ELGA PURELAB flex 1 User manual

Service Manual
PURELAB flex
Introduction Issue 4 Page 1of 45
Covers the following products:
PURELAB flex 1
PURELAB flex 2
ELGA LabWater assumes that the technician using this manual has a working knowledge of
water purification systems and has attended an ELGA LabWater technical training course.
This manual is correct for use with the PURELAB range of systems mentioned above. For
information on other products from ELGA LabWater please refer to the relevant service
manual available from www.elgalabnet.net.
If you would like to contact us with regards to training or give us any feedback on this
manual please contact technical support at [e-mail]

PURELAB flex
Introduction Issue 4 Page 2of 45
Manual Revision Notes
Issue Number
Date Issued
Details of Revision
1
26th April 2010
First Issue
4
25th January 2012
Service Bulletins Added
Product Part Numbers
Product Type
Part Number
PURELAB flex (Optional Purification Pack)
PF1XXXXM1
PURELAB flex (Purification Pack, DI & TOC)
PF2XXXXM1
Copyright Note
The information contained in this document is the property of VWS (UK) Ltd, trading as ELGA
LabWater, and is supplied without liability for errors or omissions.
No part of this document may be reproduced or used except as authorized by contract or other written
permission from VWS (UK) Ltd. The copyright and all restrictions on reproduction and use apply to all
media in which this information may be placed.
VWS (UK) Ltd. pursue a policy of continual product improvement and reserve the right to alter without
notice the specification, design, price or conditions of supply of any product or service.
© VWS (UK) Ltd. 2010 –All rights reserved.
ELGA®is a registered trademarks of VWS (UK) Ltd.

PURELAB flex
Introduction Issue 4 Page 3of 45
Index
Section Number / Title
Sub Section Title
Page Number
1 –Process Descriptions
Product Specific Flow Paths
5
Process Flow Diagrams
7
2 –Parts Identification
Consumables
9
Accessories
10
Common / Basic Parts
11
Drawings
13
3 –Electronics
Display Icons
23
Software History
24
PCB Details
24
PCB Drawings
25
Battery Replacement
28
Electrical Parameters
29
4 –Maintenance
Service Recommendations
30
Operational Parameters
31
Calibration
32
Sanitisation
36
5 –Specifications
System Specifications
37
6 –Troubleshooting
Trouble shooting
39
7 - Appendix
Appendix Index
40
Appendix A –Commissioning Report
41
Appendix B –Routine Service Report
42
Appendix C –Calibration Certificate
44
Appendix D –Service bulletins
46

PURELAB flex
Introduction Issue 4 Page 4of 45
Health and Safety
WARNING!
WARNINGS ARE GIVEN WHERE FAILING TO OBSERVE THE
INSTRUCTIONS COULD RESULT IN INJURY OR FATALITY.
CAUTION!
Cautions are given where failure to observe the
instructions could result in damage to the equipment,
associated equipment and processes.
Environment
CAUTION!
Clean dry indoor. Temp 5-40°C. Humidity max
80% non-condensing.
Failure to follow the environmental specification could
result in damage to the system.
The PURELAB flex is not designed for use in fume
cupboards where chemicals could damage the system.
Display Handset
CAUTION!
The display handset is not designed to be submersed in
water.
Electricity
WARNING!
POSITION THE POWER SUPPLY SO THAT IT CANNOT COME
INTO CONTACT WITH WATER.
Ultraviolet Light
WARNING!
UNDER NO CIRCUMSTANCES SHOULD THE LAMP BE
CONNECTED AND ACTIVATED WHEN OUTSIDE THE
HOUSING. EXPOSURE COULD CAUSE SERIOUS INJURY TO
EYES AND SKIN.
ENSURE THE UV LAMP IS DISPOSED OF IN ACCORDANCE
WITH LOCAL REGULATIONS.
Residual Biostat
WARNING!
DURING THE COMMISSIONING CYCLE TRACE RESIDUAL
BIOSTAT IS FLUSHED FROM THE SYSTEM. A MATERIAL
SAFETY DATA SHEET IS AVAILABLE UPON REQUEST.
Control of Substances Hazardous to Health (COSHH)
Material safety data sheets covering the various replaceable Purification Packs are available upon
request.
If in doubt always seek advice before commencing work on ELGA products. Please contact the technical
support department at [e-mail] for more information.

