ELGA Purelab flex 3 User manual

Service Manual
PURELAB flex
Introduction Issue 3 Page 1of 52
Covers the following products:
PURELAB®flex 3
PURELAB®flex 4
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 3 & 4
Introduction Issue 3 Page 2of 52
Manual Revision Notes
Issue Number Date Issued Details of Revision
1 6
th
January 2011 First Issue
2 6
th
July 2011 Multiple Changes
3 25th January 2012 Service Bulletins Added
4 21 February 2012 Feed water chlorine value changed
Product Part Numbers
Product Type Part Number
PURELAB flex 3 UV,DI & RO reservoir system PF3XXXXM1
PURELAB flex 4 direct supply reservoir system PF4XXXXM1
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. 2011 – All rights reserved.
ELGA®is a registered trademark of VWS (UK) Ltd.

PURELAB flex 3 & 4
Introduction Issue 3 Page 3of 52
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 10
Accessories 11
Common / Basic Parts 12
Drawings 15
3 – Electronics Display Icons 27
Warnings / Alarm Codes 28
Software History 30
PCB Drawings / Details 31
Battery Replacement 33
Electrical Parameters 34
4 – Maintenance Service Recommendations 35
Operational Parameters 36
Calibration 37
Sanitization 42
5 – Specifications System Specifications 43
6 – Troubleshooting Trouble shooting 45
7 - Appendix Appendix Index 46

PURELAB flex 3 & 4
Introduction Issue 3 Page 4of 52
Health and Safety
ELGA LabWater products have been designed to be safe, however it is
important that personnel working on these units are aware of any potential
dangers.
Electricity
Most ELGA products are powered from a mains electrical supply, this could be up to 265Vac. Please
ensure that when performing maintenance on these units that the power supply is isolated whenever
possible before any work is carried out.
Please use caution when working on systems connected to a main
power supply. If in doubt do not atempt any work on a product unless
the power supply is isolated.
Water Pressure
When possible the main water supply to a product should be isolated and residual pressure released
prior any work being carried out on the unit to prevent injury to yourself and others.
Sanitization Chemicals
During the sanitization of our products you may be required to handle chemicals such as Chlorine or
Hydrogen Peroxide. Care should be taken to ensure the safety of yourself and others around you while
using these chemicals. A material safety data sheet conforming to COSHH regulations is provided with
the chemical, please read this carefully before carrying out the sanitization.
Safety goggles and gloves should be worn at all times while handling
any chemical substance.
Ultra-violet Light
Many of our products are fitted with an Ultra-violet lamp, this lamp is enclosed in a stainless steel
housing to ensure that personnel are not exposed to UV light.
Under no circumstances should a lamp be connected and activated
outside the housing.
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 3 Page 5of 52
Product Specific Process Descriptions & Flow Paths
PURELAB flex 3
Process Flow
1. The potable water enters the system through the inlet solenoid valve before flowing into the RO
module.
2. The RO concentrate flows directly to drain through a flow restrictor.
3. The RO permeate flows through a non return valve into a 3 way solenoid valve. The solenoid
valve will direct the permeate to drain for the first 4 minutes before directing it to the reservoir.
4. The reservoir can hold up to 7 liters of water, it can be manually emptied using hand valve V4.
5. When the reservoir reaches 0.25 liters the pump will start to draw water into the recirculation
system, the water passes through quality and temperature sensors QS2 and TS2 and into the
UV chamber.
6. From the UV chamber the water passes through quality sensor QS3 and flow sensor FS1 before
entering the DI pack. The flow sensor FS1 is used to control the auto volume dispense.
7. From the DI pack the water passes through quality and temperature sensors QS1 and TS1
before entering the dispense hand set V2.
8. The water then returns to the reservoir via a non return valve.
9. Once the reservoir reaches 7 liters the inlet solenoid valve will close, this valve will not open
again until the reservoir reaches the refill level as specified in the menu or the level of the tank
reaches 0 liters.
V1
FS1
TS2
QS2
NRV1
NRV3
V4
LS1
V3
NRV4
QS3
NRV2
P1
TS1
QS1
V2
8
7
6
5
4
3
2
1
9
Flow Lines

