Thermo Scientific GenPure Standard User manual

Operating Instructions
Thermo Scientific Barnstead GenPure
Water Purification System
with xCAD
Serial no.: ................................
These Operating Instructions must be read prior to installation and start-up!
50131281 Stand: 11.12 Rights to technical changes reserved

Thermo Scientific Barnstead GenPure with xCAD
Ultrapure water system
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EC-Declaration of Conformity
in accordance with the EEC machine directive 2006/42/EC, appendix II A
We hereby certify that the following described machine in its conception and form put by us into
circulation is in accordance with all the relevant essential health and safety requirements of the
EC machinery directive 2006/42/EC as amended and the national laws and regulations adopt-
ing this directive.
This declaration is no longer valid if the machine is modified without our consent.
Manufacturer: Thermo Electron LED GmbH
Robert-Bosch-Straße 1
D-63505 Langenselbold
Description of the machine:
function: Ultrapure water system
type: GenPure with xCAD, GenPure UF with xCAD, GenPure UV with xCAD,
GenPure UV/UF with xCAD, GenPure UV-TOC with xCAD, GenPure UV-
TOC/UF with xCAD
article number: bench version: 50131286, 50131250, 50131254, 50131252, 50131296,
50131298
wall version: 50131300, 50131302, 50131317, 50131315, 50131321,
50131323
The agreement with further valid guidelines/regulations following for the product is ex-
plained:
EMC Directive (2004/108/EC)
Reference to the harmonised standards:
DIN EN ISO 12100-1 Safety of machinery, Part 1: Basic terminology
DIN EN ISO 12100-2 Safety of machinery, Part 2: Technical principles
DIN EN ISO 14121-1 Safety of machinery, Part 1: Risk assessment
DIN EN 61326-1
Authorized person for the technical documentation:
Detlef Opp
Stockland3
D-56412 Niederelbert
Niederelbert, 1. April 2010
Detlef Opp, Head of Technical documentation
Signature

Thermo Scientific Barnstead GenPure with xCAD
Ultrapure water system
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Preface
Dear Sir or Madam,
In deciding to purchase a high-purity water system of type GenPure with xCAD you have se-
lected a high-quality product.
Thank you for the confidence you have placed in us.
Before you start to install and operate your pure water system, please carefully read the infor-
mation given in these Operating Instructions on how to correctly carry out installation and how
to properly operate the system.
This is particularly important, as we, the manufacturer, cannot accept liability for any damage
occurring as a result of improper operation of this system, or from use of it for other than the
intended purpose.
Niederelbert, 20.03.2008

Thermo Scientific Barnstead GenPure with xCAD
Ultrapure water system
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1. Contents
1. Contents..................................................................................................4
2. Explanatory notes on the operating instructions .....................................6
3. Transport and packaging ........................................................................7
3.1 Examination on receipt.......................................................................................................7
3.2 Complaints .........................................................................................................................7
3.3 Packaging and return shipment..........................................................................................7
4. Safety precautions ..................................................................................8
5. Intended purpose ..................................................................................10
5.1 Application areas..............................................................................................................10
6. Extent of delivery ..................................................................................11
7. Technical specifications ........................................................................13
8. Description of how the systems function...............................................17
8.1 Flow chart, GenPure Standard with xCAD .......................................................................18
8.2 Flow chart , GenPure UV with xCAD................................................................................19
8.3 Flow chart, GenPure UF with xCAD................................................................................20
8.4 Flow chart, GenPure UV/UF with xCAD ...........................................................................21
8.5 Flow chart, GenPure UV-TOC with xCAD ........................................................................22
8.6 Flow chart, GenPure UV-TOC/UF with xCAD ..................................................................23
9. Setting up the system ...........................................................................24
9.1 Installation area ................................................................................................................24
9.2 Connectors .......................................................................................................................25
9.3 General setting up of the system / bench version xCAD ..................................................26
9.4 Setting up the system / wall version xCAD.......................................................................27
9.5 Wall mounting GenPure system .......................................................................................30
9.6 Mounting the power pack (voltage supply).......................................................................31
9.7 Examples of system set-ups ............................................................................................32
10. Putting the system into operation........................................................34
11. Operating elements.............................................................................35
12. System control ....................................................................................36
12.1 Menu ..............................................................................................................................37
12.1.1 Feedwater conductivity: ...........................................................................................37
12.1.2 Ultra pure water limiting value: ................................................................................37
12.1.3 UV-Lamp operating time and intensity:....................................................................38
12.1.4 Filter cartridge operating time counter: ....................................................................38
12.1.5 Rinsing.....................................................................................................................38
12.1.6 Disinfection ..............................................................................................................39

