ELGA PURELAB flex 3 Service Manual
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ELGA PURELAB flex 3 Service Manual

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ELGA LabWater assumes that the technician using this manual has a working knowledge of
water purification systems and has attended an ELGA LabWater technical training course.
This manual is correct for use with the PURELAB range of systems mentioned above. For
information on other products from ELGA LabWater please refer to the relevant service
If you would like to contact us with regards to training or give us any feedback on this
manual please contact technical support at
Introduction
Service Manual
PURELAB flex
Covers the following products:
PURELAB
PURELAB
manual available from www.elgalabnet.net.
Issue 3
®
flex 3
®
flex 4
techsupport@elgalabwater.com
Page 1 of 52

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Summary of Contents for ELGA PURELAB flex 3

  • Page 1 PURELAB flex 4 ELGA LabWater assumes that the technician using this manual has a working knowledge of water purification systems and has attended an ELGA LabWater technical training course. This manual is correct for use with the PURELAB range of systems mentioned above. For information on other products from ELGA LabWater please refer to the relevant service manual available from www.elgalabnet.net.

  • Page 2: Manual Revision Notes

    PF4XXXXM1 Copyright Note The information contained in this document is the property of VWS (UK) Ltd, trading as ELGA LabWater, and is supplied without liability for errors or omissions. No part of this document may be reproduced or used except as authorized by contract or other written permission from VWS (UK) Ltd.
  • Page 3 PURELAB flex 3 & 4 Index Section Number / Title Sub Section Title Page Number 1 – Process Descriptions Product Specific Flow Paths Process Flow Diagrams 2 – Parts Identification Consumables Accessories Common / Basic Parts Drawings 3 – Electronics...

  • Page 4: Health And Safety

    Electricity Most ELGA products are powered from a mains electrical supply, this could be up to 265Vac. Please ensure that when performing maintenance on these units that the power supply is isolated whenever possible before any work is carried out.

  • Page 5: Section 1 - Process Description

    Section 1 – Process Description Product Specific Process Descriptions & Flow Paths PURELAB flex 3 Flow Lines NRV1 NRV2 NRV4 NRV3 Process Flow 1. The potable water enters the system through the inlet solenoid valve before flowing into the RO module.
  • Page 6 PURELAB flex 3 & 4 PURELAB flex 4 Flow Lines NRV1 NRV2 NRV3 Process Flow 1. The pre-purified water enters the system through the inlet solenoid valve into a flow restrictor. 2. The water then enters a 3 way solenoid valve. The solenoid valve will direct the inlet water to drain for the first 4 minutes before directing it to the reservoir.
  • Page 7 PURELAB flex 3 & 4 Process Flow Diagrams The Process Flow Charts are a simplified visual representation of the software routines to assist a trained technician to understand the process flow and troubleshoot symptoms. PURELAB flex 3 Commissioning Connect the power supply to the...
  • Page 8 PURELAB flex 3 & 4 PURELAB flex 4 Commissioning Connect the power supply to the PURELAB flex Set Language Highlight correct language and press Accept Install the Composite Vent filter and Purification Pack Turn on the water supply to the flex and...
  • Page 9 PURELAB flex 3 & 4 PURELAB flex Sanitization P1 turns on for 6 Hold down PF4 to minutes access the menu P1 turns off for 60 minutes Highlight sanitization and press accept P1 turns on for 24 minutes Place a 1 liter...