Section 1 –Process Description
Section 1 –Process Description Issue 4 Page 5of 45
Product Specific Process Descriptions & Flow Paths
flex 1
Process Flow
1. The pre-purified water enters the system through the inlet solenoid valve and flow sensor (FS1)
2. It then passes through recirculation pump (P1), quality sensor (QS1*) and the optional DI pack
3. The water quality is then measured by a quality sensor (QS2*) and a temperature sensor (TS1)
before reaching the dispense handset.
4. When the system is not dispensing, the water will flow through the handset and a 15 psi non
return valve (V3) before returning to the recirculation pump.
5. When the system is dispensing, valve (V2) will open and water will be directed out of the
dispense nozzle.
* This system includes 2 sensors but only one is active at any time. QS1 is active when there is a
bypass block installed, QS2 is active when the DI pack is installed.
1
Inlet from
pre-purified
source
Flow Lines
P1
QS2
TS1
V1
V2
Notes:
V3
Optional
DI Pack
FS1
QS1

PURELAB flex
Section 1 –Process Description Issue 4 Page 6of 45
Flex 2
Process Flow
1. The pre-purified water enters the system through the inlet solenoid valve and flow sensor (FS1)
2. It then passes through recirculation pump (P1), Quality sensor (QS1) and temperature sensor
(TS1)
3. The water passed through the 185/254nm UV and quality sensor (QS3) before entering the
optional DI pack. Quality sensor (QS3) is used to monitor TOC levels.
4. The water quality is then measured by a quality sensor (QS2) and a temperature sensor (TS2)
before reaching the dispense handset.
5. When the system is not dispensing, the water will flow through the handset and a 15 psi non
return valve (V3) before returning to the recirculation pump.
6. When the system is dispensing, valve (V2) will open and water will be directed out of the
dispense nozzle.
1
Inlet from
pre-purified
source
Flow Lines
P1
QS2
QS1
TS2
V1
V2
TS1
FS1
QS3
Notes:
V3
Optional
DI Pack

PURELAB flex
Section 1 –Process Description Issue 4 Page 7of 45
Process Flow Diagrams
The Process Flow Charts are a simplified visual representation of the software routines to assist a
trained technician to understand the process flow and troubleshoot symptoms.
Commissioning
Commissioning
Complete
Connect the
power supply to
the PURELAB flex
System dispenses
5 litres
V1 opens
P1 starts
V2 opens
Press Accept
Turn on the
water supply to
the flex and
place a 5 litre
container under
the outlet
No
Highlight No and
press Accept
Yes
Remove Bypass
pack and install
DI pack. High
light Yes and
press accept
Do you want to
install a DI pack?
Set Language
High light correct
language and
press Accept
V2 Closes
System returns
to recirculation
mode

PURELAB flex
Section 1 –Process Description Issue 4 Page 8of 45
Sanitisation
Press accept
V1 closes and V2
opens to release
pressure from
the system
Remove and
dispose of the
sanitisation pack
and insert the DI
or bypass pack
Water is purged
from the system
to ensure that
all the air is
removed from
the pack
Press accept
A 2 minute timer
will start to count
down on the
screen
Sanitisation
complete
System returns
to normal
operation
A 10 minute
timer will start to
count down on
the screen
Hold down PF4
(see page 23) to
access the menu
Press accept to
start the
sanitisation
Remove the DI
or bypass pack
and insert the
sanitisation pack
V1 closes and V2
opens to release
pressure from
the system
Place a 1 litre
container under
the dispense
nozzle and press
accept
Highlight
sanitisation and
press accept
Water is purged
from the system
to ensure that
all the air is
removed from
the pack

Section 2 –Parts Identification
Section 2 –Parts Identification Issue 4 Page 9of 45
Consumables
Part Number
Description
LC208
Purification Pack
LC210
185/254nm UV Lamp
LC209
Sanitisation Pack
LC197
POU Biofilter
LC145
POU 0.2µ Microfilter
LC211
DI Pack for LA731 Pre-conditioning kit
LC208 –
Purification pack
LC210 –185/254
UV lamp
LC145 –POU 0.2µ
Microfilter
LC197 - POU
Biofilter

