TKA LabTower EDI User manual

Operating Instructions
LabTower EDI
!"Art. no.: 07.4415 !"Art. no.: 07.4445
!"Art. no.: 07.4430
Serial no.: ..........................
Read these Operating Instructions prior to starting to install and operate the
system!
29.0233, Stand: 06.09 Rights to technical changes reserved!

LabTower EDI
Ultrapure water system
2
Company
TKA Wasseraufbereitungssysteme GmbH
Stockland 3
D-56412 Niederelbert
EC Declaration of Conformity
acc. to EC Directive 98/37/EC
- Machines Directive -
We herewith declare that the design and construction of the machine named below, and the
versions of it that we have introduced into the market, conform to the fundamental safety and
health requirements of EC Directive 98/37/EC.
This declaration becomes invalid when changes which were not agreed to by us are made to
the machine.
Description of the machine: Ultrapure water system
Machine type: LabTower EDI
Article number: 07.4415
07.4430
07.4445
Applicable EC Directives: EC Machines Directive (98/37/EC)
EC Low Voltage Directive (73/23/EEC)
EC Electromagnetic Compatibility Directive
(2004/108/EC)
Standards applied: DIN EN ISO 12100-1
DIN EN ISO 12100-2
DIN EN 60204-1
DIN EN 55011
DIN EN 50082-2
Niederelbert, 18. June 2007 ________________________________
Authorized Manufacturer’s Representative

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Ultrapure water system
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Preface
Dear Sir or Madam,
in deciding to purchase a Ultrapure water system of type LabTower EDI 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 Ultrapure water system, please carefully read the
information on how it is to be properly installed and operated that is given in these Operating
Instructions.
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, 18 June 2007

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1. Contents
Preface.........................................................................................................3
1. Contents..................................................................................................4
2. Notes on the Operating Instructions .......................................................6
3. Transport and packaging ........................................................................7
3.1 Examination on receipt......................................................................................... 7
3.2 Compaints ............................................................................................................ 7
3.3 Packaging and return shipment............................................................................ 7
4. Safety instructions...................................................................................8
5. Extent of delivery ....................................................................................9
6. Technical specifications ........................................................................10
7. Flow chart .............................................................................................12
7.1 How the system functions .................................................................................. 15
8. The installation area..............................................................................17
9. Putting into operation ............................................................................18
10. Operating elements.............................................................................20
11. System control ....................................................................................21
11.1 User menu........................................................................................................ 21
11.1.1 Permeate conductivity: ............................................................................................21
11.1.2 Product water conductivity:......................................................................................22
11.1.3 Ultrapure water limiting value: .................................................................................22
11.1.4 Operating hours: ......................................................................................................23
12.1.5 Pretreatment operating hours: .................................................................................23
11.1.6 Cleaning:..................................................................................................................23
11.1.7 Disinfection: .............................................................................................................24
11.1.8 Fault storage:...........................................................................................................24
11.1.9 Unlocking the system:..............................................................................................25
11.2 OEM menu ....................................................................................................... 29
11.2.1 Maximum temperature:............................................................................................29
11.2.2 Disinfectionszeit:......................................................................................................30
11.2.3 Recirculation time: ...................................................................................................30
11.2.4 Rinsing time: ............................................................................................................30
11.2.5 Interval rinse time: ...................................................................................................31

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11.2.6 Real-time clock:....................................................................................................... 31
11.2 7 Sending interval: ..................................................................................................... 31
11.2.8 Language: ............................................................................................................... 32
11.2.9 Switching units: ....................................................................................................... 32
11.2.10 Switch off of temperature compensation:.............................................................. 32
11.2.11 Adjusting the circuit hysteris of the float switch:.................................................... 33
11.2.12 Programme choice UPW/ PW/ EDI:...................................................................... 33
11.2.13 Entering the type and serial number of the system:.............................................. 33
11.3 Printer output ....................................................................................................34
11.3.1 Standard message: ................................................................................................. 34
11.3.2 Code message: ....................................................................................................... 34
11.3.3 Fault message:........................................................................................................ 34
12. Maintenance....................................................................................... 35
12.1 Rinsing the membrane ..................................................................... 36
12.2 Replacing the pre-treatment............................................................. 37
12.3 Replacing the RO-membrane........................................................... 38
12.4 Changing the Ultrapure water module.............................................. 39
12.5 Disinfection procedure...................................................................... 40
13. Trouble shooting................................................................................. 43
14. List of replacement parts .................................................................... 46
15. Accessories ........................................................................................ 48
16. Consumable materials:....................................................................... 48
17. Terminal assignment .......................................................................... 49
18. Maintenance record............................................................................ 51

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2. Notes on the Operating Instructions
Danger notes are emphasized by a warning triangle.
Important notes are marked with an information sign.
The information provided in these Operating Instructions is only valid for the system whose
serial number is written in on the front page.
Please write the serial number of your LabTower system on
the front page.
* You can find the serial number on the type plate of your Ultrapure water system.
For all inquiries and replacement parts orders, it is important that you correctly state the
following:
- Serial no.
- Article no.