  • Page 10: Section 2 - Parts Identification

    Section 2 – Parts Identification Consumables PURELAB PURELAB Part Number Description flex 3 flex 4 LC214 Purification Pack   LC209 Sanitization Pack   LC210 185/254nm UV Lamp   LC216 Composite Vent Filter   LC145 Point of Use – 0.2µm Microfilter ...
  • Page 11 LA728 – Bypass Pack Printer Though a printer can be connected to the PURELAB flex, ELGA LabWater does not supply a printer for this application. For details of recommended printers please contact technical support. Section 2 – Parts Identification Issue 3...
  • Page 12 PURELAB flex 3 & 4 Common / Basic Parts Key: Not used Number of part used PURELAB PURELAB Part Number Description flex 3 flex 4 ADAP31299 ADAPTOR STRAIGHT 8mm OD TUBE ADAP32798 ADAPTOR STRAIGHT 8mm OD TUBE ADAP32800 ADAPTOR STEM 8mm-1/4"BSP"...
  • Page 13 PURELAB flex 3 & 4 PURELAB PURELAB Part Number Description flex 3 flex 4 LA728 BYPASS CARTRIDGE FLEX LATC39253 QUARTER LATCH TURN LC210 UV LAMP - PURELAB FLEX LC217 RO CARTRIDGE FLEX 3 & 4 MAGN39132 FLEX DOOR MAGNET MOUN38647...
  • Page 14 4 SP930P FLEX DOOR ASSY LEFT HAND SP940P FAN ASSY PURELAB FLEX SP947 PURELAB FLEX 3 & 4 WIRING ASSY SP950P PISTON CARTRIDGE ASSY - FLEX SP954P DISPENSER ARM ASSY FLEX 3 & 4 SP963 DISPENSER NRV ASSY FLEX 3 & 4...
  • Page 15 PURELAB flex 3 & 4 Drawings Please see below details of the drawings located in this section of the manual and which PURELAB flex they correspond to. PURELAB flex 3 Sub Assembly Description Page Number Main body assembly – External Main body assembly –...
  • Page 16 PURELAB flex 3 & 4 Main Body – External Parts Item Part Number Description SP919 Cartridge Bulkhead Assembly (see page 23 for a breakdown of parts) SP923 UV Assembly (see page 25 for a breakdown of parts) SP929 Right hand door...
  • Page 17 Description SP951 Bulkhead Assembly (see page 26 for a breakdown of parts) SP945 PURELAB flex 3 Tank Assembly (see page 20 for a breakdown of parts) SP958 PURELAB flex 4 Tank Assembly (see page 21 for a breakdown of parts)
  • Page 18 PURELAB flex 3 & 4 Main Body – Internal Parts Tank Removed Item Part Number Description PU010418 Connector 8mm OD tube x 8mm OD tube PCBS38875 Flex Control Board PUMP38824 Recirculation Pump SP925 Line Cell SP963 Dispenser NRV Assembly Section 2 – Parts Identification...
  • Page 19 PURELAB flex 3 & 4 Base Moulding - Bottom Item Part Number Description ELBW38327 Elbow 8mm Stem x 8mm OD Tube SP940 Fan Assembly TEE38261 Tee Equal 8mm OD Tube Section 2 – Parts Identification Issue 3 Page 19 of 52...
  • Page 20 PURELAB flex 3 & 4 SP945 Tank Assembly Item Part Number Description ADAP31299 Adaptor 8mm OD tube x 1/8” BSPT male ADAP32800 Adaptor Stem 8mm OD tube x ¼” BSPT male CONN39258 Two way divider 8mm OD tube ELBW35604 Elbow stem 6mm OD tube x 6mm OD tube...
  • Page 21 PURELAB flex 3 & 4 SP958 Tank Assembly Item Part Number Description ADAP32800 Adaptor Stem 8mm OD tube x ¼” BSPT male ELBW35960 Elbow reducing 8mm OD tube x 6mm OD tube ELBW38317 Elbow equal 8mm OD tube ELBW38327 Elbow stem 8mm x 8mm OD tube...
  • Page 22 PURELAB flex 3 & 4 Manual Drain Assembly Item Part Number Description ADAP39406 Adaptor stem 6mm OD x ¼” BSPT male ADAP32798 Adaptor straight 8mm OD tube x ¼” BSPT male ADAP39228 Adaptor 1” BSP CONN38836 Connector short cartridge ELBW35960...
  • Page 23 PURELAB flex 3 & 4 SP919 Cartridge Bulkhead Assembly Item Part Number Description ELBW38327 Elbow stem 8mm OD x 8mm OD tube PLAT38815 Cartridge plate SP919 Cartridge bulkhead assembly SP925 Line cell SP926 Flow sensor Section 2 – Parts Identification...
  • Page 24 PURELAB flex 3 & 4 SP954 Dispenser Arm Assembly Item Part Number Description CCAP39125 Arm Lock Cover Cap CLAM39128 Arm Clamp Ring DARM38805 Dispenser Arm HOLS39281 Holster SCRW39126 Arm Button Screw SCRW39209 M6 x 6 Socket Head Set Screw STUD39127 Arm Clamp Section 2 –...
  • Page 25 PURELAB flex 3 & 4 SP923 UV Assembly Item Part Number Description BALL38832 Ballast box BALL38877 UV ballast CAPS32084 Cap end 185nm UV housing DISC32084 Sealing disk UV housing HOUS38855 UV housing PU010418 Connector equal 8mm OD tube RING32087 O-ring BS115...
  • Page 26 PURELAB flex 3 & 4 SP951 Bulk Head Assembly Item Part Number Description ADAP39230 Bulkhead adaptor Non return valve BALL39247 8mm ball CONN32791 Connector bulkhead 8mm OD tube CONN38800 Connector panel mount socket CONN38836 Connector short cartridge CONN38883 Connector DC power...

