so that the final program has 151ines with the following program:
Line Time %A %8 %C Flow

1 0.00 100 0 0 5.0
2 2.00 100 0 0 5.0
3 2.01 90 10 0 5.0
4 4.00 90 10 0 5.0
5 4.01 80 20 0 5.0
6 6.00 80 20 0 5.0
7 6.01 70 30 0 5.0
8 8.00 70 30 0 5.0
9 8.01 30 70 0 5.0
10 11.00 30 70 0 5.0
11 11.01 20 80 0 5.0
12 1"3.00 20 80 0 5.0
13 13.01 10 90 0 5.0
14 15.00 10 90 0 5.0
15 15.01 0 100 0 5.0
11. After you have finished entering this program, press the NEXT LINE key. If there is a next
line, delete it and any subsequent lines in the program so that only the above 15 lines
remain.
12. Press the SET CONDITIONS button.
13. Using the INCREASE or DECREASE keys, adjust the Endtime to 17.00 minutes

14. Using the right CURSOR key, move to the action entry.
15. Using the INCREASE key, adjust the end action to Stop.
16. Once this programming is finished, start the pump by pressing the PUMP key.
17. Allow the pump to run for 2 to 3 minutes or until the baseline stabilizes.
18. Once the baseline has stabilized, autozero the detector output.
19. Again wait until the baseline becomes stable.
20. Start the program by pressing the START button on the pump.
8-14 03-914436-08:1

21 . Analyze the data in the following manner:
a. Measure the height of each of the 10% steps, 0% to 10%, 10% to 20%, 20% to 30%,
70% to 80%, 80% to 90% and 90% to 100%. This can be done either on the recorder,
integrator or workstation. Either the integrator or the workstation can be used to
measure the signal heights or the signal can be printed and the heights measured
manually.
Height 90%-100% X 0.9 < Height 0%-1 0% < Height 90%-100% X 1.1
Height 80%-90% X 0.9 < Height 10%-20% < Height 80%-90% X 1.1
Height 70%-80% X 0.9 < Height 20%-30% < Height 70%-80% X 1.1
Proportioning from reservoir C can be tested by exchanging the values for B and C in the above
method.
Date Height (High) 0.9x Height (Low) 1.1 X Pass Action taken Sign off Sign off
Height Height (YIN)
(High) (High)
(90-100) (0-10)
(80-90) (10-20)
(70-80) (20-30)
(90-100) (0-10)
(80-90) (10-20)
(70-80) (20-30)
(90-100) (0-10)
(80-90) (10-20)
(70-80) (20-30)
Date Date the test was run

Height High Height of the step at the high B or C concentrations. Enter the three
heights next to their individual designations.
0.9 x Height High Multiply the Height High by 0.9 and enter it here
Height Low Height of the step at the low B or C concentration. Enter the three heights
. next to their individual designations.
1. 1 x Height High Multiply the Height High by 1.1 and enter it here
Pass (Y/N) If the Height Low value falls inbetween the two height high values listed
next to it, them the pump passes the test and Yes should be entered.
Action taken If the pump didn't pass, what action was taken?
Sign off These are the places for the person who actually did the test and the
supervisor responsible for the testing to sign, assuring that everything was
done correctly .
03-914436-08:1 8-15
8.4.2 Optional Procedures
8.4.2. 1 Gradient Linearity

SAFETY NOTE: Make sure that the line from the purge valve and the line from the outlet of the
detector are secured in a waste container.
1. Make up two solvents. Solvent 1 should contain 98% water and 2% Isopropyl alcohol (by

volume). Solvent 2 should contain 97.5% water, 2% Isopropyl alcohol and 0.5% acetone by
volume. Mix thoroughly and degas the solvents with He before using. (While the 9012
pump does not require He sparging to operate correctly, it will be easier to compare the
results of this and subsequent tests if the mobile phase is thoroughly degassed.)
2. Put solvent 1 into the A reservoir.
3. Put solvent 2 into the Band C reservoir.
4. Attach the restrictor to the outlet of the mixer and the inlet of the UV detector.
5. Set the UV detector to 265 nm. Attach either a recorder, integrator, workstation or data
system to the detector. Set the output of the detector to 1 AUFS if a recorder is used. If an
integrator or workstation is used, set it up so that data up to 1 AUFS can be collected.
NOTE: THE LINEAR RANGE OF THE DETECTOR MUST BE GREATER THAN 1.5 AU.
6. Prime the pump and purge the solvent transfer lines from the B reservoir by opening the
prime valve and pressing the PRIME B key on the front of the instrument. Allow the pump
to prime and purge the transfer lines for at least 3 minutes or until- the transfer line is
7.
8.
completely purged of previous solvent.
Repeat the above procedure for the C and A reservoirs respectively.
Close the prime valve finger tight.

9. Program the 9012 pump as follows:
a. Press the METHOD ACTION key on the 9012 keypad.
b. Press SELECT to activate the Method Select item.
used for this test.
e. Press the %ABC FLOW key. The flashing cursor should be under the numeric value for
%A.
g. Adjust the Flow rate to 5.0 ml/min using the INCREASE or DECREASE keys.
8-16 03-914436-08:1

h. Press the INSERT LINE key and program the next line in the program following the
above procedure so that the final program has 4 lines with the following program:

1 0.00 100 0 0 5.0
2 10.00 0 100 0 5.0
3 20.00 100 0 0 5.0
4 30.00 0 0 100 5.0
i. After you have finished entering this program, press the next line key. If there is a next
line, delete it and any subsequent lines in the program so that only the above 4 lines
remain.
j. Press the SET CONDITIONS key.
k. Using the INCREASE or DECREASE keys, adjust the Endtime to 17.00 minutes
I. Using the right CURSOR key, move to the action entry.
m. Using the INCREASE key, adjust the end action to Stop.
n. Once this programming is finished, start the pump by pressing the PUMP key.
10. Allow the pump to run for 2 to 3 minutes or until the baseline stabilizes.
11. Once the baseline has stabilized, autozero the detector output.
12.
13.
14.
Again wait until the baseline becomes stable .
Start the program by pressing the START button on the pump.
Once the program is finished, print out the signal trace if either a workstation or integrator
was used to collect the data. Using a straight edge, extrapolate the lower part of the linear
gradient to the upper part of the gradient as shown in Figure 8-5. Measure the difference
between the actual gradient and the extrapolated gradient at the point of maximum
difference, and compare this value with the difference between the start of the gradient
and the end of the gradient and calculate the ratio. Th~ ratio should be less that 1%. See
Figure 8-5 for more information on how to measure and calculate this ratio .
03-914436-08:1 8-17
Actual Trace
-------------~~--
Height between start and

end of trace /
1
"
/
Extrapolated Trace

Abs
Time
Figure 8-5 This is the procedure used to measure the deviations
from linearity for the gradient test
8.5 Hardware and Software Discrepancies
8.5.1 Defining Hardware and Software Discrepancies or Bugs.

Varian is committed to producing products that are free from all design related hardware and

software discrepancies. Our major concern focuses on reproducible problems that can effect
the results generated by the instruments. We keep records of all problems reported to CSB
about discrepancies and address them as described in paragraph 8.2.1 of this document.
To help clarify what types of problems are addressed in this section, a list is provided below
with examples of possible hardware and software problems related to the 9012 pump. AT
PRESENT NONE OF THESE PROBLEMS ARE RELATED TO THE 9012 PUMP. To be a design
discrepancy, the problem must be present in all products produced either because of the
design or the manufacturing procedures even if it is only found in one of them.
The following would be hardware or software discrepancies if they were found in all the 9012
pumps produced:
1. The pump does not function at 1.2 mL/min but runs at 1.1 and 1.3 mL/min.
2. A time of 5.05 minutes cannot be entered into a pump program.
3. The pump stalls whenever it is run below 50 J.LlJmin.
8-18 03-914436-08:1

4. Relay number 3 does not stay closed permanently when it is programmed to do so.
. The following would NOT be hardware or software discrepancies if they were found in the 9012
pump:
1. Any of the discrepancies listed in the above list which occurred only on one pump. (These
are not systematic design and manufacturing problems.)
2. The pump does not pump at 12 ml/min. The pump is only specified to pump from
10 JJ.Umin to 10 mUmin.
3. The proportioning mode is selected in the configuration table and can only be changed
manually, not automatically when changing between methods. (Because changing
proportioning modes will usually require that some hardware on the pump be changed,
proportioning mode changes were designed as a manual operation manual so that the
operator would be warned to check the hardware configuration if changes were made.)
4. The pump cannot pump pentane! (The 9012 pump is the only HPLC pump in the world
that can pump pentane. However, there are solvents like cyclohexane that no HPLC pump
can pump. Cyclohexane solidifies at high pressures! The fact" that the hardware cannot
operate under every possible condition is not a hardware discrepancy.)
8.5.2 Reporting Discrepancies for the 901219002 Pump

The actual procedure in each locality may vary in detail but it will follow the general pattern
outlined below.
The first step in reporting a possible hardware or software discrepancy is to contact your local
Varian Customer Support Representative. They will attempt to analyze and repair the problem. If
they cannot solve the problem within the time set forth in the Varian escalation procedures, it will
be escalated to the next higher levels of authority and expertise with the abjective to maximize
the instrument uptime. In all cases the customer will be informed of the results.
8.5.3 Discrepancy List for the 901219002 Pump

At present there are no hardware or software discrepancies reported for the 9012 pump .
03-914436-08:1 8-19
Appendix A
A.1 General
Extended diagnostics include routines to assist the user in maintenance operations as well as test
procedures that may pinpoint component level electronic malfunctions or failures. These tests, for
many cases, will require the services of a Varian Customer Support Representative (CSR).
To access the extended diagnostics, first tum off the main power switch, then press and hold the
SELECT key while simultaneously turning the power switch to ON.
Scroll through the following by pressing the NEXT LINE key. Press START to run the selected test.
Maintenance Log (use to reset the pump stroke counter to zero)

TeleDiagnostics (use to allow a Varian CSR to run the extended diagnostics
tests remotely via a modem)
Display Test (use to test the LEDs and two line display)
Leak Test (use to test the pump or entire system for leaks)
Retract Piston (use for Seal Replacement)

Extend Piston (use for Inlet Gap Adjustment)
Keyboard Test (use to verify operation of all keys on the keyboard)
Print Pattern Test
Relays Test
Fault Signals Test
Start Signals Test
Ready Signals Test
Ready Enable Test
ADCTest
ROM Test
RAM Test
GPIB Board Test
GPIB Address Switch Test
GPIB Echo Test
MVD Gates Test
MVD Valves Test
Printer Port Loopback Test
Cold Start Loop (stops on fault)
03-914436-20:1 A-1
Maintenance Log
Press RESET to zero entry, STOP to exit
Pump Strokes XX Jii.!i

'l'elec:U.agnostics
Modem not connected. Press STOP ... Jii.!i
Display 'l'est Jii.i;li

Goes through a series of display and LED
tests then automatically returns to Main
Menu.
Leak Test
SDS Pump-Hydraulics Leak Test

Select Test Mode: CONSTANT PRESSURE
Leak Test Pressure: xxx atm
Press START Ke to Be in Pressurization

Performing Hydraulics Pressurization Jile!i
Pres x atm Leak: xxxx.xxx
RetJ:act Piston (for Seal Beplacement) I

Press START when ready, STOP to quit Jii.!i
Eztencl Piston (for Znlet Gap .Adjust)
Press START when ready, STOP to quit MI.!I
Jii.i;li
STOP to Exit
Operator presses each key and display Jii.!i
responds when stop key is pressed - return
to main menu
Print Pattern 'l'est

Print Pattern Test
Test in Progress
PRINTER TEST FAILED: Printer Timeout
Press STOP to return to MAIN MENU.
A-2 03-914436-20:1

Rel.ays Test
relays. Check for open.

to return to MAIN MENU.
iii.MI
Fau1t Signa1s Test iii.i;li

Fault Signals Test:
FAULT SGNL Err: NO INTERRUPT
iil.!i
Start Sigual.s Test ii@.!;li

Start Signals Test:
START SGNL Err: NO INTERRUPT
iii.!i
Beady Signa1s 'rest ii@.!;li

Ready Signals Test:
READY SGNL Err: INPUT LEVEL
Jile!l
Beady l!:Dab1e Test iid;li

Ready Enable Test: Jii.!i
READY ENABLE disconnected
ADC Test
Mih''
PRS(atm) REF(v) BAT(v) PRL(v)
x.xxx x.xxx x.xxx x.xxx
RCK Test Mihli

ROM Test:
ROM Bank 0/1/2 Hi/Lo B e Test Passes
iii.!I
Mii;i'
RAM Test:
RAM BANK 0/2 Passes
GPIB Board Test iiiirii

GPIB Test:
Test Passes
GPIB Address SWitch Test iiibl'

GPIB Board Switch Test:
Current Switch settin is: XX
03-914436-20:1 A-3
GPIB Echo Test
A GPIB Communication Test

Connect and turn-on Workstation
Run GPIBECHO on the Workstation
i.id;li

Press START when ready 61.!;11
Waiting for message l.illl
MYD Gates Test
MVD Gates Test:

PH2GTB: PASSED
l.illl
MYD Va1ves Test i.iihiM
MVD Valves Test:
VALVE A/B/C: PASSED
Printer Port I.oopback Test i.id;li

SIO Loop Back Test:
H/W HANDSHAKE TEST: Both Failed
l.illl
TRANSMIT/RECEIVE TEST: Char never Reed
Col.d start Loop (stops on faul.t)
Goes through series of LED lights
Maintenance Log
i.ilhli

(beginning of test series)
A-4 03-914436-20:1

Appendix B
Fault Table
8.1 General
At the conclusion of the Self Test diagnostic routine, and during the running of a method, faults may
be detected that will terminate the run and cause the FAULT indicator to flash and the fault beeper
to sound {a double beep every several seconds, and ceases after a few minutes).
When a fault is detected it is registered in the Error Log as an Error Code number and a brief
message identifying it. To display the fault and its code number, access the Error Log by pressing
the METHOD ACTIONS key, then moving the cursor to Error Log in the menu. Press SELECT. Press
NEXT LINE to check for multiple fault messages. Faults are cleared by pressing the RESET key.
The table below provides additional descriptive information for each Error Code number and any
possible action the operator may take to correct the fault. In most cases the action will be limited
to changing the affected circuit board or calling Varian.
When contacting Varian, provide them with the displayed message and Error Code number. From
this information the Customer Support Representative can advise you of necessary actions to take
to get you up and running.
Fault# Message User Action
0
1
2
3
4
RomO: Bank 0, Hi Byte
Roml: Bank 0, Lo Byte
Ram Bank 1-3
Ram Bank 0
Rom2: Bank 1, Hi Byte
Replace U1 00
Replace U107
Replace U97, U104
Replace U99, U106
Replace U101
5 Rom3: Bank 1, Lo Byte Replace U108
6 Rom4: Bank 2, Hi Byte Replace U102
7 RomS: Bank 2, Lo Byte Replace U109
8 SBC-elear int lv7 Call Varian
10 SBC-elear int lvS Call Varian
15 SBC-auto vee lev? Call Varian
16 SBC-auto vee lev6 Call Varian
17 SBC-auto vee levS Call Varian

03-914436-21 :1 B-1
Fault Table

21 SBC-auto vee levl Call Varian
22 SBC-Int prioritizer Call Varian
23 CPU +lSV regulator Call Varian
24 CPU -lSV regulator Call Varian
25 SBC-68681 DUART U29
26 SBC-8253, U31, TO U31
Z1 SBC-8253, U31, Tl U31
28 SBC-8253, U32, T2 U31
29 SBC-8253, U32, T2 U32
30 SBC-AD574 ADC U10
31 Battery Dead Replace Battery
32 Motor Rate Gen U33
33 Cam Pos . Cntr. U32
34 Cam Evt. Cntr. U32
35 Diagnostic Mux Replace SBC Board
Replace U33

36 Diagnostic Timer
37 Prop. Valve A Replace SBC Board
38 Prop. Valve B Replace SBC Board
39 Prop. Valve C Replace SBC Board
40 Prop. Valve D Replace SBC Board
41 Valve State Machin Replace SBC Board
42 8255 PIO IC U7
43 FPB-Presence Make sure J15 Ribbon Cable is

connected
44 FPB-LCD Disp RAM Replace display unit
45 FPB-8279 Interfac Replace FrontPaneiBoard U19
46 MVD Not Present Make sure J17 Ribbon Cable is
connected
47 Mtr Phase 1 Sign Replace MVB Board
48 Mtr Phase 2 Sign Replace MVB Board
49 MVD 5V Regulator Replace MVB Board
52 Dac 1 High Rail Replace MVB Board
82
53 Dac 1 Low Rail Replace MVB Board
03-914436-21 :1

Fault Table
54 Dac 2 High Rail Replace MVB Board

55 Dac 2 Low Rail Replace MVB Board
56 Motor Clock Replace MVB Board
57 GPIB Not Present Make sure J 13 Ribbon Cable is
connected
58 GPIB Board Dtack Replace GPIB Board
59 GPIB-Board Bus Replace GIPB Board
60 8291A Talker/Listener Replace GPIB Board
61 Motor TDC Replace SBC Board
62 Battery Low Replace Battery
63 (not used)
64 Power Failed Power failed or Instrument was
turned off during last run; check
last run results.
65 Methods Lost Check Battery
66 PMAX violation Check hydraulics for clogged lines
67 PMIN violation Check for leaks or loss of prime
68 Pump Stall Fault Check hydraulics for dogged lines
69 (not used)
70 (not used)
71 H/W OVer Temperature Check exhaust fan for proper
operation
72 H/W OVer Pressure Check hydraulics for dogged lines
73 Pump Strokes Uninit Initialize Pump Stroke Count in
maintenance log
74 External Fault The Fault In rear panel closure was
aC'b.Jated. Does not cause the
FAULT indicator to flash.
75 Coldstart Passes
03-914436-21 :1 B-3
Appendix C
Advisory Displays
C.1 General
Message Explanation Corrective Action
lteyboam Loclced:
Loca1 Bequest Denied The instrument is under Remove the lockout
control of the Workstation at the Workstation
and the request for local before pressing the
control of the keyboard LOCAL key again.
has been denied.
Method Locked: An attempt was made to Wait until the
edit a method or view one download is over
of the method tables while before trying the edit
a download from the again.
Work- station was in
progress.
Copying into RuluU.Dq Method Hot Al.1011ed An attempt was made to Redo the copy.
copy another method into
the method which is
currently running .
De1etion of Jbmn; nq Method Hot .Al.l.owed An attempt was made to Press STOP before
delete a method while it deleting the method.
was running.
Method X Sel.ected In automation, this mes- None required.
sage is displayed when a
new method is activated.
Its purposes are to notify
the user that a new
method has become
active and to terminate
any editing that may have
been occurring to the
previous method.
Printer Busy or Hot Cormected This message will be If printer is printing,
displayed if a request is wait until printer is
made to print when the finished before
printer is already printing requesting another
or if the printer option is print. If printer is not
not connected. printing, check cable
and printer power
switch.
Printer started Information message that None.
the request to print has
begun.
Line Methoci Runs - DAD OJILY ! The automation sequence Press the
TurD 1 1 1 AutCIIIIII.tiOD Off to Bd.it table can only be modified AUTOMATION key to
when automation is not turn automation off.
03-914436-22:1
running . Then edit the
automation sequence
table.
c-1
Advisory Displays

Press Pump Key to Start Pump The PUMP key starts the Press the PUMP key
pump. The START key to start the pump.
starts the method only if
the pump is already
running.
Press Beset Key to Abort Equil.ibration The RESET key will Press RESET to
terminate equilibration. terminate
The START key will then equilibration.
start the method after the
pump is in the READY
state.
other Instrument Moc:lul.es Hot Ready The ready_in enable Check other modules
synch signal is connected connected in the
and that module is not yet ready chain to
READY. The START key determine which one
will only start the method is NOT READY.
after all modules are
READY.
'.r.ABLE FOLL This message is displayed Either edit existing
when the method tables lines to the desired
are full and INSERT LINE conditions or delete
key is pressed. lines which are no
longer needed to
make room for new
lines.
'1'0 ADD LDIB PUSS nt~ I.Dm DY When a table contains To add lines to a
only one line, the NEXT/ table, use the

PREVIOUS LINE keys will INSERT LINE key.
generate this message.
DBCRBASB U COME'OS:ITIOH When editing the solvent To increase the
composition, this concentration of
message will appear if the solvent 8, place the
line contains 100% A and cursor at %A and use
the user attempted to the
either increase or INCREASEIDECREAS
decrease %8. Ekeys.
DECREASE %8 COME'OSr.riOH When editing the solvent To increase the
message will appear if the solvent C, place the
line contains 100%8 and cursor at %8 and use
either increase or INCREASEIDECREAS
decrease %C. Ekeys.
DBCRBASB %C COME'OSr.riOH When editing the solvent To increase the
message will appear if the solvent A, place the
line contains 1OOo/o C and cursor at %C and use
either increase or INCREASEJDECREAS
decrease %A. Ekeys.
C-2 03-914436-22:1

Advisory Displays
DlJP This message appears Because only one

just to the right of the time line can exist at each
as a warning that the time time, the user must
of the line in the display is decide which one is
the same as the time of the desired course of
another line which cannot action. To keep the
be seen. previous line intact,
the time must be
changed to some
other value before
moving the cursor or
changing the display.
Any other action will
result in the
displayed line
overwriting the
unseen line.
Method X Copied to Y Informational message None required.
that the requested copy
has taken place.
Method X Del.etecl Informational message None required.
that the specified method
has been deleted.
Note that each fault has a unique number associated with the error message text.
FauH Message Code Explanation Corrective Action
PoweJ: Fail.ecl 64 Either the power switch Press RESET to
was turned off and on or clear fault message.

the laboratory power
failed and came back on
while the pump was
running.
Methods Lost 65 When the power was The methods must
restored to the pump, the be re-entered from
methods in memory could the key panel or
not be saved. re-downloaded from
the Workstation.
Press RESET to
clear fault message.
PlmX viol.aticm 66 The column pressure Check for one or
exceeded the PMAX more of the following:
setpoint plugged filter,
plugged column,
plugged tubing, flow
rate too high, setpoint
too low. Press
RESET to clear fault
message.
PMlll viol.aticm 67 Column pressure has Check for leaks,
dropped below the PM IN prime valve left open,
setpoint setpoint too high, or
air in solvent line
(indicating loss of
prime in the pump).
Press RESET to
clear fault message.
03-914436-22:1
Advisory Displays

Pump Stal.l Faul.t 68 The position sensor in the Check for a plugged
pump has determined that outlet check valve
the pump stalled. filter. Press RESET
to clear fault
message.
H/W over Temperature 71 The temperature inside Check the cooling fan
the pump module has for proper operation.
exceeded 55C.
H/W OVer Pressure 72 The column pressure has Check for one or
exceeded 548 atm on a more of the following:
very rapid pressure rise. plugged filter,
plugged column,
plugged tubing, flow
rate too high. Tum
power off and on to
reset pump.
Pump Strokes Unit 73 The pump stroke counter Re-initialize the pump
is uninitialized-the value in stroke counter from
memory could not be within the Extended
saved at the time power Diagnostics (see
was restored. Appendix A). Press
RESET to clear fault
message.
External. Faul.t 74 A module connected Clear the fault on the
using the synchronization offending module and
signals has sent out a press RESET on the
fault message. The pump pump to clear the

has stopped pumping until fault message.
the fault is attended to.
Co1d Start Passes 75 The diagnostics automat- None required.
ically done on power-on
have been successfully
completed.

03-914436-22:1
Appendix D
Maintenance Reference Material
0.1 General
Appendix D includes copies of installation instructions supplied with field replacement kits required
when replacing the: Mixer Filter, Check Valve, Inlet Valve and Piston Seal, for either the standard
9012 pump or the Inert 9012 pump.
Mixer Filter Replacement Instructions (Standard Version) 03-914236-00
Mixer Filter Replacement Instructions {Inert Version) 03-914388-00
Check Valve Replacement Instructions (Standard Version) 03-914235-00
Check Valve Replacement Instructions {Inert Version) 03-914389-00
Check Valve with Replaceable Fi Iter 03-914413-00
Replacement Instructions (Standard Version)
Inlet Valve Replacement Instructions (Standard Version) 03-914234-00

Inlet Valve Replacement Instructions (Inert Version) 03-914390-00
Piston Seal Replacement Instructions (Standard Version) 03-914146-00
Piston Seal Replacement Instructions (Inert Version) 03-914387-00"
ADDITIONAL REFERENCE MATERIAL- CSR MANUAL ONLY
Proportioning ~alve Repair Kit 03-914231-01

Piston Replacement 03-9191 02-90
Damper Replacement 03-919544-90
03-914436-23:1 D-1
Mixer Filter Replacement Instructions
Kit No. 03-919491-90
This kit contains five (5), 0.51J. porous metal filters to 2. Turn off the main power switch and allow the
be installed as replacements in the outlet end of the system to drop to atmospheric pressure.
hydraulic mixer of the 9010 or 9012 Solvent Delivery
System (SDS). (For the 9001 or 9002 SDS, the mixer 3. Disconnect the mixer inlet line from the damper.
acts as a holder for the filter.) Disconnect the mixer outlet line to the injector
and remove the mixer unit.
All of the components required for the completion of
this installation are included in this kit and identified 4. Remove the outlet end fitting using 1/2" and 9/16"
by the quantity, short description, and Varian part end wrenches. The mixer filter will drop out when
number in the list included in this package. Check the mixer is up-ended.
the contents of the package against the list to be sure
all components listed are received. If there are any NOTE: The inlet end of the mixer is identified
parts missing, or evidence of shipping damage,
with a red ring.
please notify: 5. Install the new filter and replace the outlet end
fitting. Tighten the fitting no more than 1/8 of a
turn past finger_ tight and reconnect inlet and
2700 Mitchell Drive
outlet solvent lines.
Walnut Creek, California 94598

.Attention: Manager of Customer Service,
Phone (510) 939-2400
NOTE: Removing the filter from the mixer may
or, your local Varian Sales/Service Center become difficult or impossible after several (5-1 0)
filter changes, due to deformation of the mixer
body caused by tightening and loosening. When
this occurs, install a new mixer unit.
Mixer Filter Replacement Procedure 6. When the system is up and running, check all of
the fittings you have worked on for leaks. Tighten
A.WARNING further if leaks are found.
j~ HAZARDOUS CHEMICALS
.... Use Proper Eye and Skin Protection.
1. Flush the system with water or isopropyl alcohol

to remove hazardous or toxic solvents .
03-914236-00:2 SPEC. 03-914411..()0

1:2:3:4:6
1 of1
Mixer Filter Replacement Instructions
{Inert Version)
Kit No. 03-919623-90

This kit contains three (3), 2.0J.1 porous Titanium filters 1. Flush the system with water or isopropyl alcohol to
to be installed as replacements in the outlet end of the remove hazardous or toxic solvents.
hydraulic mixer of the inert 9010/9012 Solvent Delivery
System. 2. Turn off the main power switch and allow the system
to drop to atmospheric pressure.
All of the components required for the completion of this
installation are included in this kit and identified by the 3. Disconnect the mixer inlet line from the damper.
quantity, short description, and Varian part number in Disconnect the mixer outlet line to the injector and
the list included in this package. Check the contents of remove the mixer unit.
the package against the list to be sure all components
listed are received. If there are any parts missing, or NOTE: The correct flow direction through the mixer
evidence of shipping damage, please notify:
is identified by an arrow.
4. Remove the outlet end fitting (next to the point of
2700 Mitchell Drive the flow direction arrow) using the 9/16" end
Walnut Creek, California 94598-1675 wrenches. Pry off the old filter and ring as shown in
Attention: Manager of Customer Service Figure 1.
Phone(510)939-2400
or, your local varian Sales/Service Center 5. Press the new filter and ring in place evenly on a
clean bench top. _Re-install the outlet end fitting.
Tighten firmly using the 9/16" wrenches and
re-connect the inlet and outlet solvent lines.
Mixer Filter Replacement Procedure 6. When the system is up and running, check all of the
fittings you have worked on for leaks. Tighten further
A
WARNING
if leaks are found. Tightening should be done on
,~ HAZARDOUS CHEMICALS
the large mixer end fittings with internal pressure
_. Use proper eye and skin protection. relieved.
1 - - - Snap-on ring and 211

Titanium Filter
PIN 88-310216-00
Pry old filter and ring off
wi1h smaR screwdriver by
inserting it In gap between
filter ring a~d body
This end does not

havefrit
Peek Tubing
Inert
Replaceable Filter
Figure 1 Mixer Assembly (2J.L Trtanium Filter)
03-914388-Q0:2 SPEC. 03-914411-00 1 of 1

1:2:3:4:6
e Check Valve Replacement Instructions for the
901 0/9001/9012/9002
Kit No. 03-919465-90
The valve assembly contained in this kit is a direct

replacement for the check valve on your pump.
NOTE: Do Not overtighten the valve.
Excessive tightening can damage
Inspection internal components. Contact your local
Before installing the new valve, examine it carefully Varian Customer Support Representative
for assistance.
for any evidence of damage: scratches on polished
surfaces, or thread damage. If damage is observed,
please notify:
3. Reconnect the pump outlet line. See Figure 1
Varian Chromatography Systems for identification of components referred to in
2700 Mitchell Drive the instructions.
. Phone (510) 939-2400
or, your local Varian Sales/Service Center
Check Valve Removal

1. Remove the discharge line connected to the
check valve.
2. With a 7/16" open end or box wrench, remove
the defective valve by rotating it counter-
clockwise.
Installation of the New Valve

1. Carefully thread the new valve clockwise onto
the pump check valve port by hand until it
bottoms out.
2. With a torque wrench calibrated for inch-
pounds, tighten the valve to about 70
inch-pounds (80 Kg-em}, 80 in-lb (91 Kg-em} F"~gure 1 Check Valve Location
maximum.
NOTE: If you do not have a torque wrench,
use a 5 or 6 inch long open or box end
wrench and tighten the valve moderately
after it has bottomed out in the pump port.
03-914235-00:1 SPEC: 03-914411..00

1:2:3:4:6
1 of 1
Check Valve Replacement Instructions for the e
9010/9012 (Inert Version)
Kit No. 03-919600-90
The valve assembly contained in this kit is a direct

replacement for the check valve on your pump.
NOTE: Do Not overtighten the valve.
Excessive tightening can damage internal
Inspection components. Contact your local Varian
Before installing the new valve, examine it carefully Customer Support Representative for
asSistance.
for any evidence of damage: scratches on polished
surfaces, or thread damage. If damage is observed,
please notify:
3. Reconnect the pump outlet line. See Figure 1 for
Varian Chromatography Systems identification of components referred to in the
2700 Mitchell Drive instructions.
Phone(510)939-2400
Check Valve Removal

1. Remove the outlet line connected to the check
valve.
Pump Head
2. With a 7/16" open end or box wrench, remove the
defective valve by rotating it counterclockwise.
Installation of the New Valve

1. Carefully thread the new valve clockwise onto the
pump check valve port by hand until it bottoms
out.
2. Wittl a torque wrench calibrated for inch-pounds,
tighten the valve to about 70 inch-pounds
(80 Kg-em), 80 in-lb (91 Kg-em) maximum.
F"~gure 1 Check Valve Location
NOTE: ff you do not have a torque wrench,
use a 5 or6 inch long open orbox end wrench
and tighten the valve moderately after it has
bottomed out in the pump port.
03-914389-Q0:2 SPEC. 03-914411..00

1:2:3:4:6
1 of 1

Filter Replacement Instructions for the
9010/9001/9012/9002 Check Valve
{Replaceable Filter Design)
Kit No. 03-919594-90
This kit provides replacement filters for the latest design 3. Insert the blunt end of the tool (03-919589-00) into
9010/9001/9012/9002 check valve. This kit contains the center of the stainless steel filter retainer ring
three (3) replacement 40JJ. filter screens and a tool for and gently rock the retainer side to side (Rgure 1)
facilitating the removal of the old one. A list of until it comes free. Save the retainer as it will be
components with the quantity and brief description is reused.
included in this package.
4. Now pierce the old filter screen in the center with
Check the contents of the package against the list to be
the pointed end of the tool and extract it (Figure 2).
sure all components listed are received. If there are any
parts missing, or evidence of shipping damage, please
notify:
IL-
2700 Mitchell Drive
Walnut Creek, California 94598
Phone (51 0) 939-2400 ~ Kei-F"U Ring
(green or translucent)

(Do Not Remove)
A
wARNING
,~ HAZARDOUS CHEMICALS
. . . . Use proper eye and skin protection.
Check Valve Removal

1. Flush the system with water or isopropyl alcohol to Figure 1 Retainer Ring Removal
remove hazar(jous or toxic solvents.
2. Remove the discharge line connected to the check
valve.
3. With a 7/16" open end or box wrench, remove the
defective valve by rotating it counterclockwise.
Filter Replacement Procedure Screen

1. Flush the end of the check valve that contains the
old filter screen with IPA to remove any loose seal
wear products that may have accumulated there.
2. Place the check valve on a table top with the filter
end up .
03-914413-00:2 SPEC. 03-91441Hl0

Figure 2 Filter Screen Removal
1 of2
1:2:3:4:6
Filter Replacement Instructions

5. Flush out this end of the check valve with IPA and
examine it with a Ioupe or magnifying glass to NOTE: DO NOT overtighten the valve.
ensure that any visible particulates have been' Excessive tightening can damage internal
flushed away. components. Contact your local Varian Customer
Support Representative for assistance.
6. Insert a new filter screen (27-590985-00) into the
check valve. NOTE: The two sides of the filter look
different - one is satin-like in appearance and the 3. Reconnect the pump outlet line. See Figure 3 for
other side shows the weave of the stainless steel identification of components referred to in the
wire that is part of the structure. The filter can be instructions.
installed with either side up or down. The new filter
can be seated using the blunt end of the tool. Push
carefully around the periphery and not in the center
to prevent creasing.
7. Reinsert the stainless steel retainer ring over the
new filter and within the Kei-PM ring. Seat it evenly
by pressing the entire valve against a clean table
edge. The reinstallation of the valve into the pump
head will complete the sealing.
Reinstalling the Valve

1. Carefully thread the valve clockwise onto the pump
check valve port by hand until it bottoms out.
2. With a torque wrench calibrated for inch-pounds,

tighten the valve to about 70 inch-pounds (80
Kg-em), 80 in-lb (91 Kg-em) maximum.
NOTE: Use a torque wrench or 516 inch long open
or box end wrench and tighten the valve moderately Figure 3 Check Valve Location
after it has bottomed out in the pump port.
2of2 SPEC. 03-914411.00 03-914413-Q0:2

1:2:3:4:6
e Inlet Valve Replacement Instructions
Kit No. 03-919085-90
This kit contains 1 Inlet Valve Assembly which is a direct 2. Use a 1/2' open or box end wrench (5 or 6 inches
replacement for the inlet valve on your Star long) to remove the defective valve by turning it
9010/9001/9012/9002 Solvent Delivery System. counterclockwise.
Inspection Installing the New Valve

NOTE: Be sure the internal surfaces and threads in
installation are included in this kit and identified by the
the pump head are clean before installing the new
quantity, short description, and Varian part number in valve. A lint free wipe or the end of a swab wetted
the list included in this package. Check the contents of with IPA is recommended.
listed are received. Check the valve assembly carefully 1. Carefully insert the new valve into the pump head
for any evidence of damage: scratches on the finished port and rotate it until the pump head alignment pin
surfaces, and thread damage. If there are any parts and the slot on the side of the valve (see Figure 2)
missing, or evidence of shipping damage, please notify: are lined up, then thread the new valve into the
cleaned port of the pump head by hand until it
Varian Chromatography Systems bottoms out.
2700 Mitchell Drive
Attention: Manager of Customer Service NOTE: Be sure threads are properly aligned
Phone(510)939-2400 when starting the valve into the pump head port
or, your local varian Sales/Service Center to avoid any possibility of cross threading.
Tools required for the following repair procedures:
1/2' Open End Wrench 5/64" Allen Wrench 2. Use a torque wrench calibrated in inch-pounds to
1/8" Blade Screwdriver 0.046" Gapping Tool tighten the valve in the port. Tighten to 170
Torque Wrench, inch-pounds (200 inch-pounds maximum).
0 to 250 inch-pounds, with 1/2" socket
3. Rotate the inlet valve actuator clockwise 180
Removal of the Defective Inlet Valve degrees to realign with the inlet valve stem.
NOTE: Hold the actuator arm firmly as you rotate it,
1. Pull back the inlet valve actuator and rotate it to the
to prevent it slamming against the inlet valve stem.
left 180 degrees (see Figure 1). This will leave the
inlet valve unobstructed.
03-914234-00:2
F'~gure 1 Valve Actuator in Operating and Rotated Positions
SPEC. 03-914411-QO
1:2:3:4:6
1 of2
Inlet Valve Replacement Instructions
pressing the Next key until "Extend Piston (for Inlet

Gap Adjust)" is displayed. Press Start two times
and the piston will be positioned at TDC (the fully
extended piston position).
3. With the piston at top dead center, measure the gap
between the inlet valve stem and the inlet Actuator.
See Figure 3 for the location of items called out in
Slot in inlet valve to
fit with alignment pin
this instruction. Use the 0.046' gapping tool
included in your tool kit.
Figure 2 Inlet Valve Assembly
4. Insert the gapping tool between the actuator arm
and the inlet valve stem. The tool should fit snugly
Setting the Inlet Valve Stem/Inlet Actuator Gap between the two, just barely making contact on both
sides (see Figure 3). If the gap is too small or too
Tools required for this adjustment are included in the
large, reset it as follows:
Standard Accessory Kit or are with the new valve.
a. Loosen setscrew (1) on top of the actuator arm
1. Pressurize the pump to 200 atmospheres. To do
with the 5/64' Allen wrench just enough to
this, use the following procedure:
release the gap adjustment screw (2).
a. Plug the outlet of the damper.
b. Insert the gapping tool and turn the gap
b. Enter EXTENDED MENU by turning on power adjustment screw in either direction until contact
while pressing and holding the Select key, press on both sides of the gapping tool is achieved.
the Next Une key until "Leak Test" is displayed. The tool should move freely between the two
contact points with no free space.
c. Press Start. Press Next Une and set pressure to
c. While holding the gapping tool in place, tighten

200 atm. Press Next Une, then Start. When the
pressure reaches 200 atm, press Stop two times. the setscrew (1 ).
2. The pump stroke must be at top dead center (TDC) 5. You may now exit from the diagnostic EXTENDED
to accurately set the gap. The top dead center MODE by turning off the main power switch on the
position is most accurately and easily set by rear panel, then turning it on. The unit will proceed
entering the EXTENDED MODE and repeatedly through its normal self-test routine.
Inlet Valve
Gap (0.046')
!Setscrew
I:JI.D---Gap Adjustment (2)

- - I n l e t Valve Actuator
Afignment Pin
2of2
Figure 3 Inlet Valve Gap Adjustment
SPEC. 03-914411.00
1:2:3:4:6
03-914234-00:2

e Inlet Valve Replacement Instructions
{Inert Version)
Kit No. 03-919604-90
This kit contains 1 Inlet Valve Assembly which is a direct Removal of the Defective Inlet Valve
replacement for the inlet valve on your Star Inert
9010/9012 Solvent Delivery System. 1. Pull back the inlet valve actuator and rotate it to the
left 180 (see Figure 1). This will leave the inlet valve
unobstructed.
Inspection
All of the components required for the completion of this 2. Use a 1/2" open or box end wrench (5 or 6 inches
installation are included in this kit and identified by the long) to remove the defective valve by turning it
quantity, short description, and Varian part number in counterclockwise.
the list included in this package. Check the contents of
the package against the list to be sure all components Installing the New Valve
listed are received. Check the valve assembly carefully
NOTE: Be sure the internal surfaces and threads in
for any evidence of damage: scratches on the finished
the pump head are clean before installing the new
surfaces, and thread damage. If there are any parts
valve. A lint free wipe or the end of a swab wetted
missing, or evidence of shipping damage, please notify:
with IPA is recommended.
Varian Chromatography Systems 1. Carefully insert the new valve into the pump head
2700 Mitchell Drive
port and rotate it until the pump head alignment pin

Attention: Manager of Customer Service and the slot on the side of the valve (see Rgure 2) are
Phone(510)939-2400 lined up, then thread the new valve into the cleaned
or, your local Varian Sales/Service Center port of the pump head by hand until it bottoms out.
Tools required for the following repair procedures:

NOTE: Be sure threads are properly aligned
1/2" Open End Wrench 5/64" Allen Wrench when starting the valve into the pump head port
1/8" Blade Screwdriver 0.046" Gapping Tool to avoid any possibility of cross threading.
Torque Wrench,
0 to 250 inch-pounds, with 1/2" socket
03-914390-Q0:2
Figure 1 Valve Actuator in Operating and Rotated Positions
SPEC. 03-914411.00
1:2:3:4:6
1 of2
Inlet Valve Replacement Instructions {Inert Version)
NOTE: The inert version of

the inlet valve is identified
by a gold colored coating
on the solvent manifold.
3.
4.
With the piston at top dead center, measure the gap
between the inlet valve stem and the inlet Actuator.
See Figure 3 for the location of items called out in
this instruction. Use the 0.046' gapping tool
included in your tool kit.
Insert the gapping tool between the actuator arm

and the inlet valve stem. The tool should fit snugly
between the two, just barely making contact on both
Slot in inlet valve to sides (see Figure 3). If the gap is too small or too
fit with alignment pin. large, reset it as follows:
Figure 2 Inlet Valve Assembly a. Loosen setscrew on top of the actuator arm with
the 5/64' Allen wrench just enough to release the
gap adjustment screw.
2. Use a torque wrench calibrated in inch-pounds to
tighten the valve in the port. Tighten to 170 inch- b. Insert the gapping tool and turn the gap
pounds (200 inch-pounds maximum). adjustment screw in either direction until contact
on both sides of the gapping tool is achieved.
3. Rotate the inlet valve actuator clockwise 180 The tool should move freely between the two
degrees to realign with the inlet valve stem. NOTE: contact points with no free space.
Hold the actuator arm firmly as you rotate it, to
prevent it from slamming against the inlet valve stem. c. While holding the gapping tool in place, tighten
the setscrew.
Setting the Inlet Valve Stem/Inlet Actuator Gap 5. You may now exit from the diagnostic EXTENDED
Tools required for this adjustment are included in the MODE by turning off the main power switch on the

Standard Accessory Kit or are with the new valve. rear panel, then turning it on. The unit will proceed
through its normal self-test routine.
1. Pressurize the pump to 200 atmospheres. To do
this, use the following procedure:
a. Connect a solvent line to proportioning valve A
and prime the pump.
b. Plug the outlet of the damper.
c. Enter EXTENDED MENU by turning on power
while pressing and holding the Select key, press
the Next Line key until "Leak Test" is displayed.
d. Press Start. Press Next Une and set pressure to
200 atm. Press Next Line, then Start. When the
-Inlet Valve
pressure reaches 200 atm. press Stop two Actuator
times.
2. The pump stroke must be at top dead center (TDC)
to accurately set the gap. The top dead center A6gnment Pin
position is most accurately and easily set by
entering the EXTENDED MODE and repeatedly
pressing the Next key until "Extend Piston (for Inlet
Gap Adjust)" is displayed. Press Start two times
and the piston will be positioned at TDC (the fully
extended piston position).
Figure 3 Inlet Valve Gap Adjustment
2of2 SPEC. 03-914411-QO

1:2:3:4:6
03-914390-00:2

e Piston Seal Replacement Instructions
Kit No. 03-9191 01-90
The pump head must be removed to access the piston NOTE: The instrument cover does not have to be
seal and piston seal retainer. removed for this procedure.
All of the components required for the completion of this 1. Flush the sytem with water or isopropyl alcohol to
installation are included in this kit and identified by the remove hazardous or toxic solvents.
quantity, short description, and Varian part number in
the list included in this package. Check the contents of
NOTE: To prevent damage to the sapphire
piston, it must be fully retracted before removing
listed are received. and reinstalling the pump head. This is done by
If there are any parts missing, or evidence of shipping entering EXTENDED DIAGNOSTICS.
damage, please notify:
Varian Chromatography Systems 2. To access EXTENDED DIAGNOSTICS turn off

2700 Mitchell Drive instrument power. While pressing and holding the
Walnut Creek, California 94598-1675 SELECT key, turn the power on. After the display
Attention: Manager of Customer Service reads "Extended Menu, press the NEXT LINE key
Phone (510) 939-2400 until the display "Retract Piston (for Seal Replace-
or, your local varian Sales/Service Center ment)" appears. Press START two times. The piston
will fully retract.
Piston Seal Replacement Procedure
..,
f.::-
_AWARNING
HAZARDOUS CHEMICALS
Use proper eye and skin protection.
3.
4.
Pull the inlet valve link toward you and rotate it 180.
This clears the pump head for removal.
Disconnect the hydraulic line from the check valve.
Loosen and remove the three socket head screws
that secure the pump head. Use a 5/32" hex {Allen
wrench or equivalent).
Front
Bushing
. Retainer
SpriH ~ {observe orientation)
OUSing
Spring Housing
Bushing
Figure 1 Pump Head Detail
03-914146-Q0:2 SPEC. 03-914411..()() 1 of2

1:2:3:4:6
Piston Seal Replacement Instructions

5. Carefully slide the pump head forward until it is free 9. Reconnect the hydraulic line to the check valve.
from the guide pins. Remove the pump head and Rotate the inlet valve link to align with the inlet valve.
pump head skirt. Discard the skirt if it appears to
be damaged (a new one is provided in the kit). 10. Replace the 0.5 IJlTl filter in the mixer.
NOTE: It should not be necessary to disconnect 11. Disconnect the mixer inlet line from the damper.
proportioning valve electrical and solvent lines. Disconnect the mixer outlet line to the injector and
There is enough free play in these lines to permit remove the mixer unit.
access to the seal. 12. Remove the outlet end fitting using 1/2" and 9/16"
6. Refer to the detail in Figure 1. Lift out the steel piston end wrenches. The filter will drop out when the
seal retainer. Keep the retainer; it will be used with mixer is up-ended.
the new seal. With the special tool provided in the NOTE: The inlet end of the mixer is identified with
Standard Accessory Kit that came with the a red ring.
9010/9001/9012/9002, or a 1/8" dowel of plastic or
wood if the accessory kit tool is not available. Pry 13. Install the new filter and replace the outlet end
out the old seal. The front bushing does not fitting. Tighten the fitting no more than 1/8 of a turn
normally need replacing. If it has been damaged past finger tight and reconnect inlet and outlet
. by a broken piston, then it should be replaced solvent lines.
Be careful not to scratch any steel surfaces during NOTE: Removing the filter from the mixer may
the seal and bushing removal operation. See become difficult or impossible after several (5-10)
Figure 1 for the location of the above components. filter changes due to deformation of the mixer body
caused by tightening and loosening. When this
7. Wet the new seal with isopropyl alcohol and press occurs, install a new mixer unit.
it in place using the seal retainer.
14. Turn the power OFF, then 9N to restore the pump
NOTE: Position the retainer with the slots outward to normal operation.

(facing away from the pump head). The smooth side
of the retainer, with the concentric grooves, faces 15. When the system is up and running, check for leaks
the seal. at all of the fittings you have worked on. Tighten the
fittings further if leaks are found.
8. Position the pump head skirt and pump head and
secure in place with the three socket head screws.
2of2 SPEC. 03-914411..()0

1:2:3:4:6
03-914146-00:2

Piston Seal Replacement Instructions
{Inert Version)
Kit No. 03-919624-90
The pump head must be removed to access the 3. Pull the inlet valve actuator toward you and rotate
piston seal and piston seal retainer. it 180. This clears the pump head for removal.
All of the components required for the completion of
4. Disconnect the outlet line from the check valve.
this installation are included in this kit and identified
Loosen and remove the three socket head
by the quantity, short description, and Varian part
screws that secure the pump head. Use a 5/32'
number in the list included in this package. Check
hex {Allen wrench or equivalent).
the contents of the package against the list to be sure
all components listed are received. 5. Carefully slide the pump head forward until it is
free from the guide pins. Remove the pump head
If there are any parts missing, or evidence of shipping
and pump head skirt. Discard the skirt if it
damage, please notify:
appears to be damaged (a new one is provided
Varian Chromatography Systems in the kit).
2700 Mitchell Drive
Walnut Creek, California 94598-1675 NOTE: It is not necessary to disconnect
Attention: Manager of Customer Service proportioning valve electrical and solvent lines.
Phone(510)939-2400 There is enough free play in these lines to permit
or, your local Varian Sales/Service Center access to the seal. -
6. Refer to Rgure 2. Lift out the steel piston seal

retainer. Keep the retainer; it will be used with the
new seal. With the special tool provided in the
Piston Seal Replacement Procedure
Standard Accessory Kit that came with the
A WARNING 9010/9001/9012!9002, or a 118' dowel of plastic
';;;;.. HAZARDOUS CHEMICALS or wood if the accessory kit tool is not available,
pry out the old seal. The front bushing does not
.... Use proper eye and skin protection.
need replacing normally. If it has been damaged
by a broken piston, then it should be replaced.
NOTE: The instrument cover does not have to be
Be careful not to scratch any steel surfaces during
removed for this procedure.
the seal and bushing removal operation. See
1. Flush the system with water or isopropyl alcohol F~gure 1 for the location ofthe above components.
to remove hazardous or toxic solvents. Clean the pump head bore, if necessary, using a
wipe and IPA.
NOTE: To prevent damage to the sapphire 7. Wet the new seal with isopropyl alcohol and press
piS1Dn, it must be fully retracted before re- it in place using the seal retainer. NOTE: The inert
moving and reinstalling the pump head. This is
version piston seal has a gold plated spring within
done by entering EXTENDED DIAGNOSTICS.
it versus a stainless steel one as in the standard
901019012 seal.
2. To access EXTENDED DIAGNOSTICS turn off
instrument power. While pressing and holding NOTE: Position the retainer with the slots
the SELECT key, turn the power on. After the outward (facing away from the pump head).
display reads "Extended Menu," press the NEXT The smooth side of the retainer, with the
LINE key until the display "Retract Piston {for Seal concentric grooves, faces the seal. Improper
orientation wHI damage the pump head.
Replacement)" appears. Press START two times.

The piston will fully retract.
03-914387-00:2 SPEC. 03-914411..00 1 of3

1:2:3:4:6:7
Piston Seal Replacement Instructions (Inert Version)
Figure 1 Cross-sectional View of Pump Head
8. Position the pump head skirt and pump head and 10. Replace the 2.0 J.1ITl filter in the mixer (see
secure in place with the three socket head Figure 3).
screws.
11. Disconnect the mixer inlet line from the damper.

9. Reconnect the outlet line to the check valve. Disconnect the mixer outlet line to the injector
Rotate the inlet valve actuator to align with the and remove the mixer unit.
inlet valve.
Front
Bushing
Piston
Seal
Spring
Housing
Spring Housing
Bushing
2of3 SPEC. 03-914411-<10

1:2:3:4:6:7
03-914387-Q0:2

Piston Seal Replacement Instructions (Inert Version)
12. Remove the outletend fitting using 9/16" end 14. Turn the power OFF, then ON to restore the pump
wrenches. Pry off the old filter and snap-on ring to normal operation.
as shown in Rgure 3.
15. When the system is up and running, check for
NOTE: The flow direction of the mixer is identified leaks at all of the fittings you have worked on.
with an arrow. Tighten the fittings further if leaks are found, but
13. Press the new filter and ring in place evenly using only enough to stop the leak. Do Not Overtighten!
a clean bench top. Re-install the outlet end fitting. 16. Run the pump with IPA at 100-200 atmospheres
Tighten fittings firmly with the 9/16" wrenches and backpressure for 20-30 minutes to condition
reconnect the inlet and outlet solvent lines. seals and bushings.
- - - - Snap-on ring and 211

Titanium Filter
P/N 88-31 0216.()()
Pry old filter and ring off
with small screwdriver by
inserting it in gap between
filter ring and body
This end does not

have frit
Peek Tubing
Inert
Replaceable Filter
F"~gure 3 Mixer Assembly (2!11itanium Filter)
03-914387-00:2 SPEC. 03-91441Hl0

1:2:3:4:6:7
3of3
Proportioning Valve Repair Kit Instructions
Kit No. 03-919496-90
Introduction NOTE: References are made to Figure 1 for the

following procedure. Figure 1shows an exploded view
A clogged or sticky poppet assembly can cause bubble
formation in the solvent stream and may cause the pump of the proportioning valve assembly, for your
to lose prime. Sometimes a faulty valve can be. detected information. The valve supplied in this kit is completely
by differences in the sound the valve makes during assembled.
operation. When good valve performance cannot be 2. Disconnect the solvent inlet line from the valve.
restored by cleaning, the entire valve assembly (less coil)
must be replaced. 3. Remove the hex nut <D from the selected valve. This
frees the coil . The coil does not have to be
If there is any evidence of shipping damage to the electrically disconnected.
contents of this kit, please notify:
4. Unscrew (counterclockwise) the defective valve
Varian, Chromatography Systems assembly from the pump head.
2700 Mitchell Drive
Attention: Manager of Customer Service Installation of New Valve Assembly
Phone (51 0) 939-2400 NOTE: Once the plastic cap has been removed,
internal components can drop out of the valve body.
Hold the valve in a vertical position to prevent the loss
The assembly in this kit is a direct replacement for your
of these components.
current valve less the coil.
5. Remove the plastic cap from the new valve
Removal of the Defective Valve assembly and thread it into the pump head port.
Tighten to approximately 30 in-lbs.
1. Turn off main instrument power.
6. Position the Teflon shim a> as shown in Rgure 1.
Proceed with the replacement as follows: Install the coil @ and secure it on the valve assembly
with the hex nut <D. Tighten the hex nut finger tight plus
Plastic Cap 118 tum with a wrench.
~ Tefton~ng
.)@/----OrifiCe
fl'kr.-Gold Shim- one or more
~ ~-""
Spring~ @Coil
I
03-914231-00:1
Agure 1 Proportioning Valve (Exploded View)
SP-914411-0<l 1 of 1
P A R T S L I S T
Picked on 02/01/94 By BZ
Kit : 03-919102-90 Rev 06

Description KIT,PISTON REPLACEMENT,ANAYLITICAL
Part Number Description Qty
03-914171-00 INSTRUCT,INSTALL 1 EA
03-919180-00 ASSY,PISTON 1 EA
03-919223-00 SKIRT,PUMP HEAD 1 EA
03-919397-00 ASSY,SEAL 1 EA
03-919432-00 GREASE GUARD,PISTON 1 EA
03-919532-00 WASHER, SPRING HSG 1 EA
03-919548-00 BUSHING,SPRING HSNG 1 EA
03-919549-00 BUSHING,PISTON,FRONT 1 EA
27-180385-00 FILTER INLINE MIXER 1 EA
88-299461-00 GREASE,MOLYKOT,2.80Z 1 EA
88-299464-00 GREASE,WHITE LITHUIM 1 EA
Installation/Replacement Instructions
Piston Replacement
Kit No. 03-919102-90
This kit contains the following items: To access EXTENDED DIAGNOSTICS turn module
1 ea. Sapphire Piston Assembly, PJN 03-919180-00 power off. Press and hold SaECT while turning power
1 ea. Grease, Molykotetu, PJN 88-299461-00 on. Continue holding SaECT until an audible beep
1 ea. Grease, Uthium Lubricant, PJN 88-299464-00 is heard. Press NEXT LINE until the display reads
1 ea. Grease Guard, PIN 03-919432-00 "Retract Piston (for Seal Replacement)". Press START
1 ea. Pump Head Skirt, PIN 03-919223-00 two times.
1 ea. Washer, PJN 03-919532-00 b. With the piston fully retracted, pull back, and
1 ea. Bushing, PIN 03-919548-00 rotate the inlet valve actuator 1/2 turn
1 ea. Bushing. PJN 03-919549-00 counterclockwise.
1 ea. Seal, PJN 03-919397-00
1 ea. Filter Element, 0.5 micron, PJN 27-180385-00 c. Remove the pump head and pump head skirt
1 ea. Piston Seal Replacement Instructions by removing the three socket head screws.
PJN 03-914146-00 (Requires aS/32" hex tool.) Lay the pump head
aside (electrically connected) and refer to the
Check to be sure all items are present. If there are any Piston Seal Replacement Instructions
discrepancies, please notify: (03-914146-00) to install a new seal.
Varian Chromatography Systems d. The spring housing is secured to the pump
2700 Mildlell Drive casting by two socket head screws. Loosen

Walnut Creek, California 94598-1675 and remove the mounting screws and lift out
Attention: Manager of Customer Service the spring housing assembly.
Phone (510) 939-2400
or, your local Varian Sales/Service Center NOTE: Refer to Agure 1 while performing the
following steps. Parenthetical numerals in the
text refer to circled numbers in Agure 1.
The replacement procedure given below requires the
removal of the pump head and the spring housing
e. Holding the spring housing assembly with the
assembly. Prepare the working area with clean paper
bearing against a f1rm support (bench top),
towels or cloths.
push down to compress the internal spring.
NOTE: We recommend that a Varian Customer With the spring compressed, remove the
Support Representative perform the following guide screw {7} and washer (11). This will allow
procedure: the internal assembly to slide out of the spring
housing (1).
1. Removing the Pump Head/Spring Housing
f. Remove the spring (9) from the spring housing
Assembly.
( 1) and set the spring aside on a paper towel.
a Disconnect solvent lines from all of the Wipe the piston assembly with a paper towel
proportioning valves. to remove the excess Molykote grease (black).
NOTE: To prevent damage to the sapphire g. For earlier version sliders, hold the slider in
piston, it must be fully retracted before place by using a 1/2" end wrench on the flats
removing and reinstalling the pump head. This of the piston slider (2). Then, loosen the piston
is done by entering EXTENDED DIAGNOSTICS. hold-down nut (3) with another 1/2" box end
wrench. Remove the old piston (5) and grease
guard (4) from the slider and discard the piston
03-914171..()0:1 SPEC. 03-914411-0<l

1:2:3:4:6:7
and guard .
1of4
Jnstallation/Rep/acement Instructions
For later version sliders, hold the slider in place a Apply a small amount of the white Lithium
by inserting into the radial hole the largest

grease to the piston base at the locations
phillips screwdriver that will fit in the hole. See designated Area A and secure the piston to
Rgure 1. Then, loosen the piston hold-down the slider with the piston hold-down nut (3).
nut (3) with a 1/2" box end wrench. Remove the
old piston (5) and grease guard (4) from the NOTE: Take care in retightening the piston
slider and discard the piston and guard. hold-down nut to prevent any damage to the
new piston. A 12 point box end wrench is
2. Reassembly and Installation of the Piston, Spring recommended.
Housing, and Pump Head.
Clean the removed piston hold down nut (3) and Wrth the hold-down nut tightened securely (115
the piston mounting cavity (Area A) with paper - 125 in-lb torque), the piston should still be free
to tum. Position the new grease guard (4) on
towels to remove most of the old grease.
the piston as shown in Rgure 1.
' Area A
Whihl &lhium guase
110ft: A "'looo" IJnstoH of
'4'
~

;;;;d. !bold Is used In
Lat... YWSioft sliders..
Figure 1 Assembly Spring Housing
......_....,.,.\
Apply Molykote lightly until outside of spring
1ums dark gray to black. Apply only on one-half
112
2of4
Figure2
SPEC. 03-914411..00
1:2:3:4:6:7
03-914171-Q0:1

b. Wipe the excess Molycote off of the spring with d. Install the new bushing (PIN 03-919548~)
a paper towel and regrease the outside of the over the exposed end of the piston and seat it
spring as shown. Apply Molycote lightly on one firmly in the recess as shown.
half of the spring length until the outside of the Remove the old seal and front bushing from the
spring turns dark gray or black. See Rgure 2. pump head. See Rgure 3.
Wipe excessive grease from the spring
Clean the pump bore of any broken piston
housing bore with a paper towel and remove fragments and clean thoroughly with a wipe
the old bushing (10) from the cavity of the front and IPA.
flange. Insure that there are no broken piston
parts inside of the spring housing. NOTE: If a broken piston fragment cannot be
Regrease the bore of the spring housing with
easily retrieved, it may be necessary to remove
the inlet valve to remove it
Molykote using a small brush or cotton swab.
Apply to inner wall within Zone X only. Install the new bushing, piston seal, and
c. Drop the spring into the spring housing bore retainer as shown.
(non lubricated end enters first). NOTE: Use the retainer to finish the proper
Insert the piston slider assembly carefully into seating of the piston seal. Orient the retainer so
the spring housing. Again, holding the bearing that the crossed slots are facing away from the
end against the bench top, compress the pump head.
spring and replace the guide screw and guide
bearing making sure the small washer is
installed between the bearing and slider. (A
spare washer is provided in the kit in case of
loss.) Mount the spring housing assembly to
the pump casting and tighten securely.
\
Front Bushing
~ Spring Housing
Spring Housing Bushing
03-914171-()0:1 SPEC. 03-91441Hl0

1:2:3:4:6:7
3 of4
Replace the downstream 0.5 micron filter PIN f. For 9010 or 9012 pumps, reconnect the solvent

27-180385-00 if it has not been recently lines to the proportioning valves (if
replaced or it it starts to show an increased disconnected) making sure that Solvent A is
differential pressure drop. connected to proportioning valve A, Solvent 8
Mount the pump head to the spring housing to valve B, etc.
with a new pump skirt between them. Align the For 9001 or 9002 pumps, reconnect the solvent
pump head such that the check valve is line directly to pump head.
positioned at the top with proportioning valves
below, if your unit is a 9010 or 9012. Align the
screw holes and secure the pump head with
the three socket head screws.
e. Before completing this piston replacement
procedure, replenish the cam follower
lubricating pads (11) using the syringe and oil
provided in the accessory kit For detailed
instructions on the oiling procedure, refer to
Section 6, paragraph 6.3.2, of the Star
9010/9001 or 9012/9002 Solvent Delivery
System Operator's Manual.
4of4 SPEC. 03-914411.00

1 :2:3:4:6:7
03-914171..{)():1

P A R T S L I S T
Picked on 11/09/94 By MM
Kit : 03-919666-90 Rev 01
Description :KIT, RETROFIT, SC
--~~-~YIDQ~ ____ Q~9!~~!QD----------------------------------Q~~----

03-914492-00 INSTL. INSTR. SC-9XX 1 EA
03-919664-00 ASSY, DMPR, SO. CORE 1 EA
03-919668-00 FTG, B-HEAD, S. CORE 1 EA
03-919669-00 DMPR-PRG,SST,9.10 1 EA
03-919670-00 DMP-BHD,SST,11.85 1 EA
03-919674-00 TRAY, DRIP 1 EA
03-919677-00 TEMPLATE,9XXX RETRO. 1 EA
12-222006-04 SCRW, 6-32X1/4 SSPH 4 EA
12-222006-06 SCRW, 6-32X3/8 SSPH 4 EA
13-312006-00 NUT,#6 ,KEP SST 4 EA
L4_;,31 7214-00 WSH,EXTLOK,1/2 1 EA
14-900064-00 WASHER,PLAIN,SHIM 1 EA
15-001410-00 NUT,GC ZERO VOLUME 3 EA
22-130013-00 CLIP,FILTER NI PLATE 2 EA
24-399980-00 GROMMET,NEOPRN,1/8 1 EA
28-149020-00 NUT,GLAND 1 EA
28-149021-00 FERRULE 1 EA
28-694533-00 FERRULE,1/16 CPI SS 3 EA
71-999756-00 NUT,DRESS,DECORATIVE 1 EA
901 0/9001/9012/9002 "Solid Core" Damper
Installation Instructions
Kit No. 03-919666-90/-91
This kit provides the hardware and instructions for

retrofitting a "solid core" type pulse damper into a ~
AWARNING
9000 Series Solvent Delivery System that contains a UNPLUG POWER CORD
"U-Tube" type damper.

1. Removal of Existing Damper.
installation are included in this kit and identified by the a. Remove the module cover, secured by four
quantity, short description, and Varian part number in screws in the lower corners.
the list included in this package. Check the contents of b. Loosen the compression nuts on the inlet and
the package against the list to be sure all components outlet fittings. Remove the inlet and outlet lines
listed are received. Check the unit carefully for any from the damper. NOTE: The inlet leg of the
damage to threads or fittings. damper is installed in the top position of the
front panel, and the outlet leg in the lower
Qty Qty position. The inlet leg of the damper is
90 91 Part Number Description identified by a label.
03-919664-00 Damper Assembly, Solid Core
03-919664-01 Damper Assembly, Solid Core, Inert c. Use a 9/16" open-end wrench to loosen and
24-399980-00 Grommet, 3/4" OD x 1/S"ID, remove the dress nuts that secure the damper
Black Rubber to the front panel. Remove the damper.
03-919668-00 Bullkhead Fitting
d. Remove the inlet tubing completely by
03-919674-00 Drip Tray disconnecting the end attached to the purge
o3-9196n-oo Template
valve. This tube will be replaced by a new one.

03-919669-00 Tube, Purge Valve to Damper
03-919669-01 Tube, Purge Valve to Damper,
2. Mounting Features.
Titanium
03-919670-00 Tube, Damper to Bulkhead Fitting If the pump was shipped from the .factory prior to
03-919670-01 Tube, Damper to Bulkhead Fitting, May 1994, it most likely does not have the threaded
Titanium inserts installed in the base chassis that are used to
71-999756-00 Nut, Dress, 15/32" Decorative mount the "solid core" type damper. In this
4 4 13-312006-00 Nut, Keps, #6, SST situation, holes must be drilled in the chassis using
3 3 15-00141 0-00 Nut, GC Zero Vol Fitting, 1/16", SST the provided template. Units shipped later than
28-149020-00 Nut, 1/16, SSI May 1994 will contain the threaded inserts and
4 4 12-222006-04 Screw, 6-32 x 1/4", Panhead, SST holes for mounting, thus will not require any drilling ..
1 14-317214-00 Washer, External Lock,
0.898/0.882 OD X 0.50 ID 3. Installation.
1 1 14-900064-00 Washer, Rat, 0.620 OD x 0.50 ID, SST
a. If holes need to be drilled to provide the
3 3 28-694533-00 Ferrule, 1/16, SST mounting features, turn the module on its left
28-149021-00 Ferrule, 1/16, SSI side so the large SBC board is closest to the
2 2 22-130013-oo Glip, Component, SPN bench. Remove the front rubber foot that is
4 4 12-222006-06 Screw, 6-32 x 318 Large, Panhead, SST closest to the bench, as this chassis insert will
be used as a reference when positioning the
If there are any parts missing, or evidence of shipping drill template. Mark the centers, then punch
damage, please notify: and drill (5) holes as shown in Figure 1.
Varian Chromatography Systems b. Deburr the holes from the interior of the
2700 Mitchell Drive chassis; remove all metal crumbs and re-install
Walnut Creek, California 94598-1675 the rubber foot prior to turning the module
Attention: Customer Service
upright.
Phone (51 0) 939-2400
03-914492-00:1 SPEC. 03-914411-QO 1 of 2

1:2:3:4:6
c. Mount the polyethylene drip tray and two
damper mounting clips to the base chassis as
Front--+ 0 Center the large hole of the
0
Drill (4)Aholes .157

shown in Figure 2. templ~e over the foot insert
and position the tempiO:te Drill (1) B hole .312
parallel with the chassis edge.
NOTE:
Use (4) 6-32 X 114" long screws if the base
chassis had threaded inserts installed.
I o . . II 0
AA B A A
Use (4) 6-32 X 318" long screws and nuts if Figure 1

holes were drilled.
d. Swage one end of the longer 1/16" tubing to the
end of the bulkhead fitting as shown in Figure 3.
4 ea. 6-32 x 1/4' screws
Use (1) of the (3) 1/16" ferrules and nuts
e.
provided.
Swage the remaining tube to the end of the
"solid core" damper as shown in Figure 4.
drip tray
~J--J&!li15i&iiliiil~~~
t
2 mounting dips
1
NOTE: when holes have been
drilled. use 3/8" long
screws and nuts
-~~~-front
~ .I. I. u Tiiiliiiiid5!&1
.I.
f. Keeping the pressure transducer cable up and T
out of the way, mount the bulkhead fitting with base chassis
its associated tubing to the front panel as Figure2

shown in Figure 5. Route tubing as shown.
NOTE: The bulkhead fitting can be held in the
proper position while the dress nut is tightened by
placing a large screwdriver blade between the flats
[.___ _ _____.~.___llilililil
on the bulkhead fitting and the web on the front
panel casting.
g. Install the "solid core" damper by inserting the

1/16" tubing through the "upper" hole in the
front panel, sliding the rubber grommet over the Figure 3
tubing end and fitting it into the panel hole, then
swaging the tube from the bulkhead fitting to
the other end of the damper. Push the damper
down into the (2) mounting clips to secure it.
Connect the remaining tube end to the purge
valve using the SSI nut and ferrule. label!
4. Testing.
a. Connect the outlet fitting to a section of Teflon
tubing leading to a collection container. Purge Figure4
the pump with H20 for about 2 minutes and
then observe the pressure reading. It should
indicate a pressure less than 3 atmospheres
which in turn indicates that the new hydraulic e:d tooth
circuit is operating properly and is not lock washer ~ 11!11 we.sher
;
;
obstructed. ,!
b. Cap off the pump outlet fitting with the plug Lr!::] D llll lllliiJfl
'~ dress
ID
provided in the standard accessory kit. Run the
diagnostic leak test in the "constant pressure"
-:;:-
I
NOTE: prior to installing the damper T
J
front panel
T nut
mode at 400 ATM per instructions in the spread the dips manually drip lrl!ly o mount bulkhead
so the gap between the lips
Operator's Manual (Section 6, Maintenance! is approx. 3/4 inch.
fitting in lower panel
hole
Service).
FigureS

NOTE: Do not tighten any fittings while pump is
pressurized.
This completes the Installation.
2of2 03-914492-00:1
Appendix E
Injector Valve Reference Material
E.1 General
Appendix E consists of a number of vendor supplied data sheets which may be of use to the customer
when choosing various valving options .
03-914436-24:1 E-1
Operating Instructions for Model 7125
AHEOD:YNE Syringe Loading Sample Injector
INCORPORATED
1.0 INTRODUCTION 4.0 L'\1PORTANT SAFETY NOTICES 7.0 FLUSHING THE INJECTOR
Model 7125 is a seven-port sample injec- In the INJECT position, flush the needle
tion valve in which the sample is loaded into 4.1 WARNING: When using sample loops port with about I mL of mobile phase, using
a built-in needle port in the front of the valve. larger than 100 J.I.L, protect yourself from the needle port cleaner as shown in Fig. 3. At
Fig. I shows the flow diagram of the valve. mobile phase coming out of the needle port this time, the pump flushes the loop.
The six small circles represent the ports in the when the valve is turned from INJECT to
valve stator. The two heavy arcs represent the LOAD. Example: 1 mL loop expands 20 J.LI 8.0 COMPLETE LOOP FILLING
connecting passages in the rotor seal. The upon decompression from 200 bar. In complete filling, the volume of sample
larger circle represents the needle port. injected is set by the volume of the loop (this
4.2 WARNING: When using the Needle Port includes the valve passages). This method
Pump Cleaner, empty the syringe slowly to prevent produces the highest precision.
solvent from spurting back at yourself. See
Section 7 .0. CAUTION: To avoid liquid squirting back
at you, discharge syringe slowly.
4.3 CAUTION: Use the correct size syringe
needle to prevent damage to the valve. See
Section 5.0.
Loop
LOAD INJECT
4.4 CAUTION: Rinse the valve after using
Figure 1: 7125 Aow Diagram buffer solutions to prevent salt crystals from
forming, which can cause scratches on the
The sample loop is loaded in through the Needle Port Cleaner Knob of Valve
rotor seal. See Section 12.3.
needle port in the LOAD position. Rotation
of the knob, 60, switches the valve from 5.0 USING PROPER SYRINGES Figure 3: Use of the Needle Port Cleaner
LOAD to INJECT. In the INJECT position Syringes with0.028"0.D. x2"1ongneedle,
the mobile phase flows through the loop. without electro taper must be used. The point Overfill the loop with at least two to three
style must be 90 (square end). Not using the loop volumes of sample. Five to ten loop
2.0 SUPPLIED WITH THE VALVE correct needle size will damage the injector. volumes will provide even better precision.
Supplied with the valve in a separate bag An excess of sample is needed because
are the following items: 6.0 INSTALLATION mobile phase near the wall of the loop is
a) To mount the valve on a panel, remove displaced slowly, due to the laminar flow
~~--1/4. 5/16Wrench 7125-027 the knob by loosening the two knob set screws. pattern shown in Fig. 4.
rff
W
rr -:: ~::: :;:~~~ ~~~~~~~
aLJ-Needle Port Cleaner 7125-054
Use the two screws supplied to fasten the
valve to a panel.
b) Replace the knob by tightening the two
To completely fill the loop:
a) See Warning 4.1 and tum to LOAD.
b) Put the syringe into the needle port. You
/3 -Ferrule (4) 7010-010 set screws on the two flats of the shaft. The will feel tightness during the last 2-3 mm of
! - - - E x t r a Long Bushing(') 7010~2 third hole in the knob is left empty. travel, as the needle passes through the needle
c) Connect the two vent tubes supplied to seal and then stops against the stator face.
~--Long Bushing(') 7010-011 ports 5 and 6. To prevent siphoning, place the c) Load the sample.
A Bushing(') 7010-009 outlet ends of both tubes at the same horizon- d) Leave syringe in and tum to INJECT.
tallevel as that of the needle port. See Fig. 2.
Mounting Screws (2) 7010-019
d) Connect the pump to port 2 and the 9.0 PARTIAL LOOP FILLING
-22cm Vent Tubes (2)
7125-019
column to port 3. Leave the column discon- Ifyouonlyhavesmallquantitiesofsample,
nected from the valve during initial flushing this is the method of choice. In the partial
Quantity supplied dependent on valve model.
operations. filling method the volume of sample injected
The needle supplied with the valve should is set by the syringe. In this method, no more
be removed from the port before using the than half a loop volume of sample is loaded
valve, but it should be left inserted during into the loop. For example, load no more than
inactive periods to keep the needle seal the 10 J.LL into a 20 J.LL loop. With larger volumes
proper size. some of the sample is lost out vent tube 6. This
is because sample flows down the center of
3.0 SPECIFICATIONS the loop at twice the average speed due to the
- J
Maximum temperature is 80C. laminar flow effect shown in Fig. 4.
The valve is set to hold 345 bar. It can be To partially load the loop:
adjusted to hold up to 483 bar. Correct level a) In INJEcr, use the Needle Port Cleaner
of vent
The wetted surfaces are 316 stainless line ends needle port to flush out the needle port with about 1 mLof
steel, Vespel (a polyirnide), and alumina ce- mobile phase. This will flush out contamina-
ramic. Figure 2: Correct position of vent lines tion from the earlier injection. This liquid will
exit out vent tube 5. 11.2 REASSEMBLY r----~ Stop P1ns
b) Follow steps a-d in Section 8.0. Put the valve back together as shown in Fig. Notch
5. Give attention to the following:
10.0 ADJUSTING FOR HIGHER a) Correctly line up the rotor seal as shown

PRESSURE OPERATION/LEAKAGE in Fig. 6. The rotor seal slots face the stator.
The valve has been factory-set to hold 345 b) Replace the stator ring so that the two
bar. If you need operation up to 483 bar or if stop pins enter the mating holes in the body.
there is leakage between the stator and stator The rotor pin must be between the two stop
ring, then proceed as follows. Back the three pins. Figure 6: Correct position of rotor seal
c) Put the stator face assembly on the stator.
Line up the small notch in the rim of the
assembly with port I of the stator. 12.0 OPERATING SUGGESTIONS
d) Mount the stator and stator face assem- AND TROUBLESHOOTING
bly on the valve by pushing it onto the two
pins on the stator ring. Put the three stator 12.1 LEAKAGE
Figure 4: Laminar Aow Effect
screws in place. Tighten each an equal amount If you see liquid between the stator and
set screws part-way out of the stator. Tighten and until all parts are held firmly in place. The stator ring, then tighten the stator screws as
down the three stator screws until they just three set screws will keep the space even explained in Section I 0.0. Replace the rotor
start to grip, then tighten an additional 114- between the stator and stator ring. seal if there is a leak out the needle port or
tum. Reconnect the valve to your system and vent tube.
pump solvent through at about 500 psi above
normal operating pressure. If there is a leak, 12.2 NEEDLE SEAL LEAKAGE
continue to tighten the three stator screws 1/8- Since the outside diameter of syringe
tum each until the leak stops. Confirm that the needles can be different from syringe to
gap between the stator and stator ring is equal syringe, the needle seal (Teflon sleeve in the
all the way around. Now, tighten the screws rotor seal) may not seal correctly around a
down until they touch the stator ring. Replace needle which is smaller than average. This
the rotor seal if the leak continues. will result in a loss of accuracy in loading the
Leakage out the needle port or vent tube is sample.
caused by scratches on the rotor seal. Replace --Body To make a good seal, remove the needle
the rotor seal. Thrust Bearing from the _needle port, push on the plastic
NOTE: If the vent tubes from ports 5 and 6 needle guide with the eraser end of a pencil.

~=---Spring WaShers {4)
do not have their outlet ends at the same - - ... Rotor Pin
Repeat if necessary.
horizontal level as the needle port, siphoning Seal Pins {4)
can result, which is often misinterpreted as a .!,1,-..!l----Needle Port Tube 12.3 USE OF AQUEOUS BUFFERS OR
leak. SALT SOLUTIONS
To prevent the formation of salt crystals in
11.0 MAINTENANCE the valve, flush out the flow passages and the
With normal use, Model 7125 will give needle port with water after using salt solu-
manythousandsofinjections without trouble. tions.
The main causes of early failure:
a) The wrong needle tip can chip the cera- 12.4 USE OF HIGH pH SOLUTIONS
- Stator Ring
mic stator face, which then causesdeepscratch- The standard rotor seal is Vespel, a polyi-
ing of the rotor seal surface. mide with good wear resistance. It is sensitive
Stator Face Assembly
b) Abrasive particles in the sample can to alkaline attack, so avoid solutions having a
scratch the rotor seal surface. pH of IOormore. Use the Tefzel rotor seal for
The rotor seal wears with use and is the only alkaline solutions (see Section 11.3).
part that needs replacement
12.5 ACCURACY OF SAMPLE LOOPS
11.1 CHANGING ROTOR SEAL Sample loop sizes are not actual values.
To change the rotor seal: The actual volumecandifferbyIO%fora20
a) To simplify disassembly leave the knob Jl.l loop. There is a greater difference for
on the valve. Figure 5: Model7125 Explooed View smaller loops. Use partialy filling if you must
b) Remove the three stator screws (refer to know the actual volume injected.
Fig. 5). Do not change the setting of the set e) If the set screws need adjusting because
screws in the stator. a leak needs to be stopped, see Section I 0.0. 13.0 WARRANTY
c) Remove the stator, stator face assembly, f) After putting in a new rotor seal, it is Rheodyne products are warranted against
and stator ring from the body. usually necessary to form the needle seal defects in materials and workmanship for a
d) Pull the rotor seal off the pins. around your needle. See Section 12.2. period of one year following date of shipment.

e) Leave the white isolation seal and red Products may not be returned which are con-
bearing ring in place. 11.3 SPARE PARTS taminated by radioactive materials, infectious
f) Place a new rotor seal on the four pins. 7125-047 Vespel Rotor Seal (standard) agents, or other materials constituting health
See Section 11.2 for reassembly. 7125-079 Tefzel Rotor Seal (high pH) hazards.
P.O. BOX 996, COTATI, CALIFORNIA 94931, U.S.A. (707) 664-9050 FAX 707 664 8739
5R IHEOD!INE
Rheodyne Part Numbers for Models 7125, 7725m25i,
8125 and 9125 Sample Injection Valves
INCORPORATED
7125
--(l!Jl)}
Handle Assembly o 7125-043
~~l-~-"~
~
wl-------
Handle Set Screws (2) 7125-023 Handle Set Screws (2) 7125-023
'
Needle Guide 7125-008
f . - - - - - - S h a f t Assembly* 7125-041 I - - - - - - Shaft Assembly 8125-035
Body 8125-076
1+--+---Thrust Bearing 7125-042-
~=:!L..---Spring Washets (4) 7010.014
m+~I+--1-L.~=---Body Locating Pin 9010.015

Ill~'!--- Position Sensing SwitCh 9010-018
fL-"'ff"'''IIN----(model 7725i only)

60" Stop Ring 9010.017
Needle Poll Tube 7125-068
Tube Spring 7125-035-
Tube Spring 7125-035
o::tt~ :::n-:
' I'
aa~ctit.
- B e a r i n g Ring 7010-006
::JPD------ISOiation Seal 1010-01s-
f - - - Stater Ring 7125-044

Stater Ring 9010.016
}-Stater Face Assembly 7125-067 '"'-----'---t-..L.ri~--Statcr Loc:ating Pin 9010-014
}-stater Face Assembly 7725-026
1--+------Statcr Screws (3) 7125-025
Parts commorno all four valves

o Handle Assembly includes knOb. handle. set screws
Shaft Assembly includes Shaft. rotor pin. seal pins
P.O. BOX 996, COTATI, CALIFORNIA 94931, U.S.A (707) 664-9050 FAX 707 664 8739
Rheodyne Part Numbers for Models 7125, 7725f1725i,
8125 and 9125 Sample Injection Valves
---------------------
RHIOD!INI
INCORPORATED
8125 9125
;t-.~. ~4\\ll ...... _.,,,.

~
Handle Assembly 7725-009
Handle Set Screws (2) 7125-023 Handle Set Screws (2) 7125-023
I
I'W'l-------Needle Guide 7125-008 ~r-------Needle Guide 7125-008
1---Body 8125-076
*-!---Thrust Bearing 7125-042-
ii:o+-+---Spring Washers (4) 7010-014
I!!!"=:!:!...--- Spring Washers (4) 7010-014

_111:+-tHt---t::':::-'-::---Body I..Dcating Pin 9010-015

IHI~--Position Sensing Switch 9010-018
~:'ft::::JliiH---60" Stop Ring 9010-017
~--,s---Needle Port rube 9125-015
1 Tube Spring 7 125-035
Tube Spring 7125-035
Bearing Ring 7010-Q06o
ISOlation Seal 7010-0 t5

~BearingRing7010-Q06o
Rotor Seal 8125-038 ~ISOiationSeal7010-015
,1::~~~;;;:;;;----Body I..Dcating Pin 9010-014
1:1---Biack Plaslic Ring 8125-014
-;;;;;oa~-Pos~ion Sensing Switch 8125-059
1---Stator Ring 8125-031
t---Stator Ring 9010-016
'--_._-r-~~---Stator LDcating Pin 9010-014
'--_._-r-'1:~---Stator I..Dcating Pin 9010-014
}Stator Face Assembly 8125-094
t---Stator 8125-098
l - - 4 - - - - - - - S t a t o r Screws (3) 9125-019
Parts common to all four valves

Handle Assembly includes knOb. handle. set screws
Shaft Assembly includes Shaft. rotor pin. seal pins

~ ~- ---~ - .. -- ---~ - -- ........ ~ ----- I I C:. .d C',IQ? Drint~l"' ,~
for Model 7126
INCORPORATED
Automatic Sample Injector
1.0 INTRODUCTION information on set-up for automatic operation the flat face of the stator so that the entire vol-
The Rheodyne Model 7126 Automatic Sam- is contained in sections 5.01, 5.02. and 6.1 ume of sample discharged from the syringe
ple Injector is a Model 7125 Syringe Loading In both cases. sections 7, 8, and 9 give help- enters the stator passage which is part of the
Sample Injector with a pneumatic actuator ful operating suggestions. maintenance and sample loop. Therefore, all the sample dis-
built around it in a compact package. This servicing information and need to be referred charged from the syringe becomes injected
combination permits the user to operate the to only when needed. Be sure to red the CAU- onto the column. There is no sample loss.
injector manually as a syringe-loading device TION and WARNING notes in section 4.1 The flat stator face is polished alumina
just like the Model 7125 and also permits con- ceramic-a hard surface which cannot be
version to an automatic device for repetitive damaged by the needle tip.
2.0 WARRANTY
injections from a sample reservoir or for con-
Rheodyne products are warranted against
nection to an autosampler for automatic multi-
defects in materials and workmanship for a
sample analysis. period of one year following date of shipment.
Supplied with the valve in separate bags are
Rheodyne will make repairs or replacements
the follo.ving items (see Figure 50): free of charge upon return to the factory, trans-
a) Two socket wrenches;
portation paid, of the defective item.
b) One open-end wrench;
c) Two 22 em long tubes (0.51 mm I. D.) for
vents; 3.0 THEORY OF OPERATION
d) Four tube fittings (threaded bushing and The Model 7126 is a six port sample injec-
ferrule) for tubing connections to valve tion valve in which loading of the sample loop
ports; is accomplished through a needle port built Loop
e) One 7125 needle port cleaner; into the valve shaft.
LOAD INJECT
f) Two #8-32 screws for valve mounting; Figure 1 shows the flow diagram of the
g) Two barbed air frttings; valve. The six small circles represent the ports F19. 1: M~ 7126 Fla.v Diagram
h) One #7126-091 Needle Adapter (Figure 7). in the valve stator (rear of injector). The two
The 7126 is supplied with a #22 ga needle heavy arcs represent the connecting passages
with a CTFE hub (part #7215) which is shipped in the rotor seal. The larger circle represents
inserted in the needle port (underneath the red the needle port Qn the rotor seal). The needle The maximum operating temperature of Model
protective cap). This needle should be port is used to fill the sample loop in the LOAD 7126 is SO"C.
removed from the port before use of the valve. position. In the INJECT position the loop is In automatic unattended operation, the
A position sensing switch (SPDT) is supplied switched into the solvent stream and the nee- #7126-091 Needle Adapter is attached to the
with the 7126 for remote indication of valve dle port is vented through valve port 5. Rota- needle port to facilitate filling of the sample
position or for start of computer run, etc. tion of the knob through 60 switches the valve loop (see Figure 7 and section 6.1). In manual
The standard sample loop supplied with the from LOAD (CCW) to INJECT (CW). operation. two methods of loading the sample
7126 is the 20 microliter size (part #7022). Figure 2 shows the needle port geometry. In can be used: The complete loop filling method
Following are the standard sample loops manual operation when the syringe needle is and the partial filling method. Following is a
available. Each loop is supplied with fittings for fully inserted, the flat tip of the needle touches description of these methods.
direct connection to the valve.
Sample LDop Tubing bore

si2e
c.talog
mm
Seal)--(I
runber micrOliters inches
7020 5 .18 .007
7021 10 .30 .012
7022 20 .51 .020
..J
7023 50 .51 .020
7024
7028
100
200
.51
.76
.020
.030 ..::___ Tenon Sleeve (Needle
...<
w
7026 500 .76 .030 c
7027 1000 .76 .030 Ralcr Seal
7028 2000 1.00 .040 ---Rotor
7029 5000 1.00 .040
Needle Port Tube
1.1 HOW TO USE THESE INSTRUC110NS

Since the manual and automatic modes of
operation of the Model 7126 make use of dif-
ferent aspects of the injector, you may wish to
ignore some sections of these instructions if \.___
you are using only the automatic unattended Needle Port
mode of operation. Therefore, the note "Man-

ual Operation Only" appears at section head-
ings which apply only to the manual mode. The Fig. 2: Model 7126 Needle Port Geometry
3.0.1 FILLING THE LOOP COMPLETELY 4.2 USING PROPER SYRINGES 5.02 ATTACHING NEEDLE ADAPTER
In both methods of sample loading it is nec- For automatic unattended operation, the
(Manual Operation Only) essary to insert a syringe needle into the nee- #7126-091 Needle Adapter should be inserted
dle port. In the complete filling method it is pos- in the needle port and fastened to the 7126

This is the conventional method in which an sible to use any syringe with Luer tip together knob as shown in Figure 7. The sample loop
excess of sample is used to insure that the with the needle supplied with the 7126. In the can then be filled by flowing sample into the
sample loop is completely filled. The volume of partial filling method, conventional low pres- needle port and out port 6 or by flowing into
sample is determined precisely by the loop vol- sure microsyringes can be used. These are port 6 and out the needle adapter tube. Refer
ume and the highest degree of precision is available from several manufacturers and to section 6.1 for suggested connection
obtained. The method is explained in section should have the following needle specifica- schemes for automatic operation.
6.0.1. tions:
Needle dimensions: 0.0280 O.D. x 20 long 5.03 USING THE POSITION SENSING
3.0.2. PARTIALLY FILLING THE LOOP without electro taper. SWITCH
Point style: 90 (square end). The SPOT switch mounted on the side of the
(Manual Operation Only) Failure to use a needle of proper size can actuator body can be used to initiate an exter-
result in damage to the injector. nal action such as an event mark or the start of
If only small quantities of sample are avail- Rheodyne also supplies suitable micro- a computer run. The switch is operated by a
able. this is the method of choice. syringes. Following are the part numbers. plunger inside the body which is pushed down
In this method a microsyringe is used to on the switch actuator lever when the valve
determine the volume of sample delivered to moves to the LOAD position. Figure 5 shows
the loop. The loop has been previously filled 7201 10 ul Syringe an exploded view of the switch and plunger.
with solvent from the last run and the syringe 7202 25 ul Syringe The switch need not be removed from the
delivery causes the solvent to be displaced by 7205 50 ul Syringe valve, but if for some reason it is removed, the
the sample. The displaced solvent exits from 7210 100 ul Syringe plunger can fall out. Be sure that the plunger is
vent tube 6. 7225 250 ul Syringe replaced fully inserted before replacing the
With this method it is possible to inject sam- 7250 500 ul Syringe switch. Also be sure that the switch is fastened
ples ranging from less than one microliter up to in place so that the plunger actuates the switch
approximately 50% of the loop capacity. Sam- in LOAD and releases it in INJECT
The #7126-091 Needle Adapter is also of
ple loops can be used on the Model 7126 rang-
correct size.
ing from 5 microliter capacity up to 5 milliliters. 5.1 USING THE NEEDLE PORT CLEANER
The partial filling method of injection is
described in section 6.0.2. 5.0 INSTALLATION (Manual Operation Only)
The 7126 can be panel mounted by using the
panel hole pattern shown in Figure 3. Maximum Connect the 7125 Needle Port Cleaner (part
panel thickness is 4.8 mm (0.19 inch). There are #7125-054) to a syringe as shown in Figure 4.
also two #10-32 threaded holes in the side of the A syringe of at least 2 ml capacity with Luer tip
body for bracket mounting. (not Luer Lock) is recommended-such as
To mount the 7126 on a panel, proceed as Rheodyne part #7252. Use the cleaner to flush

folloWs: out the needle port with mobile phase with the
a) First remove the knob by loosening the valve in the INJECT position. To do this. push
two knob set screws. Use the two #8-32 the tip of the cleaner against the conical open-
screws supplied to fasten the valve to the panel. ing of the Needle Gu"ide and discharge the
b) When replacing the knob be sure that the syringe slowly. Observe WARNING 4.1.2. The
two set screws are tightened securely on the discharged liquid can squirt back at you if you
two flats on the shaft. The third threaded hole are not careful.
in the knob is left blank. The set screws should
Fig. 3: Panel Holes Required (Inches) be tightened only on flats. 5.2 INITIAL OPERATION
c) Connect the two 22 em long tubes (sup- To clean out the vai've and prepare it for con-
plied) to vai've ports 5 and 6. Use the longer necting the column, establish solvent flow
threaded bushing on port 6, and a short one on through the valve. Turn valve to LOAD, then
port 5. Both of these tubes should be bent so INJECT (to fill the sample loop). If the Needle
4.1 IMPORTANT SAFETY NOTICES
that their ends point downward to facilitate col Adapter has been attached to the valve,
lecting the vented liquid. remove it temporarily now. Use the 7125 Nee-
4.1.1 CAUTION:
To prevent siphoning effects, the outlet ends of dle Port Cleaner to flush out the needle port
Be sure to use the proper size of syringe with about 1 ml of mobile phase. This will leave
needle to avoid damage to the valve. See sec- both tubes should be at the same horizontal
tion 4.2 level as that of the needle port. the needle cavity filled with mobile phase. The
d) Connect pump to port 2 and the column excess soi'vent will flow out port 5 and leave
tube to port 3, using the longer threaded bush vent tube 5 filled with solvent. Repeat the flush
4.1.2. WARNING:
ing for the column tube. Leave the column dis- ing step with the vai've in LOAD position. This
When using the Needle Port Cleaner. dis
connected from the valve during initial clean- will fill vent tube 6.
charge the syringe slowly to avoid squirting
soi'vent back at yourself. See Figure 4 and sec- ing operations.
tion 5.1 The use of a Rheodyne Column Inlet Filter
will protect your column inlet frit from plugging CAUTION: To avoid liquid squirting back at
from particles in the sample or from pump and you, discharge syringe slowly.
4.1.3 WARNING:
valve wear particles.
(Manual Operation Only)
5.G1 MAKING PNEUMATIC
When using sample loops larger than the 20 CONNECTIONS
microliter size, protect yourself from the rapid A pneumatic supply pressure of 40 to 125
ejection of mobile phase coming out of the psi is required for operation-either air or
needle P.Qrt when the valve is turned from nitrogen. At. least 60 psi is recommended for
INJECT to LOAD. See section 9.9 reliable operation of the Model 7126. Figure 6

shows suggested control connections with
4.0 GETTING STARTED either 3-way or 4-way control valves or sole-
To prepare for initial use of the Model 7126, noid valves. Rheodyne #7164 Control Valve or
you should follow the installation and start-up #7163 Solenoid Valve Kits are useful for this
instructions in sections 5 and 6. Also be sure to purpose. Use #10-32 threaded fittings to make
read the CAUTION and WARNING notes in pneumatic connections to the ports on the two
section 4.1. cylinder caps (see Figure SA). Fig. 4: Use d Needle Pert Cleaner
/1 I
N 1 h Holesin
~Piston U-Ring (2)

w--
/Stator Ring
-
Tr._CapScrew(8) (
~ f10.32AirPort Piston-Rack Assembly (2)
- -
i
cap(2) I ___,__
Cap ().Ring (2)
I
EJ-~-~ UG',d:,_,,......., Fig. 5C: Rotor Seal Orientation. (Viewed From Stator and
With Shaft Half way Between LOAD & INJECT).
v- a--
Drive~
wr
Barbed Frttings (2) 7126-015
Rotor
~~- 1/45116 Wrench 7125027
'~fiE~;';~~- 9164 Socket Wrench 7010032
Four Punch Marks
~ - 5164 Socket Wrench 7010027
1-stopScrew(2) inUne
- 0
W u[J- Needle Port Cleaner 7125054
-Lock Nut (2)
F"og. SA: Model 7126 Body Assembly

I
Correct Meshing of
Gear & Rack Teeth ,
! ~- Ferrules (4) 7010010
Extra Long Bushing (") 7010062
~---Long Bushings(") 7010011
~ Bushings (") 7010009
Mounting Screws (2) 7010019

- 22cm Vent Tubes (2) 7125-069
"Quantity supplied dependent on wllle model.
1---- Body Assembly F"og. SD: Parts supplied in sepa1a1e bag

(See Fig. SA)
Knob
r Set Screws (2)
m
I
Fig. SB: Model 7126 \laM! Exploded V-
Before connecting the valve to the column, stator face. Do not push hard on the syringe- wall. The amount of sample in the loop
make some practice injections using mobile just be sure it is bottomed. approaches its maximum value asymptotically.
phase. Follow the instructions in section 6. d) Gently discharge the syringe to com- About 2 to 3 loop volumes of sample are
After practicing, connect the column and pro- pletely fill the loop. required to achieve 95% of maximum. This is
ceed with the chromatography. e) Leave the syringe in position and tum the the minimum recommended for good preci-
valve to INJECT. sion, but 5 to 10 loop IIOiumes will provide bet-
6.0 MAKING AN INJECTION IN THE f) Rei'TIOYe the syringe. ter precision. You should determine this experi-
MANUAL MODE g) Alternatively, use the syringe to suck up mentally for yourself.
the sample from a vial into which vent tube 6 is
6.0.1 FILLING THE LOOP COMPLETELY dipped. &.o.2. PARTIALLY FIWNG THE LOOP
(Manual Operation Only) h) Be sure that the loading passages have
been flushed with solvent after the last injec- (Manual Operation Only)
This is the conventional method in which the tion to prevent cross-contamination between
110lume of sample injected is precisely deter- runs. In this method, the syringe delivery deter-
mined by the 110lume of the loop plus valve pas- ~ In this method, wnt tube 5 is not used. mines the sample 110lume injected (see section
sges. Use a syringe of suitable capacity Flushing of the needle port and valw pas- 3.0.2).
together with the #122. ga. needle supplied (90 sages is done with the valw in LOAD position. a) With valw in INJECT position, use the
point). In the complete filing method, an excess of 7125 Needle Port Cleaner (part 117125-054) to
a) Observe WARNING 4.1.3 and turn valve sample must be used because the fluid veloc- flush out the needle port with about 1 ml of
to LOAD. ity in the sample loop tubing varies from a max- eluting solvent This will flush out residual con-
b) Load the syringe with sample. imum at the tube axis to zero at the wall. As tamination from the previous injection. The
c) Insert the syringe needle into the needle sample pushes solvent ahead of it during load- flushing liquid will exit out of wnt tube 5.
port all the W8!f until the hub almost touches ing, the locus of the sample-solwnt interface NOTE: See section 9.3 for possible elimina-
the needle guide. The needle tip will touch the becomes diffuse. Solvent remains along the tion of this flushing step.
"Quantity and type supplied dependent on \I8Ne model.

b) Observe WARNING 4.1.3 and turn valve
to LOAD. Fig. 6: Pneumatic Actuator Control Schemes
c) Load the syringe with the desired sample
volume.
d) Insert syringe needle into the needle port One4-Way

Control Valve
all the way until the hub or barrel almost '
touches the needle guide. The needle tip will
touch the stator face. Do not push hard on the
syringe-just be sure it is bottomed.
e) Gently discharge the syringe contents. Air or vent
f) Leave syringe in position and turn valve to Nitrogen
INJECT. Supply
vent
g) Remove the syringe and leave the valve in
INJECT position.
In the partial filling method, no more than
half a loop volume of sample should be passed
into the loop in order to maintain volumetric
accuracy. With larger volumes some of the Two'J..Way
sample is lost out vent tube 6. This is because ContrOl Valves
of flow velocity inequalities throughout the loop
tubing.
vent
6.1 MAKING INJECTIONS IN THE
AUTOMATIC MODE
The Model 7126 as a manual injector has all The main causes of premature failure are:
the advantages of the Model 7125. As an auto- a) Incorrect needle tip shape can cause the
matic injector it can be connected to: ceramic stator face to chip which then causes
a) an autosampler for analysis of different deep scratching of the rotor seal surface.
samples; b) Abrasive particles in the sample which
b) a sample reservoir for repetitive injec- cause scratches on the rotor seal surface. Pump
tions of the same sample for: The rotor seal wears with use and is the only
1. automated methods development. part that routinely needs replacement. It can COlumn
2. precision studies of a method, be expected to last between 6 months and 2 years.
3. preparative separation.
To control sample reservoir flow, a solenoid 8.1 CHANGING ROTOR SEAL
on-off valve in the reservoir-to-injector line is To change the rotor seal proceed as follows:
opened for a time duration sufficient to fill the a) Leave the Model 7126 attached to the
loop. This may be done at any time after the panel, but remove the knob.