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Ultrapure water system
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
12.1.7 Display of fault storage:........................................................................................... 40
12.1.8 Print-out................................................................................................................... 41
12.1.9 Unlocking the system .............................................................................................. 41
12.2 OEM-Menu: ................................................................................................................... 43
12.2.1 Setting the maximum operating temperature: ......................................................... 43
12.2.2 Setting the rinsing time:........................................................................................... 44
12.2.3 Changing the disinfection time: ............................................................................... 44
12.2.4 Setting the interval pump time:................................................................................ 44
12.2.5 Setting the interval rinse time:................................................................................. 45
12.2.6 Setting the real-time clock:...................................................................................... 45
12.2.7 Setting the sending interval:.................................................................................... 45
12.2.8 Selecting the language:........................................................................................... 46
12.2.9 Switching units: ....................................................................................................... 46
12.2.10 Switching temperature compensation on or off:.................................................... 46
12.2.11 Entering the system type and serial number:........................................................ 47
12.2.12 Water dispensing via volume control .................................................................... 47
12.3 Printer output ................................................................................................................. 48
12.3.1 Standard messages: ................................................................................................ 48
12.3.2 Code messages: ...................................................................................................... 48
12.3.3 Fault messages:....................................................................................................... 49
13. Maintenance....................................................................................... 50
13.1 Maintenance intervals.................................................................................................... 51
13.2 Replacing the filter cartridge .......................................................................................... 52
13.3 Disinfection .................................................................................................................... 53
14. Waste disposal ................................................................................... 55
15. Trouble shooting................................................................................. 56
16. Replacement parts and consumables ................................................ 58
16.1 GenPure ........................................................................................................................ 58
16.2 xCAD ............................................................................................................................. 59
17. Consumables and accessories .......................................................... 60
18. Terminal assignment .......................................................................... 62
19. Maintenance record............................................................................ 63

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Ultrapure water system
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2. Explanatory notes on the operating instructions
EU Mark of Conformity
CSA - admission
Important operating and/or maintenance instructions! Read the oper-
ating instructions with due care.
Risk of electric shock! Electrical work on the system is only to be car-
ried out by qualified personnel.
General information! Particularly important notes are marked with this
information sign.
Protective conductor connection
Connect the power supply to an electrical socket with a protective
connection.
The information provided in these operating instructions is only valid for the system which has
the serial number which is to be entered on the front page.
Please enter the serial number* of your GenPure with xCAD
system in the space provided on the front page.
* Read the serial number of your ultra pure water system from the type plate.
For quick and correct service, please include the following information on all inquiries and re-
placement parts orders which relate to your system:
- The serial number
- The article number

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Ultrapure water system
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3. Transport and packaging
Ultra pure water systems are carefully checked and packed prior to shipment but, despite this,
there is always a possibility that damage could occur to them during shipment.
3.1 Examination on receipt
Check the completeness of the delivery against the shipping papers.
Is the packaging damaged?
Check the system for damage.
3.2 Complaints
Should the system have been damaged during transport:
Immediately contact the post office, railway or forwarding agent*.
Keep the packaging, including the outer cardboard box, for a possible inspection
and/or return shipment.
3.3 Packaging and return shipment
Whenever possible use the original packaging and packing materials.
Should these no longer be available:
Pack the system in packing film and then in a strong cardboard box so that it is held
shock-proof.
* Complaints are only valid for 6 days (after receipt of the goods).
After this time, the right to claim for damages expires.

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Ultrapure water system
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4. Safety precautions
For your own safety, please observe the above safety precautions!
GenPure series systems are modern ultra pure water systems that are intended ex-
clusively for the purification of tap water of drinking quality that has been previously
treated by reverse osmosis, ion exchange or distillation.
Do not install the system and operate it until you have read through the appropriate in-
formation that is given in these Operating Instructions.
Lifting and carrying the ultra pure water system, e.g. to the installation location, should
be carried out by two people. To lift it, each takes hold of it under the base plate at two
corners.
The CE-Mark becomes invalidated when constructional changes are made to the sys-
tem or when products of other manufacturers are installed in it.
Protect the system from frost.The temperature at the installation area must be at least
+2°C.
Observe all general requirements and regulations, including current accident preven-
tion regulations, that are applicable at the ultra pure water system installation area.
The feedwater pressure must be at least 0.1 bar and at most 6 bar. Should the feed-
water pressure be higher, then an additional pressure reducer must be installed.
Water purification systems must have a safety device acc. to DIN EN 1717 to protect
the tap water from contamination.
A grounded 100 - 240V/ 50/60Hz socket must be available.
The installation area must be equipped with a floor drain with at least DN 50 pipe (40
mm o.d.).
When the system is to be wall-mounted, first check the statics of the wall. It must have
sufficient load-bearing capacity (for weights, see the technical specifications).
The maximum operating temperature is +40°C.
When the system will be at a standstill for a longer period (e.g.or during long holidays),
proceed as follows:
Switch the system off.
Close the supply of feedwater to the ultrapure water system.
Damage to the pump will occur should the supply of feedwater be turned off with the
system still on. The manufacturer does not accept liability should such damage occur.
When planning the installation of the system, ensure that there will be sufficient work-
ing room for convenient operation of the system and for maintenance such as chang-
ing the filter cartridge and opening, breaking and checking connections.