PURELAB flex 3 & 4
Section 1 – Process Description Issue 3 Page 6of 52
PURELAB flex 4
Process Flow
1. The pre-purified water enters the system through the inlet solenoid valve into a flow restrictor.
2. The water then enters a 3 way solenoid valve. The solenoid valve will direct the inlet water to
drain for the first 4 minutes before directing it to the reservoir.
3. The reservoir can hold up to 7 liters of water, it can be manually emptied using hand valve V4.
4. When the reservoir reaches 0.25 liters the pump will start to draw water into the recirculation
system, the water passes through quality and temperature sensors QS2 and TS2 and into the
UV chamber.
5. From the UV chamber the water passes through quality sensor QS3 and flow sensor FS1 before
entering the DI pack. The flow sensor FS1 is used to control the auto volume dispense.
6. From the DI pack the water passes through quality and temperature sensors QS1 and TS1
before entering the dispense hand set V2.
7. The water then returns to the reservoir via a non return valve.
8. Once the reservoir reaches 7 liters the inlet solenoid valve will close, this valve will not open
again until the reservoir reaches the refill level as specified in the menu or the level of the tank
reaches 0 liters.
Notes:
2
V2
TS1
QS1
FS1
QS3
TS2
QS2
P1
NRV2
NRV1
LS1
V4
NRV3
V3
V1
1
3
4
5
6
7
8
Flow Lines

PURELAB flex 3 & 4
Section 1 – Process Description Issue 3 Page 7of 52
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.
PURELAB flex 3
Commissioning
Timer reads 30 minutes
Checks purity every 5 minutes until it
reaches quality
Connect the power supply to the
PURELAB flex
Reservoir reaches >2 liters, P1 turns on
After 1 Hour V3 closes.
Reservoir starts to fill
V1 and V3 open
System displays estimated
commissioning 3:00:00
Turn on the water supply to the flex and
press accept
Install the Composite Vent filter and
Purification Pack
Set Language
Highlight correct language and press
Accept
Reservoir reaches 7 liters, V1 closes
Recirculates for 30 minutes then checks
for water purity
Reservoir reaches >3 liters, UV turns on
Is water purity is above user set point?
Commissioning Complete
Commissioning Complete

PURELAB flex 3 & 4
Section 1 – Process Description Issue 3 Page 8of 52
PURELAB flex 4
Commissioning
Timer reads 30 minutes
Checks purity every 5 minutes until it
reaches quality
Connect the power supply to the
PURELAB flex
Reservoir reaches >2 liters, P1 turns on
After 10 minutes V3 closes.
Reservoir starts to fill
V1 and V3 open
System displays estimated
commissioning 1:30:00
Turn on the water supply to the flex and
press accept
Install the Composite Vent filter and
Purification Pack
Set Language
Highlight correct language and press
Accept
Reservoir reaches 7 liters, V1 closes
Recirculates for 60 minutes then checks
for water purity
Reservoir reaches >3 liters, UV turns on
Is water purity is above user set point?
Commissioning Complete
Commissioning Complete

PURELAB flex 3 & 4
Section 1 – Process Description Issue 3 Page 9of 52
PURELAB flex
Sanitization
A timer will start
to count down on
the screen
1:30:00
Hold down PF4 to
access the menu
Press accept to
start the
sanitization
Remove the
purification pack
and insert the
sanitization pack
V1 closes and V2
opens to release
pressure from
the system
Place a 1 liter
container under
the dispense
nozzle and press
accept
Highlight
sanitization and
press accept
The reservoir
level is checked,
if it is <7 liters,
V1 will open and
fill the reservoir
P1 turns on for 6
minutes
P1 turns off for
60 minutes
P1 turns on for
24 minutes
V2 opens and
dispenses the
contents of the
reservoir
Place a 10 liter
container under
the dispense
nozzle and press
the dispense
button
The reservoir
reaches 0 liters,
V2 closes and P1
turns off
Sanitization
complete
System returns
to normal
operation
Remove the
sanitization pack
and insert the
purification pack

Section 2 – Parts Identification
Section 2 – Parts Identification Issue 3 Page 10 of 52
Consumables
Part Number Description PURELAB
flex 3 PURELAB flex 4
LC214 Purification Pack


LC209 Sanitization Pack


LC210 185/254nm UV Lamp


LC216 Composite Vent Filter


LC145 Point of Use – 0.2µm Microfilter


LC197 Point of Use – Biofilter


LC217 RO Assembly


LC197 - POU
Biofilter
LC145 – POU 0.2µ
Micro filter
LC216 –
Composite Vent
Filter
LC209 –
Sanitization Pack
LC217 – RO
Assembly

