Yamato WG 203 User manual

Water Purifier, Auto Still
Model WG 203
Instruction Manual
- First Edition -
Yamato Scientific America Inc．
Santa Clara，CA
Printed on recycled paper.
Thank you for purchasing "Auto Still, WG 203"
of Yamato Scientific Co., Ltd.
To use this unit properly, read this "Instruction
Manual" thoroughly before using this unit.
Keep this instruction manual around this unit
for referring at anytime.
WARNING!:
Carefully read and thoroughly understand the
important warning items described in this
manual before using this unit.

Contents
Cautions in Using with Safety...............................................................1
Explanation..................................................................................................................1
Table of Illustrated Symbols.........................................................................................2
Fundamental Matters of "WARNING!" and "CAUTION!" ..............................................3
Before Using this unit............................................................................4
Requirements for Installation .......................................................................................4
Description and Function of Each Part ..............................................12
Main Unit...................................................................................................................12
Piping System View...................................................................................................14
Principle of Operation................................................................................................15
Control Panel.............................................................................................................17
Operation Method ................................................................................18
Setup and Check before Use.....................................................................................18
Operation Procedure .................................................................................................19
Sampling of Pure Water.............................................................................................20
Display of Water Quality ............................................................................................21
Handling Precautions ..........................................................................22
Maintenance Method............................................................................23
Daily Inspection and Maintenance.............................................................................23
Maintenance Method............................................................................24
Washing of Distiller....................................................................................................24
Replacement of Heater..............................................................................................28
Washing of Water Supply Hose Filter.........................................................................29
Replacement of Hose................................................................................................29
Long storage and disposal..................................................................30
When not using this unit for long term / When disposing............................................30
In the Event of Failure… ......................................................................33
Failure indication and Its Contents.............................................................................33
Remedy for Trouble...................................................................................................35
Trouble Shooting .......................................................................................................36
After Service and Warranty .................................................................37
Specification.........................................................................................38
Wiring Diagram ....................................................................................39
Reference .............................................................................................40
List of Dangerous Substances...................................................................................40

1
Cautions in Using with Safety
Explanation
MEANING OF ILLUSTRATED SYMBOLS
Various symbolsare used in thissafety manual in order to use the unit without
danger of injury and damage of the unit. A list of problemscaused by ignoring
the warnings and improper handling isdivided asshown below.Be sure that you
understand the warningsand cautions in thismanual before operating the unit.
WARNING! If the warning is ignored, there is the danger of a problem that
may cause a serious accident or even fatality.
CAUTION! If the caution is ignored, there is the danger of a problem that may
cause injury/damage to property or the unit itself.
Meaning of Symbols
This symbol indicates items that urge the warning (including the caution).
A detailed warning message is shown adjacent to the symbol.
This symbol indicates items that are strictly prohibited.
A detailed message is shown adjacent to the symbol with specific actions not to
perform.
This symbol indicates items that should be always performed.
A detailed message with instructions is shown adjacent to the symbol.
Illustrated Symbols

2
Cautions in Using with Safety
Table of Illustrated Symbols
Warning
Warning,
generally
Warning,
high voltage
Warning,
high temperature
Warning,
drive train
Warning,
explosive
Caution
Caution,
generally
Caution,
electrical shock
Caution,
scald
Caution,
no road heating
Caution,
not to drench
Caution,
water only
Caution,
deadly poison
Prohibit
Prohibit,
generally
Prohibit,
inflammable
Prohibit,
to disassemble
Prohibit,
to touch
Compulsion
Compulsion,
generally
Compulsion,
connect to the
grounding
terminal
Compulsion,
install on a flat
surface
Compulsion,
disconnectthe
powerplug
Compulsion,
periodical
inspection