injector returns to LOAD. See Figure SA. b) Remove the three stator screws (refer to Fig. BA
Alternatively, the solenoid valve can be elim- Figure 58). Do not change the setting of the
inated by simply plugging port #5. The injector set screws in the stator at this time.
is actuated to LOAD position only long enough c) Remove stator and stator face from valve
to fill the loop. Actuation to INJECT position body by pulling axially to disengage the various
stops the sample flow. See Frgure 88. pins.
With the latter method, cross contamination d) Push the shaft out of the body.
trapped in the plugged port #5 should be e) Remove the rotor seal by prying it off of
flushed out prior to filling the sample reservoir the four seal pins, using a screwdriver or knife
with a new sample. Or a capillary bleed line blade.
can be connected to port #5 instead of a plug. f) The isolation seal and bearing ring usually Column
A continual flush of about 1 ul/min of the sam- are left in place because they rarely need
ple itself is adequate. changing.
g) Install a new rotor seal (part #7125-047)
7JJ ADJUSTING FOR HIGHER PRESSURE on the four seal pins by following the reassem-
OPERATION bly procedure in section 8.2.
The three small set screws in the stator (see
Figure 58) have been factory set so that when Flg.IB
the three stator screws are fully tightened, the
spring force between the valve rotor and stator
is sufficient to hold 34 MPa (5000 ps~. If leak-
age is to be corrected, or if operation up to 48
MPa is to be done, proceed as follows: The
three set screws should be loosened about
1120 tum each (18 of rotation) and the three
stator screws tightened an equal amount. If
this new setting fails to accomplish leak-free
operation, repeat the procedure by an addi-
tional 1/20 turn. Avoid excessive tightening
which will accomplish nothing but increased
wear of the rotor seal. If it is necessary to
loosen spring tension, either to lower the oper-
ating pressure or to adjust for a new rotor seal
,
,,
which may be thicker than the one being
replaced, reverse the above procedures: i.e.,
~X1-1/4Screw
first loosen the stator screws. Then tighten the
setscrews.
8JJ MAINTENANCE
With normal use. the Model 7126 should Fig. 7: Installation or -7126-091 Needle
give thousands of injections without trouble. Adapler Aaembly.
8.2 REASSEMBLY 9.1 LEAKAGE from touching the stator face.
Reassembly of the valve requires putting all If liquid is observed dripptng out between Even when cross-contamination is not a
parts back together as shown in Figure 5 while stator and stator ring, the stator screws should concern. it is good practice to flush the valve
observing the following: be tightened as explained in section 7.0. leak- (section 5.1) about every ten injections. This
a) Be sure that the two rotor drive pins are in age out the needle port or vent tube (other prevents buildup of contamination and also
place in the gear (see Figure SA). If they fell than that caused by loading the loop) is caused keeps the needle port and vent tube 5 filled
out, put them back in place. by scratches on the rotor seal. Try tightening with solvent, preventing air from inadvertently
b) Be sure that the rotor seal is correctly ori stator per section 7.0. or, if this fails to stop the entering the sample loop.
ented as shown in Figure SC with rotor seal leakage. replace the rotor seal (part #7125-
slots facing the stator. The needle port tube will 047). 9.4 USE OF AQUEOUS BUFFERS OR SALT
be in line with the Teflon sleeve in the rotor seal NOTE: If the vent tubes from ports 5 and 6 SOWTIONS
when the rotor seal is in the correct positions. do not have their outlet ends at the same hori- To prevent the formation of salt crystals in
c) Push the shaft and rotor seal assembly zontal level as the needle port. siphoning can the valve, flush out the flow passages and the
into the body with orientation as shown in Fig occur which is often misinterpreted as '1eakage." needle port with water after usage of salt
ure SC. and while pushing on the rotor seal sur solutions.
face. rotate the knob end of the shaft until the 9.2 NEEDLE SEAL LEAKAGE
two rotor drive pins enter the mating holes in Because the outside diameter of the syringe 9.5 USE OF HIGH pH SOLUTIONS
the shaft. The shaft will then be properly ori needle varies from syringe to syringe, the nee- The standard rotor seal is Vespel, a DuPont
ented relative to the gear. It will be in either dle seal (Teflon sleeve in the rotor seal) may polyimide which has exceptionally good wear
LOAD or INJECT position or halfway between not immediately seal properly around a needle resistance. However, it is susceptible to alka-
as shown in Figure 5C. which is smaller than average. This is true also line attack, deteriorating rapidly when used
d) Make sure that the seal disc is in place of the needle in tho #7126-091 Needle Adapter. with solutions of pH over 10. An alternative
in the stator face assembly and that its holes This will result in a loss of accuracy in loading material, Tefzel. is available for alkaline appli-
are aligned with the six holes in the ceramic. the sample. The spring loaded needle tube will cations (See Section 8.3).
This seal disc usually stays tightly in place eventually reform the Teflon sleeve to make a
inside the stator face assembly and should good seal. but is you do not want to wait, do the 9.6 PWGGED VALVE PASSAGES
not be removed. following: If valve passages get plugged, they can be
e) In replacing the stator face assembly on With needle removed from the needle port, opened by removing the stator as described in
the stator. the small notch in the rim of the face push on the plastic needle guide. This will section 8.1 and cleaning the passages with a
assembly should be in line with port 1 of the assist the spring in deforming the Teflon small wire (.015 inch maximum diameter).
stator. Make sure that the two pins enter the sleeve. Do not push so hard that the Teflon
holes in stator. sleeve is squashed too much. A few gentle trys 9.7 KEEPING NEEDLE SEAL IN PROPER
f) Mount the stator and stator face assembly will produce the desired result. SHAPE
on the valve by pushing it onto the two pins on To check tor a proper liquid seal around the
the stator ring and then adding the three stator syringe needle. fill the syringe with water and (Manual Operation Only)
screws. Be sure that the stator face assembly slowly discharge the syringe with the injector
remains properly in position on the stator. It in the LOAD position. Notice the lack of resist- During periods of idleness of the chromate
has a tendency to fall off during assembly; so, ance to syringe discharge. Now repeat the graph, such as overnight or during weekends,
be careful. Tighten each screw a little at a time action with the injector handle half-way it is advisable to leave the 22 ga needle (sup-
to keep the stator surface parallel to the stator between LOAD and INJECT. (The pump must plied) fully inserted in the needle port. This will
ring surface. If the three set screws in the be off in this position.) Now it should feel keep the needle seal (Teflon sleeve in the rotor
stator were left unchanged. then tighten the noticeably harder to discharge the syringe. seal) in proper shape and prevent it from being
three stator screws until all parts are held The needle seal is designed to seal around squeezed down too small.
firmly in place. The three set screws will insure the needle only to a few psi of pressure. Since
that the gap between stator and stator ring is a microliter syringe can produce much higher 9.8 CAUBRATING SAMPLE LOOPS
uniform and exactly as it was before pressure with just a small force on the plunger, Sample loop sizes are designated by nomi
disassembly. do not expect the needle seal to completely nal values, which can vary from the actual
g) If the set screws need adjusting because prevent syringe discharge with the handle in value by as much as 20%. This is due to the
a new rotor seal was installed or because leak the half-way position. .001" tolerance on the tubing I.D. (see table
age has to be stopped, refer to section 7.0 and below). Since both standards and unknowns
be sure that each set screw is turned an equal 9.3 FLUSHING BETWEEN INJECTIONS are usually analyzed with the same loop,
amount so that after the stator screws are knowledge of the absolute loop volume is
retightened, the gap between the stator and (Manual Operation Only) rarely needed. If the actual loop volume must
stator ring is uniform all around. be known, it is best to calibrate it in place on
h) Note that there are three threaded holes Measurements have indicated that under the valve. so that the flow passages in the
in the knob but only two set screws are used. proper operating conditions the residual sam valve (one in the rotor and two in the stator) are
The set screws should be tightened only on the pie left in the needle cavity and on the needle also taken into account.
two flats milled on the shaft. seal surface after an injection varies between
~ After installation of a new rotor seal, it is 0.001 and 0.01 microliter. This represents Tubing Volume tolerance resulting from
usually necessary to form the needle seal 0.01% to 0.1% of a 10 microliter injection. If bore .()01 " bore tolerance
around your syringe needle. See Section 9.2. this amount of cross-contamination between
successive injections is acceptable. then you .012" 17%
do not need to flush the needle port between .020" 10%
8.3 SUGGESTED SPARE PARTS .030" 7%
injections. Eliminate step (a) in section 6.0.2.
However, it is wise to check the magnitude
7125047 Vespel Rotor Seal for 712517126 9.9 USE OF LARGE SAMPLE LOOPS
(standard)
of cross-contamination periodically and to use
the flushing step when in doubt. Conditions
7125079 Tefzel Rotor Seal for 712517126
that can produce excessive cross-contamina- (Manual Operation Only)
tion are:
Spare frttings for new tubing connections:
a) Needle is too short so that the needle tip When large sample loops are used, a few
7010009 Bushing
does not touch the stator face. Minimum microliters of mobile phase will be expelled
7010011 Long Bushing
length from hub to needle tip should be 5.00 from the needle port and vent tube 6 when the
7010062 Extra Long Bushing
em (1.97 inch.) valve is returned to LOAD. This happens be
7010-010 Ferrule (one required for each
b) Syringe is not held in place with needle cause the compressed fluid in the sample loop
make-up)
bottomed in needle port while turning from expands when it is exposed to atmospheric
LOAD to INJECT. pressure. Since the compressibility of most sol
9.0 OPERATING SUGGESTIONS AND c) Dirt particles or needle seal shavings in vents is about 10- per atmosphere, the solvent
TROUBLE SHOOTING the needle port are preventing the needle tip in a 1-ml sample loop will expand about 20 ul
upon decompressing from 21 MPa (3000 psi).
Observe WARNING 4.1.3 A small test tube or
absorbent tissue can be placed at the needle
port when returning the valve to LOAD, in order

to safely catch the expelled liquid.
9.10 CHANGING SAMPLE LOOPS AND

COWMN CONNECTIONS
The depth of the tubing holes in the valve
ports may vary slightly from port to port and
from valve to valve. A fitting made up in one
port may leave a dead space in another port. It
is good practice, therefore, to label sample
loops so that if they are removed, they will be
replaced in the same orientation in the same
valve. Also be sure that the column connecting
tube at port 3 is made up with no dead space.
&
AHEOD!INE
INCORPORATED
Prinled in USA 9190
P.O. BOX 996, COTATI, CALIFORNIA 94931, U SA (707) 664-9050 FAX 707 664 87.39

For Model 7010
INCORPORATED
1.0 INTRODUCTION
Sample Injection Valve
The Model 7010 Sample InJection Valve is a six-

The isolation seal serves to prevent valve leak-
age from entering the spnng and bearing region
5 if one is used.
d) The connecting tube to column should be
port rotary valve with removable external sam- of the valve. It does not perform any high pres- as short as possible and .25 mm (.01 in.) I. D. or
ple loop designed for high performance liquid sure sealing function. smaller.
chromatography. The valve should give years of The maximum operating temperature of the e) Leave column disconnected from valve for
dependable serv1ce w1th easy maintenance. The Model 7010 is 150C. initial flushing.
Model 7010 is supplied w1th tube fittings to permit
connection of 1/16 inch tubing to the valve ports. 4.0 GETTING STARTED 6.0 OPERATION
Also supplied are two wrenches for servicing. To prepare for initial use of the Model 7010. you Before connecting the column to the valve. flow
Figure 1 shows the holes required for panel should follow the installation and start-up instruc- eluting solvent through the valve and turn the
mounting the valve as well as holes for mounting tions in sections 5 and 6. Also be sure to read the valve to both LOAD and INJECT positions (LOAD
a loop filler port accessory (described in a WARNING note in section 4.1. Sections 7. 8 and is CCW. INJECT is CW). The valve has been
separate manual). 9 give helpful operating suggestions. mamten- tested at the factory with water: so if water is to
The standard sample loop supplied with the ance and serv1cing information. be avoided. be sure that the solvent will remove
7010 is the 20 microliter size (part #7022). Follow- any remaining traces.
ing are the standard sample loops available. 4.1 IMPORTANT SAFETY NOTICE After flushing the valve. it can be turned to the
Each loop is supplied with fittings for direct con- WARNING: When using sample loops LOAD position and connected to the column. Fill
nection to the valve. larger than the 100 microliter the sample loop by sucking up the sample from
size. protect yourself from the a vial through one of the tubes connected to ports
Sample loop Tubtng bore rapid ejection of mobile phase 5 and 6 (use a syringe on the other tube for suc-
SIZe coming out of a loop filler tion). Or fill the loop by dispensing sample from
cat.log
number miCrOhlers mm tnches port when the valve is turned a microsyringe via a loop filler port (see Section
from INJECT to LOAD. See 8.6).
7020 5 18 007
Section 8. 7. An excess of sample must be used because
7021 10 30 012
7022 20 51 020 the fluid velocity in the sample loop tubing varies
7023 50 51 020 from a maximum at the tube axis to zero at the
7024
100 51 020 wall. As sample pushes solvent ahead of it during

7025 200 76 030 loading. the locus of the sample-solvent interface
7026 500 76 030 becomes diffuse. Solvent remains along the wall.
7027 1000 76 030
7028 2000 1 00 040
The amount of sample in the loop approaches
7029 5000 1 00 040 its maximum value asymptotically. About 2 to 3
loop volumes of sample are required to achieve
95% of maximum. This is the minimum recom-
2.0 WARRANTY
mended for good precision. but 5 to 10 loop
Rheodyne products are warranted against
volumes will provide better precision. You should
defect in materials and workmanship for a period
determine this experimentally for yourself.
of one year following date of shipment. Rheodyne
After filling the loop, inject the sample onto the
will make repairs or replacements free of charge
column by turning to INJECT position. Before the
upon return to the factory. transportation prepaid.
next injection, turn the valve to LOAD and flush
of the defective item.
out the loading tubes with solvent to remove all
traces of the previous sample.
3.0 DESCRIPTION OF MODEL 7010
To avoid plugging the valve passages it is
The Model 7010 operates by rotation of a flat
recommended that filtered solvents be used and
rotor against a flat stator. Figure 2 shows the port
that sample liquid be free of solids that could plug
configuration and switching pattern. Rotation of 39 (.75 if pos1t1on
sensing switch is used)
the loading tubes. The use of the Rheodyne
the shaft through 600 switches the valve from
Model 7335 or 7315 Column Inlet Filter will pro-
LOAD (CCW) to INJECT (CW). / l /.18(2) tect your column inlet frit from plugging from
Figure 3 is an exploded view of the Model 7010.
particles in the sample.
The stator is Type 316 stainless steel. The rotor
is faced with a Vespet" rotor seal. Slots in the rotor
seal make flow paths between the adjacent stator
ports, and turning the rotor 600 switches the flow Fig. 1: Panel mounting hOles. in inches.
paths as shown in Figure 2. The diameter of the
slots is .46 mm (.018 in.). Holes in the stator are
.61 mm (.024 in.) in diameter and connect to the
threaded tubing ports on the outside of the stator. 5.0 INSTALLATION
Two stop pins and the rotor pin limit the rotation a) Mount the valve on your panel with holes as
to 6~ Four conical spring washers and a thrust shown in Figure 1. Refer to section 7.3 for handle
bearing are used to push the rotor seal against attachment procedure.
the stator face with sufficient force to hold 48 MPa b) Connect pump to port 2 or 3 and column
(7000 psi) liquid pressure. Three set screws in the to port 3 or 2. Use the longer of the four threaded
stator are factory adjusted so that. when the three bushings supplied to connect the column tube.
stator screws are fully tightened. the force This will permit its being removed most easily
bet'Neen the stator and rotor is sufficient to hold - LOAD position (CCW}
because the additional bushing length makes it INJECT position (ON)
34 MPa (5000 psi). To increase the maximum more accessible to a wrench.
operating pressure to 48 MPa. follow the direc- c) Connect two tubes to ports 5 and 6 for sam- Flg.2:
tions in section 6.1. ple introduction. Connect a loop filler port to port Model 7010 Switching Pattern
P.O. BOX 996, COTATI. CALIFORNIA 94931. U.S.A. (707) 664-9050 FAX 707 664 8739
6.1 ADJUSTING FOR LEAKAGE OR :0..
HIGHER PRESSURE OPERATION 01 "'a;
The three small set screws 1n the stator (see 5 .c
;;; 01
~ c ~
,.. -""'"'
Figure 3) have been factory set so that when the 01 c. ~ g>
01
three stator screws are fully tightened. the spring
" c. c. ~ ~ j
<;; '0 5 5
.c 0 l:
force between the valve rotor and stator is sui </) cc 1- </) </)

ficient to hold 34 MPa (5000 psi). If leakage is to
be corrected, or if operation up to 48 MPa (7000
psi) is to be done. proceed as follows: The three
set screws should be loosened about 1/20 turn
Notch
each (18 of rotation) and the three stator screws
tightened an equal amount. If this new setting
fails to accomplish leak-free operation at the
desired pressure, repeat the procedure by an Shaft Assembly"
Flat on shaft
add1ttonal 1/20 turn. Avoid excessive tightening
which will accomplish nothing but increased
Rotor seal
wear of.the rotor seal. If it is necessary to loosen
spnng tension, either to lower the operating pres F'lg. 3A:
sure or to adjust for a new rotor seal which may 'Shaft Assembly 1ncludes shaft. rotor and p1ns.
Rotor Seal Orientation
be thicker than the one being replaced. reverse Fig. 3: MOdel 7010 explOded v1ew (v1ewed from stator)
the above procedures. i.e., first loosen the stator
screws. Then tighten the set screws.
If leakage cannot be stopped by tightening the 7.3 ATTACHING HANDLE 8.5 CALIBRATING SAMPLE LOOPS
valve. or if. as a result of tightening to stop the The handle has two set screws 180 apart. Be Sample loop sizes are designated by nominal
leakage. the handle is too hard to turn, the rotor sure that both set screw tips are centered on the values. which can vary from the actual value as
seal needs replacing. See the next section. hole in valve shaft before tightening (remove one much as 200/o. This is due to the .001 inch
set screw to observe alignment). Tighten both set tolerance on the tubing I. D. (see table below).
7.0 DISASSEMBLY AND REASSEMBLY screws only enough to hold handle firmly. Since both standards and unknowns are
usually analyzed with the same loop. knowledge
7.1 DISASSEMBLY 7.4 SUGGESTED SPARE PARTS of the absolute loop volume is rarely needed. If
Disassembly of the valve for servicing of the 7010039 Vespel Rotor Seal the actual loop volume must be known. it is best
liquid end is accomplished as follows: 7010071 Telzel Rotor Seal to calibrate it in place on the valve. so that the flow
a) Remove the three stator screws. Do not Spare fittings for new tubing connections: passages in the valve (one in the rotor and two
change the setting of the three set screws in the 7010-009 Bushing (nut) in the stator) are also taken into account.
stator at this ttme. 7010011 Long Bushing (nut)
b) Refer to Figure 3 and remove stator and 7010-062 Extra Long Bushing (nut) Tubing Volume IOierance resultrng from
stator ring from valve body by pulling axially to 7010-010 Ferrule (one required for each bore t OOt 1nch bore tolerance
disengage the various pins. make-up) 0121n tt7%
c) To remove the rotor seal. pry it off of the four 020 In tlO%
seal pins. using a screwdriver or knife blade. 8.0 OPERATING SUGGESTIONS 030 In t7%

d) The isolation seal and bearing ring usually AND TROUBLESHOOTING
are left in place because they rarely need 8.6 USING A LOOP FILLER PORT
changmg. 8.1 LEAKAGE A loop filler port accessory (Rheodyne Model
If liquid is observed dripping out between 7012) is available. It is simply a needle insertion
7.2 REASSEMBLY stator and stator ring, the stator screws should port with a very small dead volume surrounding
Reassembly of the valve requires putting all be tightened as explained in section 6.1. Leakage the needle when it is inserted. It permits loading
parts back together as shown in Figure 3 while out ports 5 or 6 (other than that caused by of the sample loop by means of microliter
observing the following: loading the loop) is caused by scratches on the syringes. Refer to the separate instruction manual
a) Be sure that the rotor seal is correctly rotor seal. Try tightening stator per section 6.1, or when using this accessory.
oriented as shown in Figure 3A with rotor seal if this fails to stop the leakage. replace the rotor
slots facing the stator and with the notch in the seal (part #7010039). 8.7 USE OF LARGE SAMPLE LOOPS
metal rim of the rotor seal in line with the rotor pin. NOTE: If the tubes from ports 5 and 6 do not When large sample loops are used. a few
b) In replacing the stator ring, be sure that the have their outlet ends at the same horizontal level. microliters of mobile phase will be expelled from
two stop pins are replaced in their holes in the siphoning can occur which is often misinter the loop filler port or vent line (ports 5 and 6)
stator ring, then push the stator ring squarely onto preted as "leakage." when the valve is returned to LOAD. This
the rotor assembly so that the stop pins enter the happens because the compressed fluid in the
mating holes in the body (with rotor pin between 8.2 USE OF AQUEOUS BUFFERS OR sample loop expands when it is exposed to
the two stop pins) and so that the isolation seal SALT SOWTIONS atmospheric pressure. Since the compressibility
slips inside the stator ring without hanging up. To prevent the formation of salt crystals in the of most solvents is about 10- per atmosphere.
c) Replace the stator by first pushing it onto the valw, flush out the flow passages and the needle the solvent in a 1-ml sample loop will expand
two pins on the stator ring and then adding the port with water after usage of salt solutions. about 20 microliters upon decompressing from
three stator screws. Tighten each screw a little at 21 MPa (3000 psi). Observe WARNING 4.1.
a time to keep the stator surface parallel to the 8.3 USE OF HIGH pH SOWTIONS
stator ring surface. If the three set screws in the The standard rotor seal is Vespel", a DuPont 8.8 CHANGING SAMPLE LOOPS
stator were left unchanged, then tighten the three polyimide which has exceptionally good wear AND COWMN CONNECnONS
stator screws until all parts are held firmly in place. resistance. However, it is susceptible to alkaline The depth of the tubing holes in the valve ports
The three set screws will insure that the gap attack, deteriorating rapidly when used with may vary slightly from port to port and from valve
between stator and stator ring is uniform and solutions of pH over 10. An alternative material to valw. A fitting made up in one port may leave
exactly as it was before disassembly. is available for alkaline applications (consult a dead space in another port. It is good practice.
d) If the set screws need adjusting because a factory). therefore. to label sample loops so that if they are
new rotor seal was installed or because leakage removed, they will be replaced in the same orien
has to be stopped, be sure that each set screw 8.4 PWGGED VALVE PASSAGES tation in the same valve. Also be sure that the
is turned an equal amount so that after the stator If valve passages get plugged, they can be column connecting tube at port 3 is made up with
screws are retightened. the gap between the opened by removing the stator and cleaning the no dead space.
stator and stator ring is uniform all around. Refer passages with a small wire (.015 inch maximum
also to section 6.1. diameter). "Vespet IS a trademark ol DuPont
=::::rl
=.J\.. Printed in USA 9190
IHIODHNI
INCORPORATED P.O. BOX 996. COTATI. CALIFORNIA 94931. U.S.A. (707) 6649050 FAX 707 664 8739
Rheodyne Part Numbers for
IHEOD!:fNE
INCORPORATED
Model 7010 Sample Injection Valve
[=rJL :=J- Knob Assembly 7010-060
1 - - - - - Shaft
1 - - - Body 7010-042 1 (2) Bearing Race 7010-012 &

+--+--- Thrust Bearing, consists of \ (1) Roller Assy 7010-013
r::J1-+--- Spring Ring 7010-004
s;;;;;;----- Spring Washers (4) 7010-014

- - - Rotor Pin
'[]'- Rotor
rr:::n---- Seal Pins (4) 7010-021
l Shaft Assembly
(includes rotor,
shaft & pins) 7010-038
- - - - Bearing Ring 7010-006
"""ilL-.:::::::JijJ__,.. Isolation Seal 7010-015
~ _ Rotor Seal 7010-039
-Stop Pins (2) 7010-022
- - - Stator Ring 7010-041
- - - - Stator Pins (2) 7010-018
rrw=ftl-r=--c:::ril_t-~-_-_-_-_-_ Stator Set Screws (3) 7010-017

~ Stator 7010-040
Jt------
r~
n
Stator Screws (3) 7010-016
(rf---=-~~::-_: __==::3_ :/64 Socket Wrench 7010-032

W ~ ______ ===:~ 164 Socket Wrench 7010-027
g Ferrule (4) 7010-010
1\ ---Extra Long Bushing (*) 7010-062 Parts Bag

for Model70-10
~ #~~~
lLlJ - - - Long Bushing (*) 7010-011
~ - - - Bushing (*) 7010-009
1--- Mounting Screws (2) 7010-019
*Quantity supplied dependent on valve model.
P.O. BOX 996, COTATI, cALIFORNIA 94931, U.S.A. (707) 664-9050 FAX 707 664 8739
Printecl in USA 9190
Rheodyne Part Numbers for
AHEOD!INE
INCORPORATED
Model 7012 Loop Filler Port

- Spacer 7012-001
- Panel Bushing 7012-002
- - - Teflon liner tube
1 = - - - Teflon ferrule
Needle port fitting

7012009
Printed in USA 9190

worno
Valco Instruments Co. Inc.
New Design, HPLC
Injectors and
Switching Valves
The most advanced "User Friendly" HPLC
sample injection and switching valves.
-no
needed for rotor replacement
New Design 6 and 10 Ports Sample Injectors Design

The Valco C6W and C10W are sample loop injectors for Recently, Valco has perfected a new valve design which
HPLC that may be filled partially or completely using con- represents a major advance in HPLC sample introduction
ventional microliter syringes. They are the easiest to tum of and flow switching devices. Extreme reduction in force re-
any HPLC manual injectors and are available with air or quired for actuation makes possible the replacement of the
electric actuators for automation. The C6W is also an ex- usual "T" handle with a small knob. Lifetime is increased by
cellent column switching valve. The C10W may be used as a a one-point seal loading design. Worn rotor replacement, if
single or dual injector or a combination sample injector and necessary, is as simple as replacing a fitting or changing a
column switching valve. septum. The injector does not require demounting or
removal of tube connections for rotor replacement. Figure 1
Introduction shows the pre-load assembly that holds the rotor in the
The thorough evaluation that injection methods have received valve body. When a different rotor is put into the valve, this
as a part of the overall development of HPLC instrumen- pre-load assembly places the new rotor back to the factory
tation and column development has shown clearly the set tension.
superiority of shear seal type sample valves. For sample-in-
jection with minimom bandspreading and with the
reproducibility demanded by quantitative methods a sample
injection valve is the device of choice.
For most HPLC sample injection, a removable sample loop

valve may be used. Partial loop loading methods allow < 1 Ill
to ml's to be injected with typical syringe precision. Full
sample loop loading may be used with Valco new HPLC
valves from 2,.rl to ml's for the best precision. For smaller
sample sizes, Val~ submicroliter injectors, the C14W can
inject with full loop precision from 0.06 to 2.0 "'1 (for informa-
tion, see the Valco submicroliter injector bulletin).
Figure 1
Loading Sample
Partial Loop Mode a. LOAD - SAMPLE SYRINGE
Samples are conveniently loaded with standard syringes having 22 POSITION
g (.028") x 2" needles. As shown in Figure 2, the syringe is inserted LEVEL OF WASTE
in the fill port and while the valve is in the load position, the desired

TUBE EXIT
volume is displaced. A < 1 ~o~l bubble separates the sample from the
mobile phase it displaces. The valve is then switched to the Inject
position, thus transferring the sample In the loop and the rotating
passage shown to the column. After injection, the syringe plunger
should be pulled back slightly to withdraw the approximate 0.2 ~o~l
remaining in the fill port. The design of Valco's fill port is such that
one may inject very nearly the volume of the loop in the partial loop
mode without dilution of sample (contrary to what other manufac- VALVE IS VIEWED FROM SPRING END.
turers have stated). As shown in Figure 2, the presence of the micro LOAD TO INJECT IS A COUNTERCLOCKWISE ROTATION.
bubble between sample and displaced mobile phase prevents
laminar flow in the loop and makes precise injection possible when
sample loaded is > 213 loop volume. Partial loop loading is done in b. INJECT ~j SAMPLE SYRINGE
POSITION
the same fashion with 6 and 10 port models. CONNECTING SLOT
Full Loop Loading

Full loop loading is accomplished just as partial loading, and re-
quires very little more than the volume of the loop to be displaced
for full loop precision. The 10 port injector may have two loops in-
stalled (see the 10 port applications bulletin) of different sizes
which may be accessed randomly using two separate fill ports.
Sample Injection
MANUAL
CNJ 6PORT As described above, the sample is injected when the valve is switched
C10W 10PORT 2.65" to the inject position. This may be a manual or automated
operation using the Valco air or electric actuators. The bore of the
ports and seal transfer passages (0.016") is smaller than those of
----1 ' any other manufacturer's injectors so the sample is transferred in

0.75"1.0"1 the minimum possible volume of mobile phase to the column.
~ - +---...
3.58" 1.425" Tube Connections

Tube connections are 1/16" Valco zero dead volume, an industry
standard, and are not damaged even after hundreds of uses. The in-
jector to column connection should be made with the minimum
uCI~-'-----'-'
length practical of < 0.010" 10 0.062": .002" 00 tubing for
AIR OPERATED minimum band broadening. The valve ports are 0.016" (0.4 mm).
AC6W
AC10W
Materials of Construction
The injector body is contructed of Nitronic 60, the most resistant to
I I
F5"1.o" 1
I galling of any stainless steel. Both fitting and rotor sealing sur-
faces are far more resistant to wear and galling than the type 316
SS used by others. Corrosion resistance is excellent for virtually all
HPLC conditions, however, if exposure to materials that attack
stainless steels is possible, the optional Hastelloy C model should
be ordered. The valve rotor seal is of "Valcon H"; a proprietary inert
polymer blend which is non-porous, wear resistant and is not af-
ELECTRICALLY OPERATED fected by any chemicals under HPLC conditions, even strong acids
Er:AW and bases.
EC10W
Pressure/Temperature
5.5" Each valve is tensioned and tested for 7000 psig service below 75
degrees C. After disassembly and inspection, they are reassembled
and, tensioned and tested at 5000 psig for maximum lifetime. Initial
operating torque will be 6 - 8 inchllb which will decrease slightly
with use. Filtered ( < 5 micron) carrier and sample streams should
always be used to prevent internal scratching between ports. Con-
I sult the factory for higher temperature and pressure applications.
4.0" 0.75" For example. units are in use at 2000 psig and 150 degrees C.

I I
W~ ~ rn Yalco Instruments Co. Inc.

P.O. Box 55603, Houston, TX 77255 USA
Telephone (713) 688-9345
Telefax (713) 688-8106 Telex 79-0033\IU.COHOU
Yalco Europe
Untertannberg 7 CH-6214 Schenkon, Switzerland
Telephone (045) 21 68 68
Telefax (045) 21 30 20 Telex 868342 VICI CH
Rev. 5M1
Technical Note 43
Closemount Assembly
for Air or Electric Actuators
2 Position Valves
When the valve arrives from the factory installed on an actuator, it is accurately aligned and
ready to use. Every time the clamp ring on the actuator is loosened to readjust or remove
the valve from the actuator, the valve and actuator must be realigned so that the internal
ports and slots on the rotor align properly.
Alignment Procedure
Alignment is very important to the correct functioning of the valve when valves are used
with automatic actuation, . It is important to note that the actuator actually drives only the
rotor within the valve body via a drive shaft, and that the valve body and standoff assembly
remain stationary with respect to the actuator. For the purpose of determining the align-
ment, the actuator should be stepped from one position to the other and observed for the
location of the rotor pin. The rotor pin should come to rest against either side of the cutout
in the valve body. If it does not, realignment is necessary.
To align, actuate the valve so the rotor pin is against one stop. If the rotor pin is not touch-
ing the appropriate stop, loosen the clamp ring and rotate the valve by hand to complete
the rotor pin travel. Tighten the clamp ring and check the travel. If a small gap remains be-
tween the rotor pin and the stop in either direction, rotate back to the position opposite the
gap and loosen the clamp ring. This will allow the actuator force to rotate the valve body
slightly. Tighten the clamp ring and continue to check alignment Several rotations may be
required to adjust.
CLOSEMOUNT HARDWARE
PRE-LOAD

AIR INLET SQUARE CLOSE MOUNT ASSEMBLY
DRIVER CS2 STANDOFF
SCREWS ClJTOIJT
CR4 ROTOR CS5

CLAMP TAB VAJ..VE SCREWS
AIR ACTUATOR RING BODY
Figure 1: Air actuator with W-series valve and

closemount assembly
PRE-LOAD
CLOSEMOUNT HARDWARE ASSEMBLY
ClJTOIJT
CS2
SCREWS

CR4
CS6
ROTOR
css
SCREWS SCREWS
CLAMP TAB
RING VAJ..VE
BODY
Figure 2: 8ectric actuator with W-series valve

and closemount assembly
Printed in USA C 1990 Rev. 7/90
Worn~ YalcolnstrumentsCo.lnc.Sales
P. 0. Box 55603, HouSIDn, TX 77255 USA
1iJiephone (713) 688-9345
Fax (713) 688-8106
(800)367-8424
worn~ illffi
1
VllcoEurope
Untertannberg 7 CH-6214 Schenkon, Switzerland
Telephone (045) 21 68 68
Telefax (045) 21 30 20 Telex 868342 VICICH

3. Using the two CS6 screws, attach the CR4 clamp ring to the actuator, making sure that
the square driver is centered within the clamp ring. On the air actuator, the clamp ring
attaches to the end of the actuator where the square driver is drilled with a 1/4" hole.
4. Position the black closemount standoff on the valve body so that the valve rotor pin is
visible in both LOAD and INJECT positions through the long slot ori the side of the
standoff. Attach with CSS screws. The 10 port valve will have only one CSS screw.
5. Insert slotted coupling into opening of closemount standoff, fitting the slot over the rotor
pin.
6. Firmly press the flange of the closemount standoff into the clamp ring on the actuator,
making sure that the square driver of the actuator engages the squared hole of the
standoff drive shaft. The closemount standoff should be flush against the clamp ring.
7. Tighten CR4 clamp ring with CS2 screw.
8. Align valve and actuator according to Alignment Procedure.
If the valve and actuator are not properly aligned before use, internal slots and ports in
the valve body will not align properly; flow of sample may be blocked, and other
problems may result.
CLOSEMOUNT HARDWARE
I
PRE-LOAD

AIR INLET SQUARE CLOSEMOUNT ASSEMBLY
DRIVER CS2 STANDOFF
SCREWS CUTOUT
ROTOR
I PIN
CR4 ROTOR CS5

CLAMP TAB VALVE SCREWS
AIR ACTl.JATOR RING BODY
Figure 1: Air actuator with W-series valve and

closemount assembly
CLOSEMOUNT HARDWARE PRE-LOAD

ASSEMBLY
CUTOUT
(]
CR4
CLAMP
RING
ROTOA
TAB
VALVE
BODY
CS5
SCREWS

Figure 2: Electric actuator with W-series valve
and closemount assembly
Printed in USA C 1990 Rev. 7/91J
rn
W~ ~ YalcoBoxInstruments Co. Inc.Sales
P. 0. 55603, Houston, TX 77255 USA
Telephone (713) 688-9345 (800)367-8424
w~ rn {jJ[E
~
1
Yalco Europe
Untenannberg 7 C~4 Schenkon, Switzerland
Telephone (045) 21 68 68
fax (713) 688-8106 lelefax (045) 21 30 20 Telex 868342 1C1 CH

Technical Note 201

(' .\ ~
'""(Q)JL~'-- ~/~--
. . - :-----:'~ ,---:::--
-- .,. :\ -"tl
-~~~,~~- ;-~ -r---1_~-------,-~(Q.I
. r~-.
~
-~x-:0 "'Il- __ _j __
s
/
\
Rotor Replacement
W and UW Type Valves
Air, Electric and Manual Models
k~
One advantage of this valve design is that it allows rotor
replacement without removing loops and tubing, and
PfiE.l.OAD_I
ASSEMSLY
~
without disengaging the valve from the actuator or I I

I
I 1
mounting bracket. IAI- ROl'OR
I l!! I
,, :1
Disassembly I 'I
Please read through procedure before beginning

1. See Figure 1. Unscrew the entire knurled pre-load
assembly. Do not tamper with the preset socket
adjustment screw.
2. Engage the end of the rotor with a pencil-type
magnet, available from Valco or any electronic Figure 1: C6W valve

components supplier. See Figure 3. shown
ENOOFAOTOR
Figure 2: Valve body viewed Figure 3: Pencil-type

from pre-load assembly end magnet holding the rotor
CAUTION: Any contact between the Interior of the valve body and the metal
of the rotor Is likely to cause damage
3. Cycle the valve one time to break apart the sealing surfaces and carefully withdraw
the rotor from the valve body with the magnet. NOTE: Before removing the rotor,
observe the position of the tab on the rotor, which is marked (P, T, H, or E
depending on the seal material) to allow proper orientation of the new part. The
symbol on the tab is always oriented toward the valve cutout, which is opposite

Port 1. Following is a list which shows where to orient the symbol for these Valco
valves:
Number of ports Symbol is closest to

ORIENTATION
3 port Port 2 SYMBOL--
4 port Port 3
6 port Port 4
8 port Port 5
10 port Port 6
Internal sampling valve between p and s
Cleaning the Valve Body
The following procedure is recommended:
1. Wet a cotton swab with a solvent which is compatible with the chromatographic
system. Isopropyl alcohol is recommended.
2. Gently swab the polished interior of the valve to remove any loose residue.
3. Blow with clean compressed gas to remove lint left by the swab.

Cleaning the Rotor
The following procedure is recommended:

1. Carefully grasp rotor by either end and briefly immerse
in solvent. If it is too difficult to grip securely, hemostats
or needle-nosed pliers may be helpful. Grip the tab
end, being careful not to mar the metal or touch the
polymer.
2. Gently wipe the surface of the polymer with a clean
tissue.
Figure 4:
3. Blow with clean compressed gas to remove lint left by Holding the rotor
the tissue.
Reassembly
1. Place clean rotor on pencil magnet and orient it so that the tab will properly engage
the slot of the drive mechanism. Refer to .section 1, Disassembly, step 3 for
orientation of rotor.
2. Insert rotor into valve body, again being careful not to touch the interior of the valve
body.
3. Using a pencil or other small pointed object, hold rotor in place in valve body while
magnet is pulled free.
4. Replace the knurled pre-load assembly, tightening it into the valve body until it
bottoms.
5. Cycle valve 5 to 1o times to seat the sealing surfaces, taking care that valve is not
left in mid-position.
Disassemble valve ONLY If absolutely necessary!
Note: All WT and UWT rotors must be conditioned at 3400C before being placed in
service at lower temperatures. After installation and alignment, the valve body should
be heated to 3400C and the rotor rotated several times at that temperature. This pro-
cedure insures a smooth and uniform sealing surface which reduces the likelihood of
rotor galling at lower temperatures. The valve may then be used for prolonged periods
at lower temperatures. If sticking or groaning" occurs, recondition as decribed to
return to normal operation.
Number 106- April1990
RheFiex Fittings and Sample Loops for Non-metal Connections

RheFlex fittings provide inert, a superior gripping action on 5000 psi. The ferrule can be
non-metal connections for 1/16- PEEK, Tefzel and Teflon tubing. reused many times.
inch O.D. tubing in scientific On metal tubes the ferrule grips The fittings are sold in
instruments. The unique gripping the tube in two areas, resulting in packages of 5 sets (5 nuts and 5
design ensures reliability at high increased reliability at high ferrules). Extra ferrules can be
pressure, with just finger pressures. purchased in packages of five.
tightening, on a variety of plastic The angles and surface The nuts come in two sizes,
and metal tubing. contacts between the ferrule and regular and short. See Fig. 3.
The nut and ferrule are made nut are specially designed to Part numbers for the fittings
of polyetheretherketone, PEEK. are as follows:
Rheodyne PEEK sample loops are
supplied with RheFlex fittings. 6000-051 RheFlex Ferrules
(pkg/5)
6000-054 RheFlex Fitting
Set pkg/5
6000-055 RheFlex Short
Fitting Set pkg/5.
PEEK Sample Loops

Rheodyne non-metal injection
Ficure 2. Enlarged View of Ferrule on valves are supplied with a PEEK
Tubing sample loop. Table I is a list of
sizes available.
Figure 1. Fitting Orientation prevent the nut from gripping the When PEEK tubing is bent
ferrule and twisting both the into a small radius, such as for a
These fittings and loops can be ferrule and the tube during sample loop, the structure of the
used with most Rheodyne sample tightening. This prevents the loop material is stressed. Premature
injectors, including those made of tubing from being twisted in bursting at these stress points can
PEEK, titanium, or stainless steel. opposite directions while being occur, especially at elevated
attached to the valve. Such pressures and with organic
RheFiex Fittings twisting would stress the PEEK solvents. To prevent this from
The RheFlex fitting consists of tubing, lowering the pressure occurring, RheFlex sample loops
a PEEK nut and a PEEK ferrule. rating. undergo a special annealing
Fig. 1 shows the correct The RheFlex fitting will hold process after bending. After this
orientation of the RheFlex fitting. onto PEEK, stainless steel, process the sample loop will retain
A knurled knob on the end of titanium, and Tefzel tubing to its coiled shape and will regain the
the nut makes it easy to finger original burst strength of the
tighten these fittings_. However, a straight tube.
wrench can be used if preferred.
Fig. 2 shows an enlarged view

of the ferrule and how it grips the
tubing in both the front and back
positions. The slotted backside of
the ferrule is squeezed down onto
the tube by the mating conical
surface in the nut. This results in
Fipre S. RheFlex Nubs (actualaize)
Rheodyne Product Notes Number 106 Page 2
rable L PEEK Sample Loops Available indicate burst pressures similar to

tetrahyrofuran.
Catalog Loop Tubing Bore PEEK is degraded by
Number uL mm inch concentrated nitric and
9055-020 5 .18 .007
concentrated sulfuric acids .
9055-021 10 .26 .010
9055-022 20 .26 .010
9055-023 so .51 .020
9055-024 100 .51 .020 WARNING!!! The tubing failed at
9055-025 200 .51 .020
9055-026 500 .76 .030
the pressures listed in Table II. A
9055-027 1000 76 .030 safety factor should be used .
9055-028 2000 .76 .030 Routine operation should be a
9055-029 5000 .76 .030 much lower pressure.
Burst Pressure of PEEK Tubing

PEEK is viscoelastic, without
a well-defined yield strength. No
data exists for calculating the burst
pressure; it is profoundly affected
by time under load and has to be
determined experimentally under
each set of conditions. But the
following generalizations can be
nade for l/16-inch O.D. tubes.
The tubing will burst at a

lower pressure when you:
1. Increase the I.D.
2. Increase the temperature.
3. Increase the time of exposure.
4. Increase the concentration of
organic solvent.
Table II shows the pressures at
which various tube sizes burst
during a three-week test while
exposed to a variety of solvents at
room temperature. At 500 psi
below these pressures the tubing
did not burst within a three week
period.
Tests using methlyene chloride
Table D. Pressurea (pei) at which PEEK tubing failed in a three-week exposure teet.
Tube I.D. Samole Loop Water 50/SO ACN /Water 100% ACN 100% IPA 100%THF
.007 inch 5 uL >6000 >5500 4000 >5000 2500

.010 10, 20 uL >6000 5500 3500 5000 2500
.020 50, 100, 200 uL >6000 4500 3000 4000 1500

.030 .5, 1, 2, 5 mL >6000 3500 3000 4000 1500
P.O. Box 996, Cotati, California 94931 U.S.A. Phone 707-664-9050 FAX 707-664-8739
INCORPORATED
For Model 9010 Injection Valve

NOTE: Model 9010 Sample Injection Valve also rated pressure of the injection valve. Details are in ing the knob set screw(s). Use the two #8-32
serves as a switching valve and 4-way valve by the attached Product Note on fittings and loops. screws supplied to fasten the valve to the panel.
simply removing or changing the position of the When replacing the knob be sure the two set
external sample loop. See section 7.1 for details. 3.3 WARNING: A pinhole rupture in the plastic tub- screws are centered on the hole in the shaft before
ing can emit a high velocity jet of fluid which can tightening securely.
1.0 INTRODUCTION penetrate skin and eye tissue.
Model9010 Sample Injection Valve is designed
so there is no metal in contact with the fluid stream. 3.4 CAUTION: To protect the bearings from cor- CAUTION: Use only plastic ferrules in the
Thus. applications in which metal ions are delete- rosion due to leakage do not mount the valve with PEEK stator. Metal ferrules will damage the
rious can be performed . .Acids, bases, and chloride the ports facing up. See Section 1.0. plastic stator irreparably. and void the warranty.
salts can also be safely used with this valve. Some
of the structural parts of the valve are susceptible 3.5 CAUTION: Rinse the valve thoroughly after the
to corrosion from leakage or spills of corrosive use of buffer solutions so as to prevent the forma- Use the fittings supplied with the valve to con-
liquids; care is needed to protect these parts. To tion of salt crystals, which can cause scratches on nect 1116 inch O.D. tubing to the valve ports. Be
protect the bearing from corrosion due to leakage, the rotor seal. See sections 8.0 and 9.1. sure to push the tubing to the bottom of the port
the valve should not be mounted with the ports before tightening the fitting. The valve has been
lacing up. 3.6 CAUTION: Use only plastic ferrules in the stator tested at the factory with water; so, if water is to be
ports. Metal ferrules can cause irreparable damage avoided, be sure to flush the valve with an appro-
to the plastic stator. and void the warranty. See priate solvent before connecting it into the stream.
CAUTION: Do not mount the valve with the section 5.1. Connect pump to port 2 and column to port 3.
ports lacing up. Use the provided L.uer Tube at port 5 to load sam-
4.0 DESCRIPTION ple into the loop.
Model 9010 operates by rotation of a flat rotor
Supplied with the valve in a separate bag are seal against a flat statoc Fig. 1 shows the port con- 7.0 OPERAnON
the following items: figuration and !toN switching pattern. The six small Before connecting the column to the valve, flow
a) Two socket wrenches 9164 & 5164 .circles represent the ports in the valve stator. The mobile phase through the valve and tum the valve
b)Luer tube three heavy arcs represent the connecting to both LOAD and INJECT positions. After flushing
c) Fitting sets lor 1116 inch O.D. plastic tubing passages in the rotor seal. Rotation of the shaft the valve, it can be turned to the LOAD position
d) Two #8-32 screws for valve mounting through 60 switches the valve from LOAD and connected to the column.
The sample loop is supplied in a separate bag (counterclockwise) to INJECT (clockwise). The sample loop can be filed by one of two tech-
with the required fittings. The 20 microliter (pl.) size Fig. 2 is an exploded view of Model9010 Sam- niques. In pressure loading, the sample is dis-
is standard. The attached Product Note on fittings ple Injection Valve. The stator is an inert plastic, pensed from a syringe via the L.uer Tube. In suc-
and loops lists other loop sizes available lor Model polyetheretherketone (PEEK). The rotor seal is an tion loading, sample is sucked from a vial into the
9010. Each loop is supplied with fittings lor direct inert polymec Holes in the stator connect to the loop through the L.uer lUbe. In both cases the L.uer
connection to the valve. threaded tubing ports on the outside of the stator. Tube is connected to port 5. See Fig. 4.
Four conical spring washers and a thrust bearing An excess of sample must be used to fill the loop
2.0 WARRANTY are used to push the rotor seal against the stator because the fluid velocity in the sample loop tub-
RheocJYne products are warranted against face with sufficient force to hold the set pressure. ing varies from a maximum at the tube axis to zero
defects in materials and workmanship lor a period The pressure adjusting screw at the shaft end of at the wall. As sample pushes solvent ahead of it
of one year following date of shipment. Rheodyne the valve is factory adjusted so that the force
will make repairs or replacements free of charge between the stator and rotor is sufficient to hold
upon return to the factory, transportation paid, of 34 MPa (5000 ps1).
the defective item.
Products may not be returned which are con- 5.0 GETTING STARTED
taminated by radioactive materials, infectious To prepare for initial use of Model 9010, follow
agents. or other materials constituting health the installation and operation instructions in sec-
hazards to Rheodyne employees. tions 6 and 7. Also be sure to read the WARNING
AND CAUTION notes in section 3.0. Sections 8
3.0 IMPORTANT SAFETY NOTICES and 9 !jve helpful operating and ma~ntenance, and
3.1 WARNING: When using sample loops larger servicing information.
than 100 p.L, protect yourself from the rapid ejec-
tion of mobile phase coming out of ports 5 and 5.1 USING FITTINGS SETS
6 (the L.uer Tube is connected at port 5) when the For an explanation on the use of fitllngs lor Model
valve is turned from INJECT to LOAD. See section 9010 refer to the attached Product NOie on fittings
9.5. and loops. _ . . LOAD (cx:w)
- INJECT (cw)
3.2 WARNING: The burst pressure of the plastic 6.0 INSTALLATION
tubing is affected by many factors. Plastic tubing Mount the valve on your panet With holes as = N 1: Model9010 Swilching Panem (viewed from handle
usually burst at pressures much lower than the shown in FIQ. 3. First remove the knob by loosen-
P.O. BOX 996, COTATI, CALIFORNIA 94931, U.S.A (707) 664-9050 FAX 707 664 8739
during loading, the locus of the sample-solvent
interface becomes diffuse. Solvent remains along
the wall. The amount of sample in the loop
approaches its maximum value asymptotically.
About 2 to 31oop volumes of sample are required

to achieve 95% of maximum. This is the minimum
recommended for good precision, but 5 to 10 loop
volumes will provide better precision.
After filling the loop, inject the sample onto the
column by turning to INJECT position. Before the
next injection, while still in INJECT. flush the port
with about 1 ml of mobile phase. This flows directly
out vent #6 without passing through the loop.
During rotation between LOAD and INJECT. the
flow to the column is momentarily shut off; rapid
rotation of the handle will minimize this transient Body
pressure change. t t - - t - - - Thrust Bearing
Shaft Assembly'
To avoid scratching the rotor seal and/or plug- ~-1--- Spring Washers (4)
ging the valve passages, use filtered samples and
Rotor Pin
solvent.
Position Sensing Switch Location
~--60" Stop Ring
I:[J!I-Tr=::i:=11F-~-- Seal Pins (4)
WARNING: With sample loops larger than 20
pl mobile phase may eject from the injection
port and vent line when turning the valve to the
LOAD position.
1 - - - - - Bearing Ring
7.1 SWITCHING VALVES
Model9010 can also serve as a switching valve
and 4-way valve by simply removing or changing
the position of the external sample loop. See Fig.
5 for flow-switching patterns. Refer also to Fig. 7
for various connection schemes. Stator Ring
For 4-way operation the 20 pl sample loop can
be connected across ports 1 and 5. If low disper
sion is important, the loop can be shortened or
replaced with a short piece of JXJl" I. D. tubing .
7.2 ADJUSTING FOR LEAKAGE Stator Face Seal

A single pressure adjusting screw at the shaft
end of the valve body is used in Mode19010 (see
Fig. 2). The adjustment has been factory set so
Stator Support Ring
that the spring force between the valve rotor and
stator is sufficient to hold 34 MPa (5000pSI). To stop
leakage proceed as follows:
a) If the valve is mounted on a panel or 1--1r-----Stator Screws (3)
bracket use a wrench to tighten the adjusting
screw about 1120th of a turn. There are 20 dial
markings on the body and a painted spot on the
adjusting screw facing them. These help to tell how 'Shaft assembly includes shaft. rotor. pins
far to tighten the screw.
If the new setting fails to accomplish leak-free
operation. repeat the procedure by an additional
1120th of a turn. Avoid excessive tightening which
will accomplish nothing but increased wear of the
rotor seal. Loosen each of the three stator screws (see Fig. cycles without trouble.
b) If the valve is not panel rno&mted the 2) by 1/2 to 1 tum (use 9/64 socket wrench The main cause of premature failure. which is
adjusting screw is hard to tum since the valve body supplied). This will relieve the spring tension seen as a leakage in the valve, is abrasive particles
is not held securely. In this case do the following: holding the rotor against the stator; the adjusting in the sample and/or mobile phase or crystalliza-
screw will be easier to tum (a friction compound tion of buffer solutions. E'lther can cause scratches
isonthethreadsto make it somewhat hard to tum). on the rotor seal surface.
A wrench may sliD be necessary. When replacing the rotor seal, always check the
Proceed as in (a) to make a 1120th of a turn ceramic stator face for chips or cracks. Replace
tightening, and before testing the valve. re-tighten the stator face assembly if it is damaged.
the three stator screws. These stator screws should
be tightened down at all times to keep the stator
held against the slater ring surface. HONever. since CAUTION: Flush the valve after the use of
the stator ring is plastic. the screws should not be buffer solutions.
tightened ecessively. Feel yourVBfto notice when
they are tightened enough. Correct tightening
torque is 9 kg-em (8 lt:Hn). 8.1 CHANGING THE ROTOR SEAL
To change the rotor seal proceed as follows:

8.0 MAINTENANCE a) Leave the valve attached to the panel and
The rotor seal wears with use and is generally leave the knob on. If it is necessary to remove
the only part that needs replacement. With nor- the valve from the panel before servicing, then
Figure 3: Panel Holes Required ~nclleS) mal use. Model 9010 should give thousands of replace the knob after remowl from the panel
Pump screws should be tightened down at all times
to keep the stator held against the stator ring
surface. However. since the stator ring is
plastic, the screws should not be tightened.
excessively, just snug against the stator sup-
Column port ring.
g) Using a wrench, retighten the pressure
adjusting screw about Y2 tum.
Loading Syringe 8.3 ATTACHING KNOB ASSEMBLY

The knob has two set screws. both at 90" from
the black handle. Be sure that both set screw tips
-.. ~1
are centered on the hole in the shaft before tighten-
Pressure Loading ing (rem011e one set screw to observe alignment).
Tighten both set screws only enough to hold the
handle firmly.
Syringe IUI
8.4 POSITION SENSING SWITCH
Pump To replace or remove the position sensing switch:
a) Rem011e the stator.
b) Pull the stator ring off: the 60 stop ring nor-
mally remains attached to the stator ring.
l.JJer
c) Pull the switch out of the stop ring.
Column
Tube d) Replace with a new switch, or leave the hole
empty if a switch is not needed.
9010 e) Reassemble.
The position sensing switch is a magnetic reed
switch actuated by a magnet which is sealed inside
the valve shaft. The switch is rated for 10 volts at
10 milliamperes. Do not use it to control a higher
Suction Loading voltage.
8.5 SUGGESTED SPARE/REPLACEMENT
PARTS
Figure 4: Two Methods of Loading Model 9010
9010-051 Rotor Seal
See Product Note on loops and fittings for spare
fittings.
9.0 OPERATING AND TROUBLESHOOTING.

(this simplifies the disassembly). d) Place the stator support ring onto the stator. SUGGESTIONS
b) Rem011e the three stator screws. Be sure the support ring's bumpy inner con-
c) Remove stator support ring, stator. stator face tour fits into the mating contour of the stator. 9.1 USE OF AQUEOUS BUFFERS OR SALT
assembly (this may remain attached to stator), e) In replacing the stator face assembly on the SOWTIONS
and stator ring from valve body by pulling stator. the small notch in the metal rim of the To prevent the formation of salt crystals in the
axially to disengage the various parts. stator face assembly should face the stator valw, which can cause scratches on the rotor seal
d) Remove the rotor seal by prying it off of the locating hole. Make sure the two pins enter and/or plug passageways, flush out the flow
four seal pins, using a screwdriver or knife the mating holes in the stator. passages and vent line after the use of salt solu-
blade. f) Mount the stator and stator face assembly on tions. Salt solutions should not sit stagnant in the
e) The isolation seal and bearing ring usually the stator ring with the stator locating pin valve overnight or for long periods of time.
are left in place because they rarely need entering the mating hole in the stator. Then
changing. add the three stator screws. Be sure the stator 9.2 PWGGED VALVE PASSAGES
f) Install a neN rotor seal (see section 85 for part face assembly remains property in position If the valve passages get plugged, they can be
number) on the four seal pins by following the on the stator. Tghten each stator screw a lit- opened by removing the stator and cleaning the
reassembly procedure in section 8.2. tle at a time to keep the stator surface parallel passages with a small wire, (.005 inch maximum
to the stator ring surface. Finally, tighten the diameter).
three stator screws securely. These stator The vent line can also become plugged, espe-
CAUTION: When reassembling the valve,

loosen the pressure adjusting screw BEFORE
tightening the stator screws.
Lcop
8.2 REASSEMBLY
Reassembly of the valve requires putting all the
par1s back together, as shown in Fig. 2, while
observing the following:
a) Be sure the rotor seal is correctly oriented as
shown in Fig. 6. with rotor seal stots facing
the stator.
b) Using a wrench, loosen the pressure adjust- 4-way
ing screw about Yz tum.

c) Push the stator ring squarely onto the rotor
assembly and make sure the position sens- - POSITION 1 (ccw)
ing switch falls into the mating hole in the stator .- POSITION 2 (cw)
ring, and the body locating pin falls into the
mating hole in the stator ring. Flgu.. 5: Flow-Switching Patterns of Model9010 Modified as a Switching llalw (viewed from halide end)
......
Model 9010
Model 9010 without loop

B
Model 9010 without loop Model 9010 without loop

Figure 6: Rotor Seal Orientation (viewed from stator) Two-column selection Sample clean-up (stripping) Sample enrichment
Olfline column is sealed. Tech fv.o.pump system strips highly Pre-column concentrates com
nical Notes 8 discusses the retained undesired compounds ponents of interest. They are
effect of column selection vailleS from lhe sample. Then pump B then eluted by pump B to
on resolution. flushes prEH:Oiumn. analytical column.
cially if buffer solutions are allowed to crystallize
in it (see section 9.1).1fthe line is plugged then flush
it out or replace it.
9.3 LEAKAGE
Leakage is usually caused by cross-port
scratches, i.e., new flow passages that have been
scratched onto the rotor seal. If liquid is observed
dripping out between the stator and stator ring,
or the L.uer Tube port, first tighten the pressure
adjusting screw as explained in section 7.2. If this
fails to stop the leak then replace the rotor seal (refer
to section 8.1).
If the tubes from ports 5 and 6 do not have their Moclel9010 Model 9010 wltllout lOop Moclel9010
outlet ends at the same horizontal level, siphoning with loop relocated Pre-column backflUShing with loop Nloc8tecl
from these outlet ends can occur. which is often Column backflushing
Flow continues through the
Alternaling regeneration
misinterpreted as '1eakage: Mobile phasetlow is switched to analytical column in the normal Column A is regenerabng white
If siphoning is occuring the '1eak" will stop when a backflush direction. The direcbon. Only the pre-celumn column B is analyzing. Then col-
backfluShed peak is directed to is backfluShed. umns interchange.
the loop and connecting tubes have emptied. If the detector.
the leak is due to cross-port scratches then the leak
will continue as long as the pump is pumping .

Flgunt 7: Switching Application tor Moclel9010 wilh Loop Position Modified (viewed from handle end)
9A CALIBRATING SAMPLE LDOPS
Sample loop sizes are designated by nominal
values, which can vary from the actual volume by
as much as 20%. This is due to the tolerance on
the tubing 1.0.. Since both standards and 9.6 CHANGING SAMPLE LOOPS AND b) The flat stator face is polished alumina
unknowns are usually analyzed with the same COWMN CONNECTIONS ceramic, which causes less wear on the rotor
loop, kno.vledge of the actual loop volume is rarely The depth of the tubing holes in the ports may seal.
needed. If the actual loop volume must be known, vary slightly from port to port and from valve to c) A single-point pressure adjusting screw is at
it is best to calibrate it in place on the valve so that valve. A fitting made up in one port may leave a the shaft end of the valve.
the flow passages in the valve (one in the rotor and dead space in another port. It is gooa practice, d) Plastic fitting sets are supplied. Description
two in the stator) are also taken into account. therefore, to label sample loops so that, if they are and make-up of these fittings is outlined in the
removed, they will be replaced in the same orien- attached PrOduct Note.
9.5 USE OF LARGE SAMPLE LOOPS tation in the same valve. Also, be sure that the e) The standard rotor seal will tolerate the en-
When large sample loops are used, a few micro- column connecting tube at port 3 is made up with tire pH range from 0 to 14.
liters of mobile phase will be expelled from the L.uer no dead space. f) The maximum operating temperature isSO"C.
Tube or vent line (ports 5 and 6) when the valve g) The pressure rating of the valve itself is 34
is returned to LOAD. This happens because the 10.0 SPECIFICATIONS MPa (5000 PSI} In operation, the pressure
compressed fluid in the sample loop expands The key features of Model 9010 valves are as is usually limited by the tubing used. See the
when it is exposed to atmospheric pressure. Since follows: attached PrOduct Note on fittings and loops
the compressibility of most solvents is about 10- a) The stator is made of PEEK an inert polymer. for data on tubing burst pressure.
per atmosphere, the solvent in a 1 mL sample loop Because the stator is plastic, metal ferrules h) The maximum operating torque is 17 kg-em
will expand about20 pl. upon decompressing from cannot be used for connecting tubes to the (15 lb-in), 10 kg-em is typical.
21 MPa (3000 PSI} Observe WARNING 3.0. ports.
FiR
~
IIIIOD!INI
INCORPORATED P.O. BOX 996, COTATI, CALIFORNIA 94931, U.S.A. (707) 664-9050 FAX 707 664 8739
Prinled in USA. 9190
Supplementary
INCORPORATED

No. 532
Model 9010-067 Sample Injection Valve
Model 9010-067 functions as a Model 9010, except that it is built into a pneumatic actuator for
automatic operation. Connections to the 9010-067 are the same as diagrammed in the 9010 Operating
Instructions. The injection port located in the front handle assembly is non-functional. Injections are
made in through the rear of the valve.
The only sections in the 9126 Operating Instructions that apply to the 9010-067 are: 7.1, 7.3, 9.4 (use
9010 flow diagram), 11.1, and 11.2 (use Fig. 6 in the 9010 instructions not Fig. 5c).
The sections in the 9010 Operating Instructions that DO NOT apply to the 9010-067 are: 8.1, 8.2, 8.4,
and 8.5.
Replacement part unique to the 9010-067 are:

7010-071 Rotor Seal
Apri192

P.O. BOX 996. COTATI, CALIFORNIA 94931, U.S.A. (707) 6649050 FAX 707 664 8739
for Model 9126
INCORPORATED
Auto~atic Sample Injector
1.0 QUICK SfARf INSTRUCTIONS 2.0 SUPPLIED WITH THE VALVE h) The maximum operating torque is 17 kg-
This section gives a quick overview of how In a separate bag are fittings needed to con- em (15 lb-in); 10 kg-em is typical.
to use Model 9126 Automatic Sample Injector. nect the 9126 to the HPLC system. In addition,
For more complete and detailed instructions the following items are supplied: 4.0 IMPORTANT SAFETY NOfiCES
refer to the section of interest.
1. Read the WARNING and CAUTION =-=-- 9164 Socket Wrench 4.1 WARNING: When using sample loops
notices in section 4.0. ~ r-~--~~-- 5164 Socket Wrench larger than 100 ~o~L, protect yourself from the
2. PlumbthevalveasdiagramedinFig. 1. Be rapid ejection of mobile phase coming out of the
sure the outlet of vent tubes 5 and 6 are level with needle port when the valve is turned from
the needle port.
L!::::IJ Pressure Adjusting Nut
INJECT to LOAD. See section 12.8.
3. Before connecting the column, flow mo- o-- Needle Port Cleaner
bile phase through the valve in the LOAD and 4.2 WARNING: When using the Needle Port
INJECf position. Now connect the column. Cleaner, discharge the syringe slowly to avoid
4. Use the needle port cleaner to flush the valve ~ t J- Mounting Screws (2) squirting solvent back at yourself. See section
in both the LOAD and INJECT position. See
Fig. 2. ~-Ven!Tubes(2) 6.2.
aa---
5. Use the correct needle whenever a needle 4.3 WARNING: The burst pressure of the plas-
is used to load the sample either manually or tic tubing is affected by many fuctors. Plaslic tub-
automatically. The syringe needle specifications Barbed Fittings (2) ing usually burst at pressures much lower than
to avoid damaging the injector are: the rated pressure of the injection valve. Details
.028-inch O.D. (22 gauge) are in the attached Product Note on fittings and
5.1-cm (2-inches) long The sample loop is supplied in a separate bag loops.
90 point (square end) with the required fittings. The 20 ~size is stan-
no electrotaper dard. The attached Product Note on fittings and 4A WARNING: A pinhole rupture in the plas-
6. If partial loading: load no more than 50% loops list other loop sizes available for Model tic tubing can cause a high velocity jet of fluid
ofloop volume. For example, never load more 9126. Each loop is supplied with fittings for direct which can penetrate skin and eye tissue.
than 10 ,H. in a 20 ,H. loop. connection to the valve.
7. If complete loading: load 2-3 times the loop 4.5 CAUTION: Be sure to use the proper size
mlwne. For example, load 60 ~in a 20 ,H. loop. 3.0 SPECIF1CATIONS of syringe needle to avoid damage to the valve.
8. A gas supply pressure of 60 to 100 psi is The key features of Model 9126 are: See section 6.1.
required for automatic operation of the 9126. See a) No metal in contact with the fluid stream.
Fig. 7 for suggested pneumatic and electrical b)The stator is made of PEEK-an inert 4.6 CAUTION: Rinse the valve thoroughly after
connections. polymer. the use of buffer solutions to prevent the forma-
c) The flat stator face is polished alumina tion of salt crystals, which can cause scratches
ceramic, which causes less wear on the on the rotor seal. See section 11.0.
rotor seal.
d) A single-point pressure adjustment screw
allows for less wear on the rotor seal and
makes for easy adjustment.
e) The rotor seal will tolerate the entire pH
range from 0 to 14.
f) The maximum operating temperature is
50 "C.
I.DOp g) The pressure rating of the valve itself is 34
LOAD INJECT MPa (5000 psi). In operation the pressure
Knob of vaNe
is usually limited by the tubing used. See
the attached Product Note on fittings and

F"~g~~re L Model 9126 Flow Diagram loops for data on tubing burst pressure. F"~g~~re 2. Use of Needle Pon Cleaner
P.O. BOX 996. COTATI, CALIFORNIA 94931, U.S.A (707) 6649050 FAX 707 664 8739
4.7 CAUTION: Use only plastic ferrules in the in Fig. 3. When the syringe needle is fully syringe of at least 2 mL capacity with Luer tip
stator ports. Metal ferrules can cause irrepar- inserted, the flat tip of the needle touches the (not Luer Lock) is recommended-such as
able damage to the plastic stator and void the flat face of the stator so that the entire volume Rheodyne part #7252 or #7255. With the valve

warranty. of sample discharged from the syringe enters the in the INJECT position, use the cleaner to flush
stator passage which is part of the sample loop. out the needle port with mobile phase. To do this,
5.0 DESCRIPfiON push the tip of the cleaner against the opening
Model9126 is a six port sample injection valve 6.0 GENERAL INFORMATION of the needle guide and discharge the syringe
with a pneumatic actuator built around it in a To prepare for initial use follow the installa- slowly. Observe WARNING 4.2. The dis-
compact package. The combination permits the tion and operation instructions in sections 7 and charged liquid can squirt at you if you are not
user to operate the injector manually and auto- 8. Section 9 discusses different techniques for careful.
matically. making an injection. Be sure to read the WARN-
Model9126 is a sample injector in which there ING and CAUTION notes in section 4. Sections
is no metal in contact with the fluid stream. 11 and 12 give helpful operating, maintenance Warning: To avoid liquid squirting back at
Thus, applications in which metal ions are and servicing information. you, discharge the syringe slowly.
deleterious can performed. Acids, bases, and
chloride salts can also be safely used with these 6.1 USING PROPER SYRINGES
valves. Any syringe with Luer tip together with the .18(2)
.75
Fig. 1 shows the flow diagram of the valve. needle supplied with the 9126 or a conventional
The six small circles represent the ports in the low pressure microsyringe can be used to load
valve stator. The t\\0 heavy arcs represent con- the sample loop. The needle specifications are:
necting passages in the rotor seal. The larger
circle represents the needle port. The needle port .028-inch O.D. (22 gauge)
is used to fi.Il the sample loop in the LOAD po- 5.1-cm (2-inches) long
sition. In the INJECT position the loop is 90 point (square end)
switched into the solvent stream and the needle no electrotaper
port is vented through valve port 5.
F"I(!Ure 4. Panel Holes Required (inches)
An exploded view of Model9126 is shown in Failure to use a needle of proper size can result
Fig. 5. The stator is an inert plastic, polyeth- in damage to the injector.
eretherketone (PEEK). The rotor seal is an inert Rheodyne supplies suitable microsyringes.
polymer. Slots in the rotor seal make flow paths The following are the part numbers and
6.3 USING. FTITINGS SEIS
between adjacent stator ports; turning the han- descriptions.
For an explanation on the use of fittings for

dle 60 switches the flow paths as shown in Fig.
Model 9126 refer to the attached Product Note
I. Holes in the stator connect to the threaded 7200 2.5 foiL Syringe
on fittings and loops.
ports on the outside of the stator. Four conical 720110 foiL Syringe
spring washers and a thrust bearing are used to 7202 25 foiL Syringe
7JJ INSTALLATION
push the rotor seal against the stator face with 7205 50 foiL Syringe
The panel holes required for mounting the
sufftcient force to hold the set pressure. The pres- 7210 100 foiL Syringe
9126 are shown in Fig. 4. In addition, you may
sure adjusting screw at the handle end ofthe valve 7225 250 foiL Syringe
need a hole to run the two vent tubes through
is factory adjusted so that the force between the 7250 500 JiL Syringe
the panel. Maximwn panel thickness is 4.8-mm
stator and rotor is sufficient to hold 34 MPa
(0.19-inch). Tomountthevalve, first remove the
(5000 psi). 6.2 USING THE NEEDLE PORI'
knob by loosening the t\\0 lcnob set screws. Use
There is no sample loss. All of the sample dis- CLEANER
Connect the Needle Port Cleaner (part the t\\0 #8-32 screws supplied to fasten the valve
charged from the syringe becomes injected onto
#7125-054) to a syringe as shown in Fig. 2. A to the panel.
the column. The needle port geometry is shown
When replacing the knob be sure the t\\0 set
screws are tightened securely on the t\\0 flats
of the shaft.
Caution: Use only plastic fimules in the con-

_, nections to the PEEK stator. Metal ferrules
will damage the plastic stator irreparably and
<
~Teflon Sleelle (Needle~ :;:;
wid the warranty.
RolorSeal 0
Connect the t\\0 vent tubes (supplied) to the

valve ports 5 and 6. Point the ends of both vent
tubes downward so the liquid can be collected.
To prevent siphoning effects, the outlet ends

of both tubes should be at the same horizontal
level as that of the needle port.
Connect the sample loop to ports 1 and 4, the
pump to port 2 and the column tube to port 3.
Leave the column disconnected from the valve
Fipre 3. Model 9126 Needle Axt Gcomeby during initial cleaning operations.
~
L w--
~ P1ston UR1ng (2)
Cap Screw (8) (

U 111032 A~r Port P1ston-Rack Assembly (2)
~Cap(2)i
~Cap Q.R,ng (2) Body
Stator Locat1ng Pin
tJ-c::}
v---([(@- ~A'
Bearing
I lpnng washers (4)
Pi~
Rotor Driw
Ring Screw (2)
1- Stop Screw (2)
--Lock Nut (2) Four Punch

10 Line
Marks~ F"ogure SC: Rotor Seal Orientation (Viewed from stator and
I - -
with shaft halfway between LOAD and INJECT)
Correct Meshing o1
Gear & Rack Teeth ,
F".gure St\: Model 9126 Body Assembly
Knob Stator Locat1ng Pin
Seal Pins (4)

Body Assembly
(See Fig. SA)
. . Set Screws (2)
!lsolatoon Seal
c~u-'de..l::r-'-----'
Rotor Seal Stator Screws (3)
Shaft Assembly' Stator Face Seal }

Pressure Mjust1ng Screw Stator Face Pins (2) Stator Face Assembly
Ceramic Stator Face

F".gure SB: Model 9126 Valve Assembly 'Shaft Assembly inCludes shaft. rotor and pins.
F".gure S. Model 9126 Valve Exploded VIeWS
7.1 MAKING PNEUMATIC #7126-091 Needle Adapter is inserted in the The SPDT (single pole double throw) switch
CONNECI'IONS needle port and fastened to the 9126 knob as has three different electrical connections (see
A gas (air or nitrogen) supply pressure of 60 shown in Fig. 9. The sample loop can then be Fig. 6). One electrical lead will connect to the
to 100 psi is required for automatic operation of filled by flowing sample into the needle port and C (common) terminal. If you want the contact
the 9126. Suggested pneumatic and electrical out port 6 or by flowing into port 6 and out the to be made when turning from LOAD to INJECf
connections using a Model7163 Solenoid Vdlve needle adapter tube. then wire the second electrical lead to the NC
is shown in Fig. 7. Rheodyne Model 7164 Air Refer to section 9.4 for suggested connections (normally closed) terminal. Ifyou want the con-
Control Vdlve can be used in place of the 7163 for automatic operation. tact to be made when turning from INJECf to
Solenoid Vdlve. l.DAD then wire the lead to the NO (normally
Use the supplied barbed fittings to make pneu- 7.3 USING THE POSITION SENSING open) terminal.
matic connections to the ports on the t\\0 cylinder SWI'ICH The switch is rated for 28 wits at 2.5 amperes.
caps. The position sensing switch is mounted on the
side of the actuator body. It can be used to start 8.0 INITIAL OPERATION
7.2 ATIACHING NEEDLE ADAPfER an external action such as an event mark or com- Before connecting the column to the valve,
For automatic unattended operation, the puter run. flow mobile phase through the valve in both the
LOAD and INJECf positions. In INJECf, use An excess of sample must be used because the In the partial fill method, no more than half
the Needle Port Cleaner to flush out the needle fluid velocity in the sample loop tubing varies a loop volume of sample should be loaded into
port with about 1 mL of mobile phase. This will from a maximum at the tube center to zero at the loop so to maintain volumetric accuracy. For
leave the needle cavity filled with mobile phase. the wall. This laminar flow behavior is shown example, load no more than 10 ~o~L into a 20 ~o~L
The excess solvent will flow out port 5 and leave in Fig. 8. loop. With larger volumes some of the sample
vent tube 5 filled with solvent. Repeat the To completely ftll the loop: is lost out vent tube 6. This is because of flow
flushing step in LOAD. This will fill vent tube a) Observe WARNING 4.1 and tum the valve velocity inequalities throughout the loop tubing.
6. Now connect the column. to LOAD. This laminar flow behavior is illustrated in Fig. 8.
When turning from LOAD and INJECf, the b) Insert the syringe into the needle port. You
flow to the column is briefly shut off; rapid turn- will feel some restriction just before the 9.3 WADING THE WOP BY SUCTION
ing of the handle will minimize this transient needle tip touches the stator face, this is the The two loop loading methods of above expose
pressure change. needle going through the teflon sleeve in the the sample to the metal needle of the loading
Use filtered solvents to avoid scratching the rotor seal. Do not push hard on the syringe syringe. Metal can be completely avoided by
rotor seal and/or plugging the valve passages. but be sure it is bottomed. using a syringe to suck sample into the loop.
c) Gently discharge the syringe to completely To load by suction:
fill the loop. a) With the valve in LOAD, dip the tube
d) Leave the syringe in, and tum the valve to attached to port 6 into the sample vial.
INJECI'. b) An empty syringe is inserted into the
needle port and used to suck up sample into
9.2 PARI'IALLY FULING THE LOOP the loop. Alternatively use the #9125-076
If only small quantities of sample are avail- Suction Needle Adapter (not supplied).
able, this is the method d choice. In this method, c) Leave the syringe in position and tum to
the volume in the syringe detennines the sam- INJECI' (see Fig. 9).
ple volume injected. The metal needle of the syringe will contact
To partially load the loop: the sample if an excess of sample is drawn into
a) In the INJECI' position, use the Needle Port the syringe, but this excess sample is out of the
F"JIIIR 6. Location and detail of position sensing swiiCh
on Model 9126 Cleaner (P/N 7125-054) to flush out the sample loop and will not be injected.
needle port with about 1 mL ofeluting sol- To load the loop with all of the available sam-
vent. This will flush out any contamination ple and not waste any, the loop should be at least
from the previous injection. This liquid will four times the volume of sample loaded. The
9.0 LOADING THE LOOP exit out of vent tube 5. loop is first filled with mobile phase via the dip
NOI'E: See section 12.6 for possible elimi- tube, then the whole sample is drawn into the
9.1 COMPLETELY FILLING THE LOOP nation d this flushing step. dip tube and loop, followed by more mobile
This is the conventional method in which the b)Observe WARNING 4.1 and tum the valve phase. The sample is now sandwiched between
volume of sample injected is detennined by the to LOAD. nvo zones of mobile phase in the loop. See Fig.
volume of the loop plus the valve passages (see c) With the desired sample volume loaded in 9 for an illustration of the suction method.
section 12.7 regarding calibrating sample loops). the syringe, insert the needle into the needle
The highest precision is obtained with this port. You will feel some restriction just
method. See section 9.4 for automatic injections. before the needle tip bottoms, this is the
In the complete filling method, at least two needle going through the teflon sleeve in the
to three loop volumes of sample are recom- rotor seal. Do not push hard on the syringe
mended. Five to ten loop volumes will provide but be sure it is bottomed.
even better prec~sion. d) Gently dischaige the syringe contents.
e) Keep the syringe in, tum to INIECI'.
Figure 9. Loading By Suclion Using the Suclion

Needle Adapler
9A MAKING INJECI'IONS IN THE

Initial fluid front Tube wall Ruid after flow
AU10MATIC MODE
Figure a. Laminar Flow As an automatic injector the 9126 can be con-
nected to:
a) an autosampler fur analysis of different
samples;
With this method, samples ranging from less b) a sample reservoir for repetitive injections
Figure 7. Pneumalic: and elec:uic conneclions wid! than one microliter up to approximately 50% of the same sample for:
Model9126 of the loop capacity can be injected. l. automated methods development;
2. precision studies of a method; a) If the valve is mounted on a panel or stator face assembly (this may remain
3. preparative separation. bracket remove the knob. Slip the pressure attached to the stator).
If using the sample reservoir method, to con- adjusting nut onto the valve shaft so that d) Push in on the front of the shaft until the
trol the flow of sample from the reservoir, an the tabs on the nut slip into the slots in the rotor seal is exposed above the stator ring
automatic on-off valve in the reservoir-to-injector adjusting screw. Use a wrench to tighten surface.
line is opened, with the injector in LOAD, for the adjusting screw about 1120th of a turn. e) Remove the rotor seal by lifting off of the
a time duration sufficient to fill the loop. See There are 20 dial markings on the body and four seal pins.
Fig. 10. a painted spot on the adjusting screw fac-
Alternatively, the on-off valve can be elimi- ing them. These help to tell how far to ll.2 REASSEMBLY
nated by simply plugging port 5. The injector tighten the screw. To reassemble the valve proceed as follows and
is acruated to LOAD long enough to fill the loop. If the new setting fails to accomplish leak-free refer to Fig. 5B:
Actuation tc INJECT stops the sample flow. See operation, repeat the above procedure. Avoid a) When putting the shaft back into place,
Fig. II. excessive tightening which will accomplish rotate the knob end of the shaft until the
With this last method, sample trapped in nothing but increased wear of the rotor seal. Fin- two rotor drive pins enter the mating holes
plugged port 5 should be flushed out before fill- ish by removing the adjusting nut and replacing on the shaft. Push the rotor end of the shaft
ing the sample reservoir with a new sample. the knob. If the valve continues to leak, then in to confirm that the rotor pins are in the
Instead of a plug, a capillary bleed line can be change the rotor seal (see section ll.l). mating holes.
connected to port 5, with a continual flow of sam- b) If the valve is not panel mounted then the b) Loosen the pressure adjusting screw about
ple (about 1 ,L/min). adjusting screw is hard to turn since the l/2 tum.
valve body is not held securely. In this case c) Install a new rotor seal (P/N 9125-082) on
do the following: the four seal pins. Confirm that it is cor-
Loosen each of the three stator screws by 1/2 reedy oriented, as shown in Fig. 5C, with
to I turn (use 9/64 socket wrench supplied). The the rotor seal slots facing the stator.
Sample
(""">~ Solenoid spring tension holding the rotor against the sta- d) Push on the rotor seal to snug the bearing
Valve
Reservotr tor will be relieved and the adjusting screw will ring and isolation seal into place.
Pump be easier to turn (a friction compound is on the e) If the stator face assembly came off the
threads to make it somewhat hard to turn). A PEEK stator then line the small notch in
Column
wrench may still be necessary. the rim of the face assembly with the stator
Proceed as in (a) to make !/20th of a turn to locating hole. Make sure the t\\Q stator face
tighten and, before testing the valve, retighten pins enter the holes in the PEEK stator.
the three stator screws. These stator screws -f) Place the stator support ring onto the sta-
should be tightened down at all times to keep tor. The support ring's bumpy inner con-
the stator held against the stator ring surface. tour fits the mating contour of the stator.
Loop
However, since the stator ring is plastic, the g) Mount the stator and stator face assembly
screws should not be tightened excessively. Feel on the stator ring with the stator locating
your wey to notice when they are tightened pin entering the stator mating hole.
F"~g~~re 10. Use of Sample ReseNOir and Automatic enough. Correct tightening torque is 9 kg-em (8 h) Add the three stator screws. Tighten each
On-Off v.tlve
!b-in). Finish by removing the adjusting nut and screw a little at a time to keep the stator
replacing the knob. surface parallel to the stator ring surface.
Finally, tighten the three securely. Do not
ll.O MAINTENANCE tighten the screws excessively, just snug
The rotor seal wears with use and is generally against the plastic stator support ring.
the only replacement part. With normal use, i) Replace the knob and tighten the two set
Sample
Model 9126 should give thousands of cycles screws on the two flats of the shaft.
Reservoir without trouble.
Pump The main cause of premature failure, which ll.3 SUGGESI'ED
is seen as leakage in the valve, is abrasive parti- SPARE/REPLACEMENT PAIUS
Column cles in the sample and/or mobile phase or crys- 9125-082 Rotor Seal
tallization of buffer solutions. This can cause See Product Note on fittings and loops for
scratches on the rotor seal surface. spare fittings.
When replacing the rotor seal, alweys check
the ceramic stator face for chips or cracks. 12.0 OPERATING AND
Replace the stator face assembly if it is damaged. TROUBLESHOOTING SUGGFSI10NS
Loop
12.1 USE OF AQUEOUS BUFFERS

Caution: Flush the valve after the use of OR SALT SOLUTIONS
F"lglll"e U. Use of Sample Reservoir with Pon 5 Plugged
buffer solutions. To prevent the formation of salt crystals in the
valve, which can cause scratches on the rotor
seal and/or plug passageways, flush out the flow
10.0 ADJUSI1NG FOR LEAKAGE ll.1 CHANGING THE ROIOR SEAL passages and vent lines after the use of salt solu-
A single pressure adjusting screw at the knob To change the rotor seal refer to Fig. 5B and tions. Salt solutions should not sit stagnant in
end of the valve body is used in Model 9126 (see proceed as follows: the valve overnight or for long periods oftime.
Fig.5B). The adjustment has been factory set to a) Remove the knob.
hold 34 MPa (5000 psi). To stop leakage pro- b) Remove the three stator screws. 12.2 PLUGGED VALVE PASSAGES
ceed as follows: c) Remove the stator support ring, stator, If the valve passages get plugged, they can be
opened by removing the stator and stator face tance to syringe discharge. Repeat the action with tion 6.2) after every injection. If the above men-
assembly and cleaning the passages with a small the injector handle half-way between LOAD and tioned amount of cross-contamination is not
wire (.005 inch maximum diameter). Alterna- INJECf (the pump must be off in this position). significant, it is still a good practice to flush the

tively, the stator and stator face assembly can It should now feel noticeably harder to discharge valve with the needle port cleaner after every
be placed in the ultrasonic and cleaned in an the syringe. 5 or so injections.
aqueous solution. The needle seal is designed to seal around the
The vent lines can also become plugged, needle only to 'a few psi of pressure. Since a
especially if buffer solutions are allowed to crys- microliter syringe can produce much higher 12.7 CALffiRATING THE SAMPLE
tallize in them. If the lines are plugged, flush pressure with just a sinal! force on the plunger, LOOPS
them out or replace them. do not expect the needle seal to completely pre- The sample loop sizes are designated by
vent syringe discharge with the handle in the half- nominal values, which can vary from the actual
12.3 LEAKAGE way position. value by as much as 20%. This is due to the
Leakage is usually caused by cross-port tolerance on the tubing I. D. Since both standards
scratches, i.e. new flow passages have been 12.5 KEEPING THE NEEDLE SEAL and unknowns are usually analyzed with the
scratched onto the rotor seal. If liquid is observed IN PROPER SHAPE same loop, knowledge of absolute loop volume
dripping out between the stator and stator ring, During periods of idleness of the chromat<?- is rarely needed. If the actual loop volume must
the needle port or the vent tube, first tighten the graph, such as overnight or during weekends, be known, it is best to calibrate it in place on
pressure adjusting screw as explained in section it is advisable to leave the lf1.2 gauge needle (sup- the valve so that the flow passages in the wlve
10. If this fails to stop the leak then replace the plied) fully inserted in the needle port. This will (one in the rotor and two in the stator) are also
rotor seal (refer to section 11.1). keep the needle seal in proper shape. taken into account.
Ifthe vent tubes from ports 5 and 6 do not have
their outlet ends at the same horizontal level as 12.6 FUJSIDNG BETWEENINJECI10NS 12.8 USE OF LARGE SAMPLE LOOPS
the needle port, siphoning can occur which is Measurements have indicated that under When large sample loops are used, a few
often misinterpreted as leakage. proper operating conditions the residual sam- microliters of mobile phase will be expelled from
If siphoning is occurring the "leak" will stop ple left in the needle cavity on the needle seal the needle port and vent tube 6 when the valve
when the loop and connecting tubes have surface after an injection varies between .001 and is returned to LOAD. This happens because the
emptied. Ifthe leak is due to cross-port scratches .01 microliter (JlL). This represents .01% to .1% compressed fluid in the sample loop expands
then the leak will continue as long as the pump of a 10 j.iL injection. If this amount of cross- when it is exposed to atmospheric pressure.
is pumping. contamination between successive injections is Since the compressibility of most solvents is
acceptable, then you do not need to flush the about 10-4 per atmosphere, the solvent in a 1
12A NEEDLE SEAL LEAKAGE needle port between every injection. mL sample-loop will expand about 20 j.iL upon

Since the outside diameter of a lf1.2 gauge However, it is wise to check the magnitude decompressing from 21 MPa (3000 psi).
syringe needle varies from syringe to syringe, of cross-contamination periodically, and to use Observe WARNING 4.1.
the nc:cdle seal (the Teflon sleeve in the rotor seal) the flushing tip when in doubt. Conditions that
may not immediately seal around a needle that can produce excessive cross-contaminaon are:
is smaller than average. This will result in a loss a) Needle is too short so that the needle tip 13.0 WARRANTY
of accuracy in loading the sample. does not touch the stator face. Minimum Rheodyne products are warranted against
The needle seal can be reformed after remov- length from hub to nc:cdle tip should be 5.00 defects in materials and workmanship for a
ing the syringe, push in on the plastic needle em (1.97 inch). period of one year following date of shipment.
guide (the eraser end of a pencil can be used). b) Syringe is not left in the needle port while Rheodyne will~ repairs or replacements free
If after inserting the syringe it still feels loose, turning from l.DAD to INJECf. of charge upon return to the factory, transporta-
then repeat. c) Dirt particles or needle seal shavings in the tion paid, of the defective item.
To check for a proper liquid seal around the needle port are preventing the needle tip Products may not be returned which are con-
syringe needle, fill the syringe with water and from touching the stator face. taminated by radioactive materials, infectious
slowly discharge the syringe with the injector So when cross-contamination is a concern, agents, or other materials constituting health
in the LOAD position. Notice the lack of resis- flush the wlve with the needle port cleaner (sec- hazards to Rheodyne employees.
FiR
~
IMOD!INI
INCORPORATED P.O. BOX 996, COTATI, CALIFORNIA 94931. U SA (707) 664-9050 FAX 707 664 8739
Printed in USA 8191

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A Desaiption . . . . . . . . . . . . . .
Index
. . . . . . 7-1
Injector Reference Material . . . . . . . . . . . E-1
Maintenance Procedures. . . . . . . . . . . . . 0-1
Automation Menu . . . . . . . . . . . . . . . . . 4-11 Solvent CompatibUity . . . . . . . . . . . . . . . 7-5
Injector Valve Reference . . . . . . . . . . . . . . E-1
Installation
B Mounting Injector Valve . . . . . . . . . . . 2-7
Pneumatic Requirements . . . . . . . . . . . . 2-8
Buffers, using Aqueous . . . . . . . . . . . . . . 6-2 Post Installation Leak Check . . . . . . . . . . 2-8
Serial Printer Installation . . . . . . . . . . . 2-9
Signal Cable Comections . . . . . . . . . . . . 2-4
c Site Preparation . . . . . .
Solvent Line Connections
.
.
.
.
.
.
.

.
.
.

.
.
.
.
.
.
. . 2-2
2-6
Synchronization Cables . . . . . . . 2-5, 3-7
Check Valve
Diagnostic Test . . . . . . . . . . . . . . . . 6-7
Filter Replacing . . . . . . . . . . . . . . . . . D-1
Replacing . . . . . . . . . . . . . . . . . . . . D-1 K
Configure Menu . . . . . . . . . . . . . . . . . 4-8
Copying a Method . . . . . . . . . . . . . 4-9
Keyboard Layout . . . . . . . . . . . . . . 3-3
D L
Damper, Diagnostic Test . . . . . . . . . . . 6-7
Deleting a Method . . . . . . . . . . . . . . 4-9 Leak Test . . . . . . . . . . . . . . . . . . 6-8

Diagnostic Test
Damper . . . . . . . . . . . . . . . . . . . . . . 6-7
Locating a Plugged Component . . 6-8
M
Mixer FiHer . . . . . . . . . . . . . . . . . 6-7
Outlet Check Valve . . . . . . . . . . . . . . . 6-7 Maintenance
Reservoir Filter . . . . . . . . . . . . . . . 6-7 Daily . . . . . . . . . . . . . . . . . . . 6-4
System Leak Test . . . . . . ~ .. 6-8 Every 12 Months . . . . . . . . . . . . . . . . 6-5
Every 6 Months . . . . . . . . . . . . 6-5
Log Sheet . . . . . . . . . . . . . . . . . 6-6
E Monthly . . . . . . . . . . . . . . . . 6-5
Weekly . . . . . . . . . . . . . . . . 6-4
Bectronic Faulls/Diagnostic Method Actions Menu . . . . . . . . . 4-9
Messages . . . . . . . . . . . . . 6-1 o, 81 Mixer Selection . . . . . . . . . . . 4-13
End lime, Setting ...... 4-7
Error Log, Viewing . . . . . . . 4-9 p
Error Messages .... B-1, C-1
Extended Diagnostics . . . . A-1
Piston Seal, Replacing . . . . . . . . . D-1
Prnax . . . . . . . . . . . . . . . . 4-7
F Prnin . . . . . . . . 4-7
Preventative Maintenance . . . . 6-3 - 6-5
Fault Messages . . . . . . . . . . . . . . B-1 Priming the Pump . . . . . . . 4-3
FiHers Printing Method Tables . . . . . . 4-1 0
Replacing . . . . . . . . . . . . . D-1 Programming
Testing . . . . . . . . . . . 6-7 Flow Rate . . . . . . . . . . . . . . . . . . . 4-5
Row Rate, Setting . . . . . . . . . . . . . 4-5 Pump . . . . . . . . . . . . . . . . 4-5
Relays . . . . . . . . . 4-11
Solvent Composition . . . . 4-5
Proportioning Mode Selection . . . . . 4-8, 4-12
Pump Stroke Counter . . . . . . . 4-4, A-1
Pump Hardware Description . . . 3-1

Inert Pump Purging the System . . . . . . . 4-4
Component Identification . . . . . 7-3
03-914436-30:1 1
Index
R
Rear Panel Connectors . .
Recommended Spare Parts . .
Relays, Setting . . . .
Repair Kit Instructions
Replacing
. . . . . . . . . . . 3-6
. . . . . . . . . . . 63
. . . . . . .
. . . . . .
4-11
D-1
T
Troubleshooting
Basic Procedures . . . . . . . . . . . . . . . .
Can't Prime Pump . . . . . . . . . . . . . . . .
External Leaks . . . . . . . . . . . . . . . . . .
Pressure Pulsations Too Large . . . . . . . . .
6-7
6-11
6-11
6-11

Check Valve Filter . D-1 Pressure Too High ............. 6-10
Inlet Valve . . . . . D-1 Pressure Too Low . . . . . . . . . . . . . . 6-10
Mixer Filter . . . . . D-1
OUtlet Check Valve . D-1
Piston Seal . . . . D-1
Resetting Pump Stoke Counter A-2 v
s Viewing
Error Log . . . . . . . . . . . . . . . . . . . . . 4-9
Pump Stroke Counter . . . . . . . . . . . . . . 4-4
Selecting a Method . . . . . . . . . . . 4-9 Run Log . . . . . . . . . . . . . . . . . . . 4-9
Set Conditions Table . . . . . . . . . . . . . . 4-7
Setting
End Time . . . . . . . . . . . . . . . . . . . . . 4-7
EquDibration Time . . . . . . . . . . . . . . . 4-7
Aow Rate and Composition . . . . . . . . . . . . 4-5
Method End Tune . . . . . . . . . . . . . . 4-7
Pmin and Pmax . . . . . . . . . 4-7
Relays . . . . . . . . . . . . . . . . 4-11
Solvent
Composition, Setting . . . . . . . . . . . . . . . . 4-5
Recommendations . . . . . . . . . . . . . 6-1
Solvent and Pump Compatibility . . . . . . . . . 62

Spare Parts, Recommended List . . . . . . . . . 6-3
Specifications . . . . . . . . . . . . . . . . . . 1-3
Status Displays . . . . . . . . . . . 4-4
Stroke Coll'lter . . . . . . . . . . . 4-4, A-1
Synchronization Signals . . . . . . . . . . 2-5,3-7
System Troubleshooting Procedures . . . . . 6-7
2 03-914436-30:1

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2700 mitchell drive/Walnut creek/ca 94598/u.s.a./phone (415) 939-2400
Star 9010
Field Engineering
Reference Manual
Company Private
Keep Secured
DISCLOSE ONLY AS NECESSARY
Varian Associates, Inc. 1991 Printed in U S A Rev. A

Contents
Section 1 Operators Manual
General Safety Practices
Installation
System Description
Operation
Maintenance/Service
Appendix A Extended Diagnostics
Section 2 - Front Panel
Circuit Description
Schematics
Section 3- SBC
Software Interface Description
Circuit Description
Schematics
Section 4 - Power Supply
Schematics
Section 5 - MVD
Circuit Description
Assembly Drawing
Schematics
Section 6 - Diagnostics Description
Section 7 - Position Control Description
Section 8- ATP Acceptance Test Procedure
Section 9 - Spare Par:a..&~Kit Ust
Section 10 Assembly~Orawings
Section 11 Service Bulletins
9010PUMP
901D Technical Description
Overvtew
The 9010 Is a solvent deflvery system (pump)
It can be operated as a standalone unit or can be Integrated In to the Star System

Uquld Chromatograph.
It can deliver from 0.01 mUmln to 5.00 mUmln c:A chromatographic mobie phase
automatically proportioned from one, two, or three reservoirs.
It can deliver anywhere between 0% and 100% of each reservoir In 1"' Increments
accurately and precisely.
It has bean designed to both minimize pump pUlsations af'lid minimize the dead
volume between the pump and the column.
It can perform binary and ternary gradients as well as ftow gradients In ndlplellnear

ramps.
There are 6 time programmable contact closures outputs.
The 9010 has the capabllly c:A both fUI GPIB communication wtlh the Star system
or synchronous communication with almost any other LC components.
9010. 1
9010PUMP
Physical Dncriptlon
The 9010 pump (Fig 1) Is 11.51n (29 em) wide-by 11 ln. (28 em) high by 22 in. (56 em) deep. It weighs
about 60 lbs (27 kgs.) It Is the same d!mena!ona as the 9050 detectors and can be readily stacked
on or under the detector.

It is easily portable and can be used with almost any other HPLC modules.
FIGURE 1
ThtM dirMnlioMI engineering drawing of 1he 8010 pump module.
The hydraulica .,. lhown in 1he lower front of 1he pump

The front of the pump includes a two line forty character drspay, the key pad for programming the
pump operatJon and aJJ of the hydraulic componentS which the user may have to access.
The two line 40 charader dlaplly presents aJJ status and programming Information
to the user. The display Is Yf/AION/ green to minimiZe eyestrain.
The key pad hu qiMd klyl far posJtiYe response to entries.
This allows a.-. to more aasly feet when they haW depressed a key than a touch
panel type keyboard does.
Most of the entries on the keypad are lncrglfldiCI'IIH type emtes with a shift key which ac-
celerates the movement through values.
This makes It easy to quickly scroll to the proper wlue of '" entry.
9010.2

9010PUMP
There Is a btlplng sound which is made whenever a key Is depressed. This can be turned on and
off through the keyboard and is the only entry in the configuration table.
This reconfirms when an entry has actually been successfully made but it can be
turned off to prevent user irritation.
The.JlUL are divided Into 4 groups, the operation keys, the edit keys, the table select keys and the
control key. (See Fig. 2) The operation keys allow immediately control of the pump functions from
the keyboard induding staning the pump and the program, priming the pump with any of the three
reservoirs, purging the system with the presentty set solvent proportions, resetting the program to
the conditions at the beginning, and monitoring status of the system.
This gives the chromatographer compfete control of the PUMP manually at the touch
of a button.
IIE~OO STATE _Of(RATION E:DIT TASLE SLE T

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FIGURE2
The 9010 pump k~. Thia ia detcribed turthet in the text and the operator's manual
The edit keys are used to modify the methods, configuration table and the automation table.
The table select keys allow the user to select and edit the composition. flow rate and, relays on a time
programrnec:f basis. You can also enter the set conditions and the pump configuration, activate. copy
and delate a method and read the run log and error log.
The single keystroke actions make it easy to modify entries
9010. 3
9010PUMP
Ligbts on tbt front panel tell whether the pump or the pump method Is ready, not ready, running,
stopped, powered up, stopped because of a fault. priming or purging and operating under automa-
tion or control from the wori<statlon. -
This gives the user a quick review of how the Instrument Is performing without havtng
to read the 211ne display. These lights are dlscemable even from across the room.
Under the front keyboard Is a potenttometer which can be used to both dim or brlgbttn the 2 line
display.
It can adjust the light Intensity and optimize the viewing of the dtspay from any
direction.
The user accessible pump components are all mounted on the front of the pump. These are easy
for the user to both monitor for any solvent leaks and service.

FIGUFE3
The 8010 pump tiD puellhowlng the connececn. lhllla deecrtbed In the tutlndln the operatcw'a rNnual
The rear panel c:onnectlons (Fig. 3) consist of the fallowing:
The gowwr IWitcb Is on the upper right hand side as you face the front of the modue (Upper left
hand side as you face the rear of the modue.) Tumlng It off removes all power to the system. It does
not erase methods In memory nor does it reset the system. Methods In memory are stored In CMOS
RAM and protected by a battery which will last up to 5 years In normal operation. When the main
power switches tumed off, there is no power inside the module so that It Is completely safe to remove
the covers to work Inside.

Therefore, no matter what the user might do inside of the module, all methods will
be protected from erasure while the user is protected from any electrical shock.
9010-4
9010PUMP
The power cord and mainJuu_are located directly below the switch.
They are a single unit meeti!'Q the most modem safety requirements.
The pump relay lad signal outputs are located on the left hand side of the rear of the module. The
pump has a three molex connector for an anaJog output (J2) which can be used to monitor pressure
on the system and put out a signaJ equal to 1 mV for every 5 atm of pressure.
With this the user can keep close track of the performance of the column and the
system by how its back pressure Is changing with time.
Directly below that are 6 three pin mofex connectors (J3 to J8) which are time programmable
contact cfosuru. These contact closures can be used as contact closures or they can be attached
to the powered events module (PEM) to provide the capacity to activate valves.
These could be used for applications such as cofumn switching, fraction coflecting,
solvent switching into the proportioning valves or starting an automatic Injection
valve.
Immediately below the relay connectors are two aync signal conDectoq. These provide
synchronization between the Star system modules when a workstation is not present or between the
Star system modutes and other manufacturers Instruments. These functions are discussed more ex-
tensively In the Interfacing section.
SynchroniZation provides a smooth complete Interface with any other manufacturers

instrumentation.
To the right of the connectors for the sync signaJs and relays are the GPIB connector and address
switch. The GPIB connector provides the hardware interface between the 9010 pump and the 9020
or 9021 workstation. This is fully discussed in the wori<statJOD section.
This interface provides fUI method downlo8d capablltles, status monitoring, real-
time updates to the 9010 from the workstation. and run and error log transmission.
This communication Interface provides single point control for all of the modules of
the Star system.
Above the GPIB connectors is the telldilgDOitlcl conottCtQr. This connection provides the pos-
sibllty of communication betWeen a Star system module and a remote workstation via telephone link
for troubleshooting and diagnostics purposes. This Is explained more extensively In the section on
troubleshooting and maintenance.
9010. 5
9010PUMP

Capability:
The 9010 Is a general purpose solvent delivery system for analytical HPLC. It capabtlitles and design
are similar to the 5000/5500 pump but wtth signiflcartt lmportartt differences.
The solvertt composition. flow rate along, relay program and a series d set conditions lnch.ldlng end
time, maximum and minimum pressure limits, automatic raequillbnltlon time and solvent reset are
combined together Into a 9010 method. When a method Is acdvated and run. al parameters as-
sociated with It wll be executed. Each method can have up to 80 lines. A method can be modified
whether It Is running or not so long as there Is no other method which Is running. (There is no "back-
ground/foreground" capabllty.)
This provides enough solvent and relay corttra1 functionality for any HPLC applica-
tion today and In the foreseeable future.
Ejve metbQd can be bult and stored in the pump. These methods can be activated with a single
key stroke. an OY8Mew of the software In the pump is shown In Fig. 4.
This makes the system very easy and efftclertt with which to work.
The pump Is a ternary saNent pump only. Three IQiylntl 111 prgpmiiJiblt In 1" Increments from
0% to 10()1(. for any of the three solvents. When one Is changed, one d the achers Is always adJusted
so the total always equals 1001ft.
The settable solvent resolution d 1" Is sufftcfent for any present day HPLC separa-
tion.