  • Page 27: Display Icons

    Section 3 - Electronics Display Icons Dispense Button Auto Volume Dispense Accept Down Quality Display Scroll Bar This shows the outlet This scrolling info bar quality in MΩ or µS. shows: Please be aware MΩ can TOC reading only be read when the Time optional DI pack is installed...
  • Page 28 PURELAB flex 3 & 4 Warnings Alarm Reason Action More than 250ml is added Message will be displayed until the Manual Fill Warning – directly to the reservoir, this water quality in the reservoir is Message on scroll bar is not detected during >5MΩ...
  • Page 29 PURELAB flex 3 & 4 Alarms Alarm Reason Action • Check diagnostics display • Check feed water Purity Alarm – The quality The dispense purity is less specifications reading on the display is than the defined alarm set • Change DI pack...

  • Page 30: Software History

    PURELAB flex 3 & 4 Software History PURELAB flex 3 & 4 Software Version Date Released Modifications V1.2.0 January 2011 First released version PCB Drawings / Details The PCB’s (printed circuit board) used on these products all vary due to the type of system and the software used on them.
  • Page 31 PURELAB flex 3 & 4 Section 3 - Electronics Issue 3 Page 31 of 52...
  • Page 32 PURELAB flex 3 & 4 Dispense Handset Recirculation Pump Line Cell Inlet Valve UV Ballast TH5A UV and PCB Fans Temperature Sensor Power Supply Level Sensor Drain Valve Flow Sensor Data tag and Footswitch FUSE39145 – Quick blow 3A FUSE39146 – Quick blow 2A...

  • Page 33: Battery Replacement Instructions

    PURELAB flex 3 & 4 Battery Replacement The PCB boards used on the PURELAB flex have a battery installed on them to maintain the settings when the system is powered down. If the battery needs to be replaced please be aware that all of the user settings and timers will be lost and will need to be reset once the new battery is installed.

  • Page 34: Electrical Parameters

    PURELAB flex 3 & 4 Electrical Parameters Most ELGA products are powered from a mains electrical supply, this could be up to 265V. Please ensure that when performing maintenance on these units that the power supply is isolated whenever possible before any work is carried out.

  • Page 35: Section 4 - Maintenance

    Service Recommendations This document is designed to help guide you through the component and system checks recommended by ELGA LabWater. Detailed below are some recommended checks that should be performed during a routine service visit. When arriving on site a risk assessment must be completed prior to any work being undertaken to ensure your safety.

  • Page 36: Operational Parameters

    PURELAB flex 3 & 4 Operational Parameters The operational parameters detailed in this section of the manual are to be used in conjunction with the service recommendations. Inlet Pressure Adjustment During Commissioning Install the pressure regulator between the water Feed Feed source and the PURELAB flex (fig 1).
  • Page 37 The main power will be on while performing the calibration procedure, please use caution It is good practice to calibrate the system every 12 months. This must be carried out by an ELGA trained service technician using the correct substitution (sub) boxes.

