Flow Control Test
Diagnostics (UltiMate 3000 Series)
Flow Control Test
Run the test to check the condition of the flow control system of the FLM-3x00 flow manager. The test verifies the calibration of the column pressure sensor and checks if the flow control valve (FCV) builds up sufficient back pressure to operate properly. Further test steps are used to check the flow sensor and flow splitter.
Dionex recommends performing only if a flow control valve-related error message is displayed (e.g., 'Flow Control Valve Failure!' or 'Valve Position Limit') or when the column flow or pressure is outside the expected range. The test helps to determine whether the error was caused by contamination of a component or by a mechanical failure.
Tip:
The test comprises several independent steps. Only if the flow manager passes all the test steps, the test will be completed. If it fails a single step, the test is aborted. In this case, take the troubleshooting instructions indicated on the panel before repeating the test.
Required materials and preparatory measures
To run this test, you need an UltiMate 3000 pump, HPLC-grade water as an eluent, and a blind nut. Dionex recommends using the FCV Maintenance Kit (Dionex part no. 6720.3195), which contains a blind nut, as well as all the required materials and detailed instructions for cleaning the FCV.
Caution:
Strictly observe the cleaning instructions shipped with the kit. Improper handling can cause damage to the FCV.
Note:
Perform this test using pure water. To prevent the formation of algae, the water should contain 0.1 to 0.2% formic acid or acetone. Other solvents, including premixed solvents, may lead to incorrect test results. If none of your eluent channels uses HPLC-grade water, connect the eluent bottle that contains water to an eluent channel (A, B or C) of the micro pump and thoroughly purge this channel.
How to
On the first test page, click Next> to proceed with the settings required for the test.
Tip:
If the Next> button is not active on the first test page, the flow manager is not connected in Chromeleon or is in Standby mode. Connect the flow manager to Chromeleon before you continue by selecting the Connected check box. If the flow manager is in Standby mode, also clear the Standby check box.
Optional: Enter a descriptive text in the Comments field, e.g., the reason why the test is performed.
Test Step 1: Prepare System
Prepare the system:
Reduce the flow rate to 0 ml/min by clicking Execute. This will automatically set the flow to the required value.
Select the eluent channel for water.
Remove the tubing from the flow splitter column outlet to the autosampler or switching valve and confirm by clicking Done.
Close the front panel door. The system is purged. A beep indicates that the purging is finished.
The FCV Maintenance Kit includes a blind nut (do not use other blind nuts as they may damage the flow splitter column outlet). Install the blind nut at the splitter outlet and confirm by clicking Done. Then close the front panel door. The system is now prepared.
Test Step 2: Sensor Calibration
Click Next> to start the calibration of the pressure sensor. A beep indicates that the calibration is finished. The result is shown in the Details section on the panel. If calibration fails, check whether the pump operates properly on the eluent channel used for the test, and whether all air has been removed. Another reason why the calibration has failed may be that the FCV is contaminated or defective. Clean the FCV using the FCV Maintenance Kit and repeat the test.
Test Step 3: FCV Test
If the test was passed, click Next> to start the test for the flow control valve (FCV Test).
If the FCV Test fails, verify that the connections do not leak and the pump operates properly. Repeat the test and clean the flow control valve using the FCV Maintenance Kit, if necessary. If the test still fails, the valve must be replaced.
When the FCV test is finished, the maximum column pressure with which the FCV can be operated is displayed on the panel. For a clean FCV, the maximum pressure is between 345 and 350 bar. If the pressure is lower, the FCV will usually operate as long as the actual column pressure is below the test result value.
If the pressure is equal or higher than the expected column pressure, clean the FCV using the FCV Maintenance Kit. If the FCV fails during operation, the system will always detect this failure and issue an error message.
Test Step 4: Flow SensorTest
If the FCV Test was passed, click Next> to start the Flow Sensor Test:
Remove the blind nut from the flow splitter column outlet. Do not close the outlet. Confirm by clicking Done.
Close the flow manager's front panel door. The test starts. Follow the instructions on the panel(s).
If the Flow Sensor Test fails, the flow sensor must be replaced. In this case, please contact Dionex Service.
Test Step 5: Flow Splitter Test
Clicking Next> takes you to the last step, i.e., the Flow Splitter Test:
To test the flow splitter, replace the blind nut on the flow splitter column outlet and confirm by clicking Done.
Close the front panel door. The test starts. Follow the instructions on the panel(s).
If the Flow Splitter Test fails, replace the splitter cartridge. For information how to replace the splitter cartridge, refer to the Operating Instructions.
Tip:
For splitters with a split ratio < 1:50, the split ratio is not indicated in the test report ("n.a." is displayed).
For splitters with a split ratio > 1:50, the test report also indicates the split ratio.
To view or print the report with details of the analysis, click Finish and Preview Report. Click Finish to quit the test panel without viewing the report. For information about troubleshooting, click Open Troubleshooting Guide.
For general information, refer to 
Diagnostics (UltiMate 3000 Series).
For more diagnostic tests for the UltiMate 3000 flow manager, refer to:
Thermo Unit Test
Gas Sensor Test