3
Cautions in Using with Safety
Fundamental Matters of "WARNING!" and "CAUTION!"
WARNING!
Do not use this unit in an area where there is flammable or explosive gas
Never use this unit in an area where there is flammable or explosive gas.
This unit is not explosion-proof. An arc may be generated when the power switch is turned on or off,
and fire/explosion may result. (Refer to Page 40 "List of Dangerous Substances".)
Be sure to connect grounding wire.
Connect to grounded plug socket. If no grounded plug socket is available, be sure to connect
grounding lead by use of ground adapter attached in nonstandard. Failure to do so could cause
electric shock or fire.
If a problem occurs
If smoke or strange odor should come out of this unit for some reason, turn off the power key right
away, and then turn off the circuit breaker and the main power. Immediately contact a service
technician for inspection. If this procedure is not followed, fire or electrical shock may result. Never
perform repair work yourself, since it is dangerous and not recommended.
Do not use the power cord if it is bundled or tangled
Do not use the power cord if it is bundled or tangled. If it is used in this manner, it can overheat and
fire may be caused.
Do not process, bend, wring, or stretch the power cord forcibly
Do not process, bend, wring, or stretch the power cord forcibly. Fire or electrical shock may result.
Do not disassemble or modify this unit
Do not disassemble or modify this unit. Fire or electrical shock or failure may be caused.
Do not touch hot portion
Boiler may be hot in some portion in operation or immediately after operation. Be aware of burns.
When performing maintenance of heater etc., ensure that the boiler is cooled down beforehand.
Close the tap when unit is out of service
When unit is out of service (at night or on holiday), be sure to close the tap so as to avoid water leakage
accident.
CAUTION!
During a thunder storm
During a thunderstorm, turn off the power key immediately, then turn off the circuit breaker and the main
power. If this procedure is not followed, fire or electrical shock may be caused.
Exercise care in handling washing liquid (Orgazor)
Principal component of washing liquid (Orgazor) is sulfamic acid, which is acidic almost equal to water
solution PH:1. Use protective tool (gloves, mask, and glasses) in handling. When it is touched by
human body, immediately wash it away with clean water.

4
Before Using this unit
Requirements for Installation
WARNING!
1. Always ground this unit
Connect the power plug to a receptacle with grounding connectors.
Do not forget to ground this unit, to protect you and the unit from electrical shock in case of
power surge. Choose a receptacle with grounding connectors as often as possible.
Do not connect the grounding wire to a gas pipe, or by means of a lightning rod or telephone
line. A fire or electrical shock will occur.
2. Choose a proper place for installation
Do not install this unit in a place where:
Rough or dirty surface.
Flammable gas or corrosive gas is generated.
Ambient temperature 35C and above or 5C and below.
Ambient temperature fluctuates violently.
There is direct sunlight.
There is excessive humidity and dust.
There is a constant vibration.
Not horizontal surface.
The power source is instable.
Keep space around each product above the range shown below. Install units within sink
equipment if possible.
10cm or more
Front side
10cm or more
10cm
or more 10cm or more
3. Do not use this unit in an area where there is flammable or explosive gas
Never use this unit in an area where there is
flammable or explosive gas. This unit is not
explosion-proof. An arc may be generated
when the power switch is turned ON or OFF,
and fire/explosion may result. (To know
about flammable or explosive gas, refer to
Page 40 "List of Dangerous Substances".)

5
Before Using this unit
Requirements for Installation
4. Do not modify
Never disassemble this unit.
This unit has high voltage inside in some
portion, which may cause electric shock.
Contact dealers or Yamato Scientific Co.,
Ltd. sales office for adjusting or repairing
inside.
In routine maintenance and inspection,
follow the procedure described in the
instruction manual. Do avoid
modification by customer because it may
lead to trouble.
5. Installation on horizontal surface
Set this unit to the flattest place. Setting this
unit on rough or slope place could cause the
unexpectible trouble or malfunction.
The weight of main unit is approximately 48kg.
Carry and install the equipment carefully by
two or more persons.
6. Choose a correct power distribution board or receptacle
Use a plug socket conforming to electric capacity (capacity 15A or greater).
When power capacity is insufficient, sampling of distilled water goes short, and normal control
is disabled by fall of power voltage. Connect to power equipment having sufficient power
capacity.
Electric capacity:
115V AC Single phase 13A
7. Handling of power code
Do not entangle the power cord. This will cause overheating and possibly a fire.
Do not bend or twist the power cord, or apply excessive tension to it. This may cause a fire
and electrical shock.
Do not lay the power cord under a desk or chair, and do not allow it to be pinched in order to
prevent it from being damaged and to avoid a fire or electrical shock.
Keep the power cord away from any heating equipment such as a room heater. The cord's
insulation may melt and cause a fire or electrical shock.
If the power cord becomes damaged (wiring exposed, breakage, etc.), immediately turn off the
power at the rear of this unit and shut off the main supply power. Then contact your nearest
dealer for replacement of the power cord. Leaving it may cause a fire or electrical shock.
Connect the power plug to the receptacle which is supplied appropriate power and voltage.