Proportioning solvents Is usefU to the chramatographer ...., I he Is not nmnlng a gradient Most
chromatographic applications require isocnltlc analysis made up d two or more pure solvenls or
buffers. If the ctvomatographer can &a the solvent right cu of the ballles, then he wil save time
and money In the lab and mllllrniza errors. He wl save time because there wtl be no need to premix
solvents. Also. different 101ven1 carnpoeidons w11 be..., to make up.. BecaIS8 the HPLC system
can make up most any solvent composldon by simply programming In the composition. there wHI
be less chance d error.
BeeN Mit wl be quicka'to make up new moble phases. and beca&a there wtl be
-.w.. wasted by having made up more than II needed. the costs In terms of
labor, solvent purchase and soMn disposal wll ctecr.se.
The flow r111 can be set from between 0.01 mUmin and 5.0 mLJmin In increments of 0.01 mUmin
from 0.01 to 0.99 mLJmin and in increments of 0.1 mLJmin from 1.0 mUmin to 5.0 mUmin.
This flow range addresses the erttlre range of analytical needs from 1 and 2 mm

caumns, through the standard 4 and 4.6 mm id. columns giving the chromatog-
9010-6
9010PUMP
Tlld...oaR..........
SOLVENT COIIIP08I'TICIN OIDT-
R.OWRATI OIDACTIOII
R&A"r8 (HOLOt
etn'OI".....,
__.,. wmt - .......,.,..
l ,~
1
TA&I
.....
IIUMOO
~
..,.,.Alii'
.........
CGIIIIU1DI ACnOII
j I
F1GURE4
Overview of the org.nization of the 9010 user interface. Entries in the figure are either the parameters which can be
used or modified or the entries for some of these parameters (in parenthesis).
9010 - 7
9010PUMP
rapher complete capability now and in the future as columns become smaller. Even

8 mm semi prep columns can be run at 5 ml.lmin.
Temary sotvent and flow gradients are programmable as linear segments through the entire range
of flow rates and solvent compositions. Time programming resotution Is 0.01 min from o to 1440 min.
This meets every analyticaJ HPLC need for flexibility today and In the foreseeable fu-
ture.
Six cgntac:t c!gsuru are tlme programmable at 0.01 min increments from o to 1440 min.
This allows the chromatographer to perfonn column switching and sotvent selection
and to control a fraction collector.
End time for the sotvent and relay program can be entered into the 9010 method. At the designated
end time, the pump w~l either hold the composition. flow and relay configuration at the final value,
stop the pump flow while holding the relays in the final configuration or run an equilibration program
to return all of the parameters to the initial settings.
This gives the chromatographerftexlbilltyto either maximize his productivity by being

ready to rerun the method Immediately, leave the system at the final condltlona In
case any unexpected peaks are eluted from the column later or tum the pump off to
save solvent.
pmin and pmax are settable by the chromatographer. Pmin Is designated as the lowest pressure
the system will operate at without turning the pump off and generating a talA Pmax is the highest
pressure that the system will operate at without turning the pump off. Pmin can range from 0 atmos-
pheres to the setting for Pmax and Pmax can range from the setting for Pmin to 410 atm. (6000 psi).

Pmin protects ttie system from leaks on the high pressure side of the column. If
there is a leak, the pressure wit drop and the system wit shut down preventing sot-
vent from betng wasted and spited Into the tab. Also, if the system runs out of sot-
vent. the pump wit not continue to pump. This saves pump seals and.pistons. Pmax
wll protect the instrument and column form excessive pressures due to blockages
of the flow path anywhere In the system.
An equiDbrltiQn time can be programmed Into the system. When an equUibration time Is entered
into the system, the pump wl return from the ftnaA composition of a method to the Initial composi-
tion of the same method or any other method by performing aqullbratlon run for the length of time
specified. An equllbration run consists of running a linear gradient from the final conditions of the
present method to the next composition for 10% of the equHibratlon time. The remaining 90% of the
equUibratlon time is run at the initial conditions of the new method. This applies to both solvent com-
position and flow rate.
This makes it easy for the chrornatographer get the column and the entire system

ready for the next analysis automatically. This assures that the chromatography will
9010-8
9010PUMP
not vary from run to run because the system wll always be equilibrated to the same
starting solvent conditions.
Automation Is butt Into the standalone 901 o pump. Any or all of the 5 methods In the pump can be
scheduled to run any number of times. The pump can be programmed to tum off at the end of all of
the runs or to continue to pump.
This allows the 9010 to be completely compatible with anyone else's detectors and
autosampl tor automation.
The 9010 has 4 levels c:l dtagnoltfcl buit Into the system. When the system Is Initially powered on
there Is a series of diagnostic tests which assure that the system halawant Is functional. The second
level c:l diagnostics. background dlagnosUcs, monitors the system as It runs and keeps track of
parameters such as the number of pump strokes which have occurrad on the pump since the last
time the parametM' was reset. The third level of dlagnosdcs is extancled diagnostics. This allows
most of the Individual functions to be checked by the user. Ftnaly, teledlagnosdcs allows a Varian
office to communicate directly to the Instrument at the customer's lab If the customer has a modem
that can .be hooked up to the instrument and a phone.
The complete diagnostics In the system helps assure that any problem which can
occur with the system will be quickly and corradly lderdlad.
- 9010.9
9010PUMP
901 o SpecHicatJons:
Flow rate prectafon:
0.3% relative standard deviation
This Is measured at 1 mtJmln In rnett1anot and water at a constant sotvent composition.

The flow rate precision is critJcaJ to both the retention time reproduciblity and the peak area
a
reproduclblity every peak In the chromatogram. Retention time reproduciblity Is dlredly related
to flow rate. If there Is a 3% decrease In flow rate between runs. there w11 be a 3% Increase In reten-
tion time. Peak area Is related to flow rate because most of the HPLC detectors used are concentra-
a
tion sensitive detectors. The detector detects the concentration compound In the flow cetl but
does not destroy ll Therefore. If the ftow Is sower. the compounds wll stay In the flow cea longer
and there wil be a larger area under the peak. The peak height Is not stgntflcantly effected by varia-
tions in flow rate.
The excellent flow precision of the 9010 pump assures excellent retention time
reproducibility and therefore peak identification and excalent area reproducibllty
and therefore quantitatlon.
Flow Accwacy:
+ 1- 0.5% from the set ftow rate.

The flow accuracy Is measured at 1 mUmln lsopropyt alcohol. The actual flow rate wll vary with vary-
ing solvent Water and other less compressible solvents wit have slightly higher actuat flow rates
than their set flow rates. Hexane and other more compressible sotvents will have slightly lower flow
rates than their set flow rates.
a
Flow rate accuracy Is minimal importance as long as the ftow rate Is reproducible.
Standards are usually run on the same HPLC system Immediately before running
unknown samples. Any variation in ftow rate accuracy will be compensated for by
running standards. Ony If retention times obtained on two different HPLC systems
are being compared very closely are any problems in flow rate accuracy noticed.
The chromatographer gains no benefits from extreme flow rate accuracy.
CompoaitloMI Accuracy:
0.5% at all solvent compositions.
This is true under al scMn. pressure and flow conditions.
Compositional accuracy can be extremely important for HPLC. If the chromatographer Is running
only one savant. then composltlonat accuracy is not Important. But If the chromatographer is using
the pump to mix two solvents even though their ratio is being kept constant during a run. any chan-
ges from the set composition can cause problems. Changes in sotvent composition will always cause
retention time reproducibility changes thus making it more difficult to identify unknown compounds.
In the worst cases, changes in solvent composition can cause peak resolution to decrease to the
point where the analysis can no longer be performed. This is especially true at low concentrations
of one component of the mobile phase. When the composition of a constituent in the mobUe phase
9010- 10
9010PUMP
at the 5% leva changes by 1% (to 6% total), that Is a 20% relative change. This could easily effect
the separation.
This is measured with any solvent at o atmospheres pressure.
The delay volume ~ an HPLC system Is the volume ~ solvent between the location In the hydraulic
stream where the solvents are mixed together to the head of the column. This Is the volume which
has to be swept ~ moble before a new composition can begU1 to pass through the column. A short
daay volume has seveta1 advantages. One, a short delay volume muns that the solvent on the
column can be changed quickly. This saves time and a small amount of solvent A small delay volume
means that the chromatographer has more control ~the solvent on the column. He does not need
to stan a gradient very earty In order to get the solvenl change on the column when he wants. Third-
ly, a gradient developed on another HPLC system can be mora easly duplicated on a system which
has a small delay volume because the chromatographer has this better conb'Ct c1 the composition.
All of these effects are magnified on 1 mm and 2 mm columns. A daay volume d 1 ml represents
a 1 min delay time on a typic:al4 mm analytical column but it represents about 4 min of time on a 2
mm column and up to 20 min of time on a 1 mm column.
A small daay volume makes an HPLC system mora flexible for a chromatographer
dP!P or pump pulutlona

<2% at 150 atm.
This can be measured with any single solvent at any flow rate.
The dP!P measures the change In preqsure during a run and representS the pulsations in flow rate
generated by the HPLC system. Pump pulsations can cause noise in various detectors due to the
detector's sensitivity to flow rate changes. This is especially true of the Rl detector and the
electrcchemical detactor. (The 9050 UV-VIs detector Is parttcUarty INsensitive to pump pulsations.)
Excess noise In the detector wll cause a decreased limit d detection and limit of quantltatlon.
The 9010 pump minimizes pulsations whle maintaining a low delay volume.
Gradient At:curacy and Unearity:

<0.2%RSDat
This is measured
9010 _. 1,
9010PUMP
Internal Description:
The hydraulic system pump utUizes many of the same basic concepts which the hydraulic system of
the 5000/5500 pumps did before it. However, most, but not all, of the hydraulic components have

been redesigned to achieve better reliabUity, manufacturabiity, lower gradient delay volume and bet-
ter pulse damping.
The overall hydraulic layout Is shown In Flg. 5. One two or three solvents In any sofvent container
can be attached to the three proportjoning valves on the pump head. A 10 ...,m filter at the end of
these transfer lines in the solvent botdes will prevent particulate matter from getting into the pump
from the solvent reservoirs. Any solvent containers can be used as soMtrlt bottles because no
degassing or sparglng is needed to operate the pump.
l'tiiOPORT 10111110
A x~~\!c:,
0 0
8 0
......
'! .....8. . ~
....
~
.. . ;:: 0

.. .
iii
0
iii
0
. .
0 0
iii iii
'....
;;

I~I:T VA&.VC 0
QlSI~SOO
;
..
~
MODEL 9010
03SISOOOOO
FIGURE 5
Overview of the organization of the 9010 user interface. Entries in the ftg.-. .,. either the parameters, which can M
used or modified, or the entries for some of trine parameterS Qn parenthesis).
9010- 12

9010PUMP
The three proportioning valves are used to proportion solvent into the pump head (one is shwon in
Ag. 6. These valves are identical to and Interchangeable with the valves on the 500015500 HPLC.
These valves consist of a metal poppet and a spring in side a smaJI cavity. The spring normally for
ces the poppet against a flexible fluOr-ocarbon seat which seals and prevents any solvent from flow-
ing Into the pump from the reservoir. When the reservoir is to be opened to allow solvent into the
pump head. a current Is switched into the outer co~ of the inlet valve. creating a magnetic field which
opens the valve in 1 to 1.5 msec. When this valve is open there is a free flow of solvent through the
mechanical inlet check valve and into the pump. When the current in removed from the valve, the
spring forces the poppet valve shut and prevents any flow into the pump.
.-o~~T ASS"-"'-v
, ...o"-'-'-Y c:'-oo
O~NS
su" o-ACIAfNST
~,_,.,.a ....,
- ..... ,..
C:OM. ACTIVAT.O
COl'-
FIGUAEe
Detlilled drawtng of the IOiwnt ~ing vale
Proportioning Is performed simlarty to the proportioning on the 5000/5500 HPLC with one VERY
major difference. Proporttoning for a1 three solvents Is done In ONE stroke. Therefore, if 25% of the
A solvent. 35" d the B solvent and~ d the C sotvent are to be taken Into the pump on this stroke,
then the A proportioning valve Is open 25" d the time, the B valve Is open 35" d the time and the
C V8Mt is open 40% d the time. This means that all the solvent needed to make the composition at
this time Is Included in one pump head volume, not 4 pump head volumes like In the 5000/5500. This
means that less mixing is required In the system and the delay volume can be therefore decreased.
This also means that the gradient wll be smoother because there wll never be a time when a new
solvent composition is required before all four strokes needed to proportion the solvent are finished .
9010-13
9010PUMP
The solvent Is proportioned into a compfetay redesigned mechanical Inlet check valve. The new
mechanlcaJ Inlet valve Is shown in Ag. 7. It comes as a single unit. The Inlet valve consists of a spring

VALYa aAL
FIGURE7
Oetai*1 drawing of the meChanical Inlet cMck..,..
loaded poppet In the center d a housing that screws Into the pump head. The proportioning valve
ftow enters dose the head d the inlet valve. The mechanical inlet valw Is dosed when the head d
the valve is seated firmly against the metal and fluoralloy G seal. It Is held dosed by the hydrostatic
pressure In the pump head and the spring in the outer end d the valve. When the poppet Is pushed
forward (about 0.03 In), the valve Is opened and the liquid can flow around the head and Into the
pump chamber.
The inlet valve Is opened or actuated by a mechanlcaJ actuator situated outside and In front of the
pump head (Ftg. 8). The mechanical actuator is driven by a cam mounted on a shaft common to the
main piston cam (Ftg. 9). As the motor turns. the cam wit stop pushing the actuator out and the
spring attached to the actuator wil push the actuator against the cam and In towards the pump. As
the actuator moves in towards the pump, it pushes the mechanicaJ Inlet valve inward, opening the
savent flow path.
The new mechanical inlet valve scheme has I8Y8I8I advantages over the ck:l scheme. One, the new
mechanicallrHt valva is much euier to change. The valVe comes In one piece and can be directly
screwed Into and ~ d the pump head. It Is adjusted by setting the gap between the mechanical
Inlet valve and the actuator to a specific dlstai1ce using a special tool provided with every 9010 pump.
Once this il done. nothing else has to be adjusted.
The pump stroke vaurne itself has been decreased In size from 90 tal- to 75 tal-- This decrease In size
has allowed for the decrease In volume tor savent mixing because a smaller volume needs to be
9010 14
9010 PUMP
CHECK
VALVE CAM
FIGUAE8
Detailed drawing of the pump head induding the rnechanlc* Inlet vaJw and ita ectuatar
FIGURE9
Detailed drawing of"1he entire pump motor UMmbly including the direct connection of the drive lhaft to 1he cams and
pistiOn and mechanical inlet vaJw
9010-15
9010PUMP
Blowup of the apatial relationahip of the proportioning v.,.,_, mechanical inlet valve, pump c:h8mbel and ouUet cMdc
valve
mixed. The pump fill time has been Increased for any mUtlple reservoir proportioning done. If only
one reservoir Is being used, then the til time is 200 msec. If more than one reservoir Is being used.
then the fBI stroke Is 400 msec. This longer fill stroke provides the time for all three reservoirs to be
proportioned Into the pump chamber In a single stroke. For single solvent applications. the 200 msec
fill time provides less pump pulsations which have to be dampened out down stream. This woutd be
useful for GPC when the AI detector which Is very sensitive to pump pulsations. Is being used.
The pump and mechanical Inlet valve are driven by a microstepped pump motor similar to the motor
which drives the 5500 pump. There are over 50,000 Individual steps in an entire pump motor cyde,
providing a smooth forward and fll stroke, even at low flow rates.
Unlike the 5000/5500 pump. the pump motor is dlracdy coupled to the drive shaft where the cams for
the pump piston and the mechanical Inlet valve are located. Because there is no longer a flexible
coupler, there Is no need to have a ttmng disk on top of the motor. The system always knows where
In the pump stroke cyde, the pump actualy Is. There Is any a single small Indicator attached to the
pump motor shaft which, by breaking a light beam fNfKY time the pump makes one complete cyde,
tells the system axacdy where the pump motor cyde begins.
Mounted on the top of the pump head is a spring driven single ball and seat check vaJve (Fig. 10).
This valve is pushed open against the spring by the forward stroke of the pump piston creating pres-
sure in the pump chamber. When the pump stroke is finished. the spring and the hydraulic pressure
from the rest of the system, pushes the ball against its seat, closing the ftow path. This prevents any
solvent from flowing back into the pump head from any of the downstream hydraulic system. This
valve also has a 20 micron "chunk" filter in it.
9010-16
9010PUMP
Proportioning of solvent occurs in the following steps. (See Ftg. 11) for a detaHed drawing of the
pump head mechanism.
tt
1. When the fufl forNard pump stroke has almost finished the solvent proportioning valve for
2.
the initial solvent is opened.
~ outlet
chamber.
check vaJve will then dose preventing any solvent flowing back Into the pump
3. As the pump piston starts back and the fluid in the pump chamber is decompressed. the
mechanical inlet will be forced open by the mechanical inlet vaJve aduator. This provides a
comptetay open flow path from the solvent reservoirs to the pump chamber.
4. The pump piston is now pUled back, causing the reservoirs to proportion into the pump
chamber, filing il
5. When the punp chamber Is flied, the mechanical Inlet vaJve aduator Is pushed forward by
the Inlet valve cam and the vaJve Is released. The spring in the mechanical inlet vaJve closes
the valve, preventing any liquid from flowing back Into the reservoirs.
8. The pump piston then is pushed forward by the pump cam, the ball and seat outlet check
valve Is forced open, and mobile phase Is delivered to the downsb'88m hydraulic system.
The pressure transducer is located Immediately after the outlet check vaJve. The pressure transducer
measures the pressure downstream of the pump ands reports it to the 2 line display. The
- microprocessor uses this pressure to judge whether the pump should be stopped because of viola
901017
9010PUMP
tions of Pmin or Pmax. By being dose to the pump and up stream ol the puts& damper and mixer,
it w~t detect any flow restrictions in either the pulse damper or the filter In the mixer.
The pressure tranlducer aJso provides Information for the eCectronlc flow feedback loop which
replaced the flow c:ontraller. The electronic flow feedback system en the 9010 pump uses the pres--
sure to calculate the compressibility of an average solver< (Isopropanol) In the pump chamber. It
then uses this factor to calculate how fast the next pump stroke shoUd be In order that the

programmed flow rate should be achieved as dosety as possible. This has the advantages that no
expensive falure prone mechanical flaw controller Is presanc In the system. It aJso has the advantage
that the compressibllty compensation wll function at aJI prassuras. Because the setting of the com-
pressibllty factors In the software are for an average solva"t, Isopropanol, the flaw wll be accurate
onty within 3% with different solvents If better accuracy at one particular pressure and solvent Is
desired, an adjustment can be made using DIP switches on the pump CPU board. In any case, the
flow wll be very reproducible.
The prime valve Is located lmmedlateCy after the pressure transducer. This Is the valve which used
to be located In the pump head Itself. The prime valve Is opened to provide a flow path to waste so
that the pump can be primed. Previously on the 500015500 system. when the prime valve was open,
the pump could suck air through this valve during the fll stroke If the pump was not aJraady primed.
This meant that the solvent reservoirs either had to be sllghdy pressurtza with the priming bulb or
prime valve had to be continuously open and dosed. Now the outlet check valve prevents any air
from going Into the pump chamber during the fll stroke. The chromatographer wtl no longer be like-
ly to get solvent on his hands whle priming the pump.
FIGURE 12
Oetailed drawing of the U.tujbe damper
After the prime valve is the pulse damper (F"tg. 12). The pUse damper is located inside the pump
housing. The pulse damper has been completely redesigned to emphasize rellabUity and manufac-
turability. The pulse damper is made of a single tong tube of flexible materiaJ which is immersed in
a mixture of lsopropanot and water with eiosine dye. It runs tlnear1y through the Utube without making
9010- 18
9010PUMP
any loops or being wound around a mandril as the previous damper was. A new termination is used
Internally to connect the flexible tube to the external fittings. This new method of termination utilizes
a precisely swaged ring Instead of a swagelock type fitting as used In the 5000/5500. This minimizes
the change of a shape edge on the aw&ge4ock fitting rupturing the damper material.
Although the damper Is Inside the pump housing, it Is attached to the pump by two dress nuts on
front of the pump housJng. Therefore to remove the pulse damper, onty connections on the front of
the pump must be removed.
When the pump makes Its forward stroke the damper Is pressurized to the pressure of the column.
The moble phase Inside the Inner tube will be at the same pressure as the liquid surrounding It This
pressurization stores both energy and mobile phase in the damper. When the forward pump stroke
ends and the piston chamber begins to depressurize, the outlet check valve doses and the pulse
damper begins to deliver ftow to the column. The ftow Is delivered at approximately a constant pres-
sure for the entire 400 msec of the fill stroke. This constant pressure Is the pressure that the system
was at when the fill stroke began.
In aduallty, the pulse damper does not operate at a constant pressure. As the pulse damper delivers
mobile phase to the caumn, the amount of liquid Inside the damper decreases and the pressure falls.
The more that the pressure faJis. the slower the solvent wil be delivered to the column thereby caus
ing pUsatJons wtHch coUd be picked up by the detector. The pulsation can be measured as the
change of flow or pressure on the column. We have chosen to measure the pulsations as the change
of pressure or dP. Since the absolute change of pressure (or flow) Is not as lmponant as the relative
change of pressure. our speciflcadon for pulsations Is dP/P. The change of pressure is almost con-
stant for a given flow rate. Therefore. higher pressures at the same flow rate, r8IUt In lower dP/P and
less observed pulsations.
The mixer is the next component In the ftow path after the pulse damper. The mixer Is an open tube
filled almost completely with a 0.5 micron flter. The total volume in the mixer Is about 100 ..,L. The
mixer uses a combination oflaminarflowandtortuous path mixing to produce a homogeneous mobile
phase. The mixer In the 9010 pump is smaller than the mixer In the 500015500 because proportion-
ing all three solvents In a single pump stroke and having 11 smaller pump stroke volume means that
only 75 J&l. have to be mixed In the 9010 rather than 360 J&l. in the 5000/5500. Some solvent mixing
also occurs In the pulse damper.
After the mixer, the mabie phase goes to the optional purge valve. The purge valve is used when
the chromatographer wanra to flush the entire system quickly. In the open position, the purge valve
sendsthemoblephasedlrecdytowaste. lnthedosedpositlon,themobiephasegoestothecotumn.
After the purge valve, the moble phase goes into the manual or automatic Injector
9010 . 19
9010PUMP
Introduction
9010 Wants & Needs, Features and Benefits (stand alone)
Customers have a number of wants and needs in the area ot chromatographic Instruments which our

instrumentation address with Its features and benefits. These wants and needs can be grouped In 6
broad categories.
Performance
All customers want and need to get wgood" reslits from their Instrumentation. They need to know
accurately and preclse'y how much of each component ot Interest In the mbcture being analyzed Is
present. They may also need to confirm the Identity ot compounds for which they are analyzing. An
analytical instrument must perfonn this task very well.
Productivity
Many customers need to Increase the productMty of their laboratories. They may either have more
samples coming Into the lab and therefore need a higher sample throughput or they may have less
personnef In the lab and they many need to decrease the time a tect"li1ldan spends wortdng with each
sample. The chromatographer wants resUts which are as complete as possible with a minimum of
human effort. Produc:tivtty needs and wants are found everywhere, from the quailty.controllab to the
methods development and research lab. Chromatographers li1 methods devaopment may want to

increase their productivity so that they can work on Interesting personnel scientific projects!
Flexibility
Many laboratories need a flexible system which can perform many tasks. Except In very high sample
load single assay applications like environmental monitoring or process control monitoring. most
chromatographs perform many different analyses each month If not each week or each day. Instru-
ments also are moved around and reconfigured now and then. Instruments with a 5 to 7 year lifetime
may have to perform analyses which were totalty unanticipated when they were purchased. A
chromatographer wants an Instrument which can meet all ot his applications today and Is designed
to meet his unanticipated needs tomorrow.
EaHofUH
No matter how good an lnstrumer Is, If the person using It does not know how to get the most out
of it or gets IDCir8m8fy frustrated whle worldng with 1t. that Instrument will not satisfy the customer's
needs. That model Instrument wll not be purchased again. Ease ot use means different things at
different times In different labs. Initially a system must be easy to team. Then it should be easy for
the chemist who knows a lot about the system to use. And finally It shoukt be easy for the technician
who is not really Interested In the Instrument and does not use it often, to use. Some of these needs
may be satisfied not only by the instrument but also by the vendor's suppon organization.
Reliability
An instrument must work when the chromatographer wants to use it. In some labs. this might be 24
hrs/day, seven days per week. In other labs. this maybe only 4 or 5 hours per day. In either case.
the unit must be ready to go when it is needed. Reliability, like ease of use, also means different things
at different times. First. it should work all of the time without the user doing anything to the instru-
9010.20
9010PUMP
mei'L M ~ do realiZe that .wry nt:NI and then. they may have to malnratn the lnslrument. so
rnUUrWa shoUd be as ~ and easy as possible. In fact. If the syslem COUd remind the
~when to rnaJnl011t. and when to order the pan.s before hand. that woUd be even better. When
an lnstrurNf'l does fal. II should b8 as Infrequently as possible. It shoUd be easy for the customer
to fbc I poatble and. If a saMc8 call is needed. It shoUd be done quiddy and the instrument fixed on
the first call.
Mlacellaneoua
There are some user needs and wants which don't fall Into any t:X these above categories. Some
customers want to be the first person in their area to own a new product. Some may want only ure-
search quality" products. Some needs may be specific onty to one type of Instrument. Finally, every
customer wants to be able to purchase as much Instrumentation as possible wtthln their limited
budget. Low cost. low system prices, low entry prices. and extra services included with the instru
mane are all lmponant customer needs
Needs & wants, features, and benefitS section
The following secdon on needs & wants. features. and benefits wil have the Individual customer needs
grouped by cateoorY as above. Only the customer needs and our benefits have been included in the
text Our Individual features which produce these needs are not listed. They will be covered as part
of the prasentatJon and you wll have to wrtte them In as the Instructor writes them on the overheads.
, . technique Is caBed program notes. It's purpose Is to have you. the student. write down the fea-
ture. thereby rei lforci 1Q tt In yru mind. If lito pennb you to write the faldunlln ycu own words.
alowtng you to make a mora rneaningfU errry for you. It a11o lets you check In yru own mind to
see if you understand the feature.
9010.21
...c
"'II
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J. Gulbenkian
4/9/86
FRONT PANEL BOARD
CIRCUIT DESCRIPTION
Asse~bly 03-919063-00
Sche~atic 03-919066-00
1. General
The front panel pc board contains on one printed circuit board the
interface circuitry for a ~e~brane keyboard syitch, auto-repeat functions
for INC and DEC keys, drivers for 13 LEO's, for the 40xZ line LCD
display, control for back-lighting of the LCD and the beeper.
Z. LED, Beeper. Back Licht El Control
US C74 ALS 874> is an 8-bit latch addressed at FLEDZCS on SBC (presently

at absolute address 2~3000H>. Uhenever an output goes logic L, an
indicator LEO turns on. US drives CR1,Z,3,7,8,9,10,11. Reset Yill clear
the latch, setting all the outputs to L and turning on all the LEO's. CRS
is connected to the +5 line and will be on as long as +SV exists.
U7 <74 ALS 874) is also an 8-bit latch addressed at FLEOICS on sac

(presently at absolute address Z02000H). Uhenever outputs IQI - 1Q4 go
logic L indicator LEO"s CR4,5,1Z,13 will turn on. Output ZQ3 CU7, Pin 16>
is connected to U4 C74LS 423> one-shot. Uhenever outut ZQ3 ~akes a l to H
transition, U4 will generate a positive going pulse. This pulse drives
the outpu~of US buffer to logic l, causing the beeper Yt to sound. Outut
2Q4 <U7, pin 15), in a si~ilar fashion, gets inverted by USA C74LSI4), US
(75452) and turns Ql CZN3906> on,
3. LCD Contrast Contrgl
VRI <79L05> is ~-SV

voltage r~ulator stepping down the -ISV <-IZV on
9050> input to -SV and feeding 1t to pin I of R18 10K single turn
potentio~eter. Pin 3 of R18 is connected to +SV. Thus, rotating RIB
shaft causes its output (pin Z> to swing fro~ +SV to -SV <under no load
condition). This variable voltage is fed to the LCD display as V0 as
contrast (viewing angle> adjust~ent.
4. Keyboard Encoder
'
U19 (8279) is the keyboard encoder. The data bus and the control signals
are connected to the sac via J303 . The CS signal is FKSCS fro~ sac.
Ul3 <ICM 7556> is a free runn1ng "Ultivibrator at 200 kHZ. Ul9 is

initialized to a divide by 2, thus " .. 1"0 the internal operating frequency
the required 100kHZ. SL0, SLI, SLZ outputs of U19 are a binary encoded
counter output. U18 (74LS165) is connected as an open collec~or 3 to 8
decoder. Thus, one and only one output will go to logic L at a tiMe. U 1 8 .
outputs IYl, 1Y0, ZY3, ZYZ, ZYI, ZY0, IYZ, 1Y3 will go to logic Lone at a
tiMe. The first six outputs drive the Row I - Row 6 inputs of the
MeMbrane keyboard Matrix. The coluMn outputs of the MeMbrane keyboard,
Coli - Col6 return to RL0- RLS return lines of U19 keyboard encoder.
S. Auto-Repeat Generator for INC and DEC Kevs
The lertover circuitry is two identical stages of an auto-repeat

generator.
U19 keyboard encoder <SZ79> detects a key depression by detecting a logic

L on the return lines RL0-RL7. The loQic L Must stay stable for a MiniMUM
of 10 Msec to be "de-bounced" by U19 and entered into its buffer as a key
location. The key Must be released first and depressed again for 1t to be
recognized as depressed again.
The requireMents for the INC a~d DEC keys are as follows:
- Uhen either key is depressed, a ISMs pulse is generated and sent to

Ul9 to be recognized as a key depre~sion.
- If the key is kept pressed, a wait period of 800 Msec is entered.
If at the end of this wait period the key is still depressed, a series
of pulses ISMs in duration and 8SMs apart start to be generated. U19.
detects these pulses as if the key is being depressed and released at
100Ms intervals (ISMs + 8SMs 100Ms).
The operation of the stage for the INC key will be explained. The
circuitry~s identical for the DEC key.
Figure 1 shows the enlarged portion of the INC key auto-repeat circuitry.
U17 <ICM 7556> i~ a gated oscillator. Uhen reset pin (pin 10> goes H, due
to the way R9,R8,C16 and CR14 are connected, the output (pin 9) will go H
for IS Msec, L for 85 MSec and repeat this cycle every 100 Msec CIS+ 8S
100 ~sec} until reset returns to logic L.
Figure Z shows the part of circuitry that acts as a transMission gate.

Uhen U1ZA (74LS3Zt_pin Z stays at logic H <labeled "one pulse"}, whenever
the gate" signal (fro~ the key) <U9A- pin 1, UZC- pin 10) goes to logic
H, the output <UIIO- pin 11> will gate one and only one oscillator pulse.
The output pulse will always be a full width (IS Msec) pulse regardless of
the tiMing of the "gate'' signal.
Uhen U1ZA pin Z stays at logic L <labeled "Multiple"), then if the "gate"
signal is logic H, the output <U110- pin II) will be a series of pulses
repeated every 100 ~sec until the "gate" signal goes to logic L, disabling
the transMission gate.
A siMplified tiMing diagraM is shown in Figure 3.

z
The ~equence of events will be as follows:
On instru~ent power-on ti~e. when the reset signal is generated, UtSB

pin 4 going H will turn-on the gated-oscillator U17. The pulses generated
initialize the auto-repeat circuitry.
Uhen INC key is depres~ed, USa - pin 3 <74LS14> goes l, usa - pin 4 goes
H. This is the "gate" signal as explained above. This sa~e signal also
releases the CLR pins of Ut6 - pin 3 (74LS4Z3> and USa- pin 13 (74l574A>.
The output of USa - pin 8 is now at logic H. This is the "one pulse"
signal as explained above.
The sa~e
"gate" signal is delayed by UISB <74LS3Z> and U14 <74LS31>, to
eli~inate possible race condition, and applied to U17 reset pin, ~aking it
logic H. U17 now starts oscillating, producing a 15 ~sec pulse.
This IS ~sec negative pulse goes to the keyboard encoder via UtZD <74LS3Z>
to be detected as a key closure.
!he trailing edge of the sa~e pulse triggers U1S (74LS4Z3) one shot. The
Q output (pin 4) of the one shot goes to logic L for 800 "sec. This is
the "wait" period as e?'plained above. If at the end of this period the
key is still depressed, the trailing edge of the "wait" signal acts as a
clock to the USB- pin 11. forcing the Q output (pin 8> logic L. This is
the "~ultiple" signal as explained above. As long as the INC key stays
depressed, the oscillator pulses are now gated continuously out and go to
the keyboard encoder to be detected as ftUltiple press-release cycles of

the INC key. Uhen INC key is released. USB - pin 3 goes to logic H, the
trans~ission gate beco~es disabled and the pulses stop.
~"'
s. Block Diagra~ and Interconnection Oiagra"
The black diagra~ of the board is shown in Figure 4.
The interconnection diagrBR of the Front Panel board. the LCD Display and
the required cables is shown in Figure 5 with Varian part nu~ers
3
Th
~llQ~
in th di\ol~~ module 1~ prov1~ed t~ a1\ ~rray of
~acklignting
LEO'; The 3rray 15 1r1ven b~ ~ :urr?nt ~~urc wh1Ch 1s

nomtnally ;et to 37S ~tlli~~cre5. Th ~~rr~n~ 1; ~et by res15-
t~r; ~2~ and R~3 ar~und ~P ~mo V20 r;Lpo1nt lOlSENSE> ;hould
;how 37.' ~illiv~lt5 ~~ ~tgnalC+I-10%>. Th ~ri~ary ~dvantag of
LEO bcklightin9 vrsus E~ ~trtp b~c~ll~hti;;~ l5 t~~t th LED';
~ill not d~rade over t1me; tnus. thire 15 n~ nee~ f~r the back-
llghting to o turned oFF by 5oftwar~ in ~rdr tc extend its
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OF SUPPORT PLATE, ITEM 2
EXAMPLE: 03-919442 -OO,REV 'l1) 10/87
A (i)/\L IGN CUTOUTS ON ITEM I WITH CUTOUTS ON ITEM 2

BEFORE BONDING TOGETHER. NO OVERLAP ALLOWED.
NOTES:
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ELECTRONIC HARDWARE DOCUMENTATION
NGLC 9010 SOLVENT DELIVERY SYSTEM (SDS).

(Assy 03-919055-00 (SBC) Rev. )
(Assy 03-919059-00 (MVD) Rev. )
(Assy 03-919063-00 (FPB) Rev. )
vax source: /U4/brian;vesuvius;Doc/Ckt_Des/SBC_DES.out
Version : 5.0
by Joergen Bardenfleth, Tony Chern & Brian Roussel
_____ Tom Garrett

Ken Judah
Paul ToeWater
Issued : september 27, 1988
Varian Instrument Group

Walnut creek, ca~ifornia
.~odel 9010 SBC September 1988

1. Circuit Description
TABLE OF CONTENTS
Model 9010 SBC . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 1
1.1. Section 1 . . .. .. ... .. . .. .. .. . . . . . . . . .. .. .. .

CPU . . . . . . . . . . . . . . . . . . . . . . . .. . .
2
1.1.1. 2
1.1.2. CPU Signal Descriptions ... 2
1.1.2.1. Clock ..
1.1.2.2.
1.1.2.2.
Reset .
Reset Generator Circuit
.... .... 3
3
1.1.2.3.
1.1.2.3.
DTACK .................................
DTACK Generator
3
4
1.1.3. BUS
1.1.3.1.
...... .................... ............ ..
Address Bus
4
5
5
1.1.3.1. Configuration Jumpers
....... ............
5
1.1.4.
1.1.3.2. Data Bus
Battery Back Up .
. . . .. . 6
1.1.5. Extension Bus Interface

1.1.5.1. Signal Characteristics
. . . .. 6
7
1.1.6. Front Panel Interface

. . ....
.
7
............ ......................... ............... .. .. .

8
1.2.
1.1.7.
Section 2
Test LED
......... . . . . . . . 8
9
1.2.1. ROM
... ....... ....... .......... ....... 9
1.2.2. RAM 10
1.2.2.1. Battery Backup RAM 11
1.3.
1.2.3.
Section 3
1.3.1.
................... ...............................
Extension Bus Connector
Memory Map Switch
.
.. ........
11
12
12
1.3.2. Address decoding
1.3.2.1. Block Allocation
. ............. .......... 12
1.3.3. Interrupts
1.3.3.1.
.................. ............... .. ....
Interrupt Controller
12
14
14
1.3.3.2.
1.3.3.3.
Interrupt Enable/Disable and Test
Break Interrupt ....... . . ... ........... 14
14
1.4. Section 4 .................... ... ........ ..........................
1.3.3.4. Interrupt status and Clear 15
16
1.4.1.
1.4.2.
1.4.3.
LEOs .......... ...................................................................
Valve Statemachine
Status Registers
16
18
19
1.4.3.1.
1.4.3.1.
MVD Diagnostic Register
MVD Diagnostic Mux
........... 19
19
1.4.3.1.
1.4.3.2.
Diagnostic Mux
configuration and Status Register
......... 20
1.4.4.
1.4.3.2.
Break Switch
Voltage Monitor
. . . . . . . . . . . . . . . . . . . . . . ......... 21
21
........ ................................................... ......... ...... ...................

21
1.4.5. DIP Switches . . 22
23
................ ....................................................
1.5. Section 5
1.5.1. synchronization Signals 24
1.5.2. External Events 25
1.5.3. Serial I/O Port
........................... 26
Serial Port A
1.5.3.1.
1.5.3.2. Serial Port B ...... 26
26
MJdel 9010 SBC i May 1988

Table of Contents
1.5.4. Parallel I/O Port ............ 27

1.5.4.1.
1.5.4.2.
Bidirectional Port .
Unidirectional Port
... 27
1.6. Section 6
1.6.1.
. .. ...... ......... . .. ...... .. . . . 28
29
Timer/Counters .............
1.6.1.1.
1.6.1.1.
Motor Rate Generator
cam Event Counter .
...... ... 29
30
31
1.6.1.1.
1.6.1.2.
cam Position Counter
E-Signal Based Timers
.... 32
32
1.6.1.2.
1.6.1.2.
ADC timer
System timer .
. .. . 32
33
1.6.1.2. Motor acceleration timer .
.......................................................... .
33
1.6.1.2. General Timer 33
1.6.2. Timer/Counter Interrupts 34
1.6.2.1. Top Dead Center Interrupt 34
1.6.2.2. Interrupt Status Register . 34
1.6.2.3. Interrupt Mask Registers
. .. . . . .. . . .. . . . . . . .. .. ................ 35
1.7.
1.6.3.
section 7
1.7.1.
.......................................................
Auxiliary Register
Feedback Siqnals
35
36
36
1.7.1.1. Pump Synchronization 36
1.7.1.2. Column Pressure 36
1.7.1.2. Pressure Transducer 37
1.7.1.2. Amplifier 3e
......................................

1.7.1.2. OVerpressure Monitor
1.7.2. ADC Circuitry
1.7.2.1.
1.7.2.2.
1.7.2.3.
AOC Interrupt .........................
Analog to Digital Converter
Analog Data Latches
39
40
1.7.2.4. Sample/Hold Amplifier 40
1.7.3.
1.7.2.4.
Interrupt Latches ..................................
Analog Multiplexer 41
41
2. !CE!3(ll()ct~Cl Ilea~ 42
2.1.1. Keyboard Encoder 43
3. ~~~E!rtciJllC 44
3.1. Jumper Tables 44
46
3.2.
3.2.1.
3.2.2.
Pressure output (J2)
External Events (J3 - J8)
.........................................................
connector Pinout
46
46
3.2.3. Synch Input Connector (J9) 46
Synch output Connector (J10)
3.2.4.
3.2.5. Parallel I/P Connector (J11) ....................... 46
47
3.2.6.
3.2.6.1.
3.2.6.2.
Port A (J12A)
Port B DCE (J12B)
..............................................
Serial I/O Ports 47
47
48
3.2.6.3. Port B OTE (J12C) 48
49
3.2.7. SBC
....................................................
Extension Connector (J13)

3.2.8. SBC FPB Connector (J15)
3.2.9. SBC MVD connector {J17)
Model 9010 SBC ii May 1988

-- . ., - Contents
3. 3.
3.2.10.
3.2.11.
3.2.12.
Memory Map
3.3.1.
Power Connector (Jl9)
Optical sensor {J21)
Pressure Transducer {J22)
. .. . . . .
Block 0
..... ....... . .. ......
.
.. ... ..........-.......
.....
. ...
....
51
51
51
52
3.3.2. Block 1 . . . . . . . . . ...
.. ....... .. ...................
52
52
.. ... ...........
3.3.3. Block 2 53
3.3.4. Block 3
3.3.4.1. Timers
.. 54
54
3.3.4.2.
3.3.4.3.
Parallel I/O
Status Registers
... .... ....... ... 54
55
3.3.4.4.
3.3.4.5.
ADC Data
DIP Switch Data
.. 56
56
3.3.4.6. MVD Diagnostic Register 57
3.3.4.7.
3.3.4.8.
Auxillary Output Register
Interrupt Control Register
... 57
57
3.3.4.9. Interrupt control Register 58
3.3.4.10. Timer Control Registers 58
3.3.4.11. Interrupt Test Register 58
3.3.4.12. External Event Control Register 58
3.3.4.13. Motor Valve Control Register 59
3.3.5.
3.3.4.14.
Block 4
Multiplexer Control Register
... ...... . . . .. 59
60
3.3.6.
3.3.7. . .... ... .
Block 5 ................ .
Block 6 . . . . .............. ..................
.
60
60
Block 7 ....................... ...........
60
Valve Statemachine Flowchart ........................... ....
3. 3.8.
3.4. 61
3.5. Test Points ........................ ..................... 62
4 REFERENCES .- 63
M'Jdel 9010 SBC iii May 1988

~~rcuit pescription -- Model iQlQ ~
This document addresses the circuitry depicted in schematic #03-

919058-oo.
ment.
It is intended to be used primarily as a schematic supple-
The document is comprised of nine sections. The first seven

correspond to the seven schematic sheets. The eighth section is an
appendix composed of various reference tables, charts, and code. The
last section is a list of technical references used in the design pro-
cess.
The major purpose of this document is to describe how the indivi-
dual components were used and what their specific functions are in rela-
tion to SBC operation. Refer to the manufacturer's technical literature
for functional specifications.
Much effort was put into creating a digital hardware design which
was compatible with the needs of both the 9010 and 9050 projects. Sec-
tions 1, 2, 3, and 5 reflect the success of this goal. The similarities
provided advantages in circuit layout, software design, packaging, and
service education. Note that parts with identical functions were given
the same reference designator on both the 9010 and 9050 SBC boards.
1e following conventions apply to signal names as they

~hematic and also throughout this text:
Prefix:
X
F
M
external side of extension buffer
external side of Front panel buffer
Motor valve driver
appear on the
B external side of system Buffer

Postfix:
* --- negative logic signal, see "Assertion & negation"
cs address decoding output for Chip Select
EN control signal for ENable
GE control signal for Gate Enable
I Interrupt siqnal
IC control siqnal for Interrupt Clear
IS Interrupt Status
The terms asserted and negated will be used in this document. This
is done to avoid confusion when dealing with a mixture.of "active-low"
and "active-high" signals. The term assert or asserted is used to indi-
cate that a siqnal is active or true, independent of whether that level
is represented by high or low TTL voltage level. The term negate or
negated is used to indicate that a signal is inactive or false
Model 9010 SBC 1 May 1988

ll Section 1
This section will describe the operation of the circuitry shown on
sheet 1 of schematic t 03-919058. The circuits under discussion are:

CPU, DTACK, Reset, RAM Backup Power, Free Run, and Front Panel Inter-
face.
The CPU of a micro-computer processes the data from one location of

a device then puts the result into a location of another device through
the data bus. The CPU initiates the data transfer cycle by specifying
the device and direction. This is similar to reading or writing at a
specific address. The device acknowledges the CPU when it has finished
the data transfer. -
The CPU used on the SBC is a Motorola MC68000, 64 pin DIP, ceramic
package with a base clock of 12.5 Mhz. Refer to the Motorola manual
(ref. 1) for details on signal timing, pinout, etc.
111 ~ Signal peacriptions

In order to assure signal voltaqe levels, all signal lines
pulled up by resist~rs.
All CPU signals can be classified into the following
categories:
Data Transfer:
Data Bus: DO-D15
Address Bus: Al-A23
Bus Control (Async.): AS*, UDS*, LOS*, R/W*, DTACK*
Bus Arbitration: BR*, BG*, BGACK*, HALT
M68000 Peripheral Bus Control (Sync.): B, VPA*, VMA*
system Control:
Bus Error: BERR*
Interrupt: IPLO*, IPLl *, IPL2 *, VMA*, VPA*
Processor Status: FCO, FCl, FC2
Clock: CLK, B
Halt: HALT*
Reset: RBSBT*
The siqnals BR*, BG*, BGACK*, and VMA are not used in this system.
Siqnals such as UDS*, LOS* ' AS* (Upper Data, Lower Data and Address
strobe) control the proper assertion of the address ' data lines on the
outside of the correspondinq buffers. Information about these siqnals
can be found in Motorola's MC68000 data book.
Model 9010 SBC 2

May 1988
Clock
The clock source for the CPU is a 12.5 Mhz crystal oscillator
which, via jumper (W9), can be disconnected from pin 15 of the CPU for
test purposes. The clock is also sent to the DTACK qenerator as the
timebase.
Note:
The CPU clock can be driven from the oscillator in the Timer Section
(Schematic, Sheet 6) by movinq jumper W9 to connect pins 1 and 2 of
XW9.
An internal divider circuit produces the "E" siqnal, which has a

period equal to ten clock periods. In this circuit, the E siqnal is
1.25 Mhz, and is present at pin 20 of the CPU.
J..J..11 Reset
The reset siqnal can be qenerated by the reset qenerator or the
CPU. Three conditions triqqer the reset qenerator: the reset button,
power-up and power-low (power-down included). The CPU can reset all
~~vices by executing a RESET command. In this instance, CPU pin 18
..:c.omes an output
Upon assertion of RESET*, latch Ul34A is "set". The Q* output

.:twitches to a loqic "O", and disables the battery-powered RAM. This
prevents the contents of the RAM from becoming altered during power sup-
ply transitions.
11111 Reset Generator Circuit

The reset generator is a simple two-staqe voltage comparator cir-
cuit (U132A and D). capacitor C137 and diode CR19 provide a voltaqe
hold-up for the comparator supply when the 5 volt power is lost. When
the supply voltage drops below 4.0 volts, the voltage at pin 5 (2.44
nom.) drops below that of pin 4 (2.05 nom.) and the first stage output
will switch low. Capacitor C136 will discharge, triggering the second
staqe (U132D), producing a RESET*.
Similarly, during power-up, the CPU is held in RESET until after
the digital supply has stabilized. The reset generator is also triq-
qerred by depressing switch S6
Model 9010 sse 3 May 1988

1l1J.
68000
DTACK
DTACK is an abbreviation of Data Transfer ACKnowledge. When the
CPU transfers data through its bus, it expects an active DTACK

signal from the adressed device. All valid memory locations must gen-
erate DTACK signals. When the CPU reads or writes to an address outside
existing devices, the DTACK timeout circuit will generate a timeout sig-
nal, which in turn generates a bus error (BERR*).
11121 QTACK Generator

In general, the DTACK signal inputs are address decoder outputs and
clock delai pulses. The exception to this is the DUART signal (681
DTACK*), wh chis internally generated within the device. The And/Nor
gate, 0119 is the DTACK summini node. Through this gate, the address
decoder outputs are logic anded w1th an output of the DTACK delay regis-
ter, 0118. The resultant signal is visible at TP29. When either data
strobe signal (ODS* or LOS*) is asserted, the shift register is enabled.
The next rising edge of "Clock" will cause output "A" to be asserted.
Each successive clock will cause a successive output to be asserted.
If a valid address has been selected, a delayed output will eventu-
ally be anded with the address signal, indicating proper timing for data
transfer. The CPU will negate UDS* and LOS*, which will reset the DTACl.
delay register.
The shift register produces a maximum delay of 8 clock cycles.
However, the outputs will remain high (asserted) as long as UDS* and/or
LOS* are asserted. A bus error (BERR*) is generated if the address
strobe (AS*) is asserted for more than 80 clock cycles (6.4
microseconds).
DTACK circuitry is designed based upon the response times of the
various devices. The RAM can be read with no wait states, however,
writing to it takes 1 wait state because of the timing of AS* and OS*.
The followinq table lists the maximum allowable read and write access
times for different devices in the system.
Device Max Access Wait States
RAM e 207 ns 1
Jl()ll 367 ns 3
GPIB board ...................................... . 367 ns 3
ltta!lta1: Jlatl) 447 ns 4
Devices selected by 073 (includes ADC) . 447 ns 4
Devices selected by 072 (includes battery RAM) 447 ns 4
Front Panel devices (display, keyboard, LEO's) 687 ns 7
Devices addressed in the range JOO,OOOH-JOF,FFFH 687 ns 7

Free Run circuitry 687 ns 7
Fault out, Start out . 687 ns 7

..... .... .J.. mlS.
All bus lines are 'pulled-up' through 10k resistors, to the
5 volt supply.
system
The two major bus types are Address and Data. These buses are also
subdivided as to their destinations. For schematic simplicity, the indi-
vidual signals are drawn as a solid line between interconnections.
llll Address Bus

The 23 line CPU address bus is increased to 24 lines by use of the
upper data strobe (UDS*) as the LSB of address (SAO). The majority of
I/O control is accomplished using the lower three or four address bits.
The line SAO (pSuedo Address 0) is generally used to address ports which
have no data bus interface. It operates as an LSB when reading or writ-
ing in an 8-bit bus mode. When the processor is strobing the upper data
byte, UDS, and therefore SAO is at a logic "0". When strobing the lower
data byte, UDS, and SAO are at a logic "1". The driver U111 is used to
buffer the lower 4 address bits and SAO which are distributed throughout
the board.
~l~ll Configuration Jumpers

The SBC was designed to accept two different sizes of RAM and ROM
devices. RAM can be either 8k x 8 (i.e. 6264) or 32k x 8 (43256). ROM
can be either 32k x 8 (i.e. 27256) or 64k x 8 (27512). The first twelve
jumper pairs on block XW7 are used to configure the ROM and RAM size.
The first four.jumpers control RAM sizing. If jumpers 1-2 and 3-4 are
installed, the RAM is configured in blocks of 8K byte pairs. If jumpers
5-6 and 7-8 are installed, the RAM is configured in blocks of 32K byte
pairs.
The second four control RAM sizing. If jumpers 9-10 and.11-12 are
installed, the ROM is configured in blocks of 32K byte pairs. If
jumpers 13-14 and 15-16 are installed, the ROM is configured in blocks
of 64K byte pairs.
The last four jumper pairs are used to connect address line 14 to
the RAM when using 32K devices. Note that XW7 pins 17-18 are not con-
nected. This is due to the fact that the first RAM pair is permanently
designated as 8K devices

There are 3 buffered data buses on the SBC: the extension bus

(designated by XD), the front panel bus (FD) and buffered bus (BD), each
is interfaced to the system bus. The purpose of these buffers is to
ensure isolation of electrical characteristics and to separate diagnos-
tic dependency between boards.
The CPU data bus is 16 bits wide. The entire data bus is connected
to the Memory circuits and the Extension Bus Connector. In general,
only the lower data bus (DO through D7) is connected to the memory-
mapped I/O devices. In several instances, only data bit 0 is connected.
In some cases, no data is actually required, only the device address,
and the state of the Read/Write signal are used to control output func-
tions.
The CPU data bus can be disconnected by pulling the data bus
jumpers 25-26 through 57-58 from XW7. When the CPO data bus is discon-
nected, the CPU is placed in a free run mode, by the assertion of
drivers U125D, and U121A, B, and c. These devices drive the CPU data
bus lines with op coda 7EFE which corresponds to instruction MOVE
FFFFFFFE to Data register 07 ( movaq t-1,d7 ). In this mode, the CPU
address lines will sequentially increment. This free run function is a
useful tool for analyzing fundamental CPO functions.
,l.,l.J.. Batterv ~ ~
To provide battery backed up memory, there must exist a switch to

disconnect the battery powered RAM from the +5 volt supply and connect
it to the 3 volt lithium batttery. When the instrument is powered,

resistors Rl07 and R108 bias transistor Q2 into saturation: this in turn
saturates Q1 so that the battery RAM voltage BRV (TP32) is close to 5
volts.
The chip select BRCS* toggles CMOS flip flop U134 to the active
state. MOSFET switch. QS acts functionally as an AND gate: both +5 volts
has to be present and the output of U134 has to be high to drive BRAMCS
active. This enables the battery ba~ked up RAM chips U99 and 0106.
When power is removed, either due to a power failure or due to
turning the inatrument off, the SYS RESET* siqnal goes low before the +5
volts is lost. This siqnal sets the flip flop 0134, pulling BRAMCS low.
This prevents the RAM from drawing excessive battery current while the
power is off. Aa further insurance, QS will always be off when the +5 is
gone. Diode CR18, which had been back biased when power was on, now pro-
vides a current path for the battery voltage to maintain the contents of
RAM memory. R114 and C133 are also insurance against any false glitch-
ing that would reset the flip flop. Accessing address RMCS* will also
set U134. The lithium battery can last up to four years under normal

operating conditions.

- ~-~ Extension Bus Interface
An extension bus is provided to interface to the General Purpose
Interface Bus (GPIB). The access is in four blocks starting at XCS*.
Refer to the memory map for the addresses of the individual segments.
The CPU control signals AS*, uos, and LOS*, are logic anded with
the signal xes and the DTACK delay line QB to produce the extension bus
input control signals. The signal R/W* is anded only with xes as it is
often necessary that this signal be stable for as long as possible.
RESET* is buffered to provide isolation and additional drive capability.
The signals XOTACK* and XDTEN* are outputs from the extension bus.
XOTACK* is used by boards which generate their own DTACK*, such as the
GPIB. XDTEN* is created by the decoding which addresses devices on an
external board, such as the RAM memory board; it enables the DTACK* cir-
cuitry located on the sse.
ll2l Signal Characteristics

The following table lists the AC and timing characterics for SBC
Extension Bus Connector signals.
number symbol characteristic min max unit
.3 4
5
---------------------------------------------------------------------------
tcyc clock period (internal)
txchav
txchsl
txavsl
txchrh
clock high to X address valid
clock high to X SEG* low
X address valid to X AS* OS* low
clock high to X RD valid
80
10
10
30
7
ns
79
78
55
75
ns
ns
ns
ns
ns
6 txsl X AS* OS* Width low 160
7 txasi Async. input set up time 72 ns
8 txdaldi X DTACK* low to X data in set up time 71 ns
9 txdicl X data in to clock low (read) 17 ns
10 txshdii X AS* OS* high to X data invalid 0 ns
(hold time on read)
11 txshdah X AS* OS* high to X OTACK* high 0 135 ns
12 txclsh clock low to X AS* OS* high 10 65 ns
13 txclseh clock low to X SEG* high 10 73 ns
The following table lists the maximum allowable read and write access
times for different jumper positions at XW10.
Jumper Position Access Wait States
pin 13 to 14 287 ns 2
pin 15 to 16 367 ns 3
pin 17 to 18 447 ns 4
Model 9010 sac 7 May 1988

~-~~ Front Panel Interface
The front panel contains the display, keyboard and LED's, which can
all be controlled through this interface. Furthermore, the EL light and
the beeper can be controlled. The access is in one block starting at

FCS*. Refer to the address map for the location of the keyboard encoder
control/data, the LCD module control/data, the control of the LED's and
the Electro Luminescent light (EL) for the display, and finally control
of the beeper. Upon power up reset, the LED's are all turned on and the
beeper and the EL are both off.
Front panel data is buffered through driver 0130, which is enabled
by address FCS*. The bus direction is controlled by the state of the
R/W* signal. A separate pair of read/write strobes is generated through
decoder 0123. The read and write strobes are qualified by the lower
data strobe, since data transfer is restricted to the byte-wide mode.
There is also a six clock delay difference between readinq and writing,
to accommodate the Intel keyboard encoder.
~.lZ ~ l.G
A test point (TP34) has been provided for simple siqnal diaqnos-
tics. A TTL level present at this test point will produce a visual
response throuqh LED CR17. When the TTL level at TP34 is hiqh, CR17
will remain off. If it is low, CR17 will liqht.

.....-.. Section 1
This section describes circuitry depicted on schematic sheet 2. The
circuitry is primarily memory related.
The SBC memory is composed of ROM and RAM. The memory addr~ss
sizes and delays are jumper-programmable. There is an additional pre ~
sion for memory expansion, in the form of an extension bus connector.
There are six 28-pin ROM sockets which are organized as words and
can be configured to accept 32k x 8 (27256) or 64k x 8 (27512) devices.
The maximum ROM size is therefore 6 * 64k s 384k bytes. on schematic,
sheet 1, follow the jumper table for correct positioning of the jumpers
at XW7. When 64K-byte ROMs (27512) are used, jumper W8 is installed in
XW8 to connect the A16 line to pin 1 of the ROMs.
ROM addresses are as follows:
Socket Pair Address (hex)
U100, U107 400000
U101, U108 420000
U102, U109 440000

Depending on the speed of the memory device used, jumper block XW10
on sheet 1 selects the maximum access time:
ROM Speed Dten Jumper at XW10
200 ns Qb ROM Dten (pins 7 & 8)
250 ns Qc ROM Dten (pins 9 & 10)
350 ns Qd ROM Dten (pins 11 & 12)

There are eight 28 pin sockets for RAM. TWo 28 pin sockets are for
battery backed up RAM (BBRAM, Bank 0), see "Battery backed-up RAM". The

static non-battery backed-up RAM devices used in the SBC are either Sk x
8 or 32k x 8 devices whose pin-outs are compatible with the former. Bank
o can only use Sk devices.
The available memory, excluding Bank o, can be one of several sizes
depending on configuration:
Device size Memory size
6 X 8 k 48 k
2 X 32 k, 2 X 8 k 80 k
2 X 32 k, 4 X 8 k 96 k
4 X 32 k 128 k
4 X 32 k, 2 X 8 k 144 k
At the present time, the RAM size is SOK. SK RAMs are installed as 099
and 0106, and are addressed at oooooo hex. 32K RAMs are installed as
097 and 0104 and are addressed at 020000 hex.
The maximum access time of the RAM has to be 120 ns or less i .
order to achieve no wait state in the read operation, but requires
wait state for writing. For this reason, the RAM DTACK delay is jum-
pered for 1 wait state (XWlO, pins 3 & 4). If the given RAM device is
slower, more waitstates must occur and the responding DTACK delay (XW10)
should be set up accordin~ to the following:
RAM Speed Dten Jumper at XWlO
120 ns Qa RAM oten (pins 1 & 2)
200 ns Qb -- RAM oten (pins 3 & 4)
Model 9010 SBC 10

May 1988
Battery Bactup BAM
The first RAM bank (U99 & U106) is backed up by a lithium battery.
The size is restricted to one pair of 8k x 8 static devices, for a total
of 16k bytes of backed-up memory (0-4000). Whenever reset occurs, the
battery power will feed the RAM's and the CPU will be locked out from
accessinq them. After any reset, the CPU can reqain access to the RAM
devices by assertinq control point BRCS* (See memory map for exact
address).
1-~1 Extension ~ Connector

Extension bus connection is made throuqh J13. The drivers U81
throuqh U84 buffer the data and address lines. All 16 data lines are
available at the connector. Only 16 of the 23 address lines are
present, since the external block decodinq (XSEGO throuqh XSEG3) is per-
formed usinq address lines 23 throuqh 17. Jumper XW6 is provided in
case uni-directional buffers (74LS541) are used as devices U83 and U84.
RESET* is buffered throuqh U117A to produce XRESET*. The remaining
CPU control lines are modified throuqh the DTACK delay circuitry to pro-
duce compatible external control siqnals. Refer to Section 1 for exten-
sion bus siqnal characteristics.
Two interrupt lines Xli* and X2I* are provided for use by the
.xternal interface. X1I* is at priority level 2, X2I* is not connected
~o a priority line at this time.
The line XPR* is used to determine whether or not an external dev-

ice is connected. XPR* must be asserted for the CPU to recoqnize or
acknowledqe communication throuqh this port

11 Section ~
This section covers the circuitry shown on sheet 3. Functions covered

are address decoding, interrupt control and status registers, E signal

divider, DTACK timeout, and the overpressure latch.
,l.J,.,l. Memory HG Switch

On power-up or reset, latch U60B asserts a pseudo-A22 which causes
addresses 400000 (h) throuqh 47FFFF (h) (ROM) to be decoded, rather than
addresses 000000 through 07FFFF (h) (RAM). This enables the ROM to be
used as a start-up vector for the CPU. The battery back-up RAM will be
disabled.
The memory map overlay is for the system cold-start boot. Upon
power up, the CPU automatically fetches the supervisor stack pointer
(SSP) and proqram counter from the ROM, that is swapped down to position
o. After loadinq the SSP, the ROM memory is swapped back by reading or
writing at address RMCS*.
,l.J..~. Address dec9dinq

The address decodinq circuitry contains a sat of decoder devices.
Two types of decoder devices are used: 74138, 74139 decoders and 7425.
addressable latches. Decoders are used for chip (CS) select functions.
For those control points that need a strobe siqnal, an addressable latch
is used. The CPU can simply read and write to the control point to
enable, disable or clear it. The simplest way for the CPU to generate
an active low pulse is to issue a TAS (test and sat) command. The out-
put of address decoding is compiled into a software format called a
memory map.
lJ.~l Block Allgcation
The 23 address bits give the 68000 processor a dynamic address
range from oooooo (hex) to FFFFFF (hex). The system decoders restrict
the addressable range. First laval decoding takes place at a 3-line
decoder (U87). Bits 23 and 19 are required to be at 'O' in order for
any device to be selected.
The block froa 000000 (h) to 07FFFF (h) is allocated to RAM.
From 100000 (h) to 17FFFF (h) is the external connector port (J13).
From 200000 (h) to 27FFFF (h) is the front panel address range.
From 300000 (h) to 37FFFF (h) is the range of memory-mapped I/O.
From 400000 (h) to 47FFFF (h) is allocated to ROM.
The last three blocks are not decoded further, and are used for
individual function controls. Address 500000 (h) to 57FFFF (h) causes
the 'Start out' synch siqnal to be asserted at J10. Address 600000 (h)
to 67FFFF (h) causes the 'Fault Out' synch signal to be asserted at
Address 700000 (h) to 77FFFF (h) resets the 'pseudo-A22' signal (RMCS*)
JlO.
Modal 9010 SBC 12 May 1988
-~cK Allocation Ccont.l
The second level of decoding takes place at 095, 085, and 086. U95
is a dual 4 bit decoder. One half controls ROM, the other controls RAM.
Decoding and block size are determined by the jumper configuration at
XW7 and XW8. The ROM is segmented in three blocks of 20000 (hex),
starting at address 400000 (hex). The RAM is segmented in four blocks
of 10000 (hex), starting at address oooooo (hex).
U85 is another dual 4 bit decoder. one half decodes the expansion
port into four blocks of 20000 (hex). The other half decodes the front
panel into four blocks of 1000 (hex).
The decoder 086 is enabled in the address range from 300000 (h)
thru 37FFF (h). The outputs are not fully decoded. Address bits 18,
17, and 14 are not defined, which has the affect of limitting the effec-
tive address range from 300000 (h) thru 303FFF (h) and from 310000 (h)
thru 313FFF (h).
Third level decoding takes place at 072 and 073. Both are single 8
bit decoders with segment sizes of 100 (h). 073 is enabled in the range
from 310000 (h) thru 310FFF (h) for read-only operations. Address bit
11 is undefined, which limits the effective address range from 310000
'~) thru 3107FF (h). 072 is enabled in the range from 311000 {h) thru
l1FFF (h). Address bit 11 is also undefined for this device, causing
:e effective address range to be limited from 311000 {h) thru 3117FF

. ~).
Decoder
087
The cs signals from 072 are timed by Qb (start) and Qe (end,
delayed through 074a).
starting Address Outputs
OH - 700,000H
output Step size
100,000H
086 300,000H - 303,000H 1000H
310,000H - 313,000H 1000H
089A 302,000H - 302,010H 10H
089B 30l,OOOH - 301,030H 10H
072 311,0008 - 311,700H 100H
073 310,0008 - 310,700H 100H
085B 200,0008 - 203,000H 1000H
085A 100,0008 - 160,000H 20,000H
The specific addresses and control parameters for individual dev-
ices are contained in Appendix, Section 2.5

11~ Interrupts
Interrupt processing is a subset of CPU exception processing.

For
a detailed description of exceptions, refer to the Motorola Microproces-
sor manual.
The Interrupt Controller circuit (U56) accepts and encodes all
interrupt signals (from the SBC Board as well as from FPB, MVD, GPIB
etc.). All interrupt sources generate a single level out of a 7 auto-
vector system. The vector address for each level is in RAM. Jumper block
XW4 assigns interrupt levels to the 19 incoming interrupts. An addi-
tional jumper, XW13 was included to connect interrupt PIFI* (Parallel
InterFace Interrupt) if required.
1~~1 Interrupt Controller

The interrupt controller is a simple TTL 8-line to 3-line encoder.
A three line inverted binary code will appear on the outputs corespond-
ing to the highest level input which is active. The highest level is
level seven. If this input is asserted, only the code for seven
(AOAlA20) will be output. The outputs of 056 are connected to the
Interrupt Pending Lines (IPLO-IPL2) of the CPU.
Interrupt level o is the default state of the CPU, and has no
effect on processing. The result is to produce a sat of seven multi.
plexed and prioritized interrupts. In general, when the CPU receives
code other than level o, it must check the interrupt status registers to
determine the interrupt source. The exception is interrupt 3, which has
only one source.
l~~~ Interrupt Enable/Disable And ~
The interrupt tet register is a bit-addressable latch (066) at

address ITCS*. Writing to address ITCS* + 0, will enable the interrupt
controller. Reading to the same address will disable the controller,
and activate LED CR10 (INT DIS). Individual interrupts can also be
exercised by the test register. Example: Writing to address ITCS* + 2,
will generate a level 2 interrupt. Reading from that same address will
clear the interrupt. This is true for interrupts on level 1 through 7,
corresponding to address ITCS* + 1 to ITCS* + 7.
1~I~ Break Interrupt

By pushing the "Break" switch S3 (shown on sheet 4), an interrupt
at level 7 is generated through latch 060A. The primary purpose is to
preserve the states of internal processor registers in the event CPU
operation should become abherrent. The interrupt is removed as soon as
the switch is released.
Model 9010 SBC 14

May 1988
- -~~ Interrupt Status ~ Clear
All interrupts on the same priority level are wire or-ed together.
When an interrupt occurs, the CPU has to read the appropriate interrupt
status register to determine which interrupt source is active.
Every interrupt status can be examined at the point listed under "STATUS
SOURCE" (see interrupt table below). Interrupt X1I* is generated from
the extension bus. Its status is generally available by reading the
extension port. Additionally, interrupt 681I* is wire-ored with X1I* at
level 2. It is not buffered, and therefore should be checked in con-
junction with X1I*.
The interrupt priorities (level 7 is the highest) are shown below.
NAME LEVEL DESCRIPTION STATUS SOURCE CLEAR SOURCE
------------------------------------------------------------------
BI* 7 Break (Soft Reset) 060, pin 4 RESET
PFI* 7 Power Failure 058, pin 12 XX
CEI* 6 Cam Event 020, pin 8 044, pin 6

TDCI* 6 Top Dead Center 045, pin 9 044, pin 11
T1I*(MA)5 Timer 1 (Motor Ace.) 053, pin 9 043, pin 10
T2I*(ST)5 Timer 2 (Spare Timer) 053, pin 7 043, pin 11
CPI* 5 Cam Position (stall) 045, pin 7 044, pin 7

ADCI* 4 A/D Converter 0113, pin 5 067, pin 4
PCI* 4 Parallel I/F controller 07, pin 17 07, tt
PIFI* 4 Parallel I/F Connector 065, pin 6 XX
TOI*(P'1')3 Timer o (PSOS Timer) 053, pin 4 043, pin 9

X1I* 2 Gen. Purp. Itfc. Bd. J13, pin 2 XX
SIOI* 2 Serial I/O 029, XX 029, ti
DTI* 1 Diagnostic Timer 045, pin 13 044, pin 10
RGDI* 1 Rate Gen. Diaq. 045, pin 4 044, pin 9
FISI* 1 Fault In Sync. 03, pin 9 067, pin 7
SISI* 1 Start In Sync. 03, pin 5 067, pin 6
RISI* 1 Ready In Sync. 065, pin 9 067, pin s
FPI* 1 Front Panel 093, pin a 043, pin 12
------------------------------------------------------------------
Note:
xx Status and/or Clear are not directly accessible by the CPU
tt clear is internal to device
Model 9010 SBC 15

May 1988
lJ. Section J.
This Section describes the circuitry shown on sheet 4. This sheet
contains the valve statemachine, system status registers, the MVD diag-
nostic multiplexer, and the analog voltage comparators.

l~l Valye Statemachine
The valves on the MVD board are controlled by a statemachine built
in hardware on the SBC board. The statemachine ensures the correct tim-
ing of the valve control signals, i.e. when to apply the high current to
open the valve, how long it stays on, how long it takes for a valve to
close and so on. It takes inputs as 3 valve control bits from the CPU
and outputs 1 valve current control signal for the high current, MHIVC*
(common) and one select signal for each valve, MVA*, MVB*, MVC* and
MVD*. The fourth valve, MVD* is not used at this point in time. The
statemachine also ensures that valves are selected exclusively.
The statemachine consists of the following Hardware:
1 PROM, 512 bytes, Harris 7649, U92
1 latch, LS374, U77
1 latch, LS373, usa
1 dual flip-flop, LS74, U113
1
1
1
quad flip-flop, LS175, U91
clock divider, CD4020, U114
decoder 2 x 2 to 4, LS139, U78
The latch usa holds the valve command send from the CPU in the 3
lower bits. The quad flip-flop U91 synch's the incomminq signals from

the latch to the statemachina, ensuring the sat-up time in the PROM U92.
The statemachine itself comprises of the PROM U92 and the latch U77.
The machine has 9 inputs, which breaks down into 5 real inputs, and 4
feedback inputs. The inputs are located on the PROM, U92 as follows:
In bit &(pin 19) Valve control bit 2, latched in usa
In bit 5(pin 16) Valve control bit 1, latched in usa
In bit 4(pin 5) Valve control bit 0, latched in usa
In bit 7(pin 18) 3 ms pulse
In bit 6(pin 17) 1.5 ms pulse
In bit 3(pin 4) Feedback from out bit 3, U77 pin 9
In bit 2(pin 3) -"- 2, U77 pin 6
In bit l(pin 2) -"- 1, U77 pin 5
o, U77 pin 2
In bit O(pin 1) -"-

Model 9010 SBC 16

May 1988
~+ve Statemachine Ccont. l
The statemachine has 8 outputs on 077:
out bit 8(pin 19) Clock Ena)?le, and Valve High CUrrent.
Out
Out
bit
bit
7(pin
6(pin
16)
15) . Clock
Bit 1
Enable, and Valve High current.
of valve select in 078
Out bit 5(pin 12) Bit 0 of valve select in 078
Out
Out
bit
bit
4(pin
3(pin
9)
6) .. Valve
State
Enable, state feedback to In3, 092.
feedback to In2, 092.
out
out
bit
bit
2(pin
1(pin
5)
2) . State
State
feedback to In1, 092
feedback to InO, 092.
The statemachine runs in 16 states, which are described in a state
diagram in the Appendix, Section 3.4. Refer to it for the following
explanation.
The initial state is "F", and it will loop there until given a command
to open 1 of 4 valves.
The statemachine runs off the E/4 clock, which is 312.5 kHz. The
response time is therefore - 3 us.
As an example, a command to open valve A is given. The machine state
:-tanges to "8" through the input of "OF"

f the input is still "OF", it moves on to state "O" and it will stay
~here as long as In bit 6, U92 pin 17, is low, i.e. 1.6 ms.
That means for each 1.5 us statemachine clock cycle, it loops around.
When In 6 goes high, the machine goes through to state "4", where it
will loop until a valve close command is received.
At the occurence of the valve close command, the valve control bits are
changed by the CPU on latch usa, the timer is reset, and the machine
goes to state "C", where it is waiting for 2 x 1.6 ms 3.2 ms, i.e. In
bit 7 092 pin 18, to go high.
When that happens, the statemachine goes through state "D", resetting
the timer and upon the timer output resetting, the machine returns to
"F".
Data and specifications for the PROM can be found on drawing 103-910378
Model 9010 SBC 17 September 1988

Valve Statemachine Ccont.l
boxes
The state diagram notation is square boxes for states, and hex
for inputs. The valve action is derived from the valve select

bits:
Valve control bit 2 1 o on usa Valve action
---------------------------------------------------------
0 0 0 All valves closed
1 0 0 Valve D open
1 0 1 Valve c open
1 1 0 Valve B open
1 1 1 Valve A open
---------------------------------------------------------
Note that the valve control bits are inverted from usa passing
through 091 to 092, so that the PROM address bits are the inversion of
the above scheme.
The timinq of the machine can be chanqed by chanqinq the sta-
temachine clock frequency. The input-output relation of the sta
temachina is tied toqether in the PROM 092. The PROM is proqrammed so
that the inputs produce the outputs as described in the state boxes th~
are leadinq to. ,.,
A set of tan LEOs are located at the top center of the board.
There descriptions and functions are listed below:
LED Color Name Siqnificance
=--:----------------------~-~---------~---------~--=m=~waaaaa-.w-------------===========
CR6 Green DGO Minimum Set OK (microprocessor, ROM Bank o,
and non-battery backed up RAM are workinq)
CR7 Green DG1 Front Panel Board OK
CR8 Green DG2 Motor-Valve Driver Board OK
CR9 Green DG3 sac ox
CR10 Yellow INT DIS Interrupts are disabled.
CRll Red BLT 68000 has stopped executinq instructions (HALT).
CR12 Red DTK A DTACK* timeout has occurred.
CR13 Red OVP OVerPressure latch is set.
CR14 Green 15 15 volt supply within acceptable limits.
CR15 Green +15 +15 volt supply within acceptable limits.
CR16 Green TDC Pump at Top Dead Center (Optical switch blocked).
CR17 Red TESTLED Used to diagnose on-board siqnal levels.
=-----=---=====-==-----=-=======-======--==-----------===============

~~1 Status Registers
Status registers hold the status of the system and may be read any
time by the CPU from the STSCS* decoder (U73). The registers described
this section are as follows:
Configuration Status CSCS* U120
DIP switch 1 DIP1CS* U126
DIP switch 2 DIP2CS* U133
MVD diagnostic mux MMUXCS* U116
All 4 registers are 'LS251 multiplexers, and are 'read only'
decoded. All 4 inverting outputs are connected together at Buffer Data
0 (BOO). The select lines are connected to Buffered Address lines 1, 2,
and 4. In the following descriptions, the signal levels will be
referred to as they appear at the inputs of the registers.
MYD Diagnostic Register

This register (U116) is addressed at MMUXCS* and contains 6 bits of
readable data.
Bits 6 & 7 are not connected.
3it 5 is the interrupt status for the Parallel I/O Port

A logic "O" indicates the interrupt is active.
it 4 is the Motor OVerTeMP siqnal.
A logic low indicates an over-temp condition.
Bits o thru 3 are the MVD diagnostic signals MMUXl thru 4.
~-~~~~ MYD Diagnostic HYx

This multiplexer is located on the MVD Board. Its outputs are the
signals MMUXl thru MMUX4. These siqnals are dependent on the conditions
of siqnals MMUXCA* and MMUXCB* (Motor MUX Control A & B), controlled
from Register AUXCS* (063). The following siqnals are present on
MMUX1-4 as MMUXCA* and -B* are set:
MMUXCA* MMUXCB* MMUXl MMUX2 MMUXJ MMUX4
0 0 +26V window +15V window +5V window 25 kHz
1 0 PHlDACHI PHlDACLO PH2DACHI PH2DACLO
0 1 PHlGTA PHlGTB PH2GTA PH2GTB
1 1 VALVES HI VALVESLO PHlSGN PH2SGN
----------------------------------------------------------------------

l.il.l~ piaqnostic HYX
The diagnostic mux circuit is composed of two separate multiplexer
chips. They are connected in such a way as to simulate a 16-input dev-
ice. The inverting output of one (U62), and the non-inverting of the

other (U71) are connected together and produce the signal XX7. This
signal is sent to the diagnostic timer as an input. The ndividual mux,
and subsequent output is selected via signals DMUX1 through DMUX4.
DMUXJ, DMUX2, and DMUX1 select one of the eight inputs for both
devices. DMUX4 selects which device output will be active. DMUX4
selects U62 when high, and U71 when low. The DMUX control bits are
located under AOCMUXCS*. 2 lines (DMUX1 ' 3) were inadvertently
switched, making the map a little less straightforward as shown below:
DMUX4 DMUX3 DMUX2 DMUX1 Diag. timer gate enable signal
---------------------------------------------------------------
0 0 0 0 MMUX1*
0 0 0 1 MVA, MVD valve A control signal
0. 0 1 0 MMUX3*
0 0 1 1 MVC, valve c
0 1 0 0 MMUX2*
0 1 0 1 MVB, valve B
0 1 1 0 MMUX4*
0 1 1 1 MVD, valve D
l
1
1
1
1
1
1
0
0
0
0
1
1
1
0
0
1
1
0
0
1
0
1
0
1
0
1
0
MMUX1
Low (GND)
MMUX3
no connection
MMUX2
High (+5V)
MMUX4

1 1 1 1 MHIVC, MVD valve
high current control
--~------------------------------------------------------------
Model 9010 sse 20

May 1988
~-~1 Configuration ~ Status Register
The system configuration register at CSCS* (U120) allows the CPU to
determine which pc boards are present in the system. It also contains
the voltage monitor bits, over pressure bit, and the ready-in status
bit.
Bit 0 is the expansion board status.
Bit 1 is the synch cable status.
Bit 2 is the front panel board status.
Bit 3 is the MVD board status.
The above four bits are asserted low to indicate a component as
being 'present'.
The next two bits indicate the condition of the bipolar 15 volt
supply. A logic "1" indicates an error condition.
Bit 4 is the -15 volt status.
Bit 5 is the +15 volt status.
Bit 6 indicates an overpressure ( pressure > 548 atm ) if at logic "O".
Bit 7 is the non-latched 'ready in' signal from the synch connector J10.
-f the signal is high, it-means that the ready is active.
low level means 'not ready'
~-~~1~ Voltage Monitor

The +/- 15 volt supply levels are monitored with a window compara-
tor (U61). As long as they stay within acceptable limits, the OK+15 and
OK-15 will remain low (refer to map). LEOs CR14 and CR15 will be lit to
indicate this condition.
Once a supply voltage changes to a level outside the window, the
associated comparator output will switch to a high level.
l~~ Break Switch

A process interrupt switch (53) is included to allow for diagnostic
control during test and trouble shooting. This switch causes the CPU to
discontinue processing while maintaining the status of its internal
registers

li~ QIE switches
There are two eight position DIP switches on the SBC board. The
switch data is reverse ordered, so that switch position 1 is at data bit
7 and switch position 8 is at data bit o.

Each switch position has a specific address and the data can be
read on bit 0 only. Please refer to the map for location of each bit on
DIP1CS* and DIP2CS*.
The first switch register (U126) is at address DIP1CS*. Its data
inputs are connected to the eight sections of dip switch S4. Presently,
the first set of switches are defined, in conjunction with the Model
9050 Detector:
Switch S4 Position t
1 2 3 4 5 6 7 8 Action
----------------------------------------------------------------
off off Coldstart and normal run
on off Jump to CBUG
off on Jump to PROBE-68K
on on Skip coldstart
on Pressure programming
on !socratic operation
----------------------------------------------------------------
The switch register (Ul33) is at address DIP2CS*, and is used to
offset the valves. Its data inputs are connected to the eight sections
of dip switch S5. Each switch section is binary weighted to represent a
fraction of the overall cam angle adjustment. The range is approxi-

mately 90 degrees, with the resolution being 0.3516 degrees ((360
degrees 1 rev) I (1024 bits 1 rev)).
This translates to individual delays as shown below:
swt Delay
(degrees)
1 45.0
2 22.5
3 11.25
4 5.625
5 2.8125
6 1.4063
7 0.7031
8 0.3516
Model 9010 SBC 22

May 1988
Section 2
This section describes the communication circuitry shown on sheet s
of the schematic.
User and Instrument.
The communication module includes two submodules:
From the user's point of view, the 9010 can be operated under local
mode as a stand alone instrument, or remote mode as a slave to the Work
Station. In order to satisfy the above requirement, the 9010 needs a
communication capability with its users.
The remote user interface module is the GPIB communication. The
local user interface module is the Front Panel Board, which in turn
interfaces to the keypad, Liquid Crystal Display (LCD), beeper, and
Light Emitting Diode (LED) indicators.
The 9010 is also required to communicate with other non-Varian
instruments and control non-intelligent devices. For that purpose, the
instrument synchronization and event control modules are provided.
Most user communication functions are implemented through the FPB.
The CPU accesses the front panel by addressing at FCS*. See section 1
for details of front panel control.
The FPB is not the only user communication module. The user can
terface through the serial port (J12A, B, or C) to communicate with a

inter, a modem or a terminal

l~l Synchronization Signals
There are three pairs of synchronization siqnals which define bow
the instrument will operate in an NGLC system. These siqnals are Ready

(In and out), Start (In and Out), and Fault (In and Out). All the syn-
chronization siqnals are located on two 9-pin D shell connectors, J9 and
JlO.
For Ready Out*, Start Out*, and Fault Out*, optoisolator packaqes
buffer the drive siqnals. Each output is protected aqainst reverse vol-
taqes by diodes CR1, CR2, and CR3; resistors R5, R6, and R9 current
limit the outputs to 100ma for TTL aplications. The Start out* siqnal is
a 450 millisecond pulse created by U18A with pulse lenqth determined by
C26 and R46; Fault Out* is derived in identical fashion by components
U18B, C25, and R45. Ready Out* is a level which comes from the asser-
tion of the Instrument Ready Enable siqnal (IREN) at 021-11.
To prevent qlitches from causinq false system indications, Rc net-
works are positioned in series with Ready In*, Start In*, and Fault In*.
Both Fault In* and Start In* qenerate interrupts which are latched by
flip-flops U3A and U3B. Their status can be read on TP2 (Start In) and
TP3 (Fault In). The Ready In* signal is generated by the assertion of a
Ready out* signal from another instrument connected to J10. In addition,
a level transition in either direction at Ready In* generates interrupt
RISIS* which is latched by flip-flop U5, as described in Section 7.
Inductors L1 and L3 with capacitors C2-CS and C8-C11 were placed ~
prevent high frequency signals from radiating out of the instrument via
the cables plugged into J9 and J10. A heavy ground plane tied to chassis
is located underneath connectors J2-J10 to improve FCC compliance.
Model 9010 SBC 24

May 1988
events.
External Events
The instrument can control 6 general purpose contact closure
These contact closures are implemented via relays Kl thru K6,
located at the rear of the board. They are controlled through register
U2l, base addressed at EECS*. The outputs are buffered through inverter
U6. Each output, and therefore each relay is individually addressable
by reading or writing to address EECS* + the numeric offset (O thru 5).
A write to an address will close a relay.
A read from an address will open a relay.
There is a jumper (XWlS) provided to allow an alternative function for
relay 6 (Kl). In the default position (l- 2), the relay is controlled
by address EECS* + s. When jumpered between pins 3 and 4, the relay
closes whenever the TDC* (Top Dead Center) signal is generated.
The two remaining outputs of 021 control functions unrelated to external
events.
021, pin 11 (EECS* + 6) controls the Instrument Ready ENable (IREN).
Writing to this address enables, reading disables.
21, pin 12 (EECS* + 7) controls the Pressure Transducer calibration

Jnction in the same manner.
Reset or power up opens all relays

l2J.
The
serial 1/Q E2.It
onboard DUART (Dual Universal Asynchronous Receiver
Transmitter) is a 68681 accessed at 681CS*. It has 16 read and 16 write

registers, whose addresses can be calculated as follows:
register address base address + (2 * register number)
The OUART contains a 16 bit timer, running with an input frequency
of 3.6468 MHz. The crystal can be disconnected through jumper W1 for
automated test procedures. No special task has been assigned to this
timer. Refer to the Motorola 68681 manual for initialization informa-
tion.
l~~l Serial ~ A
The onboard OOART Port A is wired as an RS-232-C OCE port (capable
of communicating with a OTE). Transmission drivers are 052. Input
receivers are 042. Port A is interfaced through connector J12A, as fol-
lows:
RS232 Siqnal Onboard OOART
(BB) RXD1 rac.data from OCE TXOA
(BA) TX01 trans. data to OCE RXOA
(CB) CTS1 clear to send from OCE
(CC) OSR1 data set ready from OCE
(CA) RTS1 req. to sand to OCE
(CO) DTR1 data term. rdy. from OCE
l~~~ Serial ~ B
OPO
OP2
IPO
IP2
The onboard OOART Port B is wired as an RS232-C DTE port through
connector J12B. Transmission drivers are 051. Input receivers are U41.
Port B is interfaced through connector J12B, as follows:
RS232 Siqnal Onboard OOART
(BA) TX02 trans. data to OCE TXDB
(BB) RX02 rae. data from DCE RXDB
(CA) RTS2 req. to send to OCE OP1
(CO) DTR2 data term. rdy. to OCE OP3
(CB) CTS2 clear to send from OCE IP1
(CC) OSR2 data set rdy. from OCE IP3
Port B ia also wired as an RS232-C DTE port (capable of communicat-
ing with a DCE) through connector J12C. The signals are identical to
the OCE connections of J12A.
For more information on RS232-C protocol refer to Ref. 3. Note
that the RS232-C siqnals names and mnemonics describe the siqnal func-
tion as seen by the OOART and software. The two sets of mnemonics agree

in the case of a DTE port and disagree in the case of a OCE port

-"'.i Parallel 1/Q ~
The programmable parallel interface consists of an Intel 8255 with

it's data port connected to the data bus, Ports A, B, and c wired to
connecter Jll. Ports A and B are wired as general purpose I/O ports.
Port c has 7 lines available as I/0, with one line (PC3) used as a
potential interrupt.
The 8255 has 3 general modes of operation. All ports can be pro-
grammed as input or output latches (Mode 0). Ports A and B can be pro-
grammed as unidirectional input or output ports with handshaking (Mode
1). Port A can be programmed as a bidirectional port with handshaking
(Mode2). Additionally, several combinations of the above modes are pos-
sible. Refer to the Intel 8255 application or design handbook for
details.
At the present time, no specific function has been assigned to this
device. The intent is for use with future upgrades or accessories hav-
ing instrument communication requirements. The major provision was that
Port A be available as a bidirectional port (Mode 2), thus line 3 of
Port c is used as interrupt PCI*. Port B is intended to be a unidirec-
tional latch (Mode 0). It is possible to use it as a communication port
(Mode 1) with the use of a little ingenuity.
Base address for the ports is PICS*.
Port A address is PICS* + o

Port B address is PICS* + 2
Port c address is PICS* + 4
control Port address is PICS* + 6
l~~l Bidirectional ~
The bidirectional bus could be confiqured in the following manner:

Action SBC signal(s) External signal (s)
---~----------------------------------------------------------
Bi-Directional data PA0-7 P1DO-D7 (J11, 9 - 16)
Write to SBC STROBE* (PC4) P1WR* (J11, 4)
Read from SBC IBF* (PC5) P1IBE* (J11, 5)
Write to external OBF (PC7) P10BF (J11, 6)
Read from external ACK* (PC6) P1RD* (J11, 3)
--------------------------------------------------------------
output Buffer Full (OBF) and Input Buffer Empty (IBE*) can be con-
fiqured to provide the interrupt signal PCI* to the SBC

l~~~ Unidirectional ~
The unidirectional bus communicates from the SBC to

from external to the SBC and can be confiqured as below:
external,

or
Action SBC siqnal External siqnal

-~-------------------------------------------------------------
Uni-directional data PB0-7 P2D0-7 (J11, 23 - 30)
Fault from external PC2 P2FAULT* (J11, 20)
External busy PC1 P2BUSY* (J11, 21)
External ready PCO P2READY* (J11, 22)
In this mode, the SBC must poll the port to determine the status.
In addition, the followinq siqnals are present on J11:
Siqnal Description
PAN IN Parallel ANaloq INput. (J11, 17)
Connected to the analog multiplexer for subsequent
processinq by the A/D converter.
PIFIN Parallel InterFace INterru~t (J11, 7)

Is latched to produce the ~nterrupt PIFI*
TMR2-0UT* Programmable timer output (J11, 32)
source is 031 with a time base of 12.8 micro-seconds.
+5V (J11, 1, 2)
GND (J11,.8, 31, 33, 34)
------------------------------------------------------------

~ Section ~
This section describes the operation of timer circuitry and the

depicted on sheet 6 of schematic # 03-919058.
devices
l~l Timer/Counters
By convention the term timer is used for a device, whose input
clock has a fixed frequency, and the term counter is used for one,
whose input frequency is variable over time.
Located on the SBC are 3 devices each containing 3 16 bit
timer/counters. They are 2 Intel 8253's and 1 Intel 8254. The 8254 is a
true superset of the 8253. Please refer to the Intel === Handbook for a
full description. Furthermore the UART 68681 holds one 16 bit timer, but
at this point in time, it is kept as a last resort, since the UART still
figures as a possible option. Please refer to Section 5 for further info
on this timer. By setting up these timer/counters, the instrument can
keep track of external and internal events.
Generally, the output of a timer/counter is connected to an inter-
rupt. The following guidelines are true for most cases:
After initializing 8253 and 8254, the timeout counts can be updated
y
:er.
the interrupt service procedure (ISP). To sat a new count, the ISP
~ads a value into the timer and also clocks the internal shift regis-
After the new count is set up, it clears the interrupt and
activates the mask.
The output of the the timer/counter is a function of the input:
f(out) f(in) * (1/n)
where n is the count, f(in) is the input frequency, and f(out) is the
output frequency.
Timer/counter enable inputs can be controlled and timeout outputs can
generate interrupts and be read according to the memory map. The input
to a timer/counter can generally be enabled/disabled, thereby
enabling/disabling that timer.
In general the timerjcounter is written a count "n" after a one time
initialization, and it will timeout after n*(1/f(in)) seconds, generat-
ing an interrupt, which will be held in a separate latch until software
services it and clears it

Timer/Counters Ccont.l
There are 8 timerjcounters in the system:
Device (mnemonic) Size CLK Source Output function freq.