  • Page 38: Usb Stick Preparation

    PURELAB flex 3 & 4 Sub Box Connection to Adaptor SUB-07 SUB-15 SUB-14 SUB-07 μS/cm MΩ.cm Calibration Calibration Calibration Calibration Position Position Position Position Feed Water Resistivity Quality Cell Used for validation Purposes Temperature SUB Box Adaptor – to JH3 on PCB Only Quality SUB Box Adaptor –...
  • Page 39 PURELAB flex 3 & 4 Calibration Process Tables Quality and Temperature Sensor Calibration Action Sub Box Value Insert the prepared USB stick into the USB port on the right hand side of the PURELAB flex The USB menu will be displayed Scroll through the menu using the Up or Down buttons (PF3 &...
  • Page 40 PURELAB flex 3 & 4 Quality and Temperature Sensor Calibration Continued Service Calibration Remove the rear cover of the PURELAB flex to expose the PCB Connect the calibration boxes using the correct connectors Set sub box to the required value and wait for the display value to settle and turn white.
  • Page 41 PURELAB flex 3 & 4 Auto Volume Calibration Action Place a 1 liter measuring cylinder beneath the dispense outlet Press and hold the Accept button (PF4) to enter the menu Scroll through the menu using the Up and Down buttons (PF3 & PF5) Once Auto Volume Calibration...

  • Page 42: Sanitization Chemicals

    PURELAB flex 3 & 4 Sanitization Sanitization Chemicals During the sanitization of our products you may be required to handle chemicals such as Chlorine or Hydrogen Peroxide. Care should be taken to ensure the safety of yourself and others around you while using these chemicals.

  • Page 43: Section 6 - Troubleshooting

    Section 6 - Troubleshooting System Specifications Feedwater Requirements System Type Model PURELAB Flex 3 PURELAB Flex 4 Pre treated preferably Source Potable tap water from RO or SDI Conductivity <2000 µs/cm <30 µs/cm Hardness <350 ppm as CaCO Free Chlorine <0.05 ppm Cl...

  • Page 44: Section 5 - Specifications

    PURELAB flex 3 & 4 Treated Water Specifications System Type Model PURELAB Flex 3 PURELAB Flex 4 Delivery Flow Rate – Maximum Up to 2 l/min Inorganics (resistivity @25°C) 18.2 MΩ Organics (TOC) - Typical <5ppb* Bacteria – Typical (with POU Filter) <1 CFU/10ml...
  • Page 45 Section 6 - Troubleshooting Symptom Possible Cause Check the tank level If empty: Check the refill level setting in the menu No water coming from dispense nozzle If full: Confirm voltage to pump Check fuses Confirm that the power supply is connected to the No display mains power inlet.

  • Page 46: Section 7 - Appendix

    Section 7 - Appendix Appendix Index Appendix Description Page Number Commissioning Report Routine Service Report Calibration Certificate Service Bulletins Section 7 - Appendix Issue 3 Page 46 of 52...

  • Page 47: System Settings

    PURELAB flex 3 & 4 Appendix A Commissioning Report System Settings Default Default Function to be set Option Installed? Actual settings Feature settings Language English Refill Level 2.5 Liters Timed Auto Refill Disabled Alarm 1 MΩ-cm Dispense Purity Mandatory Feature...
  • Page 48 Consumables Installed Date Comments DI Pack UV Lamp RO Membrane Composite Vent Filter I confirm that the above commissioning was carried out by an ELGA LabWater Trained Representative. Signed..........Date........ Section 7 - Appendix Issue 3 Page 48 of 52...
  • Page 49 PURELAB flex 3 & 4 Appendix B Routine Service Report Site History and Observations: General Questions - Site Related Concerns? Review Service History Review Customer's Operation Log Query lab manager/users about unit's operation VISUAL Check of unit's location/connections Corrected? Is the unit clear of obstruction?

  • Page 50: System Menu

    DI Pack UV Lamp Quartz Thimble & O-Rings RO Membrane Composite Vent filter I confirm that the above commissioning was carried out by an ELGA Labwater Trained Representative. Signed..........Date........ Section 7 - Appendix Issue 3 Page 50 of 52...

  • Page 51: Calibration Certificate

    JH2 (using adaptor) Sub Box 07 JH3 (using adaptor) Sub Box 07 JH3 (using adaptor) I confirm that the above calibration was carried out by an ELGA LabWater Trained Representative. Signed..........Date....... Section 7 - Appendix Issue 3 Page 51 of 52...
  • Page 52 For further information and technical details on all ELGA LabWater products please contact Technical Support at: ELGA LabWater Global Operations Lane End Industrial Park High Wycombe Bucks HP14 3BY Phone - +44 (0) 1494 887850 Fax - +44 (0) 1494 887505 Email –...

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