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Ultrapure water system
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3. Transport and packaging
TKA Ultrapure water systems are carefully checked and packed prior to shipment, but there is
nevertheless always a possibility that damage to them could occur 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 Compaints
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 packaging materials.
Should this no longer be available:
!Pack the system in packing film and 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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4. Safety instructions
!Your LabTower EDI system is a modularly constructed Ultrapure water system that
serves exclusively for the purification of tap water.
!Do not start to install and operate the system until you have read through the correspond-
ding information that is given in these Operating Instructions.
!Note that the manufacturer is freed from 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 is 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 +2°C and must not exceed + 35°C.
!Observe all applicable and appropriate regulations and requirements, including current
accident regulations, and the statics of the flooring in the area of installation of the system.
!The feedwater pressure must be at least 2 bar and at most 6 bar. If the feedwater
pressure is higher, install an additional pressure reducer.
!DIN EN 1717 requires that water purification systems be equipped with a safety device
that protects the drinking water system from contamination.
!A 230V/50Hz electric safety socket with earth contact must be planned.
!The installation area must have a drain at floor level with at least DN 50 pipe. The
manufacturer will otherwise not accept any liability for water damage. Should no such
drain be available, then we recommend that a water watcher (art.-no. 16.0129) must be
installed.
!Gravity fall to the waste drain must be ensured.
!After long standstill periods (e.g. annual holidays) the system must be rinsed and, if
appropriate, disinfected. Refer to the “Cleaning and disinfection“ section for details.
!When selecting the installation area and installing the system, make sure that there is
sufficient working area for convenient operation of it.
!Never look directly at a switched-on UV-lamp, as ultraviolet light can impair eyesight! The
UV-lamp is only to be changed by TKA or by TKA authorized personnel.
!The guarantee is valid for a period of 12 months.
! For your own safety, please observe the safety precautions given above !

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5. Extent of delivery
The LabTower EDI Ultrapure water system consists of:
1 x LabTower EDI Article no. 07.44__
1 x Assembly kit Article no. 25.0086
consisting of:
1 x Ultrapure water module Article no. 09.2005
1 x Prefilter cartridge 5µm + activated carbon, 5“ Article no. 06.5203
1 x Hardness stabilization, 5“ Article no. 06.5453
1 x Connector Article no. 14.0402
1 x Fine filter 1 µm, 10" Article no. 06.5101
1 x Connecting kit Article no. 25.0085
1 x Operating Instructions Article no. 29.0233
Connecting kit Article no. 25.0085
consisting of:
3 x Connecting hoses, 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
2 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.

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6. 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.
Conductivity <1500 µS/cm
Prefiltration 5µm + activated carbon + 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
Product water quality ASTM I (dispensing valve)
Standard UV (option)
Conductivity µS/cm 0.055 0.055
Resistance M!xcm bei 25°C 18.2 18.2
TOC ppb 5 - 10 1 - 5
Bacteria KBE/ml < 1 < 1
Particles > 0,2 µm < 1/ml < 1/ml
Flow rate L/min 1.5 1.5
Typical
volume taken 10 L/day
Product water quality ASTM II (tank quality)
LabTower EDI 15 LabTower EDI 30 LabTower EDI 30
Retention quota, salts Ø 98 % Ø 98 % Ø 98 %
Retention quota, bacteria and
particles 99 % 99 % 99 %
Conductivity 0.067 – 0.1 µS/cm 0.067 – 0.1 µS/cm 0.067 – 0.1 µS/cm
Resistance M!xcm bei 25°C 15 – 10 15 - 10 15 - 10
Performance 15 L/h 30 L/h 45 L/h
Dimensions
Height 1500 mm
Width 450 mm
Depth 580 mm
Weight, empty 58 kg
Operational weight (with full tank) 158 kg

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Cell constants of the measuring cells
Conductivity, permeate 0.16 cm-1
Conductivity, product water 0.01 cm-1
Conductivity, ultrapure water 0.01 cm-1
Water connections
Raw water inlet Hose, 8 mm od / R3/4"
Concentrate outlet Hose, 8 mm od
Ultrapure water outlet Hose, 8 mm od
Electrical connections
Voltage 230 V
Frequency 50/60 Hz
Power consumption < 0.2 kW
Serial interface RS 232