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 10 of 45
Accessories
Part Number
Description
LA731
Pre-conditioning kit (DI pack not included)
LA732
Foot Switch
LA735
Wall mounting kit
LA652
Pressure regulator
LA728
Bypass pack
LA736
BMS Kit
Printer
Though a printer can be connected to the PURELAB flex, ELGA Labwater does not supply a printer for
this application. For details of recommended printers and how to configure them to work with the flex
please see Product bulletin PB0011-10-Issue 1 available on our extranet site www.elgalabnet.net.
LA652 –Pressure
Regulator
LA731 –Pre-conditioning
Kit and
LC211 DI Pack
LA735 –Wall
Mounting Kit
LA732 –Foot
Switch

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 11 of 45
Common / Basic Parts
Below is a list of all common parts used in the PURELAB flex.
Key:
Not used
Number of parts used
Part Number
Description
flex 1
flex 2
ADAP32797
ADAPTOR (PARA) 8mm-3/8"BSP"
2
2
BALL38832-03
UV BALLAST BOX ASSY
1
BALL38877
BALLAST - BL 14W 24V
1
BASE38803
BASE MOULDING FLEX
1
1
BEND30108
BEND FLOW CLIP-ON 5/16"OD
2
2
BULK38818
CARTRIDGE BULKHEAD FITTING
1
1
BUSH38879
BUSH FILTER BULKHEAD
1
1
CAPS32084
CAP END PVC 185nm UV HOUSING
1
CCAP39125
ARM LOCK COVER CAP
1
1
CLAM39128
ARM CLAMP RING
1
1
CONN22494
CONNECTOR TERMINAL CRIMP
2
2
CONN38836
CONNECTOR SHORT CARTRIDGE
7
7
CONN38836
CONNECTOR SHORT CARTRIDGE
1
1
CONN38836
CONNECTOR SHORT CARTRIDGE
2
COUP38878-02
COUPLING FILTER BULKHEAD
1
1
COVR38804
COVER REAR
1
1
COVR38811
COVER CENTRAL TOP
1
1
COVR38847
COVER REAR FILLER
1
1
COVR39021
USB PROTECTIVE COVER
1
1
DARM38805
DISPENSE ARM
1
1
DISC32086
DISC SEALING 185nm UV HOUSING
1
ELBW30106
ELBOW EQUAL 5/16" OD TUBE"
1
ELBW30903
ELBOW STEM 5/16OD x 5/16"OD"
1
1
ELBW30903
ELBOW STEM 5/16OD x 5/16"OD"
2
1
EXTR38801
EXTRUSION REAR TOWER
2
2
FANM39062
FAN MOUNT BREAKAWAY STYLE
2
4
FILT36123
FILTER 1/2" ST/ST WASHER
1
1
FOOT38841
BUMPER FOOT - PD2014C
4
4
GASK38808
BASE GASKET
1
1
GROM31309
GROMMET QUICK FIT
1
GROM38806
GROMMET CABLE
1
HOLS38949
HOLSTER
1
1
HOUS38855-03
2" UV HOUSING WELD ASSY
1
INST38983
QUICK START GUIDE FLEX
1
1
LA728
BYPASS CARTRIDGE FLEX
1
1
LC210
UV LAMP - PURELAB FLEX
1
MLDG39087
CLAMP BAR END CAP
2
2
NUTS20816
NUT M6 HEX FULL
1
1
NUTS20865
NUT M4 HEX FULL
3
PCBS38875
CONTROLLER BOARD FLEX
1
1
PIST38816-02
CARTRIDGE PISTON
1
1
PLAT38815
CARTRIDGE MOTION PLATE
1
1
PLAT38825
BASE GLAND PLATE
1
1
PLAT38826
BASE COVER PLATE
1
1
PLAT38880
UV BLANKING PLATE
1
PLUG38882
BLANKING PLUG CODE 466929
1
1
POWE38971
POWER SUPPLY FLEX
1
1