----------------------------------------------------------------
RGCS*, 8254.0+1 32 bit lOMHz motor rate generator
RGCS*, 8254.2 16 bit 10 MHZ diag timer (emer. timer)
cccs, 8253/1.0 16 bit motor rate cam position counter
CCCS* I 8253/1.1 16 bit motor rate cam event counter
CCCS* I 8253/1.2 16 bit 625 kHz (E/2) AOC timer
GTCS* I 8253/2.0 16 bit 625 kHz {E/2) timer o {PSOS sys timer)
GTCS* I 8253/2.1 16 bit 78.125 kHz timer 1 {mot. ace. tim.)
GTCS* I 8253/2.2 16 bit 78.125 kHz timer 2 <yeneral timer)
SIOCS*,68681 16 bit 3.6864 MHZ still opt onal
----------------------------------------------------------------
The programming procedure for the 8253 or 8254 is very flexible.
Reading the Intel manual is strongly recommended. See Appendix for ini-
tialization example.
~~~~ Motor ~ Generator
The motor rate generator (U33) has an input frequency of 10 MHZ. It
consists of two 16 bit timers cascaded together. Counter 0 functions as
a prescaler to counter 1, so that if counter 0 is set to divide by 4 and.
counter 1 is set to divede by 5, the resulting frequency out is
f(in)/(4*5)f(in)/20. The minimum and maximum frequency out is there-
fore, together with the required:
f(out, max. pos.) f(in) * (1/1) 10 MHZ
f(out, max. req~) f(in) * (1/78) 128kHz
f(out, min. req.) f(in) * (1/2,500,000) 4 Hz
f(out, min~ pos.) f(in) * (l/(2A(32)-l)) 2.32 mHz
The output goes to the cam Event Counter input and Cam Position
Counter input and also to an interrupt latch RGOIS which is normally
disabled by pulling the interrupt clear control signal RCOIC* low
(read). The two counter input are gated by RGGEI so that write enables
and read disables. Please refer to the memory map.
For each pulse out, the step motor will advance 1 microstep, which
equals 1/64 of a full step, which again is 1.8 deg. The gear ratio
between the motor and the cam is 2:1, i.e. the cam moves 1/2 the angular
travel of the motor. The operation mode of the 8254 should be mode 3
(mode 2 will work too, but not 9enerate a square wave), which will
either load a new count value, 1f written prior to the counter reaching
zero, or reload the previous count. The interrupt status for this timer
output can, as previously mentioned for diagnostic purposes, be accessed
on RGOIS in ISCS*. The interrupt is cleared with RGOIC* read and then
write. Please see h/W interface example in appendix.
Model 9010 SBC 30

May 1988
~ Eyent counter
To position different events with relation to the cam angle meas-
ured from Top Dead Center (TOC) of the cam, the cam event counter is
used. The motor rate is the input, and the 16 bits are loaded with an
angle expressed in step motor micro steps * 2, after which it is counted
down to zero, and generates an interrupt. At the same time, it will take
any new an~le written to the counter, or reinsert the old count. That
means, that 1f the new angle is to be different, then it has to be writ-
ten to the counter prior to the counter reaching zero on the down count
of the previous loaded value.
Given the previous numbers on motor driver, motor and gear, each
count is (1.8 deg.)/(64*2) 0.014 deg., and a full revolution of 360
deg. is 25600 counts.
l~llll ~ Eyent Signal

Furthermore, the design assures that the register in the counter is
loaded with the count value prior to the occurrence of interrupt CEI.
THEREFORE no matter how fast the ISP executes, it will not be able to
overwrite the new count value prior to it being loaded in to the regis-
ter. The counter's interrupt status is CEIS, the interrupt clear is
-~IC*. CEI is an edge sensitive interrupt, which means that even if the
unter CE signal stays asserted, it will not interrupt more than once,
J matter how fast the ISP executes

l~ll~
revolution.
~ Position Counter
This counter is used for cam position information through a full

It's function is similar to the cam event counter, however
it counts down from an intial value i_c larger than 25600 and is there-
fore never meant to reach zero before the TDC causes a reload of the
initial value. The only instance where this counter will generate an
interrupt is when the motor stalls: the rate generator will be going
without the motor and cam turning, leading to no TDC. In this event, the
counter will reach zero and generate an interrupt to signal that the
synchronization between the cam and the motor rate is lost. If the ini-
tial value is i_c, then the current postion of the cam is related to the
current count c_c:
c_p (360/25600) * (25600- (c c- (i_c- 25600)))
c_p = 0.014 deg. * (i_c - c_c)
The interrupt status of the cam position counter counter is CPIS,
and the interrrupt clear is CPIC*. The interrupt CPI is level sensitive
and will continue to interrupt as long as the timer output is asserted.
l~l~ ~-signal Based Timers

The E-siqnal from the CPU is used to time a number of events and i .
present on the board in the form of E, E/2, E/4, E/8 and E/16. The E
signal is generated within the CPU and is one-tenth (1/10) of the clock
frequency.
l~l~l ~ timer
The A/0 converter is controlled by this timer, so that when the
timer times out, a conversion is started. When the conversion is fin-
ished the ADC will qenerate an interrupt to notify the CPU that new data
is available. Please refer to the A/0 converter section for further dis-
cussion. The ADC timer has a qated input, which is controlled by AOCGE,
write for enable, read for disable. In mode 2, this timer will automati-
cally reload the old value if no new value has been passed. If a 5 ms
interval between conversions is wanted, the timer should be loaded with
(5 ms)/(1/625 kHz) - 3125, and the timer will then timeout every 5 ms.
No interrupt is qenerated by this timer output, but the timer output
level can be read at ADCTO (asserted low) on CICS*.
Model 9010 SBC 32

May 1988
system timer
625 kHz is the frequency of the input clock for this timer, giving
a base time of 1.6 us. It is meant to run the PSOS system clock. It
gives an interrupt from the timeout, which can be read from TOIS off
CISCS*. It's cleared by the reading/writing of TOIC*, and the input can
be enabled (write) and disabled (read) on TOGE. The interrupt TOI is
level sensitive and will continue to interrupt as long as the timer out-
put stays asserted.
1~1~~ Motor acceleration timer

Input frequ~ncy is 78.125 kHz, g1v1ng a basetime of 12.8 us.
Enable/disable 1s controlled by writing/reading T1GE, interrupt status
is T1IS on CISCS* and interrupt clear is read/write of T1IC*. T10 is
level sensitive, see above.
1~1~~ General Timer

Input frequency is 78.125 kHz, giving a basetime of 12.8 us. The
output is reserved for use with a future device interfaced through the
~~rallel I/O Port (J11). This signal is present at TP41. Interrupt
~able/disable is controlled by writing/reading T2GE. Interrupt status
T2IS on CISCS* Interrupt clear is read/write at T2IC*. T2I is also

~vel sensitive

l~~ Timer/Counter Interrupts
The timer/counters outputs are used to generate interrupts via a
set of 'S-R' and 'D' latches. The status of most of these latches can
be read through buffer 046. The. interrupt latches are reset through

latches 043 (TCCS*) and 044 (ICCS*). The general operation is as fol-
lows:
While the timer gate is enabled (at a logic '1')
While the interrupt latch is enabled ('set' is at logic '1')
The device output goes active (low)
The coresponding latch 'reset' line is asserted
The latch output goes to a logic '0'
The interrupt is asserted and can be read at 046 or 030.
1~~1 IQQ ~ Center Interrupt

The exception to the Timer/Counter Interrupt process occurs
with the Top Dead Center Interrupt (TOCI*).
An 'Index' pulse occurs when the optical encoder on the pump is blocked.
Latch 0530 is reset, causing latch 020A to be clocked.
The 'Q' output is asserted, enabling 019-1D.
The next output of 033-01 (Motor Rate Generator) clocks latch 019.
output 019-1Q goes High and enables 019-20.
output 019-1Q- goes Low and clears latch 020A, and disables 019-10.
The next output of 033-01 clocks latch 019.
output 019-1Q goes Low and disables 019-20.
output 019-2Q goes Low and disables 019-30.
Output 019-3Q goes Low and disables 019-40.
output 019-4Q- goes Low and clears latch 019 and asserts 045C-'R'.
Output 045C-Q goes Low and asserts TDCI*.
1~~~ Interrupt Status Register

The buffer 046 (ISCS*) is generally a status register for reading
interrupts.
Bit 7 is the siqnal selected at the MVD diagnostic multiplexer.
Bit 6 is the status of the ADC Read/Convert siqnal (ADTC*).
Bit 5 is the status of the Cam Event Interrupt.
Bit 4 is the status of the Cam Position Interrupt.
Bit 3 is the status of the Rate Generator Interrupt.
Bit 2 is the status of the Diagnostic Timer Interrupt.
Bit 1 is the status of the Top Dead Center Interrupt.
Bit 0 is the status of the ADC Interrupt.

The status of interrupts TOI*, T1I*, and T2I* can be read at CISCS*,
data bits 5, 6, and 7, respectively.

~11 Interrupt ~ Registers
The latches U43 and U44 are bit addressable controls for the inter-
rupt latches and gates of some timers. Enabling a function is performed
by writing to the function address. Disabling is performed by reading
at the function address.
U43 is addressed at TCCS* and controls the following:
Address Function
TCCS* + 0 Timer o (TOI*) gate
TCCS* + 1 Timer 1 (T1I*) gate
TCCS* + 3 Cam Event Diagnostic Control (Test CEI*)
TCCS* + 4 Timer o (TOI*) gate
TCCS* + 7 Front Panel Interrupt Mask
U44 is addressed at ICCS* and controls the following:
Address Function
ICCS* + 0 ADC Timer gate
ICCS* + 1 Rate Generator Timer gate
ICCS* + 2 Cam Event Interrupt Clear/Mask
ICCS* + 3 Cam Position Interrupt Clear/Mask

ICCS* + 4 Rate Generator Interrupt Clear/Mask
ICCS* + 5 Diagnostic Timer Interrupt Clear/Mask
ICCS* + 6 Top Dead Center Interrupt Clear/Mask
ICCS* + 7 Top Dead Center Enable
1~1 Auxiliary Register

An additional control register (U63) is depicted on this sheet.
It's operation has little to do with the function ot the timerjcounter
circuitry. It is controlled in a similar fashion to the Interrupt Mask
Registers. The base address is AUXCS*. The outputs are addressed as
offsets to the base address. The output states are controlled by
address bit 4 (BA4). See the Memory Map in the Appendix tor details

11 Section 2

This section deals primarily with the analoq to diqital siqnal pro-
cessinq and pressure measurinq circuitry depicted on sheet 7 of the
schematic.
111 Feedback Signals

The system feedback siqnals are pump position synchronization and
column pressure. Pump position is provided via an optical interrupter
mounted on the pump castinq. The siqnal produced is a diqital pulse
indicatinq the piston to be at top dead center (TDC).
The column pressure siqnal is an analoq voltaqe produced by a
strain qauqe transducer. The transducer output is specified at 200 mv =
10,000 psiq.
1211 EYmQ Synchronization

The pump position counter is synchronized at the point where the
piston is tully compressed. The reason for this is to insure maximum
accuracy for proportioninq. synchronization is accomplished by provid.
inq a hardware interrupt to the CPU when TDC is reached.
A 0.050 diameter pin is pressed into the top of the cam shaft. An
optical interrupter pcb is mounted in such a fashion as to be blocked by
the pin when the pump piston is at TDC. The interrupter supply and out-
put siqnals are present at connector J21.
The emitter of the transistor output is at pin 1. Jumper XW5 is
provided in order to accommodate a serial output shaft encoder. At the
present time it connects the emitter to qround. The collector of the
transistor output is at pin 2. The anode of the LED input is at pin 3.
The cathode of the LED input is at pin 4.
While the pin is not blockinq the interrupter, the collector output
is low. At TDC, the pin blocks the liqht to the receiver and the output
switches to a loqic '1'. This chanqe qenerates a TDC*, which activates
LED CR16. It also starts the qeneration of the TDCI* interrupt to the
CPU as explained in Section 6.
111~ Column Pressure

The system pressure is monitored at a point near the column head.
The column pressure circuitry was desiqned to produce an analoq voltaqe
proportional to pressure. The scale factor is 10 volts 7526.4 psiq
(512 atm). ~

Pressure Transducer
A full-resistance bridqe is selected as our presure transducer.
The 10V excitation voltaqe is chosen because the A/D converter's refer-
ence output is 10V. This provides a stable and accurate reference for
the bridqe. The present bridqe output is 20 millivolts per volt of
excitation. This yields a full scale output of 200 mV for 10,000 psi at
10V excitation. The transducer sensitivity is 0.5,.
Internally, the bridqe is composed of six resistive elements. Four
of the resistances (R1, R2, R3, and R4) chanqe proportionally with a
chanqe in pressure. Voltaqe scalinq is accomplished by Rser. Calibra-
tion is performed with Real. Fiqure 7a shows the schematic for the
transducer. The numbers in parentheses are the connector pin numbers
for the transducer assembly.
-
ISE~O';;- I.
- -P22.
RSe.r
I Ry,R2.
...
WM I If )I RED CsJ;f l+J EXC IT AT ION
I II II BLU OR YEL '"~

GRN
I I l-4-J SIGNAL
I R4 RC4f 6
I I SHUNT CAL
I I BLK 3
(-J EXC IT AT ION
WHT
l-J SIGNAL
L - SHLD (r~ SHIEL 0
Fiqure 7a. Pressure Transducer Schematic

11111 AmPlifier
The output of the transducer is small, and is a differential meas-
urement besides. In order to interface the output to the CPU, an
amplifier is first required.
Signal conditioning is performed by amplifier U25. The first two
stages compose a cross coupled preamp. The resistors R16 and R17 are
bias current compensators. The resistors R54 and R60 provide saturation
bias to U25A and U25B when the transducer is unplugged or burst.
Relay K7 is provided to allow for CPU control of calibration. When
signal XCEN is asserted through latch U21, the internal calibration
resistor is connected to the excitation supply, producing an output
equal to 500 atm.
Unless the amplifier is in saturation, the gain calculation is a
simple voltage loop. The current through each of the feedback resistors
(R53 and R55) will be the same as the current through R54. The current
through R54 is equal to the bridge output voltage divided by the value
of R54. The gain of the preamp is therefore (R53+R54+R55)/R54. Substi-
tuting the schematic values for these resistors gives a gain of 18.
The third op-amp is a high common-mode rejection, unity gain, dif-
ferential amp. A matched network (R52) was chosen to guarantee accuracy.
and temperature tracking.
The final stage of the amplifier is a level-shifting amplifier.
The preamp signal can be shifted by R43 to compensate for any offset in
the pressure transducer, or preamplifier. The gain of this stage can be
adjusted from 2.5 to 4.5, through R44. This full range adjustment, will
yield a total amplifier gain from 45 to 81. The transducer output for
500 atm pressure is expected to be 147 mv. To provide a final output of
10 volts at 512 atm, the total circuit gain should be approximately 66.
11111 overpressure Konitor

op-amp U36A is a voltage comparator which saturates negative when
the final stage output is above 10.7 volts (544 atm), or the transducer
connector is unplugged. This produces the signals OVP* and OVPL*, turns
on LED CR13, and inhibits the pump motor circuitry. The overpressure
condition is cleared through RESET.

ADC Circuitry
In order to allow the CPU to monitor the various system voltages,
an Analog to Digital converter (ADC) and supporting circuitry are pro-
vided. This consists of the ADC (U10), an output latch pair (U9 and
U23), interrupt status latch (U113), sample/hold amp (U24), analog mul-
tiplexer (U35), and a multiplexer control latch (U34).
1111 Analog tQ Digital Converter

The ADC is a 12 bit AD574 converter which is trggered by the ADC
Timer. When the timer runs out, the signal ADTC* is asserted, causing
the ADC to begin its conversion. The "STS" signal becomes active, caus-
ing the sample/hold amplifier to enter its "HOLD" mode. A conversion
takes between 25 and 35 microseconds. Upon completion, the data is made
available on ADCUCS* and ADCLCS*. At the same time the sample/hold is
automaticaly set to SAMPLE mode by the "STS" signal becoming inactive.
1111 ~ Interrupt
Every ADC conversion generates a "status" pulse, indicating a vol-
age
~o.
~urn
conversion is. in progress. This pulse occurs at "STS", pin 28 of
When this signal returns low, it triggers latch U113. This in
causes the "Q" output to become active, and generates a level 4
interrupt. This indicates that the ADC data is valid.
The status for this interrupt is found at ADCIS on CISCS*. It can
be cleared or disabled by a "read" at ADCIC*, and enabled by a "write"
at the same address

11~2 Analog ~ Latches
The ADC output is 12 bits. These bits are configured as two byte-

wide units through the connection of the 12/8 input of the ADC (U10, pin
2). The inputs of the latch pair of U9 and U23 are connected to all 12
ADC outputs. The latch outputs are connected to the lower 8-bit data
bus of the CPU. U9 is addressed at ADCUCS*. The upper two bits of U23
are addressed at ADCUCS*. The lower four bits of U23 are addressed at
ADCLCS*.
The ADC data is formatted in the following fashion:
Address 7 6 5 4 3 2 1 0
+---+---+---+---+---+---+---+---+
ADCUCS* lmsbl 101 9 I 8 I 1 I 6 I 5 I 4 I
+---+---+---+---+---+---+---+---+
+---+---+---+---+---+---+---+---+
ADCLCS* I 3 I 2 I 1 llsbl undefined I
+---+---+---+---+---+---+---+---+
Note that fffO 9.998 V

0000 - o.ooo v
11~~
(1 LSB 2.44 millivolts)
Sample/HQlg Amplifier

The amplifier 024 is an analog latch which allows the input of the
ADC to remain stable during a conversion. When the signal at pin 8 is
at a logic "1", the signal at pin 3 is present at pin 5. When the level
at pin 8 drops to a logic "O", the voltage level at pin 5 is held con-
stant.
Model 9010 SBC 40

May 1988
~L~il Analog Multiplexer
The analog multiplexer (U35) is used to select 1 of 4 signals as
inputs to the sample/hold amplifier. It consists of four FET switches
with a digital interface. A logic high on an "A" input causes the "S"
and "D" lines to be internally connected.
The four drains are connected together and used as the MUX output.
The four sources are connected to different analog voltages. The first
source is the Pressure Amplifier output. The second is the RAM Battery.
It is actually one-half the battery voltage (approx 1.5 volts) as
divided through a high impedance to avoid a battery drain. The third
input is the ADC Reference Voltage output. This too is divided so as
not to load the signal. The last source is connected to the Parallel
Interface Analog Input. This is a straight connection to pin 17 of J11.
It is meant to be used as.a general feedback signal for future develop-
ment.
The four select lines, A1 through A4 are connected to the four lower
outputs of latch U34 (ADCMUXCS*). The channel selection table is shown
below:
AMUX1 AMUX2 AMUX3 AMUX4 Channel I Channel Selected
1
0
1
1
1
1
1
0
1.
1
1
1
1
0
1
1
1
1
1
0
1
2
3
4
None
Pressure
1/2 Battery voltage
5 Volts (Reference)
Parallel ANalog INput
-----------------------------------------------------------------
All other inputs will cause two or more signals to be simultaneously
connected, and are excluded in the software.
12 . .J,. Interrupt Latches

Interrupt latches 05 and 065 are shown on this sheet. us is the
latch for the Ready In* signal, described in Section s. USA is trig-
gered if the Ready In* signal is a falling edge. Inverter U4E produces
a trigger to 058 for a rising edge input signal. Both latch outputs are
'wire-orred' at 0540 and OS4E to produce the Ready In Synch Interrupt
Status signal (RISIS).
U6SA is used to latch an incoming interrupt ~rom the parallel
interface connector J11 (SectionS). The falling edge of the incoming
signal will latch the interrupt PIFI*

~.
'
Keyboard MAR
The keyboard contains 33 membrane switches organized in 4 rows and
9 columns physically and 6 rows and 6 columns electrically. The encoder

scans the whole keyboard by scanning a row each 10 milliseconds. Each
key has each own code depending on its row and column number. 28 keys
are used in the Vesuvius keypad. The rest are for future use and should
be disregarded if activated. Below is a map for the keyboard:
Switch no. Code Vesuvius Astra

-----------------------------------------------------------------------
1 1d start Start
2 14 Status Status
3 Oc Purge Attn Up
4 00 A Prime Attn Down
5
6
1c
10
-----
-----
-----
-----
7
8
08
01
-----
B Prime
-----
-----
9 18 Stop Stop
10 11 Reset Reset
11 09 Pump Lamp
12 02 c Prima Auto Zero

13 19 <- cursor <- cursor
14 12 Previous Line Previous Line
15 oa Next Line Next Line
16 03 Auto Menu Auto Menu
17 1a -> cursor -> cursor
18 13 Execute Execute
19
20
Ob
lb
Clear
----- -----
-----
21 23 Insert Line Insert Line
22 2b Delete Line Delete Line
23 3e Increase Increase
24 22 Shift Shift
25 37 Decrease Decrease
26 2a Auto Activate Auto Activate
27 20 %ABC -- Flow Lambda - Attn - A/Z
28 21 Config Menu Config Menu
29 28 Math Act Menu Meth Act Menu
30 29 Local Local
31 24 Relays Relays
32 25 Set conditions Set conditions
33 2c ----- Peak Sense

~~ Keyboard Encoder
The keyboard encoder is initialized upon reset to operate in 2-
key-lockout mode, with the prescaler set at 31. In the instrument, the
encoder should operate in the 2-key-lockout mode (as reset), with the
prescaler set at 2. Therefore it is necessary to initialize the pres-
caler by writing a control word:
0010 0010 (hex 22)
Refer to the Intel manual (5). For each keystroke, a level 1 interrupt
FI* is generated. Accessed at FKCBS*, the status of the kevboard
encoder can be read. At FPIM, the keyboard interrupt mask is accessed
in the following fashion: a write enables the interrupt, a read disables
the interrupt, and reset or power-on disables the interrupt

l
l~
Appendix
Jumper Tables
The following symbols are used to describe the jumper configurations:

o indicates jumper socket pin on PCB
I indicates default trace on PCB
J indicates a jumper must be installed between pins for proper operation.
XW1: Disconnect crystal Y1 from DUART
1 2
0 J 0
XW3: Select cam Position counter input as either

position sensor (J21) or Rate Generator output.
2 0 0 4
1 0
I
0 3
XW4: Connects interrupt sources to interrupt encoder.
2 8 14 20 26 32 38
0 0 0 0 0 0 0 0 0 0 0
I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I 0I
0
1 7 13 19
0 0
25
0
XWS: Configure pump position sensor as optical interrupter or shaft encoder.

0 0
31
0 0 0
37
2 0 0 4
I
1 0 0 3
XW6: Use LS541's for U83 and 084 when jumpered.
1 2
0 0
XW7: 1-24 determine ROM and RAM address decoding and size.
25-58 are removed to allow the 68000 to free run for diagnostics.
2 8 14 20 26
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Q 0 0 0 0
I I II I JJJJJJJJJJJJJJJJJJJ
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 57
Model 9010 SBC 44

May 1988
..ria:
2 0
I
Defaulted for 512K ROM's
1 0
XW9: CPU Clock Oscillator Source; in conjunction with XW11.

1 2 3
0 0 J 0
XW10: Selects appropriate DTACK response speeds for memory devices and GPIB.
2 8 14
0 0 0 0 0 0 0 0 0
0
I
0 0 0 0
I
0 0
I
0 0
1 7 13
XW11: Link CPU clock input to Timer oscillator source.
XW12: Select pressure transducer calibration source

3 0
J
2 0
1 0
XW13: connect Parallel Interface Interrupt to level 4.

1 2
0 0
XW14: connects GND or +5 volts to J9 as desired

2 0 0 4
I
1 0 0 3

1~ Connector Pinouts
The followinq tables detail the SBC connector pinouts.

lZ~ Pressure Output (~)
Pin # Siqnal
------------------------------------
1 Pressure + 100 mv = 512 atm
2 Pressure -
3 Shield
------------------------------------
1~~ External Events (~ - ~)
All six outputs are connected identically, as shown below:

Pin # Siqnal
1 Contact
2 Contact
3 Shield
Synch Input Connector

1~1 (~)
Pin # Siqnal Name Source

--------------------------------
1 Fault In- External
2 Fault In+ External
3 Ready out- External
4 Ready out+ External
5 Start In- External
6 Start In+ External
7 Return SBC
8 Return SBC
9 +5 volts SBC
l~~ Synch Output Connector (~)
Pin # Siqnal Name Source

----------~---------------------
1 Fault out- SBC
2 Fault out+ SBC
3 Ready In- SBC
4 Ready In+ SBC
5 Start Out- SBC
6 Start out+ SBC
7 SPR* External
8 Return External

9 +5 volts External
--------------------------------
_________
Pin
l
#
11~
Signal
+SV
Parallel I l l Connector (!lli)
, ____________________________________________________
Name Source Pin #
SBC
Signal Name
2 +SV
Source
SBC
3 PlRD* Pl 4 PlWR* Pl
5 PliBE* SBC 6 PlOBE* SBC
7 PIFI* Pl 8 GND SBC
9 PlDO 10 P1D1
11 P1D2 12 P1D3
13 P1D4 14 P1D5
15 P1D6 16 P1D7
17 PAN IN SBC 18 reserved
19 reserved 20 P2FAULT P2
21 P2BUSY P2 22 P2READY* P2
23 P2DO SBC 24 P2D1 SB
25 P2D2 SBC 26 P2D3 SBC
31 GND SBC 32 TIMOUT SBC
33 GND SBC 34 GND SBC
-------------------------------------------------------------
112 Serial l/Q Ports
l12l.
Pin #
~ A (!illA)
Functions as Terminal port for self-diagnostics.
Siqnal Name Source Pin t Signal Name source
1 Shield SBC 14 DTR1 External
2
3 -----------
TXD1
------ 15
-----------
External 16
RLSD1
------ SBC
4
5 ----------- SBC
RXD1
------ -----------
17
-----------
18
------
------
6 ------
----------- External -----------
19 ------
------
7
8
RTD1
----------- ------ -----------
20
-----------
21 ------
9
10
CTS1
----------- SBC
SBC
------ -----------
22
-----------
23
------
------
11 DSRl -----------
24 ------
12
13 ----------- SBC
Gnd
------ ----------- ------
25
--------------------------------------------------------------
..
Functions as Printer port.

Pin # Signal Name Source Pin # Signal Name Source
--~-----------------------------------------------------------
1 Shield SBC 14 DTR2 External
2 ----------- ------ 15 RLSD2 SBC
3
4
TXD2
-----------
External
------ 16
17 -----------
-----------
------
------
5 RXD2 SBC
------
18 ----------- ------
------
6 ----------- 19 ----------- ------
7
8
RTD2
-----------
External
------
20
21 -----------
----------- ------
9 CTS2 SBC
------ 22 ----------- ------
------
10
11 -----------
DSR2 SBC
23
24 -----------
----------- ------
12
13 -----------
Gnd
------
SBC
25 ----------- ------
-------------------------------------~------------------------

To be primarily used as a Console connection for diagnostics.
Pin # Signal Name Source Pin # Signal Name Source
--------------------------------------------------------------
1 Shield SBC 14 DTR3 SBC
2
3 ----------- SBC
TXD3
------ 16 ----------- ------
15 RLS03 External
4
5 RXD3
------ 1718 -----------
----------- External -----------
------
------
6
7 ----------- SBC
RTD3
------ 20 -----------
19
-----------
------
------
8
9
------
----------- External 22 ----------- ------
21
-----------
------
10
11
CTS3
-----------
DSR3
------
External
23
24 -----------
-----------
------
------
12
13 ----------- SBC
Gnd
------ 25
----------- ------
--------------------------------------------------------------
Model 9010 SBC 48

May 1988
-"-~.1
Pin #
1 GND
~ - Extension Connitor (!lli)
Signal Name
SBC
source
2
Pin # Signal Name
--------------------------------------------------------------
Source
X1I* X
3 X2I* X 4 XPR X
5 +5 v SBC 6 +5 v SBC
7 +5 v SBC 8 +5 v SBC
9 XDTACK* X 10 XRESET* SBC
11 XUDS* SBC 12 XLDS* SBC
13 XAS* SBC 14 XR/W* SBC
15 +12 v SBC 16 XDTEN* X
19 GND SBC 20 -12 v SBC
21 GND SBC 22 XAl SBC
23 XA2 SBC 24 XAJ SBC
25 XA4 SBC 26 XAS SBC
27 XA6 SBC 28 XA7 SBC
31 XAlO SBC 32 XAll SBC
37 XA16 SBC 38 XSEGO* SBC
39 XSEGl* SBC 40 XSEG2* SBC
l XSEG3* SBC 42 GND SBC
3
5
47
49
51
53
55
GND
XDO
XD2
XD4
XD6
xo8
XDlO
SBC 44
46
48
so
52
54
56
GND
XDl
XD3
XD5
XD7
XD9
-XDll
SBC
57 XD12 58 XD13
59 XD14 60 XD15
--------------------------------------------------------------

1.2.~
Pin #
~ - lED Connector
Signal Name Source
(~)
Pin # Signal Name Source

--------------------------------------------------------------
1 +5V SBC 2 +5V SBC
3 FDO 4 FD1
5 FD2 6 FD3
7 FD4 8 FD5
9 FD6 10 FD7
11. FPR SBC 12 FE SBC
13 FWS* SBC 14 FRS* SBC
15 FI* FPB 16 FA1 SBC
17 -15V SBC 18 reserved
19 reset SBC 20 FKBCS* SBC
21 FLED1CS* SBC 22 FLED2CS* SBC
23 FR/W* SBC 24 reserved (diagnostic)
--------------------------------------------------------------
J_.,i.j,. ~ - ~ Connector (!lll)
Pin t Signal Name source Pin f Signal Name Source
--------------------------------------------------------------

1 +5V SBC 2 GND SBC
3 MHIVC* SBC 4 MHOLO SBC
5 MVA* SBC 6 MVB* SBC
7 MVC* SBC 8 MVD* SBC
11 MMUXCA* SBC 12 MMUXCB* SBC
13 MVDEN* SBC 14 control spare SBC
15 MMUX1 MVD 16 MMUX2 MVD
17 MMUX3 MVD 18 MMUX4 MVD
19 reserved 20 reserved
21 MRATE SBC 22 MOVTMP* MVD
23 MPR SBC 24 MPF MVD
25 GND MVD 26 +5V MVD
--------------------------------------------------------------
Model 9010 SBC 50

May 1988
.J..,l .l.Q.
Pin #
1
Power ~.nnector
Supply Voltage
+5 Volts
(!lll,)
Circuitry
Digital
2 Ground Digital
3 +15 Volts Analog
4 -15 Volts Analog
5 Ground Analog
.llll Optical Sensor (~)
Pin # Signal Name

1 Detector Return
2 Detector output
3 Emitter supply
4 Emitter Return
~----------------------
~-1~ Pressure Transducer (~)
Pin t
4
1
2
3
5
Signal Name
Shield
Bri~ge out-
Excitation-
Bridge out+
Excitation+
6 Calibration

11
table.
Memorv HG
All mnemonics related to the schematic are listed in the following

The following conventions are used throughout this table:
addr- --- Starting address
addr.t --bit address
Don't care
n forbidden
b bit
B Byte
w Word
R Read
w -- Write
Address Signal Range Description:

(hex) (device) read(R) & write(W) permission
J,.J,.,l. Block ~
o----- RAMCS* (095B) 512KB RAM segment, R & W

000000 BBURAMCS* 16KB RAM sockets, 099, 0106, R & w, Backed-u.
010000 RAM1CS* 16KB RAM sockets, 098, 0105, R & W
J..,l.1,. Block .1
1----- XCS*(081-084) 512KB eXtension bus segment, R & w.
10---- XSEGO* 128KB X Segment o, GPIB, R & w
12---- XSEG1* 1281CB X Segment 1, GPIB, R & W
XSEG2* 128KB X Segment 2, development RAM, R. w
''
14----
16---- XSEG3* 128KB X Segment 3, development RAM, R w

-------c .-. -----------------------r-
nl.ldress Slqnal Range
__________ _.. (R)
Des~ription:
_ . ,______________________
& (W) permission
_
111. Block ~
2----- FCS*(U129,U130) 512KB Front panel segment

200--- FKBCS*(8279) 2B Front panel KeyBoard encoder, R & w
200--1 data 1B data from(R)jto(W) encoder
200--3 stat.;ctrl. 1B status(R)jcontrol(W) of encoder
201--- FLCDCS* 2B Front panel LCD(display), 2 line by 40 char.
201--1 stat.;ctrl. 1B status(R)jcontrol(W) of display
201--3 data 1B data from(R)jto(W) display
202--- FLED1CS* 1B Front panel control, w only

202---.o data 1b "stopped" LED, off(1)jon(O)
202---.1 data 1b "fault" LED, off(1)/on(O)
202---.2 data 1b "remote" LED, off(1)/on(O)
202---.3 data 1b "activate" LED, off(1)/on(O)
202---.4 data 1b n.c.
)2---.
5 data 1b n.c.
}2---.6 data 1b beeper control, write 1 then o to beep.
J2---.7 data 1b EL liqht in LCD, off(1)/on(O)
203--- FLED2CS* 1B Front panel LED control, W only

203---.o data 1b "shift" LED, off(1)jon(O)
203---.1 data 1b n.c. ("peak sense" LED in Astra)
203---.2 data 1b "purqe LED, off(1)/on(O)
203---.3 data 1b prima LED, off(1)/on(O)
203---.4 data 1b "pump LED, off(1)jon(O)
203---.5 data 1b "runninq LED, off(1)jon(O)
203---.6 data 1b "ready" LED, off(1)jon(O)
203---.7 data 1b "not ready" LED, off(1)/on(O)

Address Signal Range Description: (R) & (W) permission
----------------------------------------------------------------------

J,.J..,!. Block 1
3----- BCS* 512KB Buffered data bus
llil Timers
300--- GTCS*{U31) 48 General Timers, R & W
300--1 data 18 timer 0 {counter 0) access
300--3 data 18 timer 1 (counter 1) access
300--5 data 18 timer 2 {counter 2) access
300--7 control 18 common control register access
301--- CCCS(U32) 48 Cam Counters and ADC timer, R & w
301--1 data 18 cam position {counter O) acces
301--3 data 18 cam ev~nt {counter 1) access
301--5 data 18 ADC timer {counter 2) access
301--7 control 18 common control register acces
302--- RGCS* {033) 48 Rate Generator and diagnostic timer, R & w
302--1 data 18 first r. g. {counter O) access
302--3 data 18 second r. g. (~ounter 1) access
302--5 data 18 diagnostic timer (counter 2) access
302--7 control 18 common control register access
lli1 Parallel I/Q

303--- PICS* {07) 48 Parallel Interface, general purpose, R & w
303--1 data 18 port A access
303--3 data 18 port B access
303--5 data 18 port c access
"303--7 control 18 control register access
Model 9010 SBC 54

May 1988
n..lC1ress Signal
~-~~~
Range
Status Registers
Descri~tion: (R) & (W) permission
-------------------------------~-------------------------------------
310--- STSCS*(U73) 4KB STatus, ADC and DIP switch data

3100-- CSCS*(U120) 1B Configuration Status, Read bit o only
310001 XPR* 1B eXtension board PResent, asserted=O
310003 FPR* 1B Front panel PResent, asserted=O
310005 SPR* 1B Sync. cable PResent, asserted=O
310007 MPR* 1B Motor valve driver PResent, asserted=O
310011 OK-15 1B -15 V OK, assertedO
310013 OK+15 1B +15 V OK, assertedO
310015 OVPL* 1B Over Pressure (Latched), asserted=O
310017 RIS 1B Ready In Synch. signal, asserted1
3101--- CISCS*(U30) 1B Common Interrupt Status latch, R only

310101.0 BIS 1b Break Interrupt Status, asserted1
310101.1 RIIS 1b Ready In Interrupt Status, asserted1
"'10101.2 SIS IS 1b Start In Sync. Interrupt Status, asserted=1
.0101. 3 FISIS 1b Fault In Sync. Interrupt Status, asserted=1

10101.4 PFIS 1b Power Failure Interrupt Status, asserted=l
10101.5 TOIS* 1b Timer 0 Interrupt Status, assertedO
310101.6 T1IS* 1b Timer 1 Interrupt Status, assertedO
310101.7 T2IS* 1b Timer 2 Interrupt Status, assertedO
3102-- ISCS*(U46) 1B Interrupt Status latch, R only

310201.0 ADCIS 1b ADC Interrupt Status, asserted1
310201.1 TDCIS* 1b Top Dead Center Interrupt Status, asserted=O
310201.2 OTIS* 1b Diagnostic Timer Interrupt Status, asserted=
310201.3 RGDIS* 1b Rate Generator Interrupt Status, asserted=O
310201.4 CPIS* 1b cam Position Interrupt Status, asserted=O
310201.5 CEIS* lb Cam Event Interrupt Status, assertedO
310201.6 ADCTO lb ADC Timer OUtput, timeoutO
310201.7 DTG 1b Diagnostic Timer Gate (XX7), 1enabled

Address Signal
.J.-1!! ~.DAn
Range Description: (R) & (W) permission
----------------------------------------------------------------------
3103-- ADCCS*(U129) ADC data
310301 ADCUCS*(U23) 1B ADC Most significant byte, R only
310301.0 data 1b ADC data bit 4
310301.3 data lb ADC data bit 7
310303 ADCLCS* (U9) lB ADC Least significant byte, R only
310303.0 lb n.c.
310303.1 1b n.c.
310303.2 lb n.c.
310303.3 1b n.c.
310303.7
.J.-1~-~-
data
JU.E switch nAtA
1b ADC data bit 3
See Section 4, "DIP Switches" for descriptions of switch settings

3104-- DI~1CS* (U126_) 1B DIP switch SW4 (Read bit 0 valid only)

310401 data 18 DIP switch 48
310413 data 18 DIPswitch 42
3105-- DIP2CS*(U133) 18 DIP switch SWS (Read bit 0 valid only)
310501 data 18 . DIP switch 58
310507 data lB DIP switch 55
310509 data lB DIP switch 54
310511 data 1B DIP switch 53


n..:J.dress Signal
~-~!2 ~
Range
----~-------------------~-=----~ ..
Diagnostic Register
--..._~._._, __________________________
Desc,-iption: (R) & (W)
.__________ _
p~rmission
3106-- MMUXCS*(U116) 1B MVD diagnostic MUX input, (Read bit 0 only)

310601 MMUX1 1B MVD diagnostic MUX channel 1
310609 MOVTMP* 18 MVD over TeMPerature sense, asserted=O
310611 PIFIS 1B Parallel I/F connector Int. Status asserted=
310613 unused 1B
310615 unused 1B
11!2 Auxillary Output Register
3107-- AUXCS* (063) lB Auxillary diagnostic output, R only.
310700 TDC NOT SET lB Remove diagnostic TDC SET (default)
310702 MVD-P DlS lB Disable power stage on MVD (default)
310704 MMUXcA* lB MVD diagnostic MUX, select A, low
.., ,_0706 MMUXCB* 18 MVD diagnostic MUX, select 8, low
~0708 MDIR* 18 unused (default)

.~..070a MRUN* lB Motor Run (default)
1070c PIFIC* 18 Parallel InterFace Interrupt Clear (default)
31070e unused 18 (default)
310710 TDC SET lB Set diagnostic TDC. Removed by TDC_NOT_SET
310712 MVD-P EN 18 Enable power to the MVD
310714 MMUXCA lB. MVD diagnostic MUX, select A, high
310716 MMUXCB 18 MVD diagnostic MUX, select 8, high
310718 MDIR 18 unused
3107la MRUN 18 Motor Hold (1/2 power)
3107lc PIFIC* 18 Enable the parallel interface interrupt
3107le unused 18
311--- CTRLCS*(U72)
1-~i~ Interrupt control Register

3110-- CICCS*(U67) 88 Common Interrupt Control
311000 ADCIC* 18 ADC Int. Clear-R&W, enableW, disable=R
311001 RIIC* 18 Ready In Interrupt, enableW, disable=R
311002 SISIC* 18 Start In Synch. signal Int. Clear-R&W
311003 FISIC* 18 Fault In Synch. signal Int. Clear=R&W
311004 DIAGl LED* 18 Diagnostic LED (CR6) 1, onW, offR
311005 DIAG2-LED* 18 Diagnostic LED (CR7) 2, onW, offR
,,_1006 DIAG3-LED* 18 Diagnostic LED (CR8) 3, onW, offR
1007 DIAG4:LED* 18 Diagnostic LED (CR9) 4, onW, off=R
Model 9010 S8C 57 May 1988

Address Signal
11~~
Range Description: (R) & (W) permission
----------------------------------------------------------------------
Interrupt Control Register

3111-- ICCS*(U44) 1B Other source Interrupt Clear, R & w
311100 AOCGE 1B ADC timer Gate, Enable=W, disable=R
311101 RGGE 1B Rate Generator Gate, Enable=W, disable=R
311102 CEIC* 1B Cam Event Interrupt Clear, EnableW, Clear=R
311103 CPIC* 1B Cam Position Interrupt Clear, -"- -"-
311104 RGDIC* 1B Rate Gen. Diag. Intr. Clear, -"- -"-
311105 OTIC* 1B Diagnostic Timer Int. Clear, -"- -"-
311106 TDCIC* 1B Top Dead Center Int. Clear, -"- -"-
311107 ARMTDC 1B Arm to receive TDC, Arm=W, Disable=R
1-~~.lQ. Timer Control Registers
3112-- TCCS*(U43) 8B Timer/Counter control, R & W
311200 TOGE 1B Timer 0 Gate Enable=W, disable=R
311201 T1GE 1B Timer 1 Gate Enable=W, disable=R
311202 T2GE 1B Timer 2 Gate Enable=W, disable=R
311203 CEISET* 1B Cam Event Inter. preSet R&W
311204 TOIC* 1B Timer o Interrupt Clear-R&W, enable=W, dis.=
311205 T1IC* 1B Timer 1 Interrupt Clear-R&W, -"-
311206 T2IC* 1B Timer 2 Interrupt Clear-R&W, -".
311207 FPIM lB Front Panel Interrupt Mask enable=W, di
~~~~ Interrupt ~ Register
3113-- ITCS*(U66) 8B
3113-0 IEN lB All interrupt levels enableW, disable=R
3113-1 ILl 1B Interrupt level 1, assertW, negate=R
3113-2 IL2 1B Interrupt level 2, assert=W, negateR
3113-3 IL3 lB Interrupt level 3, assertW, negate=R
3113-4 IL4 lB Interrupt level 4, assertW, neqate=R
3113-5 IL5 lB Interrupt level 5, assertW, negateR
3113-6 IL6 lB Interrupt level 6, assertW, negate=R
3113-7 IL7 lB Interrupt level 7, assertW, neqate=R
l~~~ External Eyent control Register
3114-- EECS*(U21) 8B
311400 EElEN lB External Event 1, relay closeW, relay open=
311401 EE2EN lB External Event 2, relay closeW, relay open=
311405 EE6EN lB External Event 6, relay close=W., relay open=
311406 IREN 1B Instrument Ready, ReadyW Not Ready=R
311407 XCEN lB Pressure Xducer Calibrate, cal.=W, normal=R
Model 9010 SBC 58

May 1988
.n.ddress Siqnal Range Description: (R) & (W) permission
---------------------------------------------------------------------
J..J..J..u. Motor Valve Control Register
3115-- MVCCS*(U88) 1B Motor Valve Control register, W only
311500.0 data 1b Valve control bit o, encoded
311500.1 data 1b Valve control bit 1, encoded
311500.2 data 1b Valve control bit 2, encoded
311500.3 MVD spare 1b MVD control spare (unused)
311500.4 MVD spare 1b MVD control spare (unused)
311500.5 MVD spare* 1b MVD control spare (unused)
311500.6 MVO spare* 1b MVD control spare (unused)
311500.7 MVO spare* 1b MVD control spare (unused)
11~1! Multiplexer Control Register

3116-- ADCMUXCS*(U34)1B MUX control line output, W only
311601.0 AMUX1 1b AOC MUX channel 1, conn.O, disconn.1
AMUX1
...~11601.1 1b ADC MUX channel 2, conn.O, disconn.1

'11601.2 AMUX1 1b AOC MUX channel 3, conn.O, disconn.1
.. 11601.3 AMUX1 1b ADC MUX channel 4, conn.O, disconn.1
311601.4 DMUX1 1b Diagnostic MUX control bit 1
311601.7 DMUX4 1b Diagnos~ic MUX control bit 4
3117-- BRCS*(U134A) Back-up Ram Enable, R or W
312--~ SIOCS*(U29) 168 DUART control and data register, R & w

313--- unused

Address Signal Range Description: (R) & (W) permission
----------------------------------------------------------------------
ll-2 Block .!
4----- ROMCS* (095A) 512KB ROM, Read only, bottom row is high byte
40---- ROMOCS* l28KB ROM sockets 0100, 0107
42---- ROMlCS* 128KB ROM sockets 0101, 0108
44---- ROM2CS* 128KB ROM sockets 0102, 0109
.J. .J.... Block 2

5----- SOSEN*(Ol8A) 1B Start out sync. signal Enable, R or w
112 Block .
6----- FOSEN*(Ol8B) lB Fault out Sync. signal Enable, R or W
11..
7-----
Block 2
RMCS*(U60B) 512KB Reset ROM mapped on top of RAM, R or W

Valve Statemachine Flowchart
The following flow chart diagrams the operation of the valve
statemachine controller described in Section 1.4.1
.... ~~.~~
......
I-WI
,___
-- .
--
, ._
___
--
,
--
a..
--
-- --
-- .........
1-IW
Model 9010 SBC 61 September 1988

l~ ~ Points
The followinq table lists all test points used on the sse. The
section number refers to the area of the PCB on which the test point

appears.
PCB
# Section SIGNAL NAME FUNCTION
==============-==========-==================================================
TP 1 7 GND Diqital Ground
TP 2 5 START IN Start In Synch Interrupt Status
TP 3 5 FAULT IN Fault In Synch Interrupt Status
TP 4 5 READY Orred output of SPR* or READY IN
TP 5 5 GND Diqital Ground
TP 10 4 +15V Analoq 15 volts positive
TP 11 4 -15V Analoq 15 volts neqative
TP 15 4 A GND Analog Ground
TP 20 6 INT PEND Interrupt Pending
TP 22 3 A22 CPU Address Bit 22
TP 23 7 E/16 CPU 'E' Siqnal/16 (78.125 Khz)
TP 24 6 GND Digital Ground
TP 25 5 +5V Digital Supply
TP 28 3 BCS* Buffered Data Bus Chip Select
TP 29 1 DTACIC* Data Transfer ACKnowledge
TP 30 1 AS* CPU Address Strobe
TP 31 1 GND Digital Ground
TP 32 1 BRV Battery-Backed RAM Voltage
TP 33 1 SDTACIC Secondary DTACK
TP 34 4 TEST Test LED Input
TP 36 4 VALVE LATCH Valve Command Latch
TP 37 4 MVD-PEH MVD Pump Enable
TP 38 4 VSTAT MACH CLIC Valve command Latch
TP 39 6 TO OUT PSOS Timer (TO) Output
TP 40 4 MOTOR RATE Micro-step Rata Generator output
TP 41 6 PIO TO Parallel I/O Timer (T2) output
TP 42 7 AHPRESS FUll scala Analog Pressure Voltage
TP 43 7 AHPRESS RAW Preamplifier Pressure Measurement
TP 45 4 1.95V Comparator Voltage (-15v min)
TP 46 4 2.05V Comparator Voltage (-15v max, +15v min)
TP 47 4 2.00V Comparator Voltage (-15v ref)
TP 48 4 2.27V Comparator Voltage (+15v ref)
TP 49 4 2.50V Comparator Voltage (+15v max)
TP 50 1 +5V Digital Supply
=a=--=-=-------aa-.---------------====-==---------=--===-=======
Model 9010 SBC 62

May 1988
..:.
(1)
REFERENCES
Motorola MC68000 16-Bit Microcomputer User's Manual. Motorola,

Inc. Publication No. MC68000UM [AD3], 1982.
(2) Signetics SCN68681 Dual Asynchronous Receiver/Transmitter
(DUART). May 1983. Signetics Corp. Publication 98-8686810A.
(3) Electronic Industries Association EIA Standared RS232-C Interface
Between Data Terminal Equipment and Data Communication Equipment
Employing Serial Binary Data Exchange. 1969.
(4) Intel manual "Peripheral Components Handbook".
(5) Varian Schematic drawing, 03-915058-00, SBC board Varian Assembly
drawing, 03-915055-00, SBC board
Model 9010 sac 63 May 1988

-
PARTS LIST
rJJ?PDiller-one
II. C. PBIUtr SUPPLitS

owe~
NO~ . pL. 52 9 52.- I 0 I SHEET I
OF 4-
REV
c_
TITLE: HCAA-60W-A
P.W. E:>. A55EM~LY USED ON:
APPROVALS DATE DATE
DRAW"a ~ ,,~ ..;-~ j-//-A..J ENG. APPD. ~~ ~ ('~~LN'l ~ 77Br

CHE.PK'Eo: J,J:::..t:.. APPROVED;
4-2.6 -B;J
.
NOTE:
l...J~OR
,..,
.o
C."")
OC.HE.MATlC, ~Ef.. DRAWHJG tJO. 5a')02.. n rfil
~ . 1~\
~\~ ~1 fJl(\f' f}. l ,I .
- ~- .I ..~ ~,! 1' .. \.. 4'. I : \
\ . ). I
(J,
-
(.(';
'JULO 319GG
a..
0)
REVISIONS
LET DE SCRIPTION DATE APPD ECO LET DESCRIPTION DATE APPD
ECO
r3v, ~1 A RELEASE TO PRODUCTION >ll6l it""'
\\7Z3 e IUC. CHJ\\J6'0 PER ECO ~-l'J85 j iflfh1 11,
I
I?{)SI [_ INC. E.L.O. 7-185 ~(/
-
- ('f'''n ,~n.n,,,,r . rrtonnrrr

ITEM
LIST
PARTS
QTY POWER ONE
Pomer-one o\PL
NO. 5 2 9 fj 2.
D.C. PBUJer SUPPLieS
- 101
VENDOR NO.
SHEET 2. OF 4
REV.
SEE
SHT I
NOTE REQD DESCRIPTION. REF. DES.

NO. STD PART NO..
I I 505- 52'5'81 PRINTED WIR\N6 BOARD BD.*5Z,80 AI

.
2.
3
-1- 3 154- 20020 POTENTIOMETER , ZK , HORIZ. R7, 31, 37
5 I I '54- 20'"J37 poTNTIOMETER , 500..n..., HORil. R3
6
7 2 158- 10082 RESI~TOR" .56..n... ~ ZW" 5%" M.O. R 23, 27
5 I 150- 2037E. ~
3.6K, 1/4W, 5%, CF RB
~ I 150- 2.02C)3 l..n.. ~ ~ J R2
10 e.. 150-20315 15-ll.. .. . R5,25
.. ' .
. r I ' : ... . \: 'I,.; . .
.. .
I
I ' '
. i
II 3 150-Z0307 6.6.n... 'q Rll,l3,14
12 2 150- 20 '32.1 47.n... ~Ill: t. 'i ' \
1' I.
...;, I
I
~i RIO, 22
13 !) 150-Z-0343 l20...n.. Rl, 12 ,I~, 20 1 25
14 2 150-f0347 330...n.. R16,.3+
15 3 150-20356 750...n- R24, 40, 4Z I
16 10 150-20361 R6, ~,17,1B, 2.6,2.~,
1.2 K 35. 30,41~43
17 3 150-2036 3 1.5-K R4,t5,'3'3 I
I 15 3 150-20368 RE515TOR , 2.4 K , 1/,.W , 5% , CF R XJ, ,l,36
L ________
--~---- ---- -- . - - --
1<1\ BISttOP GOAPIIICSIACCUPRESS

rr nrnnn,.,, un ., .,.

PARTS LIST Pomer-one ILC. I'DUJ~r SUI'I'LI~S

DWb.p
NO. L. 5 2 ~8 2- I0 I SHEET 3

OF 4
REV.~
SE l
SHT I
i
1
...
ITEM QTY POWER ONE
NO. NOTE REQO DESCRIPTION. VENDOR NO. REf. DES.
STO PART NO.
jC} I 150- Z036~ RES! STOR , 2.7K , 1/-"'tW., 5/. , CF RZI
20 I 150- 2036~ RE 51 ~TOR , IOK I /-+W, 57.

1
1 CF R '3'>
2.1 3 1.30- I Ol87 I C VOLTA6E RE6ULATOR ..u.A 723 Ul, l, 3
Z2
Z.3 I 172-20771 TRANSISTOR NPN . TIPZ~A Q2.

'
Z-1 REF I? I- 2.1545 NPN ZN.3055 Ql
25 REF II I -10261
," ~
, NPN..f .. :; : : ... ZN656-,
.. Q-416
'
j
' ! ~ i .! : .. . : I l I
26 l I?Z.-1024e> TRAN515TOR , PNP
.,:. I :. . .. 2~?.,07 Q 3, 5
.. -.' . .
. . . .. I
27 ,lUI.() 3 19[)
28 I 160-10013 5C R BA 50V 50508L53 .SCRI '
I
' ' !
2.? "1- Ill - 205,0 DIODE 1.5A t IOOV IN 53~2. C.R6,7, 5, <}
' CR 3, ~.1?,11,1~,14
30 f., II~,- 10251 DIODE t lA , 200V IN4003
31 2. Ill - I OZ 56 l f,A , 50\/ MR750 CRI, 2
Ill.- I 0006 ~ ZENER , 5.6V IN75ZA C.R4

3l I
:';3 I I I Z..- I 000~ 01 ODE , ZENER , l?V lN 965 I!> CRll.
~-+
J5 I 101- .20~50 CAPACITOR. , EL[CT. 22,000.uf I 16V Cl
36 l 101- 20?3-'l- CAPACITOR , ELEC.T. 2200uf I 35V C5,?

-
PARTS LIST Pomer-one
ILC.I'DUJer SUI'I'Lie
rwr.ta.
NO.
PL . 52?02-101 SHEET 4
.,...
OF --1
RE
st:
SliT
ITEM QTY POWER ONE
NOTE REQD DESCRIPTION. VENDOR NO. REF. DES.
NO. STD PART NO.
J7 101- 10107 C.APAC.ITOR, ELECT. zeo..u.+ 1 t6V C4

' ~5V
38
3~
l
I
101-10110
101- I 0114
I ~
,
~ IOClu.f/
IO...u4= I Z5V
<:6, IZ.
C.6
z. sov
-10
~I I
101-10111
104- 100).3 1 , ELEC.T.

MYLAR .OOiuf I
Lu.:f 1.
IOOV
C3, 10
C2
42 2 10-i- 100~2 CAPACITOR , MYLAR .0033.uf I IOOY C7, II
43
I I '
44 .3 321- 1067 9 SOCKET, I.C . ., 1-4 PIN I ~~ ':,.: f I FOR: Uf, 2, 3
. ;
45 I I' I , ,:
-"1 6 . 2.. ~~~- 21170 WIRE, lfoAW6., BLK ,10" A,A

41 c;)J(.-211~?
,
I WIRE, f(:,AW6.,WHT, 10 AT
--18 z. ~14- 21065 WIRE,20AW6.,BLK, 5 'liL ~,~
/1-4-21021 WIRE 1 20AW6.,'NHT1 ~ 1:' ~T

-4fJ
50
'
'
51
52
53 I
54
"""f11~1t1 ,,. f~ntlttf"~'Arrllru.r r~
INTIINATIONAL SIIIES OESCIII'TION
Th! !NTERHATIOIIAl SERIES is a high reliability line of ooen-fratoe po""r
succi ies aes1gned to operate fro. tile wide range of ~C power sources
found 100rld'oo1de.
This feature greatly Sill!llifies your inventory anel service considerations
by allowing tile. use of one suncsant ~r supply reqarelless of aestinatiOft.
Additionally, these models are desiqned to llll!et noany domestic and Eur-opea11
requlatory agl!f'CY requi.--nts.
If you plan to distr1but1t your products I<Orld'ooide, obtaining necessary
I~TERNATIONAL SERIES
DC POWER SUPPLIES
agency approvals can be greatly siplified by specifying POWER-ONE INC.

INTERNATIONAL SERIES. DRAWING NO. 51281 REV. H
SPECIFICATIONS AND APPLICATION DATA
VOLTAGE/CURRENT
RATING CHART
.,...,.,
1::
..
.t tI =-~. -~. ~- -~~ ~..
~
t ~. ~51
":
.ak, TURES
110 transfon~~~~r
1
constl'\lction -2 hour burn-in period
tj'~~~:F]~"'~~m!I:;::=;::~;::::;:::::;::=::;::=::;:=;:=;::=:;:=:;:=:;::=;::::r-!.
-Reoote ~;ense most outputs
5\NGl \lUIP~ -I.C. re<JU It ionto
05S burned-in MIL-883 Lev. 8
I
-UL cl!coqni zed/CSA ce,.ti fi ed
HASl. 5/0VPA l. 5
I 8
I
f-chus is notched for N:. input
100!120/220/230Z40 VAC
-OVP on SV outcuts
-Full-cated to Salle.
HA15-0. 9A -~or l l 11 ~ , 8 -Industry sundard size -Foldback/curr!nt litoit
HA24-0.SA ~or1 .J!...;
H82 lA I SPt:ClF!CATtONS
HBS 3/0VPA : AC INPUT: 100/120/ZZ0/230240 VAC .. lOS. 13~. 47-63Hz.
HB 121. 7-A (Derate output current 10' for SO Hz ocer1t1on.)
H81S-1.5-A 8 SH AC connection table under APPliCATION !IOTES
H82C-1.2A 1.2 8 for jumpe,. infon!1ltion. Fuse infol"'llltion is n~,t
H828-1A l.C 8 to outl1ne and mounting drawings.
HC26A c
HCS-6/0VPA C OC OUTPUT: SH VolUqe/Curnnt Rating Chart. Adjustment range
HC12-J. 4-A c SS iniIA.
HClSlA C LINE REG\l.ATtOII:
HC24-Z.4-A 2.4 c
HC28-2A z.c C LOAD REGULATION: :.ass for a sos load change.
H0212A D OUTPUT RIPPlE: 211 to 15V unlts: S.QIIY PK-PK IIIUi,....
HOS 12/0VP -A D 20V to 2DOV units: .02: PK-PK . .xi-.
H0126.8A D
H0156A D TAANSlENT RESPONSE:SSO..seconds for a 50S load chanqe.
H024-4.8-A 4.8 D SHORT CIRCUIT

D
HD28-4-A
HE218-A '' E
AND OVERLOAD
PROTECTION:
HE518/0VP-A E
HE1210. ZA E O'IERYOt. TAG
HElS~A E PROTECT!OII: Built-in on all 5 outputs. Set at 6.211 t.4V.
HE24-7 .2-A 7.2 E Otner 110dels use opt1on.a1 o~er'WCilUge orotection.
HE286A 6.C E ROOTE SEIISIIIG: ProYtdetl on IIIOSt IIOCiels. 00...,. e" l'!CI ....a~:~~Iun
HNS-9/0VP-A
HN125.1-A
HN154.!i-A
"" STA81LITY:
built-ill.
!O.JS for 24 hour goriod after 1 hour waT'II-uo.
HN24-3.6A
11.0
"" 3.6 TE:!Pt:AATUIIE RATING; OOC to SOOC full-rated. derated linearly to 40:
HNZBlA
.L.i
t!AAS-1.5/0VP-A ' I UJ I
"
~DLA~~U~TgPIU~T~S~--~~..--~--~---r--~--~~r----r-~---r--~~T~EAAT~
I J AA COEFFICIENT:
at 700C.
HAA150.8A l.O,r0.8 ,1 1'04or 1.0ar0.8 1 AA t.OJS/C UX1-
I .,
HAA24-0.6A ,9.!or .2.... ~or i.J AA EFFICIEHCY: ;2V and SV:uliits: 45S
9
HAA512A .L! Uor~ , AA :(typical) 'lZV and lSV units: 55~
HAOIZO. C-A .2....: ~ I 20V and 24Y units: 601
HAOlS-0.4-A ~ ' .2.:,! I cav tnrou4111 250Y un i ts: 6~
Per MILSTD-810C. Method 51', Procedure X OO'.G-l
H88Sl/OYPA ll 3 0 81 V18AATIOII:
H88151.5-A
HBBZC-l.ZA
H8~5124 l.D
1.7or 1.5
L2Sar\2s
I
I
y o r !.:l I
oOor 1.7orl.5
M 1 .2
II
. . . ., 1----------------------
81
11
SMOCl: P~tr MIL-STD-810C. Method 516, Procedure Y
-Tolerance for 230'1AC ooeration is 15S, 10:
HCCS-6/0YP-A _,.0 I 1.0 cc

HCCIS-l-A
HCC24-2.4-A
HCCS12A
].Cor J.O
lr. 19
6.0 1 !5 or Z.S
1.8oj"rz.c I
3.4or 3.0
1.8orz.ccc
1 Ecc
CC
~
POWER-oN(. INC. 101rrants nch gawr supply of its unuflcture thit Ito~
J.'iH~00~1~5~-S~-~A~tm:!:=:!:;;:;!l:!=
TRIPLE OUTPt rs
,,.O~a~r~S-~0~=:!=~~=:;;:::;~~S. o~,or~S.~o=::::=::::~
'l:
not perlarw to IIUIIlished specificat1ans. u a result of defective ute
rials or wo..-ansllip. far a period of t1o10 (2) full t t l " f~ tnt !Ute
~~
HTAAISIA \r~.O . 0 . 4 ~oru.iiW
~.:.!orO~ ~4 ~. :~
AA of oriqin.al delivery.
~ 1'2l:l4itlnr"w I"' ~ft~ PQIIR..QN. INC. uslllft no liabilities for consequential dMAges of
HCS87SI-A 1-P or i.7 or 1:=,: any kind Ulroutfl tilt use or isust of its l)roducts by tnt I)UI'dlaser
Hai81DSW-A 12.0 1.7or !5 l"o.7or 1.7or1.5 1..... or oUI" 11o otller ollligattons or liabilities are upressed or i119li
CP131A 8.0 1.7or 1. 5 l"o.7or 1.7orl.S 13
HIGH ~OLTAGE
8
~ , PIIOOUCTS RETURNED FOR REPAIR
Please follow tllis l)rocltdure when returning products ror ~vic1nq:
~DEL
H8480. 5-A
HC48-1-~
rr I. Contact Power-One's Customer Service Department for authorization
to return products:
HD48lA D POWER-ONE, INC. PHONE: (805) 987-87/.l

HE84-A E 740 Calle Plano ( 805 J 087-J89l
HB 120-0.2 A 8 Cam.rillo, CA 93010 (800) 2'35-591.)
HB200-0.12A J B 1'1JC: 9lQ-JJ6-l297
8 USA -
~8250-0.1-~
12'1 (or -15V) requii'IS j ...per on PCB for .sv. z. A Returnltd Kllterial AutnoriZition (RI1A) w;J I be issued nd :nust
appear on all shipping doc,.,nts and containers.
for :12V, refer to chassis silkscreen
for 180V, refer to chassis silk screen l. Products must be returned freight pre-paid.
7 UV tc lSV adjustable output Products retu,.ned freight collect or withOut an RMA number "'I I
_indicates no ..-u senslt be rejected and returned freiqllt collect.
SoecificatiQnssu~ect to change "ithaut notice.
APPUCA TION NOTES
ROOTE SENSE ~------------~PA.
GR91JNDJII&
RII!Kite sense tenninAls MY be used to c011pensate fol" output line Grounding considerations in designing a pawer distl"ibution syst81 are
losses and provide for" a ,...,u point of l"ecJulation. Figur-e 1 shows often overlooked but can have a sign ficant impact on overall syst
the proper" tenlliration for" a power" supply with I"I!IIIOte sensing. perfa!'lllnce. A single point syster.~ gr"OUnd should be l!lllaloyed ...,ere
possible to tl i~ainate ground loops and Improve regulation.
POINT Of' REOUUTION'

our - -.,
SEMel! ; . --.._ _/ ?) M. ....J!O
~ ~
- SENSI! <>-~- - --~l T
-our:: --J FIOUAE 2
Load lines -ust be sized to pr"event an excessive voltage clrop f~ tile

output to tile load. Since tile point of l"egulation is at tile load, tile
power supply -ust c~J~~penute for" 1ine losses. Excessive load 1 ine
losses My affect cur"r-ent liiting, AC line dropout point and OVP .. ,..
gin (if applicable).
Leeds should be sized to drop no IIIOI"e tllan O.SY tile less tile better".
Use of a twisted piil" Or" shielded Plil" fo,. tile sense lines is ,.ec... Figur-e Z shows a simple but undesirable connection sch..lf. A~tgulation
mended for" nohe i-..nity. ln. probl applications, tile use of a SMll at loads 2 and 3 btcOlllts progressively worse due to v"l tage droiiS in
AC decoupling capicitor (.1 to IQ!Fd) across the sense ten~inals is tilt finite wire resistance between loads. Figure J shOWS an iprovtd
highly ,.ec-ended. In s0111e applications tller"e uy be a tendency for" connection syst in which "'gglhtion is 1111intaiftlfd at all tllr.. loads
tile JIOOitr supply to oscillate due to the additional phase shift caused beciUSif wire losses are not c-luive.
by the ser"ies r"esistance and inductance in the load l11ds. Tile
addition of capicitol" Co will ,.educe output iMpedance and provide AC liiPIIT CONSIDERATIONS
stability. The r"ec-endecl value of Co is lOO..Fd per- oer-e Or" SOuFd
per- foot and can be the su. of the dist,.ibuted decoupling CIPICitoi"S Alst all power supplies use a capacitive input filter tllat draws
found in st syst-. CUI"rlnt only &t tile peaks of tile AC input voltage. The peak t11 IIMS
P'ltfo can be very !li~n. typically 3 to 1. Whotn a supoly is tur .....:~ on,
All Powr..One supplies have open sense ieee! protection to protect tile the input tiPICftol" has a very low impedance and clraws an initia'ly
load f~ an over"Vol tage condition if the sense leads a,.e ,._ved. high surge current until it charges to its ,..inal voltage. The input
There is no need to str-ap the sense tel'lllinals to the output teminals surge current can be n high as .20 tilfs the l"lted input :urrent and
in the local sense mde. Juts for several cycles of the AC input.
OWyot,TAiiE P8!mmnN IQyPl AC gnmmiQ, 11:2 I'll~ IN
An over"Vol tage protection cir"cuit, cDOIIIIDnly l"tfe,.recl til as a c:I'OOObar, The five wire input to tile INTERIIATIOiiAL SERIES provides fou,. voltage
is used to prevent da111ge to voltage sensitive loads such u m logic. ranges: 100/1Z0/220/230-24U* +10:, -13:. See chasSIS AC connection
Tl"ip point of thlf OVP is usually set at 115: 135: of tilt output table (Figvr"e 4) for tile j~~apering l"!quirents. For co"venience thlf
voltage. The OYP wf 11 short the output tenlinAls upon SlfftSing a fault j111per sequence f~ tile Hf-Vol series is retained. Extended low Hne
condition. The pri.. ,.y fuse of the supply will blow If the supply is tDierance provides additional drop out urgin in aren wnel"t line
not foldblck cu,.,.ent Hited. Nuisance tr-ipping of tile OVP is a e - n voltages are urgiral. ln;:vts IIIUSt oe fused.
probl. Noise f~ input line spikes or load noise can causlf an OVP
to fir-e. The INTEAIIATIOIW. SERIES has OVP nobe filtering til pnvent
nuisance tr-ipping and l"educr.t tr"an'lfo,.... inurwinding capiciunce to e __________,
in'-ize input line susceptibility.
C'""*-1!00 LATCH uP
In certain instances flu.1 'power supplies can ullibit a pi'001 ~ u
c - - d e latcll up. This OCCVI"S wllen the positive SUPPlY C..S liP
fir"St and forces a revei"Se bias conditiOII 011 the neptive supply, Tile
neptive supply Iateiia up fn a current llit condition. P-One has
.incorporated a unique anti-latcll circuit into ever)' d.,.l ~r supply in
the IIITEIUIATIONAL SERIES wllicll wi 11 iniiu this prolll.
EMIIAFl
These linear power supplies have inherently low conducted and radiated
noise levels. For .ast syst applications they will ...t tile require
' 81fttS of FCC Ooctet 20780 for Cla.s A equipaent and VOE 0871 for Class A
f!!Uillllflt without additional noise filtering. For special applications
consult factory.
.m..Lrli

Convection cooling is adeq.,.te wher-e non-,.estrictecl ai,. flow is
AC INPUT, ~7- 63 HZ
available. When operating in 1 confined area, 1110ving air or con-

duction cooling is rec-nded 100 120 220 ~
SAfiD SPEClfl(AIIQ!I$_ I.:E AT VAC VAC VAC VAC
Thlt INfERMATlONAL SERIES power suppl ies were des ianed til meet or exceed 1&3 1&3 213 213
requirenU for the following specifications: IEC 380, IEC 43S, 2&4 2&4
VIlE 0730 Part Z, VOE 0804, EOIA-57, CEE 10 Part 2P, UL 1012, CSA 22.<: APflt..Y AC 115 .-&1 115 .-&1
No. 143, CSA 2:!.2 No. 154. Specifically, field tel"'lliral to te,.inal
spacing is 5.25 ~with 9.0 ~creepage to other" metal, leakage cu,.,.ent NOTE: Uslf 700t. iron for soldering input connections.
is less than S.OuA aNI dielectric wi tllstanding vul tages .,., 3750 VAC y.,.nish acts as flux and is soldltr s;ripoaDie.
input to chassis, 3750 VAC input to output and 300 VOC outout to .. Tolerance for 230VAC opel"ation is +15:, -101.
chassis.

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I'USE AT: 3.011.5 AWS FOR 1001201420240 VAC \t " 051025 AMP~ .II 1001201220240 VAC
.... 0 " / 0 . 3 " - "" :00;2Q/UD-Z40\AC
- - PART NUWER I I DESCRIPTION OR MATERIAL
PLACE LABEL, ITEM @, ON THE SIDE OF

SEE SHEET. I OF 2
54 WITH ARROW POSITION A.S SHOWN.
VIEW B-B
-SCALE: 2/1
IFOR -02 & -0.31 .B V-------~---vB 17 PL
F
SEE DETAIL "A"
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.
.
164 2 PL
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SCALE :NONE
2PL
IL-4&..81
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@ INSTALL JUMPER Wl6 A7 53 BETWEEN PIN I AND PIN 3.

7. LAST REF DESIG RI3~:,U ,37 ,CI41,TP50,J22,XWI5,05,L8,CR 19,K7 ,S6,Y3,VR3.
6. REF DESIG. NOT USED~ 1~20-32,61,82,CI3-18,39-43,45,56,57,65,77,97,9S,I25,134,135,
JI4,16,18,20,03,4,XW2,1:,:,si,S2,U8 ,U 11-17,26-28 ,U37 -40,49,50,89;90,135.
5.
c 4. FOR L 1ST OF MATERIAL SEE SHEET I OF 2.
3. DO NOT INSTALL AT T'r!IS LEVEL C64,CII9,R41,R42,S3,S6,JII,JI2C,CI39,
- 48,96,98,103,105,L5-7,X'3-5,6,8,10,11,14,15 AS SHOWN ~
2. .A/W :03-919057:.oo,SCHEM :03-919058-00
0. STAMP ASSY DASH NO, AND REVISION NO. AS REO.
NOTES.
4 PL
SEE DETAIL "A''
. FROM SOLDER SIDE
00 NOT ~CA -E DRAWING

- DRAWN I
SAL TEDESCO 3-5-86
DAI .. APPROYW
'
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J.BARDEIIFLETll 3-6-86
UAit
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.....
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CHE"""D
JS
I 3-5-86
DA E
H.M.NAAS
APPROVED
I
DATE
.....
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l!lO
ASSY.PCB.SBC
APVD - NOT OTHERWISE SPEC: ANG.t
EO
OFT
CHK
@ I'IN.VOEC .X ~
38.12 OF 210
.xx t
I 03
..JW< t
919055 I
DATE varl an
. REV DIY SHEET SIZE ORAWINC NO
--03-910380-21
___ . --
~ ..... nc.r~KI:.IIf;l:: DESIGIIATDR
---
UIOO
-
-I _._
IC EPROM 0 9010
K"tf IU"t 114 115 121 101 6 6 6 6 31-102230-00 RES I.SKo I/4W IY. MF
66
03-919571-00/-01 136 R52 I I I I 31-400101-00 RES NET SIP IOKo .I% X4
67
03-919643-00/-01 UI07 -- -- - I 03-910381-21 IC EPROM I 9010 137 R53 55 2 2 2 2 31-616174-00 RES 383Ko I/4W 1% MF
68 BTl
03-919644-00/-01 UIOI
UI08 - - -
- I
I
03-910382-21 IC EPROM 2 9010
03-910383-21 IC EPROM 3 9010
138 R54
139 R56 62 66 124
I I
4 4
I I
4 4
31-616123-00
31-616021-00
RES 45Ko,I/4W O.IY. MF
69
RES IOKo I/2W O.IY. MF
70 c 1-12192427-303358 94 9 CAP O.luF SOY CER
UI02 I 03-910384-21 IC EPROM 4 9010 140 R57 67 78 3 3 3 3 31-616139-00 RES 24.9Ko I/4W 1% MF
71 3 4,44,46-55,60-63,66
Ul09 I 03-910385-21 IC EPROM 5 9010 141 R69 117-119 4 4 4 4 31-102142-00 RES 182o,I/4W IY. MF
72 67 7172 74-76 78-96 99-112
UIIO I I 62-602158-00 IC 68000LI2 142 R72 107 2 2 2 2 31-102377-00 RES 51.1Ko I/4W 1% MF
73 I\!::14~-H:II8~.1~2i'~J-..,;12~4o4;,12~6~-l/4,!30~.~140~1-+--t--+-t--~---+-------,1{'''
c25,26 5~i,68,69 73 113 136 B 8 B B 41-516728-00 CAP 10 uF 2SY ELEC~
Ul12 I I 62-601827-00 IC 74FION 143 R73 I I I I 31-102253 -00 RES 2.61Ko I/4W 1% MF
74
Ul14 I I 62-600002-00 IC C04020B 144 R74 I I I I 31-102316-00 RES 11.8Ko I/4W IY. MF
75 C3132 2 2 2 2 41-609404-00 CAP47uF20YTANT -
U115 I I 62-600068-00 IC 74LS04N 145 R76 77 2 2 2 2 31-102275-00 RES 4.42Ko I/4W IY. MF
76 C3536~i8 3 3 3 3 41-764921-00 CAP.OiuF63YMYL .
Ull8 I I 62-601868-00 IC 74FI64N 146 RBO 81 86-90 93 95 21 21 21 21 31-400198-00 RES NET SIP IOKoX9
77 C37 I I I I 41-764920-00 CAP,.0047 uF,63Y,MYL
'\.1119 I I I 62-602029-00 IC 74F64N 147 I R98 -IOO,IU,10::1,106 78 C46 I I I I 41-159524-00 CAP 10 F MICA 500Y
Ul22 I I I 62-601825-00 IC 74FOON 148 R 109 Ill 116 129 130 13i 79 C47 70 131 132 137 5 5 5 5 41-516733-00 CAP 330 F lOY ELECT
Ul24 I I I 62-600067-00 IC 74LS38N 149 R83 92 2. 2 2 2 31-400052-00 RES NET DIP IOKoX 15 80 C 133 I I I I 41-159584-00 CAP 51 F ,500Y MICA
Ul30 I I I 62-601919-00 IC 74F245N 150 R84 85 94 3 3 3 3 31-400194-00 RES NET SIP 4.7KoX7 81 Cl38 I I I I 41-609401-00 CAP 4.7 F 35Y TANT
Ul31 ! I I 62-600720-00 IC 74LS27N 151 R96 97 2 2 2 2 32-301810-00 RES IOMo I/4W 5% CC 82 Cl41 I 1 I I 41-764926-00 CAP,.OOiuF,IOOY,MYL
F U134 I I I 62-600003-00 IC MCI4013B 152 Rl22
,.
I I I I 31-102407-00 RES 105Ko 1/4W IY. MF 83
U47 I I '~2-600843-00 IC 74LS132N 153 Rl23 __ I I I I 31-400059-00 RES NET DIP IOOKo X8 84
'
154 R63 I I I I 31-102278-00 RES 4.75Ko I/4W IY. MF 85 CRI-3,19 4 4 4 4 66-304006-00 DIODE,IN4006
155 Rl27 I I I I 31-408308 -oo RES NET,SIP 47KoX5 86 CR4,5 2 2 2 2 66-304148-00 DIOOE,IN4148
YRI 62-601725-00 RE.FERENCE,L~Z336BZ 2.5Y 156
62-601747-00 REGULATOR LM79Ll2ACZ
R43 I I I I 36-792215-00 RES POT 10Kol5 TURN YAR 87
.. CR6-914~-~16~-----~-h~~~~~~~~+*~~~~~~----
CRIO ..
7 7 7 7 67-599287-00 DIODE LEO GREEN
YR2 157 Rl32 I I I I 31-102184-00 RES 499o,I/4W 1/. MF 88 I I I I 67-599286-00 OIODE,LEO,YELLOW
YR3 62-601631-00 REGULATOR LM78LI2ACZ 158 89 CR ll-13;1;";7----+.:rl-rl-:rl7-t-F-7-~~;F-~~~~~~~!!,_--
4- 4 4 4 67-599285-00 OIOOE,LEO,REO .
15'":i 90 CRI8 . I I I I 66-306263-00 DIODE IN6263
XBTI 22-117100-00 HOLDER BATTERY 160 ~? 2 2 2 2 71-996984-00 SWITCH DIP SPST 8 POS 91
161 . 92 J2-B 7 7 7' 7 51-411038-00 CONN PC 3 PIN RT ANG
XWI XWI3 2 2 2 2 51-407216-00 CONN PC 2XI 162 93 J9 I I I I 51-340031-00 CONN PC 9 PIN RT ANG MALE
E. XW7 I I I I 51-407205 ~oo CONN PC 17X2 163 94 JIO I I I I 51-335047-00 CONN PC 9 PIN RT ANG FE MAL
XW9 I I I I 51-407215-00 CONN PC 3XI 164 95
165 96 J 12A J 12B~I5~17______-l-:'-t-::'-+~+-t?.-=-~~~~:-:.;.:.~~~~~---
4 4 4 4 51-190018-00 CONN HOR 26 PIN
XUI 136 137 3 3 3 3 54-910401-00 SOCKET 6 PIN DIP 166 U4 I I . I I 62-601956-00 IC 74HCI4N 97 J13 . I I I I 51-209238-00 CONN HOR 60 PIN
XU7 29 2 2 2 2 54-910409-00 SOCKET 40 PIN DIP 167 Ul 136 137 3 3 3 3 66-590008-00 IC CNY17-4 98 Jl9 I I I I 51-408244-00 CONN PIN HDR ASSY 5 CKi
xu 10,97,99-102,104.106-109 II II II II 54-910408-00 SOCKET 28 PIN DIP 168 U2 6 22 57 69 75 94 7 7 7 7 62-600470-00 IC 7406N 99 J21 I. I I I 51-407024-00 CONN PC 4 PIN
XU31-33 3 3 13 3 54-910407-00 SOCKET 24 PIN DIP 169 - U3 5 20 65 113 5 5 5 5 62-600714-00 IC 74LS74AN. 100 J22 I I I I 51-407100-00 CONN PC 6 PIN
XU8.Q~2 2 2 .2 2 54-910406-00 SOCKET 20 PIN DIP 170 U59 I I I I 62-600718-00 IC 74LSI4N 101
XUIIO I I I I 54-910428-00 SOC ET 64 PIN DIP 171 Ul28 129 2 2 2 2 62-600886-00 .IC 74LS32N 102 Kl-7 7 7 7 7 72-920343-00 RELAY REED FORM A
XK I-K7 7 7 7 7 54-910403-00 SOCKET 14 PIN DIP 172 U7 I I I I 62-600799-00 IC P8255A 103
I I 03-919957-00 LABEL OIP SWITCH L73 U80-84 5 5 5 5 62-601193-00 IC 74LS245N 104 Ll-3 . 3 3 3 3 43-900106-00 FERRITE BEAD 43 MATL
174 U923111 3 3 3 3 62-600831-00 IC 74LS367AN 105 L4 8 4 4 4 4 43-900102-00 FERRITE BEA0,3B MATL
175 UIO I I I I 03-919723-01 IC CONVERTER, A/0, 12 BIT 106
Yl 66-472010-00 XTAL 3.6864 MH z 176 Ul8 I I I I 62-601701-00 IC 74LS423N 107
Y2 I. 78 -908023-00 OSC XT AL 10 MH z 177 Ul9 91 2 2 2 2 62-600723-00 IC 74LSI75N 108 Ql 62-903906-00 TRANSISTOR PNP 2 -
Y3 78-908028-00 OSC XT AL 12.5 MH z 178 U21 43 44 63 66 67 6 6 6 6 62-601660-00 IC 74LS259N 109 a2 62-903904-00 TRANSISTOR NPN 2tL... - t
179 U24 I I I I 62-601603-00 IC LF398N 110 as 62-798140-00 TRANSISTOR YNIOKM
W7A-W7Q,WI,W9 51-452976-00 PLUG SHORTING 180 U25 36 2 2 2 2 62-601446-00 IC LM324AN Ill
81-099922-00 WIRE BARE C 22AWG 181 U29 I I I I 62-601857-00 IC MC68681P 112
12-220004-04 SCREW 4-40 Xl/4 PH SST 182 U30 46 2 2 2 2 62-601605-00 IC 74LS541N 113
WIG 81-559921-00 WIRE WHT 22 AWG,TFE INSUL 83 U3132 2 2 2 2 62-601326-01 IC,QP8253-5 BURNED- IN 114
184 U33 I I I I 62-602159-00 IC P8254-2 115 I I I I 32-201247-00 RES 47o I/2W 5Y. CC
UIOO 03-910502-21 IC EPROM 0 9001 185 U34 88 2 2 2 2 62-600923-00 IC 74LS373N 116 2 2 2 2 31-102526-00 RES 4.75M,I/4W IY. MF
UI07 03-910503-21 IC EPROM I 9001 186 U35 I I I I 62-601723-00 IC OG211CJ 117 5 5 5 5 31-102117-00 RES lOOn I/4W 1/. MF
c UIOI 03-910504-21 IC EPROM 2 9001 187 U41 42 2 2 2 2 62-601048 -00 . IC MCI489N 118 4 4 4 4 31-102021-00 RES IOn I/4W IY. MF
UI08 03-910505-21 IC EPROM 3 9001 188 U45 53 60 3 3 3 3 62-600932-00 IC 74LS279N 119 4 4 4 4 31-102086-00 RES 47.5n I/4W 1/. MF
Ul02 -03-910506-21 IC EPROM 4 9001 189 USI 52 2 2 2 2 62-601081-00 IC MCI488N 120 23 23 23 23 31-102309-00 RES IOKn I/4W IY. MF
U109 03-910507-21 IC EPROM 5 9001 190 U54 55 70 79 117 121 6 6 6 62-600383-00 IC 7407N 121
UIOO 03-910636-21 IC EPROM 0 9012 191 U56 I I I I 62-601134-00 IC 74LSI48N 122
Ul07 03-910637-21 IC EPROM I 9012 192 usa 12s 2 2 2 2 62-601863-00 ICJ4F04N 123 31-102433-00 RES I96Ko I/4W IY. MF
UIOI 03-910638-21 IC EPROM 2 9012 193 U61 132 2 2 2 2 62-600153-00 IC LM339N 124 31-102213-00 RES IKo I/4W IY. MF
UI08 03-910639-21 IC EPROM 3 9012 194 U62 71 116 120 126 131 6 6 6 6 62-600897-00 IC 74LS251N 125 31-616146-00 RES IOOKo I/4W 0.1% MF
UI02 03-910640-21 IC EPROM 4 9012 195 U64 93 2 2 2 2 62-600072-00 IC 74LSOON 126 31-400248-00 RES NET SIP 220oX9
UI09 03-910641-21 IC EPROM 5 9012 196 U68 I I I I 62-601223-00 IC 74LS393N 127 31-102405-00 RES IOOKo I/4W IY. MF
UIOO 03-910643-21 IC EPROM 0 9002 197 U72 73 86 87 123 5 5 5 5 62-601865-00 IC 74FI38N 128 31-400086-00 RES NET DIP 12KOX8
UI07 03-910644-21 IC EPROM I 9002 198 U74 127 2 2 2 2 62-601829-00 IC 74F32N 129 36-792212-00 RES POT 20Ko IS TURN Yt
B UIOI 03-910645-21 IC EPROM 2 9002 99 U76 I I I I 62-600724-00 IC 74LSION 130 31-102422-00 RES ISOKo I/4W 1:1. MF
UI08 03-910646-21 IC EPROM 3 9002 0 0 U77 I I I I 62-600900-00 IC 74LS374N 131
Ul02 03-910647-21. IC EPROM 4 9002 0I U78 85 95 3 3 3 3 62-601866-00 IC 74FI39N 132 XJ-91905503 REFURBISHED 900Z 03-91905503
UI09 03-910648-21 IC EPROM 5 9002 0 2 U92 I I I I 03-910378-01 IC PROM BIPOLAR 133 l0-919055-0Z REFURB !SHED 9012 03919055-0Z
0 3 U99 106 z z z z
62-601767-00 IC 6264LP-15 134 X3-9190S5-0I REFURBISHED 9001 03-91905501
L./?(~ 00 NOT SCALE DRAWING

X391905500 REFURBISHED 9010
PART NUMBER CESCR IPTION
03919055-00
PART HUI.IBER CES
APPROVED FOR .. ltlo

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c
....
DRAWN
SAL TEDESCO
1 DATE
3-5-86
?
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CHECK0
JS
I DATE
3-5-86
9 ~! i:lll
0
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JUN 2 5 199G 1!:
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NOTES: SEE SHEET 2 OF 2
FABRICATION
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MVD CIRCUIT DESCRIPTION
RH-04/86 til.. R.l)./.
10-24-88
1.0 GENERAL
The function of the Motor Valve Driver (MVD) is to translate low
level control signals from the ..ingle Board Computer (SBC) into
high level drive signals for the pump motor and proportioning
valves. In addition the MVD supplies diagnostic signals to the
SBC for the purposes of cold-start testing and facilitation of
troubleshooting.
The MVD board is broken down into the following functional
blocks to aid description: e
1) OPTO - Isolator Interface

2) Microatep Generator
3) Motor Driver
4) Power Supply and AC Power Fail
5) Diagnostics
8) Valve Control Logic
Figure I, the Block diagram, shows the functional relationship of
1.1
these modules to each other.
schematic pap.
OPTO-ISOLATOR INTERFACE
Each block corresponds to a
The opto-tsolator iDterface is composed of U1,2,3,4,8, 7. Its

purpose is to pl"''ride electrical fsolaticm between the MVD and
SBC, thua preventmar chopper noble and any cataatl'opblc failures
of the MVD board fl"'OIl pzvpaptiDs back iDto the SBC. Two
type8 of opto-lsolator ue uaed: 1) an BCPL-2830 for "fast"
siiD&ls, and 2) ILQ-74 for "slow" stiJDII)a, and coat reduction.
A liat of sipala and a dcripticm of their function are listed in
Table I.
1. 2 MICROSTEP GINIRATOR
The adcro.tep generator is compoaecl of a "miCI'088Cluencer"
(U22, 24,25, 28), synchronoua counters (U31, 32) , SIN I COS lookup
PROM (U33), and pbaae 1 and phaae 2 DAC's (U34,.35).
The purpose of the microatep generator is to advance the stepper
motor one Mlcroatep (84 lllicroateps = 1 full step = 1.8) for each
rising edge of the MRATl signal. The operation of the
microatep pnerator can beat be understood. by referrlns to the
tillling diagram iD figure II

Assuming that the microsequencer starts from its resting state
(U22-13 = U22-1 = 0, U25 oscillator = OFF, U26 = "0"), the rising
edge of MRATE initiates a "load" operation by setting U22-13 =
1. This advances the PROM address counter (U31, 32) and allows
the oscillator U25 to run. The PROM contains signals for both
the SIN and COS for each microstep. The oscillator clocks the
combination counter-decoder (U28) generating a programmed
sequence of control signals. These signals control the latching of
the sign and magnitude data from the PROM into the phase 1 and
phase 2 DAC's and SIGN flip-flops. In addition these signals also
provide timing pulses to the FET driver control logic.
The MRUN control signal from the SBC, when it goes high,
allows the pump motor to be stopped with reduced holding torque,
irrespective of the state of MRAT!. This is accomplished by
disabling the PROM address counter (U31,32) and reducing the
DA outputs by 50\ via U23 and voltage dividers at the DAC
outputs. "
The DAC outputs comprise the voltage reference inputs to the
current regulator portion of the F!T CONTROL logic, and
determine the level to which the current in the separate phases is
regulated.
1. 3 MOTOR DRIVER
Figure III shows the F!T control lope for one wtncUDc of the
stepper motor. CoiDIDOn to both windinp are a 25 KHZ clock and
a 5 ..,_ S one-shot.
It should be noted that there are three control fUp-fiop per

winding. The first fUp-fiop is the SIGN fUp-fiop and controls
the "steertnc" of the current into the approprJate phase,
depending upon. the state of the SIGN bit. The second flip-flop
is the SIGN TRANSITION flip-nop. Ita purpoae is to detect when
a SIGN traDaition occun ancl to diaable both phaaes of the
winding for about 5 ~ S clurlnc the tra.Daitton. This enaures that
both ph cannot be "on" simultaneously, which woulcl produce
an effecrtlve short clrcu1t.
The third fUp-fJop is the PWM regulator control nip-fiop, which is
embedcled in the feedback loop to replate the current in the
motor ph
CUrrent replation ia accomplished by com~ the voltage
generated acrou the 0.1~ "current sanae" resistors R40 ancl R41
(lOOalv = 1.0 A) to the input reference voltap.. When the
feedback voltap exceeda the input reference voltage, the output
of the first comparator soe high causing the output of the
second comparator to 1'0 high after a nominal time delay of 5.,_ S.
This action causes the PWM control flip-flop to change state, thus
turning off the FET switch on the active phase. This causes the
current in the phase to "commutate" ancl beeln decaying, until
the next one-shot pulse again initiates a PWM control flip-flop to
its ON state.
The regulation scheme is "true PWM" in that the FET switch is
forced both ON and OFF for a portion of each chopper cycle.
This minimizes audible chopper noise in the stepper motor.
These logic signals are "anded" in gates U28 and U29, the
outputs of which drive the level shifter U30. The level shifter
translates the 5V logic signals into 15V drive signals for the FET
gates.
The level shifter also allows the PUMP STOP signal to inhibit the
gate drive signals to the FET switches, leaving the motor (and
the valves) unpowered.
Q4, Q5, Qll and Q12 are the power driver FE~S for the four
motor phases. Their gates are driven by the LEVEL SHIFTER
(U30) through the protection network composed of two resistors
and a diode. These FET's act only as switches, being either
hard ON or hard OFF. Current regulation is achieved by
adjusting the duty cycle. This is also known as fulse Width
Modulation (P'WM).
There is, in addition, an active snubber formed by Q3, QlO and
VR7. The snubber network is necessary to dissipate the energy

stored in the leakage inductance associated with each phase when
the drivers turn off. Otherwise the breakdown voltap of the
driver FET's would be exceeded, eventually causing catastrophic
failure. The snubber Umtta these "fiy-back" voltapa to safe
levels.
1.4 POWER SUPPLY

The primary input power to the MVD board is 20 VaM supplied
by the dual secondary of the power transformer. This is
rectified by the full-wave bridp (CR5) IUld mtered by C24;. C25,
and C28 to pt"Ovide IUl UD1"8gulated +28 volts, which is the baste
power source for the valv IUld motor.
Regulated +15V IUld +5V are developed from +28V by VRl and VR2
respectively. Current sense resistors are provided by +15V
(R33) IUld +5V (R34).
Moat of the electronics are run off of +5V. The +15V is supplied
only to pt"Ovide sufficient gate drive levels, via level shifters U12
and U30, to the MOSFET driver transistors
1.4.1 AC POWER FAIL

The MVD also supplies the SB C with a signal MPF* which
indicates to the SBC an impending power loss. This signal
feeds the level 7 interrupt on the SBC. MPF* is generated
by fully rectifying the transformer secondary voltage

available at Jl03. This rectified voltage is then passed
through a voltage divider and filter to comparator U16A,
where it is compared to the +2. 5V reference. The
comparator has hysterisis with a negative going threshold
equivalent to a Una voltage of 98VAC and a positive going
threshold of 105VAC. The output of the comparator is
conditioned through voltage divider R53-R54, Schmitt
trigger V20F, one-shot U21A. The MPF* flag to the SBC is
then asserted via driver U20A and optoisolator U4. The
MPF* flag will be asserted when the Una voltage drops
below 98VAC and will disappear (its normal state) when the
Una voltage rises above 105VAC. ;
1. 5 DIAGNOSTICS
The diagnostic portion of the MVD clrcu1try provides the SBC
with a means of determildng whether or not the MVD board is
operating properly. The djapostica are operated solely from the
+5 supply.
The ttiapoatic circuitry is composed of a +2. 5 voltap reference

(VR3, U15); comparators Ult, U17, and U18; noiae mters at the
output of the coaaparators conaiating of a lOX resistor and 0.022F
capacitor; Sc:bmitt trlgpr drivers US and US i and multiplexers
UlO and Ull.
Four groups of four signals are multiplexed to the SBC via
commands~ MIIUXCA and MMUXCB. The sipala are divided
into the four pot.ipa u followa:
"BBII..5l
''+26Y II1Ddcllr I
.,,
"-1~111 .....
--z
1, a.ta ,.
ml.l
Yal..aiii
"+15 II1Ddcllr I ,._.lDICtof ..... 1, a.ta. vat. . r.o
"+SY ~ I ..... 2, a.ta l "-1SW
"251111 Clock I
"-2DKIII
..... 2D1Ctol ..... 2,Gate. ..... 2 S19D
TM llipaJa -.rked with an aaterlak are ctiapostic loGe level

stpala which feed the output multiplexers directly. The other
sir' are coaaparator outputs which are derived by comparlnc
key analog voltape in tbe system to :refeNnca voltapa generated
from the +2.5V NfeNnca. The analoS portion of the dJapostic
circuitry will be separated into its component parts and discussed
separately to facll1tate understandinC.

1. 5. 0 +2. 5V REFERENCE
The +2.5V reference is comprised of VR3 and buffer
amplifier U15. In addition to providing +2.5V to the
window comparators, it supplies reference vol~s of 70mV,
250mV, 400mV, and SOOmV for use by the comparators
sampling the microstep DAC signals and the valve feedback
signals.
1.5.1 +28, +15, and +5 WINDOW COMPARATORS
These comparators (U14, U17) sample the three supply
voltages and, if they are within their respective windows
(i.e., within tolerance), then "OK" signals are sent to the
SBC. Also, the appropriate green LED indicators are
activated on the MVD board.
1.5.2 DACS HI and LO COMPARATORS
The DAC for each motor winding is monitored by two
comparators: ( 1) a HI level comparator with reference
voltage of SOOmV, and (2) a LO level comparator with an
input reference voltage of 250mV.
The DAC outputs are equivalent to a tully rectifiec:l sine
wave with a peak value of 700mV. With this sigual as input
to the above comparators, the HI level comparator will

generate a duty cycle of about 50\, and the LO level
comparator will pnerate a duty cycle of about 75,, relative
to one full step of the motor. If this Is not the case, the
SBC wt11 generate an ERROR measap.
1.5.3 VALVES HI and LO COMPARATORS
The valve feedback aipal is monitored by two comparators
with input reference voltaps of 400mV and 70mV
reapectlvely. The ftnt represents VALVES HI and
indlcat tbat the pullin current or HI level is OK. The
latter NJ)NII&nta VALVES LO and indicates that the sustain
or hold current Is OK.
1.5.4 LOGIC SIGNAL DIAGNOSTICS
In addltkm to the analol voltaps that must be monitored,
there are several logic tcnala which must also be
monitored. These logic stcula reqWJ'e no extra hardware
u they are generated u a by-product of 'the circuit
operation. They must only be IIIUltiplexed. out to the SBC.
The logic signals of interest an the following: (1) 25 KHZ
chopper clock; (2) four pta control aipala for the motor
driver FETs (PHlGTA, PHlGTB, PH2GTA, PH2GTB); phase
1 and 2 SIGN bits

1.6 VALVE CONTROL LOGIC
There are five valve command signals composed of the four valve
select signals, MVA*, MVB*, MVC*, MVD*, and the pull-in
command MHIVC*. The valve select signals are mutually
exclusive, and each signal, after being translated by level shifter
U12, controls its own steering FET (QS thru Q9). These FET's

act as switches, either entirely ON or OFF.
When a valve is actuated by the simultaneous assertion of a valve
select signal and MHIVC*, the following signal will appear as the
input voltage reference to the valve current regulator amplifier
(UlS-5).

1.6 VALVE CONTROL LOGIC (cont.)
~ l.S~s
/.0 v ---f-
.......
I
l
i
1001'1\.V
I.-
I \ -
~~ I><lt.AnoN OF 1'1H/ k ~
~-..-----I>ufATIIN 01' .-'ALV& SlUt
The valve current feedback loop is comprised of error amplifier

U16, transistors Ql and Q2, and the current sense resistor R35.
The feedback loop operates ln such a manner u to minimize the
difference between the input reference voltage and the valve
feedback siJD&l which Ia developed acroas R35

Since the valva feedback signal is a direct representation of the
valve current ( lOOmV. = 1. 0 A.), the valve current is thus
regulated to the input reference.
The initial 10.0 A. step is to optimize pull-in time. The 1.0 A.
pJatu repreaenta the "sustain" portion of the valva cycle and
impUes the assertion of one of the valve select sipals.
The valva solenoid snubbers 81"8 comprised of CR8-CR9 and VR4
TABLE I
MVD - SBC INTERFACE SIGNALS

SBC ----> MVD COMMENTS
MVDEN Enables power portions of MVD

MRUN Allows motor to stop wI holding
torque
MRATE Determines motor stepping rate
MHIVC Valve pull-in command
MVA Valve select A
MVB Valve select B
MVC Valve select C
MVD Valve select D .
MMUXCA Diagnostics multiplexer control
MMUXCB Diagnostics multiplexer control
MVD ----> SBC

MMUXl . Diapostic output
MMUX2* Diagnostic output
MMUX3*
MMUX4*
MPF*
Asserted low
Diapostic output
Diapostic output
AC power fail

,..
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..... ~--------- ---- - -- -- ------

VR4 ~-
07-9 1201
~-
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REF REF REF ON BOTH 5 IDES OF
INSULITOR
DETAIL A 3 PL REF
SEE DETAIL C NO SCALE
SEE DETAIL A
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DETAIL D 0
03-5,010-IZ
~
STAMP ASSY REV NUMBER AS REOU IRED.
,
X391973001 REFURBISHED
139 REF
. APPLY 1/2'' WIDE KAPTON TAPE, ITEM Q , 03-91973001 PART
I SHADED AREAl ON cOMPONENT sIDE ARHOWN' DETAIL C I REF 03-919730-00 DRAWING ONLY
NO SCALE oo NOT SCALl u"~AW:I:N:G----~~--------~~P~A~RT~N~UM~B~EfR~-r~O~Et,S~CfR~IFP~T~I~OfN~-.~~
TO PROTECT TRACES FROM HEATSINK EDGES.
KEEP TAPE OUT OF HOLES. 1 ~\ j' ~-i -
..... ;..:} DRAWN
ST I 11-10-95
DATE I.?PkOVE.O I DATE COO
4. LAST DESIGNATORS USED: C5Z,CR35,R93,TP6,U40,VR7,01Z CHECKED I DATE

,/j_
APPROVED
17'...1.--
I DATE
1/~fq(
CLASS
3. DESIGNATORS NOT USED: CR4,6,11,ZI,30,06,R36,RTI. S1 1-lo'l~ ,n .f'..J~,, '''--''
@ INSTALL TRANSISTORS OZ-05,010-IZ AND REGULATOR VR6 AFTER WAVESOLDERING.

I. FOR A/W SEE 03919732-00. FOR SCHEM SEE 03-919733-00. ASSY, PWA. MVD
FOR FAB DRAWING SEE 03-919731-00. FOR PART SEE 0391973101. APYD f" ~ ---1
. . _ __.__ _.:._.___:,_,__ _ _ _ _ _
NOTES
EO
OFT
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CHK
DATE
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9. ln-DiZ.q-. I APPROVED DATE CODE
FOR. ASSY DWC:, SeE 03-qJQ730-00,FOR. PIIR:T SEE03-9197:SO-o/. ~ n.w~~~-.

Ho-~h "~~~A~~- I '.....:llo.....:i'_'_.__ _1
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Q~ CHECKED I DATE APPROVED DATE CLASS
.3. CuD= P!AJ7, +SV = PIJJ/4= U5,3, '!,J3n,zo, 22-25, 2 7-2'!, 3 7-40, 17b ;::~
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RfV
- - - - - - - - - - - - - - - - - - - - - - - - - 1 varian
- - - - - - - - - - - ----------~ - -
38
OIVISION
-- ___ ... .,,....._ ltM REFERENCE DESIGNATOR REO PART NUMBER DESCRIPTION :~ N.&iL~IAl. :_
I 31-102375-00 RES 48.7KO 1% I/4W MF 68 I 03-919731-01 F"AS,?WA MVO

I Ut:L:I~~56-00 F'AN '5V 70 CF'IA 138 I 31-563100-00 RES,IOOO 1% 2.5W WW 69
IVR6 03-5 010-1211 7 62-899011-00 INSU:..ATOR T0-220 MICA 139 I 31-588571-00 RES 330 1% lOW WW 70 Cl,5,6,18,23,27 10 41-290010-00 CAP,.l u F",50V,:ERM
1021 I 62-899012-00 INSU-~TOR T0-218 MICA 140 r13S I 31-560100-00 RES 0.10 1% 2.5W WW 71 29 30 39 40
IHEATSINKI 4 12-222006-06 SCRE"' 6-32 X 3/8 PH PHIL SST 141 '137-39 3 31-102185-00 RES 5110 1% I/4W MF 72 C2 -4 16.17,19,31 9 41-206998-00 CAP .OiuF50VCERt.!
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IF ANI 4 12-222006-26 SCRE ,o; 6-32 X I 3/4 PH PHIL SST 142 2 31-588570-00 RES 0.10 1% lOW WW 73 32,38
IVR6,02 -5.010-121 8 12-222004-08 SCRE ,o; 4-40 X 112 PH PHIL SST 143 I 32-501410-00 RES IKO 5% 1/ZW MF' 74 C7-15,50 10 41-764923-00 CAP .022uF" IOO"I.MYLAR
IF'AN HEATSINKI 8 14-202006-00 WAs;-;:~ 6 S?LIT 144 I 31-102434-00 RES 200KO 1% I/4W MF 75 C20 I 41-708570-00 CAP .I uF' IOOV 2% F'!LM c
IVR6 02-5 010-121 8 14-122004-00 WAS'-o'l 4 FLAT 145 '"'6,48,50.52 4 31-102155-00 RES 2490 1% I/4W MF 76 C21 I 41-609404-00 CAP 47 Ut 20V -:'ANT
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9010 Diagnostics Description
Version: $Revision: 1.1 S $Date: 88/08/11 12:56:56 S
Author: Norman Woo
Varian lnstrumeDI Group

Walnut Creek Divisioa
Walnut Creek. euforaia
printed oa: Sepcembcr 28, 1988

9010 Oi:sgnostics Description
TABLE OF COr-ri'Er-ri'S
1. Introductioa ........................................................................................................................... .
1.1. The Coldstart Test ............................................................................................. .
1.2. Exteaded Tests .................................................................................................... .
1.3. Cbug Moaitor Mode .......................................................................................... .
Selecting Modes of Instrumeat Opcratioa ..................................................... .
1.4.
.,
2. Diagaosiag the 9010 ............................................................................................................. . 3
3. The 9010 Coldstart Test ...................................................................................................... .
3.1. 9010 Coldstart Test Keruel ............................................................................... . .
3.2. How tbe 9010 Reports Coldstart Enors ........................................................ .. .
3.2.1. Errors Displayed after Coldstart ..................................................... ..
3.2.2. Coldstart Run Loa Entries ............................................................... .
3.2.3. Coldstart LED Display ..................................................................... ..
3.3. Interpreting 9010 Coldstart Error Codes ...............................................;......... 5
3.4. Detailed 9010 Coldstart Tesc Descriptiou ...................................................... 7
3.4.1. CPU Module Coldstart Tesc Descriptiou .................................... 7
3.4.1.1. Rom Checksum Tesu .........- .................................... 7
3.4.1.2. CPU Ram Tesc ................................................................ 7
3.4.1.3. Interrupt Hardware Tesc ................................................

3.4.1.4. Duart Tescs .......................................................................
3.4.1.5. Proarammable Interface Tests ......................................
3.4.1.6. Diapostic Multiple~er Tests .........................................
3.4.1.7. Tamer Tescs ..........-.....................................................
7
8
3
8
8
3.4.2. Pre-Drive Module C!)ldswt Tesc Descriptiou ............................ 9
3.4.2.1. Couater Tests ..----------.................... 9
3.4.2.2. Rate Geacrator Tesc ....................................................... 9
3.4.2.3. Vahe Tescs .............-...................................................... 10
3.4.2.4. Top Dead Ceater Tesc .................................................... 10
3.4.3. ADaJoaiDierfac:e Module Coldswt Tesc Descriptiou ................ 11
3.4.3.1. ADC Tamer Tesc ............................................................. 11
3.4.3.2. Allaloito-DiPUJ Converter Tesc ................................. 11
3.4.3.3. Battery Tests .................................................................... 12
3.4.4. Power Supply Module Coldswt Tesc Descriptiou ..................... 12
3.4.4.1. Rcplator Tests-----..-.......................... 12
3.4.5. Motor Vahe Drive Board Coldstart Tcsc Descriptiou .............. 12
3.4.5.1. Motor Valve Driw Board Presence Test .................... 12
3.4.5.2. MVD Board Power Supply Tests ................................. 12
3.4.5.3. Motor Driver DAC Tescs ............................................... 12
3.4.5.4. Motor Driver Phase Tescs .............................................. 12
3.4.5.5. Motor Clock Test -------------......

3.4.6. Front Paacl Board Coldstart Test Ocscriptiou ...........................
3.4.6.1. FroDl Paael Board Presence Test .................................
3.4.6.2. Keyboard Encoder Tesc __........................................
13
13
13
13
-1 Sa..tsioa: 1.1 S
9010 Di:~gnostics Description
3.4.6.3. Liquid-Crystal-Display RAM Test ............................... .

3.4.6.4. Front Panel LED Test .................................................. ..
3.4.7. GPIB Expansioa Board Coldstart Test Descriptioas ................ ..
3.4.7.1. GPIB Expaa.sioa Board Preseacc Test ...................... ..
13
13
13
1~

3.4.7.2. GPIB Expaa.sioa Board Dtack Test ............................ . 1~
3.4.7.3. GPIB Expansioa Board Bus Test ............................... .. 1~
3.4.7.4. 8291A Talker/Listeaer Test ........................................ .. 14

4. laspectina tbe Power Supply ............................................................................................... . 15
5. Exteaded Mode .................................................................................................................... .. 16
5.1. Selectiaa tbe Exteaded Tesu ............................................................................ . 16
5.2. Exteaded Test Descriptioas .............................................................................. . 16
5.2.1. lastrumeat Loa MaiateDaDcc ........................................................ .. 16
5.2.1.1. Setup .................................................................................. 17
5.2.1.2. Operatioa .......................................................................... 17
5.2.1.2.1. User-Mode Operatioa .................................. 17
5.2.1.2.2. Field Service Mode Operatioa .................... 17
5.2.2. Coldstart Diapostic --.............. 18
5.2.2.1. Setup .................................................................................. 18
5.2.2.2. Operatioa .............- ..-. ..................................................... 18
5.2.2.3. Error Messap ................................................................. 18

5.2.3. CPU Module ..............- -...................................................... 19
5.2.3.1. ROM Exleaded Tesr ...~................................................... 19
5.2.3.1.L Setup - -...................................................... 19
5.2.3.1.2. Operalioa ........................................................ 19
5.2.3.1.3. Error Messages .............................................. 19
5.2.3.2. ~ Exleaded Tesr ....................................................... 19
5.2.3.2.1. Setup _,_....................................................... 19
5.2.3.2.2. Operatioa ........................................................ 19
5.2.3.2.3. Error Messages .............................................. 20
5.2.4. Froac Paacl Boarcl . ___,................................................. zo
5.2.4.1. Display Exlcaded Tcst .................................................... 20
5.2.4.1.1. Scnap _ ................................................... 20
5.2.4.1.2. Opcr.- _ ................................................... 20
5.2.4.1.3. Error Mcsaapa .............................................. 21
5.2.4.2. Keyboard Exleaded Test ----.................................... 21
5.2.4.2.1. Setup ......_ .................................. 21
5.2.4.2.2. Operlliae - .................................................. . 21
5.2.4.2.3. Error Mcsaaps .............................................. 21
5.2.5. Exlcraal Sipals Tesc ...................................................... 21
5.2.5.1. Syuchronizcioa Sipala Exleadcd Test ........................ 21
5.2.5.1.1. Setup _ _................................................... 22

5.2.5.1.2. OpctMiae ._................................................. 22
5.2.5.1.3. Error M - . ............................................... 22
5.2.5.2. Exlcraal E11ea1 EJicwtcd Test ....................................... 23
SRIYisloa: 1.1 S
5.2.5.2.1. Setup ............................................................... .

5.2.5.2.2. Operation ....................................................... .
5.2.5.2.3. Error Message .............................................. .
5.2.6. GPIB Exlended Test Descriptions ................................................. .
5.2.6.1. GPIB Functional Test .................................................... .
5.2.6.1.1. Setup ............................................................... .
5.2.6.1.2. Operation ...................................................... ..
5.2.6.1.3. Error Message .............................................. .
5.2.6.2. GPIB Echo Extended Test .......................................... ..
5.2.6.2.1. Setup ................................................................ 2~
5.2.6.2.2. Operation ........................................................ 25
5.2.6.2.3. Error Message ............................................... 25
5.2.6.2.4. Obse~d Error Condition ........................... 25
5.2.6.3. GPIB Switches Extended Test ....................................... 25
5.2.6.3.1. Setup ................................................................ 26
5.2.6.3.2. Operation ........................................................ 26
5.2.6.3.3. Error Message ............................................... 26
5.2.6.3.4. Obse~d Enor Condition ........................... 26
5.2.7. MotorfV aiYe Driver Extended Tests ............................................. 26
5.2.7.1. Motor Driver Extended Test ......................................... 26
5.2. 7.1.1. Setup ................................................................