6
Before Using this unit
Requirements for Installation
8. Connection of power cord
Always ensure that breaker on power unit side is "Off" before connecting power cord. Power
plug of this unit uses 3-core cord including grounding wire, and the plug is grounded type. If
your plug socket is not compatible (2P), use a ground adapter attached in nonstandard. In
using ground adapter, be sure to ground a grounding lead.
9. Observe the specified pressure range of raw water from waterworks
Apply the range of city water pressure between 0.5 X 100kPa and 5 X 100kPa (0.5 - 5kgf/cm2)
including nighttime.
Range of raw water pressure is the same when "Water Supply Port Unit" (optional accessory)
is used.
10. Connect the water supply hose securely
If not connecting the water supply hose securely, the water supply hose or connection port
may be disconnected, resulting in water leakage such as water bursting forth.
Take the connection port body and supply hose out of attachments to the unit. Install the unit
on a horizontal and stable place nearby tap and sink.
11. Connect the tap side
1. Slide the sleeve of socket ③on connection port side in the arrow direction, then connection
port body and water supply hose can be separated. There separate the two parts.
2. Once loosen the plug ②from the ring ①.
3. Tighten the 4 mounting screws ⑤uniformly while pressing the ring ①slightly and uniformly
to make the packing ⑥in flat contact with water tap. If the tap is a chemical tap, adjust the
position so that the mounting screw is located at the bottom valley of tap nipple as shown.
4. Turn the plug ②clockwise to tighten securely. This will allow the tap and connection port to
be sealed by packing ⑥.
5. Insert the socket ③securely to the plug ②with the sleeve slid in the arrow direction. The
sleeve returns to the original position when released, and then connection is completed.
In case that the socket is removed, the valve attached on the connection side of the main unit
stops the flow of water.
Tap
Connection
port body
Socket on
connection
port side
Water supply
hose
Water supply port
Sleeve on water
supply port
Connection Port Body
①Ring
②Plug
③Socket
④Spacer
⑤Mounting Screw
⑥Packing
⑦Filter
One-touch
Joint
④
⑤
⑥
⑦
①
②
③
Tap
Sleeve
Water supply hose

7
Before Using this unit
Requirements for Installation
12. Connection on body side
1. Remove the rubber cap from the water supply port plug
⑧.
2. Insert the socket ⑨securely to the plug ⑧on body
side with the sleeve slid in the arrow direction. The
sleeve returns to the original position when released,
and then connection is completed. The socket
contains a valve inside, which opens only when the
socket is connected by plug; otherwise, water is not fed
because this valve does not open.
13. Connect the water supply hose to the tap provided with sink equipment
If the water supply hose is
connected to a tap without
sink equipment, flood damage
may be caused when water
supply hose is disconnected
or damaged; therefore be
sure to connect to a tap
having sink equipment.
Tap
Water supply hose
Socket on
connection
port side
Connection port Body
Sink
Sleeve
⑧
⑨
Body side