Thermo Scientific Barnstead GenPure with xCAD
Ultrapure water system
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The term of the guarantee is12 months!
Never look directly at a switched-on UV-lamp, because UV light endangers eyesight!
Never switch the UV-lamp on when is has been taken out of the metal cylinder!
Only authorized personnel are to carry out UV-lamp replacement.

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Ultrapure water system
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5. Intended purpose
The continuous increase in ultra pure water quality requirements, technologies that are increas-
ingly more sophisticated, lowered detection limits in laboratories and the need of for user-
friendly systems and complete solutions were the basic for the development of the novel ultra
pure water systems that we call GenPure with xCAD.
GenPure with xCAD has been specifically developed for the production of salts-free, organically
pure, particle-free and sterile filtered ultra pure water.
To ensure long service lives of the high-quality purification media, this type of ultra pure water
system must be fed with water from upstream pre-purification steps (reverse osmosis, ion ex-
change, distillation).
5.1 Application areas
- Analytical techniques in laboratories:
- HPLC ( High Performance Liquid Chromatograhy )
- IC ( Ion Chromatography )
- ICP ( Inductive Coupled Argon Plasma )
- AAS ( Atomic Absorption Spectrophotometry )
- TOC-Analysis (
Total Organic Carbon )
- DNA-Research
- etc.
- Preparation of reagents and solutions:
- Cell culture media
- Tissue culture media
- Make-up water for reagents for
online automatic analyzers
- Ultra pure water for demanding laboratory rinsing processes

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Ultrapure water system
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6. Extent of delivery
The GenPure with xCAD ultra pure water system is available in the following versions:
GenPure Standard, article no. 50131286 (Basic system) with xCAD, bench version
GenPure Standard, article no. 50131300 (Basic system) with xCAD, wall version
GenPure UF, article no. 50131250 (Basic system + Ultrafiltration module) with xCAD,
bench version
GenPure UF, article no. 50131302 (Basic system + Ultrafiltration module) with xCAD,
wall version
GenPure UV, article no. 50131254 (Basic system + UV-photooxidation) with xCAD,
bench version
GenPure UV, article no. 50131317 (Basic system + UV-photooxidation) with xCAD,
wall version
GenPure UV/UF, article no. 50131252 (Basic system + UV-photooxidation + Ultrafiltration
module) with xCAD, bench version
GenPure UV/UF, article no. 50131315 (Basic system + UV-photooxidation + Ultrafiltration
module) with xCAD, wall version
GenPure UV-TOC, article no. 50131296 (Basic system + UV-photooxidation and TOC meas-
urement) with xCAD, bench version
GenPure UV-TOC, article no. 50131321 (Basic system + UV-photooxidation and TOC meas-
urement) with xCAD, wall version
GenPure UV-TOC/UF, article no.50131298 (Basic system + UV-photooxidation and TOC meas-
urement + ultrafiltration) with xCAD, bench version
GenPure UV-TOC/UF, article no.50131323 (Basic system + UV-photooxidation and TOC meas-
urement + ultrafiltration) with xCAD, wall version
(Please check your version against the article number given on the delivery note)
1x GenPure with xCAD (acc. to the version) Article no. 5013xx
incl. Assembly kit for bench and wall version,
consisting of: Article no. 50131283
(bench version)
Article no. 50131380
(wall version)
Filter cartridge for the ultra pure water system Article no. 09.2005
Sterile filter capsule, 0.2 µm Article no. 09.1003
PE-Hose 8 x 1 mm, 2 m Article no. 18.0036
PE-Hose 6 x 1 mm, 5 m Article no. 18.0047
PE-Hose 4 x 1 mm, 5 m Article no. 18.0053
SUB-D Extension cable, 25-pin, 5 m, 2x Article no. 16.0375
Screw, 4 x 40 mm (only wall version version) Article no. 21.0001
Plug, 2 x S8 Article no. 21.0035
Screw hook 2 x 5,2 x 50 mm Article no. 21.0057
Plug 4 x S6 (only wall version) Article no. 21.0002
Operating Instructions Article no. 50131281
Tabletop power pack, 24V DC Article no. 50134196
Universal adapter Article no. 21.1006
Universal holder Article no. 21.1007
Connecting cord (rubber connector to nema plug connector) Article no. 50132200
Connecting cord (rubber connector to british ST plug connector) Article no. 50132203
Connecting cord (rubber connector to euro plug connector) Article no. 50132215