5.2.7.1.2. Operation ........................................................
5.2.7.1.3. Error Messages ..............................................
5.2.7.2. Valve Driver Extended Test ..........................................
5.2.7.2.1. Setup ................................................................
27
27
28
28
29
5.2.7.2.2. Operation ........................................................ 30
5.2.7.2.3. Error Messages .............................................. 30
5.2.7.2.4. Obse~d Error Conditions .......................... 31
5.2.8. Hydraulic System Extended Test .................................................... 31
5.2.8.1. Leak Test .......................................................................... 31
5.2.8.1.1. Setup ................................................................ 31
5.2.8.1.2. Operation ........................................................ 31
5.2.8.1.3. Error Messages .............................................. 32
5.2.8.1.4. Observed Error Conditions .......................... 33
5.2.9. Pump Calibration/MaioteiWlce functions ................................... 34
5.2.9.1. Extend Piston function .................................................. 34
5.2.9.1.1. Setup ----.............. 34
5.2.9.1.2. Operation -----............. 34
5.2.9.1.3. Error Messages .............................................. 34
5.2.9.2. Retrad Piston Fundion .................................................. 35
5.2.9.2.1. Setup ................................................................ 35
5.2.9.2.2. Operation ........................................................ 35

5.2.9.2.3. Error Messages .............................................. 35
5.2.10. Printer Extended Tests ................................................................... 35
-Ill Sltmsloa: 1.1 S

5.2.10.1. Printer Character Test ...................~ ..............................

5.2.10.1.1. Setup ............................................................. .
5.2.10.1.2. Operatioa ..................................................... .
5.2.10.1.3. Error Messaaa ...........................................
35
35
36
36

5.2.10.1.4. Observed Error Coaditioas ........................ 36
5.2.10.2. Printer Loopback Test .................................................. 37
5.2.10.2.1. Setup ............................................................. . 37
5.2.10.2.2. Operatioa ...................................................... 37
5.2.10.2.3. Error Mes.saacs ............................................ 37
6. Cbug Moaitor Mode ............................................................................................................. 39
6.1. Set-up for Cbug Moaitor .................................................................................... 39
6.2. Usiag Cbug ........................................................................................................... 39
7. Coldstart Moaitor Mode ..................................................................................................... . 40
7.1. Set-up for Coldstart Moaitor ..........----.................................................... .w
7.2. Coldstart Moaitor Results.-..............................................- ........................... 40
8. Tef'llliD,al Exl:ea.decl Mode -----------~ 41
8.1. Set-up for Tef'llliD,al Exteaded Mode ............................................................... 41
41
8~ Opcratioa ---------------------
9. Telediposrics Mode ------------------ 42
9.1. Set-up for TeledipOilia .................................................................................. 42
10. Coaaec:a:iaa A Serial Device ------------
43

Slmsloa: 1.1 S

1. Introduction
This document describes the diagnostics which are built-in to the 9010. It is intended as a reference
explaining bow the diagnostics work. It is also designed in such a way as to expedite the process ot
board repair. Using the step-by-step procedure outlined in the next section one can move quickl\
from a reported Coldstart Error to the specific area within the instrument where the fault is located.
The 9010 contains a self test performed at power up, background tests performed automatically while
the instrument is running. Extended Tests. and the Cbug monitor. This manual section offers a brid
description of types of diagnostics.
1.1. lbe Coldstart Test

When the instrument is turned on under normal circumstances, it performs an automatic self-test
called a Coldstart Test. After this self-test, it will "boot" the instrUment software, resulting in the ini-
tial "Power Recovered" display screen. When the instrument is configured to boot the instrument
software it is said to be in Normal Mo<U. It is possible to configure the instrument to skip the
Coldstart Test in a mode called Normal/No Cold.f'"rt. Additionally, it is possible to select a mode
whereby certain test data will be sent to a CRT ter.;....nal while the self test is running. This is knov. n
as Coldstart Monitor Mo<U.
Coldstart tests most of the 9010's functionality without disturbing the external environment in which it
is situated. This has two ramificatioas:
(1) No special precautioas need to be taken and no harm is caused to any device connected to
9010 when the Coldstart test is performed.
(2) Because some of the modules being tested interface to the enema! environment, the
Coldstart Test cannot perform a complete functional test of the instrUment. In order to com-
plete the test a second test type is used--the Extended Test.
1.%. Extended Tests

As stated above, the need for the Extended Test type arises from the fact that 9010 interfaces to an
external enviroa.ment. Completing a functional test disturbs and requires monitoring of the external
enviroa.ment. This caD only be done by way of human assistance. Thus the Extended Tests are a
suite of user-interactive tests. Tbia Muaual will direct the diaposer to select necessary Extended
Tests when he suspects that there is a problem with the instrument (or system of instruments). Some
tests require the diapolcr to effect s1iabl changes to the configuration but nothing too complex.
Most extended tests wiD loop indefillitcly (UDtil the user requests a stop), thus exercising the
hardware continuously. Tbia loopq feature is designed as a trouble-shooting aid.
The Extended Tests may be iDwked by the diagnoser ill various means, giving rise to submodes of
operation:
o A fronc panel illlerface allows the extended tests to be run ill what is called Front Panel
E:tunMd MoM. This is the basic operating mode for extended diagnostics, intended primarily
for usc by the end user (chromatographer). Using the front panel keyboard and display, the
user is presented with a scrollinl menu of tests from which to choose.
o A CRT Terminal may also be employt:ed ill running the extended tests in a mode called Ttmti-
nal Eztt!Ukd Mod6. Tbia mode is illlended for service and factory personneL
o F'J.Dally, Ttltdillgnostics Mod6 allows the extended tests to be run remotely via a phone connec-
tion. In all other respects this mode is identical to Terminal Extended Mode.
1.3. Cbua Monitor Mode

The standard Cbug hardware executive is also made available. It is intended for use by service and
fadory personnel only. Cbug reqiures the connection of a CRT terminal. Cbug operation is not
available ill T elediagnostics Mode.
$Revision: 1.1 S
1.4. SelecdDI Model ollastrumeat Opentloa

The user caD mlllipulate the DIP switch located oa the SBC and the front panel SELEcr key to
choose the desired operating mode for the iastrumeat. Whenever the power is turned on or the
Reset switch located on the edse of the SBC board is pressed, the 9010 rust probes the state of the

rust three positions on the switch marked as 54, thea checks the state of the SELEcr key on the
front panel key pad before deciding the proper course of actioa. Table 1 shows the switch seuing
and actioa the User must take to select the desired mode of operation. It also lists the section that
describes its operatioa in greater detail.
TABLE 1--MODES OF OPERATION

Switch S4
PositiDII
OM Two '17uw SELECTkq Moct. Section
Off Off Off Not Pressed Normal See User Manual

Off Oa N/A Not Pressed Normal/No Coldstart See User Manual
Oa Oa N/A Not Pressed Normal/No Coldstart See User Manual
Off Off Oa Not Pressed Coldstart Moailor 7
Oa Off N/A Not Pressed CbugMode 6
N/A N/A Off Pressed FroatPanel~aded s
N/A N/A Oa Pressed TenaiDal Exleaded 8
Telediaposrics mode is selected from Froat Panel Exteaded Mode. It is described in Section 9.
.z. SRmsloa: 1.1 S

9010 Oiapostics Description
z. Dlaposlaa tbe 9010

The diapostic procedure for the instrument consists of the foUov.i.ag sequence of steps:
(1)
(2)
Run Coldstlllf a detailed in Section 3.
If necessary, ins~ct the Powt' Supply a detailed in Section 4. This step is only necessary
when the Coldstart Test cannot execute. U Coldstart can execute then it will teU the Cser
what are the problems. The Power Supply inspection is used to isolate faults which prevent
the SBC from running to either the Power Supply or the SBC Board.
(3) U necessary, 1WI Extended Tests a detailed in Stcti011 5.
Sltlvislon: 1.1 S
9010 Diapostics Description
3. Tbe 9010 Coldstut Test
3.1. 9010 Coldstan Test ICerael

The Coldstart test is performed oa system power-up. Although it may be thought of as a single test,
it is in fact a number of tests which are performed in a spec:ifaed order. The ordering of these tests is
based oa the hierarchy of module dependence, and is necessary iA order to assure the integrity of the
test. This means that l~r order functions are tested r~rst before they are used to test higher order,
dependent functions. For example, the ADalogt~Digital Coa~ner is aot tested until the ADC
Timer has been functioaally verified. This techaique is known u 'kemel testing' and forms the basis
of the Coldstart Test. The attached Kemel Diagram shows the dependency of all the tests.
As a result of kernel testing, the errors reponed by Coldstart are always independent of one another.
I.e., if Coldstart reports three errors thea there are three faults in the i.Dstrumeat each of which will
require repair.
3.l. How tbe 9010 Reports Coldstut Errors

The results of the Coldstart Test are displa~d oa the Front Panel LCD Display at the completion of
the Coldstart Test and stored in the Rua Log for later references.
3.l.1. Errors Dlspla,ecl after Coldstut

While the Coldstart Test is fUJID.iDg the display will show 'Self Test'. After a period of twenty seconds
to a minute and a half. the unique error codes and messaps auociated with the various i.Dstrument
functions will be displa~d sequentially at a rate of about oae per second. After all errors (if any) are
displayed the display will tum off for oae second. If normal operation is seleded (with proper setting
of the dip switches) the LCD Display will remain off until the System Software takes command of the
i.Dstrumeat.
3.l.l. Colds~ Rua Lot Eatrles

If any faults were detected by Coldstart they will be placed iA the Rua Log as time-zero entries.
Each entry coasists of a texnaal messap ud a unique error code. It is the unique error code which
identifies where iA the iastnuDeat each fault is to be found. If DO errors were detected by Coldstart
thea aothias will be placed iA the error loi-
3.l.3. Coldstut LED DlsplaJ

Oa the edp of the SBC, tbcre are four LEDs labeled 000, 001, DG2, ud 003. Each LED will
tum oa ll dift'ereDl time duriaa the Coldswt Test after a set of tests are completed successfully.
When all foar LEDI are lit, that aaeau the Coldswt Test bas finished without a siagle fault. Each
of the foar LED represeDll a aroup of tests, ud the DIAG LED coiWilll iA Table 2 shows how each
test is icleatificcl by the LEDs. These LEDI are provided u u alteraate iD.clicatioa of where errors
ha~ occurred wbea the primary method of displayiq error mesup oa the &oat panel LCD is not
possible. Table 2 SUIIlmaries the sipificuc:e of the Diapostic l.EDs.
TABLE 2--MEANING OF THE DIAGNOmC LEOs

DIAG LED M11111ing
The ROMO, ROMl, and CPURAMSEG 1 tests ba~ passed. This represents

DGO
the minimum hardware required to carry oa with the remaiaiag
Coldstan Test or Extended Test.
SRemloa: 1.1 S
DIAGLED
DG1
TABLE 2MEANING OF THE DIAGNOSTIC LEOs
Mtaning
All the tests on the Front Panel Board have passed.
DG2 All the tests on the Motor-Valve-Driver Board have passed.
DG3 All the tests on all other hardware on the SBC, excluding ROMO,
ROM1, and CPURAMSEGl, have passed.
3.3. Interpretlna 9010 Coldstal1 Error Codes

The previous section explains how to obtain Coldstart Error Codes. This section provides the details
of the tests wbic:h generate those codes.
The Table 3 summarizes the tests performed by the Coldstart Test. One may iDdex iDto the table
usiDg the error c:ode. The Acronym column provides a symbolic abbreviation for cac:h function. The
Section column provides the section number that describes the test wbic:h generates the error code.
TABLE l--9010 COLDSTART ERRORS CROSS REFERENCE

Error DIAG
Cod4 Function Ac1011ym Stction Schematic LED
Rom Zero ROMO 3.4.1.1 SBC DGO

1 Rom Oae ROM1 3.4.1.1 SBC DGO
2 CPU RAM segment oae CPURAMSEG1 3.4.1.2 SBC DGO
3 CPU RAM segmeat zero CPURAMSEGO 3.4.1.2 SBC DG3
4 Rom Two ROM2 3.4.1.1 SBC DG3
s Rom Three ROM3 3.4.1.1 SBC DG3
6 Rom Four ROM4 3.4.1.1 SBC DG3
7 Rom Ftve ROMS 3.4.1.1 SBC DG3
8 Clear Vector Lcvel7 CLRIR07 3.4.1.3 SBC DG3
9 Clear Vector Level 6 CLRIRQ6 3.4.1.3 SBC DG3
10 Clear Vector Level S CLRIROS 3.4.1.3 SBC DG3
11 Clear Vector Level 4 CLRJR.Q4 3.4.1.3 SBC DG3
u Clear Vector Level 3 CLRJR.03 3.4.1.3 SBC DG3
13 Clear Vector Level 2 CLRJR.Q2 3.4.1.3 SBC DG3
14 Clear Vector Levell CLRJR.Ol 3.4.1.3 SBC DG3
1S Auto Vector Level Seven IR07 3.4.1.3 SBC DG3
16 Auto Vector Lewl Six IRQ6 3.4.1.3 SBC DG3
17 Auto Vector Lewl f"'tve IROS 3.4.1.3 SBC DG3
18 Auto Vector Lew~ Four IR04 3.4.1.3 SBC DG3
19 Auto Vector Lew~ Three IRQ3 3.4.1.3 SBC DG3
20 Auto Vector Level Two IRQ% 3.4.1.3 SBC DG3
21 Auto Vector Level Oae IRQl 3.4.1.3 SBC DG3
22 Interrupc Prioritizer IRQ PRJ 3.4.1.3 SBC DG3
23 CPU Positiw S Volt CPU P 1SV 3.4.4.1 SBC DG3
24 CPU NegatM: S Volt cru:N:lSV 3.4.4.1 SBC DG3
2S 68681 DUART SIO 3.4.1.4 SBC DG3
26 8253 pSOS T-.mcr THE PSOS TMJl 3.4.1.7 SBC DG3

27 8253 Motor Acceraltioa MTR:Acc:na 3.4.1.7 SBC DG3
SRevislon: 1.1 S
Error
Cod4
TABLE 3-9010 COLDSTART ERRORS CROSS REFERENCE
Furu:ti011 Acronym SectiOI'I Schematic

O[AG
LED

Timer
28 8253 Unused Timer UNUSED TMR 3.4.1.7 SBC DG3
29 8253 ADC Timer ADCTIMER 3.4.3.1 SBC DG3
30 Analog-to-Digital ADC 3.4.3.2 SBC DG3
Convener
31 Battery Dead BTRY DEAD 3.4.3.3 SBC DG3
32 8254 Rate Generator RATE GEN 3.4.2.2 SBC DG3
33 8253 CAM Positon CAM CNTR 3.4.21 SBC DG3
Counter
34 8253 Event Counter EVNT CNTR 3.4.2.1 SBC DG3
35 Diagnostic Multiplexer DIAG-MUX 3.4.1.6 SBC DG3
36 8253 Diagnsotic Timer DIAG-TIMER 3.4.1.7 SBC DG3
37 Proportioniq Valve A VAL~ A 3.4.2.3 SBC DG3
38 Proportioniq Valve B VALVE-S 3.4.2.3 SBC DG3
39 Proportioning Valve C VALVE-C 3.4.2.3 SBC DG3
40 Proportioniq VaJve D VALVE-D 3.4.2.3 SBC DG3
41 Valve State Machine VA SEQ 3.4.2.3 SBC DG3
42 8255 Programable P 8255 3.4.1.5 SBC DG3
Interface

43 front Panel Board FPB_PRES 3.4.6.1 FPB DG1
Presence
44 Liquid Crystal Display LCO_RAM 3.4.6.3 FPB DGl
RAM
45 8279 Keyboard Encoder KEYBD ENCODER 3.4.6.2 FPB DG1
46 Moter Valw Dmer MVD_PREs 3.4.5.1 MVD DG2
Board Presence
47 Motor Phase l's sip PHASEl SIGN 3.4.5.4 MVD DG2
48 Motor Phase 2's sip PHASE2-SIGN 3.4.5.4 MVD DG2
49 MVD Board SV Regulator MVDsV 3.4.5.2 MVD DG2
so MVD Board 1.5V Regulator MVD-lSV 3.4.5.2 MVD DG2
51 MVD Board ']f,V Regulator MVD-']f,V 3.4.5.2 MVD DG2
52 Motor DAC Oac Hip Rail DAClHI 3.4.5.3 MVD DG2
53 Motor DAC Oac Low Rail DACl-LOW 3.4.5.3 MVD DG2
54 Motor DAC Two Hip Rail DAC2-HI 3.4.5.3 MVD DG2
55 Mocor DAC Two Low Rail DAC2-LOW 3.4.5.3 MVD DG2
56 25KHz Motor Cock MTR CLK 3.4.5.5 MVD DG2
57 GPIB Expension Board GPIB-PRES 3.4.7.1 GPIB
Preseace
58 GPIB Board Dtack GPIBDTACK 3.4.7.2 GPIB
59 GPIB Board Bus Dl AD BUS 3.4.73 GPIB
60 8291AGPIB n.iat LsTNR 3.4.7.4 GPIB
Talker /Listener
61 Motor Top-Dead-Center MOTOR TDC 3.4.24 SBC DG3
62 Battery Low BTRY_LOW 3.4.3.3 SBC DG3

$Revision: 1.1 $
3.4. Detailed 9010 Colclstart Test DescrtptJoas
3.4.1. CPU Module Colclstart Test Descriptions
3.4.1.1. Rom Checksum Tests

This section desaibes the test for the functioa.s ROMO, ROMl, ROM2, ROM3, ROM4, and ROMS.
A checksum is generated for each rom. This sum is compared to a checksum stored in a table
located in roms one and two. For each rom, if the generated sum does not match the stored sum
and the stored sum is not zero, then an error is reported for that rom. The correspondence between
these faults and the roms is as foUows:
Varimt Product ROMP/N
ROMO Q3..91Q380.01
ROM1 ()3..910381..()1
ROM2 ()3..910382~1
ROM3 ()3..910383-01
ROM4 ()3..910384..()1
ROMS Q3..91038S-01
For Terminal Extended Mode and Coldstart Monitor Mode a shon repon consists of the checksum
generated and the checksum stored in ROM is outputed throop the serial port
Note: Any faulty .rom must be replaced before further testing; and in case of a tkad rom, the sys
tem will not be able to run any test at aU.
3.4.1.l. CPU Ram Test

This section desaibes the test for the function CPURAMSEGO and CPURAMSEG 1.
Each word of CPU ram .is read and stored in a regiSter within the 6am. The word is then comple-
mented, re-written, aDd read apiD. U the value read is DOC equal to the complement of the word
saved in the register, thell an error is reported. U DO error oc:aan, the oriainal value is written back
to the same locatioa in the memory. Tbea tbe memory word is read oace more to verify the original
content was restored. AD error is reported if the ~ fails. This test does DOt alter the stored
contents of the RAMs.
3.4.1.1. Interrupt Han1wuw Test

This seclioll describea the test for the functiona CLRIROl, CLRIRQ2, CLRIRQ3, CLRIRQ4,
CLRIRW, CLRIRQ6, CLIURQ7, IROl, IRQ2, IRQ3, IR04, IRQS, IRQ6, IRQ7, and INTPRI.
CLRIROl, CJUR02, CLIURQ3, CJUR04, CLRIRQS, CLRIRQ6, and CLRIRQ7 are dear inter-
rup( tests. Eaclt tat ia rapoasiblc for tcstina the illlerrup( lcYcl numbered in the name itself. The
tests involve issuina disable interrupt commuds to any clcvica aaacbed to tbe same or higher inter-
rupt levels being deared, 1owcrina tbe illlerrup( mask to the same leYel being tested, and verifying
that no inrerrup( is receiwcl U an interrup( does occur, the lest for that leYel is said to have failed.
IRQl, IRQ2, IR03, IR04, IRQS, IRQ6, and IRQ7 test the AUI~vector hardware located on the
CPU Board by means of Ill lnterrup( S&imulus Port. This port allows uy combination interrupts to
be assened and c1eare4 Beainnins with lewl seven, (the higbcst priority interrupl), each interrupt
line is assened. U DO illlerrup( is pnerated, then an error is reported for that interrupt and no
further interrupts are tested.
1 SReYisioa: 1.1 S
INTPRI tests the iDterrupt prioritizer. After each and all levels are tested successfully, then combina
tioos of iDterrupts are asserted with the Interrupt Stimulus Port. If the highest level asserted is not
serviced first thea an error is reported for the interrupt prioritizer.

3.4.1.4. Duart Tests
This sectioa desaibes the test for the fuactioos SIO, the DUART oa the 68681.
Each of the clwmels of the Dual Asynchroaous Receiver and Transmitter (DUART) are configured
in Local Loop Back mode. In this mode the 68681 will echo back to the processor any bytes output
ted to it without actually transm.ittiag them. This effectively tests the 'processor side' of the serial
connections without disturbiq instruments c:oD.Dected to the 9010. If either of the channels fails this
loop back test, thea an error is reported for that channeL
3.4.1.!. Prosrammable Interface Tests

This sectioa describes the teat for the fuactioa P_82S5, the Programmable Peripheral Interface dev-
ice.
The test begias by tryiag to clear aad disable all devices that have the same or higher interrupt level
that the 8255. U this fails, the test stops and reports a failure because it is highly unlikely that the test
oa the 8255 aad its supportiq circuit will return valid resuks.. The 8255 iaput buffer is cleared and
its output buffer full flag is set. WheD the interrupt mask of the 8255 is eaabled and the reading of
the 8255 status register iadic:ates a peadiag iaterrupt, the 8255 is said to be faulty. Next, the input
buffer aad the output buffer are maaipulated to test whether the status register caa produce the
proper iadicatioDS. f'mally, the iDterrupt prioritizer is eubled to test iaterrupts geaerated from the
8255. If ao iaterrupt is receiwd, or oace received aad u.aable to pt reset, the problem is very likely
to be located somewhere betweea the 8255 and the iDterrupt prioritizer.
3.4.1.4. Dlapostlc Multlplaer Tall

This sectioa describes the test for the fuactioa DIAG Ml1X, the multiplexer used to select the dif-
fereat sipa.ls that are evmiaed by the diapostic timef.
Two of the clwmels OD the multiplexer are connected respectively to the positive five volt, represent-
ing 1 logical oae, aad srOUDd. represeatiq a logical zero. U the readiap of the multiplexer show
these two clwmels are ill the SUDC Josica1 state, a fauk is reported aad the test is termiaated
immediately. Lastly, the test probea two additioaal chnls that are expected to produce c:omple-
meawy outputs to verify the fuactioa ol the multiplaer. Oaly wbea both parts of the test show
satisfactory results, thea the Dipa-ric Multiplexer is considered to be operatioaal.
3.4.1.7. n.... Tau

This sedioa describea the test for the fwactioa niE PSOS TIMER, MTR ACC .TMR,
UNUSED_TMR. aDd DIAG_TIMER. - - - -
The functkw THE PSOS TIMER, MTR ACC TMR. ud UNUSED TMR are wiped to the
three limen conriiw Widua a siDale- latef 82$3 Propammable -IDterval TUller chip, and
DIAG TIMER is illlplemellleel with oae of the timer ia IDid 8254. Sillce each timer bas 1 similar
set of ~en aDCl couaren ia citber 82$3 or ~ ud a similar set of supportiq circuitries, the
procedures to test each timer will be the same. Ia order to fully exercise a timer the foUowing tests
are used to examiae the timer itself aad its exrei"Dal c:ircuirria:
(1) iDterrupt status register test - the timer iaterrupt is cleared and disabled. If the status register
shows a peadias iaterrupt, this test will record a failare.
(2) iatenupt Oip-Oop test - this test iavolws cf.isablial 1M tiaaer, cleariag the timer interrupt, and
thea eubliq the iatenupt prioriti:zer. If aad illlcmapc il sensed, this teat will record 1 fail as
the result.
SRevtsioa: 1.1 S
(3) counter ac.c:essibility test with the timer disabled, this test writes ~d reads an internal re2'is
ter in the timer device with a number between OxOOOO and Oxffff. If the data resulted fr-;m
the read operation doesn't agree with the original value written into the register, a failure is
recorded.
( 4) enable counter to count test after the counter is properly initialized, the counter is enabled
to run for a short instance. After the timer is stopped, the internal value of the counter is
examined. If the value of the counter shows no change from the original value, a failure is
recorded for this test.
(5) toggling interrupt status register test for this test the timer is programmed to trigger an
interrupt. U the status register associated with this timer does not indicate an interrupt is
pending for this timer, this test will record test failed.
(6) timer generates uuerrupt test similar to the previous test. the timer is programmed to gen-
erate an interrupt. However, this test enables the interrupt prioritizer to verify that the inter
rupt received is from the timer being tested. If the verification fails, the test will report as
such.
(7) timer tolerance test in this test the timer is programmed to operate in the real application
mode and to generate an interrupt within a specific interval. While the timer is l'Ul1.Ding in the
background, a software timer is also numing in the foreground. This software timer will stop
as soon as the hardware timer generates an interrupt. If the tiDal count of the software timer
falls outside of the predetermined window, the test will interpel the timer is out of tolerance
and repons a fail u the result.
Each timer is tested independently of each other. A timer is considered operatioaal when aoae of
the above listed tests produce an error.
3.4..%. Pre-Drive Module Coldstart Test Descriptions
3.4..%.1. Coaater Testa

This section describes the tests for the fuactioas CAM_CNTR, aacl EVNT_ CNTR.
Two of the three timers/couaten iD u latel 8253 are dedicated to fuactioa as a CAM position
counter, CAM CNTR, aacl IS a CAM ~at counter, EVNT CNTR. The method used to test
THE_PSOS _TIMER, MTR_ACC_TMR, or the UNUSED_ TMR
is also applicable here in testing
these couaten. WbeD the CAM politiaa COUDter passes aD the tests described in Section 3.4.1.7,
CAM CNTR will record a PASS IS the result. ADd for the CAM ~at counter, it hu one more test
in addltioa to the tests iD Sedioa 3.4.L7. Tbe sapplemeat test exercises the coatrol circuit that can
directly triger a CAM eva~ iaterrupc. A tat failure for CAM_CNTR will be reponed if ao CAM
eveat iaterrupt cu be puerated with the maaipulatioa of the coatrol circuit or if it failed any of the
stated tests for the timer.
3.4.l.l. Rat8 Geaerator Test

This sectioa describca the tests for the fuactioa RATE_GEN.
The Rate Geaerator, RATE GEN, is formed by c:asc:adiaa two of the three 16 bits timers/counters
coataiaed within aa late! 8254. The similarities betweea the 8253 aad 8254 allow the tests for other
timers/counters be usc here iD testiaa the Rate Geaerator. All the tests ue same u those described
in Sectioa 3.4.L7 with oac minor difl'ereace. The exc:eptioa being that cucadiaa two timers/ counters
together elimiDates direct coatrol oa the most sipificaat couater, so the counter accessibility test is
performed oaly oa the least signi6caa counter. The Rate Geaerator is reported inoperative if any
failure is eacouatered from the tests.
.C). SRmsloa: 1.1 S

3.4.l.J. Valve Tests

This sectioa describes the tests for the fuDctioas VALVE A, VALVE 8, VALVE C, vALVE D.
and VA_SEQ. - - - -
The valve tests arc divided into two categories. the individual valve test ud the valve sequence test.

Their fuDctioas are to verify the proper working order of the state macb.ine that controls all the valve
activities.
The individual valve test, represeated by VALVE A, VALVE 8, VALVE C, ud VALVE 0, exam-
a
ines the outputs of the Valve State Macb.ine wbeii it receives valve commud. The individual valve
test begins with a commaad to dose all valves. This test will terminate ud report an error if the
state macb.ine indicates uy valve activities. After is is confirmed that all the valves are dosed a
request to open a valve is issued. Immediately following the commud the high current drive enable
signal ud the valve eaable control lines are monitored for proper duratioa. The test will stop and
report aD error it any deviation ouuide the acceptable limiu is detected. Next, after dosing all valves
again the same valve is opened once more. This is done to verify that no other valve is enabled con-
curreody. And when it is detected that more thaa one valve is active at any one time, the test will
record tlUs as a error. f"mally, the test will end and returD aD affirmation oa valve control if it can
successfully dose all the val~
VA_SEQ examines the actions of the Valve State Machine wbea multiple valve actions are requested,
specifically wbea two valves are opened ill sequence. The test beams by dosing all the valves, thea
one valve is opened. As soon as the opened valve reaches the steady holding state, a commud to
open a second valve is issued. At this time the duration required to dose the first valve is recorded
ud the three mmisecoads period requirement between dosing of one valve ud opeaiag of uother is
measured. The test will thea dose all the valves after the second valve reaches the holding state. A
positive result will be reported it all two-valves combillatioas caa complete the described action with
measurements relatias to the high current enable period, valve closing delay, ud the duration
between valve actions are all within toleruces.
3.4.l.4. Top Dead Cater Test

This section describes the test for the fuactioa MOTOR_TDC.
This circuit generates aa interrupt wbea the motor reaches the top dead center positioa. the follow-
ing tests are used to determillc the fuDaioaality of the Motor Top Dead Center circuit aad its sup-
porting logics:
(1) Clear laterrupta Tat a seria ol commaads are issued to dear aad disable aay devices capa-
ble of geaeratiaa aa interrupt thac has the same or bjgher priority thaa as the Motor_TDC.
With the interrupt mask set to matcb Motor_TDCs. the illtcrrupt bus is probed at the end of
the last disable c:omaad Allcl it aa interrupt is sensed the Motor_TDC test will be aborted
aad a fail result is reponccl.
(2) Stahll Reper Test the Motor_TDC interrupt statui register is checked with the
Motor_TDC iaterrupt remaiaiq disabled. A fail is recorded if the status register indicates u
interrupt peJldiaa.
(3) Interrupt F1ip-F1op Test the Oip-flop used to latcb the interrupt is eaabled while the motor
index circuit remaiaa disabled. Tbe test thea lower the interrupt mask to wrify that this flip-
flop remaiDs illactiw. The test will rcpon u error if the Oip-Oop show a peading interrupt.
(4) Togle Swus Register Test the Motor TDC illterrupt is artificially geaerated. The status
register is verified to show the pending interrupt. If this verificatioa fails the status register is

considered faulty aad aa error is recorded.
(5) TDC illterrupt test - for this test the index seasillg circuit aad the supporting logic are allowed
to function as a complete uait. The interrupt flip-flop is reset, aad a Motor_TDC interrupt is
introduced. The interrupt received must be the same assigned to the Motor_TDC and the
SRmsioa: 1.1 S
status register must also show the proper indication in order for this test to pass.
If any of the above tests produces a negative result, a fail result is recorded for function Motor_TDC.
3.4.3. Analog lnttrfac::e Module Coldstart Test Descriptions
3.4.3.1. ADC nmer Test

This section describes the test for the function ADCI1MER.
Since the output of this timer is used to initiate an analog-to-digital conversion cycle and cannot be
monitored, therefore the test here will be limited to the timer device itself. Three simple tests are
performed:
(1) Timer Accessibility Test after a value between OxOOOO and Oxffif is written into one of the
device's internal register, the same register is read. If the read operation returns a different
value an error is recorded.
(2) Enable Counter to Count Test the counter is allowed to operate for a short instance. If the
intensal value of the counter remains equal to the original value, the counter is reported as
inoperative.
(3) TUDer Tolerance Test the timer is allowed to run for a fJXed duration. After the timer is
stopped, its internal state is examined. WbeA the fiDal count of the timer is not within an
acceptable limits, a fault is recorded.
The ADCI'IMER will report a failure if any of the three tests produces 1 DCptM result.
3.4.3.l. Aaalog-to-Dlaftal Coaverter Test

This section describes the test for the functioa ADC.
At the end of a conversion cyde an interrupt is generated, therefore the analog-to-digital converter
and its supporting circuitries must be tested. The foUowiDg tests will accomplish the task:
(1) Clear Interrupts Test aU devic:a capable of geaeratiDg u interrupt that hu the same or
. higher priority thaD the ADC are disabled. With the interrupt mask set to match ADC's
priority, the illterrupt bus is probed. ADd if an interrupt is seasecl the ADC test will be
aborted and 1 fail result is reported.
(2) Clear Interrupt Tal tbia tal \Wifies the ability to clear and to disable the ADC interrupt
latch.
(3) Clear Status f181 Tal tbia tal loots for Ill iDactM: iDc:licatioa wbCD the ADC interrupt
latch is c:Jcared IDd disabled. .
( 4) Eaable Swus f1aa Tal the ADC interrupt latch is eaabled, and the ADC TUDer is pro-
lfllllllled to iaitiate 1 CODYCtSioD cyde. ~ 1 resuk the ADC interrupt swus flag must be set.
Tbis tal wiD record u error if the status flq remaias dear.
(S) Eaable latcrrupt Test - after the illterrupt prioritizer is eaabled and 1 coDYersioa cyde is
requested, if ao ADC iDtenupc is eacountered aa error is reported for this test.
(6) ADC Reference Voltage Test the whole aaalo&tCHfiaiW module is aUowed to fuactioa as a
unit. The ADC input mux is programmed for the chuael which provides 1 five volt static
input. If the value converted by the ADC for this c:haaael is aot wilhiD 1 tolerance of 500
mV, thea 1 error is reported.
The ADC module is said to be fuD.ctioaal if aoae of the tests listed show 1 failure.
-11 SRmsioa: 1.1 S

9010 Diapostlcs Description
3.4.3.3. BatterJ Tesa

This section deacribes the test for the functions BTR Y_LOW, BTR Y_DEAD.
Both tests utilize the analog-to-digital converter to measure the battery voltage. The only difference
being that each test uses different limits to determine the test result. The battery low, BTRY LOW,
uses 1.29 volt as the limit, and if battery voltage level falls below this limit the test ..Ju fail.
BTR Y_LOW serves as a wiU'1liq that the battery should be change at the earliest convenience. In
the battery dead test, BTRY DEAD, the limit is 1.24 volt. When BTRY DEAD fails the data stored
in the battery backup RAM Can oo loager be guaranteed and the battery-should be replaced immedi-
ately.
3.4.4. Power Supply Module Colclstart Test Descriptions
3.4.4.1. Replator Tests

This section describes the lest for the functions CPU_P_15V, and CPU_N_15V.
Both positM 15v and aegatiw 15v regulator status bits are examined. U the 'regulator okay' line for
a regulator is not asserted, thea an error is reported for that regulator.
3.4.5. Motor Vam Orne Board Colclstart Test Descrtptlou
3.4.5.1. Motor Vam Drift Board Prueace Test

This section describes the test for the function MVD_PRES.
As part of the sse_~ Board interface definition, a bit is assiped to indicate the presence of the
MVD Board. If this bit is not asserted, then a board presence error is reported.
3.4.5.%. MVD Board Pawer SappiJ Tall

This section describes the test for the functions MVD_SV, MVD_lSV, MVD_26V.
The S velt, 15 volt, and the 26 volt regulator status bits are examined. If the 'regulator okay' line for
a regulator is DOt asserted, thea 111 error is reported for tlw regulator. Ill addition, three leds are
provided on the MVD Board to pvc a Yisua1 indication on the status of the three regulaton.
3.4.5.3. Motor Drmr DAC Tall

This section dcscribea die tat for tbe fiiDCiioas DACl_IU, DACl_LOW, DAC2_HI, DAC2_LOW.
The tests oa the motor DACa are DOC ialeDdccl to be complete tests, only providiag a good confi
deace lew~ tbal the DACa are funcrioainl Each outpuc of the DACs is also CODDec:ted to a set of
companlall. DACa HI (wllae a Clll be 1 or 2) will be asserted when the output of DACn reaches
abcM a pre-de6aect hip limiL Silllilarly, DACD_LOW will be auened when the outpuc of DACa is
abcM a pea low limit. W'dla this ia aaiad uad with the rate pnerator set to a pre-defined constant
speed, a seria of pullel Clll be obserYed at boda DACD_HI and DACD_LOW outpUlL The pulse
widths of the rectaqu1u wa~ produced at these outpucs are measured, ud if these measurements
are DOt within specific:atioa u error is reported.
3.4.5.4. Motor Driftl' Phase Tall

This section describes the test for the functions PHASE1_SIGN, PHASE2_SIGN.
The current through the motor is coauoUed by two functions-a sine and a cosine function. Both
magnitude and sip portions of these functions are stored in PROM. ADd wbea the rate generator is
set to I'WI at a constat speed, the outputs of the sip bit associated with both the sine and cosine
function will produce a square wa~. Here ill these tests the rate generator is programmed to a pre-
SRmsloa: 1.1 S
defmed speed and measure the pulse width of the square waves. If the measurements are beyond the
acceptable limits an error is reported.
3.4.5.5. Motor Clock Test

This section desaibes the test for the function MTR_CLIC.
The state of the motor clock line is sampled. The test terminates and reports an error if no traasac
tioa is detected. Otherwise the pulse width of the motor clock is measured, and the measurements
must be within tolerance to produce a passing result.
3.4.6. Front Panel Board Coldstart Test Descriptions
3.4.6.1. Front Panel Board Presence Test

This section desaibes the test for function FPB_PRES.
As part of the interface defmitioa between the SBC and the Front Panel Board, a bit is assigned to
indicate the presence of the FPB Board. If this bit is aot asserted; thea a board presence error is
reported.
3.4.6.l. Keyboard Encoder Test

This section desaibes the test for function KYBD_ENCODER.
lbere are ei&bt bytes of RAM located witbill the IDtel 8219. 11ae 8219, Programmable
Keyboard/Display Interface, is used to sease and encode the key pad located oa the Front Panel.
The RAM portion of the device is used to test the device indirectly. A pattern is written into the
RAM. and if readiaa the RAM Pel a different pattern aa error is reported. A total of three pat-
teras are used in this test.
3.4.6.3. Uquld.CrystaiDispla)' RAM Test

This sectio~ desaibes the test for fuactioa LCD_RAM.
Every byte in the LCD RAM is filled with the ha word SS. Thea every byte is read. If it is other
than the what wu written into the RAM. aa error is reported. 1be same procedure is repeated for
ha word AA. ba word 00. and ba word FF.
3.4.6.4. Froat Paael LED Tilt

This section describes the test for fuactioa fPB _LED.
This test requires the aiel of the user. All the LED's are Oasbed and the user will have to identify the
faulty LED. No mesup is paeratecl for this test.
3.4.7. GPIB Ezpaasl Board Coldstart Test DescrlptiODI

This module iadudes the GPIB board, and the GPIB cable assembly from the SBC to the Expansion
Board.
Because the IEEE-488 SWldard specifies that aa unaddressed iasuumeat oa the bus must remain
completely passM. aot much caa be done in the way of testiaa this board duria& coldstart. Most of
the testiaa of this module is placed ill its beaded Test in which the User is directed to discoaaect
the iasuumeat from the GPIB Bus. The Coldstart Test for the module establisbs a reasonable level
of coa(ldeace in the module at power-up. With the PPI, a ProsriiDlaable Peripheral Interface, added
for the extended test, the processor caa monitor the GPIB and verify the illput to the Intel 8291A
Talker /Listener IC.
13- Slmsloa: 1.1 S

3.4.7.1. GPIB Espusloa Board Presea~ Test

This sec:tioa describes the test for fuactioa GPIB_PRES.
As part of the interface defulitioa between the SBC and the GPIB Expansion Board, a bit is assigned
to indicate the presence of the GPIB Board. If this bit is not asserted, thea a board presence error is
recorded. However, the result is not reported since failure of this test is an indication that the GPIB

option is not installed.
3.4.7.l. GPIB Expaasioa Board Dtack Test

This section describes the test for the fuactioa GPIBDTACK.
The Dtack hardware for this board is exerc:ised by a small set of read and write operations. If the
board fails to produce any of its required Dtacks, thea an error is reported.
3.4.7.3. GPIB Expaasioa Board Bus Test

This sectioa describes the test for fuactioa DT_AD_BUS.
A special pon is added to the. board to facilitate the testiag of the address and data busses. When
this port is read, the states of the lowest 8 bits of the address of the curreat operatioa is returned.
The bus test executes 256 read operatioas with a uaique pattera oa the lowest 8 bit address bus.
Thus all possible c:ombiDatioas are tested. If any oae of the pattera is missiDg. an error is reported.
3.4.7.4. I%91A Talker/Usteaer Test

This sectioa describes the test for fuactioa TLKR_LSTNR.
The latel 8291A caa DOt be fully tested without di.sturbiaa other deYic:es c:oaaected to the GPIB. This
test will oaly write ad read some of tbe iateraal rqistm oa the 8291A, leaviaa the actual complete
fuactioaal testiq to be doae ill the Exteadecl Tesc Mode. If a differeat data pattena is read from the
same register immediately followiq a write operatioa to the register, a fault is reponed.
SRmsloa: 1.1 S

4. laspecdaa tbe Power Supply

The 9010 Power Supply is u studard produd offered by Power-One ud bas DO visual indication on
uy of its outputs. This sectioa details a muual inspection which determines if the five volt portion
of the Power Supply is worldq or Dot.
This inspection is undertaken in order to isolate a fault to either the CPU Board or the Power Supply
and must be performed whenever the Coldstart Test will Dot execute:
(1) TW'D the power off.
(2) Remove the top cover of the instrument.
(3) Discoanect the Power Supply from the SBC Board.
(4) TW'D oa the power.
(5) Use a volt meter to measure the five volt portioa of the Power Supply to make sure that it is
DOl below 4. 75VDC and Dot higher tbu 5.2SVDC. If the volt meter shows the five volt sup
ply withiD specificatioa thea there are DO problems in the Power Supply and Coldstart should
ruo. If Coldstart will aot ruo thea the problem is oa the CPU Board. cat eXIead.me
/
SReYisioa: 1.1 S
5. Extended Mode
A messap. EXTENDED MODE, appears oa the display to iDdic:ate the instrumeat has entered
this mode of operatioa. Ia this mode the user caD step thru the test meau and select a test with the
keyboard on the !roat of the instrwDeat, and the result of the test is display oa the LCD Display.
The tests provided here are to supplemeat the Coldstart Tests, and a more detailed descriptioa on

each test is givea iD the nell! sectioa. These tests are desigaed to improve the instrUment's reliability
and to help isolate faults wbea they arise.
The foUow hardwares must be fuDctioaal iD order for the system to operate correctly ia the Extended
Mode:
(1) ROMl and ROM2
(2) RAMs iD bank 2
(3) The !roat panel and the LCD display
5.1. Selecdq the Extended Tesll

With the limited LCD display, oaly one eatry from the Test Menu is Showa at a time. However, the
user c:an use the PREVIOUS LINE and the NEXT LINE keys to scroD thru the whole meau. When
the desired test appears oa the display, the START key is used to begia the test. Most of the tests
are repeated iDdefiaitely. The STOP key is used to terminate a test, and iD some cases the test is
exited when an error occurs. To miaimize coafusioa, iD the Exleaded Mode, audio respoases are
givea wbea valid keys are pressed; all other keys that do not beep have ao sigaific:aDt meanings. A
help display is provided by pressiaa the STATUS key.
STATUS
START
TABLE 4-KEY DEFINITIONS
A.ctiott
display help messages

Begia test

STOP TermiDate test
PREVIOUS UNE scroD backward to the previous entry
NEXTUNE scroD forward to the next entry
INCREASE incremeat parameter value within a test
DEcREAsE dec:remnet parameter value within a test
The INCREASE and DECREASE keys may DOC be used ia all the tests.
5.l.l. Instrument LCJ1 Malalellaace

The lastrumeat Log Maiateaance opdoa provides a way for Field Service and the instrument user to
check oa the health of the iastrumenL Within the Battery-Backed-Up RAM of the instrument, a
number of locatioas have beea set aside for the logging of certain faults and events that occur during
iastrumeat operatioa. By recordiDg the aumber of occurrences of each fault/eveat, the health and

status of the instrument c:an be determined. The items that are currently logged include:
Sletslon: 1.1 S
/nsti'Ument Log Contents
o Lamp Hours/Pump Strokes

o All Coldstart Faults
o All Rua Time Faults
The Log Maintenance Option has two modes of operation. The rlfSt, User Mode, allows the user to
check-on the Lamp Hours and Lamp Intensity (9050) or Pump Strokes (9010). Additionally, the
Pump Strokes may be reset &om here in the 9010. The user should reset this value whenever the
Pump Seals are replaced. ID this way he can track the usage of these consumable items.
The second mode, Field Service Mode, is inteaded for Field Service PersoDDel use and provides an
expanded list of logged items. While in Field Service Mode the operator can display and modify all
of the above-mentioned items. He may &JobaUy reset ALL entries to zero, reset them individually, or
set them to a particular quaatity.
It is intended that individualiDsuumeat Fault Loi Entries are reset to zero after correaive mainte
aance is performed oa the subsystem or component that generated the faulL Ia this way, the effec-
tiveness of a particular fix can be verified.
5.2.1.1. Setup
No setup is required or applicable for this option.
5.2.1.2. Opentloa
5.2.1.2.1. UserMode Opendoa
When eateriag the tog MaiateDaDce Optioa, User Mode is iD effect. User mode simply displays the
Lamp Hours/Lamp IDteDSicy/Pump Strokes aad pea the user the opponUDity to reset the value to
zero (9010 oaly). This would aormllly be doae after chnaing the Pump Seals. There is another
Extended Test in the 9050 to resec Lamp Hours aad IDteasity. The foUowiag outliaes the User Mode
fuaaioaalicy:
. 11UI1'UifNIIt LDf Nllinlllulnce User MoM F1111cdotu
Key Action
RESET Reset Current Entry to 0

STA11JS Displays Staadard Help
STOP Exit Loa ~inteaance
After prcuiaa RESET, a message is displayed, aMal the user the choice to contiDue with the opera-
tioa by preuiaa RESET apiD or abortiaa the reset by Pressias STOP.
5.2.1.2~ 1'11141 Senlce M. . ()plntl

After emeriaa the LCJI MaiateDaDCC Optioa iD User Mode, FJeld Service Penoaael may switch to
Faeld Service Mode by pressiDa the LOCAL key three times coasecutMly. Ia aa attempt to conceal
Faeld Service Mode, the keyboard beeper is aot activated wbeD pressiaa the LOCAL key. Fault
Eauia represea~ the cumulatM sum of detected faults siDce the last time the IDsrrullleDl Loi was
reseL When Fault Entries are displayed, their descriptioa is foDowed with their two diait Fault Code
(ia brackets). This Fault Code is the same oae displayed iD the IDStruiDeat Error LCJI. F"aeld Service
Mode bas the followiDg lllldUioNIJ fuactioaalicy (beyond User Mode):
17 SleYislon: 1.1 S
Key
lnstrum~nt
-----------
NEXT LINE
Log MainttnQIIc Fi~ld Suvice MOO. Functions
Action
-
S c r o 1 1 to Next Log En t r y

PREViOUS LINE Scroll to Previous Entry
ACTIVATE- ( 3) Reset ALL Entries to 0
INCREASE Increment Log Entry
DECREASE Decrement Log Entry
The NEXT_UNE/PREVlOUS_UNE keys are used to scroll through the different Log Entries. The
ACI'IVATE key, when pressed three times coasecutively, will c:ause a message to be displayed that
gives the user the choice of continuing with the reset of ALL of the Log Entries by pressing RESET
or aborting the reset by pressing STOP. This is useful for initializing the instrument after manufac-
ture or alter losing Battery Backed-Up RAM. Tbe INCREASE/DECREASE keys allow Field Ser-
vice to set a specific value in an entry. This is useful for restoring a logged value to its original level
alter forcing a particular test to fail (or after losing battery backed-up RAM). Each Log Entry has a
different increment value (for the INCREASE/DECREASE keys) u described below:
Log Entry lncmnmu
Log Entry Increment
Pump Strokes 10000

s

Lamp Hours
. All others 1
For the Pump Strokes and Lamp Hours, the increment values are on the order of a day's usage.
When (iD/de)crementiag. these values will roD CM:r from/to their Absolute Maximum Values.
5.l.l. Coldstart Dlaposdc

The Coldstart Diapostic executes all the coldstart tests iD the same ma.a.ner as described iD section
2.1, Coldstart Test KerneL Unlike the Coldstart Test where after oae pass the control is transferred
to the System Software. here the same tests are repeated until the user presses the STOP key toter-
minate testing at the cad of the current pua. The Coldswt Diapostic is a flexible way to run
Coldstart Test without baWl& to reset the iastrumeDL
5.l.l.1. Setup
No special setup is required for this tea because all co&dswt tests do not disturb any extemal device.
5.l.l.l. ()pend
After this tal is selectecl from the Exzended Meaa. aD foar diapostic LEDs are turned off. a "Self
Test messap appears OD the display ud coldstart tests an CICC:Uled iD the order defiDed iD the ker-
neL At the cad of one pus the screea will so bluk for a sccoad before bep)naiag another pass. If
error is detected by any of the coldstart tests. the appropriale error message will be displayed and
testing is terminated. lA the event of multiple failures aD cnor messages are scrolled on the display
and testiDg is stopped with the last error message remiaina on the LCD display. Another way to
stop testing is to press the STOP key.
5.l.l.3. Error Messqe
No error message is generated except those resulted frota uy coldstart test railures.
11- Sltmsioa: 1.1 S

!.2.3. CPV Module
!.2.3.1. ROM Estended Test

The purpose of the ROM Elaended Test is to verify the iDtegrity of the data stored iD the ROMs.
This test is particularly useful when trying to isolate intermineDt problems. This test, designed to run
without supervisioa, will stop on the fli'St error encountered or by pressing the STOP key.
!.2.3.1.1. Setup
The ROM Elaeaded Test requires no special setup. However, the designated ROM should be prop-
erly inserted iDto the appropriate socket.
!.2.3.1.2. Operation
Once the ROM Extended Test is selected from the Exleaded Menu a check sum test is performed on
each aad every ROM. A checksum is generated for each rom. This sum is compared to a checksum
stored in a table located iD roms one aad two. For each rom, if the generated sum does not match
the stored sum aad the stored sum is not zero, then aa error message stating the faulty rom is
displayed aad further testing is halted; otherwise a -rest Passed message for that rom is displayed
aad testing is proceeded to the next rom. After all the roms are tested, the same procedure is
repeated begia.aiDg with the fii'Sl rom. Uno er : is e'Yer encountered the testing will continue indc
flllitely. The user caa stop the test aay time by pressing the STOP key.
5.2.3.1.3. Error Messaps
One of the foUCJWiaa error messages is generated depead.iq Oil which rom failed the check sum test:
(1) ROM Btlllk 0-Hi B)* Tut FtliltL

(2) ROM Btlllk 0-l.Dw Byt Tut FtliJ.tL
(3) ROM BII1IJc 1-Hi ByM Tat FMIL
(4) ROM BII1IJc 1LDw ByM Tat FtliW.
(5) ROM BII1IJc 2-Hi ByM Tat FMIL
(6) .ROM Bllllk 2-LDw Byte Tat FMIL
5.2.3.2. RAM Elleaded Test

ReteadoD of aD dala ia die t.aery backed up RAM necessitates the implementation of a non
desuuc:tM test IDd lilllila the ways the RAM ca be tested. Tile purpose of this test is to catch any
dynamic error that may DOC be detected ill the Coldslan Test.
5.l.J.l.l. Setap
The RAM Elladed Test requires DO special setup. HOM'Yel', bank 0 sockets should be occupied
with 16K Sialic RAM cleW:a. and bank 2 with 64K de\'ices.
5.2.3.2.2. ()plndGa
The RAM are tested with the Coldstart RAM test ill an endless loop until the user teUs it to stop by
press the STOP key, or UDiil aa error resulted from the test. Eacb word of CPU ram is read and
stored ill a rqister widliD the 68000. Tile word is thea complemented, re-written, aad read again. If
the value read is DOC equal to the complement of the word saftd ill the repter, then an error is
reported. U DO error occun, the oripw value is written back to the same location ill the memory.
Thea the memory word ia read oace more to verify the oriaiDal CODCent wu restored. AD error is
reported if the verific:adoD fails. Wbea error oc:cun an error manp spec:ifyiDa the faulty RAM
device(s) is displayed and further testias is halted; otherwise a -rest Pused messap for that bank of
RAM is displayed and testing is proceeded to the next bank. After all the RAMs are tested, the
same procedure is repeated begiDDiag with bank 0. U no error ia C'Yef eDcouatered the testing will
SleYtsloa: 1.1 S
continue indefulitely. The user caa stop the test any time by pressing the STOP key. This is a non
destrUctive RAM test.
S.Z.J.l.J. Error Messaps
Ooe of the following error messages is generated depending oo which is the faulty device:

(1) RAM BANK 0: Ewtn Byt Faild.
(2) RAM BANK 0: Odd Syt FaiWL
(3) RAM BANK 0: Evn ~ Fail~d, Odd Syt Fail~d.
(4) RAM BANK 2: EV~t~ Syt Faild.
(S) RAM BANK 2: Odd Syt Faild.
(6) RAM BANK 2: Ewtn Byt Faild, Odd Byt~ Fail~d.
Note: Error message for RAM BUlk 2 may oot appear if the damages on the RAMs i.a Bank 2
are too exteosive.
5.2.4. Froat Puel Board
5.2.4.1. DlsplaJ Emaded Test

The LCD Display ucl tbc LEDs, which pe visual indic:atioas oa the iatenaal workiq condition of
the iasuument, are located on the Front Paael aad oot fully self testecl dlll'iq Coldstan. Thus, the
Display Extended Test is provided to the user to identify a faulty LCD display or aay broken LEO .
During Coldstart, the LCD-RAM test verit-.es the fuac:tioDality of an the intenaal RAM contained
with the LCD Display. However, the display elements aad tbc character ROM remaia untested. The
maay test patreras shOWD oa the LCD let the user determiae the iategrity of the display elements aad
the character ROM.
The LED must also be veriraed with the aid of the user, because a faulty LED caa provide much

disinformatioa about the iasuumeat. Alter scrolliag thru all the display test paaeras oa the LCD,
the LED are flashed oae at time allowias the user to ideatify the faulty LED.
5.%.4.1.1. Setup
The Display Exleaded Tat requires ao special setup. Please adjust the LCD Display iateasity so that
each character is clearly lqible. H~, il sbou1cl be aotecl that aa erroaeous LCD_RAM test will
make the display test iDcoDclusiw.
5.%.4.1.%. Opend
~ the Display Exleaded Tat is selected from the Extended Meau, the followiD& sequence of event
will appear:
(1) Tbc READY IIMI RUNNING LEOs are oa, aad so is ewry pixel oa tbe LCD Display. The
display is shifted UDti1 "Variaa LC Display Test'" is shOWil ia the ccater of the first liae.
(2) All audio beep is souad to iaclicate tat paneras oa the display are to follow. The READY
aad RUNNING LEDs remaia OIL Two liaes, oae 11 the top aad the other II the bottom of
the display, appear oa the LCD Display. They bcgiD to scroll, the top liae on a downward
motioa ucl the bottom liae toward the top, until they reach the opposite end.
(3) The READY ucl RUNNING LEDs remaia oa. Forty venical bars are shown on the LCD
Display. The odd aad ewa columas are shifted to the left aad to the right, in the opposition
directioa.
SReftsloa: 1.1 S
(4)
(5)
The READY and RUNNINQ LEOs remain on. A blank LCD Display appears momentary.
Then valid ASCD characters are shifted in oo both lioes, ooe character at a time from the
right hand side of the display until the last ASCII character is displayed at the right most posi-
tion on the saecn.
An audio beep is sound to indicate LED display patterns arc to follow, and the message
"Varian LC LED Test" also appears centered oo the first lioe. Every LED, except the
POWER indicator, is oow turned off. Then begi.nniq with NOT READY, each LED is
turned on and off once. The order of testing the LED is always from top to bottom, from left
to right. After the last LED on the Front Panel is tested, all LED and the LCD back light
arc turned oo and off once more. The LCD back light is turned bac:k on, and the audio beep
is also heard in the same process. This test pattern for the LED is repeated one time.
(6) The message "Varian LC Display Test" appears centered oo the r1rst lioc with NOT READY
being the ooJy LED lit. The LCD Display is then rUled from both end of the display. When
the whole display is rilled with the message DO longer visible, the Display Test is completed.
5.%.4.1.3. Error Messqes
No special error message is generated for this test.
5.l.4.l. Keyboard Extended Test

During Coldstan only the presence of the 82'79 is sensed, leaving its function untested. The Key-
board Extended Test ia provided as a mean to ~rily the key encodina mechanism, which includes the
membrue switches, the abiliry of the 82'79 to scaD the keys properly, and the ability to generate
repeating INCREASE and DECREASE keys, etc.
5.l.4.l.1. Setup
The Keyboard Extended Test requires no special setup.
5.l.4.l.l. Operatloa
When tbe Keyboard Extended Test is selected from Extended Menu tbe following message is
appeared oa the display:
Keyboard Test:
Press any key
As keys ue preued by tbe aser, mes11gea iDdic:atiDg which key was pressed will appear oo the
display. For example,. if STAnJS key is pressed, the following message is displayed:
Keyboard Test :
STAnJS key preuccl
When tbe STOP key is preued, three seconds later the test ia tel'1Dinaled.
5.l.4.l.3. lnw Mesnr
No spec:W error mesuae ia pnerated for this test.
5.l.J. ExteruJ Slpals Tat
5.%.$.1. Syacbroalzadoa Slpals Extended Test
The purpose of the Syachroaizatioa Sipals Extended Tests is to wrily proper operation of each indi-
vidual sigaal independent of any exlernal iDstrument The sipals used to communicate with other
iDstrumeots are READY ENABLE, READY, START, ud FAULT. To test these lioes the
SRmsiOD: 1.1 S

9010 Dlapostics Description
instrumeDt is asked to scad the sigaals back to itself. If the instrumeat is successful iD commuaicat
iDg with itself, it should have no difficultic,;s sending and receiviag the sipal from other instruments.
!.2~.1.1. Setup
These tests require that the sync sigaals are loop back to the instrument itself. FoUow the steps
below before selecting a test:
(1) DiscoDDect all sync: sig:aals with other instrumears wbile both input and output cable is stiU
attached to the instrumeat.
(2) CoDDect the output sipa1 to correspoadiq iaput, i.e. FAULT IN to FAULT OUT, START
IN to START OUT, etc.
(3) Select the test.
!.2~.1.2. Opentloa
There are four tests relatiq to the Syuchrollizatioa Sipals, Ftm/1 Signllls Tat for the FAULT IN and
FAULT OUT sipals, R~tldy Signllls Test for the Ready IN and Ready OUT sipals, Stlllf Signllls Test
for the Start IN and Start OUT sipals, and Retldy Enllb/4 Test for t:he READY ENABLE IN and
READY ENABLE OUT sipals.
Once a test is selected, a title with the aame of the sipa)s being tested is shOWD oa the fust line, and
the result of the test is displayed oa the secoad line. The test togles the output aad monitoring the
input for the correct respoase. Either a message explainiJas the type of fault detected or a pass
message is showa depeadias oa the test result. This message is updated at the ead of the test, aad
the test is applied coatilluously UDtil the STOP key is pressed. As 111 illdicatioll of coatilluous execu
tioa of the test, a set of Duhial sran appears at the ead of the result message.
!.2~.1.3. Error Mesuae
For the foUowiq message, "rd caD be replaced with READY SGNL. READY SGNL aeg. edge,
READY SGNL pos. edp, FAULT SGNL, or START SGNL:
(1) READY ENABLE discOMWl. This messap meaDS that assertiq READY ENABLE OUT
has ao affect oa READY ENABLE IN. Verify the cables are properly coDDected and

obsene the test result apiL If the result remaias the same, check coatinuity of the cables
before repeatinl the test. If the test fails ill the same maDDer, check both the output and
iaput circuit.
(2) .a::r: UNCLEAR. INTERRUPTS. DuriJia testinl other iaterrupt(s) is seased aad caDDot be
disabled, readeriaa funber testiDa impouiblc. Use Coldstart to pinpoial the problem before
returllial to f'.llelldecl Mode.
(3) .a::r: LOCK STA7VS REG. The interrupt status register for the sipal is set at aU times aad
gives a false interrupt status. If the ~e failure is seea alter discollllCctilll the cables, check
the input sectioa; otherwise, check the output sectioa.
(4) .a::r : LOCK INT. FfF. This error message meaDS that the interrupt latch ill the input signal
circuilry is set uacl aerates a fictitious interrupt as sooa as it is eaabled. If the same failure
is 5cea after disc:oallec:tin the cables, check the iaput sectioa; otherwise check the output sig
aaL
(S) .a::r: NO INTERRUPT. No ialerrupt is detected despite the fact that the output signal is
beilll toggled. Verify the cables are properly CODDected aad obsene the test result apia. If
the result rcmaias the same, check coatiauity of the cables before repeatin1 the test. If the
test srlll fails ill the same maDDer, check both the output aad input circuit.
(6) .a::r: NO STATUS REG. All iatcrrupt is detedcd, but the status register is not giving a
proper illdicatioa. If ao other device is assigned to the same interrupt level, check the input
signal status register.
SRmlloa: 1.1 S
(7)
(8)
.x=: WRONG INTERRUPT. A higher priority interrupt is detected and masks out interrupt
from the syac sipal. Identify the source by rwmiD& Coldstart or nmning Extended Test on
devices that have a higher priority level
READY SGNL : INPUT LEVEL The logical level of the READY_IN signal is sensed while
toggling READY_OUT. There are several possible errors associated with this error message:
(a) no change in READY_IN despite R.EADY_OUT is being togled, (b) an incorrect polar
ity in READY IN in response to READY OUT, or (c) a glitch iD either the READY IN
section or the READY_OUT circuit. - -
5.l.5.l. Extenal Eveat Extended Test

The purpose of the Exleraal Eveat Extended Test is to verify operation of the relays located on the
back of the iastru.ment. The test solicits the aid of the user to check the continuity of each relay to
determine the workiDs condition of the individual oae.
5.l.5.l.l. Setup
The user should have ID ohm-meter haady aad all the relays oa the instrument should be discon
nected before proceeding with the test.
5.Z.5.Z.Z. Opentloa
As. the lest is seleded, the relays are dosed ud the user is asked to check the continuity of the relays
with the ohm-meter by the followiq message:
Closed aD relays. Check coatiauicy.
Press uy key to continue:

After a key is pressed, the user is apia asked to check the contiDuity by this message:
Opened all relays. Check for open.

Press STOP to retuna to MAIN MENU.
5.l.5.l.3. Error Mesuae
No error message is paerated for tbia test.
5.2.6. GPIB I"Mded Til& Dllcrlpdolll
5.Z.6.1. GPIB FDDdloal Til&

The GPIB baa bu a ser of16 sipaJ liDcs, 8 data IDd 8 control The test here is desiped to test the
openliala of the late18291A, GPIB Talker/Listener, ud the bus clrMrs. Ia this case, the 8255 Pro-
grammable Peripberallalerfacc is used u both the GPIB Controller IDd tbe bus monitor to verify
the fanc:daa of die GPIB Exptnsioa Board. ADd ill order to properly test the fullctioaality of all 16
of the sipa1 &-. a "'Caaee ~ tal is illlplcmeated. AD of the GPIB primitive fuactioas,
such u the Atteadoa PUDdioa, Senice Requat PUDCtioa, Liscca PUildioa, Talk PIIDCtioD, etc., are
tested ill the order based upoa their clcpeadeac:ies so that a code dcscribiaa the result of the test is
retunaed. A message is pnerated for each retuna code whether it is a aood result or ID error
detected.
5.l.6.1.1. Setup
Because the IEEE-488 staDdard speafies that au unaddressed iascrumeat oa the bus must remain
completely pusiw aad duriag testiaa the 82.55 usumes the role of a bus CODtroller, the instrument
UDder test should be discoaaccted from the GPIB bus. Please discoDDect the iasuument from the
GPIB bus before selectiaa the GPIB Test.
Sltmsloa: 1.1 S
S.l.6.1.l. Opend011
After selectiq the "GPIB Test" from the Extended Menu, a message indicating that the instrument is
now performiaa the GPIB Test appears on the firSt display line. Another message showing the result
from the continuous testing is displayed on the second line. This test will only terminate with the

STOP key.
5..%.6.1.3. EJTOr Messqe
The foUowing message is generated ii error is encountered:
(1) GPIB BOtUd is not p~Ystnt As part of the interface defmition a bit is assigned to indicate the
presence of the GPIB expansion board. This test examines the board present bit before
proceeding on with the test. If this message appears iastaU the GPIB Board before retrying.
If this error is seen when the GPIB Board is properly coanected. check the buffer on the
sse.
(2) 8291.A INTERRUPT. An error is detected during an interrupt cyde generated by the Intel
8291A GPIB Talker/Listener.
(3) DIO IN UNES. An operational error is detected in the GPIB Data Input Lines(DIOl
DI08).
( 4) EO/ IN UNE. An operational error is detected in the GPIB EOI(End or Identify) Input
Line.
(S) GPIB REN UNE. An operational error is detected in the GPIB REN(Remote Enable) Line.
(6) GPIB SRQ UNE. An operational error is detected in the GPIB SRO(Service Request) Line.
(7) 8291.A. An operatioaal error is detected in the lntel8291A GPIB Talker/Listener.
(8) D/0 OUT UNES. An operatioaal error is detected in the GPIB Data Output Lines(DI01
DI08).
(9) EO/ OUT UNE. An operational error is detected in the GPIB EOI(End or Identify) Output
Line.
(10) IFC UNE. An operatioaal error is detected in the GPIB(Iaterface Clear) Line.
(11) DAV UNE. An operatioaal error is detected in the GPIB DAV(Data Valid) Line.
(U) NDAC UNE. AD operatioaal error is detected in the GPIB NDAC(Not Data Accepted)
Line.
(13) NRFD UNE. An operatioaal error is detected in the GPIB NRFD(Not Ready for Data)
Line.
(14) ATN UNE. An operatioaal error is detected in the GPIB ATN(Attention) Line.
5..%.6.1. GPIB EcH Ezteacled Ta&

The purpGIO ol GPIB eM Ex:tDIMd Tat is to test the communication link between the iasuument
and the Work Statioa. AJtbouP the GPIB Fwac:tioaal Tests described earlier cu be used to examine
most of the lwdware iD the GPIB upensima board, the coaaector and the cable remain untested.
This test may be used to \'erily the pbysicallink betweea this insUumeat and other devices.
5..%.6.%.1. Setup
The foUowiq equipmeats are needed for this test to work properly:
(1) An GPIB Expansion Board should be properly iastaUed iD the instrument.
(2) Work Station. A Work Station with a \'ersion of the GPIB Diagnostic Software should be
coanected to the instrument via a IEEE-488 cable.
Sltmsloa: 1.1 S
!.l.6.l.l. Opendoa
After selec:tiDI the "GPIB Echo Test, a simple instruction askiDg the operator to turD on the Works-
tation ud nm the GPIBECHO.EXE will scroU thru the display. When the operator is ready and
presses the START key, the test will proceed by displaying a message indicating that the instrument
is waiting:
GPIB ECHO Test :

waiting for message
A different message as data are passed bac:k aDd forward between the Workstation aDd the instru-
ment appears oa the display:
GPIB ECHO Test :

Number of messaaes pass thru: :a
indicates the number of messaaes received from the Workstation ud seat out by the instrument.
'Y:J('
The user c:aa stop the test by pressiDg the STOP key.
5.%.6.%.3. EITOI" Mes. . .
The foUowiDg messaae is generated if error is enc:ouatered:
(1) GPIB BOGTd is 1101 ,aent. M part of the interface defiDitioa a bit is a.s.siped to indicate the
presence of the GPIB expansioa board. Tbia test euines the board present bit before
proceedina oa willa the test. If this message appears iastaD the GPIB Board before retrying.
If this error is seen wbea the GPIB Board is properly COGDeCted. cbect the buffer on the
SBC.
(2) Utlllb to 0.. .All INTI. Wbea this messap is displayed. it meaas thai some interrupts.
uaable to be deactivated. are preveatiDg this test from proceeding uy further. Rua Coldstart
or other Exleaded Test to determille the source of the problem before returDiaa to this test.
5.%.6.%.4. Obsenetl EITOI" Coaclldoa
Supplemelllillg the dispJayed mesaapa. there are additioaal illdicaton loc:aled oa the GPIB Expan
sioa Board. Tbree LEDI are ased to sbaw the GPIB ExpenW Board's curre11t state. If error
oc:cun, the foiJowiDa a1Dditiaal may be observed:
(1) SRQ LED dDa .lttll f/IIIIL 1'be GPIB E'lp'nsjcw Board ia 1llllble to paerate a GPIB Service
Request. Rua GPIB Paac:cioDal Test to determiDe the cause of the error before reuyiag this
test.
(2) LST LED dDa 1tt11 /IIIIIL 1'be GPIB Expension Board is uaable to receive any message from
the Worblalioa. Ran GPIB Panc:tional Tat to deleniUne the cause of the error before retry
ina this test.
(~) TLJC LED dDa 1tt11 f1tuJt. Tbe GPIB E-cpansion Board is uaable to send any message to the
Worbtatiaa. Rua GPIB Functioul Test to determiac the cause of the error before retrying
this test.
5.%.6.3. GPIB Swtlcba Exteaded Test

The GPIB Swildta EztendMI Tat provides a mean to dc..,..,ate the proper workina condition of
the rotary GPIB address swilcb. Tbe user c:aa ~eM addreu the insuument displayed oa the
front Panel from readina the swilcb apinsl the ICI1Ial ...._
11- SRmslon: 1.1 S

5.2.6.1.1. Setup
No special sec up is required for this test because this test will not Jisturb other instruments con-
nected to the GPIB.
5.2.6.1.2. Opendoa

When this test is selected, the following message will appear if the GPIB option is installed in the
instrument:
GPIB ADDRESS SWITCH Test :

Current Switch Setting is : xx
"r:X' is the decimal address interpreted by the instrument. The instrument updates the display as the
user changes the switch setting.
5.2.6.1.1. ErTOr Messap
The following message is generated if error is encountered:
(1) GPIB Board is 1101 ptYsenL As part of the interface defulition a bit is assigned to indicate the
presence of the GPIB expansion board. This test examines the board present bit before
proceeding on with the test. If this message appears install the GPIB Board before retrying.
If this error is seen when the GPIB Board is properly connected, check the buffer on the
SBC.
5.%.6.3.4. Obsened EITOI' Condltloa
Ia addition to the error message, the foUowiq condition may be observed by the operator:
(1) Displllyed Addtm tllld Swildl [)iQJ M'ISiftGiched. If this condition is obsened, run Coldstart
Diagnostic to look for any failed GPIB test. A faulry GPIB DATA-ADDRESS BUS test
invalidates this test. If ao Colc:lstan error is detected, the source of the problem is likely con-
fmed .to the switch and/or its buffer.
5.%.1. MotorfVam DriYer Extadecl Tesu
5.%.1.1. Motor Driver Extended Test

The purpose of the MOtor Driwr Extended Test is to verity the proper operation of the pump's
motor. and motor driwr. The Motor/VIM Driver PCB (MVD) provides a window to the Single
Board Computer (SBC) by allowiq it to monitor certain key MVD sigaals. The motor-related sig-
nals that are tested iadude the Phase 1/l Gate A/B sipa1s and the Phase 1/2 sip signals. A brief
description of the signal characteristics will be pea below, howe'ler, for more information oa their
theory of operatioa aad implemeatatioa, please refer to the MVD Schematics ( #03-919062-00),
MVD Assembly DrawiJia ( #03-91.9QS9.00}, MVD Circuit Descriptioa and the SBC Schematics
( #03-919058-00). Suffice it to say thai the above signals should have cenaia characteristics, limits
and relative timiap for a pea motor velocity as described below:
SR.msion: 1.1 S

Phase 1 Sign
MottN Driver Signal Tuning Characteristics
_I r-
Phase 1 Gate A IIIII 1111111111 1111111111
Phase 1 Gate B __._1111111111 1111111111 IIIII
Phase 2- Sign
Phase 2 Gate A 1111111111 1111111111 1111111111

Phase 2 Gate B 1111111111
AAA
II II II 1111
----
Ill
These regions should have a 23-27 ~ rate
with an average 4~60% duty cycle.
There are 2S6 motor micro-steps (1 full step 64 u-steps) from leadiag sip edge to leading sign
edge. Duriag the "bip" portioa of a P,:a sip sipa1. the uaoc:iated a Gate sipa1 is active with a
frequency ud duty cycle u described aheM:. The "A" Gate sipal is active duriag the low portion of
a givea sip sipa1 aad bas similar dwacterist.ic::a. This IClM period will be referred to u the active
interval. The two pbases are "90-degrees apart as illustrated above .

For the test. the motor is nm IE 128 u-steps/sec:oad which meus that the width of the sip pulses
aad the duratioa of the "active iDtervals are 1 sec:oad. The rqioa of the IClM interval that is tested
is the 2SO ms period just after the middle.
The test fwlctions by verifyiq that the above sipals are wilhia the described limits.
5~.7.1.1. Setup
The Motor Driver &leaded .Test doeSD't require uy special setup. However, the foUowing must be
adhered to:
(1) The motor mUll be CODDCC!ed to the MVD Board (PCB) for the feedback loop to operate
properly.
(2) If tbc tat is laiD& to be 11111 ovenaipl, removal of tbc pump bead mipt be deairable to pro-
tect tbc pump seals hiD nllllliDa dry. A tat nm ol SC\VIl boun should NOT, ~r. pose
uy problem to tbc pump hydnulica. Note t1w siDce tbc proportioaiDg valves will not be
opaecl duriDa tbc fill portioa of tbc IU'Oke, DO liquid will be pumped.
(3) for bell raub, tbere sbould aor be uy back pressure OD tbc pump that would aeate a large
torqae nquiremeat for tbc motor. This may be accomplisbed by opeaiq a dowastream
bydraulica finiDa or the purp YaM:.
5~7.1~. Opendoa
Alter selectina the "Motor Driwr &leaded Test" from tbc &leaded Test meau. the 9010 will start
the motor ud, after a few sec:aDda, lqia moaitoriDa tbc Pbue 1/2 Gate ud Sip sipaJs. The test
will coatiDuously moaitor each ol tbc pre sipaJ1 (PHlGTA, PHlGTB, PHlGTA ud PH2GTB)
ud display tbc results. Succcuful completioD ol the tat is illdicated by PASSED mesaqes after
each of the gates tested. Testiaa will coatinue until the STOP key is pressed.
SRmsloa: 1.1 S
5.2.7.1.1. EtTor Messaaes

The foUowiq error messages are generated by this test if an error condition is enc.Juntered. For
each of the messages below, replace a with either 1 or 2 and replace r- with either A or 8:
(1) MOTOR/YALVE DRIVER NOT PRESENT. The test was unable to detect the presence of

the Motor/Valve Driver (MVD). Verify that the 26-pin coDDector, J17, located at the top of
the the SBC is CODDected via a ribbon cable to the coDDector, 1101, on the MVD. If discon-
nected, power down before re-coDDecting.
(2) MOTOR/YALVE DRIVER .POWER PROBLEMS. The test detected problems with one or
more of the voltage requlators on the MVD board. Verify that coDDector 1103 is connected to
the appropriate power source and that the three leds, CRl, CR2 and CR3 are illuminated. If
not. perform the appropriate MVD power supply diagnostic tests.
(3) MOTOR/VALVE DRIVER OVER PRESSURE. The test detected a Hardware Over Pressure
condition. When the hardware detects an Over Pressure condition, it disables the Motor and
Valve Drivers, preventiq their proper operation. Hardware Over Pressures can be caused by
out-of-range pressures on the hydraulics/transducer OR by a discoDDected pressure trans-
ducer (see J22 on the SBC). Correct the over pressure condition. complete a hardware reset
(by pressiq 56) aad retry ~ test.
(4) PHnGTz: SIGN PULSE TRAIN NOT FOUND. No Phase a sip signal pulse train was
found. This pulse train should have a frequency of ..S Hz. If this error occurred, then no logic
level trusitions occurred within the 3 seconds allowed.
(S) PHnGTz: GATE PULSE RATE NOT FOUND. Tbc specified pte either bas no pulse train
present duriaa its "actiw interval" or bas a very low frequency (less than 1kHz).
(6) PHnGTz: GATE DU7YCYCLE TOO LOW. The spec:ifiecl pte sipal bas a duty cycle during
its "act.M: iDteMI" that is too low.
(7) PHnGTz: GATE DU7Y CYCLE TOO HIGH. The spec:ifiecl gate sipa1 bas a duty cycle dur
i.ag its "actiw interval" that is too bigb. This error will occur if the pump stepper motor is not
coiUlectecl to the MVD at J102. If discoiUlected, power down before re-connecting.

(8) PHnGTz: GATE PULSE RATE TOO LOW. The spec:iJied gate signal bas a pulse rate during
its "active interval that is too low.
(9) PHnGTz: GATE PULSE RATE TOO HIGH. The specified gate sipal bas a pulse rate dur-
ing its "act.M: interval" that is too bigb.
5.2.1.2. Valve DriYer Eataded Tes&

The purpo10 ol the Valve DrMr Exleadecl Tal is to~ die proper operatioa of the Valve Finite
State Macbiae (FSM), tbe Valve Driver ud, fiDally, the pamp's proportioniq valves. The Valve
FSM is locl&ecl Oil tbe SBC aacl is respoasible for ~ die appropriate \'aM control signals to
the Valve Driter. Tbae sipala are MVA, MVB, MVce, MVO (aot used) and MHIVC. It is
the FSM's rapoasibiJilJ to provide mutually-cxdUIM vahe openiap ud to enforce other timiDg
related c:oastniall. Tbe Valve Driver applia tbe MCCSwy currents to tbe \'aM solenoids to open
them and maiDta.iD their opea Slate as directed by tbe FSM. Tbc enersiziag of tbe \'aM solenoids
should cause the valve poppets to open.
Testiq is performed by issuilla a request to opea eada ol tbe valves and monitoring the above-
mentioned siplaJI and currents to sec if they are wiWa precfiacd limits. The foUowing diagram
shows the typical iDput vokap refereacc to the va1w curra1 rqulalor and the associated current
applied to the valw soleaoid u a fuactioa of time. See tM MVD Schematics ( #03-919059-00 and
#03-919062-00) uad the MVD Carc:uil Description for ..,. illormatioa on the theory of operation.
SRmsloa: 1.1 S
l.OV
I
I
Valve Input Volta~ Rtftrtnce Tuning
10.0 A
I IAt rat ion of

I~
I < t.Sms >
I (fixed)
I
I Pull-In
I Olrrent
0.1 v I l.OA
o.o v _I Sustain Olrreot I_ O.OA
<Duration of Valve Select (Variable) >
The following diagram shows the relationships of the sipa1s that the test verifies. The "#" symbol
shows the poinu in time that the various sigDa.ls are sampled ud verified for the proper state. In
addition, the VALVES_LO and VALVE_SEL signals are verified to be asserted immediately after
VALVES_HI goes low.
Vahoe Sigtllll Tuning Rtliottships
VAL\S_ID
VAL\S_HI _______ I # i\TCJLW:C'

I__ _
Klt.liHIIIill
I #
#
VALVE_~ ~------------------
1 2 3 4
TUDe (.~) 0123456789012345678901234567890123456789012345
5~7.2.1. Sdap
The Valw DrMr ExleDded Tat doeut't require any special seNp. However, the following condi-
tions should exist:
(1) The mechanical valYes/poppets should be properly assembled and installed on the pump
head.
(2) 1 :e valve actuator solenoids should be slipped-on over the val'Yel Uld fastened with the
appropriate out.
(3) ' The valve ac:Nator solenoids sbould be coDDeded to the MVD, at COIIIlector J106, with valve
A in the back ud prosresaiol forward with valve B, vaJve C Uld valveD (uaused).
Sltevlsloa: 1.1 S
5.%.7..Z.l. Operadoa
After selectiaa the "Valve Driver Extended Test" from the Extended Test menu. the 9010 will stan
testing each of the valves in order. Suc:cessful completion of the test is indicated by PASSED mes
sages after each of the valves tested. Testing will continue until the STOP key is pressed.

5.%.7..Z.l. Error Mes.saps
The foUowiDg error messages are generated by this test if an error condition is encountered. Note
that there are two types of messages, those referencing the FSM (indicating a problem on the SBC)
and those that don't (indicating a problem on the MVD). For each of the messages below, replace -~
with either A. B or C:
(1) MOTOR/VALVE DRIVER NOT PRESENT. The test was unable to detect the presence of
the Motor/Valve Driver (MVD). Verify that the 26-pin coa.nector, Jl7, located at the top of
the the SBC is conaected via a ribbon cable to the coa.nector, JlOl, on the MVD. If discon-
nected, power dowa before recoa.necting.
(2) MOTOR/VALVE DRIVER POWER PROBLEMS. The test detected problems with one or
more of the voltage requlators on the MVD board. Verify that coa.nector J103 is coanected to
the appropriate power source and that the three leds, CRl, CR2 and CR3 are illuminated. If
not, perform the appropriate MVD power supply diapostic tests.
(3) MOTOR/VALVE DRIVER OYER PRESSURE. The test detected a Hardware Over Pressure
condition. When the hardware detects an Over Pressure conditioa, it disables the Motor and
Valve Drivers, preventing their proper operation. Hardware Over Pressures can be caused by
out-of-raage pressures on the hydraulics/transducer OR by a disconaected pressure trans-

ducer (see J22 on the SBC). Correct the over pressure coaditioa, complete a hardware reset
(by pressiag 56) and retry the test.
(4) VALVE z: FSM VALVE SELEcrJON ERROR. The Valve Finite State Machine (SBC) did
not provide the coned VALVE_SEL (MVA, MVB, MVC) sipal ill the time required.
It may have provided a sipal that was not requested.
(S) VALVE z: FSM MHIVC- SIGNAL NOT PRESENT. The Valve F"mite Scate Machine (SBC)
did not provide the MHIVC (High Current) Sipal ill the time required.
(6) VALVE z: FSM MHIVC- SIGNAL TOO SHORT. The Valve F"mite State Machine (SBC) did
not provide a sufficieady long MHIVC (High Current) sipal.
. (7) VALVE z: VALVE HIGH CURRENT NOT PRESENT. The high, "pull-ill" current for this
valve was not present. This will prevent this valve from opening properly.
(8) VALVE z: FSM MHIVC- SIGNAL TOO LONG. The Valve F'mite Stale Machine (SBC) did
not termiaate the MHIVC sipal ill the required time.
(9) VALYE z: VALYE HIGH CURRENT TOO LONG. The hip, "pull-ill current for this valve
wu oa too to~~~o If the high current is on too loq this could cause the solenoids to overheat
or tile valve driver irsclf to fail.
(10) VALYE z: VALYE HIGH CURRENT TOO SHORT. The bigb, "pullill current for this valve
was not oa lOIII eaoup. If this high current is not on Joaa enouP, the valw may not open
properly. This messap will occur if the valve soleaoid is not illstalled on a proportioning
valve. IDStall the solenoicland try agaiD.
(11) VALVE z: FSM VALYE SEL SIGNAL TOO SHORT. The Valve F'mite State Machine
(SBC) termillated the VAi.VE_SEL signal prematurely.
(12) VALVE z: VALVE LOW CURRENT NOT PRESENT. A proper low, "holding" current for
this valve wu never observed. If a sufficient holdia& current is DOl applied after the valve is
opened. it will dose prematurely.
SRmslon: 1.1 S

5.2.7.2.4. Obsened EITor Coaclitloas.

In additioa to the above error messages, the following error conditions may be observed and must be
diagnosed by the operator:
(1) No Audibl~ Valve Actiort. If audible valve actions are not beard for each of the three valves.
then one or more of the valves may be malfunctioning. Possible causes might be missing or
jammed poppets or improperly installed valves or actUator solenoids.
5.2.1. Hydraulic System Exteaded Test
5.2.1.1. Leak Test

The Leak Test's purpose is to fmd and diapose problems with the pump hydraulics. It may be used
to fiDd leaks ia boch the pump bead as weD as the other compoaeats dowD stream.
5.2.1.1.1. Setup
The Leak Test requires oaly a simple setup: cap-off the system uader test. A cap may be placed any-
where ia the system AfTER THE PRESSURE TRANSDUCER and the resultiq system tested for
leaks. This may iadudc mixers, dampers, tubiag. valves aad evea columas. AgaiD. the operator
MUST ALWAYS iDdude the pressure ttansduccr iD the system uadcr test, otherwise, the 9010 bas
ao way to coatrol (or read) the pressure aad would mOlt likely c:realC a larpr leak by blowiag-out
the hydraulics aad causia& serious damage to the hydraulics and poteatial iajury to the operator.
The cap used may either be a special bydraulica fittiq or a purae VIM. A purp vahe is preferred
siace it allows a slow, coatroUed dosiaa of the hydraulica aad permits solveat to be directed to the
appropriate wasce receptade.
5.2.1.1.2. ()pend
After selectiq the "Leak Taa- ftaaa the beaded Test Meau. the 9010 will prompt the operator for
the followiag parameters. Tbe operator may use the NEXT_LINE aad PREVIOUS_LINE keys to
move from oae puamecer to IDOtber. The Leak Test may be aborted at aay time by pressiDa the
STOP key. The parameten are a foiJoM:
(1) utlk Tat Mod& Tbe mode of opcndoa ia either CONSTANT PRESSURE or PRESSURE
DECAY. This also . .y be togled by the INCREASE aad DECREASE keys. CONSTANT
PRESSURE mode lltelllpCI to mainraia the desired pressure (by ruaaiaa tbe pump) aad then
calculata the leak by aaaaicarial pump piltOD displac:cmeaL Tbe display wiD show the
Clllftlll pnuure (ia -> ad the leak rate (ill micro-liten/miaute). PRESSURE DECAY
mode will pampoup to the daired preuure aad thea stop the pump. Tbe display wiD then
. , . die carrea1 preuun (ia IIID) aad die elapiCd time (ia secaada) liDce die start of the
Leak Tat. If die ay~tem \'Oiume ia bon, thea die clapiCd time ucl the c:urreat pressure
...., be Died to caJculatc die leak rate.
(2) lMk Tat Prrulu& The Leak Test Preuure may be specified ia tea-lbllospbere iDc:rements.
Use the INCREASE ucl DECREASE keys to specify the desired preuure ucl thea the
NEXT_LINE key to ao to the Dell prompt.
After eaterias the puameters, the test wiD request thai the operator preu the START key to begin
the Pump Pressurizatioa phase. Wbea the START key is pressed, the test wiD beP.,.
As mCDtioaed abo\~ there are EWO modes of operatioD. While differeDI ia operatioa duriaa the
actual Leak Test, they work similarly duriaa the Pump Pressurizatioa phase. Pump Pressurization.
oace started, wiD attempt to acbicw the desired pressure ill a sban period of time. That is, it wiD
rua tbe pump quickly, aot slowiaa don uati1 the claircd preuure ia aarly acbiewd. Pump
SRmlloa: 1.1 S

9010 Oiapostlcs Description
Pressurization will allow 30 full pump suokes for the system to come-up to pressure and will then
abort if uasuccessful. There is a S second delay after an unsuccessful pressurization before an error
message is reNnled. This will be discussed later in the Error Messages sectioa.
The Leak Test bas a maximum analytical head Oow rate of 1000 micro-liters/minute.
It is recommended that the Leak Test be performed ia the foUowiag manaer.

{1) Iastall the cap (or purge val'le) at the desired point in the hydraulic;:s. Do not completely
tighten yet, the system should leak for now. Remember, the pressure uaasduc:er must
ALWAYS be included ia the system.
(2) Aaswer the prompts described above, startiag the Pump Pressurization phase.
(3) Let the pump deliver approximately 15-20 suokes, allowing solvent to Dow through the
hydraulic::s. This will purge the system of ua-wanted air bubbles.
(4) Tighten the cap (or valve) oa the end. allowiq the system to become fully pressurized. The
Leak Test phase will now begin.
CONSTANT PRESSURE Moa
For CONSTANT PRESSURE mode, the display of the c:urreat pressure ud leak rate will begin.
The leak rate is heavily filtered at low tlow rates, which meus that it will take 30 seconds or so for
the displayed value to stabilize after the higb Pump Pressurization leak rate. This heavy filtering is
necessary to provide u accurate as well as dyaamic now rate pea the eJictiaa aruularity of the
motor.
If there is a leak, differeat pressures will probably she differeat leak rates. There may be a leak at
400 atm but aot oae at 200 atm. Different pressures may be tested to determiae this.
The CONSTANT PRESSURE mode is especially useful for iaterac:tive leak fixiDa. That is, fittiags
may be tightened while the test is nllllliD& &iviaa positive feedback of the fix.
Certain hydraulic components. such as dampers, may have both long-term as weD as the obvious .
short-term compressioa cbaracteristia. That is. a damper pumped-up to 400 atm may coatiaue to
compress slowly for sewral hours after reachina that pressure. A correspoadiq leak rate would be
observed duriaa this proceu. For this reasoa. it is a good idea to remow the damper from the sys-
tem uader test once the damper is no loapr suspect. Keep in mind that a damper-less system has
very little compliance aDd will pump-up very quickly causing the motor to stop abruptly when ending
the Pump Pressurizadoa pbue.
PRESSURE DECAY Mt1M
For PRESSURE DEC\Y aaode, the display will show the c:urreat pressure (ia atm) ud the elapsed
time (ia secoads) siDce the Lak Tal bepa. 1he pressure will decay over time ud the operator
may press the STOP key wbea the pressure decays to a desired poiat, or, he may let the pressure
decay to zero. Ia eitber case, the timer will stop ud the filial pressure aDd time will remain on the
display. Tile open101 may thea use this iDformatioa. a1oaa with syscem volume, to calculate a leak
rate as followl:
f(PtimeO, PtimeN, Vsystem, time)> Oleak
(Leak Rate Equation Goes Here

SliD waitiDg for Chris to provide)
5.%.8.1.3. Enw Messap~

The foUowiq error mess1ps are geaerated by this test if u error condition is detected. These mes-
saps represeat only the mOll serious of error conditions. The tea will mOll likely rwa successfully

-Jl SRmsloa: 1.1 S
9010
Dlapostics Description
with a rela~ small displayed leak rate. The absenc.c of any error messages does NOT nec.cssarily
indicate a perfectly functioning pump. The leak rate must be interpreted by the operator to deter
mine the suitability of the system for the applicatioas used. Sec the "Observed Error Conditions sec
tion for more information.
(1) LEAK TEST ERA: nJBING LEAK OR NO PRIME. If this error is observed during the
Pump Pressurization phase then the pump was unable to generate the leak test pressure. This
probably indicates a lack of pump prime or a gross hydraulics leak. If this error is observed
during the Leak Test phase then the pump was no longer able to maintain any pressure. This
probably indicates that the pump lost prime or ran out of solvent.
(2) LEAK TEST ERR: PUMP HEAD LE.AK. This error is only observed after an unsuccessful
hydraulics pressurization. This probably indicates a badly-worn pump seal or an improperly-
torqued inlet valve (though many air bubbles in the inlet lines could cause the same problem).
The Pump Pressurization phase pumps until either the Leak Test Pressure is achieved or 30
strokes have elapsed. If the Leak Test Pressure is not achieved in the 30 strokes allowed, the
pump is thea stopped. If after S seconds there is residual pressure in the hydraulics, then the
most probable reason that the Leak Test Pressure was not achieved was a faulty pump bead
and not leaky downstream hydraulics (though they may also have a smaller leak).
(3) LEAK TEST ERR: PUMP STALL This error is Dormally observed wheD the Pump's stepper
motor step lags more than 5 degrees. It may also occur whea the optical switch re-synch. sig
Dal (TDC) is malfuactioo.iq. If this error occurs repeatedly it probably indicates a Motor
Driver, mechanical or optical switch problem. Verify that the optical switch oa the pump
frame is couected to J21 oa the SBC. Verify also that LED CR16 011 the SBC O.ashes wbeD
the light beam oa tbe optical switch is blocked. If Dot, thea the optical switch is malfuactioD
ing. Refer to the appropriate documeatati011 for diaposing the above problems.
(4) LEAK TEST ERR: PERPETUAL 7DC This error is observed whea the TDC signal from
the optical switch caDDot be cleared. It probably indicates that the optical switch is Dot con
aected to J21 oa the SBC. It could also be a malfuactioDing optical switch. Verify proper
optical switch operatioa before proceediDI
(S) LE.AK TEST ERR: H/W OVER PRES, RESET HjW. This error is observed wheD the
Hardware Over-Pressure circ:uiuy 011 the SBC detecu u ~-Pressure coaditioa. Ia order
to clear this error, a "hardware reset" must be effected either by pressiD1 switch S6 Dear the
upper leadiq edp of the SBC or by c:ydiDa the power switch. This error may be caused by
malfuactiolliD& ADIJoiTo-J>iPal circ:uiuy, u improperly adjusted hardware pressure limit or
software failure (wbich may be caused by yet a myriad of other problems). If the problem
persisls, rwa all coldsiart diapOidca 11 well as the exzeaded tests for the ADalog-To-Digital
circuitry.
5~.1.1.4. Olllened Error Coadltlou

While tbc lbcwe error messages diapose the most serious of errors. the 9010 will Dot Dormally have
such defiDitM problems Uld thus will require the operator to iDterpret what the leak rate means for
his appticadons.
The foUowiaa outliaes a pattera to follow wbeD ualyz:iaa Uld imprOYillg the leak performuc.c of the
pump:
(1) IHtll'ffliM A Lellk RIIU. Perform the Leak Test ud determiae the leak rate. Use the CON
STANT PRESSURE Mode ud a prcsaure that is 1~ areater tbu the applicatioa uses. For
most accurate results, the operator should wail uatil the displayed leak rate is reasonably
stable aad ao laager paerally decreasiq before recordiq the leak rate (sewral minutes at
least).
(2) EwllJUUt Lelllc FM ApplicGliOfl. If the leak rate displayed represeDts a sipi.ficaat percentage
of the Oow for the appllcatioos ud Oow rate used, thea the leak should be correc:ted. This
-33- SRevlsloa: 1.1 S

step represeats a chromatographic judgemeDl call by the operator. Generally speaking

thougb. a leak rate of 1.0 mia~liter/miaute or below is acceptable for Oow rates above 1000
mi~liten/millute aad leaks of less thaD 0.2% for now rates less thaa 1000 micr~
liten/miaute. U the leak is aa acceptable one, thea no more action is necessary. Otherwise,
go onto the nest step.

(3) DetermiM uQJc Loclltion. laitiaUy, the way to fmd leaks is to look for fluid seepiag out of the
tubiag or other hydraulic components aad tigbteaing/correc:tiag aay obYious sources. Tight-
eaiq (aad/or reseatiag) of aU the fittiap ill the system, evea ill the abseace of obvious leaks,
is recommeaded. The inlet, outlet aad proponioaiaa valves should be re-torqued as well.
These torque values may be fouad ia the 9010 Operatioas maaual. After this initial actioa.
the leak locatioa may be determined by the process of elimination. With each iteration of this
process, rem~ aa hydraulic compoaeat from the system aad re-test. Apia, remember that
the TilE PRESSURE TRANSDUCER MUST ALWAYS BE INCLUDED. Once all of the
extemal compoaeau have beea tested, if the leak rate is still at aa unacceptable level. the
pump itself should be examiaed. Possible illtemal problems miabt include a wom pistoa seal
or a leaky inlet valw IIDOIII other tbiap. Uafonuaately, pump compoaears may not be
removed &om the system; they must be replaced aad thea re-tested. Refer to the 9010
Operatioas maaual for iaformatioa oa specificatioas, toleraaces, assembly aad maintenance
procedures.
(4) COMCt Laic. After the faulty compoaeat bas beea ideatified, refer to the 9010 Operatioas
maaual aad foUow the corrective actioa(s) outliaed there.
(5) k-E'VtllluiN Situtltion. Go to step 1 aad repeat the process.
5.l3. Pump Calllndoa/Malateaaac:e Fuacdou
5.23.1. Extad Plstoa Facdoa

The purpose of the Extead Pistoa FUDC:tioa is to positioa the pump cam such that the saphire pistoa

is fully estellded. This fuactioa is primarily for adjustiag the lalet Valve Gap but may be used to test
the rudiaaeatary operatioa of the opcical switch as weU.
5.23.1.1. Setup
There is ao special setup required. Howewr, be aware that the pump will be moviag aad could
~r-pressure if this tell were rua oa a closed system.
5.l.9.1.l. Opentloa
After selecdaa the "Extead Pistoa fuac:tioa &om the Exteadecl Test meau, the 9010 will prompt the
user to pnu START to c:aada or STOP to quit. U START is pressed, the pump will thea begia
positioaiaa llld iafona the aser of dliL WileD the optical switch uigers, the pisloa is fully meaded
aad the pump is stopped. All iaformatioaal meuap is temporarily displayed aocifyiaa the user that
the pistoa is fuDy elteaded aad the cam pasitioaed at Top Dead Ceater (TDC). The lalet Valve
Gap may thea be sec. The 9010 will thea place a Wll'Diaa 011 the display iDclicatiag that the pistoa
should be retracted before performiaa aay pump bead replacemeat or maillteaaace. To exit the test
at this poiat, presa STOP. Noce that wbea exitiq this test, the pisloa remains ia the FULLY
EXTENDED POSMON.
5.2.9.1.1. Error Messqa

The foUowiag error messages are geaerated by this test if aa error coaditioa is eacouatered:
SReYtsloa: 1.1 S

3+
9010 Dlapostics Description
(1) Pump Sllllkd- Test FQiled. This error message can indicate a number of problems, including:
hardware ~r-pressure, optical switch malfuDctioa. motor drive problem or others. Refer co
tests for these areas should this error occ:ur.
5.2.9.2. Retract Plstoa Function

The purpose of the Retract Piston Fuuction is to position the pump cam such that the saphire piston
is fully retracted. This function is primarily used during pump seal replacement but may be used to
test the rudimentary operation of the optical switch as well.
5.2..9.2.1. Setup
There is no special setup required. However, be aware that the pump will be moving and could
over-pressure if this test were run on a closed system.
5..2.9.2.2. Operation
After selecting the "Retract Piston function from the Extended Test menu, the 9010 will prompt the
user to press START to coatmue or STOP to quit. U START is pressed, the pump will thea begin
positioniq and inform the user of this. Wbea the optic:.al switch trigers, iateraal counten will begin
trac:k.iq the position of the cam and stop the pump wbea the piston is fully retracted. AD informa-
tional message is displayed aotifyiaa the user that the piston is fully retracted and the cam positioned
at Bottom Dead Ccater (BDC). The pump seal may aow be replaced. To exit the test at this point,
press STOP.
5.l.9.l.3. Enw Messaps

The following error messages are generated by this test if an error coaditioa is encountered:
(1) Pump Sllllled - Tat Fllikd. This error message c:aa iadicale a aumber of problems, including:
bardwvc over-pressure, optical switch malfuactioa, motor drive problem or others. Refer to
tesu for these areas should this error occur.
5.l.10. Prlater Exteaded Tau
5.l.10.1. Prlater C11anc1er Tat

The Primer Clwader Test's purpoiC is to tat for tbe proper opcratioD of a priDler attached to the
SOS 9010. It may be used to verify both that the primer is sct-ap c:orrecdy ud that it is fu.actioniq
properly. Refer to the priarcr IIWlufac:hlrer's operatioa awaaal for your printer for any printer-
specific quesdou.
5.%.10.1.1. . . . .
The Primer Oancter Tat requires the same setup u thal aecded for DOrJDa1 operatioa. To work
properly, the foUowiaa sctup llllllt be performed:
( 1) Prin#r Typt. The priDter to be COIIIIeeled to tbe 9010 slaoaJd support ASCII, serial. asyadlro-
aous uasmiscion via aa EIA RS-232-C compatible 25 (or 9) pia iDterface.
(2) Cllbk Colljigurgtion. The cable used to coDDCd a prilllcr to .JIC 9010 sbou1d have a "male"
25-pia 0-subm.iDi.alure coaaeaor OD the 9010 (DCE) eM aad a CODDector appropriate for the
desired primer (DTE) OD the other (either 25 or 9 pia). For I cable with the 25-pia CODDeC
ton oa both ads, pial 1 througb 7 ud 20 sboaJd be pracm ill 1 straip~.thfoup (NOT
auU-modem) coafipnlioa. Tbe sipaJ1 used are Olllil Grouacl, XMT, RCV, RTS, CI'S,
DSR, Sipal Grouad aad DTR.
Sltmsloa: 1.1 S
9010 Oiapostics Inscription
(3)
( 4)
Cable Cotutrioou. One end of the a~ cable should be coonected to the D-subminiature
type coanector located on the lower left side of the back of the 9010 and the other end to the
EIA RS-232-C compatible serial port of the printer.
Printer s~rup. The printer should be set-up at 9600 baud and either 8 bits/no parity or 7
bits/zero parity. The printer may be set-up to use either hardware (DTR) or software

(XON/XOFF) character flow control (the 9010 will use either). The printer should support
the "printer attached" (RTS) sipal as weU.
5.%.10.1.%. Operatloa
After selecting the "Printer Character Test" from the Extended Test menu, the 9010 will send a rotat
ing pattern of characters to the printer. This rotating pattern may be used to verify printer setup and
operation. If the printer remaiDs ready, the 9010 will continue sending characters to the printer until
the STOP key is pushed. The foUowiog is similar to the pattern scot to the printer:
Printer ChtUQCt~' Test Test Pattem
!"#fr~'()+,./01234S67890:;<>~J~[)A_'abcdefghij
!"#fr~'()+,./01234S67890:;<>~J~[]A_'abc:defghijk
"#fr~'()+,./01234S67890:;<>~~[]A_'abcdefghijkl
#fr~'()+,./01234S67890:;<>~~[]A_'abcdefghijklm
Jr~'()+,./01234S67890:;<>~~[]A_'abcdefghijklma
o/~'()+,./01234S67890:;<>~J~[]A_'abcdefghijklmao
&'()+,./01234S67890:;<>~J~[]A_'abcdefghijklmaop
etc.
A continuous pattera. as abo\le. indicates that the printer is workUlg properly. To thoroughly test the
printer, several pages of output should be printed siDce many printers have large interaal buffers and
flow control problems may aot show up until those buffers are full. Note: There is a single space in
the a~ pattern and it may be found just before each exclamation point (or after each tilde).

5.%.10.1.3. Error Messaaa
The following error messages are generated by this test if an error coaditioa is encountered:
(1) PRINTER TEST FAILED: Dlllltt AbsiiiL If this message is observed, it means that the 68681
DUART chip is either absCDt from the SBC (Single Board Computer) or its DTACK circuitry
is aot func:tiollilll properly. Ia either case, replace the DUART chip before coatiauing.
(2) PRINTER TEST FAll.ED: l'1inUr 7inwout. If this messap is observed, it means that the
printer was in a aoc ~ state for more than 3 sccoads. If the 9010 is operating properly
(passes PriDter Loopback Test) thea this could be attributed to a setup problem or a printer
that is discoDDCcted, powered off, off tiDe, or malfuactioaiag.
5.%.10.1.4. Obtelved Enw Coadldou

Ia addition to the above error messages, the following error coaditioas may be observed and must be
diaposed by the operator:
(1) Brrak in ChlllfiCttr Patttm. It there is a break in the pattera scat to the priater, thea charac-
ters scat to the printer are beiDg lost. Verify that oae of the above modes of flow control
(either hardware or software) is prescat and fuac:tioaiDg in the printer.
(2) Random Chart~etB Pattun or GtUba,_ If random c:haracten (those not in the above order-
ing) are observed, thea the printer is interpreting the c:harac:ten improperly. Verify the printer
setup parameters for Baud Rate, Number of bits, and Parity.
36- SR~Yisloa: 1.1 S

(3) Notltinf No Raponst. U notbin& bappeu wbea se1cc:tiDg the Printer Character Test, then
there may be a problem with the 9010 DUART or with the printer itself. U the Printer Loop-
back Test is nm successfully, thea the problem may lie ill the printer itself. Sillce the Prillter
Character Test properly diaposes printer "not ready" coaditioDS, thea, ill this case, the printer
must be properly eoabled and receiW. characters but simply not printiag them. If ao fault
can be found in the printer thea re-check the set-up described a~.
5.l.10.l. Printer Loopback Test.

The purpose of the Printer Loopback Test is to verify proper operation of the 9010's internal serial
port circuitry illdepeadeatly of any external devices. The method used to accomplish this is to have
the 9010 "ta(k- with itself via the serial port. U it caD do this successfully, thea the 9010 serial port
(and DUART) is probably working properly.
5.2.10.2.1. Setup
The Printer Loopback Test requires a special "loopback collllector" to complete the test. This con-
nector may take oae of several physical forms:
(1) A mate 25-piD D-submilliature couector with certaill piDs looped-back to others specifically
for this purpose. For example, the Variu UART Test CoDDec:tor iD the Field Se~ce Kit.
(2) A properly-collfigured, commollly-available "breakout boa- manufactured for the specific pur-
pose of diaposiDg geaeral E1A RS-232-c illterface problems.
(3) A simple set of 3 wires whose ellds c:aa be appropriately placed ill the 9010 Printer Port pill
receptacles.
Thougb the loopback couector may take oae of several physical forms, the logical couector is sim
ply the foUowiDg pills looped-back (beace, the ume) to each other.
Loop Blldc C'onnectDr Pill Collftrunuion

Pill 2 to Pia 3
Pill 4 to Pia 5
Pill 6 to PiD 20
5.2.10.2.2. Opendoa
After selec:liq the "Priiller Loopback Tar fraaa the &leaded Test mau, the 9010 will coatilluously
test the looped-back COIIDCCtiaaa abaft and priDt the results OD the display. TestiDg will coatinue
UDti1 the STOP key is paabcd. Succcuful campledoa of the tests ia iDdicated by PASSED messages
after each of the two tesll pcrformecl (Hudshke and XMlTfRECV).
5.2.10.2.3. Enw .......