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 12 of 45
Part Number
Description
Flex 1
Flex 2
PU010418
CONNECTOR 8-8MM PM0408E
1
PUMP38824
PUMP DIAPHRAGM 88-ELG-38824
1
1
RING32087
RING O" BS115 RED SILICON"
1
RING32088
RING O" BS119 RED SILICON"
1
RING38850
O RING 3.5 x 1.0mm NITRILE X/S
2
RING39086
PISTON SECURING RING
1
1
RING39091
SILICONE O'RING
2
2
SCRW31313
SCREW No.4 x 3/8" PAN HEAD"
4
4
SCRW36138
SCREW SELF TAPPING NO.4 x
2
2
SCRW36846
SCREW M4x35mm POSIDRV PAN
2
2
SCRW36895
SCREW M3x8mm POSIDRV PAN HEAD
2
SCRW37566
SCREW SELF-TAPPING NO6 x 3/8"
2
SCRW38321
SCREW - M3 x 6mm POZI PAN HEAD
2
SCRW38799
SCREW M3 X 6
2
SCRW38888
DELTA SCREW M2.5 X 8LG
6
7
SCRW38889
DELTA SCREW M2.5 X 16LG
2
2
SCRW38890
DELTA SCREW M4 X 12LG
5
5
SCRW38898
SCREW No8 X 3/8 POSI HD FLANGE
11
11
SCRW38963
POZI HEAD TAPTIE SCREW C'SK
4
4
SCRW38964
POZI HEAD TAPTIE SCREW
6
6
SCRW38969
SCREW M3 X 8
3
5
SCRW38970
SCREW M6 X 12
1
1
SCRW39079
4-40UNC X 5/16" POZI PAN HEAD
2
2
SCRW39126
ARM BUTTON SCREW
1
1
SCRW39209
M6 X 6 SOCKET HEAT SET SCREW
1
1
SEAL38838
FLAT SEAL - 17DIA x 12DIA x 2
2
SLEV37309
SLEEVE EXPANDABLE NEOPRENE
2
2
SP925
LINE CELL
2
3
SP926
FLOW SENSOR
1
1
SP928
PURELAB FLEX1 WIRING ASSY
1
SP929
FLEX DOOR ASSY RIGHT HAND
1
1
SP930
FLEX DOOR ASSY LEFT HAND
1
1
SP964
DISPENSER ASSEMBLY
1
1
SP936
PURELAB FLEX2 WIRING ASSY
1
SP940
FAN ASSY PURELAB FLEX
1
2
SPAC38978
SPACER - NYLON M3 X 37
1
SPRG38843
COMPRESSION SPRING
1
1
SPRG39051
COMMPRESSION SPRING
2
STUD39127
ARM CLAMP
1
1
TABS10697
TAB BRS NI PLT 45DEG
4
TERM38835
CONVEX RADIUS HD PROBES
2
2
TUBE31957
TUBE HIPURE 8mm OD x 5mm ID
5
5
TUBE38870
QUARTZ THIMBLE FLEX
1
VALV37258
VALVE NON RETURN 3/8" BSPF 1
1
1
VALV38881
SOLENOID VALVE FLEX
1
1
WASH10534
WASHER 19mm OD x 11mm ID x
1
1
WASH11483
WASHER 1.1/8ODx5/16IDx1/8"
1
WASH12250
WASHER M3 PLAIN
4
4
WASH20879
WASHER M4 SPRING
3
WASH39037
WASHER M3 SPRING A2
2
WASH39037
WASHER M3 SPRING A2
4

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 13 of 45
Drawings
Please see below details of the drawings located in this section of the manual and which
PURELAB flex they correspond to.
Flex 1
Description
Page Number
MAIN BODY - EXTERNAL PARTS
14
MAIN BODY –INTERNAL PARTS
15
SP931 DISPENSER ARM ASSY
17
SP921 BASE MOULDING BOTTOM
18
SP921 BASE MOULDING TOP
19
SP919 CARTRIDGE BULKHEAD ASSY
21
SP926 FLOW SENSOR ASSEMBLY
22
Flex 2
Description
Page Number
MAIN BODY (EXTERNAL PARTS)
14
MAIN BODY –INTERNAL PARTS
16
SP931 DISPENSER ARM ASSY
17
SP921 BASE MOULDING BOTTOM
18
SP921 BASE MOULDING TOP
19
SP923 UV HOUSING ASSY
20
SP919 CARTRIDGE BULKHEAD ASSY
21
SP926 FLOW SENSOR ASSEMBLY
22

