Thermo Scientific LabTower AFT 20 User manual

Operating Instructions
Thermo Scientific Barnstead LabTower AFT
Water Purification System
[
[[
[]
]]
]Art. no.: 50135466 AFT 20 [
[[
[]
]]
]Art. no.: 50135467 AFT 40
Serial number: ................................
Be sure to read these Operating Instructions prior to installing and operating
the system!
50135464, Stand: 01.13 Rights to technical changes reserved!

Thermo Scientific Barnstead LabTower AFT
Pure water system
2
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 it's 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This declaration is no longer valid if the machine is modified without our consent.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
Stockland 3
D-56412 Niederelbert
Description of the machine:
function: Pure water system
type: LabTower AFT
article number: 50135466, 50135467
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 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 LabTower AFT
Pure water system
3
Preface
Dear Sir or Madam,
in deciding to purchase a pure water system of type LabTower AFT you have selected 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 on how it is to be properly installed and operated that is given in these Operating Instruc-
tions.
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, 01.04.2010

Thermo Scientific Barnstead LabTower AFT
Pure water system
4
1. Contents
Preface.......................................................................................................3
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. Extent of delivery...................................................................................9
6. Intended use........................................................................................10
7. Technical specifications.......................................................................11
8. Flow chart............................................................................................13
8.1 How the system functions .................................................................................. 15
9. The installation area ............................................................................16
10. Installation .........................................................................................17
11. Putting the system into operation......................................................19
11.1 Mounting the power pack (voltage supply)....................................................... 22
12. Venting the ion exchanger: ................................................................23
13. Operating elements ...........................................................................24
14. System control...................................................................................25
14.1 User menu........................................................................................................ 25
14.1.1 Permeate conductivity:.......................................................................................... 25
14.1.2 Ultrapure water limiting value:............................................................................... 26
14.1.3 Operating hours: ................................................................................................... 26
14.1.4 Pretreatment operating hours:............................................................................... 27
14.1.5 Cleaning:............................................................................................................... 27
14.1.6 Disinfection: .......................................................................................................... 28
14.1.7 Fault storage:........................................................................................................ 28
14.1.8 Unlocking the system:........................................................................................... 29
14.2 OEM-menu....................................................................................................... 31
12.2.1 Maximum temperature: ......................................................................................... 31
14.2.2 Disinfection time:................................................................................................... 32

Thermo Scientific Barnstead LabTower AFT
Pure water system
5
14.2.3 Recirculation time:.................................................................................................32
14.2.4 Rinsing time:..........................................................................................................32
14.2.5 Interval rinse time:.................................................................................................33
14.2.6 Real-time clock:.....................................................................................................33
14.2.7 Sending interval:....................................................................................................33
14.2.8 Language: .............................................................................................................34
14.2.9 Switching units: .....................................................................................................34
14.2.10 Switch off of temperature compensation:.............................................................34
14.2.11 Adjusting the circuit hysteris of the float switch:...................................................35
14.2.12 Programme choice TII UV/ RO:...........................................................................35
14.2.13 Entering the type and serial number of the system:.............................................35
14.3 Printer output ....................................................................................................36
14.3.1 Standard message: ...............................................................................................36
14.3.2 Code message:.....................................................................................................36
14.3.3 Fault message:......................................................................................................36
14.4 PIN Assignment/ 8 pin socket...........................................................................37
15. Maintenance ..................................................................................... 38
15.1 Maintenance intervals.......................................................................................39
15.2. Rinsing the membrane.....................................................................................39
15.3 Change of the pre-treatment.............................................................................40
15.4 Replacing the ion exchanger.............................................................................41
15.5 Replacing the RO membrane............................................................................42
15.6 Disinfection .......................................................................................................43
16. Waste disposal.................................................................................. 45
17. Trouble shooting ............................................................................... 46
18. Emergency supply............................................................................. 50
19. List of replacement parts................................................................... 52
20. Accessories....................................................................................... 54
21 Consumables..................................................................................... 54
22. Terminal assignment......................................................................... 55
22.1 LabTower AFT 20 (24V)....................................................................................55
22.2 LabTower AFT 40 (48V)....................................................................................56
23. Maintenance record .......................................................................... 57

Thermo Scientific Barnstead LabTower AFT
Pure water system
6
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 LabTower AFT system in the
space provided on the front page.
* Read the serial number of your 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