The followiaa errar '"""P' are puratecl by tbia test if an error CODCiitioD is eDCOUDlercd:
(1) PRJNI'ER. (HANDSHAKE or XMlT/RECVJ TEST: Dutltr Abslllt. U tbia messaae is
oblened, it meaa that tbc 68681 DUART chip is either lbselll from the SBC (SiDgle Board
Computer) or its DTACK circuilry is DOC fuDcbolliq properly. Ill either case, replace the
DUART chip before coadDuiq.
(2) PRINTER HANDSHAXE TEST: RTS/CTS FfliW U tbia messap is obsened. it meaas tbat
the RTS/CfS budsb.ake test failed. Verify tbal pills 4 and 5 are looped-back oato each
other ucl repeal the tat. U it still fails iD the same IIIIDilCr, check iDterDa1 cable CODDectiou
to the DUART ucl the DUART chip itself

(3) PRINTER HANDSHAXE TEST: DSR./DTR FllilltL If tbia measap is obsened, it meaas that
the DSR/DTR budsb.ake test failed. Verify that pills 6 ud 20 are looped-back ODto each
other ud repeal the test. If it still fails iD the same miDHr, check illteraal cable coucc:tiou
-31 Sltmlloa: 1.1 S

(4)
to the DUART ud the DUART chip itself.
PR.INTER HANDSHAKE TEST: Both FGiled. If this messase is observed, it means that both
pairs of lwldsbake sipals (DSR/DTR tJnd RTS/CI'S) failed the test. Take action as out-
liDed above.

(5) PRINTER XMn'/RECV TEST: OM' Neve Reed. U this message is observed, it means that
the character as seat oa pill 3 was never received oa pill 2. Verify that pills 2 and 3 are
looped-back onto each other and repeat the test. If it still fails ill the same manner, check
illtei"DDl cable conaections to the OUART and the DUART chip itself.
(6) PRJNTER XMn'/RECV TEST: Wrong OM' Reed. If this message is observed, it means that
the character as seat oa pill 3 was Dot received correctly oa pia 2. This may be caused either
by a faulty DUART or a loose conaectioa. Check for loose conaec:tions and repeat the test.
If it still fails ill the same manner, the DUART itself may be faulty.
SRmsloa: 1.1 S

6. CbUI Moaltor Mode

The Cbug Diapostic Monitor is provided in 9010. This monitor is very helpful in servicing and trou
ble shootiDg faulty hardware.
The foUow hardwares must be functional in order for the system to operate correctly in the Cbug
Monitor Mode:
(1} ROM1 and ROM2
(2) All RAMs
(3) The serial I/O port, the RS232 drivers and the connector
( 4} A terminal
6.1. Setup ror Cbu1 Moaitor

Using Cbug in 9010 requires that a CRT terminal be connected to the instrumenL See Section 10 on
how to connect a serial device. The Cbug Monitor is shipped as part of the product roms, thus elim-
inating the need to replace any of the origi.Dal roms in the instrumeoL
6.l. Usiq Cbu1

For instructions and informatioa about how to use Cbug refer to the separate document, "Cbug
User's Manuat.
It may be useful to mow bow to re-boot the instrumeat from Cbuc- The Cbug command, 'go
400410' caD be used to accomplish this.
Sltmsloa: 1.1 S
7. Coldstu1 Moaitor Mode

As the name implies, in this mode the activities of the instrument during Coldstart Diagnostic can be
monitored through the serial port. This is designed to be part of the fma.l test and to build a history
me on individual instrument. In this mode, the instrument is powered up and begins the Coldstart

kernel testing a.s though it is in the Normal Mode, except that a.s each test is conducted the test result
is seat out thru the serial port. More than just a "Pass" or "Fail" message seen in the Run Log, this
information stream contains data from each test. This way there is a record on the instrument for
future reference when it is ready to leave the factory floor.
7.1. Set-up for Coldstart Monitor

Follow the simple steps below to operate the instrument in Coldstart Monitor Mode:
(1) Connect a serial device, preferably a printer for generating a bard copy report or a PC for
recording the data information in a flle, to the serial port oa the instrument. This is required
in order for the instrument to function properly. If no device is connected to the instrument
and Coldstart Monitor Mode is selected, the instrument will be trapped at the first instance it
tries to write to the serial port. The instrument will wait forever to output a byte thru the
port and will oaly respond to a hardware reset. See Section 10 oa bow to connect a serial
device ..
(2) Set the appropriate DIP switchs using Table 1.
(3) Switch power on or press the Reset button on the SBC.
7.l. Coldstart Monitor Results

Since in the Coldstart Diagnostic tests are executed in order based on the hierarchy of module
dependence, a test will aot be executed when oae of its dependents failed. Therefore the information
received via the serial port contain oaly data from all the executable tests. cat term.me

SRmsion: 1.1 S

8. Termiaal Esteaded Mode

This mode of operation provides the user or the service people direct access to each individual
Coldstart Tests and all the Extended Tests, particularly useful wbea trying to isolate faulty chips.
With the aid of Test LED oa the SBC Board or a logic probe, or a scope, the states of the IC chips
that made up a functional module can be examiDed while the test is ruaning. Thus, signals can be
traced to identify the cause of the problem.
The follow hardwares must be functional in order for the system to operate correctly in the Extended
Mode:
(1) ROM1 and ROM2
(2) All RAMs
(3) The serial I/O port, the RS232 drivers and the coanector
1.1. Setup for Termiaal Extended Mode

The foUowina is a step by step procedure oa how to set the iastrumeat to the Terminal Extended
Mode:
(1) Coanect to the serial port oa the back of the iastrumeat a serial device which has both input
and output capabilities. like a terminal or a PC. This is a requirmeat; otherwise the in.stru
meat wiD haag iD a loop waiting for an output device. Sec Sectioa 10 oa how to connect a
serial device.
(2) The coaaector labled '"TERMINAL is comJFed as an RS232 DTE (Data TermiDal Equip
(3)
(4)
meat) aad it therefore expects to coanect to an RS232 DCE (Data Commuaicatioa Equip
meat) device. Whea coaaectiag a termiaal (DTE device), an illliae RS-232 aull modem,
which c:haages the iastrumeat sease from a DTE to a DCE. is required.
Configure lhe termiaal to lhc foUowiag asyacbroaous settiags: 9600 Baud, 8 bits, ao parity, 1
stop biL
Set the appropriate DIP switcbs usiag Table 1.
(S) Switch power oa or press lhc Reset buttoa oalhc SBC Board.
Note: nc termiaal must assert the RTS (ReqUCSlto-Sead) liac ill order to receive output.
8~ Opendoa
Meaus are provided as a meus to facilitate illterac:lioa bctweca the user aad lhc iastrumeat. Tests
are separated iDeo cateaoria accorclias to fuac:tioa, aacl there is a mcau pap for each functional
module willa aU the tesu ill lhal module. After a meau is prcseated, lhc user simply makes a selec
tioa or follows the iDsttuclioa showD oa the screea.
.... SRmsioa: 1.1 S

9. Teled.iapOitlcs Mode
Telediagllostics are provided with these instruments so that customers can be serviced from a remote
site. When users experieace problems with their instruments, they can put the instrument ia the
Teleldiagaostics Mode and let the Varian Serivc:c Center aQ:CS.S the instrument over a phone line and
make a determination oa the state of the iil.strumeaL
The following hardware must be fuactioaal ia order for the system to operate correctly ia the Teledi-
agnostics Mode:
(1) ROM1 and ROM2.
(2) All RAMs.
(3) The serial I/O port. the RS232 drivers and the coaaector.
A modem that meets the following criteria is required:
(1) Hayes Command Compatible.
(2) Frequency Standard: Bell 212A (US and Canada), CCITI V .22 (Europe).
(3) Transmission Mode: 1200 Baud, Full-duplex, 8 bits, ao parity.
(4) Must be coofigurable via software control Does not have to be dip-switch coofigurable.
(S) Must coanect to a female, 25-pia, RS-232C, O-shell coanector.
Note: The RTS/CTS and DTR/DSR handshake liaes are not used ia telediagDostics mode. The
modem is required to assert/dis-assert the RLSD (Received Liae Signal Detector, also known as
Carrier Detect) when the phone liae carrier signal is detected/lost, respectively.
9.1. Set-up
(1)
(2)
ror Teledlqa01dcl
Using TelediagDostics requires that a modem be cooaected to the instrument. See Section 10
oa bow to cooaect a serial device.
Cooaect a direct-dial phone liac to modem's phone jack.

(3) Turn the power to the modem oa.
(4) Eater Exteaded Diagnostics Mode by turaiag the power to the instrument on while the Exe-
cute key is depressed; Use the Next Line/Previous Line keys to scroll to the Telediagaostics
entry; Start Telediapostics by pressing the Start key. The display should now say, "waiting
for service c:all", uacl the iastrumelll is ready to go.
The service represeatatiYe may DOW call the illstrumellt from the regional service center. The follow-
ing fuactioas are available to him via this remote liaJc
o Review of the iastrumeat's Maiateauce iq. This coataias the miJeage of the instrument-
lamp hours or pump stroke cydes, lamp intensity at iastallarioa, etc. Also available is a history
of iucnuDelll faults-sipi(J.Calll fault events that have occurred since the last time the Maiate
aance l.oi wu reviewed. The service represaatative may also dear the Maintenance Log, i.e.,
reset recorded faults, pump stroke counts, etc.
o Run an eXEeasive suite of diagnostic tests. These consist of the coldstart tests. which run when
the instrument powers up, and eltteaded tests, which are available (locally) ia extended mode.
Basically aU the standard tests can be run remotely but there are obvious limitations to some
tests which require the physical presence of the tester at the instrument.

SRmsion: 1.1 S
9010 Oi:lgnostics Description
10. Coaaecdlaa A Serial Devic:e

In some operailill modes. connecting a serial device to the instrument is required in order for the
instrument to fuDctioa properly. The following is a step by step procedure on how to connect a serial
device to the insuumeat:
(1) Remove the cover to the instrument.
(2) If it is nor already present, connect an interface cable, Varian P /N 03-919307-00, to the coo-
aec:tor labeled -rERMINAL" and marked as Jl2A oa the SBC Board (Some adjustment to
the positioa of the GPIB Board is needed if ir is installed as an option).
(3) Connect the RS232 cable from the serial device to the interface cable .
SRmsloa: 1.1 S
NGLC Solvent Delivery System 9010
Vesuvius
Timing and Position Control Overview
Author: David Michelsen
LC Engineeriq Department
VariaD lastrumeot Group
Walnut Creek Divisioa
Walnut Creek, Califoraia
October 24, 1988
Copyright 1988 by Varian Associates IDe.

NGLC SDS 9010 Timing/Position Overview
TABLE Of CONTENTS
1. SCOPE ...................................................................................................................................
2. PUMP CONTROL SUBSYSTEM OVERVIEW ...........................................................
1
1
3. TIMING/POSmON CONTRO.L DESCRIPTION ....................................................... 1
3.1. The Circle Model ................................................................................................ 1
3.2. The Mechanical Hardware ................................................................................ 2
3.3. The Position Device Software Model ............................................................. .. 2
3.4. How the Electronics Support the Software ..................................................... 3
3.5. Pump Geometries ................................................................................................ 4
3.5.1. Top Dead Center (TDC) ................................................................. 5
3.5.2. Bottom Dead Center (BDC) ........................................................... 5
3.5.3. Fill Stroke ........................................................................................... s
3.5.4. Valve Offset ........................................................................................ s
3.5.5. Effective Fill Angle (EFA) .............................................................. 5
3.5.6. Base End Fill (BEF) ......................................................................... 6
3.6. Fill Stroke Duration ............................................................................................ 6
3.7. Proportioning Algorithms ------- 6
3.7.1. Single Stroke Proportioning ............................................................. 6
3.7.2. Solvent Ordering --------------... 6
3.7.3. Glitch Correction ............................................................................... 6

3.7~4. Secondary Valve Offset .................................................................... 6
3.7.5. Cam Noa-Linear Regioa Correc:tioa ----.. 7
3.8. Tb.e Cam Events -----------... 7
3.8.1. DUMMY_POS ----------- 7
3.8'~ V.AL'VEl_POS ---------------- 7
3.8.3. V.ALVE2_POS ---------..---- 7
3.8.4. V.ALVE3_POS .........----------- 8
3.8.5. V.AL'VE_CI.,OSE_POS ------- 8
3.8.6. END_FILL...POS ------------ 8
3!1..7. CHK_POIN'r_POS ----------- 8
3.8.8. BEGIN_FILL_POS ------------...... 8
4. f1GURE 1 Pump Coatrol Device DI'Wer Structure Chart ----... 10
5. f1GURE 2 1'be Circle ------------... 11
6. APPENDIX. ------..------ 12

6/15/88
J. Bennett
FUIP SPKCIPIC&ftal a.IPARI80118
LC5500 LC 9010 HP 1050
Flow Rate 0.00 to 1.00 ml/min in 0.010 to 5.0 ml/min in 0.001 - 9.999 ml/min in
0.01 1/ain steps and 0.010 ml/min steps between 0.001 ml/min increments.
1.00 to 15.00 ml/min in 0.00 and 1.00 ml/min and
0.1 ml/min steps. 0.1 ml/min steps between
1.0 and 5.0 ml/min.
Operating Pressure 0-410 ata (6000 psi). 0-410 ~ (~000 psi) 0-400 atm (5880 psi)
up to 5 ml/min;
0-200 atm (2950 psi)
up to 10 ml/min.
Flow Precision t0.3' RSD at 1.0 ml/ain <0.3' RSD at 1.0 ml/min <0.3' RSD (typically
with ACH/water at 1000 psi; MeOH/water. <0.15\) based on
1.0, RSD at SO ~l/min with retention time, at 0.5
ACH/water at 1000 psi. ml/min and 2.5 ml/min.
1-'luw Accuracy t0.5' at 1.0 ml/in IPA 10.5' at 1.0 ml/min IPA. Mot specified.
at 2000 psi.
Coalpositional t0.1' absolute atany 10.1' absolute. tQ.25' absolute (typically

Precision isocratic flow rate. t0.15\), peak to peak, water/
ACH 0.5 ml/min to 5.0 ml/min
without mixer.
C011p0altional 10.5' absolute at any tO.S\ absolute. Hot specified.

Accur.ay isocratic flow rate.
Delay Vol._. Hot specified. 1 1 at 0 atm. 800-1000 ~1. dependent on

backpressure.
dP/P Not specified. <2\ at 150 atm. <2\ (typically <1\)

at 1 ml/min IPA at all
pressures >10 bar.
loc
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IP PU.soCJil4L
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.711'~ pot ,n-- Ci/4"96.1 4S
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6JD. Ru ~LdC-~IY

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~-(!,()

1. SCOPE
This document gives an overview of the Timing and Position aspects of the NGLC Solvent
Delivery System 9010 Pump Control Task (PerL}, the POSITION Device driver and their control of
the physical hardware. It is not meant to be a comprehensive description of the pump hardware and
software designs but rather is meant to tie the desigDs together, describing bow the hardware sup-
ports the software in the operation of the pump.
This documentation also contains some brief descriptions of the Proportioning Algorithms, the
device drivers, Pressure Regulation and other algorithms. AgaiD, these topics are covered in more
detail in other documents and are only covered well-enough here to make the rest of the discussion
understandable.
For more information on the hardware designs, see the 9010 schematics (Drawing no. 03-
919058-00) and the SDS 9010 Circuit Description.
For more information on the software desigDs, see the 9010 Pump Con11'01 Task Design Specifi
clltiora and the the device driver design documents: Cam Po.ridon Subsystem Design Specification,
Motor Control Subsystem Design Specificlltion and Flow Coni1'0I Subsystem Design Specification.
See the Appendix for a complete list of references that more-completely describe many aspects
of the SDS 9010.
2. PUMP CONTROL SUBSYSTEM OVERVIEW

The SDS 9010 makes use of SC\'t:ral software processes to control the various hardware associ-
ated with the 9010. The Pump Control Task is the process that is responsible for controlling the
pump hydraulics. Its inputs include flow rates and soMal compclitioas. Its outputs are pump
stepper motor, pump cam position and valve control commands.
The Pump Control Task interacts with three devices: POSmON, MOTOR and FLOW_CTRL.
The POSITION device accepts data items called Position Vecton. These vectors include
instructions for the valve and motor actions that ue to occur at different" cam positions. It is the
POSITION device's respoasibillty to see to it that these ac:tioaa take place wbea the pump's cam is in
the specified pclitioa.
The primary purpose of the MOTOR ctmcc is to provide coatroDed (ac/de)celerations to the
aew desired velocity usiDg the appropriate acceleradoa algorithm. It is controlled by both the POSI-
-
TION and FLOW CI'RL devicea.
.
The purpose of the FLOW_CTRL device is to determine the aew desired velocity. The
FLOW CTRL device baa two operatioaal modes, OpeD-Loop flow Control and Oosed-Loop Pres-
sure Regulation. Pressure Regulation is aot curreatly used in the product. The FLOW_CTRL dev-
ice reads and uses the curreat operatiaa pressure iD its motor \'eloc:ily cletermiDatioa.
See the appendix for a list of documents that discuss the~ ill more detail. See F'lpl'e 1,
the Pump CDnii'OI Device DrMr Sll'lletln C7ulrr, for a pictorial representation of the above-meatioaed
compoaeats.
3. TIMING/POSmON CONTROL DESCRIPriON
3.1. The Clrde Model

To visUalize the position dependencies within the pump, a coaveaieat model for discussion has
beea prepared, the Circle. Figure 2 contains the Circle Diagram that will be referred to ill the fol-
lowing discussion.
The Circle represents the positions of the cam as it trawls throughout its fuU pump stroke.
The left side of the Circle represents the rill portioa, while the right side represents the Empty por-
tion. The 9010 camshaft rotates ill a counter-clockwise direction as seea &om above and the Circle
model was designed to give a similar view. The 9010 is a pclitioa-drivea system and different actions
NGLC SDS 9010 nminlfPosition Overview
are performed when the pump reaches these positions. When the pump reaches a programmed posi-
tion, a software interrupt is generated. This is called a eam Event. The Cam Events are indicated
by black dots on the Circle. Simple lines on the Circle denote other imponant locations on the cam
but no Cam Events occur at those positions.
The unit of angular distance in the pump is the eam Step and those arc the units labelling the

positions on the Circle. There are 4096 cam steps per cam revolution. The Circle is also labelled
with degrees (0 degrees being Top Dead Center) for the reader's convenience. These units of meas-
ure are related to, but different from, the motor steps applied to drive the motor. AU measures arc
in reference to Top Dead Center (i'DC).
3.2. The Mechanical Hardware

The physical pump consists of the pump frame with motor, belt, cams, cam followers, optical
switch and the pump head. The pump head consists of the machined head, inlet valve, outlet check
valve, proportioning valves and piston.
The piston moves backwards (retracts) while the cam is in the f"ill portion of the stroke and
moves forward (extends) while in the Empty portion. There is a 10 degree dwell just before the stan
of the Empty portion where the piston is stationary. This dwell keeps the solvent still while the inlet
valve is closing. preventing undesired effects.
The inlet valve is physically opened when the cam is positioned at 30 degrees. The solvent,
however, may not enter the pump head until later depending on the operating pressure. The higher
the pressure, the more piston retraction is neCdecl before a vacuum is pneratecl to draw more solvent
iDto the head.
The proportioning valves are opened at specific 1ocaliou in the Fill stroke according to their
programmed percentages. During Single Stroke proportionina, if a 75'5 A I 2S% B composition is
desired, then valve A is opened for the first 7S% of the f"ill stroke and then B is opened for the
remaining 25%.
The outlet check valve prevents dowDstream so1Yeats from moW~& bact into the head while it is
refimng It remains dosed IS long IS the pressure ill the dowastream hydraulic:a is greater than that
in the head. It will open again when the pump repressurizes after entering the Empty portion of the
stroke and the head pressure exceeds that of the dowDs"tream hydraulics.
The pump is driven through a belt arrugement that provides 1 cam ~lution for every 2
motor revolutions. An optical switch triger mounted on the cam shaft a11owa the electronics to mon-
itor the pump's location and syachronize with it.
3.3. 1be Posltloa DeYice Software Model

The POsmoN DeYice is aa output device that accepts POiilioa Vectors from the Pump Con-
trol Task. Each POiitioa Vcc:tor is aa iastructioa that specifies both the cam position aad the actions
that are to take place at that cam positioa. Each POiition Vector wiD eveatually produce a Cam
Ewat ud caasc the actions to take place ill the system.
Tile POSMON Device is a buffered device. Tbat is, the Pump Task places these Position
Vcc:ton on the back of a queue ad the POSmON Device taka diem off. IS DCCded, from the front.
At each cam event, after the actions associated with a partic:ular cam CftiU are executed, then the
actions for future cam events arc setup. In fact, due to the hardware clesip descn"bed later, the three
actions (Motor, Valve aad Position) associated with a siDgle cam CftiU are setup at three different
Cam Events as follows:
l

NGLC SDS 9010 nming/Positlon Overview
Cam Event Action Setup Location
Cam Event N Motor Action

Cam Event N Valve Action
Cam Event N Position Action
Setup at Cam Event N
Setup at Cam Event N-1
Setup at Cam Event N-2
What the above table indicates is that the POSmON Device is processing Position Vectors for
Cam Events two in advance. In reality, the Pump Task must have this vector ready BEFORE the
two in advance. The Pump Task places a whole strokes worth of Position Vectors in the queue just
after the CHK_POINT_POS position (see Figure 2). In this way, the POSmON Device can begin
setting-up the actions at the next Cam Event (BEGIN_FD..L_POS) for the Cam Event at
VALVEl_POS.
For each of the three VALVEn_POS Cam Events listed on the rill side of the Circle in Figure
2, there are listed the Actions Performed/Setup at that Cam Event. Note that the VALVE3 POS
Position Request, the VALVE2_POS Valve Action and the VALVEl_POS Motor Action are 'Setup
at the VALVEl POS Cam Event. Similar actions are setup for the VALVE2 POS and
VALVE3_POS Cain Events. -
3.4. How the Electronics Support the Softwan

Now that a little of the software operation of the pump bas been described, we can proceed to
describe the electronic hardware that supports the software. .AgaiD. please refer to the 9010
Schematics for more detailed information.
The motor that drives the pump is a m.icr~stenped stepper motor. There are 64 mia~steps to
a full motor step and 200 full steps per motor revolution. The Siagle-Board-Computer (SBC) pr~
vides the Motor Valve Dmer (MVD) Board with a square-waw pulse train of miao steps which
causes the motor to take a mia~step with each pulse. This is generated through the use of a
lOMHz crystal input to a pair of cascaded 16-bit timer /coUDters. The counters can be loaded with
different values to output pulse trains with different frequencies to the MVD. The higher the fre
quenc:y, the faster the motor turns.
In addition to being directed to the MVD, tbe motor rate pulse train is used as input to two
other timer/counters. They are the Cam POiiDoa counter ud the Cam E~t counter. The Cam
Positioa counter bas two functioaa. It is used for staB detec:tioD ud for obtaining the current cam
positioa. The Cam Posidoa counter is preloaclcd a sinale time wbea the software is initialized ud
reloaded by the optical switch once per miOiutioa. 1'1til CIOUider is pre-loaded with the number of
micro-steps per cam revolution plus some for slop. U tbe c:ountcr ever apires (counts down to zero)
before being reloaded by tbe optical switch, then the IDOCor is step-llgiag (not following the steps
that have been applied to it), a software inrerrupc is ~ uad a pump stall is reported. This
counter may allo be read while it's c:ountiDc dowa to obcaiD tbe current position of the cam. The
read fUDctiGil is not currently used by the software.
The sec:oad counter, the Cam Event counter, is used to prOifiDI offsets between Cam Events
Interrupts. Wben the Cam E~t counter expires, scvenl tbiDp happen simultaneously:
(1) A Cam Event Interrupt is returned to the software. The software then (a) Performs the
current Cam Event's Motor Action, (b) Prosrama the Valve Action for the NEXT Cam Event
and, (c) Programs the Position Request for tbe C.. E1'Cnt AFI'ER NEXT.
(2) The hardware latches the previously-programmed Valve Action into the Valve State Machine.
The hardware Valve State Machine thea buena providiag the appropriate signals to the
MVD to open the desired valve.

(3) The hardware loads the previously-programmed POiiliae Request (offset) from the pre-load
register into the counter register and begins dowtl cx:Mi for the next Cam Event.
3
NGLC SDS 9010 nmini/Posltlon Overview
By having the last two actions clocked-in by the hardware, any software latency and rcpoducibil-
ity problems are avoided.
Both of the above counters arc reloaded by the optical switch at Top Dead Center. The TDC
signal from the optical switch is connected to a Oip-flop which converts a relatively wide signal into a
single, rising clock edge. This ARM_TDC Oip-flop will not re-triggcr again until explicitly re-armed
by the software.
This rising clock edge is loaded into a second Oip-flop which is used as input to a four-stage
flip-flop arrangement whose clock is the motor rate signal When the first stage of the four-stage
arrangement is set, then the gate inputs of Cam Event and Cam Position counters arc driven low and
then high again at the next pulse, loading the counter registers with the pre-load values.
When the last flip-flop is set four micro-steps (pulses) after the TDC signal, then an interrupt is
signalled to the software. The above-described circuit ensures that the counters arc reset and
reloaded before the software interrupt service procedure places a new value in the Cam Event pre-
load register.
The Valve State Machine mentioned above is a hardware state mac:hinc that consists of a
PROM, flip-flops, decoder/multiplexer and a clock input. When a Cam Event interrupt occurs, the
previously-loaded valve action is clocked as an input to the state machine which then proceeds to take
the steps necessary to perform the requested valve action. The input valve actions arc:
VLV OPEN A Open Proportionina VaJve A

VLV-OPEN-B Open Proponioaina VaJve B

VLV-OPEN-C Open ProporUoaiDg VaJve C
VLV-OPEN-D Open Proponioaina VaJve D
VLV-ALL CLosE Clolo All Proportioniq Vahes
Note that VaJve D is cumady unused.

The outputs of the state machine (and inputs to the MVD) are the four Valve Select signals
(MVA, MVB, MVC and MVD) and a shared "Higgl CurreDt sipa1 (MHIVC).
The above valve actions aren't necesaarily performed immediately when requested. For exam-
ple, if Valve A is open when a request fcw Valve B is made, thea the state machine must first dose
Valve A before openiq Valve B. These delays are typically oa the order of a couple of milliseconds.
There arc two different current levels required to open a valve. Tbe first is the puU-in c:urreDt that
opeas the valve. Once opeaed, the current is dropped to the lower, holcfins current. The valve state
machiae coatrols the tiJDiaa of these c:urreat levels paeratecl by die MVD. See the YIIM SliD
MfldaiM Hflldwtn DuaiptiDia for the derails and timing illformadoll of the state machine. See also
the MYD Cilr:uil Duaiptioll for more oa the theory and operatioa of the proponioning vaM:a.
3.5. Puap Geoaletrles

There are several c:oastants, variables and calcultiou that are used ia determining the loca-
tions of the various Cam Events. Some of these pometrica are defined below. Ally positions
described arc ia terms of Cam Steps (with degrees ia parentheses). Note that position 0 for this dis-
.cussion (and internal to the Pump Control Software) corresponds to Top Dead Center and that in
some mechanical design documentation a position of 0 degrees may correspond to Bottom Dead
Center. Let the reader beware.
Some of the terms below represent values that were empirically derived. If that is the case,
then they arc subject to change based on further testing or algorithm development
.
NGLC SDS 9010 Timini/Posilion Overview
3.5.1. Top Dead Center (TDC)

The Top Dead Center position is that point in the pump stroke where the piston is fully
extended and the direction of piston motion changes from extending to retracting. Top Dead Center
is at Cam Position 0 (0 degrees). Top Dead Center is the reference point for all discussion of angu-
lar distances.
3.5.2. Bottom Dead Center (BDC)

The Bottom Dead Center pesition is that point in the pump stroke where the piston is fully
retracted and piston motion ceases. That is, the point at which the cam enters the 10 degree dwell at
the end of the Fill portion of the stroke. Bottom Dead Center was empirically derived and is at Cam
Position 2200 (193 degrees).
3.5.3. Fill Stroke

This term may refer to several different things in other contexts. However, for purposes of this
documentation, it will mean the angle between the BEGIN FILL POS position and the
END_FILL_POS position. That is, the angle during which the motor is travelling at (or accelerating
to) Fill velocity. Others may use Fill Stroke to mean the angle between TDC and the end of the
mil at the end of the Fill stroke. Still others may say it is strictly the portion between TDC and
zns Cam Steps (200 degrees).
3.5.4. Valve Offset

The Valve Offset is the offset from TDC at which the pump begiDs to draw in solvent. This
position is a function of the current operating pressure. The followiDg describes the calculation used
to determine the Valve Offset position. The constaDts in the calculation have been empirically
derived and may be further adjusted to account for manufacturiag tolerances throup the use of the
SBC SS Dip Switch.
INLET ANGLE - 0 Cam $teps (0 degrees)

VLVOFF PER lOOATM 30 Cam Steps/100 ATM
CURRENT PREssURE <Current Pressure in ATM>
CALIBRATION_VALVE_OFFSET <SBC Dip Switches SS/1-7>
(IDlerpretecl as bbwy Cam Steps)
VALVE_OFFSET INLET ANGLE +

(VLVOFF_PER_100ATM CURRENT_PRESSURE) +
(CALIBRATION_VALVE_OFFSET 2) .
The VALVE_OFFSET is subject to a:

Minimum of: 11 Cam Steps (1 degree)
Maximum of: BDC - 114 Cam Steps (BDC - 10 degrees)
3.5.5. Ell'ectlve Fill AnaJe (EFA)

The Effective Fill ADgle is the angle over which proportioaiag is actually taking place. This
angle does not simply map to any of the defiDitiona of f"'ill Stroke from abcm:. It generally c:owrs
most of the angle where the piston is being retracted but has different bouDdaries. The Effective Fill
ADgle is the angle between the Valve Offset position and the BDC position.
5
NGLC SDS 9010 nmlni/Posltion Overview
3.5.6. Base End Fill (BEF)

Pressure pulsations can be minimized within the pump by varying the cam position at which the
motor switches from Fill velocity back to Empty velocity. This position is both a function of pressure
as well as flow rate. The Base End Fill position is the theoretical position at which the velocity
change should take place when operating at a flow rate and pressure of zero. This "End Fill Adjust

ment is discussed in more detail in the Cam Events section. The Base End Ful was empirically
derived and is at Cam Position 2280 (200 degrees) for 200 millisecond fill strokes and at Cam Posi-
tion 2330 (205 degrees) for 400 millisecond fill strokes.
3.6. FIJI Stroke Duration

The 9010 uses two different fill velocities, yielding 200 ms and 400 ms fill stroke durations. The
fast fill is used during single solvent operation when time-critical proportioning is not used. The slow
fill is used when proportioning 2 or 3 solvents and also at sub 100 ul/minute flow rates.
3.7. Proportloniaa Algorithms
3.7.1. Slape Stroke Proportioning

With Single Stroke proportioning. the entire solvent composition is proportioned on a single
stroke. That is, of the 75 micro-liters delivered, if the desired composition is 33.3% A, 33.3% B and
33.4% C, the~ 25 micro-liters of each solvent will be proportioned and dcliwred on that stroke. The
Effective Fill Angle is simply divided into three equal angles and the Cam Events programmed
appropriately. This is in contrast to the 5000 series pumps which use a Four Stroke algorithm (see
Temt~~Y Gnzdient Pllletlt Disc/OSI.W in appendix).
3.7.2. Solvent Ordering

The Valve Offset correction after Top Dead Center attempts to minimize the effects of solvent
decompression. However, it is not perfect and could cause significant proportioning inaccuracies if a
small amount of solvent was proportioned at the begiaaiaa of the Effective Fill Aqle. If the solvent
left in the head was not fully decompressed, thea the bead miabt not start dri.wina in solvent until
after that first valve was since closed. For this reason, to minimize error, the solvent with the largest

mapitudc is always proportioned fii'SL AD absolute error is a smaller perceatage of a large quantity
than a small quantity.
3.7.J. Glitch Correctloa

The above Solvent Orderina solves one problem but creates another. Since there is a residual
(dead) volume within the pump head, a small amOUDl ol solveal will remaiD in the bead &om. stroke
to stroke. That is, the last 20 mic:ro-liten or so drawn in oa a given stroke will not exit the pump
head until the liCit stroke. This posea no problem wbea the solvent ofderina remains the same.
However, wileD the relative magnitudes of the solveau chap, and hence the solvent ordering. thea
it is pouible for the fint solvent proportioned OD a pa suoke to exit the head with some of that
same soheat &om the pre'Yious stroke (if it was preWglJ tbe smallest solvent), thus creatina a
glitch. The Siqle Stroke aJaorithm from above will proponioa u iatermedial:e transition stroke to
eliminate this glitch whenever the solvent order cha..,.
3.7.4. Secondary Valve Olrset

The Secondary Valve Offset is applied to the~ politioa of the second valve duriaa ter
nary proportioning. It purpose is to correct for the aoa-a.ruc.neous valve opeaiaa times. Its value
is 6 Cam Steps.

'
NGLC SDS 9010 Timini/Position Overview
3.7.$. Calli NoaUaear Repoa Correction

The Effective Fill Angle is the region between the Valve Offset and the BDC position. The
dwell region of the cam begins at Cam Position 2162 (190 degrees) and continues to Cam Position
2275 (200 degrees). From above, the BDC position was empirically derived as being at Cam Position
2200 (193 degrees). This shows that the end of the Effective Fill Angle covers a non-linear region of
the cam. That is, the relationship between angular distance and piston motion is no longer a linear
function. The Inlet Valve poppet is closing at this point, dispiac:iag solvent and causing additional
ooa-liaearities as well. For these reasons, an empirically-adjusted algorithm has been included that
ac:c:ouats for this change and bas the effect of slightly modifying the end of the Effective rill Angle.
3.1. 1be Cam Events

There are between 6 and 8 Cam Events per cam revolution depending on the proportioning
algorithm in use and the number of solvents used. Cam Events are restricted to be no closer than
approximately 1 degree from each other since the software latency in serviciag those Cam Events at
Fill velocity causes severe timing problems. That is, the software c:aDDOt service the interrupU fast
enough. Refer again to the Circle Diagram for the following descriptions of the individual Cam
Events:
3.1.1. DUMMY_POS
There are two coaflicting requirements with regard to the VALVEl_POS Cam Event. The
valve opened at the VALVEl_POS Cam Ewnt should be determilled IS late in the Empty Stroke as
pouable to conform to the solvent composition specified in the method at the time the pump eaters
the fill stroke. However, the actions associated with Cam Ewats must be set up two Cam Ewats in
advance. Since there aren't otherwise the required number of Cam EYCats between the position the
Cam Ewats are requested (in the form of Position Vecton) and the position the VALVEl_POS
Cam Ewat occurs, a dummy" Cam Event has been programmed to allow the desired late specifica
tioa of the Position Vectors. This is the sole purpose of the DUMMY_POS position.
3.1.2. VALVEl_POS
The valve regulating the first sol'Veat to be proportioned on this stroke is opened at this Cam
E'Vellt. The solvent with the largest percentage to be proportioaed (on this stroke) is always opened
first regardless of the proportioaiag algorithm in use. Tbe cam positioa of this Cam Event is deter
mined in Cam Steps IS follows:
Ynl PDiillcll ~
VALVEl POS VIM Ofl'sct
VALVEl POS is subject to a:

Minimum of: DUMMY_POS + 23 Cam Steps (2 dqrees)
Note that the VIM Offset position cu be smaller thall the VALVEl_POS position. What this
meaas is that the entire Effectift f'dl Aqle cu be wped to pardcular soheats for calculational
purposes. Howewr, the actual Cam E'Veat that opeas the first valve will Dot occur at least uatil the
.minimum position described abcwe. This doesa't pose a problem siace the minimum position of about
8 dqrees is far less thaD the physical pump head's ia1et aaalc of 30 dearecL
3.8.3. VALVEZ_POS
The valve regulating the second solveat to be proportioned OD this stroke is opened at this Cam
Ewat. This Cam Event is only programmed when aecessary and must occur oae degree inside the
7
NGLC SDS 9010 nming/Position Overview
angle defined by VALVEl_POS and the minimum of VALVEJ_POS (if defmed) and the end of the
Effective rill Angle.
3.8.4. VALVE3_POS
The valve regulating the third solvent to be proportioned on this stroke is opened at this Cam
Event. This Cam Event is only programmed when necessary and must occur one degree inside the
angle defmed by VAL VE2_POS and the end of the Effective rill Angle.
3.8.5. VALVE_CLOSE_POS
The last valve opened during the Fill portion of the stroke is closed at this position. This Cam
Event is programmed to occur at Cam Position 2445 (214 degrees) but may move 1 degree either
direction depending on the position of the END_FILL_POS Cam Event.
3.8.6.. END_FILL_POS
This Cam Event specifies the position at wbich the motor chaDges from the rill Velocity to the
Empty Velocity. The END_FILL_POS Cam Event varies between Cam Positions 2280 and 3674 (200
to 323 degrees) and is a function of Flow Rate and Pressure as follows:
End Fill Position CA/cullllion
PRES COEF .4042 (200 ms) FLOW_COEF .1001 (200 ms)

PRES:coEF .3700 (400 ms) FLOW COEF .1900 (400 ms)

BASE END FILL 2280 (200 ms)
BASE:END:FILL 2330 (400 ms)
END_FILL_POS (Cam Steps) BASE END FILL +

PRES-COEF CURRENT PRESSURE +
FLOW COEF CURREN'f FLOW RATE
Since the END FILL POS Cam Event caD move between BASE END FILL and
CHK_POINT_POS (lesi S deiees). the END_FILL_POS Cam Event might be before, after or share
the same position as the VALVE_CLOSE_POS Cam Event.
Since Cam Events ve restricted from being closer than 11 Cam Steps (1 degree) from each
other, when the END FILL POS Cam Event is witbiD that distance of the VALVE CLOSE POS
Cam Event, they then will Share a CODUDoa Cam Event at the END_FILL_POS_positioa._The
END FILL POS Cam Event is the one used since it is much more sensitive to changes and the
VALVE_cLosE_POS Cam Event is DOL
3A7. CHK_POO'-f_POS
The CHIC POINT POS Cam Event occurs at a point approximately ~ of the way through
the Empty pordoa of the stroke. It is at this point that several of the control parameten are re
calculated, the filtered pressure is checked for cleterllliDillg Valve Offset and End rill Correction and
the Position Vecton are determined for the llC1I stroke. This position was chosen for the above
activities because the pressure is most stable at this point. The CHK_POINT_POS Cam Event
occurs at Cam Position 3731 (328 degrees).
3.8.1. BEGIN_FILL_POS
The purpose of the BEGIN_FILL_POS Cam Event is to start the motor acceleration from
Empty velocity to rill velocity. This acceleration is begun at the point where the piston starts slowiDg
I
NGLC SDS 9010 Timini/Position Overview
down to change direction at TDC. The increased velocity at this point compensates for the slower
piston travel per angular distance and also has the motor fully accelerated shortly after TDC to com-
plete a quick F'ill stroke. The BEGIN_FILL_POS Cam Event has been empirically derived and
occurs at Cam Position 4060 (3.56 degrees) .
9
NGLC SDS 9010 Tlmlng/Poslllon Overview
FIGURE 1
Pump Control Dnlce Driver Structure Chart
p
lJ
(iexch) t----, M
(oexch} p
1'
A
Position Vectors s
)(
poaclrl mtrclrl flwctrl s

w
Data Store
Items D
'Q_ailioll AcUo1 Uolo. f~
uata :store Dala Store v
s I
Stall Usg c
E
(iexch mtracisp I "\. I flwisp
D
R
I
pos 1 IPOS pos ).folor Timer Column Conversion v
vivid read Rale Expiration Pressure Complete E
H
Valve
s
A.clion
H
A
H
n
----'
Ex pirn lion
A
H
w
I'
NGLC SDS 9010

FIGUREl
The Circle

Tlmlng/Poslllon Overview
TOP- DEAD-CENTER (TDC) CP 0 (0)
BEGIN-FJU.-POS
CP 4060 (356)
VALVEl-POS
CHK- POINT- POS
ACTIONS SET-UP 0 VALVEI-POS
(I) VALVEl-POS Nolor Action CP 3731 (328)
(2) VALVE2-POS Valve Action
(3) VALVE3-POS Position Request
CAM
ROTATION
......
VALVE2-POS
ACTIONS SET-UP 0 VALVE2-POS
(1) VALVE2-POS Motor Aclion
(2) VALVE3-POS Valve Aclion
(3) VALVE-CLOSE-POS Pos. Requesl
END-FILL-POS CP 2110-3674 (200-323)

VALVE3-POS VALVE-CLOSE-POS CP 2434-2456 (213-215)
ACTIONS SET-UP 0 VALVE3- POS ASE-END-FJLL (BEF) CP 2.~80 (200)
( l) VALVE3- POS Motor Action .
(2) VALVE-CLOSE-POS Valve Action BOTTON-DEAD-CENTER (BDC) CP 2200 (193)
(3) END-FILL-POS Position Request Beginning of Cam Dwell Region CP 2162 ( 190)
NGLC SDS 9010 Timing/Position Oveniew
6. APPENDIX
(1)
(2)
(3)
SDS 9010 Schematic, PCB, SBC, Drawing No. 03-919058-00
SDS 9010 Schematic, PCB, MVD, Drawing No. 03-919062-00
SDS 9010 SBC Circuit Description, by Tony Chern and Joergen Bardenfleth

(4) SDS 9010 MVD Circuit Description, by Ross Harrower
(5) SDS 9010 Top Level Design Specification, by John Hartman
(6) SDS 9010 Pump Control Task Design Specification, by David Michelsen
(7) SDS 9010 Cam Position Subsystem Design, by David Michelsen
(8) SDS 9010 Motor Control Subsystem Design, by David Michelsen
(9) SDS 9010 Flow Control Subsystem Design, by David Michelsen
(10) Val~ Pre-Driver State Machine Desaiption, NGLC SDS 9010, by Joergen Bardenfleth.
Apri116, 1985, Revised May 28, 1986.
(11) Glitch Removal from NGLC Gradients, by St~ Schachterle. Memo #SS-1/86, January 8,
1986.
(12) Ternary Gradient Patent Disclosure, by Jonathan Ryshpan and signed by Ken Judah, Febru-
ary 28, 1980.
(13) Intel Miaoprocessor and Peripherals Handbook, Copyright 1982, Intel Corporation.
u

s-u~ ~o \O
~"(~~~ . ~~C....r\ ~\~C..'~~~
1:.1-'m
MoTe- ~4!::~:=Tf::::...._J FLDw
C:.O~\..
Y~\'T\ow ~.:)~
Vt\&.V"i.S
OV\\.~\.. ~\\t..~
~~c:...

9012 SOLVENT DELIVERY SYSTEM
MAINTENANCE LABORATORY
1
name: ________
date: _ _ _ _ _ _ __
instrument #'s
-----
LCSTAR 194 LABORATORY #1
SYSTEM FAMILIARIZATION AND EVALUATION
Connect the 9012 SDS, 9050 UVNIS, PEM, Manual Injector, Column, Mixer/Filter, and
Backpressure Regulator according to the attached schematic.
Connect power cord to 9012 pump, turn power ON
This is a WARM START all methods will be saved.
What Revision is your 9012 running?_ _ _ __
Were methods saved?_ _ __
Connect each of the one liter bottles to Valves A, 8, and C:

Valve A to H20 + 2% 2-propanol
Valve 8 to H20 + 2% 2-propanol + 0.5% Acetone {fresh) for use with
procedures to follow.
Valve C to MeOH or ACN
What is the purpose of the 2-propano/?_ _ _ _ _ _ _ _ _ _ _ __
If valve Cis not in use should it be capped off or connected to a line? If yes,
Why?_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
Purge Procedure: Place a container underneath the purge valve spout and open the
purge valve counter clockwise one full tum.
On the keypad OPERATION section of the 9012 press the A button.
This will start the pump at 1Omllmin through valve A. Continue pumping until all
air has been removed from the lines and a steady stream is pumping out of the
purge valve. Repeat this procedure for Valves 8 and C.
Press STOP on the keypad OPERATION section.
Connect the power cord to the 9050 UVNIS Detector, tum power on.
This is a WARM START, all methods are saved.
The 9050 will go through an internal check during which SELF TEST is
displayed on the monitor.
At the completion of self test press the LAMP key. The lamp light will blink as
the lamp completes a startup procedure and then remains on.
2
LCSTAR 194 LAB ORATORY #1
Run Parameters for 9012 SDS:
On the keypad TABLE SELECT: press %ABC FlOW

. EDIT press SHIFT, DECREASE
continue pressing DECREASE until %A reaches 20%, note that
as %A decreases %8 increases. Set %C=80, %8=0.
EDIT press right cursor arrow=> until it is blinking beneath

Flow
EDIT press INCREASE
continue pressing INCREASE until flow reaches 1 mllmin.
On the keypad TABLE SELECT: press SET CONDITIONS

You should be using Meth 1.
Using the right=> and left e: cursor and the increase and decrease keys set the
following conditions:
Endtime
Action
Pmin
8.00 (assay will stop at 8 minutes)
Hold (method will wait for start signal to begin method)
6 (Pmin/Pmax are the minimum and maximum
pressures allowed for the pump to continue running)
Pmax 400
Equil time 0
If a PEM (Power Event Module) is in use:

On the keypad TABLE SELECT: press RELAYS
press cursor to select the first dash under the Relays ON position.
press INCREASE, a "1. should appear in the first position.
Line 1 .00 1 (relay on at time zero)
Line 2 .03 - (relay off at .03 minutes)
On the keypad OPERATION: press RESET

The Method, %A, %B, and %C, Flow, Pressure, Relays and Time
will appear on the LCD.
The 9012 is ready for a start signal.

3
Run Parameters for 9050 UVNIS Detector:
On the keypad TABLE SELECT: press AAUFS A/Z
Use the right~ and left<= cursor keys and the increase ft and decrease U
keys to set the following conditions:
"- 254
Aufs 0.5 (This is the sensitivity and will affect peak height,
inversely. It many require adjusting.)
AJZ yes
Using the right~ and left <= cursor keys and the increase ft and decrease U
keys set the following conditions:
Endtime 8.00
End Action Reset
Time Constant 1.0

The Method, actual absorbance units, Rcdr Aufs, Wavelength, Runtime and
Endtime will appear on the LCD.
/ .
He
or
Air
POWERED EVENT MODULE
J406
[li]
- INJECT
ELIVERY SYSTE 9050 UVNIS DETECTOR

'""' ~= ~ .d w ...
...."
----
ITI>mOoo
...... c
rn
- 0:
_.. 0: ...
--
---
Q-
._.. ;:::;::.
--
~ ~=I I I CUART RECOR01 I
----.. ;~~ ITill ~

-~ lOmV
Q-
,._, 1 em/min
200ul IN
REC
1.4ml OUT
START AT
START AT ~)I I f\il' '
BACK PRESSURE REGULATO~( ) . ~ v/(.6-\~

70% ACN RUN 70%MEOH

Flow Rate (ml/min.)
Pressure (atm)
Full Scale Range
I I Retention Times (min.) I I

80%ACN RUN 80/o MEOH
Flow Rate (mVmin.)
Pressure (atm)
Full Scale Range

90/o ACN RUN 90o/o MEOH
Flow Rate (mVmin.)
Pressure (atm)
Full Scale Range
PREVENTATIVE MAINTENANCE CHECK LIST
D 1.
LC9000 SERIES PUMP
With power cord disconnected, remove covers and clear out

accumulated dust.
0 2. Visually inspect circuit boards and check that all cable connections
are secure.
0 3. While powering up and down ensure that the cooling fan is running
quietly and is not sluggish at turn on.
0 4. Clean/Lubricate spring housing assembly

Inspect piston surface for scratches
clean cam shaft
replace and grease grease guard
replace piston seal
5. Check/Replace outlet check valve filter.
0 6. Leak test system
0 7. Set inlet valve gap
0 8. Test reservoir filters
0 9. Calibrate pressure sensor readout. (ADC TEST)

Check/replace battery
0 10. Check replace mixer filter
0 11. Test damper
0 12. Check/calibrate volumetric efficiency
0 13. Verify operation as part of LC system (with UV test sample or

customer sample).
0 14. Update Customers' Maintenance Log Sheet

9012 MAINTENANCE PROCEDURES
LEAK TEST
Purge lines with water to remove all air. Insert and tighten a 1/16" Teflon
plug (Varian P/N 28-211489-00) in the outlet end of the damper.
In Extended Diagnostics access "Leak Test."
Press START.
Display reads: Select test mode: CONSTANT PRESSURE
Press NEXT LINE
Display reads: LEAK TEST PRESSURE: 200ATM
Press NEXT LINE
Display reads: Press START key to begin pressurization
Press START
Pump motor should start to tum, and pressure will begin to build. Check that all
fittings are tight and free from leaks. When the pressure reaches 200Atm, the
9012 begins to measure the "leak rate." The 9012 has passed the leak test when
the ul/min has dropped below O.Sul/min within approximately 5 minutes.
Typically the ul/min readout will drop to O.OOOul/min within 10 minutes.
Press STOP
Leave system pressurized for the inlet gap adjustment procedure.
INLET GAP ADJUSTMENT
The inlet valve timing is very critical, therefore the clearance of the inlet valve
must be adjusted to 0.046" using a gapping tool. If the valve gap is <0.046", the
mobile phase solvent may leak into an opposing solvent reservoir on a piston
compression stroke. If the valve gap is too wide, there may be cavitation with the
pump head resulting in low flow rate and erroneous proportioning.
Pressurize pump via the leak test.

In Extended Diagnostics access: EXTEND PISTON (for inlet Gap Adjust)
Press START X2
Display will flash through the following screens:
Positioning is in progress, please wait
Piston is extended (at Top Dead Center)
Retract Piston Before Replacing Head
When piston is extended, manually rotate the pump motor clockwise four
"clicks." This will ensure that the piston cam is at its highest point and
the inlet actuator is on the pressure side of the stroke.
Loosen the set screw (top) holding the inlet gap adjustment flathead
screw in place.
Adjust the gap to 0.046" with the gapping tool by adjusting the set screw.
Relieve Pressure
Continue to ADC Test
ADC TEST (PRESSURE TRANSDUCER CALIBRATION)
This test calibrates the pressure transducer zero and gain settings .
Relieve all pressure from the system.

In Extended Diagnostics access: ADC TEST
Press START, the following parameters will appear on the LED:

XXX 5.000 3.000 0.000
Adjust the offset screw at R-43 on the upper left comer of the SBC board
so that PRS(atm) reads 0.125. Clockwise increases.
Press SHIFT, PRS(atm) changes to PRS(atm) and the readout will
increase to the upper calibration value. Adjust R-44, located next to R-43,
so that this parameter reads 500.00.
These numbers are affected by temperature. Assure that the pump is on for at
least an hour with the cover on. The lower number affects the upper (but not vise
versa) so go back and forth until you are comfortable that the numbers are
holding at their set points .
2
9012 SDS LABORATORY
Start-up,
Assure that all plumbing and electrical connections between the 9012 SDS and
9050 UVNIS are properly connected.
Power up the 9012 (switch in right rear upper corner).

Power up the 9050 UVNIS. (switch in right rear upper corner).

The 9050 will go through an internal check during which SELF TEST will
be displayed on the LCD.
At the completion of this test press the LAMP key to turn on the lamp.
The light will blink as the lamp completes a 70 second startup procedure
and will remain illuminated.
To access Extended Diagnostics in the 9012 SDS simultaneously press

SELECT and turn power ON
This connects the Diagnostics Menu.
Follow the Extended Diagnostics procedures Addendum A.
Access, and become familiar all procedures in the Extended Menu and
answer relevant questions.
3
9012 SDS LABORATORY
INSTRUMENT TEST PROCEDURES
4
9012 SDS LAB ORATORY
SUMMARY OF PROCEDURES
Certification Procedures page

Flow Rate Accuracy 22
Verifies the flow accuracy of the pump; requires
a calibrated digital flow meter.
Gradient Linearity 20
Verifies the linearity of the proportioning adjustments.
If it meets the 1% specification there is no need to run
the AB/AC proportioning.
Optional Certification Procedures
AB Proportioning 8
Determines slight differences between proportioning
valves A and B.
AC Proportioning 8
valves A and C.
Proportioning Procedures
20-25% Proportioning 10
Establishes full scale in a range that is known to be
linear on the 9012.
1% Proportioning 12
Mechanically adjusts optical switch.
5% Proportioning 14
50-51% Proportioning-AS 16
50-51% Proportioning-AC 18
Adjusts electronics of optica1 switch.
Off-line Procedures
Solvent Filter Test 5
Verifies the solvent filter is not clogged and _
contributing to a slowed or variable flow rate.
Mixer Filter Test 6
Verifies the filter is not clogged and contributing to
high backpressure.
Pulse Damper Test 7

Verifies the integrity of the damper, i.e., no leaks
or blockages.
Appendix A: Workstation Methods 23

5
9012 SDS LABORATORY
t .-. 9012 SOLVENT DELIVERY SYSTEM
Start-up
Perform a Warm Start of the 9012 SDS.
Connect each of the one liter bottles to Valves A, B, and C:

Valve B and Valve C to H20/2-propanol + 0.5% Acetone,
(place both solvent lines in one bottle)
What is the purpose of the 2-propano/?_ _ _ _ _ _ _ _ _ _ _ __
a line? If yes,
If valve C is not in use should it be capped off or connected to
Why?______________________________
purge valve counter clockwise one full turn.
On the keypad OPERATION section of the 9012 press the "A" PRIME button.
This will start the pump at 1Oml/min through valve A.
If you were priming a 9010 SDS what would the prime flow rate be?_ _ _ __
Continue pumping until all air has been removed from the lines and a steady stream is
pumping out of the purge valve. Repeat this procedure for Valves B and C.
SOLVENT FILTER TEST
-- - __ I'Uige .
I liter bottles
......
The following procedure verifies that the solvent filter is not clogged and contributing to
a slow or variable solvent flow.
What would be the effects of a slowed flow chromatographically and
instrumentally? -
-
6
9012 SDS LABORATORY
SOLVENT FILTER TEST (continued)
Perform a siphon test by disconnecting the filled solvent line from the valve, raising the
line vertically so that the flow back into the one liter bottle through the solvent filter can
be observed. The back flow should take no more than 10 seconds for an 18 inch line
and 18 seconds for a 36 inch line.
If the flow is faster than the specified time, how would you correct the problem?
If the flow is slower than the specified time, how would you correct the problem?
Replace the solvent lines to the appropriate valves and repeat the purge procedure
(page 4) to clear all air from the lines.
MIXER FILTER TEST
Attach the mixer/filter to the outlet of the pulse damper, place a receptacle under the
open exit end of the mixer/filter.
Is the mixer/filter directional?_ __

Which end does the filter go into, inlet or exit?_ _ _ _ __
What is the purpose of the mixer/filter?_ _ _ _ _ _ _ _ _ _ _ _ _ __
Pump Sml/min water through the mixer, (according to the following procedures). If the
pressure exceeds20 atm, replace the O.Sfl mixerfrit. (P/N 27-180385-00)

On the keypad EDIT press SHIFT, INCREASE
continue pressing INCREASE until %A reaches 100%, note that
as %A increases %8 decreases
On the keypad EDIT press right cursor arrow=> until it is blinking beneath
Flow
On the keypad EDIT press INCREASE
continue pressing INCREASE until flow reaches 5 mVmin.
On the keypad OPERATION press PUMP

pump will start, there will be a flow from the exit enct of the
mixer/filter
On the keypad OPERATION press STATUS

observe LCD pressure value.
What is the pressure on your instrument?_ _ __
7
9012 SDS LABORATORY
PULSE DAMPER TEST
Purpose: to establish the integrity of the damper, i.e., that there are no leaks or
blockages.
Disconnect the tubing from the outlet of the damper. Place a receptacle under the
outlet to collect the water.
Start the pump with 1OO%A, ~0 + 2-propanol, at 5ml/min.
On the keypad TABLE SELECT press %ABC FLOW

continue pressing until %A= 100
On the keypad EDIT press right cursor arrow::::> until it is blinking beneath
Flow
continue pressing until flow reaches 5ml/min
On the keypad OPERATION press RESET

pump will begin pumping.
The back pressure should not be greater that 20 atm as shown on the pump LCD.
If the pressure is greater than 20 atm, loosen the inlet fitting to the damper.
If the pressure drops this is an indication that the damper is plugged and should
be replaced.
What troubleshooting procedure can be used to clear the damper prior to replacing?
If the pressure stays high, continue loosening fittings one at a time, working
backwards to the pressure transducer until the plugged fitting is located .
8
9012 SDS LABORATORY
Proportion Valves AlB

PROPORTIONING TEST METHOD
Purpose: This procedure determines slight differences between each of the

proportioning valves. In this test 10% increments of solvent B (0.5% Acetone, which is
a strong absorber at 265A.) are added to 100% A (water) from 0-30%. This is then
reversed 'and 10% increments of A solvent (water) from 30% down to 0% are added
creating a stairstep looking chromatogram. (see chromatogram following.)
Calculation: percent difference= (difference+ mean) X 100
Failed Test: If the comparison of the steps is not within a 10% difference, the relevant
proportioning valves need to be replaced.
Instrument settings: Workstation Method: ABPROP (see Appendix A)
9050 Detector settings: Rcdr AUFS= 1.0, may require adjusting
A/Z=Y
Wavelength = 265nm
Time Constant= 5.0 seconds
End Time = 17 minutes
End Action = Reset
Enter the following method into the 9012 : (see next page for complete method)
On the keypad TABLE SELECT: press %ABC
EDIT press SHIFT, INCREASE
EDIT
EDIT
EDIT
continue pressing increase until A%=1 00
press right cursor arrow=> until it is blinking beneath
press INCREASE
Flow
continue pressing increase until flow reaches Smllmin

press INSERT LINE
line 2 will appear on LCD with time at 2.00
EDIT press INSERT LINE
using the INCREASE/DECREASE keys set the time @2.01
set o/oA at 90 and %8 at 10
line 4 will appear, set all parameters according to the chart
below.
Continue entering all 15 lines.
TABLE SELECT press SET CONDITIONS
Using the INCREASE and DECREASE keys and cursor set the
following conditions: Endtime = 17 min
=
Action STOP
Pmin/Pmax 6/400 =
Equil time = 0.00
OPERATION press RESET
press PUMP
after baseline becomes stable
press START
Proportion Valves AJC . Workstation Method: ACPROPOR

Repe~t the above procedures substituting valve C for valve B.
9012 SDS LABORATORY
9
Prouortioning Test Method

DETECTOR CHART RECORDER
RECORDER: 1 AUFS INPUT: 10 mvfs
WAVELENGTH: 265 nm CHART SPEED: I em/min
Line Time %A %B %C Flow

1 0.00 100 0 0 5.0
2 2.00 100 0 0 5.0
3 2.01 90 10 0 5.0
4 4.00 90 10 0 5.0
5 4.01 80 20 0 5.0
6 6.00 80 20 0 5.0
7
8
9
10
11
6.01
8.00
8.01
11.00
11.01
70
70
30
30
20
30
30
70
70
80
0
0
0
0
0
5.0
5.0
5.0
5.0
5.0
12 13.00 20 80 0 5.0
13 13.01 10 90 0 5.0
14 15.00 10 90 0 5.0
15 15.01 0 100 0 5.0
END TIME-> 17.00
Auto Zero with 100% A. Run the method and compare the changes in percent composition,
0- 10% step should =in mag. to the 90- 100% step 10%
10- 20% step should =in mag. to the 80- 90% step 10%
20-30% step should= in mag. to the 70-80% step 10%
i.tle 9012 A/B Valve Proportioning Test

m File C:\STAR\MODULE03\STAR050.RUN
~thod File C:\STAR\ABPROP.MTH
:~.mple ID Manual Sample
141ttion Date: 20-JAN-95 11:45 AM Calculation Date: 20-JAN-95 12:01 PM
=> cor jean Detector Type: 9050

)rkstation: COMPAQ 66M Bus Address 3
1strument : certification Sample Rate 10.00 Hz
~annel 1 = 265 nm Run Time 15.978 min
********** Star Chromatography Software ********** Version 4.0 ***************
hart Speed 1.24 em/min Attenuation = 1102 Zero Offset = 2%

tart Time = 0.000 min End Time = 15.978 min Min I Tick = 1.00
AU I I I I I
-0.028 0.538
I-
I. 3 - 80o/oA : 20/oB
IL llfV't"tV'~
1' ' 5 - 70/oA : 30o/oB
COMPARISON OF AB PROPORTIONING
1- 90%A: 10%8 =14mm 14-12 X 100 = 15% difference

2- 10%A: 90%8 =12mm (14 + 12 )+2
(/fh\M) 6 - 30o/oB : 70%A
=14mm 0% difference
3 - 80%A : 20%8
=14mm
4- 20%A: 80%8
5 -70%A: 30%8 =14mm 0% difference

.6-30%8 :_70%A =14mm
~~2 -10/o~
: 90/oE
f'f'!INTCO It _o.s~.
9-8.5 X 100
/o Difference =
0 = 5.7o/o
9 + 8.5
2
10
20%-25% PROPORTIONING CALl BRATION CHECK
Purpose: The 20-25% procedure establishes the full scale range on the chart recorder.
The 20-25% offset is a sample of the proportioning for a region that is known to be
linear, and that is unaffected by adjustments. The full scale range can be established
by adjusting the Rcdr AUFS on the 9050 detector or adjusting the strength of the
acetone as indicated below. It may be necessary to adjust both the acetone
concentration and the Rcdr AUFS. However, once full scale at 20-25% has been
established no adjustments should be made for the completion of all testing.
If the workstation is in use it is not necessary to adjust the acetone for 20-25%. Run
the test with autoscale on and then use the chosen attenuation for all tests. Our
Workstation chromatogram example, next page, has selected attenuation 57.
Instrument Settings: Workstation Method: 20PROPOR (see Appendix A)

9050 Settings: Rcdr Aufs = 0.05
AIZ=Y
Wavelength = 265nm
Time Constant= 5.0 sec
End Time = N/A, method not running
End Action = N/A, method not running
Autozero as required to set the chart recorder pen at 10%.
9012 Settings: %A %8 %C Flow

80 20 0 5.0
Establish baseline at 10% on chart recorder with 80%A and 20%8 solvents.
Change 9012 settings to:
%A %8 %C Flow
75 25 0 5.0
press RESET
The chart recorder pen should move from the 10% baseline setting to
a 70-80% baseline.
Acetone Adjustment:
If the offset is less than 70% add Acetone to solvent 8 in 1 ml increments.
If the offset is greater than 80% add water to solvent 8 in 5 ml increments.
Measure the distance between the 20%8 baseline and the 25%8 baseline. Divide this
number by 5. This is the desired offset of the 1% adjustment to follow. Our workstation
chromatograms, next page, show a 1% offset of 31.4 :t 50% and a 5% offset of
157 :t10%.
~u~~~u~ ~U/~~% PROPORTlUNlNG T~~T
un File C:\STAR\MODULE03\STAR068.RUN
ethod File C:\STAR\20PROPOR.MTH
ample ID Manual Sample
r~~ction Date: 6-JAN-95 12:55 PM Calculation Date: 6-JAN-95 1:02 PM
tor : free Detector Type: 9050

'- .station: COMPAQ 66M Bus Address 3
nstrurnent Certification Sample Rate 10.00 Hz
hannel 1 = 265 nrn Run Time 6. 480 min
********** Star Chromatography Software **********Version 4.0 ***************
hart Speed 3.06 em/min ( Attenuatigp - 51 ) Zero Offset = 2%

tart Time 0.000 min End Time - 6.480 min Min I Tick 1.00
milliAU I I I I
-1.535 28.248
+II
Offs~-t ~v- 11, ~ 5ofG11. AB

1~1 -:. !>Ll\-.,.h\ &So--J, =-'? IP5.7 -4--l.IY~tt\1
11
9012 SOS LABORATORY
20%-25% PROPORTIONING CALIBRATION CHECK

CHART RECORDER CHROMATOGRAM
I",
I ----_--
AB
12
9012 SDS LABORATORY
1% OPTICAL SWITCH ADJUSTMENTS
1% PROPORTIONING ADJUSTMENT
Purpose: The purpose of the optical switch adjustments (1 %, 5% and 50-51%) are to
provide a mechanical and electrical starting point for the piston movement so that all
other timing points are determined correctly. The 1% and 5% are used as mechanical
adjustments and the electronics are adjusted by the 50-51% procedures. If the
software sees the starting point too early the proportioning valves will open before the
pump is ready to draw solvent into the piston chamber. This results in poor
proportioning and possibly low flow. If the software sees the starting point too late, the
proportioning will again be compromised.
9012 Settings: %A %8 %C
100 0 0
Press AUTOZERO on 9050 to establish stable baseline set at 10% of the chart paper.
Change the 9012 Settings: %A %8 %C
press RESET on 9012

99 1 0
The chart pen will establish a new baseline based upon the addition of the 1%8
solvent, allow this new baseline to stabilize. The difference between the 0%8 baseline
and 1%8 baseline should be one-fifth of the 20%-25% baseline offset 50%. (i.e., the
number established in the 20-25% procedure), if it isn't adjust the optical switch.
If the workstation method is in use set the attenuation and zero offset to match those
obtained in the 20-25% proportioning procedures.
Optical Switch Adjustment

Remove 9012 cover
Loosen, slightly, the two optical switch assembly screws. This permits the
thumbwheel adjustment knob to tum. (These assembly screws are sealed
with an epoxy at Varian final testing prior to shipment ).
Turning the thumbwheel away from you (clockwise) increases the 1% and
5% values.
Turning the thumbwheel toward you (counter clockwise) decreases the
1% and 5% values.
NOTE: When making adjustments move the thumbwheel and wait for the pen on
the chart recorder to readjust.
itle 9012SDS 1% PROPORTIONING TEST
un File C:\STAR\MODULE03\STAR071.RUN
ethod File C:\STAR\1PROPOR.MTH
r~~ction Date: 6-JAN-95 2:11 PM Calculation Date: 6-JAN-95 2:16 PM
. or free Detector Type: 9050

o1.,_,station: COMPAQ 66M Bus Address 3
nstrument CertifTcation Sample Rate 10.00 Hz
hannel 1 = 265 nm Run Time 5.478 min
(0
....
0
N
en
0
en
~
OJ
0
~
-f
0
()..a. ;:u
::r:~ -<
)>0
::00
-I""C
::o::!
mo
())>
or-
0
::0(1)
8 O:JE
m-
60 :;o-1
>.)
0. ()()
::r:::r:
:;ol>
oc
:s:c...
l>c
-1(/)
0-1
G)~
::oz
l>-1
3:(/)
_..
w
14
9012 SDS LABORATORY
Purpose: refer to 1% proportioning adjustment .
Instrument Settings: Workstation Method: SPROPOR (see Appendix A)
100 0 0

95 5 0
The chart recorder pen should move from the baseline to a new baseline within 10% of
the 25% baseline established in the 20-25% Proportioning Test. Adjust the
thumbwheel to attain the correct baseline. (see Optical Switch Adjustment, page 12)
Once the 5% adjustment is correct redo the 1% proportioning to assure that the 1%
baseline remains correct at 1/5th 50% of the 20-25% baseline. Adjusting the 5%
affects the 1% and vice versa .
ritle 9012SDS 5% PROPORTIONING TEST

Run File C:\STAR\MODULE03\STAR072.RUN
~ethod File C:\STAR\5PROPOR.MTH
Sample ID Manual Sample
T4i'ction Date: 6-JAN-95 2:50 PM Calculation Date: 6-JAN-95 2:56 PM

~a tor
:...~ free Detector Type: 9050
Norkstation: COMPAQ 66M Bus Address 3
Instrument Certification Sample Rate 10.00 Hz
:hannel 1 = 265 nm Run Time 5. 478 min
*********** Star Chromatography Software **********Version 4.0 ***************
:hart Speed 3.61 em/min Attenuation = 57 Zero Offset = 2%

Start Time 0.000 min End Time = 5.478 min Min I Tick 1.00
milliAU I I I I
-1.112 27.836
ILl I. 3- 11l.i ~~
~----- \34~~ ~-------
\
Title 9012SDS 5% PROPORTIONING TEST
Method File C:\STAR\5PROPOR.MTH
I.r~~ction Date: 9-JAN-95 1:16 PM Calculation Date: 9-JAN-95 1:22 PM
c ator free Detector Type: 9050
Workstation: COMPAQ 66M Bus Address 3
Instrument Certification Sample Rate 10.00 Hz
~hannel 1 = 265 nm Run Time 5.487 min
Chart Speed 3.61 em/min Attenuation = 57 Zero Offset = 10%
Start Time = 0.000 min End Time = 5.487 min Min I Tick = 1.00
milliAU I I I I I I I
- -5.566 27.836
<WI=2.0
~------ \4-l\: YV'W\~--------~~
<WI=4.0
<WI=B.O
15
9012 SDS LABORATORY
50fc, OPTICAL SWITCH ADJUSTMENTS

Important Notice for 9002 and 9012 Users
If your pump is equipped with a GPIB option, please take a few seconds to consider the
following questions:
Will this pump be controlled by Version 4.0 of the Star Workstation software?
YES
Go on to the next question.
NO
The older software does not know about the 9002 and 9012 pumps. In order to control
the pump, you need to flip a switch inside the pump to make it pretend to be a 9010
when communicating with the older software. The default setting of the switch has been
changed so that Version 4.0 of the Star Chromatography Workstation software will
properly identify 9002 and 9012 pumps shipped after June 30, 1994 as 9002 and 9012.
-
Action required: 12345878 12345878 .i>
1. Locate the switch blocks in the DDDDODDD ODDDOOOO

-Open- -Open- /
upper right comer of the CPU
S5
board. The switches are easily S4

accessibl~ once the pump
cover is removed.
Pump CPU Board
2. Set switch 8 of block S4 to the
'open' (OFF) position.
Will more than one 90xx pump be controlled by the same Workstation?
YES
All modules on the GPIB bus must have a different address. Since all pumps are
configured with address 1 in the factory, there would be an address conflict.
Action required:
Chang~ the GPIB Device Address of all but one of the pumps using the rotary dial on
the back panel. Make sure that all modules connected to the same Workstation have
different addresses. Avoid the default addresses of other LC Star modules:
9100 default address 2

NO
No action required.
03-914526-00:1 1
16
9012 SDS LABORATORY
50%- 51% OPTICAL SWITCH ADJUSTMENTS
AlB: 50% - 51% PROPORTIONING ADJUSTMENT
Purpose: The 50/51% procedure provides the electrical starting point adjustment for
the optical switch so that all other timing points are determined correctly by the
software. (see also 1% optical switch adjustment).
Instrument Settings: Workstation Method: AB50PROP (see Appendix A)
50 50 0

49 51 0
Switching from the 50% to 51%8 solvent will cause the chart recorder pen to reposition
itself at a new baseline. Allow this baseline to stabilize. The offset (or distance)
between the 50% and 51% baseline should be the same as established in the 20-25%
proportioning procedure. Our workstation example chromatogram, next page, gives the
offset= 31.4mm, range 15.7mm-47.1mm.
To adjust the baselines, i.e. 8 and C valve timing, use DIP switch S-5 on the S8C
board.
Dip Switch S-5 has a hexadecimal configuration

Switch # 1 2 3 4 5 6 7 8
Value 1 2 4 8 16 32 always ON always OFF
The value of each switch has twice the effect in minor divisions on the chart paper. For
example, turning #3 off will decrease the offset by approximately 8 minor divisions.
However, the effect is that 4 minor division are added to the 50:50 baseline and 4 minor
divisions are subtracted from the 49:51 baseline. Therefore, it will be necessary to
switch back and forth between the 50:50 and the 49:51 methods to verify actual step
offset size.
_ _ _ _ -4,
I
Switch #3 OFF
baseline_ _ _ __.. +4
17
50/o - 51% OPTICAL SWITCH ADJUSTMENTS

AlB VALVES
>. LIC 0100.0026 -

itle 9012SDsA0S0%-51% PROPORTIONING TEST
.un File C:\STAR\MODULE03\STAR019.RUN
:ethod File C:\STAR\AB50PROP.MTH
Calculation Date: 10-JAN-95 1:59 PM
r.~P.ction Date: 10-JAN-95 1:54 PM
Detector Type: 9050
tor jean
r, .station: COMPAQ 66M Bus Address 3
nstrument certification Sample Rate 10.00 Hz
Run Time 3.978 min
:hannel 1 = 2 65 nm
***************
********** Star Chromatography Software **********Version 4.0
Attenuation = 57 Zero Offset = 10%
:hart Speed 4.98 em/min
End Time = 3.978 min Min I Tick 1.00
:tart Time 0.000 mln
I
milliAU I I 27.836
-5.566

18
9012 SDS LABORATORY
50%-51% OPTICAL SWITCH ADJUSTMENTS
AJC: 50% -51% PROPORTIONING ADJUSTMENT
Purpose: Same as the AB proportioning.
Instrument Settings: Workstation Method: AC50PROP (see Appendix A)
Connect valve C to 0.5% Acetone+2% 2-propanol/water solvent and prime pump

through valve C.
50 0 50

49 0 51
The 50:51 C offset should be equal to the 50:51 8 offset 20% (3 minor divisions on
the chart recorder paper)
If the 50:51 C offset is out of spec adjust the offset via the S-5 Dip switch. Rerun the
50:51 8 method to verify that it is still within the specified limits .
Title 9012SDS AC 50/51% PROPORTIONING

t1ethod File C:\STAR\ACSOPROP.MTH
Ir~ection Date: 10-JAN-95 3:11 PM Calculation Date: 10-JAN-95 3:16 PM
: . a tor jean Detector Type: 9050

Nv~kstation: COMPAQ 66M Bus Address 3
Instrument certification Sample Rate 10.00 Hz
::::hannel 1 = 265 nm Run Time 4.988 min
~********** Star Chromatography Software **********Version 4.0 ***************
:::hart Speed 3.97 em/min Attenuation = 57 Zero Offset = 10%

milliAU I I I I I
-5.566 27.836
I S<p ~t '5 u""'\ e 41 A?.;, - 'l.D i
+-(- - 51 ~ ~ ---~u
A0 = w~ r m1. :9 3~'t - c; l. l.. IM.~
19
9012 SDS LABORATORY
50% -51% OPTICAL SWITCH ADJUSTMENTS

AIC VALVES
PRINTED IN U.S.A.
20
9012 SDS LABORATORY
GRADIENT LINEARITY
GRADIENT LINEARITY
Purpose: The gradient procedure graphs the linearity of the adjustments made during
the preceding proportioning checks and adjustments. This procedure is part of the
pump Certification procedures and can be run prior to proportioning adjustments as an
indication that they are properly set.
Instrument Settings Workstation Method: 9000GL (see Appendix A)
9012 Settings:
Valve A = H20 + 2% 2-propanol
Valve 8 and Valve C = H20+2-propanol + 0.5% Acetone,
1 0.00 100 0 0 5.0 ml/min
2 10.00 0 100 0 5.0 ml/min
3 20.00 100 0 0 5.0 ml/min
4 30.00 0 0 100 5.0 ml/min
End Time =30 minutes .
=
End Action Stop
9050 Settings:
press: AAUFS AJZ, enter the following values
Rcdr AUFS = 1.00
AJZ=Y
=
Wavelength 265nm
press: SET CONDITIONS, enter the following values
=
End Time 30 minutes
=
End Action Reset
press: RESET
Chart Recorder: 1OmVFS, 1 em/min
See sample chromatogram, next page.
9012 SDS LABORATORY

21
GRADIENT LINEARITY
,,, .. !"Jfrrrrr.~
Varian Instrument Group PRIHTEO IH U S.A.
.l. ~ "t:.Le
Method File C:\STAR\9000GLT.MTH
Injection Date: 10-JAN-95 5:29 PM Calculation Date: 10-JAN-95 6:00 PM
~ator : jean Detector Type: 9050

. .kstation: COMPAQ 66M Bus Address 3
Channel 1 = 265 nm Run Time 29.987 min
Y'\0 off-~, CO..'Ano-\- to..-\UA.l~+e._

.f.. \1- (s.E,k. (\~ e-'5
Vl.f.-"-t" f..JC.~~)

- -T-----------~~--
Actual Trace
Height between start and / Extrapolated Trace

end of trace /
Abs
\00Mm
Expanded View---?\
Time

Specifications: <1 /o deviation at 50o/o point A to B,

B to A and A to C.
3mm + 1OOmm X 100 =3o/o deviation
22
9012 SDS LABORATORY
FLOW RATE ACCURACY
Purpose: This procedure verifies that the actual pump flow rate corresponds to the
value that is set in the program.
Instrument Settings: Workstation Method: N/A

100 0 0 1.00 ml/min
Procedure:
Place all three solvent lines (A,B, &C) into H20/2% 2-propanol.
Install 25' restrictorcoil between 9012 pump and Varian Liquid Digital
Flowmeter.
Prime lines A, B, and C.
Set pump flow rate to 1ml/min, allow backpressure to stabilize.
Take three flow rate readings through each Valve A, B, and C.
Results should be 3% .
Repeat this procedure at 5 ml/min.
Flow rate can be adjusted using the S-4 Dip Switches, however, an accurate flow meter
that can measure to two decimal points is required.
Table of Efficiency Switch Settings
Switch 4 Switch 5 Switch 6 OFFSET
down down down + 1.5%

up down down + 1.0%
down up down + 0.5% more flow
up up down nominal
down down up -0.5%

up down up - 1.0% less flow
down up up -1.5%
up up up -2.0%
23
9012 SDS LABORATORY
APPENDIX A
WORKSTATION METHODS
ABPROP 9012 AlB Valve Proportioning Test

ACPROPOR 9012 AIC Valve Proportioning Test
20PROPOR 9012 20/25% Proportioning Test
1PROPOR 9012 1% Proportioning Test
AB50PROP
AC50PROP
9000GLT
9012 AB 50/51% Proportioning Test
9012 AC 50/51% Proportioning Test
9012 Gradient Linearity
************************************************************************
Star Chromatography Software - Method Listing Fri Jan 20 11:47:19 1995
Method: C:\STAR\ABPROP.MTH
~********************************************************************
************************************
************************************
Module Address: 01
Maximum Pressure 400 atm
Minimum Pressure 6 atm
0.00
0.00
Relays
Flow Rate
------
5.00 ml/min
0.00 Composition . 100% A, 0% B, 0% c
0.00 Equilibration Time: 1.00 min
2.00 Composition 100% A, 0% B, 0% c
10.00 Composition 30% A, 70% B, 0% c
10.01 Composition 20% A, 80% B, 0% c
12.00 Compo~ition 20% A, 80% B, 0% c
12.01 Composition 10% A, 90% B, 0% c
.4.00 Composition 10% A, 90% B, 0% c
; 4. 01 Composition 0% A, 100% B, 0% c
16.00 Composition 0% A, 100% B, 0% c
16.00 Method End Action Stop at End
****************************
9050 UV-Vis Detector
****************************
Module Address: 03
Time Constant .
1.00 sec
0.00 Wavelength 265 nm
o.oo Attenuation 1. 000 AU
0.00 Timed AutoZero
...
0.00 Peak Width : 4 sec
0.00 S/N Ra.tio 8
0.00 PeakSense State Off
o.oo Relay Period 4 sec
o.oo
o.oo
Relay Trigger
Relays
.
Off Next Peak
16.00 Method End Action Reset at End

Detector Information
Detector Bunch Rate : 4 points (10.0 Hz)
~ Monitor Length : 64 bunched points (6.4 seconds)
~ Data File Name : STAR
Integration Parameters Address J. Channel 1

----------------------------------------------
Subtract Blank Baseline : No
S/N Rat.l.O 5
Monitor Noise Before every run
Initial Peak Width 4 sec
Tangent Height % 10%
Measurement Type _ _ Peak Area
PPak Reject Value 1000 counts
, r t Unidentified Peaks Yes
~rt Missing Peaks No
Calculation Type Percent
Unretained Peak Time 0.00
Reference Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%

Other Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
Origin Force
Curve Fit Linear
Deviation Tolerance : 100%

Out-of-Tolerance Action: No Action
Peak Table Address 3 Channel 1
Peak Table Empty
Time Events Table Address 3 Channel 1

~~~i~-~~~~~~~~~-~-----~~~i--~~~ii ____ 16.00
Report Format Address 3 Channel 1
Title 9012 A/B Valve Proportioning Test

Print Chromatogram Yes
Chromatogram Options:
Start Retention Time 0.00 minutes
End Retention Time 1440.00 minutes
Length in Pages 1
Initial Chart Speed 0.0 em/min
Minutes per Tick 1.0
Autoscale On
Time Events Off
Chromatogram Events Off
Retention Times Off
Peak Names Off
Baseline Off
Print Results No
Convert Results to ASCII?: Off
. 1t Report : No
Convert Report to ASCII? : Off
Print Copies 1
~tar Chromatography Software - Method Listing Fri Jan 20 15:35:07 1995
1ethod: C:\STAR\ACPROPOR.MTH
~ 411J*******************************************************************
t*-~********************************
t***********************************
1odule Address: 01
Maxii"Q.um Pressure 400 atm
0.00 Relays
0.00 Flow Rate 5.00 ml/min
o.oo Composition 100% A, 0% B, 0% c
0.00 Equilibration Time: 1. 00 min
2.00 Composition 100% A, 0% B, 0% C
10.00 Composition 30% A, 0% B, 70% C
10.01 Composition 20% A, 0% B, 80% C
12.00 Composition 20% A, 0% B, 80% C
12.01 Composition 10% A, 0% B, 90% C
14.00 Composition 10% A, 0% B, 90% C
.01 Composition 0% A, 0% B, 100% C
. .J.OO Composition 0% A, 0% B, 100% C
r***************************
r***************************
1odule Address: 03
.Time Constant 1.00 sec
0.00 Attenuation 1.000 AU
0.00 Timed AutoZero
0.00 Peak Width 4 sec
0.00 S/N Ratio 8
o.oo PeakSense State Off
0.00 Relay Period : 4 sec
0.00 Relay Trigger Off Next Peak
0.00 Relays
Detector Bunch Rate 4 points (10.0 Hz)
Monitor Length : 64 bunched points (6.4 seconds)
Data File Name : STAR
:ntegration Parameters Address 3 Channel 1

---------------------------------------------
;ubtract Blank Baseline : No
.:>
Measurement Type .. Peak Area
PP.ak Reject Value 1000 counts
r t Unidentified Peaks Yes
rt Missing Peaks No
L_ ~culation Type Percent
Unretained Peak Time o.oo

Origin Force
Curve Fit Linear

Peak Table Empty
~bit Integrate : 0.01 until 16.00
9012 A/C Valve Proportioning Test

Title
Print Chromatogram .: Yes
..
Length in Pages 1
...
Minutes per Tick : 1.0
Auto scale On
Time Events Off
Retention Times
Peak Names . Off
Off
Baseline Off
Print Results . No
. t Report No
..
J
ert Report to ASCII?
Cw , Off
Print Copies 1
~***********************************************************************
~tar Chromatography Software - Method Listing ~ue Jan 17 15:11:13 1995

~ethod: C:\STAR\20PROPOR.MTH
: ~*******************************************************************
~***********************************
~***********************************
iofodule Address: 01
Maxintum Pressure 400 atm
0.00
0.00
Relays
Flow Rate
------
5.00 ml/min
o.oo Equilibration Time: 1.00 min
~***************************
~050 UV-Vis Detector
. ************~**********
iofodule Address: 03
Time Constant 5.00 sec

o.oo Wavelength 265 nm
o.oo Attenuation 0.050 AU
0.00
o.oo
Timed AutoZero
Peak Width. .
4 sec
0.00 S/N Ratio a
o.oo
0.00
Relay Period
Relay Trigger ..
4 sec
Off Next Peak
o.oo Relays
.

Monitor Length : 64 bunched points ( 6. 4 seconds)
Cntegration Parameters Address 3 Channel 1
)~act Blank Baseline .. No

atio 5
... ~........ tor Noise Before every run
rnitial Peak Width
L'angent Height % .. 410%sec.
~easurement Type
?eak Reject Value . Peak
1000
Area
counts
Report Unidentified Peaks Yes
Report Missing Peaks No
--
41t~rence Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%

u_ .er Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
Origin Force
Curve Fit : Linear
Deviation Tolerance 100%

Peak Table Empty

Inhibit Integrate : 0.01 until 16.00
Renort Format Address 3 Channel 1

41t~~-----------~--------~--~~i;~~~-;0/25% PROPORTIONING TEST
Pr~nt Chromatogram Yes
Length in Pages
Initial Chart Speed .. 1
0.0 em/min
Minutes per Tick
Autoscale .. 1.0
On
Time Events On
Chromatogram Events .. On
Retention Times
Peak Names . Off
Off
Baseline . Off
Print Results : . No
Print Report . No
Convert Report to ASCII? :
Print Copies
. Off
1
************************************************************************
Star Chromatography Software - Method Listing Tue Jan 17 15:21:36 1995
Method: C:\STAR\1PROPOR.MTH
. ***************************************.*****************************
************************************
************************************
Module Address: 01 .

0.00
0.00
Relays ------
Flow Rate 5.00 ml/min
1. 00 Composition : 100% A, 0% B, 0% c
1. 01 Composition 99% A, 1% B, 0% c
****************************
.9050 UV-Vis Detector
************~***********
h. ..J.le Address: 03
0.00
Time Constant
Wavelength ..
5.00 sec
265 nm
0.00 Timed AutoZero
0.00 Peak Width. 4 sec
0.00 S/N Ratio 8
o.oo
0.00
PeakSense State
Relay Period ..
Off
4 sec
o.oo
0.00
Relay Trigger
Relays
..
Off Next Peak

Monitor Length : 64 bunched points (6.4 second~)
Data File Name STAR
Integration Parameters Address 3 Channel 1

St,~tract Blank Baseline . No
Ratio . Before
5
:.tor Noise
:iru.:tial Peak Width .. 4 sec every run
Tangent Height % 10% .

Measurement Type Peak Area
Peak Reject Value 1000 counts
Report Unidentified Peaks No
Report Missing.Peaks No
Unretained Peak Tim~ o.oo
...
~renee Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%

v, ~r Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
Origin Force
Curve Fit : Linear

Peak Table Empty
Time Events Table Empty
RP~ort Format Address 3 Channel 1

-~~-----------~--------~--~~l;~~~-l% PROPORTIONING TEST
Pr~ritChromatogram Yes
Start Retention Time : 0.00 minutes
Initial Attenuation 57
Initial Zero Offset
Length in Pages . 10
1
Initial Chart Speed : 0.0 em/min
Minutes per Tick
Autoscale . 1.0
Off
Time Events
Chromatogram Events .. On
On
Retention Times Off
Peak Names
Baseline
. Off
Off
Print Results . No
Print Report .. No
Convert Report to ASCII? Off
P . t Copies . 1
************************************************************************
Method: C:\STAR\5PROPOR.MTH
~********************************************************************
************************************
************************************
Module Address: 01

0.00 Relays ------
****************************
J
*************~**********
M~~~le Address: 03

0.00 Timed AutoZero
0.00 S/N Ratio 8
0.00 Relay Period 4 sec
0.00 Relays

Data File Name STAR
[ntegration Parameters Address 3 Channel 1
3.P~~ract Blank Baseline No

Ratio 5
.tor Noise . Before every run
[nitial Peak Width 4 sec
~angent Height % : 10%
~easurement Type Peak Area
?eak Reject Value : 1000 counts
'~ence Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%

~ r Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
:>rig in Force
:urve Fit Linear
)ut-of-Tolerance Action: No Action
?eak ~able Address 3 Channel 1
Peak Table Empty
~ime Events Table Address 3 Channel 1
tP~0rt Format Address 3 Channel 1

,41J------------~-------;--~~i2~~~-~% PROPORTIONING TEST
,:i. .t Chromatogram : Yes
itart Retention Time
:nd Retention Time
.
0.00 minutes
1440.00 minutes
:nitial Attenuation 57
:nitial Zero Offset 10 .
...
ength in Pages 1
nitial Chart Speed 0.0 em/min
linutes per Tick 1.0
.utoscale . Off
'ime Events On..
hromatogram Events
.etention Times
On
Off.
eak Names Off
aseline Off
rint Results : No
onvert Results to ASCII?: Off
rint Report . No
onvert Report to ASCII? :
. Off
\t Copies 1
************************************************************************
~ethod: C:\STAR\AB50PROP.MTH
~*******************************************************************
************************************
************************************
~odule Address: 01

0.00
o.oo
Relays ------
1. 50 Composition 49% A, 51% B, 0% c
****************~***********
t.************************
l. le Address: 03

0.00 Timed AutoZero
0.00 S/N Ratio 8
o.oo Relay Trigger Off Next Peak
o.oo Relays

Monitor Length 64 bunched points (6.4 seconds)
Data File Name STAR
Subtract Blank Baseline No

Sl. .... Ratio 100
. t o r Noise Before every run
l~ .ial Peak Width 4 sec
rangent Height % : 10%
~easurement Type : Peak Area
Peak Reject Value : 1000 counts
F.'rence Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%

. r Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
Or1gin Force
Curve Fit Linear

Peak Table Empty


.. 9012SDS AB 50%-51% PROPORTIONING
_- . . Chromatogram Yes
\. -hromatogram Options:
Start Retention Time
Bnd Retention Time . 0.00 minutes
1440.00 minutes
Initial Attenuation : 57
Initial Zero Offset
Length in Pages . 10
1
~inutes per Tick 1.0
!\utoscale : Off
rime Events Off
~hromatogram Events . Off
~etention Times
?eak Names ..
Off
Off
3aseline Off
?rint Results : No
~onvert Results to ASCII?: Off
?rint Report . No
!onvert Report to ASCII? : Off
?rint Copies 1
r***********************************************************************
)tar Chromatography Software - Method Listing Tue Jan 17 15:56:17 1995
1ethod: C:\STAR\AC50PROP.MTH
~*******************************************************************
r***********************************
r***********************************
iodule Address: 01
0.00 Relays ------
o. oo Equilibration Time: 10.00 min
'***************************
'411{***********************
. e Address: 03
0.00 Timed AutoZero
0.00 Peak Width : 4 sec
0.00
o.oo
S/N Ratio
PeakSense State
.8
Off
o.oo
o.oo
Relay Period ..4 sec
0.00
~elay Trigger
Relays . Off Next Peak
5.00 Method End Action : Reset at End

---------------------------------------------
iubtract Blank Baseline . No

Ratio
;1 ....
or Noise .. Before
100
every run
.. . ~ial Peak Width 4 sec
~angent Height % 10%
leasurement Type Peak Area
'eak Reject Value
teport Unidentifi~d Peaks . No
1000 counts
- ------ --- --- . -- -.
~ . reneePeaks Time Windows:Width: 0.10 min. Retention Time 2.0%

r Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
Origin Force
Curve Fit Linear
Peak Table Empty
e
. 9012SDS AC 50/51% PROPORTIONING
t Chromatogram Yes
~hromatogram Options:
Start Retention Time . 0.00 minutes
Initial Attenuation
Initial Zero Offset
.. 57
10
Length in Pages 1
Initial Chart Speed
Minutes per Tick
.. 0.0 em/min
1.0
Autoscale
Time Events
:
. Off
On
Chromatogram Events
Retention Times
.. On
Off
Peak Names
Baseline

.. Off
Off
Print Results : No
Convert Results to ASCI~?: Off
Print Report
Convert Report to ASCII? :
. No
Off
Print Copies . 1
~***********************************************************************
)tar Chromatography Software - Method Listing Mon Mar 13 12:44:58 1995

~ethod: C:\STAR\9000GLT.MTH
~*******************************************************************
~***********************************
~***********************************
~odule Address: 01

0.00 Relays ------
10.00 Composition 0% A, 100% B, 0% c
20.00 Composition 100% A, 0% B, 0% c
30.00 Composition 0% A, 0% B, 100% c
~***************************
~***************************
~odule Address: 03

00 Attenuation 1.000 AU
.00 Timed AutoZero

0.00 S/N Ratio 8
0.00 Relays

Data File Name STAR
;ubtract Blank Baseline No

;/N Ratio 5
ionitor Noise Before every run
:nitial Peak Width 4 sec
~angent Height % : 10%
ieasurement Type Peak Area
,~Reject Value 1000 counts
~t Unidentified Peaks : No
~~ t Missing Peaks : No
:alculation Type
Jnretained Peak Time . Percent
0.00
Origin : Force
Curve Fit Linear
~tion Tolerance : 100%

v. of-Tolerance Action: No Action
Peak Table Empty
rime Events Table Address 3 Channel 1
~eport Format Address 3 Channel 1
ritle . 9012 GRADIENT LINEARITY AB/BA/AC

?rint Chromatogram Yes
)tart Retention Time . 0.00 minutes
~nd Retention Time . 1440.00 minutes
: . . h in Pages . 1
0.0 em/min
: .al Chart Speed
-Ii.. _... tes per Tick . 1.0
\utoscale . On
~ime Events . Off
~hromatogram Events Off
~etention Times
,eak Names . Off
3aseline . Off
Off
,rint Results . No
:onvert Results to ASCII?: Off
No
1rint Report
:onvert Report to ASCII?
:
. Off
'rint Copies : 1

1
9012 SDS LA BORATORY
ADDENDUM A
EXTENDED DIAGNOSTICS - 9012 SDS
Extended diagnostics include routines to assist in maintenance operations as well as test

procedures that may pinpoint component level electronic malfunctions or failures.
To access the extended diagnostics, press and hold the SELECT key while simultaneously
turning the power switch to ON. Display reads: Extended Menu Maintenance Log.
EXTENDED MENU
Maintenance Log (resets the pump stroke counter to zero)

TeleDiagnostics TM (permits a Varian CSR to run the extended diagnostics tests remotely via
a modem)
Display Test (tests the LEOs and two line display)
Leak Test (tests the pump for leaks)
Retract Piston (retracts the piston for Sea/ Replacement)
Extend Piston (extends the piston for Inlet Gap Adjustment)
Keyboard Test (verifies operation of all keys on the keyboard)
Print Pattern Test (verifies printer/9012 connection via RS232 port)
Relays Test (verifies that relays are functioning properly)
Fault Signals Test (verifies Fault signals functioning properly- Sync Cable Connection)
Start Signals Test (verifies that Start signals functioning properly- Sync Cable Connection)
Ready Signals Test (verifies that Ready signal functioning- Sync Cable Connection)
Ready Enable Test (verifies that Ready Enable is functioning- Sync Cable Connection)
ADC Test (verifies analog-to-digital converter and its supporting circuitry properly to calibrate
the pressure transducer)
ROM Test (verifies integrity of the data stored in ROM)
RAM Test (verifies integrity of data stored in battery backed-up RAM)
GPIB Board Test (verifies presence of GPIB Board)
GPIB Address Switch Test (indicates# address setting of the 9012)
GPIB Echo Test (verifies communication link between the 9012 and Workstation)
MVD Gates Test (motor/valve driver, verifies proper operation of the pump's motor and motor
driver)
MVD Valves Test (motor/valve driver, verifies proper operation of valves A, 8, C)
Printer Port Loop back Test (verifies proper operation of internal serial port circuitry)
Cold Start Loop (runs all cold start tests and stops if a fault is found)
2
9012 SDS LABORATORY
MAINTENANCE LOG
Press START
Display pump strokes: xxx. How many pump strokes?
Press LOCAL three times.
By pressing NEXT LINE, display will scroll through 75 errors. The number in brackets
represents the number of times that particular error has occurred. Press RESET to zero
errors from the memory. Press STOP to return to Extended Menu Program. The Diagnostics
Description section of the 9012 manual explains the error codes.
Press STOP
Press NEXT LINE
TELEDIAGNOSTICS
Press START
Modem not connected. Press Stop ...
Press STOP
Press NEXT LINE
DISPLAY TEST
Press START
Goes through a series of display and LED tests, then automatically returns to Main Menu.
P_ress STOP
Press NEXT LINE
What pump problems might prompt the use of display t e s t ? - - - - - - - - - - - -
9012 SDS LABORATORY
LEAK TEST
Press START
SDS PUMP-Hydraulics Leak Test

Press INCREASE or DECREASE

Leak Test Pressure: PRESSURE DECAY
Press NEXT LINE

Leak Test Pressure: 200 atm
Press NEXT LINE
Press START Key to Begin Pressurization
Press START
Performing Hydraulics Pressurization

Pres xx atm Leak: xxxx.:xxx Jll/min.
Press STOP
Press NEXT LINE
Record: atm Leak: _ _ _ _ _ _,Jll/min.

Why is the leak volume so high?_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
RETRACT PISTON (for Seal Replacement)

Press START
-
Press START when ready, STOP to quit.
Press START
Positioning in progress, please wait...
Position Retracted (at Bottom Dead Center)

Press STOP
Press NEXT LINE
4
9012 SDS LABORATORY
EXTEND PISTON (for Inlet Gap Adjust)
Press START
Press START when ready, STOP to quit
Press START

Retract Piston before replacing head
Press STOP to return to MAIN MENU
Press STOP
Press NEXT LINE
KEYBOARD TEST
Press START
Keyboard Test:
Press any key-Press STOP to Exit
Operator presses each key and display responds when stop key is pressed - return to main
menu.
Press STOP
Press NEXT LINE
PRINT PATTERN TEST
Press START
Print Pattern Test

Test in Progress
PRINTER TEST FAILED: Printer Time-out


Press STOP
Press NEXT LINE
I
5
9012 SDS LABORATORY
RELAYS TEST
Press START
Closed all relays. Check continuity.

Press any key to continue:

Press STOP
Press NEXT LINE
FAULT SIGNALS TEST
Press START
Fault Signals Test:

Press STOP
Press NEXT LINE
START SIGNALS TEST
Press START
Start Signals Test:

Press STOP
Press NEXT LINE
READY SIGNALS TEST
Press START
Ready Signals Test:

READY SGNL Err: input level
Press STOP
Press NEXT LINE
6
9012 SDS LABORATORY
READY ENABLE TEST
Press START
Ready Enable Test:

Press STOP
Press NEXT LINE
ADCTEST
Press START
PRS (atm)
x.xxx
REF (v)
X. XXX
Press STOP
BAT (v)
X. XXX
Press NEXT LINE

PRL (v)
X. XXX
Record: PRS
REF(v)_ _
BAT(v)_ _
PRL(v)_ _
ROM TEST
Press START
ROM Test:
ROM Bank 0/1/2 Hilla Byte Test Passes
Press STOP
Press NEXT LINE
RAM TEST
Press START
RAM Test:
RAM BANK 0/2 Passes
Press STOP
Press NEXT LINE
7
9012 SDS LABORATORY
GPIB BOARD TEST

Press START
GPIB Test:
Test Passes
Press STOP
Press NEXT LINE
GPIB ADDRESS SWITCH TEST

Press START What is the number address for your instrument? _
When would you change this number?_ _ _ __
Current Switch setting is: XX How would you change this number?_ _ _ _ __
Press STOP
Press NEXT LINE
GPIB ECHO TEST

Press START

Press START when ready
Press START
Waiting for Workstation messages ...
Press STOP
Press NEXT LINE
MVD GATES TEST

Press START
MVD Gates Test:
PH2GTB: Passed
Press STOP
Press NEXT LINE
8
9012 SDS LABORATORY
MVD VALVES TEST
Press START
MVD Valves Test:

VALVE AJB/C: PASSED
Press STOP
Press NEXT LINE
PRINTER PORT LOOPBACK TEST
SIO Loop Back Test:

Press STOP
Press NEXT LINE
COLD START LOOP (stops on fault)
Press START
Press STOP
Press NEXT LINE
'

name: ________
date: _ _ _ _ _ _ __
instrument #'s
-----
8ackpressure Regulator according to the attached schematic.
Connect power cord to 9012 pump, tum power ON

Valve 8 to H20 + 2% 2-propanol + 0.5% Acetone (fresh) for use with
What is the purpose of the 2-propanol?_ _ _ _ _ _ _ _ _ _ _ __
Why?_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____
On the keypad OPERATION section of the 9012 press the "A "button.
This will start the pump at 1Oml/min through valve A. Continue pumping until all
Connect the power cord to the 9050 UVNIS Detector, turn power on.
This is a WARM START, all methods are saved .
2

EDIT press SHIFT, DECREASE
EDIT press right cursor arrow => until it is blinking beneath

Flow
EDIT press INCREASE
continue pressing INCREASE until flow reaches 1 mUmin.

Using the right=> and left<= cursor and the increase and decrease keys set the
Endtime
Action
8.00 (assay will stop at 8 minutes)
Pmin 6 (Pmin/Pmax are the minimum and maximum
Pmax 400
Equil time 0

press INCREASE , a "1. should appear in the first position.
line 1 .00 1 (relay on at time zero)
line 2 .03 - (relay off at .03 minutes)

will appear on the LCD .

1
name: ________
date: _ _ _ _ _ _ __
instrument #'s
LCSTAR 194 LABORATORY#1

-----

Why?_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
This will start the pump at 1Omllmin through valve A Continue pumping until all

r ,
2
Run Parameters for 9012 505:

EDIT press right cursor arrow => until it is blinking beneath

Flow
EDIT press INCREASE
continue pressing INCREASE until flow reaches 1 mllmin.

Using the right=> and left <= cursor and the increase and decrease keys set the
Endtime 8.00 (assay will stop at 8 minutes)
Action Hold (method will wait for start signal to begin method)
Pmax 400
Equil time 0

press INCREASE, a "1 should appear in the first position.
Onthe keypad OPERATION: press RESET

{ The 9012 is ready for a start signal.

<.,,

3
Use the right=> and left <= cursor keys and the increase 11 and decrease U
I.. 254
AJZ yes
Using the right=> and left <= cursor keys and the increase 11 and decrease U
Endtime 8.00
End Action Reset
Time Constant 1.0


..r- ,,

He
or
Air
J401i
[ill
- INJECT
EUVERY SYSTE 9050 UVNIS DETECTOR
gO] -,{-~~
......
--
--
"
T1'D<1lOoO
,.v.c o: .=.\U -
ii:':Ao
-
~ -
Q
~
LJ.
CJ Q
--
----
c- _,.
o: .::.
~ \Jcu..rl-,;.. : : ;:. m 0:
~=I I I
CHART RECORDEil
~~~ IT~ I~
MIXER
----
.-...;......u
c-.
lOmV
Q ._. ... 1 em/min
lN
200ul REC
1.4ml OUT
START AT n-cr I::'.CTOIR

START AT ~)I!~~~ I '
BACK PRESSURE REGULATO}c ) . ~we6-te..--

70% ACN RUN 70% MEOH

Flow Rate (ml/min.)
Pressure (atm)
Full Scale Range

80/o ACN RUN 80/o MEOH
Flow Rate (mllmin.)
Pressure (atm)
Full Scale Range

90/o ACN RUN 90% MEOH
Flow Rate (ml/min.)
Pressure (atm)
Full Scale Range
-I t Retention Times (min.) I I
LC9000 SERIES PUMP
D 1. With power cord disconnected, remove covers and clear out

accumulated dust.
D 2. Visually inspect circuit boards and check that all cable connections
are secure.
D 3. While powering up and down ensure that the cooling fan is running
D 4. Clean/Lubricate spring housing assembly

clean cam shaft
replace piston seal
D
5.
6.
Check/Replace outlet check valve filter.
Leak test system
D 7. Set inlet valve gap
D 8. Test reservoir filters
D 9. Calibrate pressure sensor readout. (ADC TEST)

D 10. Check replace mixer filter
D 11. Test damper
0 12. Check/calibrate volumetric efficiency
f
" D
D
13.
14.
Verify operation as part of LC system (with UV test sample or
customer sample).
Update Customers' Maintenance Log Sheet

LEAK TEST
Press START.
Press NEXT LINE
Press NEXT LINE
Press START
the ul/min has dropped below O.Sul/min within approximately 5 minutes.
Press STOP
Leave system pressurized for the inlet gap adjustment procedure .