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 14 of 45
Main Body –External Parts
Item
Part Number
Description
1
SP964
Dispense Handset Assembly
2
SP929
Left Hand Door
3
SP930
Right Hand Door
4
COVR38804
Rear Cover
1
3
2
4

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 15 of 45
Main Body –Internal Parts (flex 1 only)
Item
Part Number
Description
1
ADAP32797
Adaptor Straight 8mm TUBE x 3/8” BSP
2
ELBW30903
Stem Elbow
3
SP919
Cartridge Bulkhead Assembly
4
SP925
Line Cell and Thermistor Assembly
5
TUBE31957
8mm OD Clear Tube
6
VALV37258
Non Return Valve 3/8” BSPF 1 Bar
4
1
6
1
3
2
4
5

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 16 of 45
Main Body –Internal Parts (flex 2 only)
Item
Part Number
Description
1
ADAP32797
Adaptor Straight 8mm TUBE x 3/8” BSP
2
ELBW30903
Stem Elbow
3
SP919
Cartridge Bulkhead Assembly
4
SP923
UV Housing Assembly
5
SP925
Line Cell and Thermistor Assembly
6
TUBE31957
8mm OD Clear Tube
7
VALV37258
Non Return Valve 3/8” BSPF 1 Bar
4
1
7
1
3
5
2
6

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 17 of 45
SP931 –Dispenser Arm Assembly
Item
Part Number
Description
1
CCAP39125
Arm Lock Cover Cap
2
CLAM39128
Arm Clamp Ring
3
DARM38805
Dispenser Arm
4
HOLS38949
Holster
5
LABL38996
Manual Retaining Label
6
SCRW38970
M6 X 12 Machine Pan Screw
7
SCRW39126
Arm Button Screw
8
SCRW39209
M6 x 6 Socket Head Set Screw
9
STUD39127
Arm Clamp
6
2
1
3
4
7
9
8
5

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 18 of 45
Item
Part Number
Description
1
BUSH38879
Filter Bulkhead Bush
2
CONN38836
8mm Short Cartridge
3
COUP38878
Filter Bulkhead Coupling
4
FANS38837
Fan 24v
5
FILT36123
Stainless Steel Mesh Filter
6
GASK38808
Base Gasket
7
PLAT38825
Base Gland Plate
8
PLAT38826
Base Cover Plate
9
SP926
Flow Sensor Assembly
10
VALV38881
Solenoid Valve
11
WASH10534
Washer
1
5
3
10
9
6
4
7
8
2
11
SP921 –Base Moulding Assembly - Bottom

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 19 of 45
SP921 –Base Moulding Assembly - Top
Item
Part Number
Description
1
ELBW30903
Stem Elbow
2
PIST38816
Cartridge Piston
3
PUMP38824
Recirculation Pump
4
RING39091
O-Ring
5
SPRG38843
Compression Spring
2
5
4
1
3

PURELAB flex
Section 2 –Parts Identification Issue 4 Page 20 of 45
Item
Part Number
Description
1
BALL38832
UV Ballast Box
2
BALL38877
UV Ballast
3
CAPS32084
Threaded Cap
4
DISC32086
Lamp Sealing Disk
5
FANS38837
Fan 24v
6
HOUS38855
UV Housing
7
PU010418
Adaptor Equal 8mm OD
8
RING32087
O Ring BS115
9
RING32088
O Ring BS119
10
SP925
Line Cell
11
SP936
UV Lamp Wiring Assembly
12
TUBE31957
8mm OD Clear Tube
13
TUBE38870
Quartz Thimble
5
4
8
3
9
13
6
2
1
12
7
11
10
SP923 –UV Housing Assembly