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Ultrapure water system
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Feedwater connector kit Article no. 25.0075
consisting of:
Union nut, R 3/4“ Article no. 14.0003
Insert, R 1/4“ Article no. 14.0189
Screwed connector, R 1/4“ Article no. 14.0075
Gasket, R 3/4" Article no. 21.5008
PE-Hose, 8 mm o.d., 2 m Article no. 18.0036
Dirt-trap sieve for union nut, R 3/4“ Article no. 14.0390

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Ultrapure water system
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7. Technical specifications
Demands on the feedwater
Source Tap water pretreated by reverse osmosis, ion ex-
change or distillation.
Silt density index (SDI) max. 1 for all versions. For water that is not pretreated
by reverse osmosis, a prefilter with a 1 µm membrane
is recommended.
Feedwater resistance >0.5 Mxcm
Free chlorine max. 0.05 ppm
TOC max. 50 ppb
Bacteria count < 100 CFU/ml
Turbidity < 1.0 NTU
Carbon dioxide (CO2) max. 30 ppm
Silicate max. 2 ppm
Particles Filtration to 0.2 µm is recommended to protect the in-
ternal filter and, if appropriate, the final filter.
Temperature 2 - 35 °C
Pressure 0.1 - 6 bar
Product water quality
Standard UV UF UV/UF UV-TOC UV-
TOC/UF
Resistance
(Reference
temperature
25°C)
Mxcm
at 25°C 18.2 18.2 18.2 18.2 18.2 18.2
TOC ppb 5 - 10 1 - 5 5 - 10 1 - 5 1 - 5 1 - 5
Bacteria CFU/ml < 1 < 1 < 1 < 1 < 1 < 1
Bacterial En-
dotoxines EU/ml -- -- < 0.001* < 0.001* -- < 0.001*
Particles > 0.2 µm < 1/ml < 1/ml < 1/ml < 1/ml < 1/ml < 1/ml
Flow rate L/min** up to 2 up to 2 up to
1.7 up to1.7 up to 2 up to 1.7
Flow rate with
volume control L/min 1.2 1.2 1.2 1.2 1.2 1.2
* Depending on feedwater and appropriate disinfection
** Depending on feedwater pressure
Dimensions, GenPure
Height 615 mm
Width 372 mm
Depth 330 mm
Weight:
GenPure Standard 22 kg
GenPure UF 23 kg
GenPure UV 23 kg
GenPure UV/UF 24 kg
GenPure UV-TOC 24 kg
GenPure UV-TOC/UF 25 kg

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Ultrapure water system
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Dimensions, xCAD (bench version)
Height approx. 725 mm
Width 260 mm
Depth approx. 530 mm
Weight 12 kg
Dimensions, xCAD (wall version)
Height approx. 655 mm
Width 260 mm
Depth approx. 530 mm
Weight 5 kg

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Ultrapure water system
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Cell constants, measuring cells
Conductivity, feedwater 0.16 cm-1
Conductivity, after UV-photooxidation 0.01 cm-1
Conductivity, ultra pure water 0.01 cm-1
Connectors for water genpure
Feedwater Hose, 8 mm o.d.
Rinse water Hose, 8 mm o.d.
Ultra pure water/outlet Hose, 6 mm o.d.
Ultra pure water/recirculation Hose, 4 mm o.d.
Connectors for water, xCAD
Ultra pure water/inlet Hose, 6 mm o.d.
Ultra pure water/recirculation Hose, 4 mm o.d.
Ultra pure water/outlet R 1/4"
Sterile filter outlet Hose, 8 - 10 mm o.d.
Electrical connections / external switched mode power supply
Input voltage AC 100 – 240 V, 50 – 60 Hz, 5 – 3.8 A
Output voltage DC 24 V, 3,8 A
System connection DC 24 V, 80 W
Serial interface RS 232
Protection Class Class II (external SMPS certified as Class I)
Electrical connections, xCAD
2x SUB-D socket 25 pin
Airborne sound emission
Sound-pressure level 49 db(A)
Ambient conditions (DIN EN 61010-1 (VDE 0411-1):2011-02)
Usage Indoor rooms
Height Up to 2000 m
Temperature range From 5° C to 40° C
Relative humidity Maximum relative humidity 80 % at temperatures of
up to 31° C, linearly decreasing to 50 % relative hu-
midity at 40° C
Line-voltage variation Not more than ± 10 % of the line voltage
Transient overvoltages As usually occur in the supply network (overvoltage
category II acc. to IEC 60364-4-443).
Note: The rated level of transient overvoltage is the
withstand impulse voltage acc. to overvoltage cate-
gory II of IEC 60364-4-443
Ventilation requirements There are no special requirements with regard to ven-
tilation.
Degree of pollution 2