Thermo Scientific Barnstead LabTower AFT
Pure water system
7
3. Transport and packaging
Pure water systems are carefully checked and packed prior to shipment but damage could nev-
ertheless occur during transport.
3.1 Examination on receipt
-Check the completeness of the goods received against the delivery note.
Is the packaging damaged ?
-Examine the system for damage.
3.2 Complaints
Should the system have been damaged during transport:
-Contact the post, railway or forwarding agent immediately*.
-Save the packaging and the outer cardboard carton (for a possible inspection and/or
return shipment of the system).
3.3 Packaging and return shipment
If possible, use the original packaging and materials.
Should these no longer be available:
-Pack the system in a suitable plastic bag or sheet and a strong cardboard box
-so that it is shock-proof.
*The time limit for claims is 6 days after receipt of the goods.
After this deadline, all rights to claims for damages are invalid.

Thermo Scientific Barnstead LabTower AFT
Pure water system
8
4. Safety precautions
For your own safety, please observe the above safety precautions!
Your LabTower AFT system is a modularly constructed, pure water system that
serves exclusively for the purification of tap water.
Do not put the system into operation until you have taken notice of all of the appropriate
information that is given in these Operating Instructions.
Lifting and carrying the pure water system, e.g. to the installation location, should be car-
ried out by two people. To lift it, each takes hold of it under the base plate at two corners.
Note that the manufacturer is freed of all liability for damages that result from improper
operation of the system, or from use of it for other than the intended purpose.
The CE-Mark becomes invalidated should constructional changes be made to the system
or products of other manufacturers be installed in it.
Protect the system from frost. The temperature in the area in which the system is installed
must be at least +5° C and must not exceed +40° C.
Observe all regulations and requirements, including current accident regulations, that are
applicable and appropriate at the installation area, including those for the statics of the
flooring (see weight under „Technical specifications).
The raw water pressure must be at least 2 bar and at most 6 bar, should it be higher, then
an additional pressure reducer must be installed.
DIN EN 1717 requires that water purification systems be equipped with a safety device
that protects against contamination of the drinking water piping.
A grounded 100-250V / 50/60Hz socket must be available..
The installation area must have a drain at floor level with at least DN 50 pipe, otherwise
the manufacturer will not accept any liability for water damage. Should no such drain be
available, then a water watcher (240V only) (article no. 16.0129) must be installed.
Gravity fall to the waste drain must be ensured.
After long standstill periods (e.g. holidays), the system must be subjected to rinsing and, if
appropriate, disinfection. Refer to the section on ”Cleaning and disinfection“ for details.
When selecting the installation area and installing the system, make sure that there is
sufficient working area around the system for convenient operation of it.
Never look directly into a switched-on UV-lamp, as UV-light is dangerous to eyesight. The
UV-lamp is only to be replaced by authorized person to do this.
The guarantee is valid for a period of 12 months.

Thermo Scientific Barnstead LabTower AFT
Pure water system
9
5. Extent of delivery
The LabTower AFT pure water system consists of:
1 x LabTower AFT Basic unit Article no. 5013xxxx__
1 x Assembly kit LabTower AFT 20 Article no. 50135461
or
1 x Assembly kit LabTower AFT 40 Article no. 50135462
consisting of:
1 x Prefilter cartridge 5µm + hardness stabilization, 10“ Article no. 06.5204
1 x Fine filter 1µm-10” Artikel no. 06.5101
1 x Ion exchanger DI 2800 S Article no. 02.2850-
RDS
1 x Connecting kit Article no. 25.0085
1 x Operating Instructions Article no. 50135464
1x Connecting cord (rubber connector to nema plug connector) Article no.: 50132200
1x Connecting cord (rubber connector to british ST plug connector) Article no.: 50132203
1x Connecting cord (rubber connector to euro plug connector) Article no.: 50132215
1x Table power unit 24V DC Article no.: 50134196
1x Table power unit 48V DC (only AFT 40) Article no.: 50134184
1x Universal adapter Articel no.: 21.1006
1x Universal holder Articel no.: 21.1007
1 x Connecting kit Article no. 25.0085
consisting of:
3 x Connecting hose PE, Ø8/Ø6 x 3m Article no.: 18.0036
2 x POM-Insert Article no.: 14.0189
2 x Gasket, 3/4" Article no.: 21.5008
2 x Union nut, R 3/4" Article no.: 14.0003
1 x Screw connector, d8-1/4" Article no.: 14.0075
Please check the parts delivered against this list. Contact the manufacturer
should a part be missing.