8
Before Using this unit
Requirements for Installation
CAUTION!
14. When the sink equipment is remote from water tap, use "Water Supply Port Unit"
(optional accessory)
"Water Supply Port Unit" is designed to loosen the connection to the tap harder than the set of
standard water supply hoses when water pressure fluctuates.
15. In case that there is no tap
In case that there is no tap, use appropriate joint shown in the optional "Coupler joints for feed
water".
16. Connect the drain hose securely
If the drain hose is not connected securely, it may be disconnected, leaking water in the unit,
or leading to trouble of system.
1. Pick up the drain hose (with elbow) and the hose clamp from the main unit accessories.
2. Always make sure that the earth leakage breaker of the unit is "OFF".
3. Remove the rubber stopper from the outlet of the drain port hose on the main unit.
4. Push the hose clamp into the elbow of the drain hose, and next, put the elbow into the drain
outlet hose of the main unit, then tighten the hose clamp securely.
5. Pull the hose out from the drain hose-end outlet at right/left or backside of the main unit.
Hose
clamp
Drain port hose
on the main unit
Elbow
Drain hose (accessory)

9
Before Using this unit
Requirements for Installation
WARNING!
17. Use care in routing of drain hose
Do avoid making bend or projection of drain hose.
In case that the drain hose is bent and the drain cannot be performed, back-flow or breakage
of the cooling hose might occur.
Place the drain hose lower than the drain port of this unit. Further, avoid piping which allows
paddle in the hose or at the hose outlet, because it is a resistance against drain.
Place the end of drain hose where drain is allowed. When distilled water is being prepared,
cooling water is drained approx. 2 liters/min. Also drain further increases when boiler water is
drained, and sufficient drain equipment is required.
18. Check the drain temperature of cooling water
Drain temperature may exceed 60℃in drainage from boiler. Drain to a place remote from
working environment not to be touched easily because there is a danger of burns.
High-temperature cooling water could flow out. If vinyl chloride tube is used for the water
drain unit of the sink, such a tube could deteriorate. Water should be drained to a place away
from the drain tube of the sink. Even if VP tube (JIS K6741) is used for the vinyl chloride
tube, DV-RR joint is used for the joint, and even if insert socket (JIS K6739) is used, the water
drain trap in the nonstandard options should be used when the control temp. cannot be
lowered (60℃or lower). Even if the drain temperature is 60℃or lower, and if the
above-mentioned tubes and joint are not used, the drain trap in the nonstandard options
should be used.
19. When drain temperature of sink equipment does not fall under 60℃
Use a drain trap (optional accessory).
Drain trap makes temperature fall by accumulating cooled drain water temporarily. Further, it
mixes city water and cooled-down drain water, makes mixed water temperature fall, then lets
drain to sink equipment.
Contact your dealer or Yamato Scientific sales office for detail of drain trap.

10
Before Using this unit
Requirements for Installation
20. Install the ion exchange resin cartridge (CPC-S) securely
Install the ion exchange resin cartridge (CPC-S) following the procedure shown below.
Connect securely because insecure connection may cause water leakage.
1. Make sure that the earth leakage breaker of this unit is "Off" and that the tap is tightened.
2. Take the ion exchange resin cartridge out of attachments to the unit.
3. Place the ion exchange resin cartridge taken out on the receiver within the unit. (See Fig.1.)
4. Fix the ion exchange resin cartridge with the band of receiver. (See Fig.2.)
5. Remove the rubber cap attached to the inlet and outlet of ion exchange resin cartridge.
6. Fit in the coupler marked with (IN) to the inlet of ion exchange resin cartridge (left) until click is
heard. (See Fig.3.)
7. Fit in the coupler marked with (OUT) to the outlet of ion exchange resin cartridge (right) until
click is heard. (See Fig.3.)
Coupler may be hard at first. When applying force in inserting, do not make it curved because
insertion port may be broken.
IN
Reset switch
INOUT
OUT
8. Coupler can be removed easily from the ion exchange resin cartridge by pulling it toward
yourself while pushing the black part of the coupler to the depth.
Fig.1
Fig.2
Fig.3
Fig.4