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 11 of 52
Accessories
Part Number Description PURELAB
flex 3 PURELAB flex 4
LA732 Foot Switch


LA734 Leak Detector


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 please contact technical support.
LA652 – Pressure
Regulator
LA732 – Foot
Switch
LA735 – Wall
Mounting Kit
LA728 – Bypass
Pack

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 12 of 52
Common / Basic Parts
Key: Not used Number of part used
Part Number Description PURELAB
flex 3 PURELAB flex 4
ADAP31299 ADAPTOR STRAIGHT 8mm OD TUBE 1 1
ADAP32798 ADAPTOR STRAIGHT 8mm OD TUBE 2 2
ADAP32800 ADAPTOR STEM 8mm-1/4"BSP" 1 1
ADAP39228 ADAPTOR STAINER 1" BSP 1 1
ADAP39230 ADAPTOR NR VALVE BULKHEAD 1 1
ADAP39406 ADAPTOR STEM 6mm-1/4” BSP 1 1
BALL38832 UV BALLAST BOX ASSY 1 1
BALL38877 BALLAST - BL 14W 24V 1 1
BALL39247 POLYPROPYLENE BALL 8MM 1 2
BASE39105 BAE MOULDING FLEX 3-4 1 1
BEND30108 BEND FLOW CLIP-ON 5/16"OD 7 7
BRAC39233 SOLENOID VALVE BRACKET 1 1
BUSH38879 BUSH FILTER BULKHEAD 1 1
CAPS32084 CAP END PVC 185nm UV HOUSING 1 1
CLIP39255 COMPONENT CLIP - VM-1010 1 1
CONN32791 CONNECTOR BULKHEAD 8mm TUBE 2 2
CONN38836 CONNECTOR SHORT CARTRIDGE 3 3
CONN39229 NRV BULKHEAD CONNECTOR 1 1
CONN39258 TWO-WAY DIVIDER 8mm TUBE 1
CORD39210 FLEX DOOR MECHANISM CORD 2 2
COUP39046 FILTER BULKHEAD COUPLING 1 1
COVR38811 COVER CENTRAL TOP 1 1
COVR39021 USB PROTECTIVE COVER 1 1
COVR39117 REAR COVER FLEX 3 1 1
COVR39252 VALVE ACCESS COVER 1 1
COVR39290 PLASTIC COVER FOR CAPACITOR 1 1
COVR39394 COVER REAR FILLER FLEX 3-4 1 1
DISC32086 DISC SEALING 185nm UV HOUSING 1 1
ELBW35604 ELBOW STEM 6mm OD x 6mm OD 2
ELBW35960 ELBOW REDUCING 8mm OD TUBE x 2 1
ELBW36122 ELBOW SWIVEL 8mm OD TUBE x 2 2
ELBW38317 ELBOW EQUAL - 8mm OD 3 4
ELBW38327 ELBOW STEM - 8mm OD STEM x 8mm 5 4
ELBW39259 JG TUBE TO HOSE ELBW 2 2
EXTR39116 EXTRUSION REAR TOWER FLEX 3-4 2 2
FANM39062 FAN MOUNT BREAKAWAY STYLE 4 4
FILT36123 FILTER 1/2" ST/ST WASHER 1 1
FILT39250 FILTER WASHER REF 4370250.950 1 1
FOOT39251 BARBED RIVET FOOT - FBR-1 4 4
GROM31309 GROMMET QUICK FIT 1 1
GROM38806 GROMMET CABLE 1 1
HOUS36124 HOUSING FLOW RESTRICTOR DRAIN 1 1
HOUS38855 2" UV HOUSING WELD ASSY 1 1