Thermo Scientific Barnstead LabTower AFT
Pure water system
10
6. Intended use
The LabTower AFT pure water system is a reaction to the continually increasing requirements
that water of pure quality must fulfil, the increasingly strict demands resulting from technological
advances and the need for user-friendly systems and complete solutions.
LabTower AFT systems have been solely and specifically designed to excel in the intended use,
which is to produce sterile filtered pure water free of particles, salts and organic compounds.
To benefit from the long possible service lives of the high-quality purification media, feed the
pure water system with water which has been subjected to an upstream pre-treatment step (re-
verse osmosis, ion exchange or distillation),
- Analytical techniques in laboratories:
- HPLC ( H igh P erformance L iquid C hromatography )
- IC ( I on C hromatography )
- ICP ( I nductive C oupled Argon P lasma )
- AAS ( A tomic A bsorption S pectrophotometry )
- TOC Analysis ( T otal O rganic C arbon )
- DNA Research
- etc.
- Reagent and solution preparation:
- Cell culture media
- Tissue culture media
- Make-up water for reagents for on-line analytical systems
- Water for high-purity rinse processes on a laboratory scale

Thermo Scientific Barnstead LabTower AFT
Pure water system
11
7. Technical specifications
Demands made on the raw water
Source Potable tap water softened or hardness stabilized.
Blocking index (SDI) < 3, with higher values, an upstream pretreatment
(article no. 09.4000) is to be installed.
Resistance >0.001 MΩxcm
Prefiltration 5µm + hardness stabilization
Free chlorine < 0.1 mg/Litre
Manganese content < 0.05 mg/Litre
Iron content < 0.05 mg/Litre
Colloid index < 3
ph-Range 4 – 11
Temperature 2 – 35 °C
Pressure 2 – 6 bar
Pure water quality
LabTower AFT
Retention quota, salts Ø 98 %
Retention quota, bacteria and particles 99 %
Performance 20 – 40 L/h, acc. To the version
Dimensions
Height 1500 mm
Width 450 mm
Depth 580 mm
Weight, empty 66 kg
Operational weight (with full tank) 166 kg
Cell constants of the measuring cells
Conductivity, permeate 0.16 cm
-
1
Conductivity, pure water 0.01 cm
-
1
Water connections
Raw water inlet Hose, 8 mm od
Concentrate outlet Hose, 8 mm od
Pure water outlet Hose, 8 mm od

Thermo Scientific Barnstead LabTower AFT
Pure water system
12
Electrical connections / external switched mode power supply AFT 20
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 / external switched mode power supply AFT 40
Input voltage AC 100 – 250 V, 50 – 60 Hz, 4 – 2.5 A
Output voltage DC 48 V, 2.5 A
System connection DC 48 V, 120 W
Serial interface RS 232
Protection Class Class II (external SMPS certified as Class I)
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
Materials of parts that contact water
Pump head Nylon with glass fibre
Filter cartridge PP
Rinsing solenoid valve PA
Conductivity measuring cell POM, stainless steel
Distribution block POM
Connectors POM
Hoses PE
Gaskets EPDM

Thermo Scientific Barnstead LabTower AFT
Pure water system
13
8. Flow chart
B1 Storage tank:
Stores the pure water produced.
F1 Prefilter 5µm
and
hardness stabilizer:
(storage tank inlet)
Prevents the penetration of particles > 5µm
Stabilizes calcium and magnesium.
F2 RO-Module: Semipermeable, thin-film, composite, spiral wound mem-
brane.
F3 Ion exchanger: Removes inorganic ions and traces of dissolved organic sub-
stances.
F4 Sterile filter
(option)
Retains particles > 0,2µm.
F5 Sterile vent filter:
(option)
Prevents the penetration of airborne bacteria and particles >
0,2 µm.
F6 Sterile filter
or
fine filter:
(option)
Retains particles > 0,2µm.
Retains particles > 1µm.
LIS 100 Float switch: Determines the filling level in the tank.