11
Before Using this unit
Requirements for Installation
21. Secure the pre-treatment cartridge securely
Connect the hose in the body securely following the procedure shown below.
Insecure connection may cause disconnection of connection hose, resulting in accident by
water leakage.
1. Make sure that the earth leakage breaker of this unit is "OFF" and that the tap is tightened.
2. Take the pre-treatment cartridge ①out of attachments to the body.
3. Inlet and outlet of the pre-treatment cartridge ①are provided with a cap, so remove it.
4. When the front door of this unit is opened, connection hose marked IN and OUT is found in
the coupler; there make connection matching them with IN and OUT on pre-treatment
cartridge ①.
5. In connecting, mate the coupler and port of cartridge while sliding the blue portion ③of
coupler toward the hose, push in, then release the blue portion ③.
6. When connection is finished, place the pre-treatment cartridge at the position shown on the
right (near side on the left of distilled water tank) as paying attention to the bend of hose.
22. After installation
This unit may topple over due to unexpected earthquake or shock causing injury. Take an
appropriate measure against toppling for safety.
②
①

12
Description and Function of Each Part
Main Unit
Multi-purpose distilled water intake opening
The multi-purpose distilled water intake opening is located at right side surface of the unit, and
one-touch joint (refer to Page 13) is installed at the opening. Distilled water in the tank can be filled by
removing the plug stopper, and connect the hard tube of φ8mm of outer diameter. Moreover, the
one-touch joint is available as connection port for optional goods.
Notice that distilled water pours when removing the plug stopper because the one-touch joint
does not have the check valve.
Heater terminal block
Drain cock
Ion exchange resin cartridge
(CPC-S)
Boiler
Leakage detection electrode
Distilled water tank
Water level meter
Reset switch
Pre-treatment cartridge
Heater
Earth leakage breaker
Product number sticker
Drain port
(2pcs each at right/left)
Control panel
Water level meter
Multi-purpose distilled water
sampling port
Distilled water
sampling port
Ion exchange water
sampling port

13
Description and Function of Each Part
Main Unit
How to use one-touch joint
Use one-touch joint following the procedure shown below.
Notice that distilled water pours when removing the plug stopper or tube because the one-touch joint
does not have the check valve.
● Fitting of tube
1. Make certain that the end of the tube is cut at right angles, the tube surface is free from flaws, and
the tube is not deformed into an ellipse.
2. When fitting a tube, insert the tube completely to prevent leakage.
3. On completion of fitting, make certain that the tube does not come out at your pulling.
●Release of tube
Push the release ring fully inside and pull out the tube. Unless you push it completely in, the tube
may not come out and scrapings of tube may be left inside the joint.
Release ring

14
Description and Function of Each Part
Piping System View
1
Pressure reduction valve
15
Boiler water supply solenoid valve
2
Pressure switch
16
Initial accumulated water drain
solenoid valve
3
Cooling water solenoid valve
17
Ion exchange water sampling solenoid valve
4
Raw water supply solenoid valve
18
Distilled water sampling solenoid valve
5
Pre-treatment cartridge
19
Ion exchange water sampling port
6
Ion exchange resin cartridge (CPC-S)
20
Distilled water sampling port
7
Float cylinder
21
Distilled water tank
8
Float switch 1
22
Float switch 3
9
Float switch 2
23
Air filter
10
Boiler drain cock
24
Distilled water sampling pump
11
Boiler
25
Distilled water tank drain port
12
Heater
26
Water level meter
13
Condenser
27
Multi-purpose distilled water sampling port
14
Ion exchange water quality gauge electrode

15
Description and Function of Each Part
Principle of Operation
1. Boiler Water Supply and Distilling Operation
Turn ON the earth leakage breaker, and press the power switch. Then, the raw water supply solenoid valve
(4) and the boiler water supply solenoid valve (15) open at the same time to supply water to the boiler (11).
When the float switch 1 (8) in the float cylinder (7) detects water level, the heater (12) is energized to start
distillation. The water supply to the boiler is controlled by the raw water supply solenoid valve (4) and the
boiler water supply solenoid valve (15) both opened/closed by the float switch 2 (9).
2. Flow of Cooling Water
During distillation, water is supplied and discharged in the order: (1) pressure-reducing valve, (3) cooling
water solenoid valve and condenser (13). When the distilled water tank is full, or when ion exchanged water
is sampled, distillation is stopped, and the cooling water is also stopped automatically.