Press START X2
When piston is extended, manually rotate the pump motor clockwise four
screw in place .
Relieve Pressure


XXX 5.000 3.000 0.000
Adjust the offset screw at R-43 on the upper left comer of the SBC board
holding at their set points.
9012 SDS LABORATORY
Start-up,

What Revision is your 9012 running? _ _ _ __

be displayed on the LCD .

3

9012 SDS LABORATORY
i
<,
4
9012 SDS LABORATORY

AB Proportioning 8
valves A and B.
AC Proportioning 8
valves A and C.
linear on the 9012.
1% Proportioning 12
5% Proportioning 14
Adjusts electronics of optical switch.
Off-line Procedures
Verifies the solvent filter is not clogged and
Mixer Filter Test 6
high backpressure.
Pulse Damper Test 7
or blockages.

5
9012 SDS LABORATORY
Start-up

Valve Band Valve C to H20/2-propanol + 0.5% Acetone,
What is the purpose of the 2-propano/?~-------------
Why?________________________________________________________________________
purge valve counter clockwise one full turn .
On the keypad OPERATION section of the 9012 press the "A" PRIME button.
This will start the pump at 1Omllmin through valve A.
If you were priming a 9010 SDS what would the prime flow rate be?_______
SOLVENT FILTER TEST
I liter bottles
r
;<~-
instrumentally?
6
9012 SDS LABORATORY
MIXER FILTER TEST
Is the mixer/filter directional?_ __

pressure exceeds20 atm, replace the 0.5Jl mixer frit. (PIN 27-180385-00)

Flow

pump will start, there will be a flow from the exit end of the
mixer/filter

7
9012 SDS LABORATORY
PULSE DAMPER TEST
blockages.
Start the pump with 100%A, ~0 + 2-propanol, at Sml/min.

continue pressing until %A =100
Flow
continue pressing until flow reaches 5ml/min

be replaced.
backwards to the pressure transducer until the plugged fitting is located.
8

9012 SDS LABORATORY

a strong absorber at 2651..) are added to 100% A (water) from 0-30%. This is then
reversed 'and 10% increments of A solvent (water) from 30% down to 0% are added
AJZ=Y
Wavelength = 265nm
End Action = Reset
Enter the following method into the 9012 : (see next page for complete method)
EDIT
EDIT
EDIT
press SHIFT, INCREASE
continue pressing increase until A%=1 00
press right cursor arrow==> until it is blinking beneath
press INCREASE
Flow
continue pressing increase until flow reaches Sml/min

set %A at 90 and %8 at 10
below.
Action = STOP
Pmin/Pmax = 6/400
Equil time = 0.00
press PUMP

press START
i
.. ..
Proportion Valves AIC . Workstation Method: ACPROPOR
Repe?t the above procedures substituting valve C for valve B.
9012 SDS LABORATORY
9
Pronortioning Test Method

RECORDER: 1 AUFS INPUT: I 0 mvfs
WAVELENGTH: 265 nm CHART SPEED: 1 em/min

1 0.00 100 0 0 5.0
2 2.00 100 0 0 5.0
3 2.01 90 10 0 5.0
4 4.00 90 10 0 5.0
5 4.01 80 20 0 5.0
6
7
8
9
10
6.00
6.01
8.00
8.01
11.00
80
70
70
30
30
20
30
30
70
70
0
0
0
0
0
5.0
5.0
5.0
5.0
5.0
11 11.01 20 80 0 5.0
12 13.00 20 80 0 5.0
13 13.01 10 90 0 5.0
14 15.00 10 90 0 5.0
15 15.01 0 100 0 5.0
END TIM:E -> 17.00
0- 10% step should= in mag. to the 90- 100% step 10%
tle 9012 A/B Valve Proportioning Test

tn File C:\STAR\MODULE03\STAR050.RUN
!thod File C:\STAR\ABPROP.MTH
.mple ID Manual Sample
l~ ~on Date: 20-JAN-95 11:45 AM Calculation Date: 20-JAN-95 12:01 PM

h cor jean Detector Type: 9050
>rkstation: COMPAQ 66M Bus Address 3
Lstrument : certification Sample Rate 10.00 Hz
Lannel 1 = 2 65 nm Run Time 15.978 min
'********* Star Chromatography Software **********Version 4.0 ***************
tart Speed 1.24 em/min Attenuation = 1102 Zero Offset = 2%

:art Time 0.000 min End Time = 15.978 min Min I Tick 1.00
AU I I I I
- -0.028 0.538
100/oA
!'-
I.
!---
3- 80/oA: 20/oB
-....__
lL I4Yl't'Y\.._
1' ' 5 - 70/oA : 30/oB
1 - 90%A: 10%8 = 14mm 14 -12 X 100 = 15% difference

2 -10%A: 90%8 = 12mm (14 + 12 )+2
3 - 80%A : 20%8 = 14mm 0% difference

4- 20%A: 80%8 = 14mm
I
1 \4w, 4 - 20/oA
.i._- 70%A : 30%8 = 14mm 0% difference
, - 30%8: 70%A= 14mm
I : 80o/o8
i
'>
\.
9-8.5 X 100
/o Difference =
0 -
9 + 8.5
2
10
9012 SDS LABORATORY
20/o-25% PROPORTIONING CALl BRATION CHECK
established no adjustme.nts should be made for the completion of all testing.

A/Z=Y
Wavelength = 265nm


80 20 0 5.0
%A %8 %C Flow
75 25 0 5.0
press RESET
a 70-80% baseline.
Acetone Adjustment:
chromatograms, next page, show a 1% offset of 31.4 :1:50% and a 5% offset of
157 :t10%.
LL....J....C: ~U~LOUO LU/L~~ PROPORTlUNlNG T~~T
1n File C:\STAR\MODULE03\STAR068.RUN
~thod File C:\STAR\20PROPOR.MTH
3.mple ID Manual Sample
,-'..,.on Date: 6-JAN-95 12:55 PM Calculation Date: 6-JAN-95 1:02 PM

tor free Detector Type: 9050
station: COMPAQ 66M Bus Address 3
J.strument Certification Sample Rate 10.00 Hz
1.annel 1 = 265 nrn Run Time 6. 4 80 min
~********* Star Chromatography Software **********Version 4.0 ***************
1.art Speed 3.06 em/min (Attenuation - 57 :J Zero Offset = 2%
milliAU I I I
-1.535 28.248
+II
Qf(siG.-t- .fov l1o ~ '50/GI 1. AB

1~1 -:. :OLL\-..... h\ ~o1. =''? 1'5.7 -4--l.l ~txt11

11
9012 SDS LABORATORY

12
9012 SDS LABORATORY
1/o OPTICAL SWITCH ADJUSTMENTS
100 0 0
Change the 9012 Settings:
press RESET on 9012

%A
99
%8
1
%C
0

Remove 9012 cover
thumbwheel adjustment knpb to turn. (These assembly screws are sealed
5% values.
1% and 5% values .
_tle 9012SDS 1% PROPORTIONING TEST
m File C:\STAR\MODULE03\STAR07l.RUN
!thad File C:\STAR\1PROPOR.MTH
-'<=!.on Date: 6-JAN- 95 2: 11 PM Calculation Date: 6-JAN-95 2:16 PM

.tor free Detector Type: 9050
>l..n.station: COMPAQ 66M Bus Address 3
tstrument Certification Sample Rate 10.00 Hz
tannel 1 = 265 nm Run Time 5.478 min
'********* Star Chromatography Software **********Version 4.0 ***************
1art Speed ' 3.61 em/min Attenuation = 57 Zero Offset = 2%

millil\U I I I I I
-1.112 27.836
<WI=2.0

13

14
9012 SDS LABORATORY
5%, OPTICAL SWITCH ADJUSTMENTS
100 0 0

95 5 0
baseline remains correct at 1/5th 50% of the 20-25% baseline. Adjusting the 5%
~itle 9012SDS 5% PROPORTIONING TEST

~un File C:\STAR\MODULE03\STAR072.RUN
1ethod File C:\STAR\5PROPOR.MTH
>ample ID Manual Sample
-- . i o n Date: 6-JAN-95 2:50 PM Calculation Date: 6-JAN-95 2:56 PM
_a tor free Detector Type: 9050

7orkstation: COMPAQ 66M Bus Address 3
:nstrument Certification Sample Rate 10.00 Hz
:hannel 1 = 2 65 nm Run Time 5.478 min
'********** Star Chromatography Software********** Version 4.0 ***************

>tart Time 0.000 min End Time = 5.478 min Min I Tick 1.00
milliAU I I I I
-1. 112 27.836
141. 3 - 11l.i V>t. ~
~----- \34h\~ ~-------
______.- .
\
ritle 9012SDS 5% PROPORTIONING TEST
~ethod File C:\STAR\SPROPOR.MTH
3ample ID Manual Sample
[r'.ion Date: 9-JAN-95 1:16 PM Calculation Date: 9-JAN-95 1:22 PM

a tor free Detector Type: 9050
'Vo.ckstation: COMPAQ 66M Bus Address 3
rnstrument Certification Sample Rate 10.00 Hz
::hannel 1 = 265 nm Run Time 5.487 min
""********** Star Chromatography Software **********Version 4.0 ***************
:hart Speed = 3.61 em/min Attenuation = 57 Zero Offset = 10%

3tart Time 0.000 min End Time = 5.487 min Min I Tick = 1.00
milliAU I . I I
-5.566 27.836
<WI=2.0
~------ \ 4-Lt ryw't'\*----------=?d
<WI=4.0
<WI=B.O
15
9012 SDS LABORATORY

YES
NO
,-
Action required: 123(5575 123(5575 p
1. Locate the switch blocks in the DDDDDDDO DO DODD DO

-Open- -Open-

board. The switches are easily S4 S5
cover is removed.
Pump CPU Board
YES
All modules on the GPIB bus must have a different address. Since_ all pumps are
configured with address 1 in the factory, there would be an address conflict.
Action required:
the back panel. Make sure that all modules connected to the same Workstation have _

NO
No action required.
03-914526-00:1
1
16
9012 SDS LABORATORY
50% - 51% OPTICAL SWITCH ADJUSTMENTS
AlB: 50%- 51% PROPORTIONING ADJUSTMENT
Instrument Settings: Workstation Method: AB50PROP (see Appendix A)
50 50 0

49 51 0
Switching from the 50% to 51 %8 solvent will cause the chart recorder pen to reposition
To adjust the baselines, i.e. Band C valve timing, use DIP switch S-5 on the SBC
board.

Switch # 1 2 3 4 5 6 7 8
- - offset size.
_ _ _ _ -4,
I
Switch #3 OFF
baseline_ _ _ _.... +4
17
9012 SDS LABORATORY
50%, - 51 /o OPTICAL SWITCH ADJUSTMENTS

AlB VALVES
..
\.
). LIC 0 I 00-0026
.tle 9012SDSA650%-51% PROPORTIONING TEST
m File C:\STAR\MODULE03\STAR019.RUN
!thod File C:\STAR\AB50PROP.MTH
tmple ID Manual Sample
'~e~on Date: 10-JAN-95 1:54 PM Calculation Date: 10-JAN-95 1:59 PM
_._tor jean Detector Type: 9050

Bus Address 3
.station: COMPAQ 66M 10.00 Hz
1strument certification Sample Rate
1 = 265 nm Run Time 3.978 min
1annel
~*********
Star Chromatography Software **********Version 4.0 ***************
4.98 em/min Attenuation = 57 Zero Offset = 10%

1.art Speed min Min I Tick 1.00
:.art Time 0.000 min End Time = 3.978
I
milliAU I I 27.836
-5.566
~
18
9012 SDS LABORATORY
50% 51% OPTICAL SWITCH ADJUSTMENTS
AIC: 50% - 51% PROPORTIONING ADJUSTMENT
Purpose: Same as the A8 proportioning.

through valve C.
50 0 50

49 0 51
The 50:51 C offset should be equal to the 50:51 B offset 20% (3 minor divisions on
50:51 B method to verify that it is still within the specified limits.
ritle 9012SDS AC 50/51% PROPORTIONING
'iethod File C:\STAR\ACSOPROP.MTH
[rillfion Date: 10-JAN-95 3:11 PM Calculation Date: 10-JAN-95 3:16 PM
. ator jean Detector Type: 9050

"Nc..,~kstation: COMPAQ 66M Bus Address 3
rnstrument certification Sample Rate 10.00 Hz
::hannel 1 = 265 nm Run Time 4.988 min
::hart Speed 3.97 em/min Attenuation = 57 Zero Offset = 10%

milliAU I I I I
-5.566 27.836
, (
S<~ ~...c.:\- s Ct. V'w\ t 4S. AP:J 1-o '7
A0:. Ll~r.m1. :9 ::,4.l- c;;l.l..~W\
.i.
''\
19
9012 SDS LABORATORY
50/o- 51% OPTICAL SWITCH ADJUSTMENTS

AJC VALVES
PRINTED IN U.S.A.
20
9012 SDS LABORATORY
GRADIENT LINEARITY
GRADIENT LINEARITY
9012 Settings:
Line Time %A %8 o/oC . Flow
1 0.00 100 0 0 5.0 ml/min

2 10.00 0 100 0 5.0 ml/min
3 20.00 100 0 0 5.0 mllmin
4 30.00 0 0 100 5.0 ml/min
End Time =30 minutes
End Action =Stop
9050 Settings:
press: AAUFS NZ, enter the following values
Rcdr AUFS = 1.00
NZ=Y
=
Wavelength 265nm
Time Constant =
5.0 seconds
=
End Time 30 minutes
=
End Action Reset
press: RESET
See sample chromatogram, next page .

r-
N
+iJ#tf!:
:-p:m':J-t hln::-rr-,_ ---~n-;----flli:--r~--r--1~~~~
1I his:H :- ! :~_ '__; I :::11!
'- -- - --- -~ ~;f~-i ft;-r~
~H-1------
]--'
::2:
~
(!)
0
r::~-
_<
o::::2: .a.
<(0 ~
wo::
z:c ~*ttEOOmltm c: I
:;.1 (!)
!I o ~ I
[~~~11111111111111
:JU ;;;
.5
[l1l=
J-0:: 2
-~
zw H-i=
we
-o::
~+f~
11~: :-,~:pr"'
-!!
co --Ti-H-RT-1
~(.) ~
C>w
0::
..... IHfi
,,
I
~..

0::
< It
lw
>- :X:
0:: (.)
0
1-
[2
0
m
~ lit-c
(/)
c ~
(/)
N
.....
111111111111111111111111111!11111111111?
0
Q)
"'~
CD
~'"' ~

,__J'l
J.~t:.l.e

IntiJtion Date: 10-JAN-95 5:29 PM Calculation Date: 10-JAN-95 6:00 PM

rater jean Detector Type: 9050
.kstation: COMPAQ 66M Bus Address 3

Start Time = 0.000 min End Time = 29.987 min Min I Tick 1. 00
AU I I I I
-0.027 0.520
+II
Y\0 ofF-~ , C0..\1\ no-\- e.A.\UAlCA+e_

1.. \ 1,. (s-~. ~\~ 6-'5
vt e.~<-t- P"" ';:)'"")
,.

Actual Trace
- -------------~------
T
Height between start and
~/
/~-- Extrapolated Trace
end of trace /
Abs
\OO....,m
Time

Specifications: <1% deviation at ~Oo/o point A to 8,

8 to A and A to C.
3mm + 1OOmm X 100 = 3% deviation
22
9012 SDS LABORATORY
FLOW RATE ACCURACY

100 0 0 1.00 ml/min
Procedure:
Place all three solvent lines (A,8, &C) into H20/2% 2-propanol.
Flowmeter.
Prime lines A, 8, and C.
Set pump flow rate to 1ml/min, allow backpressure to stabilize.
Take three flow rate readings through each Valve A, 8, and C.
Repeat this procedure at 5 ml/min.
Swifch 4 Switch 5 Switch 6 OFFSET

up down down + 1.0%
up up down nominal
down down up -0.5%

up down up - 1.0% less flow
down up up -1.5%
up up up -2.0%
::
:.;,

23
9012 SDS LABORATORY
APPENDIX A
WORKSTATION METHODS

ACPROPOR 9012 A/C Valve Proportioning Test
5PROPOR
AB50PROP
AC50PROP
9000GLT
9012 5% Proportioning Test
************************************************************************
3tar Chromatography Software - Method Listing Fri Jan 20 11:47:19 1995
~e~d: C:\STAR\ABPROP.MTH
********************************************************************
************************************
************************************
Module Address: 01

0.00 Relays
10.00 Composition 30% A, 70% B, 0% c
10.01 Composition 20% A, 80% B, 0% c
12.00 Composition 20% A, 80% B, 0% c

01 Composition 10% A, 90% B, 0% c
.00 Composition 10% A, 90% B, 0% c
16.00 Composition 0% A, 100% B, 0% c
****************************
****************************
Module Address: 03
Time Constant 1. 00 sec

0.00 Attenuation 1. 000 AU
0.00 Timed AutoZero
0.00 S/N Ratio 8
0.00 Relays
D.ctor Bunch Rate 4 points (10.0 Hz)

.. Monitor Length 64 bunched points (6.4 seconds)
i, Data File Name STAR
Integration Parameters Address ~ Channel 1

----------------------------------------------
S/N Ratl..O 5
Mea.rement Type .. Peak Area
PP. Reject Value 1000 counts
- rt Unidentified Peaks Yes
~rt Missing Peak No
CaLculation Type Percent

Origin Force
Curve Fit Linear

Peak Table Empty
=~~~~=~:~_::~==---~~~==~~-=--=~:~~==-!
.bit Integrat~
: 0.01 until 16.00

Start Retention Time . 0.00 minutes
End Retention Time : 1440.00 minutes
Length in Pages
Initial Chart Speed .. 1
0.0 em/min
Autoscale On
Time Events Off
Retention Times
Peak Names . Off
Off
Baseline Off
Print Results . No

/
\ .... 1t Report
Convert Report to ASCII?
:
. No
Off
Print Copies 1
:ar Chromatography Software - Method Listing Fri Jan 20 15:35:07 1995
!thod: C:\STAR\ACPROPOR.MTH
41k*****************************************************************
-~********************************
'**********************************
)dule Address: 01

o.oo Relays
10.00 Composition 30% A, 0% B, 70% C
10.01 Composition 20% A, 0% B, 80% C
12.00 Composition 20% A, 0% B, 80% C
12.01 Composition 10% A, 0% B, 90% C
160 Composition 10% A, 0% B, 90% C
,.,01 Composition 0% A, 0% B, 100% C
***************************
***************************
odule Address: 03
.Time Constant 1.00 sec

0.00 Timed AutoZero
0.00 S/N Ratio 8
0.00 Relays

~onitor Length : 64 bunched points (6.4 seconds)
WJOata File Name STAR
ntegration Parameters Address 3 Channel 1

---------------------------------------------
ubtract Blank Baseline : No
::>
Measurement Type __ Peak Area
PP~eject Value 1000 counts
~ Unidentified Peaks Yes
)rt Missing Peaks No
L, -..culation Type Percent

Origin Force
Curve Fit : Linear

Peak Table Empty

--~-~~~;~~~~;-~-----~~~~--~~~ii ____ 16.00
ritle 9012 A/C Valve Proportioning Test
3tart Retention Time 0.00 minutes
~nd Retention Time 1440.00 minutes
Length in Pages 1
rnitial Chart Speed 0.0 em/min
~inutes per Tick : 1.0
~utoscale : On
rime Events . Off
~etention Times . Off
?eak Names . Off
3aseline . Off
.
...
?rint Results No
~L ,t
Report
~i::::::;'.; ert
Report to ASCII?
.. No
?rint Copies . Off
1
***********************************************************************
tar Chromatography Software - Method Listing Tue Jan 17 15:11:13 1995
et11t: C:\STAR\20PROPOR.MTH
k*******************************************************************
***********************************
***********************************
odule Address: 01

0.00 Relays ------
**.**********************
50 UV-Vis Detector
k************~**********
odule Address: 03

0.00 Timed AutoZero
0.00 S/N Ratio 8
0.00 Relays

- -Monitor Length 64 bunched points (6.4 seconds)
Data File Name STAR

;~41i~;-~i~~k-~~;~ii~~-------;~--------------
~ ~t1o 5
- .-:~tor Noise Before every run
nitial Peak Width : 4 sec
~ngent Height% : 10%-
eak Reject Value : 1000 counts
--
Calculation Type
Unretained Peak Time
--
~renee Peaks Time Windows:Width:
v_ . er Peaks Time Windows :Width:
Percent
o.oo
0.10 min.
0.10 min.
Retention Time 2.0%
Retention Time 2.0%
Origin Force
Curve Fit Linear

Peak Table Empty

R e . t Format Address 3 Channel 1

t --------------------------------
Le 9012SDS 20/25% PROPORTIONING TEST

P~~nt Chromatogram Yes
Length in Pages 1
A.utoscale On
Time Events On
Chromatogram Events on
Retention Times
Peak Names
:
. Off
Off
Baseline Off
Print Results No
Print Report . No
Print Copies 1
l
.,,"_.
************************************************************************
Met~d: C:\STAR\1PROPOR.MTH
: _..,*******************************************************************
************************************
************************************
Module Address: 01 .

0.00 Relays ------
***~~**********************
. ~50 UV-Vis Detector
: '************************
h .~le Address: 03

0.00 Timed AutoZero
0.00 5/N Ratio 8
0.00 Relays

Data File Name STAR
5l1 . a c t Blank Baseline No

~, atio 5
'l .
..____./;. t or NoJ.se
. : Before every run
In~tial Peak Width : 4 sec
Tangent Height % : 10%.
Measurement Type : PeakArea
~eport Unidentified Peaks No
~eport Missing.Peaks No
::alculation Type Percent
o.oo

Jnretained Peak Time
renee Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%

~r Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
Jrigin Force
:::urve Fit Linear
Jeviation Tolerance 100%

Jut-of-Tolerance Action: No Action
Peak Table Empty
~p~:_:~=~::
e
__
~~~==~~-=--=~:~~==-=--
9012SDS 1% PROPORTIONING TEST
0 57
Initial Zero Offset 10
Length in Pages 1
Initial Chart Speed 0. 0 em/min
Autoscale 0
0 Off
Time Events On
Chromatogram Events On
Retention Times Off
Peak Names : Off
Baseline Off
Print Results
- : No
Print Report : No
C o . r t Report to ASCII? 0
0 Off
p Copies : 1
:i'
'.
'
'***********************************************************************
itar Chromatography Software - Method Listing Tue Jan 17 15:29:15 1995
iet~d: C:\STAR\SPROPOR.MTH
********************************************************************
'***********************************
'***********************************
iodule Address: 01

0.00
0.00
Relays ------
1. 00 Composition 100% A, 0% B, 0% c
'**.**********************
50 UV-Vis Detector
' ************************
1~ .... L1le Address: 03
Time Constant s.oo sec

o.oo
0.00
Timed AutoZero
Peak Width .4 sec
0.00 S/N Ratio 8
o.oo Relays

Data File Name STAR
[ntegration Parameters Address 3 Channel 1

----------------------------------------------
~~~,.,._ci; Blank Baseline No
1 ~at~o 5
1_\.. tor Noise : Before every run
[nitial Peak Width : 4 sec
l'angent Height % : 10%
.feasurement Type : Peak Area
~eport Missing Peaks No
;alculation Type Percent
-- ----
Jnretained Peak Time
renee Peaks Time Windows:Width:

r Peaks Time Windows :Width:
0.00
0.10 min.
0.10 min.
Retention Time 2.0%
Retention Time 2.0%
>rig in Force
~urve Fit Linear
)eviation Tolerance 100%

'eak Table Address 3 Channel 1
Peak Table Empty
'ime Events Table Address 3 Channel 1
' ~
__
t~~~-:~:~:: ~~~::::_=--~~:~~==-=--
.t Chromatogram
'l._ Yes
itart Retention Time 0.00 minutes
!nd Retention Time 1440.00 minutes
:nitial Zero Offset 10
.ength in Pages 1
:nitial Chart Speed 0.0 em/min
[inutes per Tick 1.0
,utoscale _ Off
'ime Events On
~hromatogram Events On
~etention Times Off
'eak Names Off
,aseline Off
rint Results No
rint Report No
on~t Report to ASCII? Off
copies : 1
'***********************************************************************
;tar Chromatography Software - Method Listing Tue Jan 17 15:54:23 1995
iettlf: C:\STAR\AB50PROP.MTH
********************************************************************
'***********************************
'***********************************
1odule Address: 01
Maxirtmm Pressure 400 atm

0.00
0.00
Relays
Flow Rate
------
5.00 ml/min
~***************~***********
50 UV-Vis Detector
**********************
le Address: 03

0.00 Timed AutoZero
o.oo S/N Ratio 8
o.oo Relays

Data File Name STAR
rntegration Parameters Address 3 Channel 1

----------------------------------------------
S.ub1Ect Blank Baseline No
s1 tio 100
;' or Noise Before every run
l.'.< ~ial Peak Width . 4 sec
~easurement Type Peak Area
~eak Reject Value : 1000 counts
Report Unidentified Peaks : No
:alculation Type Percent
Jnretained Peak Time o.oo
=' -~~ce Peak~- Ti~e- Windows :Width: 0.10 min. Retention Time 2.0%
JrJ.gin Force
:urve Fit Linear
Jeviation Tolerance 100%

?eak Table Address 3 Channel 1
Peak Table Empty
(eport Format Address 3 Channel 1

--.--------------------~--;~~;~~~-~ 50%-51% PROPORTIONING
t Chromatogram Yes
-hromatogram Options:
>tart Retention Time 0.00 minutes
:nitial Zero Offset 10
Jength in Pages 1
1inutes per Tick 1.0
.utoscale Off
'ime Events Off
:hromatogram Events Off
letention Times Off
eak Names Off
laseline Off
'rint Results No
rint Report No
onvert Report to ASCII? Off
~i~ Copies 1
l,,_ "
~ ">.._~ ..
~**********************************************************************
:ar Chromatography Software - Method Listing Tue Jan 17 15:56:17 1995

~t. C:\STAR\AC50PROP.MTH
~*******************************************************************
~**********************************
~**********************************
:::>dule Address: 01

0.00 Relays ------
o. oo Equilibration Time: 10.00 min
***************************
50 UV-Vis Detector

**********************
le Address: 03

0.00 Timed AutoZero
0.00 S/N Ratio : 8
o.oo ~elay Trigger Off Next Peak
o.oo Relays


---------------------------------------------
)ub~act Blank Baseline No
;/"W:tio 100
~.-or Noise Before every run
.:- -<ial Peak Width : 4 sec
leasurement Type : Peak Area
'eak Reject Value : 1000 counts
teport Unidentifi~d Peaks : No
teport Missing Peaks No
Jnretained Peak Time 0.00
-~c~. Peak;;- Tl~e-Windo~~ :Width:

. -
0.10 min. Retention Time 2.0%
)rig in Force
;urve Fit Linear
?eak Table Address 3 Channel 1
Peak Table Empty

---.--------------------------------
: 9012SDS AC 50/51% PROPORTIONING
1t Chromatogram Yes
Length in Pages 1
!\utoscale Off
rime Events On
~hromatogram Events
Retention Times . On
Off
Peak Names
Baseline . Off
Off
Print Results : No
:onvert ~esults to ASCII?: Off
.
(.
Print Report No
Print Copies : 1
l.
"'-~
***********************************************************************
tar Chromatography Software - Method Listing Mon Mar 13 12:44:58 1995
et~: C:\STAR\9000GLT.MTH
~*******************************************************************
***********************************
***********************************
:odule Address: 01

0.00 Relays ------
10.00 Composition 0% A, 100% B, 0% c
20.00 Composition 100% A, 0% B, 0% c
30.00 Composition 0% A, 0% B, 100% c
***************************
'***************************
~dule Address: 03

00 Wavelength 265 nm
00 Attenuation 1. 000 AU
).00 Timed AutoZero
0.00 S/N Ratio 8
0.00 Relays
Data File Name STAR
iubtract Blank Baseline No

i/N Ratio 5
loni tor Noise Before every run
lea.ement Type Peak Area
~~;:- eject Value 1000 counts
k ~t Unidentified Peaks No
~~-t Missing Peaks No
!alculation Type Percent
eference Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%
ther Peaks Time Windows :Width: 0.10 m.1.n. Retention Time 2.0%
rigin Force
ur~Fit Linear
ation Tolerance 100%
of-Tolerance Action: No Action
eak Table Address 3 Channel 1
Peak Table Empty
ime Events Table Address 3 Channel 1

nhibit Integrate : 0.01 until 30.00
eport Format Address 3 Channel 1
itle 9012 GRADIENT LINEARITY AB/BA/AC

rint Chromatogram Yes
tart Retention Time 0.00 minutes
ndt~ntion Time 1440.00 minutes
~~ 1n Pages 1
, ial Chart Speed 0.0 em/min
:i.. _~tes per Tick 1.0
.utoscale On
'ime Events Off
hromatogram Events Off
.etention Times Off
eak Names Off
aseline Off
rint Results No
rint Report No
rint Copies 1
ADDENDUM A
EXTENDED DIAGNOSTICS - 9012 SDS

EXTENDED MENU

TeleDiagnosticsTM (permits a Varian CSR to run the extended diagnostics tests remotely via
a modem)
Retract Piston (retracts the piston for Seal Replacement)
GPIB Board Test (verifies presence of GP/8 Board)

driver)
' .. . MVD Valves Test (motor/valve driver, verifies proper operation of valves A. B, C)
Printer Port Loop back Test (verifies proper operation of internal serial port circuitry)
2
9012 SDS LABORATORY
MAINTENANCE LOG
Press START
Press STOP
Press NEXT LINE
TELEDIAGNOSTJCS
Press START
Press STOP
Press NEXT LINE
DISPLAY TEST
Press START
Press STOP
Press NEXT LINE
3
9012 SDS LABORATORY
LEAK TEST
Press START


Press NEXT LINE

Press NEXT LINE
SDS PUMP.,.Hydraulics Leak Test

Press START

Pres xx atm Leak: xxxx.xxx Jlllmin.
Press STOP
Press NEXT LINE
Record: atm Leak: _ _ _ _ __r-1/min.


Press START
Press START
Press STOP
Press NEXTLINE
4
9012 SDS LABORATORY
Press START
Press START
Positioning in progress, please wait. ..

Press STOP
Press NEXT LINE
KEYBOARD TEST
Press START
Keyboard Test:
menu.
Press STOP
Press NEXT LINE
PRINT PATTERN TEST
Press START
Print Pattern Test

Test in Progress

Press STOP
Press NEXT LINE
5
9012 SDS LABORATORY
RELAYS TEST
Press START


Press STOP
Press NEXT LINE
FAULT SIGNALS TEST
Press START
Fault Signals Test:

Press STOP
Press NEXT LINE
START SIGNALS TEST
Press START
Start Signals Test:

Press STOP
Press NEXT LINE
READY SIGNALS TEST
Press START
Ready Signals Test:

Press STOP
Press NEXT LINE
6
9012 SDS LABORATORY
READY ENABLE TEST
Press START
Ready Enable Test:

Press STOP
Press NEXT LINE
ADC TEST
Press START
PRS (atm)
x.xxx
REF (v)
X. XXX
Press STOP
BAT (v)
x.xxx
PRL (v)
x.xxx
Record: PRS
REF(v) _ _
BAT(v)_ _
PRL(v)_ _
Press NEXT LINE
ROM TEST
Press START
ROM Test:
Press STOP
Press NEXT LINE
RAM TEST
(.
Press START
RAM Test:
RAM BANK 0/2 Passes
~
<,
'~ .
Press STOP
Press NEXT LINE
7
9012 SDS LABORATORY
GPJB BOARD TEST

Press START
GPIB Test:
Test Passes
Press STOP
Press NEXT LINE
GPJB ADDRESS SWITCH TEST

Press START What is the number address for your instrument? _
Press STOP
Press NEXT LINE
GPJB ECHO TEST

Press START

Press START
Press STOP
Press NEXT LINE
MVD GATES TEST

Press START
MVD Gates Test:

PH2GTB: Passed
Press STOP
Press NEXT LINE
MVD VALVES TEST

8
Press START
MVD Valves Test:

VALVE A/8/C: PASSED
Press STOP
Press NEXT LINE
SIO Loop Back Test:

Press STOP
Press NEXT LINE
Press START
Press STOP
Press NEXT LINE
(.

name: ________
date: _ _ _ _ _ _ __
instrument #'s
-----
Connect power cord to 9012 pump, tum power ON

Valve B to H20 + 2% 2-propanol + 0.5% Acetone (fresh) for use with
a line? If yes,
If valve Cis not in use should it be capped off or connected to
Why?_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____
This will start the pump at 1Oml/min through valve A Continue pumping until all
This is a WARM START, all methods are saved .
2

EDIT press right cursor arrow=> until it is blinking beneath

Flow
EDIT press INCREASE
continue pressing INCREASE until flow reaches 1 ml/min.

Using the right=> and left <:::: cursor and the increase and decrease keys set the
Endtime
Action
8. 00 (assay will stop at 8 minutes)
Pmax 400
Equil time 0

press INCREASE, a "1. should appear in the first position.

will appear on the LCD .

1
name: ________
date: _ _ _ _ _ _ __
instrument #'s

-----
Backpressure Regulator according to the attached schematic.

Why?______________________________
purge valve counter clockwise one full turn.
This will start the pump at 1Oml/min through valve A. Continue pumping until all
2

EDIT press right cursor arrow :::::> until it is blinking beneath

Flow
EDIT press INCREASE
continue pressing INCREASE until flow reaches 1 ml/min.

Using the right=:> and left <= cursor and the increase and decrease keys set the
Endtime 8.00 (assay will stop at 8 minutes)
Action Hold (method will wait for start signal to begin method)
Pmax 400
Equil time 0

press INCREASE, a "1 should appear in the first position.



3
Use the right=> and left <= cursor keys and the increase ft and decrease U
).. 254
AJZ yes
Using the right=> and left <= cursor keys and the increase ft and decrease U

Endtime 8.00
End Action Reset
Time Constant 1.0


:!......... ---
\.,
,(.
He
01
Air
J40&
[UJ
- lNJECT
ELIVERY SYSTE 9050 UVNJS DETECTOR
.....
g[IJ
----
4rn>moot
vc o:
o: -
vAG
---
--
_......._.
c:a-
---
o: :...
"HJ \Jr.,.u-1-.::.. : : :. m -
-
~;,1 I I CUART RECORDEI t
~~~ ITill ~
MIXER
---
c-
12'-'. .
200ul
IN
OUT
lOmV
1 em/min
REC
1.4ml
START AT "f)'CT~CTOIR
START AT ~ )t' ~~~~
BACK PRESSURE REGUL.ATO~( ) . ~""'(.61 e..,

70% ACN RUN 70% MEOH

Flow Rate (ml/min.)

Pressure (atm)
Full Scale Range

80o/o ACN RUN 80/o MEOH
Flow Rate (ml/min.)
Pressure (atm)
Full Scale Range

90/o ACN RUN 90o/o MEOH
Flow Rate (ml/min.)
Pressure (atm)
Full Scale Range
-I I ...
Retention Times (min.) I I
i\

' ... '
LC9000 SERIES PUMP
D 1. With power cord disconnected, remove covers and clear out

accumulated dust.
D 2. Visually inspect circuit boards and check that all cable connections
are secure.
D 3. While powering up and down ensure that the cooling fan is running
D 4. Clean/Lubricate spring housing assembly

clean cam shaft
replace piston seal
D
5.
6.
Check/Replace outlet check valve filter.
Leak test system
D 7. Set inlet valve gap
D 8. Test reservoir filters
D 9. Calibrate pressure sensor readout. (ADC TEST)

D 10. Check replace mixer filter
D 11. Test damper
D 12. Check/calibrate volumetric efficiency
i
'-. D
D
13.
14.
Verify operation as part of LC system (with UV test sample or
customer sample).
Update Customers' Maintenance Log Sheet

LEAK TEST .
Press START.
Press NEXT LINE
Press NEXT LINE
Press START
the ul/min has dropped below O.Sullmin within approximately 5 minutes.
Press STOP
Leave system pressurized for the inlet gap adjustment procedure .

Press START X2
When piston is extended, manually Fotate the pump motor clockwise four
screw in place.
Relieve Pressure


XXX 5.000 3.000 0.000
Adjust the offset screw at R-43 on the upper left corner of the SBC board
holding at their set points .

2
9012 SDS LABORATORY
Start-up_


be displayed on the LCD .

3
9012 SDS LABORATORY
4
9012 SDS LAB ORA TORY

AB Proportioning 8
valves A and B.
AC Proportioning 8

valves A and C.
linear on the 9012.
1% Proportioning 12
5% Proportioning 14
Adjusts electronics of optical switch.
Off-line Procedures
Verifies the solvent filter is not clogged and
Mixer Filter Test 6
1.
\
high backpressure.
Pulse Damper Test
or blockages.
7

5
9012 SDS LABORATORY
Start-up

Valve B and Valve C to H20/2-propanol + 0.5% Acetone,
What is the purpose of the 2-propano/?~-------------
Why?________________________________________________
purge valve counter clockwise one full turn .
.. On the keypad OPERATION section of the 9012 press the "A" PRIME button .
This will start the pump at 1Oml/min through valve A.
If you were priming a 9010 SDS what would the prime flow rate be?______
SOLVENT FILTER TEST
I liter bottles
(.
;<~-
instrumentally?
6
9012 SDS LABORATORY
MIXER FILTER TEST
Is the mixer/filter directional?

---
pressure exceeds20 atm, replace the O.SJ.t mixer frit. (P/N 27-180385-00)

On the keypad EDIT press right cursor arrow~ until it is blinking beneath
Flow

pump will start, there will be a flow from the exit end of the
mixer/filter

7
9012 SDS LABORATORY
PULSE DAMPER TEST
blockages.
Start the pump with 1OO%A, H20 + 2-propanol, at Sml/min.

continue pressing until %A= 100
Flow
continue pressing until flow reaches Sml/min

be replaced.
backwards to the pressure transducer until the plugged fitting is located .

9012 SDS LABORATORY

a strong absorber at 2651..) are added to 100% A (water) from 0-30%. This is then
reversed and 10% increments of A solvent (water) from 30% down to 0% are added
A/Z=Y
Wavelength = 265nm
End Action = Reset
Enter the following method into the 9012: (see next page for complete method)
EDIT
EDIT
EDIT
press SHIFT, INCREASE
continue pressing increase until A%=100
press right cursor arrow=> until it is blinking beneath
press INCREASE
Flow
continue pressing increase until flow reaches Sml/min

set %A at 90 and %8 at 10
below.
Action = STOP
Pmin/Pmax = 6/400
Equil time = 0.00
1.
.... _
Proportion Valves A/C .

press PUMP
press START
Workstation Method: ACPROPOR

Repe~t the above procedures substituting valve C for valve B.
9012 SDS LABORATORY
9
Pro~ortioning Test Method

RECORDER: 1 AUFS INPUT: I 0 mvfs
WAVELENGTH: 265 nm CHART SPEED: I em/min

1 0.00 100 0 0 5.0
2 2.00 100 0 0 5.0
3 2.01 90 10 0 5.0
4 4.00 90 10 0 5.0
5 4.01 80 20 0 5.0
6
7
8
9
10
6.00
6.01
8.00
8.01
11.00
80
70
70
30
30
20
30
30
70
70
0
0
0
0
0
5.0
5.0
5.0
5.0
5.0
11 11.01 20 80 0 5.0
12 13.00 20 80 0 5.0
13 13.01 10 90 0 5.0
14 15.00 10 90 0 5.0
15 15.01 0 100 0 5.0
END Tl1\1E -> 17.00
10-20% step should= in mag. to the 80- ~0% step 10%
20-30% step should= in mag. to the 70-80% step 10%

......... ''
tle 9012 A/B Valve Proportioning Test
!thod File C:\STAR\ABPROP.MTH
l~ ~on Date: 20-JAN-95 11:45 AM Calculation Date: 20-JAN-95 12:01 PM

>, cor jean Detector Type: 9050
>rkstation: COMPAQ 66M Bus Address 3
tstrument : certification Sample Rate 10.00 Hz
tannel 1 = 2 65 nm Run Time 15.978 min
"********* Star Chromatography Software ********** Version 4.0 ***************
tart Speed 1.24 em/min Attenuation = 1102 Zero Offset = 2%

AU I I I I I
- -0.029 0.539
100/oA
!
i
~Lh-.,W\> 1 - 90/oA : 10/oB
I
;
i
I. 3- 80o/oA: 20/oB
1 - 90%A: 10%8 =14mm 14 -12 X 100 = 15% difference

2- 10%A: 90%8 =12mm (14 + 12 )+2
1/tw.W\) 6 - 30/oB 70%A
I
3- 80%A: 20%8 =14mm 0% difference
4- 20%A: 80%8 =14mm I
1 \4rr, 4 - 20o/oA
- 70%A : 30%8 =14mm 0% difference
-30%8: 70%A =14mm
I : 80%8
.f
\.
Divisions
Divisions % DIFFERENCE= 0%
Divisions
Divisions % DIFFERENCE= 6.5%
PP.INT0 It _IJL-
9-8.5 X 100
/o Difference =
0 -
9 + 8.5
2

10
9012 SDS LABORATORY
20/o-25% PROPORTIONING CALl BRATION CHECK
established no adjustments should be made for the completion of all testing.

AIZ=Y
Wavelength = 265nm


80 20 0 5.0
%A %8 %C Flow
75 25 0 5.0
press RESET
a 70-80% baseline.
Acetone Adjustment:
chromatograms, next page, show a 1% offset of 31.4 :t 50% and a 5% offset of
157 :t10%.
J.. '-.J.. c ~u~L~u~ ~U/L~' PROPORTlUNlNG ~~~T
c1n File C:\STAR\MODULE03\STAR068.RUN
=thod File C:\STAR\20PROPOR.MTH
3.mple ID Manual Sample
~~~tiJon Date: 6-JAN-95 12:55 PM Calculation Date: 6-JAN-95 1:02 PM

t:.or free Detector Type: 9050
.station: COMPAQ 66M Bus Address 3
~strurnent Certification Sample Rate 10.00 Hz
.>annel 1 = 265 nrn Run Time 6. 480 min
:1art Speed 3.06 em/min ( Attenuatigp - 57 'J Zero Offset = 2%

tart Time 0.000 min End Time - 6.480 min Min I Tick 1.00
milliAU I I I I I
-1.535 28.248
+II
Of[s~-t- fby 11. ~ 6ofG11. AB

1;1 -:. !>LL\-'Mh\ ~o1. ::a'? 1&5.7 -4-1.1 ""'-1\1

11
9012 SDS LABORATORY

12
100 0 0
Change the 9012 Settings:
press RESET on 9012

%A
99
%8
1
%C
0

Remove 9012 cover
thumbwheel adjustment knpb to turn. (These assembly screws are sealed
5% values.
1% and 5% values .
.tle 9012SDS 1% PROPORTIONING TEST
m File C:\STAR\MODULE03\STAR07l.RUN
!thod File C:\STAR\1PROPOR.MTH
-'~on Date: 6-JAN-95 2:11PM Calculation Date: 6-JAN-95 2:16 PM
tor free Detector Type: 9050
>l.""station: COMPAQ 66M Bus Address 3
tstrument Certification Sample Rate 10.00 Hz
tannel 1 = 265 nm Run Time 5.478 min
'********* Star Chromatography Software ********** Version 4.0 ***************
1art Speed = ' 3.61 em/min Attenuation = 57 Zero Offset = 2%

milliAI1 I I I
-1.112 27.836
<WI=2.0

13
9012 505 LABORATORY

'.
14
9012 SDS LABORATORY
5%, OPTICAL SWITCH ADJUSTMENTS
Instrument Settings: Workstation Method: SPROPOR (see Appendix A)
100 0 0

95 5 0
baseline remains correct at 1/Sth 50% of the 20-25% baseline. Adjusting the 5%
'itle 9012SDS 5% PROPORTIONING TEST

~un File C: \STAR\MODULE03\STAR072. RUN
[ethod File C:\STAR\5PROPOR.MTH
.ample ID Manual Sample
, - i o n Date: 6-JAN-95 2:50PM Calculation Date: 6-JAN-95 2:56PM
~ ~a tor free Detector Type: 9050

rorkstation: COMPAQ 66M Bus Address 3
nstrument Certification Sample Rate 10.00 Hz
:hannel 1 = 2 65 nm Run Time 5. 478 min

:tart Time 0.000 min End Time = 5.478 min Min I Tick 1.00
milliAU I I I I
-1.112 27.836
1~1. 3- 11l.i ~~
~---------\34~~~--------------
l. \
~itle 9012SDS 5% PROPORTIONING TEST
1ethod File C:\STAR\SPROPOR.MTH
3ample ID Manual Sample
[r'.ion Date: 9-JAN-95 1:16 PM Calculation Date: 9-JAN-95 1:22 PM

a tor free Detector Type: 9050
oJorkstation: COMPAQ 66M Bus Address 3
Cnstrument Certification Sample Rate 10.00 Hz
:hannel 1 = 265 nm Run Time 5.487 min
::hart Speed 3.61 em/min Attenuation = 57 Zero Offset = 10%

3tart Time 0.000 min End Time = 5.487 min Min I Tick = 1.00
milliAU I . I I I
-5.566 27.836
<WI=2.0
~------ \ lfl{: I'YWY'\*--------_,.i?d
*A~e~tJ':oL -~ Of1i~\ -sw,t~ O.d~v.~+vvte-~

- <WI=4.0
<WI=8.0
15
9012 SOS LABORATORY

YES
NO
-
Action required: 12345171 12345171
p
1. Locate the switch blocks in the DDDDDDDD ODDOOOOO

-0,...- -Open- /

board. The switches are easily S4 S5
cover is removed.
Pump CPU Board
YES
All modules on the GPIB bus must have a different address. Since_ all pumps are
configured with address 1 in the factory, there would be an address conflict .
Action required:
the back panel. Make sure that all modules connected to the same Workstation have

NO
No action required.
03-914526-00:1
1
16
9012 SDS LABORATORY
50% -51% OPTICAL SWITCH ADJUSTMENTS
AlB: 50%-51% PROPORTIONING ADJUSTMENT
Instrument Settings: Workstation Method: ABSOPROP (see Appendix A)
50 50 0

49 51 0
Switching from the 50% to 51 %8 solvent will cause the chart recorder pen to reposition
To adjust the baselines, i.e. 8 and C valve timing, use DIP switch S-5 on the SBC
board.

Switch # 1 2 3 4 5 6 7 8
- ~offset size.
_ _ _ _-4,
Switch #3 OFF
baseline._ _ _ _""'" +4
17
9012 SDS LABORATORY
50%,- 51% OPTICAL SWITCH ADJUSTMENTS

AlB VALVES
'-~++'
I'
t'.f
'l -
>. LIC 0 I 00-0026 -

.tle 9012SDSA0S0%-51% PROPORTIONING TEST
!thod File C:\STAR\ABSOPROP.MTH
Lmple ID Manual Sample
~e~on Date: 10-JAN-95 1:54 PM Calculation Date: 10-JAN-95 1:59 PM
_._tor jean Detector Type: 9050

COMPAQ 66M Bus Address 3
.station: 10.00 Hz
1strument certification Sample Rate
1 = 265 nm Run Time 3.978 min
1annel
~*********
Star Chromatography Software **********Version 4.0 ***************
4.98 em/min Attenuation = 57 Zero Offset = 10%

1.art Speed Min I Tick 1.00
:art Time 0.000 min End Time = 3.978 min
I I I
milliAU I I 27.836
-5.566
~
18
9012 SDS LABORATORY
50o/o- 51% OPTICAL SWITCH ADJUSTMENTS
AIC: 50% - 51% PROPORTIONING ADJUSTMENT
Purpose: Same as the AB proportioning.

through valve C.
50 0 50

49 0 51
The 50:51 C offset should be equal to the 50:51 8 offset 20% (3 minor divisions on
50:51 8 method to verify that it is still within the specified limits.
Title 9012SDS AC 50/51% PROPORTIONING
Method File C:\STAR\AC50PROP.MTH
Ir~ion Date: 10-JAN-95 3:11 PM Calculation Date: 10-JAN-95 3:16 PM
. ~ator jean Detector Type: 9050

W~J~kstation: COMPAQ 66M Bus Address 3
*********** Star Chromatography Software********** Version 4.0 ***************

milliAU I I I I I
-5.566 27.836
S<-p~t S~lfr\t 41 A?.:> 1...0 ~0

+-(- - 51 W. W\ - - - H
A0: L\ ~ r m1. ~ 3~ .t - ~ l. t, w.~

19
9012 SDS LABORATORY
50% - 51/o OPTICAL SWITCH ADJUSTMENTS

AJC VALVES
PRINTED IN U.S.A.
20
9012 SDS LABORATORY
GRADIENT LINEARITY
GRADIENT LINEARITY
9012 Settings:
Line Time %A %8 %C ... Flow
1 0.00 100 0 0 5.0 ml/min

2 10.00 0 100 0 5.0 ml/min
3 20.00 100 0 0 5.0 ml/min
4 30.00 0 0 100 5.0 ml/min
End Action = Stop
9050 Settings:
press: AAUFS AJZ, enter the following values
Rcdr AUFS = 1.00
AIZ=Y
Wavelength = 265nm
End Action = Reset
press: RESET
See sample chromatogram, next page.

9012 SDS LABORATORY
21
GRADIENT LINEARITY
~fFr.rrr.rrrrr.~
00-997289-oo Vanan Instrument Group PRI:HEO 1H U.S.A..

1.~c1.e

I n . t i o n Date: 10-JAN-95 5:29 PM Calculation Date: 10-JAN-95 6:00 PM

rator jean Detector Type: 9050
.kstation: COMPAQ 66M Bus Address 3
Channel 1 = 265 nm Run Time 2 9. 98 7 min

Start Time == 0.000 min End Time = 29.987 min Min I Tick = 1.00
AU I I I
-0.027 0.520
+II
Y\0 CC\.V\ 1'1 o-'t u..-\ c.-vJCA+e_

(s-E-. (\~ e-5
V1. e.x-t- P"- ':)c..)

_T_____ Act_<;!~!!"<e_c~~~~--
Height between start and / Extrapolated Trace

end of trace /
Abs
\OOvvt m
..___r--- Height between
Expanded VieW----7\
..~-.:-- extrapolated and
actual traces
Time

Specifications: <1 /o deviation at ~Oo/o point A to B,

8 to A and A to C.
3mm + 1OOmm X 100 =3% deviation
22
9012 SDS LABORATORY
FLOW RATE ACCURACY

100 0 0 1.00 mllmin
Procedure:
Place all three solvent lines (A,8, &C) into H20/2% 2-propanol.
Flowmeter.
Prime lines A, 8, and C.
Set pump flow rate to 1mllmin, allow backpressure to stabilize.
Take three flow rate readings through each Valve A, 8, and C.
Repeat this procedure at 5 mllmin.
Switch 4 Switch 5 Switch 6 OFFSET

up down down + 1.0%
up up down nominal
down down up -0.5%

up down up -1.0% less flow
down up up -1.5%
up up up -2.0%
,
:'.

23
9012 SDS LABORATORY
APPENDIX A
WORKSTATION METHODS

ACPROPOR 9012 AIC Valve Proportioning Test
5PROPOR
AB50PROP
AC50PROP
9000GLT
9012 5% Proportioning Test
************************************************************************
Star Chromatography Software - Method Listing Fri Jan 20 11:47:19 1995
~elltd: C:\STAR\ABPROP.MTH
********************************************************************
************************************
************************************
Module Address: 01

0.00
o.oo
Relays . ------
10.00 Composition 30% A, 70% B, 0% c
10.01 Composition 20% A, 80% B, 0% c
12.00 Compos_ition 20% A, 80% B, 0% c
01 Composition 10% A, 90% B, 0% c
.00 Composition 10% A, 90% B, 0% c
4.01 Compos.:i,.tion 0% A, 100% B, 0% c
16.00 Composition 0% A, 100% B, 0% c
****************************
****************************
Module Address: 03
Time Constant 1. 00 sec

0.00 Timed AutoZero
0.00 S/N Ratio 8
0.00 Relays
--------------------
D.ctor Bunch Rate : 4 points ( 10.0 Hz)
' Monitor Length : 64 bunched points (6.4 seconds)
i, Data File Name : STAR

----------------------------------------------
S/N Rat~o 5
Mea.rement Type .. Peak Area
PP. Reject Value 1000 counts
rt Unidentified Peaks Yes
~rt Missing Peak No

Origin Force
Curve Fit Linear

Peak Table Empty
=~~~~=~=~-=:~~=---~~~:=~~-=--=~:~~=~-1
_bit Integrat~
: 0.01 until 16.00

Length in Pages 1
Autoscale On
Time Events : Off
Retention Times Off
Peak Names . Off
Baseline Off
Print Results . No

.
~
..
~ '''~-. 1t Report : No
Print Copies 1
tar Chromatography Software - Method Listing Fri Jan 20 15:35:07 1995
~thod: C:\STAR\ACPROPOR.MTH
41l*****************************************************************
~-~********************************
~**********************************
~dule Address: 01
Maxi~um Pressure 400 atm

0.00 Relays
10.00 Composition 30% A, 0% B, 70% C
10.01 Composition 20% A, 0% B, 80% C
12.00 Composition 20% A, 0% B, 80% C
12.01 Composition 10% A, 0% B, 90% C
1Ao Composition 10% A, 0% B, 90% C
~01 Composition 0% A, 0% B, 100% C
***************************
***************************
odule Address: 03
.Time Constant 1. 00 sec

o.oo Timed AutoZero
0.00 S/N Ratio 8
0.00 Relays
--------------------
~onitor Length 64 bunched points (6.4 seconds)
1 ~ata File Name : STAR
'~....,
ategration Parameters Address 3 Channel 1

---------------------------------------------
~btract Blank Baseline : No
~
Measurement Type .. Peak Area
PP~eject Value 1000 counts
~ Unidentified Peaks Yes
)rt Missing Peaks No
L, ~culation Type Percent

Other Peaks Time windows :Width: 0.10 min. Retention Time 2.0%
Origin Force
Curve Fit Linear

Peak Table Empty

--111(~-~~~~~;~~~-~-----~~~~--~~~ii ____ 16.00
... ;
ritle 9012 A/C Valve Proportioning Test

3tart Retention Time : 0.00 minutes
C..ength in Pages 1
0.0 em/min
rnitial Chart Speed
>linutes per Tick . 1.0
\utoscale
rime Events . On
Off
:hromatogram Events
~etention Times
. Off
Off
?eak Names : Off
3aseline Off
.
.
?rint Results No
,
~L ,t
Report
~;:;;:..:....-ert
. No
Report to ASCII?
?rint Copies . Off
1
~**********************************************************************

~t11t: C:\STAR\20PROPOR.MTH
k*******************************************************************
k**********************************
k**********************************
)dule Address: 01

0.00 Relays ------
**.**********************
50 UV-Vis Detector
k************~**********
odule Address: 03

0.00 Timed AutoZero
0.00 S/N Ratio 8
o.oo Relays

Data File Name STAR

~:41i~;-;i~~~-;~~~ii~~-------~~--------------
~ ~t10 5
_ --~ ..... tor Noise Before every run
nitial Peak Width 4 sec
angent Height% : 10% .
.easurement Type : Peak Area
eak Reject Value : 1000 counts
-
-
~renee Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%
u_ . er Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
Origin Force
Curve Fit Linear

Peak Table Empty

~e~=-:~:~:=--~~~::::_:
Le
__ :~:~~==-=--
9012SDS 20/25% PROPORTIONING TEST
P~~nt Chromatogram Yes
Length in Pages 1
Auto scale On
Time Events On
Chromatogram Events on
Retention Times : Off
Peak Names Off
Baseline Off
Print Results No
Print Report No
l.
Print Copies
\, .. _.
1
************************************************************************
Met~d: C:\STAR\1PROPOR.MTH
; ..,*******************************************************************
************************************
************************************
Module Address: 01

0.00 Relays ------
***~~**********************
. ~50 UV-Vis Detector
; '************************
h ...1le Address: 03

0.00 Timed AutoZero
0.00 S/N Ratio 8
0.00 Relays

Data File Name STAR

----------------------------------------------
S\,.act Blank Baseline No
r, atio 5
'l ' t .
...../;.. or No~se Before every run
In~tial Peak Width 4 sec
Tangent Height % : 10%.
Measurement Type : PeakArea
Report Missing.Peaks No


:::>rig in Force
Curve Fit Linear

Peak Table Empty
~p11t:_:~:~::
e
__~~~==~~-=--~~:~~==-=--
Length in Pages 1
Autoscale . Off
Time Events : On
Chromatogram Events . On
Retention Times Off
Peak Names Off
Baseline Off
Print Results . No
Print Report : No
Co.rt Report to ASCII? : Off
~; Copies : 1
'i~
************************************************************************
~et~d: C:\STAR\5PROPOR.MTH
' ********************************************************************
k***********************************
k***********************************
~odule Address: 01

0.00
0.00
Relays ------
1. 00 Composition 100% A, 0% B, 0% c
~**.**********************
50 UV-Vis Detector
' ************************
~0-ale Address: 03

o.oo Timed AutoZero
0.00 S/N Ratio 8
o.oo Relays

Data File Name STAR
Cntegration Parameters Address 3 Channel 1

----------------------------------------------
~~~~c~ Blank Baseline No
~ 'llllllra t ~ o 5
~.\ . . tor Noise : Before every run
[nitial Peak Width : 4 sec
l'angent Height % : 10%

teport Missing Peaks No
:alcula tion Type Percent
-- - - ---

)rig in Force
~urve Fit Linear

Peak Table Empty
t~~41J_:~:~:: ~~~==~~-~--~~:~~=~-=--
. 3
__ 9012SDS 5% PROPORTIONING TEST
>1.._t Chromatogram Yes
:tart Retention Time 0.00 minutes
:nd Retention Time 1440.00 minutes
:nitial Zero Offset
.ength in Pages . 10
1
1.0
tinutes per Tick
.utoscale _ . Off
'ime Events
:hromatogram Events . On
On
~etention Times Off
'eak Names Off
;aseline Off
rint Results No
rint Report No
onwt Report to ASCII? Off
copies 1
t
;;
"- ' -~. '"
'***********************************************************************
itar Chromatography Software - Method Listing Tue Jan 17 15:54:23 1995
tettlf: C:\STAR\AB50PROP.MTH
********************************************************************
'***********************************
'***********************************
1odule Address: 01

0.00 Relays ------
o.oo Flow Rate 5.00 ml/min
~***************~***********
50 UV-Vis Detector
**********************
le Address: 03

0.00 Timed AutoZero
o.oo S/N Ratio 8
o.oo Relays

rntegration Parameters Address 3 Channel 1

----------------------------------------------
5ub1Ect Blank Baseline No
51 tio 100
{ or Noise Before every run
:t..';:.,:_ ~ial Peak Width . 4 sec
~eak Reject Value : 1000 counts
~eport Unidentified Peaks : No
F -~xi~e Peak~. Tl~e. Windows :Width: 0.10 min . Retention Time 2.0%
. r Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
OrJ.gin Force
Curve Fit Linear

Peak Table Empty


~-llt--------------------~--~~i;~~~-~ 50%-51% PROPORTIONING
t Chromatogram Yes
-hromatogram Options:
[nitial Attenuation 57
Cnitial Zero Offset 10
~ength in Pages 1
~nitial Chart Speed 0.0 em/min
1inutes per Tick 1.0
~utoscale Off
~irne Events Off
tetention Times Off
,eak Names Off
!aseline Off
'rint Results : No
'rint Report . No
:onvert Report to ASCII? :
'ri~ Copies . Off
],
l'
f.,.___...
'-.,_
~**********************************************************************

: ! t . C: \STAR\ACSOPROP.MTH
~*******************************************************************
~**********************************
k**********************************
:>dule Address: 01

0.00 Relays ------
a. oo Equilibration Time: 10.00 min
1. 00 Composition 50% A, 0% B, 50% c
s.oo Method End Action Stop at End
***************************
50 UV-Vis Detector

**********************
le Address: 03

0.00 Timed AutoZero
o.oo
0.00
Peak Width
S/N Ratio . 48 sec
0.00 ~elay Trigger Off Next Peak
o.oo Relays


---------------------------------------------
iub~ct Blank Baseline : No
;/' tio
~-or Noise . Before
100
every run
.:" -<~ial Peak Width 4 sec
~angent Height % . 10%
leasurement Type
,eak Reject Value . Peak
1000
Area
counts
leport Unidentifi~d Peaks No
~eport Missing Peaks No
~alculation Type Percent
. -
-~c~. Peak;-Ti~e.-Windo~~:Width:
-.
0.10 min. Retention Time 2.0%
Jrigin Force
::urve Fit Linear
Jut-of-Tolerance Action: No Action
~eak Table Address 3 Channel 1
Peak Table Empty

---.--------------------------------
: 9012SDS AC 50/51% PROPORTIONING
1t Chromatogram Yes
8nd Retention Time 1440.00 minutes
Length in Pages 1
!\.utoscale Off
rime Events . On
~hromatogram Events . On
Retention Times . Off
Peak Names Off
Baseline : Off
Print Results : No
~onvert ~esults to ASCII?: Off
(.
Print Report No
~onvert Report to ASCII? : Off
Print Copies : 1
t-.:,,
***********************************************************************
tar Chromatography Software - Method Listing Mon Mar 13 12:44:58 1995
: e t . : C: \STAR\9000GLT.MTH
'*******************************************************************
***********************************
***********************************
lodule Address: 01
Maximum Pressure 400 atrn

Minimum Pressure 6 atrn
0.00 Relays ------
0.00 Flow Rate 5.00 rnl/rnin
10.00 Composition 0% A, 100% B, 0% c
20.00 Composition 100% A, 0% B, 0% c
30.00 Composition 0% A, 0% B, 100% c
***************************
'***************************
Iodule Address: 03

00 Wavelength 265 nrn
00 Attenuation 1. 000 AU
J.OO Timed AutoZero
0.00 S/N Ratio 8
0.00 Relays
Detector Bunch Rate 4 points (10.0 Hz}

Monitor Length 64 bunched points (6.4 seconds}
Data File Name STAR
:ubtract Blank Baseline No

:/N Ratio 5
Ionitor Noise Before every run
'angent Height % 10%
Iea. .ement Type Peak Area
1 7~..,eje?t Va~u7 1000 counts
z ~t
Un1dent1f1ed Peaks No
~~-rt Missing Peaks No
~eference Peaks Time Windows:Width: 0.10 min. Retention Time 2.0%
>ther Peaks Time Windows :Width: 0.10 min. Retention Time 2.0%
>rigin Force
:ur.Fit Linear
ation Tolerance 100%
of-Tolerance Action: No Action
Peak Table Empty
:nhibit Integrate : 0.01 until 30.00
:eport Format Address 3 Channel 1
.'itle .. 9012 GRADIENT LINEARITY AB/BA/AC

rint Chromatogram Yes
:tart Retention Time 0.00 minutes
:ndt~ntion Time 1440.00 minutes
~~- 1.n Pages 1
~ ial Chart Speed 0.0 em/min
Ii... __.tes per Tick . 1.0
,utoscale . On
'ime Events Off
~hromatogram Events
:etention Times . Off
Off
eak Names Off
>aseline Off
'rint Results : No
'rint Report No
rint Copies 1
1
ADDENDUM A
EXTENDED DIAGNOSTICS- 9012 SDS

EXTENDED MENU

TeleOiagnostics TM (permits a Varian CSR to run the extended diagnostics tests remotely via
a modem)
Retract Piston (retracts the piston for Seal Replacement)
GPIB Board Test (verifies presence of GPIB Board)
driver)
MVD Valves Test (motor/valve driver, verifies proper operation of valves A, 8, C)
Printer Port Loopback Test (verifies proper operation of internal serial port circuitry)
2
9012 SDS LABORATORY
MAINTENANCE LOG
Press START
Press STOP
Press NEXT LINE
TELEDIAGNOSTICS
Press START
Press STOP
Press NEXT LINE
DISPLAY TEST
Press START
Press STOP
Press NEXT LINE
3
9012 SDS LABORATORY
LEAK TEST
Press START


Press NEXT LINE

Press NEXT LINE

Press START

Pres xx atm Leak: xxxx.:xxx J.tllmin.
Press STOP
Press NEXT LINE
Record: atm Leak: _ _ _ _ _ _ J.!IImin.


Press START
Press START
Positioning in progress, please wait. ..
Press STOP
Press NEXT LINE
4
9012 SDS LABORATORY
Press START
Press START

Press STOP
Press NEXT LINE
KEYBOARD TEST
Press START
Keyboard Test:
menu.
Press STOP
Press NEXT LINE
PRINT PATTERN TEST
Press START
Print Pattern Test

Test in Progress

Press STOP to return to MAIN MENU .
Press STOP
Press NEXT LINE
5
9012 SDS LABORATORY
RELAYS TEST
Press START


Press STOP
Press NEXT LINE
FAULT SIGNALS TEST
Press START
Fault Signals Test:

Press STOP
Press NEXT LINE
START SIGNALS TEST
Press START
Start Signals Test:

.Press STOP
Press NEXT LINE
READY SIGNALS TEST
Press START
Ready Signals Test:

Press STOP
Press NEXT LINE
6
9012 SDS LABORATORY
READY ENABLE TEST
Press START
Ready Enable Test:

Press STOP
Press NEXT LINE
ADC TEST
Press START
PRS (atm)
x.xxx
REF (v)
x.xxx
Press STOP
BAT (v)
x.xxx
PRL (v)
X. XXX
Record: PRS
REF(v) _ _
BAT(v) _ _
PRL(v) _ _
Press NEXT LINE
ROM TEST
Press START
ROM Test:
Press STOP
Press NEXT LINE
RAM TEST
Press START
RAM Test:
RAM BANK 0/2 Passes
Press STOP
Press NEXT LINE
7
9012 SDS LABORATORY
GPIB BOARD TEST

Press START
GPIB Test:
Test Passes
Press STOP
Press NEXT LINE
GPIB ADDRESS SWITCH TEST

Press START What is the number address for your instrument?_
Press STOP
Press NEXT LINE
GPIB ECHO TEST

Press START

Press START
Press STOP
Press NEXT LINE
MVD GATES TEST

Press START
MVD Gates Test:

PH2GTB: Passed
Press STOP
Press NEXT LINE
9012 SDS LABORATORY
MVD VALVES TEST

8
Press START
MVD Valves Test:

VALVE NB/C: PASSED
Press STOP
Press NEXT LINE
SIO Loop Back Test:

HIW HANDSHAKE TEST: Both Failed
Press STOP
Press NEXT LINE
Press START
Press STOP
Press NEXT LINE
(.
STAR 9010 SOLVENT DELIVERY SYSTEM - KIT PART NUMBERS
DESCRIPTION DESCRIPTION
03-919103-90
03-919297-00
29-900159-00
29-900044-00
03-919477-00
29-899866-00
KIT TOOL
TOOL. SEAL REMOVAL
WRENCH, OPEN END 5/16"-1/4"
SCREWDRIVER. 1/8" BLADE
TOOL. GAPPING, .048 THK
WRENCH, ALLEN 5/32"
03-919495-90 KIT. RESERVOIR HOLDER & BOTTLES
89-500105-00 BOTTLE, RESERVOIR, GLASS, 1 LITER
03-919252-00 HOLDER, RESERVOIR BOTTLE
03-919496-90 KIT. REPAIR. PROPORTIONING VALVE

03-905263-01 ASSY, PROP VALVE W/0 COIL
03-914231-00 INSTRUCTIONS, REPAIR KIT, PROP VALVE
03-919102-90 KIT. PISTON REPLACEMENT, ANALYTICAL
03-914171-00 INSTALLATION INSTRUCTIONS
03-919180-00 ASSY, PISTON 03-919511-90 KIT. CSA HEAT SHIELD
03-919432-00 GREASE GUARD 12-222008-04 SCREW, N0.8-32 X 1/4, PHMS, SST
03-919460-00 BUSHING, SPRING HOUSING 14-122008-00 WASHER, FLAT, NO. 8, SST
88-299464-00 GREASE, WHITE LITHIUM, 1.5 OZ TUBE 14-202008-00 WASHER, SPLIT-LOCK, N0.8, SST
03-919223-00 SKIRT, PUMPHEAD 03-919510-00 HEAT SHIELD, CSA
03-929101-90 KIT. REPLACEMENT PISTON SEAL. ANALYTICAL 03-919256-90 KIT. VALVE MOUNTING. UNIVERSAL
03-919397-00 SEAL ASSY 03-919242-00 TRACK, VALVE & COLUMN MTG
03-919223-00 SKIRT, PUMP HEAD 03-919246-00 PLATE, VALVE MOUNTING
03-914146-00 INSTALLATION INSTRUCTIONS 03-919247-00 PLATE. AUTO-V VALVE MTG
03-919248-00 BRACKET, COLUMN MTG
03-919249-00 BRACKET. COLUMN RETAINER
03-919074-90 KIT. STD ACCESSORY 03-919250-00 PLATE, UNIVERSAL MTG
03-905638-90 KIT, RESERVOIR CAP 03-919271-00 UNION, 1/16" BULKHEAD
27-180387-00 FILTER, SST, 10 MICRON 03-916374-00 VALVE, PRIME/PURGE

28-694563-00 FERRULE, 1/8" TUBE, TEFLON 89-988832-00 SYRINGE, 10 UL
28-694533-00 FERRULE, 1/16", SST 89-988973-00 ASSY. ZERO VOLUME FITTING, 1/16"
03-919397-00 SEAL 03-906014-00 ASSY, SAMPLE LOOP 10 UL
03-905640-00 ASSY, PRIMING PUMP 03-919336-00 TUBE. STR, PIP VALVE TO INJ VALVE, 7"LG
67-135420-00 FUSE, 2A, 250V, SB, 3AG 03-919336-01 TUBE, STR, INJ VALVE TO COLUMN, 8 3/4"LG
55-500333-00 FUSE, 1.6A 250V, TYPE T, 5X20 mm 03-919336-02 TUBE, STR, COLUMN TO DETECTOR, 10"LG
28-693989-00 NUT, 1/8" TUBE, SST 03-919337-00 TUBE, B/H FITTING TO P/P VALVE
15-001410-00 NUT, ZERO DEAD VOLUME 03-919339-00 TUBE, COLUMN TO COLUMN
02-001954-00 CABLE, ASSY, SIGNAL OUTPUT 28-849710-00 FITTING, HALE BARB, 1/16" TO 110-32
03-919103-90 KIT, TOOL 14-202008-00 WASHER, SPLIT LOCK. 18, SST
03-919468-00 MIXER/FILTER ASSY 13-929886-00 WELD NUT, 18-32, SST
67-135410-00 FUSE, 1A 250V, SB, 3A6 03-919272-00 JAM NUT, UNION
13-312006-00 KEPSNUT, 16-32, SST
13-312003-00 KEPSNUT, 18
03-919076-90 KIT. VQLTAGE SELECTION OPTION 12-222008-03 SCREW, 18-32 X 3/16. PHMS, SST
67-135420-00 FUSE, ZA sa, 250 V 03-919326-00 ASSY, THUMB SCREW, 18-32 X l/4, BLK
55-500333-00 FUSE, 1.6A sa, TYPE T,250 V (SXZO mm) 03-919326-01 ASSY, THUMB SCREW, 18-32 X 1/2, BLK
03-919040-00 LABEL, WIRED FOR 220V AC 03-919326-02 ASSY, THUMB SCREW, 18-32 X 3/4, BLK
81-821499-00 LINE CORD, 6 1/2 FT (120 V) 03-914155-00 INSTALLATION INSTRUCTIONS
81-821551-00 LINE CORD, 8 FT (220 V) 12-222006-07 SCREW, 16-32 X 7/16, PHMS, SST
67-135410-00 FUSE, 1A SB, 250V, 3AG 12-222008-05 SCREW. 18-32 X 5/16, PHMS, SST
03-919238-00 LABEL, WIRED FOR TWO PHASE 220VAC 14-202006-00 WASHER. SPLIT LOCK, 16, SST
03-914248-00 INSTRUCTION SHEET, 220VAC INSTALL. 03-919470-00 TUBE. MIXER/FILTER TO 8/H FITTING
03-919471-00 TUBE, DAMPER TO MIXER/FILTER
15-001410-00 NUT, ZERO DEAD VOLUME. SST

03-919491-90 KIT. MIXING CEll FILTER REPLACEMENT ZS-694533-00 FERRULE, 1/16", SST
27-180385-00 FILTER, 0.5 MICRON :-399915-00 GROMMET 1/4" THK
03-914236-00 INSTALL INSTR, FILTER REPLACEMENT
Page 2
STAR 9010 SOLVENT DELIVERY SYSTEM - KIT PART NUMBERS
03-919910-90
DESCRIPTION
KIT. 9010/9050 TO 9000 SERIES UNIVERSAL SYNC

SIGNAL CABLE
03-919900-90 ASSY, CABLE, 9010/9050 TO 9000 SERIES
03-919491-90
DESCRIPTION
KIT. MIXING CELL FILTER REPLACEMENT

27-180385-00 FILTER, 0.5 MICRON
03-914236-00 INSTALL INSTR, FILTER REPLACEMENT

UNIVERSAL SYNC SIGNAL (P9)
03-919902-00 ASSY, CABLE, 9010/9050 TO 9000 SERIES
UNIVERSAL SYNC SIGNAL (P10) 03-919102-90 KIT. PISTON REPLACEMENT. ANALYTICAL
03-914226-00 INSTALLATION INSTRUCTION, 9010/9050 TO 03-914171-00 INSTALLATION INSTRUCTIONS
9000 SERIES UNIV. SYNC SIGNAL CABLE 03-919180-00 ASSY, PISTON
03-919432-00 GREASE GUARD
03-919548-00 BUSHING, SPRING HOUSING
03-919080-90 KIT. RS232 INTERFACE 88-299464-00 GREASE, WHITE LITHIUM,1.5 OZ TUBE
03-919307-00 ASSY, CABLE, RS232 INTERFACE 88-299461-00 GREASE, MOLYKOTE G, 2.8 OZ TUBE
51-339972-00 KIT, FEMALE SCREW LOCK ASSY 03-919223-00 SKIRT, PUMPHEAD
03-914154-00 INSTALL. INSTR, 9010/RS232 03-919532-00 WASHER, SST
03-919500-00 PLATE, RS232C CONN MTG 03-919549-00 BUSHING, PISTON FRONT
03-919501-00 LABEL, PRINTER/RS232C 03-919397-00 SEAL ASSEMBLY
27-180385-00 FILTER, ELEMENT, 0.5 MICRON
03-919009-90 KIT. PQWEREO EVENTS MODULE

03-914142-00 INSTALLATION INSTRUCTIONS 03-919101-90 KIT. REPLACEMENT PISTON SEAL. ANALYTICAL
81-821499-00 CABLE ASSY, POWER, 6 1/2 FT, (120V) 03-919397-00 SEAL ASSY

81-821551-00 CABLE ASSY, POWER, 8FT, (220V) 03-919223-00 SKIRT, PlJIP HEAD
03-908348-02 CABLE ASSY, OUTPUT SIGNAL 03-914146-00 INSTALLATION INSTRUCTIONS
28-158600-00 TUBING, 1/8"0D, RED, POLYUR'TH'N 27-180385-00 FILTER ELEMENT, 0.5 MICRON
28-158603-00 TUBING, 1/8"0D, GRN, POLYUR'TH'N 03-919549-00 BUSHING, PISTON, FRONT
28-158923-00 TUBING, 1/8"00, CLR, POLYUR'TH'N
03-919185-00 ASSY, FINAL PEM, 120V
03-919185-01 ASSY, FINAL PEM, 220V 03-919251-90 KIT. PURGE VALVE. WITH MTG BRKT
03-919302-00 BRACKET, PRIME/PURGE VALVE
03-916374-00 VALVE, PRIME/PURGE
03-907517-90 KIT. INSTALLATION. PRINTER 12-222008-06 SCREW, NO. 8-32 X .38 LG, PHMS, SST
78-910403-00 PRINTER, COMPUTER (120V) 14-202008-00 WASHER, SPLIT LOCK, NO. 8, SST
78-910405-00 PRINTER, COMPUTER (220V) 03-914153-00 INSTALLATION INSTRUCTIONS
03-907570-00 CABLE, RS232. 8', SHIELDED 03-919471-00 TUBE, DAMPER TO MIXER/FILTER
03-919240-00 TUBE, MIXER/FILTER TO PURGE VALVE
03-919914-90 KIT. CA8LE AQAPTER. 90QO SERIES TO SPADE LUG 03-919554-00 TUBE, 1/16" 00 X .020 WALL, 13" LG, SST
UNIVERSAL SYNC SI6NAL
03-9191908-00ASSY CABLE ADAPTER, 9000 SERIES TO SPADE
LUG UNIVERSAL SYNC SIGNAL (OUTPUT)
03-919909-00 ASSY, CABLE ADAPTER, 9000 SERIES TO SPADE
LUG UNIVERSAL SYNC SIGNAL (INPUT)
03-914230-00 INSTALLATION INSTRUCTION, 9000 SERIES TO
SPADE LUG UNIVERSAL SYNC SIGNAL CABLE
ADAPTER
03-919495-90 KIT. RESERVOIR HOLDER &BOTTLES

89-500105-00 BOTTLE, RESERVOIR, GLASS, 1 LITER
03-919252-00 HOLDER, RESERVOIR BOTTLE

lt<I::.YJ 1-'ART NUMBER 1 DESCRIPTION OR MATERIAL
-90 03-919643-00/-01
-91 9002 03-919644-00/-01
I - - - - - - - - S E E BELOW
-92 INERT 9012 03-919643-02/-03
-9_4__-+__--9~~--_,___-~92~---r-~-9~/~-r--~-9~0--~--~PAW~T~N~U=MB~~~R__
________-_95________r-__
_ 3 EA
--
- 3 EA
--
_3EA
_ I EA
__ I EA
--
__ I EA
_JEA
- 3 EA
- 3 EA
- - 3 EA
_ I EA
-
03-905638-90
27-180387-00
28-694563-00
28-694533-00
~SCR~nON
KIT, RESERVOIR CAP
FILTER, SST. 10 MICRON
FERRULE. 1/8 1 TUBE. TEFLON
FERRULE, 1/16 .. SST
ITEM
I
2
3
4
28-211516-00 FERRULE. 1/8 1 TUBE. PLASTIC 5
- _ I EA _ I EA - 1 EA -- -- - 01-900011-01 PEEK TUBING, 1/16 1 OD X .010" ID 6
7
8
-- -- -- __ 3 EA -- - - 3 EA 28-693989-00 NUT, 1/8 1 TUBE. SST 9
-- - -- __ 3 EA - 1 EA - 1 EA 15-001410-00 NUT, ZERO DEAD VOLUME 10
D _ I EA - 1 EA _ I EA -- -- - Al-121590-12 COLUMN
0 II
_ I EA _ I EA - 1 EA -- -- - 03-919103-90 KIT. TOOL 12
CN -lEA 03-919468-oo MIXER/FILTER ASSY 13 (
0
T 14
_lEA _lEA -lEA 28-211489-00 PLUG 15
s _lEA _lEA -lEA 88-299423-00 LUBRICANT, OIL, 1/4 OZ VIAL 16
c _lEA _lEA _lEA 89-988984-00 SYRINGE, ICC X 1/IOOCC 17
A _lEA _lEA -lEA
L 89-988985-00 NEEDLE, SYRINGE, 20 GA. 112" LG. 18
_E -lEA
.l
27-180385-00 FILTER ELEMENT. 0.5 MICRON 19
_lEA -lEA 03-919397-00 SEAL ASSY 20
APPROVED FCJR
D _lEA 03-9194 71-00 TUBING, DAMPER TO MIXER 21
_3EA _lEA 28-211518-00 NUT. 118 1 TUBE, TEFZEL 22 M'AR 12199G
w _lEA 88-310216-00 FRIT, 2/Jm, TITANIUM 23
I
N 24 FABR~CPJ~()N
B G _3EA 28-211523-00 FERRULE. 1116 1 , PEEK 25
-lEA 03-919622-00 ASSY, CHAMBER, MIXING CELL. 4.6mm X 5cm 26
_lEA
E
03-919609-00 SEAL ASSY. INERT 27 -95 KIT, INSTALL/MAINTENANCE 9012 INERT
28 -~4 KIT, INSTALL/MAINTENANCE 9002
_lEA 03-919614-00 TUBING, DAMPER TO MIXER/FILTER 29
_3EA 28-211524-00
-93 KIT, INSTALL/MAINTENANCE 9012
FILTER, Ti, 10 MICRON 30
_lEA _lEA -lEA 03-914418-01 INSTALLATION CHECKLIST 31 . c~
~ ~~=-~~----~~~~~~-----_,
9
INERT 9012
90_Q_g_
- DO NOT SCALE DRAWING
90 9~ t--
z M
IDASH N 0.
DRAWN
J CK
DATE
8-24-86
APPROVED
K.J.
I8 -25-861-
DESC_R IE_T ION
DATE -
ow
-C!l
1-Z
a..<
-:::r:
~<.:1
~
LLJ
-
f-.
CHECKED
J. S.
I8-24-86
DATE APPROVED
H. N.
I8-25-86
DATE CLASS
0
Clli..L. 0')
A wo
0 ....JI
LLJ
0
WCTl
oo
0
<( KIT, STD ACCESSORY ,.
REG PART NUMBER. DESCRIPTION ITEM
_ I EA 03-905638-90 Kl T. RESERVOIR CAP

m
I
1'0 _ I EA 27-180387-00 FILTER. 10 MICRON, SST 2
0
_ 2 EA 28-211505-00 NUT. 1/8" OD TUBE, ALUM 3
D _ 2 EA 28-211509-00 BUSHING. KEL-F. 1/8" OD TUBE 4

0
N
0
T
s
c
A
I L
E
I
~!
I N
I
APPROVED fOR
FEB 161996
I G
fABRiCAT\ON
-91 FIELD INSTALLATION

-90 NOT USED
-01 NOT USED
-00 DRAWING ONLY
DASH N0. DESCRIPTION
DRAWN
z
ow Fl
-<!J
1-Z
a.< C~ 11"\DATE
-z
It:(.)
(,.)
..J /7 pl--15"-?h
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m _ I EA 03-919745-91 KIT, ACCESSORY, 9012Q 3

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_ I EA 03-919737-01 PANEL, LOWER FRONT W/ VALVE, 90120 4
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D _ 5 IN 03-919508-00 TUBING, 1/8', SOLVENT RESERVOIR, TFE 6

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_ I EA. 03-919074-92 KIT, STANDARD, ACCESSORY I

o:;t" _ I EA. 03-919600-90 ASSY, CHECK VALVE, TITANIUM 2
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-(j) _ I EA. 03-919607-00 HEAD, PUMP, TERNARY, TITANIUM 4
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_ I EA. 03-919548-00 BUSHING, SPRING HOUSING 5
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0 _ I EA. 03-919612-00 VALVE, PRIME/PURGE, INERT 6
_ I EA. 03-919608-00 PIN, INLET VALVE ORIENTATION, TITANIUM 7
_ I EA. 03-919609-00 SEAL ASSY I INERT 8
_ I EA. 03-919298-20 NAMEPLATE, INERT 9012 9
_ 2 EA. 03-919459-00 WASHER, ORIENTATION SCREW 10
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_ I EA. 03-919620-00 TUBE, PURGE VALVE/DAMPER, TITANIUM 12
N _ I EA. 03-919621-00 TUBE, TRANSDUCER/PURGE VALVE, TITANIUM 13
0
T _ I EA. 03-919446-00 TUBE, DRAIN, PURGE VALVE 14
_ I EA. 28-211497-00 FERRULE, 1/16~, TEFZEL, BLUE 15
s _ 6 EA. 28-694533-00 FERRULE, 1/16~, SST 16
c NUT, GC ZERO VOLUME FITTING, 1/16~, SST
A _6EA. 15-001410-00 17
L _ I EA. 28-211502-00 NUT, 1/16~, DELRIN, BLACK 18
E _ I EA. 03-914437-00 INSTALLATION INSTRUCTION, 9012 TO INERT 9012 19
D _ I EA. II- 622060-04 SET SCREW, 10-32 20
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_ I EA. 03-919549-00 BUSHING, PISTON FRONT 21
_ I EA. 03-919664-01 ASSY, DAMPER, SOLID CORE 22
I _ I EA. 03-914504-00 INSTL INSTR, SOLID CORE DAMPER REPL KIT 23
N _ I EA. 03-919740-02 TUBE, PURGE VALVE TO DAMPER, TI 24
G _ I EA. 03-919670-01 TUBE, DAMPER TO BULKHD FITTING, TI 25
_ 2 EA. 28-149021-00 FERRULE, 1/16~, SST 26
*IT IS RECOMMENDED THAT THIS UPGRADE BE INSTALLED BY A SERVICE REPRESENTA T!VE.
DRAWN DATE APPROVED

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CHECKED DATE APPROVED
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_ I EA 00-997325-00 PRINTER PAPER, 8 1/2 X II (500 SHTS/PKG), 5 PKGS 5
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NOTE: "-91"= NMR P/N 01-903167-00
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DRAWN DATE APPROVED
JCK 9-21-95 G.DENN IS
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10 --- I
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- - - ------------
i 3 7 I 1 _j
1
G IIZOVACl REPAIR !TEI.IS-
1220VACl
/'---------~---------"
------------------------------------------------------,---------------------------------,
~
I I
I _ I
25
2 3 4 ASSY, PCB.
GPIB
KIT ,(i'JB
INTERFACE
I
1
iKIT.RESERVOIR
HOLDER &
: KIT.
REPAIR. PROP
SCHEMATIC. l.iANUAL ACCESSORY KIT "*""
~
--+-- BOTTLES :- VALVES
HYDRAULIC
SYSTEM IREFI
SCHEMATIC.
INTERCONNECT
VOLT AGE OPTION
KIT
A!:.
BA 03-919118 -00 03-91907300~0
I
l r,3-919495-90 1
I
~---=o""3-'-9="1"'"9-'-'"9:-;6;...--=-9o-=---",
!REF!
F
03-919017-00 03-914123-00 03-919074-90
I 5
03-919075-00 03-919076 -90
w -91
1120VACl~S
1220VACI ASSY. CABLE.
(i'!B !IF
K!T.RS-232
INTERFACE
I
1
--;--
: i- KIT,
.'URGE VALVE
_ W/MTG BRKT
:
1
I
~-
KIT.REPLACEMT
PISTON SEAL
ANALYTICAL
I
KIT, TOOL
9010
ASSY, MIXER 03-919334-00 03-919080-90 1 03-919251-90 1 ~-'o"'3:.:.._:::-9:-::19"'"'1o""l"'-g?:o~,
FILTER I - I
03-919103-90 03-919468 -oo
KIT, SPARGE
OPTION _J_
: ~-
I <IT,VALYE IHG
UNIVERSAL
KIT.
REPLACEMENT t--j
: I
1 WI PURGE V SEAL !PURGE VI 1

03-919104-90 I L-;)3919256-90 27-189153-00 I
I - I
I I
I _ I
6 .----=-:'L-----, 10 KIT,C.I8LES, I { UT r.t8LE AIW'TER -*"" 1-'f- I
ASSY ASSY
ASSY, 2 ASSY,
13 SYIIC SIGilli. I ,..
REPLACEMENT
INLET VALVE 1
REPLACEMENT
CHECK VALVE
*15
ASSY
POWER SUPPLY TRANSFORMER ~10/9(15() TO 9000 srnt---;-- SlKC SIGHIL ASSY --:-- ASSY I
"*"" FRONT PANEL I.IVO CHASSIS TERNARY
PUMP 03-319910-90 : !l3-919914-90 03-919085-90 l ho""3'-9~19;;:..::i_6"""s'-s"'o,....:i
03-9 9265-00 03-919006-00
03-919002 -oo 03-919004-00 03-919082-00
E I
I ....
I
I
POWER SUPPLY
7 TRANSFORMER KIT/INSTALL : { MANUAL INJ : KIT, PISTON REPL
78-590397-00
SPEC.
03-919221-00
FRONT PANEL
!DIE CASTING! MEI.IBRANE
SWITCH
ASSY,
PCB. sse * ,----.
;e:.;y r6 17 ~y
PUMP BASE
PRINTER
03-907517-90/91
--+--
1
:
_
IRHEOOYNEl
- .?3 -905080 -00

L--
I
:
ANALYTICAL
03-919102-90
CAI.I SHAFT
r- r--
: ~-
03-919054-00 03-919436-00
ASSY, HARNESS ASSY, GND

WIRE. r;- LG
03-919055-00 03-919059-00
12 EAI
~j'1Q.:U 03-919517-00
KIT, CSA : MANUAL INJ
: : KIT, FlL TER.
I
PIS PRI!.IARY --+--
~8
l
HEAT SHIELD tVALCOl L- REPLACEJ,IENT
W/ 8 RING LUG OVERLAY, ASSY ASSY, CABLE I.IVD ASSY ASSY. PCB,
03-918269-00 03-905466-10 DISPLAY FRONT PANEL RS 232C HEATS INK CAll S:lAFT OPTICAL SWITCH OPTOSEHSOR 03-919511-90 L"o3:::--"""9'""16""'4"'"9"8-"""o:-;:;o-l 03-919491-90
PCB INTERPCE
f-- f--
03- 19295-00 03-919106-00
:l-{"
03-9190!)3-00 03-91930i-OO 03-919'i39 -00 03-919084-00 03-917386-01
ASSY, CABLE POWER 1 AUTO IHJ
PIS OUTPUT ENTRY IRHEOOYNEI
IAOOULE
03-919270-00 NAUEPLATE ASSY. DISPLAY ASSY I . '="""=""'"""~:--!
43-399702-00 ROTOR : .03-915024-00
-
I
03-919298 -o 03-919012-00 03-919087-00 I
9
* ASSY,
DAMPER
U-TUBE
03-9!9452-00
ASSY, CABLE
OPTICAL SW.
03-919267-00
KNOB,
DISPLAY
PLAE,
, . op
-- f-:~~~~-1
1120 VACl!--""'--==-""--7.---l
-..1..-
: { - AUTO INJ
IVALCOI
.0_3-91649700
CONTRAST
f-- 1220 VAClc__-.-~..__.
03-919211-0 ~Q.:QL
26 .------''----,*
* ASSY.
ISOLATOR
03-919'156-00
ASSY
HARNESS
03-919007-00 ASSY
ASSY, CABLE,
POWERED
EXT EVENTS
UOOULE
c KEYBOARD
OVERLAY DISPLAY
BACKLIGHT
nzo vACl o3-919r85-oo
1220 VACI '------r---"0"-1-'
03-919+42-00
ASSY, PRIME/
PURGE VALVE
MODIFIED
OVERLAY
-- -t 19
i$5( + ASSY, CHECK
VALVE
ASSY, HARNESS
AC POWER 1--t--l
ASSY,
PEU
rcid!7
03-919448-00 PROPORf!Cll VAL""
KEYBOARD 03-919191-00 J--:o"'3.-"'"91""9""1o::::'o
MODEL 9010 03-9052!;~ 03-919465-00
03-919'139-00
PRESSURE
TRANSDUCER
0-10,000 PS IG ,------
A3S"f
0 21 ASSY
ASSY. CABLE ASSY. CJ8LE
--~
I 'i' WR ON LAMP 120V OUTLET
03-919430-00 I SUPPORT PLATE INLE, 'I AL VE r-~ P ISTONISPR IN G
03- 9193.'i>Jo
I KEYBOARD HOUSING 03-919319-00
I 9010/9050
r----------, I 03-919438-00
03-91'lOii"5=QO
-"~
03-919088 -00 OR,----
c/8l-~::
8
I
I
ASSY. 1
PRESSURE
~.JB~~.Q!,!_~E.B_-f
I j
I
I ASSY,
zzov au~!:: T
'-..Q;!:._T_.:~_.J ~PRING HOUSING 03-9193;1_:)0
REF KEYPAD NOTE: 00101 = FACTORY
2nd SOURCE I
03-919405-00 90/91 = CUSTOMER
r----.1-----, 03-919'137-01
1 PRESSURE 1
1 TRANSDUCER 1
l 0-7,500 PSIG I
t:9I~I9}1E9:C
22 03-919086-00 MOTOR STEPPING,PUMP
I
I
23 03-919255-00 ASSY, PISTON GLAND DRAw><
CW
I OAiE
9-12-85
.;.?~;..~.,c.. ... .).lit.
I 24 03-919435-00 S/ ASSY, TIMING ADJUST CJ1(CK.E.O
I
()AI[ .tt.iF"!C'f(Q ~:.iE. C.
~
I
I f- : ATP REQUIRED
I
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II
I
I
I
I
I
I
I
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II E
I
II
I
I
I I
I 0 0 I
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II I
I I
I
I
I
II c
I
II
I
INSERT FROM THIS SIDE
II WICKS, ITEM (5) TO BE SATURATED WITH LUBRICANT ITEM @ I
I PER ASSY INSffiUCTION 03-919294-00 BEFORE Bl
B INSTALLING IN SLIDER ITEM @
I
I
@ TORQUE TO 115 TO 125 IN/LB I
I
I @ APPLY A MAX. OF 0.2 GRAM OF MOL YKOTE G, GREASE I
ITEM @ PER ASSY INSTRUCTION 03-919294-00.
II @APPLY WHITE LITHIUM ITEM @ PER ASSY INSTRUCTIONS.
I
I
I I
@
I
I A
LUBRICATE Sl_ IDING SURFACES WITH .15 GRAM MAX.
MOL YKOTE G GREASE, ITEM @ I
I ASSY, SPRING HOUSING AI
I. FOR ASSY INSTRUCTIONS REFER TO 03-919294-00. I
I NOTES:
I
7
11
I 7
* 5 4 !<-.
t .
'
6
II
I'
I
'i
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rtt r"
0 "'"~Tf:o..& COV&R PLATf: 1 1TU" Q, TO ,.,.,ltl. I! "' 1

~-
ll>.
...
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A
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1
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.-
-00,-02,-90,-92
i -03,-04.-93
I
C REt
!NOTES CONTINUE ON SHT ZJ

SECTION A- A.
G) TORQUE TO 70/80 LB -IN
G) TORQUE TO 40!2 IN-OZ IN ONE SMOOTH MOTION

A
(j) EXTEND&. ROTATE ITEM @
ISO FROM OPERATING POSITION
TO INSTALL AND REMOVE ITEM @OR ITEM@ OR ITEM @.

I.
NOTES:
ll 10 9 8 7 5 4 3
----------------- ------------------------------------------------------------------::::-,=
10 9 8 7 5
I
I
I
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-~.
-oo. -oz. -90, 92 ,. ... -----------------------------.............., I

: :
G ,~""'
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'..,,... _______________________________ ,.,) I
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I
-00,-02,-90,-92 I
-03,-04,-93
I
I
I
F F I
I
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I
I
3 PL
I
E E
DETAIL A SCALE 2:1
DETAIL C SCALE 4 :I
' I
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3 PL
!SEE
c c
----~-------__]
fALL AROUNOl
DETAIL B SCALE 2:1
@ WICKS, ITEM Q ~ BE SATURATED WITH

LUBRICANT ITB; PER ASSY INSTR~TION
8 BE FORE INSTALL I IN SLIDER ITEM rc9 8
TIGHTEN ITEMs@~ h?'lwrTH ITEM ABEINGIN DETAIL D SCALE 4:1
APPROX. VERT!CA[ POSI"fTCJN. FINAL POSf'f!ONING OF ITEM @TO OCCUR
LATER PER ASSY INSTRUCTIONS.
@PROPORTIONING VALVES liTEM 91 USED ON -00,-03,-90,-93

TERNARY UNITS OIIIL Y. THIS PART NU,mER IS BE lNG OBTAINED WITH DO NOT SCALE DRAWING
9. PURCHASING KIT 03-919001-70. CHANGE TO

THIS NUMBER MUST BE REFLECTED ON THE
@ TORQUt: TO 170/175 LB-IN 03-919001-70 !JRAWING.
A
(f) TIGHTEN SEISCREWS FINGER TIGHT ONLY.
FINAL TIGHTENING TO OCCUR LATER PC"l ASSY INSTRUCTIONS.
9 ATTACH TAG, ITEM @)WIT!j DIP SWnCH DATA.
@ WET ITEM @ OR WITH IPA OUR lNG INSTALLATION 13.------
11 10 9 8 7 5 4 3
- - ------------------------------:- ------...!
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REF
~--------------------------1.41 REF----------------------------~
II
B Bi
~----~~~~~~=---------~ I
4. PACKAGE INDIVIDUALLY IN CLEAN CONTAINER I
TO PREVENT DAMAGE.
3. LEAK TEST AS FOLLOWS: DO NOT SCALE DRAWINB I
~~~~0--~-r~~---------------------4~~~~;~~~~~~~~~--~
'!"
=
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II
I
(D INSTALL ITEM @ USING USING FIXTURE T- ASSY, INLET VALVE Ai
NOTES: I
7 6 5
'-------------------
F
E E
j
1
I
f
1
l ~
.~
"/
l
0 GLOSSY SlOE D
/
/-
3. PACKAGE JNDIVIDUALL Y IN PLASTIC BAGS. DO NOT SCALE DRAWINB
REFER TO ASSY tEST PROCEDURE 03-919547-00.
ITEM @ IS A MATCHED SET CONSISTING OF A

SAPPHIRE BALL AND SEAT. BALL SEAT MUST BE INSTALLED
A WITH CHAMFER !Gi_OSSY SIOEl TOWARDS THE BALL. VALVE A
HANDLE WITH PLASTIC OR BRASS TOOLS ONLY.
NOTES:
7 6
r-------------------------- -----
1 5 . . 4
-----~~................~..,------.-2 ----------------1~----ll
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f D ~+=~~~~~~~~~. ~~~~~~~~~ ol
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DRAWN
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'
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F WHT /REO WHT /GRN
F
~------ 5.10 REF ------l
DETAIL ..A''
VIEW A- A
E E
SCALE :NONE
1.19
1 3.26 MAX,
REF
2 PL .3750 DIA
REF 2.730 TYP
.3745 2.750 REF .
SPEC IF ICA TION:
2 PL REF
I. STEP ANGLE: 1.8 2.875 DIA

REF'
D 2. TOTAL STEPS PER REVOLUTION: ZOO
I D
3. TIME PER SINGLE STEP: 3.4 rns 1
SEE NOTE 3
I I SEE DETAIL "A"
~ ~ :''_2_
I
4. VOLTS, DC.: 1.54V
_1fL OlA THRU
I~ 5. AMPS PER WINDING: 11.0 A
.16
REF 218 4 PL REF.
I 6. RESISTANCE !OHMS PER WINDING AT 25 cJ: 0.14

I FOUR -STEP !NPUT SEQUENCE
!FULL -STEP MODEl
7. INDUCTANCE (f11H PER WINDING): 0.85
c 8. NOMINAL RATED TORQUE !OZ/!Nl: 300
STEP RED WHT /RED GRN WHT/GRN
I ON OFF ON OFF RED

9. HOLDING TORQUE !OZ/INJ: 450
2 ON OFF OFF ON
10. MIN. RESIDUAL TORQUE !OZ/INJ: 6.9
WHT /RED
II. ROTOR INERTIA !LB/IN2 l: 0.64 3 OFF ON OFF ON
BLK
3
12. TORQUE TO INERT !A RATIO: 16.8XIO 4 OFF ON ON OFF WHT
MFG EY: SUPER lOR ELECTR !C
8 13. LEADS: 18 GA, 16" LG, 6 EA. I ON OFF ON OFF
GRN BRISTOL, CONN. a:i
' PART NO: I
14. MAX. OVERHANG L OAO !LBJ: 25 i
PROVIDES CW ROTATION AS VIEWED FROM NAMEPLIITE END OF
!
WHT /GRN
15. MAX. THRUST L OAO !LBJ: 50 MOTOR.TO REVERSE DIRECTION OF MOTOR ROTATION PERFORM
SWITCHING STEPS IN THE FOLLOWING ORDER :1, 4, 3, 2, I.
16. ALLOWED TEMP.R!SE 65C, CLASS B INSULATION.
0 w
:z Ul <.:>
z
0"-'
-<.:>
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AMP. PART 350689-1. !VARIAN 51-408217-00J
NOTES:
7 6 5 3
'------------------------------------------------------------------------ ---------------
~~~~~~~~~~~~~~~F \
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ASSEMBLE FINGER TIGHT ONLY
~~~~-.:....:::..:::~,\
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2 PL !
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5
0
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~HHES EO NFC 1588 8
OFT 5 1(8
CHK ;s j ~
7 6 5 2
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I DASH NO TlPE OR RillE!. IIEXT .ISSEldlLY REQ REO P.~T NUMBER DESCRIPTION OR MATERIAL ITEM
I -00 9012 03-919642-00 03-919660-00 HOUSING, DAMPER
03-~19662-00
I -OJ 9012 03-919642-02
- 03-!~19660-01
ROD, TEFLON
HOUSING, DAMPER, TI
2
3
I F 2 03-919661-00 CAP, DAMPER 4
I I 03-~19665-00 LABEL; DAMPER 5 F
2 2 27-402113-00 '0' RING, .801 10 X .941 00, TFE 6
:I 2
2
-
2
03-319661~01
12-~i00922-00
CAP, DAMPER, TI
SCREW, 10-32 X 1/4 LG, NYLON
7
8
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!III
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II
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II -01 INERT IT II
-00 316 SST
III .&. FOR -0 I ASSYS ONLY 1 STRIKE OUT THE SUFFIX .. -00" N
DO NOT SCALE DRAWING CASH NO.
DRAWN I DATE
DESCRIPTION
APPROVED DATE
Fl 2-4-94 K.JUDAH 13-25-94

I AND ADD THE SUFFIX .. -01 ... USE PERMANENT MARKER. z
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i<.JUDAH 3-25-94 C. TRAVIS 3-25-94
II
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TORQUE CAPS, ITEM OR(!). TO 400 LBS-IN. "''-' w "'"'w 0I ::1;
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RBW EB
HilT OTHERWISE SPEC: ANG -
.X- .XX.06 .XXX- varian
2 1
II.J I IDESCRIPTION OR ,.ATERIAL ITEI.A
REO PART NUMBER
!I I 03-919451-00 HOUSING. U- TUBE I
z 28-694003-00 NUT, 1/Z. SST 2
.I 2 28-694005-00 FERRULE. BACK, 1/2, SST 3:~--
l
'I"
F 2 28-694004-00 FERRULE. FRONT. 1/2. SST
I 03-919456-00 ASSY, ISOLATOR
2 03-919450-00 NUT, ISOLATOR
2 28-693995-00 FERRULE, FRONT, 1/8, SST
2 28-693998-00 FERRULE, BACK, 1/8, SST
2 03-919449-00 FITTING, END, U-TUBE
03-919458-00 LABEL. DAMPER
~.".'.,
5
6
7
8
9
10
I
2 28-995809-00 CLOSURE, PROTECTIVE II
E 2 PL
2 PL
2 PL 2 PL
D
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JUL 01 1988
8
~--~.50 REF-!
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I. FOR ASSY AND TEST PROCEDURES -o
,..z =
REFER TO 03-919484-00 d.<
a:-
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uu Ul
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WO
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0
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0
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NOTES:
UA:JH ftU I Tl't. UH IIJ~ ~ lltxl A:i:ii:JijLT
[STR LGITERM FROM TO TERM STR LG UNIT REO PART NUMBER DESCRIPTION OR MATERIAL ITEM
-01 90120 03-919642-06 f---- - f - - ___ ....... . .. !="A J l03-SO.aa4S----00 VALVE, SOLENOID, 24V, 3 WAY I
-OJ " L4 PI07-I 2 WIRE. YEL
WIRE. YEL
L4 PI07-2 2 .
EA 2 51-411004-CO CONTACT, 22-30AWG, GOLD 2
EA I 51-411145-00 CONNECTOR, 2 PIN 3
EA 3 22-119650-00 CABLE TIE 3 5/8 L G 4 I
D
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--
0
CN
0
T
2 zx
4 3X 3
s L4
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1-ooa-------------, 1\\..--_ _ 13.5 0 --------------=-~
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-00
DA!3H N0.
DRAWING ONLY
DESCRIPTION
z
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DRAWN
Fl
I DATE
2-8-96
APPROVED
~ 1
DATE
2-tSH
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A wo
0
ASSY, VALVE, 90120
~AP~V~D----------------------------JNOT OTHERWISE SPEC:

1-!E~OI---------------------------------IFIN . ./
!DFT
[CHK
[DATE
1/1
DEC.X- .XX .25.XXX -
38 I 0F I 8
SHEET
ANG -
varian!
03-919746-00 I 1
IREV SCALE DIV JSIZE DB_AWING NO. REV

I I
- - - .. , I L.l \ I RL llt:.M
-v OJUIC.W u~-:m1 f't't-~1
I 3 P3 P106 3 I IN 19 81-721893-00 CABLE, 2 COND, 22 AWG, SHLD I
P3
-..,
(SBC PWAl
I n I
.
PI06-D
(MVD PWAl
-
3/16
3/16
--
4
4
P3-2
P3-l
- PI06-2
PI06-I
&.
4
4
-- --
3/16
3/16 .
WIRE, BLK
WIRE, CLR
CLR 4 P3-3 WIRE, SHLD ...