Thermo Scientific Barnstead LabTower AFT
Pure water system
14
P1 Booster pump: Increases the input pressure to the required operating pres-
sure.
P2 Booster pump: On withdrawal, pumps pure water through dispensing valve
(V9) and sterile filter (F4) to the pure water outlet,
as well as over the filter (F6) to the consumer.
PS200 Pressure switch: Switches booster pump (P2) on when pure water is with-
drawn from tank (B1), and switches the pump off dispensing
valve (V9) is closed.
QIA300 Pure water con-
ductivity measuring
cell:
Measuring device for the determination of the conductivity
(after RO) as parameter for the pure water quality.
QIA301 Pure water con-
ductivity measuring
cell:
Measuring device for the determination of the conductivity
(after filter cartridge) as parameter for the pure water quality.
TIA500 Temperature sensor: Measures the temperature for temperature compensation.
UV1 UV-Disinfection: Reduces the germ respectively bacteria content.
UV2 UV-Disinfection:
(option)
Reduces the germ respectively bacteria content.
V1 3 way ball valve:
To switching normal operation to emergency supply.
V2 Feedwater solenoid valve: Is closed during stand-by and standstills. It prevents water
from flowing into the system when it is not in operation.
V3 Pressure hold valve: Serves to adjust the operating pressure and the WCF-rate.
V4 Rinsing solenoid valve: Opens for cleaning of the membrane prior to pure water-
production, after pure water production and at least every 12
hours.
V5 Residual water drainage: For complete emptying of the storage tank.
V6 Sterile overflow:
(option)
Prevents the penetration of bacteria and other microorgan-
isms.
V7 Check valve: Prevents pure water from flowing back into the tank.
V8 Pressure reducer:
For adjustment of the pure water pressure in the system.
V9 Dispensing valve: Allows pure water to be withdrawn from the tank.
V10 Check valve Prevents permeat from flowing back into the device

Thermo Scientific Barnstead LabTower AFT
Pure water system
15
8.1 How the system functions
When the ON/OFF key is pressed, the system starts running either in the operating mode or in
the stand-by mode, according to the float switch.
The feed water flows with a maximum pressure of 6 bar into the system.
Feedwater solenoid valve (V2) is closed when the system is at stand-by or at a standstill. This
prevents feedwater from flowing into the system when it is not in operation and so protects stor-
age tank (B1) from overflowing.
Semi-permeable membrane (F2) retains all salts dissolved in the water up to the specified re-
tention quota. The molecular size of the membrane pores is so small, that 99% of bacteria, py-
rogens and particles are also removed from the feedwater.
The pure water flows past pure water probe (QIA300) and into the storage tank.
The retained feedwater constituents are led away with the rest of the concentrate.
Booster pump (P2) pumps the pure water in storage tank (B1) through pressure reducer (V8)
and ion exchanger (F3) and on past the special conductivity measurement probe (QIA301) with
temperature compensation (TIA500) to dispensing valve (V9). The conductivity measuring
probe determines the conductivity and the temperature of the pure water subsequent to UV-
disinfection*(UV1).
The measured values can be called in the microprocessor system control.
* Option
Valve (V3) has been pre-adjusted at the factory. A change in the adjustment
of this valve can result in damage to the reverse osmosis module! Because
of fluctuations in the feedwater temperature and pressure, the adjustment
of the pressure hold valve and the concentrate flow that it governs must be
checked, and readjusted if necessary, on putting the system into operation
and at regular intervals thereafter.
The measured values must be recorded in the maintenance record.
Concentrate flow for LabTower AFT
Check and adjust at least 1x monthly
System Permeate-
flow [l/h] Concentrate- flow [l/h] adjustable up to [%]
LabTower 20 AFT 20 60 40
LabTower 40 AFT 40 60 40

Thermo Scientific Barnstead LabTower AFT
Pure water system
16
Your pure water system is equipped with automatic flushing. Flushing is carried out when the
system is switched on, at the end of each production, and also every 12 hours. For this, rinsing
solenoid valve (V4) is opened and the strong flow of water across reverse osmosis module (F2)
then flushes coarse particles and other contaminants away from the surface of the membranes
and carries them with it to drain.
This automatic flushing has a positive effect on the service life of the reverse osmosis module.
An additional advantage of automatic flushing is that it prevents bacterial growth from occurring
in the reverse osmosis module when the system is at a standstill for a long time. For this rea-
son, we highly recommend that you leave the system switched on over the weekend and during
holiday times, so that the 12 hour flush can effectively guard against bacterial growth.
9. The installation area
The following criteria must be taken into consideration when choosing the installation
area.
⇒Minimum temperature in the installation area: +2° C - +40o C.
⇒The surface that your pure water system is to be stood on must be strong enough
to support it (for weight, see chapter „Technical Specifications").
⇒A floor drain with waste pipe of DN 50 size (38.5 mm i.d.) is required. Should this not be
available, then a water watcher (article no.: 16.0129) must be installed to protect against
damage from water flooding!
⇒An unrestricted gravity flow of concentrate to the floor drain is obligatory.
⇒An electrical socket appropriate to the voltage given on the type plate of the system must
be positioned directly alongside the system. The safety fuse must be appropriate for the
power required (see chapter „Technical Specifications").
⇒Position the system so that there is no difficulty in separating the device from the electric
mains.
⇒Ensure that there is sufficient working room around the system.
⇒An R 3/4" R male thread tap water connection which can be shut off must be installed in
the direct vicinity of the system. Easy access to this must be ensured.