16
Description and Function of Each Part
Principle of Operation
3. Sampling of Distilled Water
The distilled water condensed in the condenser (13) is stored in the distilled water tank (21) after discharging
the initial boiled water via the initial boiled water discharge solenoid valve (16) for about 10 min. after power
switch is turned ON. If the float switch (22) on top of the tank trips, it is deemed as Full Tank, and the
distillation is stopped. When any specified amount of distilled water is sampled and consumed, distilled
water is produced automatically.
The distilled water so stored is sampled by way of the distilled water sampling solenoid valve (18) and the
distilled water sampling port (20) by the distilled water sampling pump (24).
4. Sampling Ion Exchanged Water
Ion exchange water is sampled by way of the pressure-reducing valve (1), raw water supply solenoid valve
(4), pre-treatment cartridge (5), ion exchange resin cartridge (6), ion exchange water quality electrode (14),
ion exchange water sampling solenoid valve (17) and ion exchange water sampling port (19).

17
Description and Function of Each Part
Control Panel
ON
LEAK LOW PRESSURE
OVERHEAT
CONDUCTIVITY
WARNING
PRE-FILTER
ION EXCHANGE RESIN
0 5 10
×10-4S/m
∞1
POWER
0.5
DISTILL
DISTILLED
WATER
PURE
WATER
①
POWER key
Turns on/off the power of the controller.
②
DISTILL lamp
Lights up during distillation.
③
CONDUCTIVITY indicator
Lights up when the conductivity of pure water keeps between 0.0 to ∞μS/㎝.
④
LOW PRESSURE lamp
Blinks when low pressure error is detected.
⑤
OVERHEAT lamp
Blinks when overheat of the heater is detected.
⑥
DISTILLED WATER key
Starts/stops drawing distilled water.
⑦
PURE WATER key
Starts/stops drawing pure water.
⑧
LEAK lamp
Blinks when water leakage is detected.
⑨
ION EXCHANGE RESIN
exchange indication
Lights up when the conductivity of the ion exchange resin enters the caution
area (orange), and blinks when it enters the warning area (red).
⑩
PRE-FILTER
exchange indication
Lights up when the conductivity of the pretreatment filter enters the caution
area (orange), and blinks when it enters the warning area (red).
⑪
ON lamp
Lights up while the power of the controller is turned on.
①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪

18
Operation Method
Setup and Check before Use
WARNING!
1. Check of water supply
Check that the water supply hose is securely connected.
Open the tap.
Check that water does not leak from connection of water supply hose.
2. Check of drain
Check that the drain hose is securely connected.
Check that the drain hose is free from bend or projection.
When the drain hose is bent or the like, system does not operate normally, and in addition, it may
lead to water leakage accident. Inspect from time to time, and ensure that water is drained
properly.
3. Check of power supply
Check that the power cord is connected to appropriate plug socket.
4. Before operation
Turn on the earth leakage breaker, then, perform calibration before pressing POWER key.
Perform calibration operation at first-time using this unit (refer to page 19) and when changing the
heater of the boiler (refer to page 28).
Press POWER key while holding PURE WATER key and DISTILLED WATER key. Perform
calibration operation (all of ON, DISTILL, PURE WATER, and DISTILLED WATER lamps blink at
the same time) for about five minutes, after then, distillation (ON and DISTILL lamps light up)
starts automatically. Key operation becomes disable while calibration operation. In case that
power failure occurs while calibration operation, please perform calibration again.
5. Caution at initial operation
In sampling distilled water in initial energization and drain from distilled water storage tank, air is
contained in the pump and piping, and it takes time until sampling is started.
In sampling ion exchanged water immediately after changing pre-treatment cartridge or ion
exchange resin cartridge, it also takes time until sampling is started. Further, when each
cartridge is changed, drain about 5 liters in order to remove initial impurities.