Thermo Scientific Barnstead GenPure with xCAD
Ultrapure water system
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Materials of parts that contact water
Pressure reducer NBR
Pump head Nylon with glass fibre
UV-Lamp High purity quartz
UV-Housing Stainless steel
Filter cartridge PP
UF-Housing Polycarbonate
Rinsing solenoid valve PA
Dispensing valve PVDF
Conductivity measuring cell POM, stainless steel
Distributor block POM
Connections POM
Hoses PE
Gaskets EPDM

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Ultrapure water system
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8. Description of how the systems function
GenPure versions: Standard, UV, UF, UV/UF with xCAD
Tap water that has been pretreated upstream by reverse osmosis, ion exchange or distillation
passes through a pressure reducer and into the GenPure ultra pure water system, where the
conductivity is monitored. A pump forces this feedwater through UV-photooxidation (only with
GenPure UV and GenPure UV/UF) and the filter cartridge, from where it flows through an ul-
trafiltration module (only with GenPure UF and GenPure UV/UF), after which the conductivity is
measured by a special conductivity measuring cell (with temperature compensation).
When ultra pure water is taken from the system, it flows through a sterile filter before reaching
the dispensing outlet. During interval operation, the water is circulated around an internal circuit
at regular intervals.
GenPure versions: UV-TOC, UV-TOC/UF with xCAD
Tap water that has been pretreated upstream by reverse osmosis, ion exchange or distillation
passes through a pressure reducer and into the GenPure ultra pure water system, where the
conductivity is monitored. A pump forces this feedwater through UV-photooxidation, after which
the conductivity is again measured to determine the TOC-value. The water then flows through
the filter cartridge and an ultrafiltration module (only with GenPure UF-TOC/UF), after which the
conductivity of it is measured by a special conductivity measuring cell (with temperature com-
pensation).
The TOC value is calculated by taking the difference between the values measured by the
measuring cells QIA300 and QI302.
The measurement range is 0 - 30 ppb.
When this measurement range is exceeded, the number 99 is shown in the display instead of
the measured value.
In Stand-by operation, "___" is shown instead of the measured value.
When ultra pure water is taken from the system, it flows through a sterile filter before reaching
the dispensing outlet. During interval operation, the water is circulated around an internal circuit
at regular intervals.

Thermo Scientific Barnstead GenPure with xCAD
Ultrapure water system
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8.1 Flow chart, GenPure Standard with xCAD
A-F1 Filter cartridge
A-F2 Sterile filter
A-P1 Circulation pump
FIS400 Digital flowmeter
QIA 300 Conductivity, feedwater
QIA 301 Conductivity, ultra pure water
TIA 500 Temperature sensor
V1 Pressure reducer
V2 Check valve
V3 Solenoid valve
V4 Rinsing solenoid valve
V5 Check valve 1 bar

Thermo Scientific Barnstead GenPure with xCAD
Ultrapure water system
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8.2 Flow chart , GenPure UV with xCAD
A-F1 Filter cartridge
A-F2 Sterile filter
A-P1 Circulation pump
A-UV1 UV-Photooxidation
FIS400 Digital flowmeter
QIA 300 Conductivity feedwater
QIA 301 Conductivity, ultra pure water
TIA 500 Temperature sensor
V1 Pressure reducer
V2 Check valve
V3 Solenoid valve
V4 Rinsing solenoid valve
V5 Check valve 1 bar

Thermo Scientific Barnstead GenPure with xCAD
Ultrapure water system
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8.3 Flow chart, GenPure UF with xCAD
A-F1 Filter cartridge
A-F2 Sterile filter
A-F3 Ultrafiltration module
A-P1 Circulation pump
FIS400 Digital flowmeter
QIA 300 Conductivity, feedwater
QIA 301 Conductivity, ultra pure water
TIA 500 Temperature sensor
V1 Pressure reducer
V2 Check valve
V3 Solenoid valve
V4 Rinsing solenoid valve
V5 Check valve 1 bar