Thermo Scientific Barnstead LabTower AFT
Pure water system
17
10. Installation
Before the pure water system can be put into operation, it must be to move to the back
of designated wall with screws.
Note: The distance from the pure water system to the wall is 20 mm.
Use the assembling kit available in wall bracket, the 2 screws 4x40 mm and the 2 dowels
(Ø 6 mm)
Plug the wall bracket into the backside of the pure water attachment, as shown graphi-
cally on the following page.
The wall bracket must shown with the notches (see position “X”) down.
Now position the pure water system at the proposed wall and attach it with the dowels
and screws.

Thermo Scientific Barnstead LabTower AFT
Pure water system
18

Thermo Scientific Barnstead LabTower AFT
Pure water system
19
11. Putting the system into operation
1) LabTower AFT pure water system
2) Front hood, removable
3) Rotary knob for pure water dispens-
ing
4) Sterile capsule filter (option)
5) Operating unit
6) Front cover, storage tank
7) Feedwater inlet
8) Concentrate outlet
9) Pure water outlet
10) Residual water drainage
11) Pressure reducer
12) Pressure gauge, pure water pressure
13) Ion exchanger
14) Feedwater connector/ion exchanger
15) Pure water connector/Ion exchanger
16) Prefiltration
17) Sterile filter or fine filter (option)
18) Power supply for booster pump/tank,
connector level control
19) Power supply 24/48V
20) Printer connection
21) connector level control
22) Pure water connector, (from storage
tank), Ø8 mm
23) Permeate connector, Ø8 mm
24) Raw water connector, Ø8 mm
25) Concentrate connector, Ø8 mm
26) Pure water connector, (to consumer),
Ø8 mm

Thermo Scientific Barnstead LabTower AFT
Pure water system
20
1. Place the pure water system on the table of the storage tank. Connect the hoses positioned
at the table by putting the connectors in with the appropriate connections (21-25) at the
equipment (see „Views and connectors “, side view).
2. Remove the covering hood (2) of the storage tank.
3. Turn the filter housing of the pre-treatment (16) loosely. Insert the pre-treatment unit con-
tained when assembling (pre-filter + hardness stabilization) into the filterhousing and screw
this again firmly (see chapter „Change of the pre-treatment “).
4. In the case of use of the optional sterile or fine filter you turn the filter housing (17) loosely.
Insert the filter into the filter housing and bolt this on again.
5. Connect the Ø8 – ¾“ female thread feedwater hose supplied with feedwater inlet (7) of the
storage tanks and a water tap that can be turned off. The connecting hose is marked with
„Rawwater“.
6. Connect Ø8 concentrate hose supplied with concentrate outlet (8) of the storage tank and
to the drain provided on-site. The concentrate hose is marked with „Concentrate“.The drain
to the stewer must be max. Are 1 m above the rinsing water connector of the unit.
Caution! Concentrate must be able to flow under free gravity fall to the drain!
7. Place the ion exchanger (13) into the hollow of the storage tank.
8. Press the quick-connector of the raw water hose (14) on connection of your ion exchanger,
marked with „Rawwater“.
9. Press now the quick-connector of the pure water hose (15) on connection ( of your ion ex
changer marked with „Purewater“.
The quick-connector must engage audibly.
Do not get the raw water and pure water hoses mixed up!
10. Plug the 4-pin plug of the level control system (storage tank), marked with „Niveau“, in the
4-pin socket (20) of the pure water systems and screw the milled nut of the plug. tight.
11. Screw the sterile filter capsule (4) into the withdrawal tap G1/4 “.
12. Now fit the hose of the Ø8 mm sterile overflow in the overflow on the back of the tank and
connect it with the drain.
13. Ensure that residual water drainage (12) is turned closed.
14. Check the feedwater pressure; it must be within the permissible pressure range
(see chapter „Technical specifications”).
15. Open the feedwater tap.
16. Plug the line plug in.
Before you now switch the system on, read through the rinsing out
procedure for reverse osmosis membranes packed with preserving
agent in the „Rinsing the membrane“ section!