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Ultrapure water system
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7. Flow chart
B1 Storage tank: Stores the product water produced.
F1 Prefilter, 5µm + activated
carbon and
hardness stabilisation
(not with upstream
softener)
Prevents the penetration of particles > 5µm and too high
chlorine concentrations.
Stabilizes calcium and magnesium.
F2 RO-Module: Semipermeable, thin-film, composite, spiral wound
membrane.
F3 Ion exchanger: Removes inorganic ions and traces of dissolved organic
substances.
F4 Ultrafiltrationcapsule:
charged (option)
Retains particles > 0,2µm.
F5 Sterile vent filter or
Sterile vent filter +
CO2Adsorber (option)
Prevents the penetration of airborne bacteria and particles >
0,2 µm.
F6 Fine filter
Sterile filter
(option)
Retains particles > 1µm.
Retains particles > 0,1µm.

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FIA400 Product flow meter,
EDI cell:
Permanently shows the amount of pure water that is fed into
the EDI cell (product inlet)
FIA401 Concentrate flow
meter, EDI cell:
Permanently shows the amount of pure water that is fed into
the EDI cell (concentrate inlet)
LIS100 Float switch: Determines the filling level in the tank.
P1 Pressure booster pump: Raises the input pressure to the required operating pressure.
P2 Recirculation pump:: On withdrawal, pumps ultrapure water through dispensing
valve (V7) and sterile filter (F4) to the ultrapure water outlet,
as well as through filter (F6) to a user.
During interval switching, pumps ultrapure water back
through the system via UV-lamp (UV1) and ion exchanger
(F3).
PS200 Pressure switch: Switches pump (P2) on when ultrapure water is withdrawn
from tank (B1), and switches the pump off when dispensing
valve (V7) is closed.
PS201 Pressure switch
rawwater:
Switches the system off when the feedwater inlet pressure is
too low.
QIA300 Permeate conductivity
measuring cell:
Measuring device for the determination of the conductivity
(after RO) as parameter for the permeate quality.
QIA301 Product water
conductivity measuring cell:
Measuring device for the determination of the conductivity
(after EDI) as parameter for the product water quality.
QIA302 Ultrapure water
conductivity measuring cell:
Measuring device for the determination of the conductivity
(after ultrapure water module) as parameter for the ultrapure
water quality.
UV1 UV-photooxidation:
(option)
Reduces the content of bacteria and other microorganisms.
UV2 UV-Disinfection:
(option)
Reduces the content of bacteria in the water and so serves to
prevent bacterial growth and the formation of a biofilm on the
inside surfaces of the storage tank.
V1 Feedwater solenoid valve: Is closed during stand-by and standstills. It prevents water
from flowing into the system when it is not in operation.
V2 Pressure hold valve: Serves to adjust the operating pressure and the WCF-rate
(see section 7.1).
V3 Rinsing solenoid valve: Opens for cleaning of the membrane prior to ultrapure water-
production, after pure water production and at least every 12
hours.
V4 Check valve: Prevents pure water from being pressured back in the RO-
module.
V5 Check valve: Prevents ultrapure water from flowing back into the system.

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V6 Recirculation solenoid
valve:
Opens for recirculation.
V7 Dispensing valve: Allows ultrapure water to be withdrawn.
V8 Regulating valve, product,
EDI cell:
Valve for adjustment of the amount of pure water that is fed
into the EDI cell (product inlet).
V9 Regulating valve
concentrate, EDI cell:
Valve for adjustment of the amount of pure water that is fed
into the EDI cell (concentrate inlet).
V10 Residual drainage: Allows complete emptying of the tank.
V11 Check valve:: Prevents ultrapure water from flowing back into the tank.
V12 Sterile tank overflow
(option):
Prevents the penetration of bacteria and other micro-
organisms.

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7.1 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.
Pressure switch PS 201 checks the available inlet feedwater pressure and switches the system
off should this be below the minimum pressure.
Feedwater solenoid valve (V1) 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
storage tank (B1) from overflowing.
Semi-permeable membrane (F2) retains all salts dissolved in the water up to the specified
retention quota. The molecular size of the membrane pores is so small, that 99% of bacteria,
pyrogens and particles are also removed from the feedwater.
The pure water flows now over the pure water measuring cell (QIA300) by the electrode
ionization into the storage tank. The conductivity measuring cell (QIA301) measures the
conductivity of the product water.
Recirculation pump (P2) pumps the ultrapure water from storage tank (B1) through the special
conductivity measuring cell (QIA301) with temperature compensation (TIA500) to dispensing
valve (V7) as well as through filter (F6) to a user. The conductivity measuring probe determines
the conductivity and the temperature of the ultrapure water subsequent to UV-photooxidation*
(UV1) and ion exchanger (F3). The measured values can be called in the microprocessor
system control.
Recirculation pump (P2) runs every 15 minutes to recirculate the water that is in storage tank (B1)
through the system. The time interval begins 10 minutes after switch-on to avoid dry-running of
recirculation pump (P2).
* Option
Valve (V2) has been pre-adjusted at the factory. A change in the adjustment
of this valve could 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 re-adjusted 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 EDI
Check and adjust at least 1x monthly
System Permeate-
flow
[l/h)
Concentrate-
flow RO
[l/h]
adjustable
up to
[%]
Concentrate-
flow EDI
[l/h]
LabTower EDI 15 20 min. 60 40 2
LabTower EDI 30 40 min. 60 40 4
LabTower EDI 45 50 min. 60 40 5