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 13 of 52
Part Number Description PURELAB
flex 3 PURELAB flex 4
LA728 BYPASS CARTRIDGE FLEX 1 1
LATC39253 QUARTER LATCH TURN 4 4
LC210 UV LAMP - PURELAB FLEX 1 1
LC217 RO CARTRIDGE FLEX 3 & 4 1
MAGN39132 FLEX DOOR MAGNET 2 2
MOUN38647 MOUNTING CLIP - 1 1
MOUN39237 FLAT CABLE TIE HOLDER 2
MOUN39288 MOUNT FLEX 3-4 3 3
NUTS20865 NUT M4 HEX FULL 6 6
NUTS39276 COUPLING NUT 1/2" BSP 2 2
PCBS38875 CONTROLLER BOARD FLEX 1 1
PLAT38815 CARTRIDGE MOTION PLATE 1 1
PLAT39108 PUMP MOUNTING PLATE 1 1
PLAT39212 TANK DRIP PLATE 1 1
PLAT39226 PCB AND FAN MOUNTING PLATE 1 1
PLAT39227 PLATE BASE COVER 1 1
PLAT39231 TANK LOCATING PLATE 1 1
PLAT39242 BULKHEAD MOUNTING PLATE 1 1
PLUG32802 PLUG BLANKING 8mm OD STEM 3 3
PLUG38882 BLANKING PLUG CODE 466929 1 1
POWE38971 POWER SUPPLY FLEX 1 1
PU010418 CONNECTOR 8-8MM PM0408E 1 1
PUMP38824 PUMP DIAPHRAGM 88-ELG-38824 1 1
RING32087 RING O" BS115 RED SILICON" 1 1
RING32088 RING O" BS119 RED SILICON" 1 1
RING39248 O RING BS 014 12.5 ID X 1.78 1 1
RING39249 O RING BS 125 - 33ID X 2.62 1 1
RIVT10328 RIVET POP 1/8" DIA SHORT" 2 2
RIVT39296 SNAP RIVET BLACK 2 2
SCRW11946 SCREW M4 x 6mm POZI PAN HEAD 4 4
SCRW22008 SCREW SET M4x16mm PAN HEAD 2 2
SCRW22187 SCREW M4 x 20mm POZI CSK HEAD 2 2
SCRW31311 SCREW No 8 x 1/2" PAN HEAD" 2
SCRW31313 SCREW No.4 x 3/8" PAN HEAD" 4 4
SCRW32690 SCREW M5x12mm POZI PAN HEAD 4 4
SCRW36845 SCREW M4x10mm POSIDRV PAN 4 4
SCRW36895 SCREW M3x8mm POSIDRV PAN HEAD 3 3
SCRW37566 SCREW SELF-TAPPING NO6 x 3/8" 2 2
SCRW38040 SCREW 3.5MM DIA X 38MM LONG 2 2
SCRW38888 DELTA SCREW M2.5 X 8LG 6 6
SCRW38890 SCREW FLEX PUMP 9 9
SCRW38963 POZI HEAD TAPTIE SCREW C'SK 4 4
SCRW38964 POZI HEAD TAPTIE SCREW 6 6
SENS39131 CONTINUOUS LEVEL SENSOR 1 1
SP919 CARTRIDGE BULKHEAD ASSY 1 1
SP925 LINE CELL 3 3
SP926P FLOW SENSOR 1 1
SP929P FLEX DOOR ASSY RIGHT HAND 1 1

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 14 of 52
Part Number Description PURELAB
flex 3 PURELAB flex 4
SP930P FLEX DOOR ASSY LEFT HAND 1 1
SP940P FAN ASSY PURELAB FLEX 2 2
SP947 PURELAB FLEX 3 & 4 WIRING ASSY 1 1
SP950P PISTON CARTRIDGE ASSY - FLEX 1 1
SP954P DISPENSER ARM ASSY FLEX 3 & 4 1 1
SP963 DISPENSER NRV ASSY FLEX 3 & 4 1 1
SP965 DISPENSER ASSEMBLY GREEN 1 1
SPAC38978 SPACER - NYLON M3 X 37 1 1
SPAC39211 CIRCUIT BOARD SPACER 4 4
TANK39114 RESERVOIR TANK FLEX 3 1 1
TEES38261 TEE EQUAL - 8mm OD 1 1
TUBE10285 TUBE 8mm ID x 11mm OD PVC 0.37 0.37
TUBE31957 TUBE HIPURE 8mm OD x 5mm ID 8.5 8.5
TUBE35949 TUBE 6mm LDPE NATURAL 0.25 0.25
TUBE38870 QUARTZ THIMBLE FLEX 1 1
VALV32039 VALVE SHUT-OFF JG 8mm 1 1
VALV38199 VALVE 3-WAY SOLENOID 1 1
VALV39016 JG SINGLE CHECK VALVE 1 1
VALV39254 SOLENIOD VALVE TYPE 6240 24VDC 1
VALV39261 SINGLE CHECK VALVE 6MM TUBE 1
VALV39286 SOLENOID VALVE FLEX BURKERT 1
WASH10534 WASHER 19mm OD x 11mm ID x 1 1
WASH12250 WASHER M3 PLAIN 4 4
WASH20879 WASHER M4 SPRING 6 6
WASH20884 WASHER M4 PLAIN 2 2
WASH22186 WASHER M4 SHAKEPROOF INTERNAL 3 3
WASH31246 WASHER M5 PLAIN 6 6
WASH39037 WASHER M3 SPRING A2 2 2
Notes:

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 15 of 52
Drawings
Please see below details of the drawings located in this section of the manual and which
PURELAB flex they correspond to.
PURELAB flex 3
Sub Assembly Description Page Number
N/A Main body assembly – External 16
N/A Main body assembly – Internal 17
N/A Main body assembly – Internal (tank removed) 18
N/A Base moulding 19
N/A Manual drain assembly 22
SP919 Cartridge bulkhead assembly 23
SP923 UV assembly 25
SP945 Tank assembly 20
SP951 Bulk head assembly 26
SP954 Dispenser arm assembly 24
PURELAB flex 4
Sub Assembly Description Page Number
N/A Main body assembly – External 16
N/A Main body assembly – Internal 17
N/A Main body assembly – Internal (tank removed) 18
N/A Base moulding 19
N/A Manual drain assembly 22
SP919 Cartridge bulkhead assembly 23
SP923 UV assembly 25
SP951
Bulk head assembly
26
SP954 Dispenser arm assembly 24
SP958 Tank assembly 21

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 16 of 52
Main Body – External Parts
Item Part Number Description
1 SP919 Cartridge Bulkhead Assembly (see page 23 for a breakdown of parts)
2 SP923 UV Assembly (see page 25 for a breakdown of parts)
3 SP929 Right hand door
4 SP930 Left Hand Door
5 SP950 Piston Assembly
6 SP954 Dispenser Arm Assembly (see page 24 for a breakdown of parts)
7 SP965 Dispenser Assembly
3
5
2
4
6
7
1

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 17 of 52
Main Body – Internal Parts
Item Part Number Description
1 SP951 Bulkhead Assembly (see page 26 for a breakdown of parts)
2 SP945 PURELAB flex 3 Tank Assembly (see page 20 for a breakdown of
parts)
3 SP958 PURELAB flex 4 Tank Assembly (see page 21 for a breakdown of
parts)
4 VALV39254 PURELAB flex 4 Inlet Solenoid Valve
5 VALV39286 PURELAB flex 3 Inlet Solenoid Valve
1
3
5
4
2

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 18 of 52
Main Body – Internal Parts Tank Removed
Item Part Number Description
1 PU010418 Connector 8mm OD tube x 8mm OD tube
2 PCBS38875 Flex Control Board
3 PUMP38824 Recirculation Pump
4 SP925 Line Cell
5
SP963
Dispenser NRV Assembly
1
3
2
4
5

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 19 of 52
Base Moulding - Bottom
Item Part Number Description
1 ELBW38327 Elbow 8mm Stem x 8mm OD Tube
2 SP940 Fan Assembly
3 TEE38261 Tee Equal 8mm OD Tube
1
3
2

PURELAB flex 3 & 4
Section 2 – Parts Identification Issue 3 Page 20 of 52
SP945 Tank Assembly
Item Part Number Description
1 ADAP31299 Adaptor 8mm OD tube x 1/8” BSPT male
2 ADAP32800 Adaptor Stem 8mm OD tube x ¼” BSPT male
3 CONN39258 Two way divider 8mm OD tube
4 ELBW35604 Elbow stem 6mm OD tube x 6mm OD tube
5 ELBW35960 Elbow reducing 8mm OD tube x 6mm OD tube
6 ELBW38317 Elbow equal 8mm OD tube
7 ELBW38327 Elbow stem 8mm x 8mm OD tube
8 HOUS36124 Housing flow restrictor
9 SENS39131 Level Sensor
10 TANK39114 7 liter Reservoir
11
VALV38199
3 way solenoid valve
12 VALV39016 Non return valve 5/16
13 VALV39261 Non return valve 6mm OD tube
11
5
6
6
2
3
7
9
1
8
12
4
1310