I I I I
BLK 2 I 2''
_ .J
SHLD u 3
N/C-,
L _
EA 2 51-407015-00
51-407011-00
CONNECTOR, HOUSING, 3 SOC 3
EA 5 CONTACT, CONN., 18-24 AWG 4
>
I
5
IN .75 88-498440-00 TUBING, INSUL, .042 10 X .016 W, GRN 6
EA I 88 -360101-00 LABEL, 15/16 X 3 1/2, WHT 7 1-
I
D
,r-- 19.00 +50__}
-:oo 11 -- -
-
0
CN 5 MAX 2X .75 MAX
~
0
T zl
3
s
c
A
P3
(SBC PWAl 1\ V 5}(\ 1-
"
-
-2
I
3
[]a I~II P106-D
(MVD PWAJ
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l
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-~w
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I
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I
C)
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- >
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. '( ~~ r.:oo
t I'\.
N CTl o w
o m o::
B G FEB 16 1~~f~6
FABR...!_.-An . .. i
t~-
.. i . . . ){ .~
.-,~
~~
& MARK BOTH SIDES OF LABEL, ITEM Q), WITH PART NUMBER,
NAME AND REV IS ION LEVEL_ AS SHOWN. LOCATE LABEL
-01 PART
APPROXIMATELY MIDWAY ON CABLE. -00 DRAWING ONLY
DO NOT SCAI.E DRAWING DASH N 0. DESCRIPTION
~ CUT OFF SHIELD EVEN WITH OUTER
z
DRAWN
Fl
DA
2-8-96
JACKET BUT NOT DRAIN WIRE, ow
AT rrHIS END.
-CJ
1-Z
a.<(
-I
5u
I~l!t/7t DATE
A ffi CUT OFF SHIELD AND DRAIN WIRE

EVEN WITH OUTER JACKET,
CllLL
wo
Cl
ASSY, CABLE, 90120 RELAY
AT THIS END ONLY.
OTHERWISE SPEC: ANG -
~~-----------------------------.FIN .../ DEC.X- .XX.06.XXX- varian~

NOTES:
t--+--9-0_I_0-+-0-:-3-'~"-=-~-=1~~~:-::~:-::~-~~-:-0":-10 E~~ I NUMBi::.i-i !
PRINTER CONFIGURATION FOR SUCCESSFUL COMMUNICATION r lEA 03-919307-00 ASSY,CABLE,R5232 INTERFACE

VIA THE 9010 RS-232 SERIAL PORT:
Requirements:
9600 baud
XON/XOFF protocol
character length 8 bits
C>
co
C>
cJ)
cJ)
r0
I
I
lEA
lEA
lEA
51-339972-00
03-914154-00
03-919500-00
KIT, FEMALE SCREW LOCK ASSY
I NSTALL . IN S T R , 9 0 I 0 /R S 2 3 2
PLATE, RS232C CONN MTG

parity disabled (none) C>
lEA 03-919501-00 LABEL, PR INTER/RS232C

Switch locations and setting descriptions for both the NEC P6 and
the HP Thinkjet are attached.
1. FOR THE NEC P6, the switch settings used match the NEC 0
factory default settings as shown on the following pages with these 0
exceptions:
SW3 bit 8 ON . for the 80 column printer N
SW5 bit 7 ON 0
The NEC P6 shipped under kit PIN 03-907693-90/91 (same part T
number for the DS-650 high resolution printer option) is properly
set. To ensure that the switch settings are correct, depress the
s
font button while powering on the printer and keep it depressed
c
A
until the printing begins. _The switch settings displayed should L
match the following: E
SW1 00000000 SW2 OOOOOOXX SW3 00000001 0

SWS 01100010 SW6 X0000011
The printer will continue to print a self test until powered oft.
2. FOR THE HEWLETT PACKARD THINKJET, all RS-232 switch

w
I
N
G
settings must be down. You may leave the mode switches 2 and 5
in the up position as is necessary for interfacing with the DS-650
or polychrom, or you may leave all of the mode switches down as
received from the factory. It makes no difference. F"'!"'r.. c-;~.r C:.rit:.NC ~i."U...'(
To do a self test on the HP Thlnkjet, depress the FF (form feed} FEB ll 1928
button or LF (llne feed) button while powering on the printer. -
Release the FF or LF button and the self test will start.
l:fJml
If the print quality is poor on the HP Thlnkjet, "burp" the lnk
bladder buy inserting a paper clip into the small hole in the bottom
and wipe the face of the print head cartridge with a tissue.
I6-3-96 I
i!
U'l DRAWN APPROVED DATE
a: DATE
z 4.1 U"l
cw ROUSSEL 2-29-85
Part numbers for the HP Thinkjet outboard power supplies are: '-~
I
Ow..! od
78-910416-00 power module for US thinkjet 2225C or D

(HP part number 82241A)
-<CJ
f-Z
Cl_<l:
~
::.::
v_,
cr:- u""' 0 -"u . ,
"--:::
~=:
...,..
U'l
::::l:
4.1
CHECKED
JS 8-25-86
DATE APPROVED
H.M. NAAS
I DATE
9-2-85
CLA
E
uu 0 t::
78-910417-00 power module for European thinkjet 2225C or D _J~><2:
cnu. 3:-.:ac. c:::
{HP part number 82241AB} wo '
KIT,RS232 IN-I ERFACE
W-J'VZ: LU
0 a:O....<:: 0
UUJVI-- Cl
UlC: .. U1 ...;
I
EO - I 15334 I
NOT OTHERWISE SPEC: ANG SCAL_
NO~;
o~-
r ,
CHK
JC;<
-
I JCK
I :::J ~
I
I
@ Fl N . .J DEC. X::
WCIDjl OF
.XX .XXX::
II AJ 03-919080-90 I
0 t, ::: ;:5 AUc 85: 10 FEB 88 /
r:: ~ .' I -- varian
. 2 I C I'/ I ::r.=~, Is rzE I JRAWING NO. I
-- _,
,.,.,_. I
--
n.r111rM 7H/
< t
-00 l/')llU ~ .~ 47 71, miJ{)._ 2'l/..'...
.,:=..
I
I 151-lfLq31-00 l'f)JJJh IUJ CA!J.l: .2.bl/:JlJO.. if DIZ 2
I [51-.::DOoii-DD CDIJJJ. R.AT 1!4Y.E .2.SC1JJJt:J, D ~
- r-- t. .,o---J
P IZAIB
~ED IJ' 8LU ~1EJPE.
P/Jl~l JZ00/2.01
(~LElNO'I..IE)
7.80
[[] 5)
frt
.___..
I f - 1G.80
I
P.E.F
j PI'Z.A/~
r------------s.oo ~E"------------lj
u
I
( SCAI..E:. ~ FUI..L 'I

CA&L.C." FOL.DINGo Ot,IAIL.
EOR REF~~ENCE ONL-y

MAY 2 1988 ' g
-,
DO MOT SOU DRA,.,IMC
-
::JS
,_
10-~
...... .....
CUT ~CK CONOUC.TOR -..u;. ~v 1 I"'C
... H o..., .rz.ao 1 -u, 1
8
E"'OR.E IN""T .r..L.L.U..!Go rT:M
NOTE:
PHYSICAL DATA ENVIRONMENTAL DATA UII.IU:~~ OTI-4E.RWI'!ol: 'S.Pe:c.JFU!!:1) TO
CONFORM ro UL. Su&..leC.i I"Zt..2..
I. Enclosure I. Ambient Temperature f:o ..ge
a) Open Frome "'fi!!:S d) Potted_-::::::..._Hermetically Sealed.:-:::-_ a) Operating: Min-==- C; Max. __ JO C.
ELECTIICAL DATA b) Full Shell - = = - - - e) Encapsulated-=. _Mat'l. --- - - - - b) Slorag!! Min.~--- c, Max ...__roq c.
RMS VOlTAGE AT RAlfO '=IJRRENT SPECIFY ACTUAl TEST POltNTIAl c) Half Shell-~--- f) Other (Specify} ~--------- 2. Duty Cycle: Continuous )'ES _Orh!!r ~-~ ~93~ ~-. ---- ..
WINDING LOAD WITH fOI.EIIANCE TAPS (DCIIMSl 2!, WOitltiNG VOLTAGE
2. Finishl----=======--- 3. Temperature rise based on duty cycle: ______SS_ C Moxmum
PR1~IO-to SE CS.CHeMA"TIC
- ,, - 3. Outl.ne Drawing (Include minimum space limitations, dimensions with tolerances, 4. Maximum Altitude: 0ferohniJ. ~ . Ft; Storage... --=-- .Ft.
.
II
sec;t terminal or lead arrangement and marking. lead lengths, mounting arrangement,
SEC#2 - - and pkxement of nameplate and/or schematoc), S. Maximum Relative Hunaidiry: Operatong__~O ,.,, Storllge.-:---
6. Cooling
. -,
SEC#3
a) ~mol conduchon c.nd t:on,e<:toon .. :f~... ----
SEC#4
SEC#5
b) Other: . ---==-=------ _ .... --------- --- _ -------
,SEC#6
.~ll ".40C. OSOUND
ADDITIONAL PRIMARY INFORMATION ~PL
1. Frequencv S0/(,0 cps: 7. A.dditior.ai remark~ as lc: reQt~irement~ for protK":'On r.;o:"~' -c~,\t.:;~. ~un~n.:s. -..:::~
spray, vobruaian, shack. actele-o::!.on. t:!c:
2. Elitraordinary exciting current requirements U:S'=o TI-4AN O.~o.!l. (i) 24te'IAC, i$0 HJ.
N/;~
3. Phase: StNGtl.E , connected in PARALLe-L FOR 1'20V AND "S~IeS FOR '240V.
4. '!oee B&:LO'W UNOI:.R. 'TH t-teADINGI"ADDITIONAL. PRIMARY l~fiMATION,CONT." 'SEC.ONDARY

ADDITIONAL SECONDARY INFORMATION
I.. Filter Type He SC-HE-MATIC
a) Sec# _ __, ---...:wove (bridge)rectif~er_ _ _-l,nput filter.

b) Sec # wave (bridge)rectifoer 'nput falter.
c) Sec~--- wave (bridge)rectifoer input filt'!l'.
d) Sec #: wave (bridge)rectifier nput filter.
8. life ekpeocncf (10.000 1-os. "'in,..,a.:m is srondurdl _'SiQ ..
3. Regulation-=-load ra full lacd - ~
/ TEST DATA ReFER 10 u.'. SU&.lE:C::T 12t..2 f"'ll

tied to G.R::~ YELLOW l.E:.I'D
L_
4. ElectrostatiC Shield: Location PRIM/SEC. 4.SO MAX
~EE- &E:LOW1 NOTE 4 CONT.
s. Magnetic Shield: - .... 1 Dielectric resr shall cons:!t of .applvino res: rx;:~ntioo fo c O<"rooa ~i . -~
seconds betwee<l each v r.dinq a;,d ~ ...e :ns!! and -:::re ._.,.,r, -:;! -:rh~ ,,,,a.~: ~~
see SC.Hi!'MAIIC.
........ grounded to the case umi core. The ;:st p:::l'!'liais shali be :hose ,~..:,,c,.,::i :l=' 1-nge ..DI
~\' .
6. Polarrty of Windings:
7. SchematiC (include associated circuitry, if possible, and terminal designation):

IG) Sec.oN"OA~Y
1 of these spedfocalions. or if not ~peciiieo. shall be n cc::erdcn:~ ~. ,, S.:;.:>-
-4.7.5 and Table XVI of f'IL-T-27A.
( Soe~ Si;L.OW ) ore reauored' TRANSPoRME::R ML.ST
~ests
2. The followona cdditionai
NOTE 4 C.ONT. . ELE:C.TROSTATI C SHIE:L.D~ 5 111\tl.. COPPER FOIL.. 8E CON~TRUCTE:l) ANt> IE:'STeD IN ACCOR DA~Ce WITH lJ
. UNDERWRITE:RS LA&ORATOR \E'S STANDARDS. FO~
Pl<lMAI<'f SE:C.0"-1 OA R.'f LABORATORY INSTRUMENTS 5U&..1eC.T 12.C.2.
REF. PARA lq.J THIZIJ ICI!.:S AND 3!i.l% lHR:U "!>$.18.
17.0V/'Z40V
SLk/WIIT tl.ED/ 'Vt!L .... Additional terminal information (specafoc type, size, location. etc.)
ISLKf~: ~ OCEh20VIfl'll\ (!) AU.. LI!ADS IO 8E Zo" ~ ( UL. ....ae lOIS oR CQUI'II),
IOO'II"'"
: =
-
~
I~ GAUGe'\ ~- cct.oR. AS SHOWl\1.
.-
:::l
: >- VARNI~fot and baked after assembly.
ijEUT
eLK ~. R:I!!:D
5 The coils shall be vacuum imprto9nated with
I5A$e MUSI er: CL.E:AN FRQM VARNISH.
6. Marking:
I'ZOV/240VO
JRN/WifT
3 8L.U/YeL
~ OCI!:20VIlM'i
MAS:Z"' ~ASE: W11'H VARIAN PAr:2T "--!!.
~ *'" o"
AND CURRENT Rev N2. 3. During all oerformance te,.ts there shoJI be no evdence ci oudobl~ or ~sbie coon"
E.)(AMPLE:~ ~o"'3-Gtlc:;2.'2.1-oo RE'II I"
~ \!)
.fUTJ
::....
,_
~
..... SLU
+lT
@I, SA@
'ZO,OOOJIF
~ R, SA
? ~- OI .. WN
1 oAr'
i Z-1"5-&.l ...r . - HC.

! L:!'lflUI or"ll'.,'\t vtto
7
... \'/
..--
F:t - All(,'-
l~f'J.i'/~t/j~ -i'-_'1~';, :1\lo.~e-

0
~N/"f'EL I ;;
( H f ( l f 0
j~UoLDO z 0
:JS I _ _ ...l'.;:r._Lf._ _ _ .~
~ TRANSFORMER SPECIFICATION
u
MOTOR. X'FMR
c . C
-- t'": ...
~ T~l$
~I
1'5 A MINIMUM DC VOL TAC:.c AT FULL LOAD, LOW LINE ( -10/o

"""
reo
I . . . . ., ... 0 .... f(j; Sf
i
:
w,._NUr CIIUK
I H
8 --
TI-l ESE SE:CONOARIES Alee z
'5"{o ~ t-JO LOAO~ h!CMINAL AC
OF t.JOMINAL),
LI~E:. ,..
r-on- -
(:."""';,VARtAN
, IIGI~--'-----
oa !c
. 0=3-~lqZZI-00
....... - I
NOTE:S ~
&Q ... 11.$~ .,
- ...
04.11
-~
--
~I" 'II a."' a I '"" I ~ 0 1 "' &
:tl ., .--:-:-:-
kto.. J.,._l
/
'
,;
UAl>ft flO TnE 01 MODEl
NUY ASSEMBlY
I
J '
i 8 to:;-~l944s-ool 2 l 1
- <70\0 03-9tC1oo \-oo
IEQ PAll HUM.EI DESCIIPTION 01 MATERIAl ITEM
I 28-C)9S~6 \ -oo C.LO~URE:"I PR.OIE~'T\'\1:- \

I 0~- 91f.D 374--D 0 VALV'C. 'l P~\ME/ PuR!=E 2
...---
,l
"'
(I~)
~00
D
0 _L_
CN
0
T
s
c ( OUI)
(~EAR VIeW') l ?ID DIA x .. 277 OP,
D
R
f.J g S -:; Z -UtJC 'ZP.: '1- .. 19 t:1 P
FULL THO.) "Z. PL -~
A
w
I
N
G
8
F.OR REFERENCE ONLY
DEC 1 Gi987
-- -
C LEA"-! PE:R S PE: \ F I (AI 1 :nJ

DRAWN I DATE APPROVED I DATE
8
CODE
8{0- ooz.oolD-oo.
WA'TEJ2.:S e-Z0-81 ~ OC110,g7
0 REMOVE WA~TE PoRT FttTI~b CHECKED I DATE APPROVED I DATE CLASS
..=:rs &-~-87 u~
I
/l-/1-ti
I
~ IUE,I~G At.JO .DI~~ARD-,Jt-.lScR
P~<.OTELTIVE PLue:: ITEM (!)
OR eQUI\/ALEt--JT "'TO P~o-rE,:T
_ Moo., P~IME: 1Pu ~c...ft= VALve:
,.
SCALE
DPE:NlN'= lt-...1 IT~ PLAC.E.
FULL
-TE"'S:
G
DETAIL A
...
SCAL' z lloNE
PAIZT" OF'
c c
' ~1:~~
,,~'---~r-1
I '.
I
I' ' FEB 2 0 ,992
'
;.1 I
I P/JI5
B B
I FOR SCHEMA.TIC. SEE 03-~190"75-00.
NOTE5:
,
- - - - - - - - - ----------- - ""-- J . . . - .....
I
REF DESIGNATION REO
-
PART Nt~ER
J
DE~CRIPTION OR MATERIAL fli:.&~
I
03-919079-00/90 I 03-9191 9-00 FAB, PCB, GP!B I I
- 2
F
Cl-3,6-10,
20-26 29-31
18 41-2900!fl-00
-
CAP., .IMF SOY tZOY.CER. 3
4
I
I
C4,11,12,14, 7 41-2069~~-00 CAP., IMF, SOV, t20Y., CER. 5 FI
-
17,27,28 6
Cl3,15,16,18,19
C5
C32
5
.I
I
41-2900'1-00
41 - 7093~~ -00
41-5167~-g-oo
CAP., IOOPF, SOV, CER.
CAP. NETWORK,IOOPF X 80IF 8
CAP. 330UF IOV ELECT.
7
9
I
I
I
1------ ... ___ __
-""
- 10
UI
U2

...:::.---~---
U3.6 -8
_[ 62-60182G-OO
I 62-600114-00
4 62-6018~;-oo
I. C. 74F74N
!.C., 74LS74N
!.C., MC3448AP
II
12
13 I
I
U4 I 62-60JSZ..~-oo !.C., 74LS642N 14 I
U5,9,!6,20 4 62 -600C68. -00 l.C ., 74LS04N IS
E UIO
Ull
I 62-60 17)() -00
I 62 -6oJs:o-oo
I.C. 74LSS40N
I.C., P8291A
16
17 I
E I
Ul2 I 62-60079:3-00 I.C., P8255A 18 I
Ul3 I 62-601877-00 I.C. 74LS640-IN 19
U14
UIS
I 62-6007q-oo
I 62-6018.2~1-00
I.C. 74LS30N
I.C., 74F32N
20
21 I
I
Ul7 _. I - .61.. 600777 -00 !.C., 74LS164N 22 I
Ul8 I 62-600470-00 I.C., 7406N 23
I
---------
I
U19 I 62-60007:2-00 I.C ., 74LSOON -24
'''--
I U21 I 62-60 15~3El-OO l.C. 74LS645N 12?_ I
I D U22 I 62-60160~i-OO !.C. 74LS541N 26. I 0
U23 I 62-60 181;:; -00 !.C., 74FI38N 27
II UZ4 I 62-602tn-oo
-
I.C. 74FI12PC 28
29 I
I
I
R 1,2,4
R3.5.o.~:: iB 8
3 31-10217400
31-1023C9-00
RES. 3921 I/4W, IY.I MF
RES .. I OK, 1/4W, IY., MF 3i m I
I
R7 I 31- 4002' 7 1-00 RES. NETWORK,!20 X 9 SIP 32

I 31-4001~8-00
R9 I RES. NETWORK,IOK X 9 5 IP 33
I
R 10-14 5 31-10212500 RES. 121L-lf4W, 1:1. 1 M- r 34 J--..
35 0
CR I- 3 3 67-599287-00 LED. GRN. IOmo 36 01 0 -
c 3(_ I
~
5201 I 71-998671-00 SWITCH BIN,0-15 P!JS. TH~BWL 28
Yl I
---,
78 -908( 1<'.-00 OSC. XTAL, 4MHZ IY.
39
40
41._
XU3,6-8 4 54- 9104()~ -00 SOCKET, I.C .. 16 PIN 42
43 .._
XUII,I2 2 54-910409-00 SOCKET, l.C .. 40 PIN
--
"!4 :
41J
J201 I 51- 5002}0 -00 CONN., 24 POS., FEM.
46
--
J202 I 51-209189-00 CONN., 60 POS., R"[. ANG. I
I 51-5002E;O-OO HOW. KIT, CONNEL TOR 47
B XWI (E 1/EZJ I 51-407216 :_90 CONN .. PC, 2 PIN 48
BI
I- 9
1 TP 9 51-91015 -00 CONN. ~!.040 OIA 49
I
00 NOT SCALE ur:,.~;.~.~ 25' i
0 TRIM FRONT PIN OF S201 "LUSH WITH PC BJARD.
3. E3-t:l8 ARE NOT INSTALLED AT THIS TlME.
STAMP ASSY REV LEVEL AS REQUIRED

A
FCR SCHEMATIC SEE 03-919i21-00. t~SSY. PCB. GPIB A'I
FOR J../W SEE 03-919120-00.
NOTES:
I
7 6 5 ---- ---,-
t
10 5 fi?IO":.:!Iqle,;-oo 2 ! 1
--~----...J._____.:______.__________...J._.--...J=.J.:;. et !1 ....... Cl\<o o ~-~
1 l =~.:.C144i-O!;:NC.L.O~Uite.. ;.o.;ALF ~OP 1
I I 01'1014410ii~C:.L.OO:.uR~ ""A~t= !l'r"O~
I 'O~Cjlqi8~-00'PAt.lli:L !fUR PE/Io'l t'2.0V ;.
I - , O>C!tq 8~..::>11 PANIOL .<EAR PEM '2:ZOV .:.
G
sec De1Au.. 'c' \
: ~: ~:~:~=~~:~~~::.~~~:::,"c::!:\J;~'~~v ~
- I C~qlC!I'!OOO ~-;~ PC8 9wa ~~ ~Vo..,f'5 llOV : -
G
f-'l+.:..l_,:_;::o'=~-~'l.;'!I_:'0)A~V "'41f"E"''> A' Po""f:~ ~
- 2 i0'!>'!t'B2100)A~V (A~L.,;U)VA(. OUT~~'!''!
2 - Ol"lt"!~:Z~.x''A'i.'i.vCA8LE..:70VAC O:J'TI.. &.~~
I :l:l-"!l"!~I.,.:OOIA<;S"''. L~MP ""OWER o-:" ..
I I 1.>7-;qe~I-OO(MT(a ~l..IP (ll.t1.1Co,8 .....C.K. . ::z -
: I o?;-'!1C,!-Z0001LA&I:L,PCI!I <l:iY LI<VI!L. I~
1 1 OlC!Oio~:Zt-oOI_lAIUi~ l.t). (~&ll.ta.L se.)---.;...:_"!_
- '2 iSt~'I:Z"'4100IOuTLt:T '.>NAPI .. (I:ZOV) ~ .;;
4P~ 2'>
'Z - :c;l-40t..=;o-oo OLJTLI!T 'fleN'H STOf'ZZOv) ~
REF
'2 -!11714QC.I~' -OQ(~ .. M~,~UPJtOstT, ~NAPt"'roo .'"!
PL.,
,...!... ~ 1 , ,,._,ooss.oor::.c,u .,.~u-u -- ~ F
I I lo?;-"07S7~.-00~c A.t HARNE.SS ll"' !C)
EF ~ " 28-84"1"110"0w.n,;. .. A06Pnl!. ><>42TOl!l~- 20
I
I 3Y4 ~- 2!-1';8C.OOOC:.-T~&t,.<o,'/a"o.o. UO. POL'fUU 'Z:Z
2:
lli ~li ZS-'H!,c.o~-oo ~:.~11<" .. t~oo C:.O:N.Po ....,~orl!! .;
\ I
~
~
of I I
2~z 27," 281~8q:Z'l>OOi'T!..-1fN(o 'l!jOO .. '' 2 :OOLTUO:I! ~~~
4 4 n<.'l8"1800010:00_! 81 \0 .~":'UK. ~':'.<OkON 1<;
,,,.
-l
~
) !I
2
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LCSA95-1
3/20/95
SERVICE ADVISORY
VARIAN CHROMATOGRAPHY SYSTEMS
INSTRUMENT
AFFECTED: 9000 Series LC Pumps
PROBLEM: Chromatography Systems has been made aware of a few instances of

failure of the camshaft bearings within the pump assembly. The initial
reported problem is the sporadic occurrence of the error Fault 68: Pump
Stall, which usually indicates a faulty outlet check valve or optical switch,
or a problem with the Piston Spring Housing or Inlet Slider assemblies (see
Service Bulletin LC91005). Upon closer inspection, however, it might be
found that one or both of the bearing assemblies located on either end (top
or bottom) of the camshaft is sh<;>wing signs of significant wear, sometimes
to the point that the bearing has actually come apart. In the more extreme
case, the problem might be easy to diagnose as the pump assembly will be
noticeably more difficult to rotate by hand.
INTERIM
ACTION: Unless the bearing has become frozen on the end of the camshaft or is
fused within the top or bottom plate of the pump base assembly,
replacement can be accomplished without too much difficulty. The part
number for the bearing assembly is 21-109982-00. You should order two
as we recommend that both bearings be replaced at the same time. When
the bearings are replaced, either the inner race shouldfit snug io the
camshaft, or the outer race shouldfit snug within the pump base assembly.
If the bearing appears to have a loose fit at both contact points, you may
want to try another set ofbearings, or replace the camshaft if necessary. If
the pump base is damaged, please contact Technical Support to arrange for
a replacement pump assembly.
Chromatography Systems is investigating the cause of early camshaft

bearing failure, but it is essential that we receive as much field data as
possible. Please return failed bearings and any other associated parts
(camshaft, drive belt, etc.) to Walnut Creek Technical Services along with
the pump serial number, number of pump strokes, symptoms of problem
and any other details of the repair (i.e., the bearing was frozen to the
camshaft, the inner/outer race was destroyed, extremely dirty pump, drive
belt extremely tight, loose screws, etc.).

Number LC95005
lssueDate MARCH 10, 1995
Page _ _1"-- of 2
Service Bulletin
Product Line:
Model Number
9012/9002 SDS
SIN AffAir
SEPARATION SCIENCE
Originator
Approval
Dean Waterbu

Martm O'Donogh
***INFORMATION ONLY * * *
FAULTY SOLID-CORE PULSE DAMPER

OPERATION AT LOW COLUMN HEAD PRESSURES
SYMPTOM:
A number of Customers have recently experienced problems which have been attributed to Solid-
Core Pulse Dampers manufactured within approximately the past six months. Although the
symptoms may vary, most Customers report either an increase in pump pulsations visible on the
detector baseline, or oscillating pressure changes visible on the 9012/9002 display. In most
cases, these Customers are running with columns and flow rates which produce less than 100 atm
of column head pressure. The problem may also develop during a gradient run where the column
pressure may fall naturally due to changes in the mobile phase composition, as would be the case
with an increase in organic solvent during a reverse phase gradient analysis.
PROBLEM:
The efficiency specification for the solid-core damper (as well as the U-tube damper) is <2% AP/P
at 150 atm (i.e. pulsations ofless than 3 atm at 150 atm column head pressure). Although the
solid-core does meet this spec, a recent manufacturing tolerance error of the damper housing may
cause AP/P- to increase significantly at pressures below 150 atm, causing baseline fluctuations as
described above. Chromatography Systems has removed all solid-core dampers from stock
(stand-alone SST and inert dampers, 9012/5000 retrofit kits), and damper housings are currently
being reworked to the new co"ected tolerances.
SOLUTION:
The Troubleshooting Tip on the following page Ca.n help you determine whether the damper is the
primary cause of your Customer's problem. Replacement solid-core dampers can then be ordered
using PIN 03-919675-90, with all charges billed to Warranty. Old dampers may be returned to
Walnut Creek, if desired, so that housings can be. recycled. Otherwise, as these dampers cannot
be reworked in the field, they should be properly disposed of.
-Over-
2
TROUBLESHOOTING TIP:
D~unpers n: y be tested for AP/P by running the 9002/9012 isocratically, preferrably with
methanol o: water, and monitoring the J2 Pressure Out connection on the rear panel of the pump

with a strip chart recorder (the output ofJ2 is SatmlmV). Using a column or a 3 meter length of
.005" SST tubing and adjusting the flow rate to obtain the appropriate backpressures, the width
of the resulting recorder trace determines the AP, and the column head pressure (P) is then
obtaiued directly from the Q0 1 " 19002 display. As an example, a recorder set for 10mV/FS might
show a 2mV or 20' ' .; pump stroke for a given damper, or a AP of 1Oatm. If the
9012 display showc... . ,...,sure of 150 atm, AP/P would then be 10atm/150atm, or 6.6%.
Agooci 1per should provide a AP/P on the order of 1.5% (~2atm pulse width) at 150atm, and
<5%(~ ;. pulse width) at 50atm. Between 50 and 150atm, llP/P should be fairly linear. A
faulty d: er may provide a good AP/P at 150atm, but up to 40% at 40atm (~:~15atm pulse
width).
Note: The actual procedure for determining AP/P is performed by using different lengths of
.005" SST tubing so that a variety of column head pressures can be obtained at a specific flow
rate. Although this method will provide a higher degree of accuracy with regard to AP, using a
single piece of tubing and simply changing flow rates to get the desired backpressure should be
sufficient to determine a faulty damper.

Number LC94005
Issue Date July 29. 1 994
Page of 2
Service Bulletin
Product Line:
Model Number
9012/9002 SDS
SIN Affected
SEPARATION SCIENCE
Originator
Dean Waterbury
varian
Reviewed By
N/A Jean Free
* * * INFORMATION ONLY * * *
NEW SOLID-CORE PULSE DAMPER FOR LC SYSTEMS
Beginning in August 1994, Chromatography Systems will be installing a new generation of pulse
damper on all9012/9002 Solvent Delivery Systems. Designed as a direct replacement for the U-
tube damper in existence for the past seven years, the solid-core damper consists of a Teflon rod
inserted into an SST cylinder, sealed at the inlet and outlet with identical SST threaded end-caps
and Teflon 0-rings.
Dampening of pulsations is accomplished as the Teflon rod is compressed by the mobile phase
during the high pressure pump stroke (damper volume increases by approximately 1.2 uL per
atmosphere). During the inlet stroke, the energy stored in the Teflon rod is allowed to quickly
expand or rebound, forcing mobile phase out of the damper through the column. This is the same
basic mechanism used in the U-tube damper. However, since there is no support fluid in the new
damper, and because the only materials used are stainless steel and Teflon (titanium and Teflon
for the inert version), reliability is greatly increased over U-tube damper.
As an added benefit to the customer, the Teflon rod is designed with a small groove down its
length to aid in the quick flushout of mobile phase during gradient analyses. With a 250 uL
decrease in gradient delay volume, and a flushout volume on the same order as the previous U-
tube design, pump program changes should not be required for the majority of applications.
However, analyses of early eluting peaks on very steep gradients may experience slight decreases
in retention times, requiring slight method adjustments.
Because the U-tube damper is being discontinued, Chromatography Systems has put together
retrofit kits for both 9000 and 5000/5560 series LC pumps. The 5000/5560 retrofit kit can be
easily installed by the customer. However, because the 9000 series pump requires the careful
drilling of five holes to the bottom of the chassis, it is highly recommended that this kit be
installed by a Customer Support Representative. Once the retrofit kit is installed, a damper can be
easily replaced, if ever required, by the customer.
In addition, we will also offer a Damper Rebuild Kit consisting of a Teflon core and 0-ring seals,
which will allow Customers to easily rebuild their own solid-core damper when damaged by
precipitated buffers or other materials not compatible with Teflon. (Please note that some
corrosive solvents may cause damage to the SST or titanium damper cylinder and end-caps, which
would require entire damper replacement.)
For more information on the new Solid-Core Pulse Damper, please refer to Product Information
Bulletin# LC9414.
Solid-Core Damper Kits

Description Installation
03-919666-90 9000 Series Solid-Core Damper Retrofit Kit Senncereconunended

(includes damper, all hardware, instructions)
03-919666-91 Inert 9000 Series Solid-Core Damper Retrofit Kit Senncereconunended

(same as above, except titanium damper and
tubing)
03-919671-90 5000/5560 Solid-Core Damper Retrofit Kit User installable

(includes damper all hardware, instructions)
03-919675-90 Solid-Core Damper Replacement Kit User installable
03-919676-90
(includes damper only--for replacement in
9000/5000/5560)
Solid-Core Damper Rebuild Kit (includes new

Teflon core, 0-rings to rebuild any solid-core
User installable

damper)

Number LC93012
Issue Date Ju1y 21 1 1993
Page 1 of .....1=:-.._
Service Bulletin
Product Line:
Model Number
SEPARATION SCIENCE
9000 Series Pum s
SIN Affected
Originator
Dean Waterbu
varian8
Reviewed By
Ken Judah
All
** INFORMATION ONLY **
THE "CLACKING" PUMP SYNDROME: REPLACEMENT OUTLET
CHECK VALVES WITH OVERsiZED SAPPHIRE BALLS
SYMPTOM:
A clacking sound emanating from the 9000 Series pump usually indicates that the outlet check
valve is faulty. The sound is not the check valve itself, but rather, the inlet slider bearing
slamming against the face of the lower cam lobe. A leaking check valve (usually caused by
particulate material caught between the interface of the ball and seat) prevents the required
depressurization of the mobile phase within the piston chamber (when there is sufficient
column backpressure to do so). The high pressure within the pump head is forced against the
inlet valve poppet, which in tum prevents the inlet valve from opening properly.. Normally,
the spring-loaded inlet valve slider would open the inlet valve. But the internal head pressure
now overcomes the spring tension and the slider assembly is allowed to float off the low side
of the cam surface. As the cam continues to rotate, the inlet valve is opened, pressure within
the piston chamber is released, and the inlet valve then slams against the cam surface.
PROBLEM:
Although usually caused by an outlet check valve that is simply not checking due .to material
caught in the seat, a recent batch of check valves erroneously built with oversized sapphire
balls .is prod~cing a similar situation.. As the problem is .~t only :~hen the pump is
working agamst some backpressure, Le.. when a column JS installed, original outlet check
valves on 9000 Series ~ shipped f1'0m the factory should not be affected. Only
replacement check valves are iffec:ted, as these were not tested against column backpressure.
SOLUTION: ,. ..
;- ...
,
When installiilg a repJacelMnt check v8Ive onto any 9000 Series pump~ .be stare
to test the
system under column ~ coodidons for a few minutes and lisfen for the obvious
clacking. If the clacldng is observed, replace the check valve with oae fmiiJ current stock
and charge to parts warranty. Chromatography Systems bas recently purpd 8ild tetested all
SVL and CSB check valves.. .
NOTE:
Sapphire Ball and Seat Sets used on SOOOISS60 check valves (these use same ~ balls as
9000 check valve) may also be affected . Althoup the symptom of their use m..
not been
documented, recently purchased 03-905324-00 kits (between March 1 and June 21) should be
suspected as bad and returned for replacement.
PART NUMBERS AFFECTED:

03-919465-00 Check Valve Assy, replaceable frit type (non-inert 9000)
03-919600-90 Check Valve Assy, Inert 9000
03-905324-00 Sapphire Ball and Seat Set (for 500015560 check vllve)
Service Bulletin
Number LC93012
Issue Date July 21, 1993
Page 1 of ~1_ _
varian
Product Line: SEPARATION SCIENCE chromatography systems
Model Number Originator Reviewed By
9000 Series Pum s Dean Waterbu Ken Judah
SIN Affected
All
THE "CLACKING" PUMP SYNDROME: REPLACEMENT OUTLET
CHECK VALVES WITH OVERSIZED SAPPHIRE BALIS
SYMPTOM:
A clacking sound emanating from the 9000 Series pump usually indicates that the outlet check
valve is faulty. The sound is not the check valve itself, but rather, the inlet slider bearing
slamming against the face of the lower cam lobe. A leaking check valve (usually caused by
particulate material caught between the interface of the ball and seat) prevents the required
depressurization of the mobile phase within the piston chamber (when there is sufficient
column backpressure to do so). The high pressure within the pump head is forced against the
inlet valve poppet, which in tum prevents the inlet valve from opening properly. Normally,
the spring-loaded inlet valve slider would open the inlet valve. But the internal head pressure
now overcomes the spring tension and the slider assembly is allowed to "float" off the low side
of the cam surface. As the cam continues to rotate, the inlet valve is opened, pressure within
the piston chamber is released, and the inlet valve then slams against the cam surface.
PROBLEM:
Although usually caused by an outlet check valve that is simply not checking due to material
caught in the seat, a recent batch of check valves erroneously built with oversized sapphire
balls is producing a similar situation. As the problem is apparent only when the pump is
working against some backpressure, i.e. when a column is installed, original outlet check
valves on 9000 Series pumps shipped from the factory should not be affected. Only
replacement check valves are affected, as these were not tested against column backpressure.
SOLUTION:
When installiilg a replacement check valve onto any 9000 Series pump, be sure to test the
system under column backpressure conditions for a few minutes and listen for the obvious
"clacking." If the clacking is observed, replace the check valve with one from current stock
and charge to parts warranty. Chromatography Systems has recently purged and retested all
SVL and CSB check valves.
NOTE:
Sapphire Ball and Seat Sets used on 5000/5560 check valves (these use same sapphire balls as
9000 check valve) may also be affected .. Although the symptom of their use has not been
documented, recently purchased 03-905324-00 kits (between March 1 and June 21) should be
suspected as bad and returned for replacement.
PART NUMBERS AFFECTED:
03-919465-00 Check Valve Assy, replaceable frit type (non-inert 9000)

03-919600-90 Check Valve Assy, Inert 9000
03-905324-00 Sapphire Ball and Seat Set (for 5000/5560 check valve)
Service Bulletin
Number LC93009
Issue Date June 18, 1993
Page 1 of 1
varian
Product Line: SEPARATION SCIENCE chroma to rap y_ systems
Model NIJITlber Originator
9012/9002 LC Pump Dean Waterbu
SIN Affected Approval
All Dave Pandrea
*** INFORMATION ONLY ***

STAR LC 9000 SERIES SOLVENT DELIVERY SYSTEM UPGRADES
To avoid any confusion with regard to Star LC pump upgrades, the following information is
provided. Please note that most kits are available as Main Sales items only-they are not
available from Sunnyvale. Also note that some kits require handling of static-sensitive
devices, and that complete pump calibration may be necessary. As such, we do not
recommend that Customers attempt to install any of these kits on their own. Varian
installation is extra and will be charged at current billable rates.
The following kits are available from Sunnyvale:
9010 to 9012 Upgrade Kit 03-919641-90

9001 to 9002 Upgrade Kit 03-919645-90
The above kits contain appropriate EPROM set, Nameplate, Operator's Manual and
instructions. As removal of SBC PCB and handling of static-sensitive devices is required,
installation by Varian Service is recommended.
The following kits are available as Main Sales items only:
9001/9002 to 9012 Upgrade Kit 03-919646-90
This kit contains appropriate EPROM set and Nameplate, and all necessary pump
hardware. As complete pump calibration is necessary, installation by Varian Customer
Service is required. Service shop installation is recommended.
9010 to 9010 Inert Upgrade Kit 03-919627-90

These kits contain corrosion-resistant pump hardware only. As pump calibration may be
necessary, installation by Varian Customer Service is highly recommended.
Note: For Customers wishing to upgrade a 9010 to 9012 Inert pump, the 9010 to 9012
Upgrade Kit, p/n 03-919641-90, is required in addition to the 03-919640-90 kit.
This kit has been discontinued. Customers should use 9001/9002 to 9012 Upgrade Kit,
p/n 03-919646-90.

Number LC93010
Issue Date June 18, 1993
Page 1 of ----'1;;,.___
Service Bulletin
Product Line:
Model Number
SEPARATION SCIENCE
9000 Series LC Pum s

SIN Affected
Originator
Approval
Dean Waterb
varian
Reviewed By
Tra~
VIS
All Dave Pandrea

DICRONITE COATED INLET VALVE BODY
PROBLEM:
In response to an occasional thread-galling problem which has resulted in the

seizure of the inlet valve within the pump head of some 9000 Series LC pumps,
Chromatography Systems will begin shipping instruments with a slightly modified
inlet valve. The cause of this problem was originally assumed to be related to either
the dimensional tolerances of the inlet valve and pump head, or from discrepant
material. It is now perceived to be a by-product of usmg fine-pitched threads with
316 stainless steel, and the high torque required to seat the inlet valve.
Note: This problem was previously reported via Service Advisory LCSA93-2 in
January 1993.
SOLUTION:
A very thin (20 millionths inch) coa~ of Dicronite will be added to the threaded
area of the valve body to ease installation and eliminate possibility of seizure of the
inlet valve (per ECO #18372). Dicronite is a grey-colored tungsten-disulfide dry
film lubricant which is chemically bonded to the valve body during manufacture, and
should not flake or peel off during installation or removal of the inlet valve.
The Dicronite coated body will be used on all inlet valves, including the inert
version. Replacement parts in Sunnyvale will be of the new design when current
stock is used up, and part numbers will not be affected The to;b\ue specs for the
inlet valve remain at 175 in/lbs, and all parts should be thorou y cleaned with
isopropyl alcohol prior to installation.
PART NUMBERS:
03-919085-90 Inlet Valve Replacement, Standard

03-919604-90 Inlet Valve Replacement, Inert
Service Bulletin
Number LC93007
Issue Date S LOS /93
Page ---=1'---- of __,8..___
varians
Product Line: SEPARATION SCIENCE chromatogrpphy systems
Model Number Originator
90U 9002 LC Pum Dean Waterbu
All Dave Pandrea

INTRODUCTION OF THE 9012/9002 SOLVENT DELIVERY SYSTEM
Chromatography Systems has been shipping the new 9012 Ternary and 9002 Isocratic
Solvent Delivery Systems since mid March. Introduced at the Pittsburg Conference, the
latest versions of the successful 9000 Series pump feature flow rate capability from 10 uL
up to 10 mL/min. The 9012 has the additional feature of allowing the user to select from
the keypad either one-, two-, or four-stroke proportioning modes. Electrically and
mechanically, the 9012/9002 remains identiCal to the 9010/9001. Performance
enhancements are all accomplished through changes to the pump software, thereby
permitting easy upgrade from 9010/9001 to 9012/9002. A more thorough description of
the features and functions of the 9012 can be found in the attached Product Information
Bulletin.
As noted in the Pffi, current Star Workstation software will not fully support the new
features of the 9012/9002 pump. The Workstation will recognize the 9012/9002 as a
9010/9001, and as such, flow rates in the Workstation methOd will be limited to SmL/min,
and the different proportioning modes cannot be selected. However, the pump will be
properly recognized and these new features will be available when Star LC Workstation
software is revised sometime in the future. An addendum explaining the operational
caveats of the 9002/9012 with Rev. C Workstation has recently been added to the
Workstation Operator's Manual and is also attached to this bulletin. Included are
suggestions and "workarounds" you should be aware of, as questions from your Customers
will undoubtably arise. Please keep this information on hand as an aid to future
installations~
From a Service standpoint, operation in two- or four~troke modes does not require any
recalibration of the pump. Once properly calibrated in the one-stroke mode, proper
operation should be maintained in all modes. With regard to upgrades, however, unless
you (or your Customers, as they may be performing their own upgrades) are absolutely sure
that the pump calibration was correct to begin with, proportionmg should be rechecked
after installing the new software. This would include inlet valve torque and gap, optical
switch (1%), and proportioning crossover (51%) adjustments.
Another potential Customer problem to be aware of is the solvent mixing requirement for
the different proportioning modes. As only the standard 200 uL low volume mixer is
shipped with the 9002/9012, operation in 2- or 4-stroke proportioning modes may produce
unsatisfactory baseline stability. The Operator's Manual states that the standard mixer may
be adequate for two-stroke proportioning: however, the larger 1.4mL static mixer will
provide better gradient mixing and therefore better baseline results. Also, the optional
dynamic mixer will outperform both static mixers for four-stroke proportio~ especially
in difficult mixing situations. Part numbers for optional mixers may be found m the Pffi.
Page 2
Number:
Prepared By:
LC930S f/tf
Kent Varble
Approved By: Gary Burce
PJN Approval: Dick Orr~
Date: March 10, 1993
INTERNAL VARIAN USE ONLY
.,
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~ NEW PRODUCT INTRODUCTION n
-t
9002 !SOCRATIC
9012 TERNARY
INERT 9012 TERNARY
-.,z
Q
SOLVENT DELIVERY SYSTEMS
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Page 3
Keywords: gradient, isocratic, mechanical inlet valve, pump, proportioning, ternary, Workstation
Mcx:Jels: 9001, 9002, 9010, 9012, Inert 9010, Inert 9012
TABLE OF CONTENTS
1. Ordering Information
2. General
3. New Features
3A Mixing Considerations
3B. Pressure Pulsations
3C. Other Changes
4. Upgrades
5. Installation and Warranty
6. System and Trade-in Discounts Policy
7. Competitive Summary
1. ORDERING INFORMATION
Ternary Pumps
03-919643-00 9012 Ternary Pump, 120V $12,250.00
03-919643-01 9012 Ternary Pump, 220V $12,250.00
03-919643-80
03-919643-81
03-919643-02
03-919643-03
QUICK DELIVERY 9012 Ternary Pump, 120V
QUICK DELIVERY 9012 Ternary Pump, 220V
Inert 9012 Ternary Pump, 120V
Inert 9012 Ternary Pump, 220V
$12,860.00
$12,860.00
$13,650.00
$13,650.00
!socratic Pumps
03-919644-00 9002 Isocratic Pump, 120V $7,695.00
03-919644-01 9002 Isocratic Pump, 220V $7,695.00
Upgrade Kits
03-919645-90 9001 to 9002 Upgrade Kit $ 500.001
03-919641-90 9010 to 9012 Upgrade Kit $ 500.001
03-919646-90 9001/9002 to 9012 Upgrade Kit $ 4,685.002
03-919640-90 9012 to Inert 9012 Upgrade Kit $ 2,000.002
1 Installation by a Varian CUstomer Support Representative Is strongly recommended. Contact Varian

Customer Support for detaHs.
2 Installation by a Varian Customer Support Representative Is required. Contact Varian CUstomer Support
fordetaHs.
Page 4
2. GENERAL
At the 1993 PittCon, Varian officially introduced the latest models in the unique 9000
Series of LC Star Solvent Delivery Systems.
New Product Structure

Model Description
9002 !socratic
9012 Ternary Gradient
Inert 9012 CorrosiOn Resistant Ternary Gradient
The pump design remains the same as that in the 9001 and 9012, a single piston design
with mechanical inlet valve, fast refill stroke, and high speed, in-line proportioning valves
(gradient models), and high pressure mixing (gradient models). Improved performance of
the new models is gained through software changes.
.,
3 .NEW FEATURES
These software modifications permit the new models to achieve flow rates as high as 10
mL/min. The new software also allows 1, 2, or 4 stroke proportioning. For now, this
choice can only be made at the front keypad of the pump module. The next revision of LC
Star WorkstatiOn software will allow the selection of proportioning mode at the
Workstation.
New Features
Flow Rate:
Proportioning Modes:
0.01 to 10.0 mL/min
1, 2, or 4 stroke, selectable
Higher flow rates permit the use of semi-preparative columns with this pump. Through the
use of 8 mm ID columns, milligram quantities can be isolated.

The choice of proportioning modes gives a user great flexibility in choosing the best
compromise of delay volume/flushout, mixing noise, gradient linearity, step accuracy, and
pressure pulsations for a particular analysis. Think of it as a way to fine tune the
performance of the pump, thereby customizing pump operation to the particular needs of a
given analysis.
The choice of mode is made in the Confi~re menu. After a choice is selected, the
software prompts the user to read a specific manual section before proceeding.
How to Ootimize Various Pumo Parameters Throue:h Choice of Prooortionin2 Mode
Pump Parameter Good Better Best Algorithm
Delay and Flushout ~stroke 2 stroke 1 stroke
Mixing Noise 4 2 1
Pressure Pulsations 1 2,4
Gradient Linearity 1 2 4
Step Accuracy 1 2 4

Page 5
For the lowest delay volume (1 and 2 nun ID microbore) or best mixing (difficult
gradients), choose one stroke proportioning. This is the default setting and is identical to
9010 operation. Most customers should use this setting without any other recommended
changes for normal operation.
For more linear gradients,more accurate gradient steps, and lower pulsation, choose four
stroke proportioning. Four stroke proportioning should always be used when a customer's
primary need is the most accurate gradients obtainable (e.g. peptides or other compounds
which have multiple separation mechanisms).
Four stroke proportioning allows a 9012 to imitate the performance of 5000 or 5500 series
pumps. Most methods can transfer directly from a 500015500 to a 9010 or 9012 without
problems. If problems are encountered, four stroke proportioning will give the most
consistent results.
Two stroke proportioning provides an intermediate choice. It provides more accurate and
precise proportioning than single stroke and requires less mixing than four stroke.
..,
Most users will not notice any significant differences in analytical performance using
different proportioning modes as long as they select an appropriate mixer (see below).
3A. MIXING CONSIDERATIONS
Four stroke proportioning requires more mixing of the mobile phase than does one stroke
proportioning. In one stroke mode, the entire solvent mixture 1sproportioned in a 75
microliter volume. For this, the standard mixer is adequate. In four stroke mode, the
solvent mixture is created in a 300 microliter volume. This requires more mixing than the
standard mixer achieves. If your customer will be using four stroke proportioning, one of
the following mixers should be added to the quotation.
Mixer Choices for Dift'erent Prooortionin2 Modes
Mode Suggested Mixers Part Number Price
One Stroke Standard Mixer (supplied) included wI pump
Two Stroke Standard Mixer (supplied) included wI pump
or 500015500 Static MiXer, 1.4 mL vol 03-905985-90 $155
Four Stroke 500015500 Static Mixer, 1.4 mL vol 03-905985-90 $155
or Rainin Dynamic Mixer 00-997876-00 $735
The Rainin mixer provides 2x to 4x better mixing than the 500015500 Static Mixer.
For most applications {>erformed with two stroke proportioning, the standard mixer
provides sufficient mixmg. For difficult gradients, use the 5000/5500 mixer.
3B. PRESSURE PULSATIONS
Both two and four stroke proportioning provide smaller pulsations than one stroke. One
stroke mode uses a 400 msec fill time to achieve accurate and precise proportioning. Two
and four stroke proportioning use a 200 msec fill time, half the time reqwred for one
stroke. Accordingly, the pulse. damper supplies flow for only 200 msec m two and four
stroke mode. Since the damper provides flow for half the time (200 vs 400 msec),
pulsations are half the size in two and four stroke mode as they are in one stroke.
Page 6
3C. OTHER CHANGES
Purging and priming rate is now 10 mL/min instead of 5 mL/min. Pump priming and line
purging will occur even faster than before .
.LC Star Workstation does not yet recognize a 9012. A 9012 connected to LC Workstation
(rev. C) will log on and operate as a 9010. In order to operate a 9012 or 9002 attached to a
Workstation at flow rates above 5 mL/min, you must download the method from
Workstation to pump, take the pump off-line using the local/remote button, and then
select flow rate from the keypad. The next revision of LC Star Workstation will support all
features of the 9002 and 9012 and will differentiate between 9010's and 9012's.
The proportion;-:g mode is not selectable from LC Workstation. When the LC
Workstation soHware is next revised, a dip switch on the 9012 motherboard can be set to
make it log on the Workstation bus as a 9012.
4. UPGRADES (see ordering information section for P/N's and prices)
..
The new pumps once again demonstrate Varian's deep commitment to its customers. Our
products are inherently more valuable than other brands because we usually allow older
models to be upgraded to the full capability of the latest models.
Available Uperade Paths
A) 9001 == = > 9002
B) 9010 = ==> 9012
C) 9001/9002 = == > 9012
= == >

D) 9012 Inert 9012
Options A and B are software changes achieved by removing and replacing the pump's
PROM set. It is strongly recommended that this upgrade be performed by a Varian
Customer Support Representative. Options C and D require hardware changes.
Installation of these upgrades by a Varian Customer Support Representative is required
Upgrade kits will begin shipping approximately May 1.
5. INSTALLATION AND WARRAN1Y

For installation and warranty purposes, 9012's are identical to 9010's.
6. SYSTEM AND TRADE-IN DISCOUNTS POLICY
All factory discounts that include 9010 Pumps now apply identically to 9012 Pumps.

Page 7
Addendum
Date: March 29, 1993

0224
Publication Affected: LC Star Workstation Manual

Publication Number: 03-914220-00
Operation of the 9002 and 9012 Solvent Delivery Systems

with LC Star Workstation, Rev. C
This addendum.,.describes procedures for operating the LC Star Workstation, Rev. C, to support the
features of the 9002 and 9012 Solvent Delivery Systems.
Hardware Configuration
1. Each 9002 or 9012 will log on and be displayed as a 9010.
NOTE: For the 9002 and 9012 modules, the DIP switch (position 8 on switch S-4 of the SBC) on
the module must be in the OFF position.
Solvent Composition for 9002 Module

As with the 9001, the solvent composition for a 9002 Workstation method must be 100% A.
Flow Rates Greater Than 5 mUmin

The maximum flow rate setting for a 9010 Workstation method is 5 mUmin. However, for both the
9002 and 9012, there are two procedures for operating a pump at a flow rate greater than 5
mUmin when using the Workstation:
Procedure 1
1. Download the Workstation method.
2. At the pump module, select the local control mode.
3. Set the flow rate at the front panel of the module.

4. Perform the injection.
NOTE: Each time a method is downloaded, the flow rate setting in the method will overwrite any
flow rate set at the pump module. Therefore, you must reset the flow rate at the pump.
Addendum 0224 SPEC. 03-914411.00

1:2:3:48:6
1 of 2
Page 8
Series of Injections
When performing a series of injections at a higher flow rate, there are two requirements;

The Workstation Sequence must have only one line (no activation of a method between runs).
Each time you activate the Workstation Sequence (resulting in the downloading of the
method), you must then change the flow rate at the front panel of the pump.

The Solvent Delivery System Status and Control window and the Run Log will report the actual
flow rate. even if it exceeds 5 ml/min. The Run Log will also include this entry for the
proportioning mode:
Unknown OpCode: 7
A future release of the Workstation software will display the actual proportioning mode used.
No Method Upload
If you have programmed a method at the front panel of a 9002 or 9012 module for a flow rate
greater than-5 ml/min, do not attempt to upload it to the Workstation (Get Active Method
command):
Procedure2
1. If a GPIB cable connects the pump to the Workstation, remove the cable.
2. Take the pump off-line by selecting the New Instrument command in System Control.
3. Connect a synchronization cable (PIN 03-919948-90) from the pump module to the detector
module.
4. Set all pump parameters for all methods, including the flow rates, at the front panel of the pump.
5. If necessary, program an automation sequence table that matches the Workstation Sequence.
6. Perform the injection(s).
2of2 SPEC. 03-914411.00

1:2:3:48:6
Addendum 0224

Service Bulletin
Number _ __....I.Cw..;Q....,.2.w.O.&.I10,____ __
Issue Date_-=--91......0=8'"-/9=2==-----
Page _ ___..l~ of 1
varian@
Product Line: SEPARATION SCIENCE chromatography systems
Originator
Dean Waterbu
All Dave Pandrea
REPLACEABLE FILTERS FOR
9010/9001 CHECK VALVES
Beginning in October, standard 9010 and 9001 LC pumps will be shipped with new
outlet check valves designed with a replaceable filter. This change will provide a
maintenance cost advantage for our Customers, as the previous design required
complete check valve replacement when the old style filter became plugged. The
part number for the new check valve will remain the same as the original design, 03-
919465-00/90.
The new design incorporates a 40 micron screen-type filter held in ,Place with a
stainless steel filter retainer, as opposed to the old style, which consisted of a 20
micron filter surrounded by a Kel-F seal and permanently pressed into place. To
replace a plugged filter, a special tool is used to remove .both the retainer and filter.
A replacement filter is inserted into the check valve cavity, the retainer is then
placed over the filter and simply pressed into place on a flat surface.
A Check Valve Filter Replacement Kit, p/n 03-919594-90, consisting of three
replacement filters, special removal tool and instructions will be available from
Walnut Creek and SUnnyvale. Oa instnunent orders, this kit must be ordered
separately, as spare filters and the tool will not be included in the 9010/9001
Standard Accessoey Kit.
NOTE: Because a replaceable 40 micron filter is not currently available in titanium,
the Inert 9010 will continue to~ with the existing design inert check valve. To
avoid compromising biocompanoility, it is not recommended to use the new check
valve as a replacement in the Inert 9010 pump.
PART NUMBERS
03-919465-90 Check Valve Assy, Replaceable Filter Design

03-919594-90 Check Valve Filter Replacement Kit
03-919600-90 Check Valve Assy, 9010 Inert
Service Bulletin
Number LC9200S
Issue Date Aprf.1 29, 1992
Page 1 of 1
varian@
Product Une: SEPARATION SCIENCE chromatography systems
SIN Affected App10tiBl

All Dave Pandrea
**
INFORMATION ONLY * *
CHANGES TO 9000 TELEDIAGNOSTICS OPriON
Be~nning in June, 9010/9001~and 9050 detectors~ from Walnut Creek will

no onger have an RS-232C IJF cable installed inteJ."Dally between the SBC PCB (or
Detector PCB) and the rear ~1 bulkhead (J200 Te~cs port). As a cost of
goods reduction, this cable aild its associated hardware, used for coDDection of the
Telediagnostic:s modem, has been removed from the basic assembly.
The optional cable, with hardware and instructions, will be available as the RS232
Telediagnostics Interface Kit, 03-9~,., for the Field ldt, or 03-9J.M36.00 for the
Factory iDstalled option. Customers requiring the Telediagnostics qJtion will need to
order one of these kits for each 9001, 9010 or 9050 in their system, in adcHtion to the
Telediagnostics Modem Kit. Only one modem kit is required per LC system.
PABT NUMQEBS
03-919~,_, RS232 Teledlapostlcs Interface Kit. Includes RS-232C 1/F cable,

hardware, instructions. Required for each 9001/9010/9050 in LC system.
03-91MJ6.00 RS232 T+dlapostlcs Interfaee Kit. Factmy IDstalled.

03-919555-,., Teledla....., Medela D. Includes modem, phone cable, instructions.
Only one Modem ICit required per system. .
NOTE: The new RS232 Telecti~cs Interface Kit should not be coufiJsed with
the RS232 Interface Kit, 03-919Q80..90; which allows 9010 Customers to print_methods, run
1~ and automations~~ to a serial~- This tit, altllOUgb it could be
used to interface the modem, iDdudes extra hardwai'e and a label, and mounts to J201 of
the 9010 bact panel when the GPIB is not being utilized.
Number _ _---=~~::::=----
lssue Date _ _-=='-==-=:.=._ _ __
Page _ _...__
Service Bulletin
Product Line:
Model Number
SEPARATION SCIENCE
Star LC Modules
SIN Affected
Originator
Dean Waterbu
Approval
...,
varians
chromatography,........,systems
Jim savo
Reviewed By
All Dave Pandrea
NEW DEDICATED SYNC CABLE KITS
AVAILABLE FOR STAR LC MODULES
A new series of cable kits is now available from Chromatography

Systems to interface the following Varian LC products without the
confusion and expense often associated with the older
SwitchCraft type connectors. The new cables are dedicated: i.e.,
they are a single cable terminated at either end with the
specific connectors required by the modules they were designed to
interface.
9010/9001/9050 to Marathon Sync Cable Kit
03-909126-90
03-909125-00 Replacement cable only (SVL)
03-919948-90 9010/9001 to 9050 sync Cable ltit
03-919949-90 9010/9001/9050 to 9100 A/S Sync Cable Kit
03-919950-90 9010/9001/9050 to Star ADC Sync Cable Kit
03-919945-00 Cable only (SVL)
Also available is a new Rheodyne Position sensinq switch
terminated with a O-shell connector (instead of bare wires) that
allows interfacing directly to J9 of either the 9001, 9010, or
9050. Part number for this kit is 03-919947-90.
Note: The SwitchCraft sync cables are being phased out.

Sunnyvale and Walnut Creek will continue to supply the
SwitchCraft cables and kits through the end of this year.
Availability after January 1992 is slim at best
Service Bulletin
Number __~LC~9~1~0~1~4_________
Issue Date __-=..9~.-/-=-09:...<./....:9....:1:.._.________
Page 1 of 4
varian
Product Line SEPARATION SCIENCE chromatography systems
Model Number Originator \ill\~ ) Reviewed By ....-:-y
9010 Pump Dean waterburYtl\t\ ") Terry Sheehan/
SIN Affected Approval "'" ~/1 Reviewed By
All Dave Pandrea /'JIY
PHOSPHATE BUPPER PRECIPITATION i .
WITHIN THE ACETONITRILE PROPORTIONING VALVE
AND MOBILE PHASE SOLVENT LINE
The attached memo from Terry Sheehan describes a problem commonly

misdiagnosed as a 9010 pump component failure. It has sometimes
resulted in the replacement of inlet valves, proportioning
valves, and check valves, etc., none of which permanently solved
the original problem. The memo attempts to familiarize the
reader with the conditions required for buffer precipitation so

that a correct diagnosis can be made, as well as to suggest
method parameter changes that may eliminate or, at least, reduce
the problem.
Information from the field is vital in determining the magnitude
of the problem so that a permanent fix can be found and
implemented. If you see this occurrence, please document
pertinent details such as method parameters, mobile phase
concentrations, column, etc., and mail or FAX this to the
attention of Dean Waterbury or Terry Sheehan in Walnut Creek, or
to Leon Hendrickx in Zug for VEO
page 2 of 4
TO:
FROM:
VARIAN CHROMATOGRAPHY SYSTEMS
WALNUT CREEK, CA 94598
Specialists/Service Engineers
Terry Sheehan, Market Development

Jim Savoy, Field Marketing
Dean Waterbury, Technical support
cc: Leon Hendrickx, Zug
M. Joseph, F. Lai
DATE: August 12, 1991
MEMO NO: TSJ0-91
SUBJECT: Phosphate Buffer Precipitation into the Acetonitrile

Proportioning Valve and solvent Line of the 9010
Recently, several field personnel have observed phosphate buffer

precipitation in the acetonitrile proportioning valve and reservoir
line. If you have seen this situation, please FAX the customer's name
and pertinent details about the mobile phase (if available) to our
attention in Walnut Creek. Before drawing this situation to the
attention of the QIT, we need more information from the field as to
the magnitude of the problem. Please help by documenting your
awareness of the problem in your region.
OBSERVATION: Fine, white slurry in proportioning valve and reservoir

line immediately before the proportioning valve; flushing line with
water eliminates the precipitate.
RESULTANT MALFUNCTION: Proportioning valve operation is non-
reproducible; poor retention time RSD.
POSSIBLE MISDIAGBOSIS: Bad inlet valve that is allowing leak back

into the reservoir lines during the compression stroke; even with a
new inlet valve, the white slurry returns.
This situation is the result of a well understood solubility problem:

1. Phosphate salts are not soluble in high concentrations of
acetonitrile.
2. As buffer pH increases, the solubility of phosphate salts in
acetonitrile decreases.
While the final mobile phase mixture may not have any problems with
phosphate salt solubility, there are volumes within the pump head
where solubility limits may be exceeded due to a high ratio of
acetonitrile/phosphate buffer.
Page 3 of 4
The aspect of the pump design that can create this precipitation is
fairly easy to understand. Within the pump head, there are three
short passageways from the proportioning valves to the volume around
the valve stem of the inlet valve (see the attached Figure 1). During
the proportioning cycle, phosphate buffer can come into contact with a
column of pure acetonitrile. At that interface, micro-precipitation
of the phosphate salts can occur. The effect of gravity is to pull
these crystals down toward the proportioning valve. Even so, there
still may not be an observable problem unless other ~factors are set
within certain limits.
If the fine crystals of phosphate salt are drawn into the pump head by
the next proportioning of acetonitrile, the crystals quickly
redissolve and no operational problems are seen. In other words, if
the flow rate of acetonitrile into the pump head is faste~ than the
rate at which gravity pulls these micro-crystals down towards the
proportioning valve, no problem will be observed. Therefore, the
worse case situation to observe this salt precipitation problem is as
follows:
A. Low flow rates as with microbore columns or
B. Low percentages of acetonitrile.
Think about the confusion this creates. Two 9010 systems use the same
buffer (same concentration and pH), but only the system with a low
percentage acetonitrile ever shows the precipitation problem. The

chromatographer has used his mobile phase oil a 4. o mm column (flow
rate 1 mLjmin) for a year without any problems. To reduce solvent
waste, he switches to a 2. 0 mm column (0. 25 mL/min) and suddenly
starts to have problems with salt crystals in the acetonitrile
proportioning valve. The chromatographer changes from a C18 column
(30% acetonitrile in the mobile phase) to a C8 column (10%
acetonitrile in the mobile phase) and starts to have retention time
precision problems.
POSSIBLE SOLUTIONS WITH CURRENT DESIGN: While there are not any true
"fixes" to this situation, there are several things that can be done
to eliminate or reduce the problem. First, always run acetonitrile on
Reservoir c. The angle below horizontal of the Reservoir c passageway
to the inlet valve is much less than Reservoir A orB (see Figure 2).
As a result, phosphate crystals do not move toward the proportioning
valve as quickly in Reservoir c. secondly (and this may not seem
reasonable to the user), diluting the acetonitrile with even 10 or 20%
water will usually allow acetonitrile (diluted) to be used on any
reservoir line.
INLET VALVE FAILURES: A leaking inlet valve will increase the problem
with phosphate precipitation. On the compression stroke, a leaking
inlet valve will force liquid back into all three reservoir lines.
Any phosphate buffer forced back into the acetonitrile passageway is
almost certain to precipitate. The improved design of the 9010's

inlet valve has made this less common. If precipitation is observed
with acetonitrile on Reservoir c of a 9010, the inlet valve should be
replaced.
Page 4 of 4
FUTURE 11 FIXES 11 : The solution to this problem may be as easy as

reorienting the passageways_within the head or inlet valve. Update o f .
existing pumps should not be difficult. Like any other project, the
work required to make these changes (drafting, model shop, etc) and
the subsequent pump performance tests will require good justification.
Again, we ask you to FAX knowledge of this problem as soon as
possible.
NOTE ON 5000/5500: This problem has also been obserVed on both 5000
and 5500 LCs. For these pumps, Reservoir C is a worst case since it
i= ro~itioned directly below the inlet valve.
INLET VALVE ASSEMBLY

FIGURE 1
POSSIBLE INTERFAC
OF ACETONITRILE
AND BUFFER .TYPICAL SOLVENT INLET CHANNEL

FILLED WITH ACETONITRILE
BEST POSITION FOR

c ACETONITRILE

A B
FIGURE 2
PROPORTIONING VALVE ANGLE
IN 9010 PUMP HEAD
Number LC91005
Issue Date February 4, 1991
Page _ _.___ of 4
Service Bulletin
Product Line:
Model Number
9001/9010
SEPARATION SCIENCE
~:n Water))ury-~ \\_' ,'

varian@
walnut creek instrument division
Reviewed By
KeD Judah
SIN Affected
All ~e Panc!rea j ptJ -w-
liN
1
PAULT 68-PUKP STALL PAULTS
SYMPTOM:
FAULT 68, as displayed in the 9010 ERROR LOG, can occur when
the pump is first powered up or at any time while the pump is
runninq. The fault indicates the position sensor has determined
that the pump has stalled, usually due either to some mechanical
bindinq of the pump assembly, or a possible component failure in
the position sensor circuit. Sometimes a simple reset will clear
the fault, allowinq the pump to operate normally for a period of
time.
PROBLBJI:
The first place to look in determininq the cause for FAULT

68 is the outlet check valve, as recommended in the Operator's
Manual. As the pressure transducer is downstream from the check
valva, a cloqqad filter will causa the pump to stall, rather than
indicate an overpressure.
However, as 9000 pumps aqe, we are seeinq mora FAULT 68
occurrences that are found to be due to qrease conqealinq in the
area of the spring housing, inlet valve slider, crankshaft and
cam follower bearinqs. The dirty, dried qrease restricts the
movement of the sprinq . housinq assembly which makes it more
difficult for the crankshaft to turn. The SBC and MVD
electronics, in conjunction with the optical switch, monitors the
timinq of each icrostep of the pump motor, and senses that the
motor is step-lagging. A software interrupt is than qenerated,
and the ~ stall is reported.
SOLUTIOB:
If replacement of the outlet check valve does not solve pump
stall probleas, and you have exhausted the possibility of other
obvious causes, lubrication within the pump assembly may be the
problem, and cleaning and relubricating lillY be all that is
required.
The procedure for removinq, cleaning and- lubricatinq the
sprinq housing and related assemblies can be found in the
instructions included with the Piston Replacement Kit. These
instructions, with associated part numbers, are attached for your

convenience, however it may be to your advantaqe to have the kit
at hand in case replacement parts are required.
To help avoi4 pu.p stalls due to lu))rication pro))lems, this
procedure must be perfor.ae4 durinq a PK or piston replacement. 1r.
Piston Replacement
Kit No. 03-919102-90

This kit contains the following items: on. Continue holding SELECT until an audible beep
1 ea. Sapphire Piston Assembly, PIN 03-919180-00 is heard.
1 ea. Grease, Molykoteru, PIN 88-299461-00 b. Wrth the piston fully retracted, pull back, and
1 ea. Grease, Uthium Lubricant, PIN 88-299464-00 rotate the inlet valve actuator 1/2 turn
1 ea. Grease Guard, PIN 03-919432-00 counterclockwise.
1 ea. Pump Head Skirt, PIN 03-919223-00 c. Remove the pump head and pump head skirt
1 ea. Washer, PIN 03-919532-00 by removing the three socket head screws.
1 ea. Bushing, PIN 03-919548-00 (Requires a 513Z' hex tool.) Lay the pump
1 ea. Bushing, PIN 03-919549-00 head aside (electrically connected) and refer
1 ea. Seal, PIN 03-919397-00 to the Piston Seal Replacement Instructions
1 ea. Riter Bement, 0.5 micron, PIN 27-180385-00 (03-914146-00) to install a new seal.
1~ Piston Seal Replacement Instructions d. The spring housing is secured to the pump
PIN 03-914146-00 casting by two socket head screws. Loosen
and remove the mounting screws and lift out
Check to be sure all items are present. If there are any
the spring housing assembly.
discrepancies, please notify:
Varian, Walnut Creek Instrument Division

NOTE:,., to Rgure 1 rtdl/111 pedonnlntJ the foiiOfllllng
..... ,.,.,.,.,. ,.,.,.,.,. , . ,_,,.,.,.to t:ln:l<
2700 Mitchell Drive , . , . , . , ,_... 1.
Walnut Creek, C8lfomia 94598-1675

Attsndon: Manager of Customer Service e. Holding the spring housing assembly with the
Phone (415) 939-2400
or, yow 1ocat Varian SalesiService Center bearing against a finn support (bench top),
push down to compress the internal spring.
The replacement procedure given below requires the Wdh the spring compressed, remove the
removal of the pump head and the spring housing guide screw (7) and washer (11). This will
assembly. Prepare the working area with clean paper allow the internal assembly to slide out of the
towels or cloths. spring housing (1).
NOTE: We triCOIIIIIIIIIJ that a VMin s.r.nc. Ent1Jne1w f. Remove the spring (9) from the spring
perform the foiiOfllllng pt'OCIItlul'e: housing ( 1) and set the spring aside on a
paper towel Wipe the piston assembly with a
1. Removing the Pump Head/Spring Housing paper towel to remove the excess Molykote
Assembly. grease (black).
a. Disconnect solvent lines fran all of the g. For earlier version sliders. hold the slider in
proportioMlg valves. place by using a 1/'Z end wrench on the flats
of the piston slider (2). Then, loosen the piston
. , . to,. wn h,., ..,.,,.,...,_"'

IIIPORTANT NOTE: To , . . 1M pr.dJBity of holc:t-dc:Mn nut (3) with another 1/'Z box end
wrench. Remove the old piston (5) and
,.,.,.lngthellfiiiiPIIMtl. Jlillle...,__,...
Bottom DMtJ c.at.r (8DC) ,.,_. ~ and
byMifll*'tlEXTEIIDEDIIODE.....,_md_,.,.
grease guard (4) from the sflder and discard
the piston and guard.
Md~llllll~.,., ...,....,.,..,
to -.r.IIIICI Platon (lws.l ~In,_...,
hof/1 to-=-- and,_. 11M EXTENDED DfAGIN'OSJJICS,
For later veraion sliders, hold the slider in
place by Inserting iniD the radial hole the
largest phillpa screwdriver that wiD fit in the
tefer to Appendix A of fiN . . 11110111t1111 Solwnt hole. See Fig\1'8 1. Then, loosen the piston
Dellwll'y Sy8fem o,..w........ . hold~own nut (3) with a 1/'Z box end wrench.

Remove the old piston (5) and grease guard
To access EXTENDED DIAGNOSTICS tum module
( 4) from the slider and discard the piston and
power off. Press and hold S8..ECT while turning power
guard.
03-914171-QO:C 1
Piston Replacement
Reassembly and lnstal.lation of the Piston, Spring With the hold-down nut tightened securely
Housing, and Pump Head. ( 115 - 125 in-lb torque), the piston should still
Clean the removed piston hold down nut (3) and
be free to tum. Position the new grease guard
the piston mounting cavity (Area A) with paper
(4) on the piston as shown in Rgure 1.
towels to remove most of the old grease.
b. Wipe the excess Molycote off of the spring
a Apply a small amount of the white Uthium with a paper towel and regrease the outside
grease to the piston base at the locations of the spring as shown. Apply Molycote lightly
designated Area A and secure the piston to on one half of the spring length until the
the slider with the piston hold-clown nut (3). outside of the spring turns dark gray or black.
See Rgure 2.
NOTE: Take C1118 In lflllghtenlng the piston lrokklorm
nut to prevent any danlage to the llllfll piMKL A 12 point Wipe excessive grease from the spring
box end rrrenclr Is ffiCOifiiiHinde housing bore with a paper towel and remove
,_1/l
2 03-914171-oo:C
PisiDn Replacement
the old bushing ( 10) from the cavity of the front NOTE: Use the retainer to finish the proper seating of the
flange. Insure that there are no broken piston piston seal. Orient the retainer so that the crossed slots
parts inside of the spring housing. are lacing away from the pump head.
Regrease the bore of the spring housing with Replace the downstream 0.5 micron filter PIN
Molykote using a small brush or cotton swab. 27-180385-00 if it has not been recently
Apply to inner wall within Zone X only. replaced or if it starts to show an increased
c. Drop the spring into the spring housing bore differential pressure drop.
(non lubricated end enters first).
Mount the pump head to the spring housing
Insert the piston slider assembly carefully into
with a new pump skirt between them. Align
the spring housing. Again, holding the
the pump head such that the check valve is
bearing end against the bench top, compress
positioned at the top with proportioning
the spring and replace the guide screw and
valves below, if your unit is a 9010. Align the
guide bearing making sure the small washer
screw holes and secure the pump head with
is installed between the bearing and slider. (A
spare washer is provided in the kit in case of
the three socket head screws.
loss.) Mount the spring housing assembly to
e. Before completing this piston replacement
the pump casting and tighten securely.
procedure, replenish the cam follower
d. Install the new bushing (PIN 03-919548-00) lubricating pads (11) using the syringe and oil
over the exposed end of the piston and seat provided in the accessory kit. For detailed
it firmly in the recess as shown. instructions on the oiling procedure, refer to
Remove the old seal and front bushing from Section 6, paragraph 6.3.2, of the Star
the pump head. See Agure 3. 9010/9001 Solvent Delivery System
Operator's Manual.
Clean the pump bore of any broken piston
fragments and clean thoroughly with a wipe f. For 9010 punps, reconnect the solvent lines
and IPA to the proportioning valves (if disconnected)
making sue that Solvent A is connected to
NOTE: II btoluln plmln ,.,.,_, C11111101 be Mfll/y proportioning valve A. Solvent 8 to valve 8,
,.,.N4/t may
to nNnOWJ II.
be,.,.,_,.
.
aD IWIICWW 11M lnllll nfw etc.
For 9001 pumps, reconnect the solvent line
directly to pump head.
Install the new bushing, piston seal, and
retainer as shown.
Allliner
(oblerw orleidallon)
Spring Hauling
03-914171-QO:C
Rgure 3 Pump Hetld DeiJI/1
3

Number LC91 003
Issue Date 12(l2/90
Page 1 of _2_ _
Service Bulletin
Product Une:
Model Number
9010
SEPARATION SCIENCE
Originator
Dean Waterbu
varian
Revittlwed By
steve Schachter!
SIN Affected Apptoval Reviewed By
All Dave Pandrea
** ACTION ** -
REVERSED IHLET VALVE SEALS
SYMPTOM:
Any problems related to proportioninq, such as but not

limited to, varyinq retention times, loss of prime, erratic
flow rates, etc., that remain unsolved after performinq all
routine troubleshootinq procedures.
PROBLEM:
Instruments shipped from Walnut Creek in the past few months

may have faulty inlet valves installed. Field replacement
inlet valves may also be affected.
the assembly process.
The specific problem
relates to a sprinq seal that was inadvertently reversed in
When solvents are proportioned,
minute air bubbles pass throuqh the inlet valve via the
proportioninq valve ports and may collect on the exposed
sprinq within the seal. As this bubble qradually qrows
larqer, it may impede the operation of the inlet valve and
the above symptoms will be displayed. Do not assume an
affected inlet valve. to leak--it will seal very well.
SOLUTIOB:
When your patience has been exhausted, remove and carefully
disassemble the inlet valve and examine the position of the
seal. Usinq the attached inlet valve assembly drawinq,
remove the E-rinq securinq the sprinq retainer and separate
the body froa the .anifold. You should now be able to see
the seal within the .anifold, and the sprinq side should be
towards you as shown. If not, and only if a new inlet valve
is not available, pull the inlet valve poppet from the
manifold, and then cautiously push the seal out of the
manifold usinq the blunt end of the poppet. Reverse the
seal on the poppet shaft and reassemble the inlet valve.
Use extreae care to avoid damage to the seal ADd yellow

-seatipq surface of the yalve. Damage to the seat or seal
will cause solveDt leaks, BiDt: PUmpinq IPA throuqh the
system prior to disassembly will aid in removal of the seal
and reassembly of the valve. This service may be billed to
Warranty.
INLET VALVE SEAL
NOTE: SPRING-SIDE OF SEAL FACES OUT
""-
r
CD
t.tANIFOLO
(!) c
SPR lNG RET AI HER

POPPET (!)
RING, RETAINING
@
P?Pf\OVED FOR
NOV 0 G1~.:)
FABRICATION
DO NOT SCAlE ORAWIHQ
NOTES:
7 6 5 3
Number LC900 I 9
Issue Date 9/21(9Q
Page _ ____;I~ of ---=2..___
Service Bulletin
Product Une:
Model Number
SEPARATION SCIENCE
9010 Pump
Originator
Dean Waterbu
varian
ut creek instrument division
Reviewed By
Terry Sheehan
SIN Affected Approval Reviewed By
All Dave Pandrea
PROPORTIONING VALVE PROBLEMS
SYMPTOM:
A CUstomer performing gradient or isocratic analyses

requiring the use of two or more proportioning valves may
complain of shifting retention times for his peaks of
interest. (A secondary symptom might appear to be "bad
mixing"--actually long-term proportioning imprecision--which
shows up as baseline instability. See service Bulletin
LC90016)
PROBLBX:
Due to its one-step proportioning algorithm, correct

operation of the proportioning valves on the 9010 is more
critical than on previous pumps. Engineering has found that
variances in poppet diameters and finish affect closing
times of the valves, and that closing times in excess of 4.5
mSec of any valve can produce solvent composition
inconsistencies which may significantly reduce retention
time precision .
Until recently, closing times of proportioning valves were
not checked at the factory. As such, some valves may
operate on the border of acceptable, and may eventually
display the above symptom.
SOLUTION:
Poppets are now manufactured to a tighter specification and
with a better finish, and proportioning valves are
individually tested for closing times of better than 4 mSec.
current proportioning valve kits in Sunnyvale, P/H 03-

919496-90,. as well as 9010 Pumps shipped after June 1990
all include the newer pretested valves.
Page 2
Proportioning Valve Problems
When the above symptoms are encountered in the field, a bad

valve can sometimes be isolated by substitution (running
reservoirs AC rather than AB). An alternate method is to
measure the closing times of the individual proportioning
valves, and replace only the bad valve. This can be
accomplished using a special microphone probe attached to a
dual trace oscilloscope. A limited number of these probes,
with instructions, are being distributed to various Field
offices. Contact your local office or Dean Waterbury in
Walnut Creek for availability.
NOTES:
Proportioning Valve Failures
Dirty proportioning valves will also adversely affect
closing times. customers should be advised of information
found in the Maintenance Section of the Operator's Manual
regarding periodic flushing of the valves, especially when
using buffered solutions.
Iplet Valve Failures
An inlet valve, P/11 03-919085-90, which fails to close
completely or seal properly may cause solvent from one
reservoir to leak into the solvent line of another via the
pump head and proportioning valves, causing terrible
precision problems. Inlet valves should be torqued properly
or replaced if necessary to ensure a good internal seal.
USB TBB DIAGMQSTICS PROCBDQRBS IB THE OPERATOR'S KANQALI
Number_---.L.-C=-=9....,.0...,.0_18_ _ _ __
/~ueDaw_~B/~2~3~/~~~o_______
1 2
Page of
Service Bulletin
Product Line: SEPARATION SCIENCE
varian
9010 Pump Dean waterbu
All Dave Pandrea
BASELINE INSTABILITY/MIXER VOLUME DEFICIENCY
PROBLEM:
Complaints from both CUstomers and Sales/Service personnel
with regard to poor UV baselines have prompted Walnut Creek
to look closely at sol vent mixing characteristics of the
9010 Pump.
Problems are likely to occur when proportioning solvents in
which one has very high absorbance at the selected
wavelength, and the other has little or no absorbance.

example would be methanol in reservoir A and water/acetic
acid in B at 210 nm, or TFA gradients, also at the lower
wavelengths.
In the above cases, the baseline may exhibit an irregular
An
sine wave characteristic with a magnitude and period that

will vary with operating conditions, making integration
difficult at best. Appearing to be due solely to
insufficient m1x1ng, the causes are actually small
proportioning inconsistencies (a bi-product of the 9010's
single-stroke design), coupled with the small internal
volumes of the static mixer and U-tube damper. A quick
diagnosis of the problem can be made by simply premixing the
solvents and examining the baseline. The problem should
disappear.
SOLUTIOH:
When possible, manually prem1x1ng and degassing the mobile
phases will produce the best results. As this is not
possible with gradient chromatography, mixing volume must
then be increased. The standard accessory kit for the 9010
now includes the larger 1.4 mL volume LC 5560 static mixer,
P/N 03-905985-90, in addition to the standard 150uL mixer

LC90018
9010 Pump - Baseline rnstability/Mixer Volume Deficiency

Paqe - 2
Problems that cannot be solved by premixing, altering the

method, or by adding the larger static mixer, will probably
benefit with the use of a dynamic mixer. Varian has made
available from sunnyvale, as an accessory for the 9010 Pump,
the Rainin Dynamax mixer which has been shown to be very
effective at removing proportioning inconsistencies, thus
producing a usable baseline. Part number for this item is
00-997876-00. The price is $650 complete and delivery, when
ordered, will be three weeks. customer serviceable, parts
and supplies will be available from Rainin {information in
the instruction manual) and they will also honor their one-
year warranty.
Number LC90008
Issue Date KAJlCJI 2, 1990
Page 1 of 2
Service Bulletin
varian@
Product Line: SBPARATIOH SCIBHCB walnut creek instrument division
Model Number Originaror ~By
9010 PUm Dean waterb Kell Judah

SIN Affected ApptOVIII Reviewed By
Prior to 0565 Dave Pandrea
** ACTION **
Illlet Valve Replaceaent and Gap Chanqe
Recent chanqes to the 9010 factory test procedures have been made
which will affect some service procedures of the pump module, as
well. Beqinninq with 9010 S/H 0565, the Inlet Valve qap adjustment
was chanqed from .050" to .046". To prevent confusion in the Field,
the inlet qap specification for all 9010 pumps has been chanqed to
.046" and, as a consequence, the .050" qappinq tool has become
obsolete. The new .046" qappinq tool, P/B 03-919477-00, is included
in the Inlet Valve Kit, P/B 03-919085-90

The 9010 's which were oriqinally qapped at the 050" spec may need to
be recalibrated when an inlet valve is replaced and qapped at the new
specification. It should be noted that the majority of customers
will never see any differences in chromatography. However, symptoms
relatinq to chanqes in the qradient performance of the 9010, espe-
cially when workinq with percentaqes of less than 5% of one or more
solvents, may indicate the necessity for recalibration. When other
common causes have been ruled out and it has been determined that
calibration is necessary, the followinq three procedures should be
followed:
1. Readjust the inlet valve qap to the new spec of .046" accordinq
to instructions provided with the Replacement Inlet Valve Kit
(or usa procedure in the Service Manual, ATP section 1.5.1.).
2. Perfora the Optical Switch Adjustment. (See 9010 Service Man-
ual, ATP Section 1.5.3.)
3. Perform the Proportioninq Step Adjustment for reservoirs AB, AC,
and BC. (See 9010 Service Manual, ATP Section 1.5.4 throuqh
1.5.4.2.)
HOTB: The follovillq factors are critical for the proper calibra-
tioll of the 9010 PUmp:

Solvellts: The solvents used for the calibration both contain 2% iso-
propyl alcohol. IPA improves the wettinq properties of the water,
lesseninq the possibility of havinq air bubbles trapped in the Teflon
solvent line, or within the proportioninq valves and pump head.
Inlet Valve Replacement and Gap Chanqe Paqe 2
Deqassing: Vacuum degassing with ultrasonic agitation (or magnetic

stirring, manual shaking) is required to ensure that the pump can be
properly primed.
Priming: Priming each solvent liberally assures that the composition
of the sol vent in the pump head is identical to the composition in
the reservoir bottle. Connecting degassed IPA to the "C" proportion-
ing valve and priming with that solvent will improve the chances of
gett;nq the pump properly primed on the first try. (First prime "A",
fol~Qwed by "B", so that the lines are full of the reservoir solvent,
then "C" until no bubbles are seen. Then prime "B", followed by "A"
for another 10 strokes each.)
If the cali~ration procedures are attempted with a pump that is not
quite primed, incorrect settings aay ~ o~tained and erratic detector
traces may aake completing th~~cedure very difficult.
If you have received this Bulletin and have read its contents,
contact Dean Waterbury in Walnut Creek for a free gift. Offer good
until 3/20/90. To qualify you must be a Varian Shop Tech or Field
Service Engineer. Service Management is ineligible for this offer.
Number LC89009
Issue Date MARCH 17, 1989
Page _.::.1__ of 2
Service Bulletin
Product Line:
Model Number
9010 Pump
SIN Affected
SEPARATION SCIENCE
Orifl!nator
Dean waterbury
Approval
varian@
Reviewed By_
Ken Judah
ALL Below 246 Dave Pandrea
** INFORMATION ONLY. **
9010 PUMP BUSHING MATERIAL CHANGE
SYMPTOM:
Check Valve may clog prematurely causing performance problems

such as loss of prime, low volumetric efficiency, unstable
column backpressure, and the "clacking" noise indicative of a
faulty check valve.
PROBLEM:
Two bushings within the Pump Assembly, one located in the

pump head and one in the spring housing, were previously made
of Fluoroloy-X and could be identified by their rust color.
This material contains tiny glass rods which are shed from
the bushings as they wear with piston movement. The worn ma-
terial gets trapped in the 20-micron check valve frit which
can become clogged, giving the above symptoms.
SOLUTION:
Fluoroly-X bushings are now obsolete, and have been replaced

with new bushings ma,de of a PEEK material. Note that Part
Numbers of the two bushings have also been changed. The re-
placement bushings can be easily identified by their gray
color. They are less prone to wear, which will increase
check valve life and help prevent pump-related problems.
ACTION:
The Spring Housing bushing included with the Analytical Pis-

ton Replacement Kit, P/N 03-919102-90, is already made of
PEEK. If piston replacement is necessary, the bushing within
the Pump Head should also be changed to the new material.
Otherwise, bushing replacement can be performed whenever the
opportunity arises. This may be whenever the Pump Head is
removed, during seal replacement, when work to the Spring

Housing is performed, during PM's, etc.
This is not a mandatory change requiring immediate action.
W-2011 :1189
9010 PUmp Bushing Material Change - Page -2-
When dis-assembling the Pump for any reason, be sure to clean

~-
all internal parts thoroughly with isopropyl alcohol before
and during re-assembly. After re-assembly, the Pump should
be operated for approximately 15 to 20 minutes by pumping
isopropyl alcohol against some column backpressure to help
seat and lubricate replacement parts. (Be sure to remove
customer's column to prevent any damage - use your own test
column.)
PART NUMBERS:
Description
Front Piston Bushing 03-919509-00 03-919549-00

Spring Housing Bushing 03-919460-00 03-919548-00
REFERENCES:
ECO #16002
Drawing - 03-919082-00 ASSY, PUMP, TERNARY

LCSA90-1
03/22/90
SERVICE ADVISORY
WALNUT CREEK INSTRUMENT D
Engineering Review: Ken Judah
Technical support Manager: Dave Pandrea
INSTRUMENT
AFFECTED: 9010 Solvent Delivery System
PROBLEM: Because the 9010 proportions solvents during every

pump stroke, as opposed to the 5000/SSOO's four
strokes, closing times for the proportioning valves
are extremely critical. A valve with poor closing
times may exhibit retention time imprecision during
analyses, or non-linearity if gradient performance is
checked. To ensure the performance of the 9010 pump,
proportioning valves are carefully matched during the
test process before being shipped from Walnut Creek.
INTERIM
ACTION: The replacement proportioning valves obtained from
Sunnyvale Parts are not currently tested for their
gradient performance and, as such, may not solve a
given proportioning problem on a 9010 Pump. Be aware
of the fact that it may be necessary to try more than
one valve to solve a given proportioning problem.
Many problems associated with the proportioning valve.

can be attributed to improper maintenance. It may be
to your advantage to try cleaning or sonicating the
suspected valve before attempting any replacement.
CUstomers using buffered sol vents should adhere to
the advise found in the Maintenance Section of the
9010 Operator's Manual.

Number _ __...J,Ca&;qz.o~oz.wll004oeL-___.___ _
Issue Oate_...sAp*"rl1~...... 2~7L.-!:..Ol9~92L-
Page 1 of _:1...___
Service Bulletin varian@

Product Une: SEPARATION SCIENCE chromatography systems
9000 Series LC DeanWaterb
SIN Aflected ApptrNal
All Dave Pandrea
INFORMATION ONLY
9000 SERIES LC-cHANGES TO STANDARD ACCESSORY KITS
As an attempt to lower the overall cost of goods for LC products shipped out of Walnut
Creek, Chromatography Systems bas JUde some duulges to the StuUrd Aftessory Kits
for the 9001/9010,9050, and 90S. 1be followiDg ~are mostly minor and involve
the removal of an excess of ~es, or the removal of items deemed to be uDI!f'W!S8ry for
the sua:essful installation of the instrument. If you experience difficulties during
installations due to any of these changes, please contact me in Tech Support, or Gary Burce
in LC Marketing.
9010j9001 Pmgp
Removed the larger 1.4mL Static Mixer (03-905985-90, 9010 only). ~be ordered
separately, if required, for special sohent mixing situatiODL (see Semce Bulletin
1.00018.) .
Removed Priming Bulb (03-9QS640.00). 9010/9001 is self-primiDg w/purge valve
Cved Wrench and Screw Driver from tool kit. Customer shoUld
bb. .
have
these in
Removed Piston Seal Kit (03-919101-90). Substituted a siDgle Seal (03-919397-00)
with instructions fot entire kit.
Removed two of three ema O.Su Mixer Filters (rl-18038S-00). A single spare
reDDin~
Removed one of three 1/1fl' SST DiltS (15-001410.00) and ferrules (28-694533-00).
Three each are not required for iDstaDtion.
9050 Deteetor
Re:IIICll'ed one Signal Cable (02-001954-00). Two are not required unless external
. event is used. .
9Q6SPo\ychrom
Removed one Si&Dal Cable (02-001954-00). With GPIB, none recpred.
Removed two o~};l~ ~ S/B :Fuses (67-135415-00~ aDd two of three O.S
~;:=:c,sesJ~/Wm'U: (if.OO::iO:r:nt1~:rB:=ta (28-
694533-00). Four each not reQUired for installation.
- Removed a 4 x 1/1fJW SST 1'ube ~ously used on the cfiscontinued Ad~le
~ Restrictor. (New preadjusted 40 PSI Restrictor does not require
tubing.) .

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VARIAN

Instrument Group/Walnut Creek Division

Varian Associates, Inc. 1994 Printed in U.S.A. 03-914436-40:3

Spare Parts Availability

U.S. Sales and Service Information

Send Orders, Bids and Correspondence to:

s{ Heat: Very hot surfaces

instrument. hervorrufen. Tragen Sie est recommande durant Ia radiaci6n ultravioleta.

Fire: The potential for fire

When safe procedure is in doubt, contact

4. Do not allow flammable and/or toxic solvent

WARNING: This equipment generates, uses, and can radiate

residential area is likely to cause interference in which case the

1 . Installation Procedures and Special Requirements

10. Manual (labeling) I Revision Date

3.4.1 START . . . 3-3

4. 7.5 RELAYS . . . . . . . . . . . . 4-11

6.4 Troubleshooting Procedures . . . . . . . . . . . 6-7

1.2 How to Use The Manual

Section 3 System Description

Section 6 Maintenance and Service

Appendix B Fault Table

Appendix C Advisory Displays

Appendix D Maintenance Reference Material

Appendix E Injector Valve Reference Material

NOTE: An optional solvent reservoir holder designed to hold three

2.2 Receiving Inspection

Varian Chromatography Systems

NOTE: The contents of the Standard Accessory Kit are itemized

2.4 Location of Solvent Delivery Module

2.5.2 Voltage and Fuse Rating Check

Figure 2-1 9012 Module and Solvent Reservoirs

Neutral Hot Neutral Hot

Ground (green/yellow or green)

2.5.2. 1 Checking _the Voftage Selection

Figure 2-4 Main Power Fuse ReplacementNoltage Selection

2.5.2.2 Checking and/or Changing Power Fuses (F1 J

2.6 Signal Cable Connections (Rear Panel)

2.6.3 J3-J8 RELAY 1 through RELAY 6

Figure 2-5 Correct Matching of Molex Connectors

2.6.4 J9 and J1 0 Synchronization Signal Ports

General Purpose Gables

2.7 Solvent Line Connections

Figure 2-6 Hydraulic System Plumbing

NOTE: It is important that you install these filtars. They prevent

should be labeled A, 8, and C) are connected to the matching proportioning valve .

NOTE: It is critical to your chromatographic results that the correct

Figure 27 Solvent Delivery System with a Valve Mounting Assembly Attached

Figure 2-8 Reservoir To Pump Head Fitting Assembly

2.8 Mounting Peripheral Components

2.9 Pneumatic Requirements (Compressed Gas)

2.10 Post Installation Leak Check

2.11 Powered Events Module (PEM)

2.12 Serial Printer Installation

Table 22 RS232C Configurations for the 9012 Serial Printer

3.2 Pump Hardware

3.2.1 Piston Stroke Control

3.2.2 Solvent Proportioning (Star 9012 SDS)

F'~gure 3-1 Pump Components

3.2.3 lsocratic Solvent Delivery (Star 9002 SDS)

3.3 Front Panel Display

3.4 Front Panel Keys

Keys located in the OPERATION section of the front panel