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Your Ultrapure 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 (V3) 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
reason, 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.

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8. The installation area
The following criteria must be taken into consideration when choosing the installation area.
#Minimum temperature in the installation area: + 2°C - +35oC.
#The surface that your pure water system is to be stood on must be strong enough
to support it (for weight, see "Technical Specifications").
#A floor drain with waste pipe of DN 50 size (38.5 mm id) 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 "Technical Specifications").
#Ensure that there is sufficient working room around the system.
#An R ¾“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.

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9. Putting into operation
1) LabTower EDI Ultrapure water
system
2) Front hood, removable
3) Rotary knob for pure water
dispensing/dispensing valve
4) Ultra filtration capsule (option)
5) Operating unit
6) Front cover, storage tank
7) Feedwater inlet
8) Concentrate outlet
9) Pure water outlet
10) Residual water drainage
11) Product flow rate meter
12) Concentrate flow rate meter
13) Pretreatment
14) Sterile or fine filter
15) Power supply 230V/50Hz
16) Printer connector
17) Power supply EDI 230V/50Hz
18) Power supply for the pressure
pump/tank
Level control connector
19) Feedwater connector Ø8 mm
20) Permeate connector Ø8 mm
21) Pure water connector (in) Ø8 mm
22) Concentrate connector Ø8 mm
23) Pure water connector (out) Ø8 mm
24) Power supply connector for the
pressure pump/tank
Level control connector
25) Power supply EDI 230V/50Hz

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1. Place the Ultrapure 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 (19-23) at
the equipment.
2. Remove the covering hood (6) of the storage tank.
3. Turn the filter housing of the pre-treatment (13) loosely. Insert the pre-treatment unit con-
tained when assembling (hardness stabilization, pre-filter and connector) into the filter
housing 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 (14) loosely.
Insert the filter into the filter housing and bolt this on again.
5. Connect the Ø8 – ¾“ female thread feedwater hose supplied to the feedwater inlet (7) of
the storage tank and to a water tap that can be turned off. The connecting hose is marked
“Feedwater“.
6. Connect the Ø8 concentrate hose supplied to the concentrate outlet (8) of the storage
tank and to the drain provided on-site. The concentrate hose is marked „Concentrate“.
Caution! The concentrate must be able to flow under free gravity fall to the drain!
7. Plug the 4-pin plug of the level control system (storage tank), marked „Niveau“, in the 4-pin
socket (18) of the Ultrapure water system and screw the milled nut of the plug tight.
Connect the plug (power supply EDI, 230 V), marked “EDI 230V”, to coupling (17) of the
Ultrapure water system. Fix the plug by firmly pressing the clamp.
8. Screw the optional ultra filtration capsule (4) into the withdrawal tap G1/4 “.
9. Now fit the hose of the Ø8 mm sterile overflow to the overflow on the back of the tank and
connect it to the drain.
10. Ensure that residual water drainage (10) is turned closed.
11. Check the feedwater pressure; it must be within the permissible pressure range
(see Technical specifications).
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“!
12. Plug the line plug in and switch the Ultrapure water system on with the on/off key on the
operating unit (5).
13. Check that all connections are leak-tight.
14. Replace the covering hood on the storage tank.
After a short rinsing phase, your system begins to produce pure water into the storage tank.

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10. Operating elements
INTERVAL
menu
enter
NONSTOP
Switches the UV-lamp on or, in the menu,
allows you to select the position in a number
that you wish to change
Switches "Interval" operation on or, in the menu,
decreases a value on display
UV
Switches the menu to the next menu
point
Confirms the value shown in a menu
point
Switches "Nonstop" operation on or, in the menu,
increases a value on display
Switches the system on or off
menu
INTERVAL
UV
TKA-Pacific
Production 70%
0,100 µS/cm
18,5°C UV/TC
NONSTOP
enter