Service Manual

PURELAB flex

Covers the following products:

PURELAB® flex 3
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.

If you would like to contact us with regards to training or give us any feedback on this
manual please contact technical support at techsupport@elgalabwater.com

Introduction Issue 3 Page 1 of 52

PURELAB flex 3 & 4

Manual Revision Notes

Issue Number Date Issued Details of Revision
1 6th January 2011 First Issue
2 6th July 2011 Multiple Changes
3 25th January 2012 Service Bulletins Added
4 21 February 2012 Feed water chlorine value changed

Product Part Numbers

Product Type Part Number

PURELAB flex 3 UV,DI & RO reservoir system PF3XXXXM1
PURELAB flex 4 direct supply reservoir system 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. The copyright and all restrictions on reproduction and use apply to all
media in which this information may be placed.
VWS (UK) Ltd. pursue a policy of continual product improvement and reserve the right to alter without
notice the specification, design, price or conditions of supply of any product or service.

© VWS (UK) Ltd. 2011 – All rights reserved.

ELGA® is a registered trademark of VWS (UK) Ltd.

Introduction Issue 3 Page 2 of 52

PURELAB flex 3 & 4

Index

Section Number / Title Sub Section Title Page Number

1 – Process Descriptions Product Specific Flow Paths 5

Process Flow Diagrams 7

2 – Parts Identification Consumables 10

Accessories 11
Common / Basic Parts 12
Drawings 15

3 – Electronics Display Icons 27

Warnings / Alarm Codes 28
Software History 30
PCB Drawings / Details 31
Battery Replacement 33
Electrical Parameters 34

4 – Maintenance Service Recommendations 35

Operational Parameters 36
Calibration 37
Sanitization 42

5 – Specifications System Specifications 43

6 – Troubleshooting Trouble shooting 45

7 - Appendix Appendix Index 46

Introduction Issue 3 Page 3 of 52

PURELAB flex 3 & 4

Health and Safety

ELGA LabWater products have been designed to be safe, however it is

important that personnel working on these units are aware of any potential
dangers.

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.
Please use caution when working on systems connected to a main
! power supply. If in doubt do not atempt any work on a product unless
the power supply is isolated.

Water Pressure
When possible the main water supply to a product should be isolated and residual pressure released
prior any work being carried out on the unit to prevent injury to yourself and others.

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. A material safety data sheet conforming to COSHH regulations is provided with
the chemical, please read this carefully before carrying out the sanitization.
Safety goggles and gloves should be worn at all times while handling
! any chemical substance.

Ultra-violet Light
Many of our products are fitted with an Ultra-violet lamp, this lamp is enclosed in a stainless steel
housing to ensure that personnel are not exposed to UV light.
Under no circumstances should a lamp be connected and activated
! outside the housing.

If in doubt always seek advice before commencing work on ELGA products. Please contact the technical
support department at techsupport@elgalabwater.com for more information.

Introduction Issue 3 Page 4 of 52

 Section 1 – Process Description
Product Specific Process Descriptions & Flow Paths

PURELAB flex 3

Flow Lines 9
V3
LS1
NRV1 8

3 NRV2
QS3 FS1
NRV4

4
V2
2
6
V4
P1 5 7

1 V1 NRV3

QS2 TS2 QS1 TS1

Process Flow
1. The potable water enters the system through the inlet solenoid valve before flowing into the RO
module.
2. The RO concentrate flows directly to drain through a flow restrictor.
3. The RO permeate flows through a non return valve into a 3 way solenoid valve. The solenoid
valve will direct the permeate to drain for the first 4 minutes before directing it to the reservoir.
4. The reservoir can hold up to 7 liters of water, it can be manually emptied using hand valve V4.
5. When the reservoir reaches 0.25 liters the pump will start to draw water into the recirculation
system, the water passes through quality and temperature sensors QS2 and TS2 and into the
UV chamber.
6. From the UV chamber the water passes through quality sensor QS3 and flow sensor FS1 before
entering the DI pack. The flow sensor FS1 is used to control the auto volume dispense.
7. From the DI pack the water passes through quality and temperature sensors QS1 and TS1
before entering the dispense hand set V2.
8. The water then returns to the reservoir via a non return valve.
9. Once the reservoir reaches 7 liters the inlet solenoid valve will close, this valve will not open
again until the reservoir reaches the refill level as specified in the menu or the level of the tank
reaches 0 liters.

Section 1 – Process Description Issue 3 Page 5 of 52

PURELAB flex 3 & 4

PURELAB flex 4
8
Flow Lines
V3 LS1
NRV1 7

2 NRV2
QS3 FS1

3
V2
1 V1
5
V4
P1 4 6

NRV3

QS2 TS2 QS1 TS1

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.
3. The reservoir can hold up to 7 liters of water, it can be manually emptied using hand valve V4.
4. When the reservoir reaches 0.25 liters the pump will start to draw water into the recirculation
system, the water passes through quality and temperature sensors QS2 and TS2 and into the
UV chamber.
5. From the UV chamber the water passes through quality sensor QS3 and flow sensor FS1 before
entering the DI pack. The flow sensor FS1 is used to control the auto volume dispense.
6. From the DI pack the water passes through quality and temperature sensors QS1 and TS1
before entering the dispense hand set V2.
7. The water then returns to the reservoir via a non return valve.
8. Once the reservoir reaches 7 liters the inlet solenoid valve will close, this valve will not open
again until the reservoir reaches the refill level as specified in the menu or the level of the tank
reaches 0 liters.

Notes:

Section 1 – Process Description Issue 3 Page 6 of 52

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
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

press accept

V1 and V3 open
System displays estimated
commissioning 3:00:00

After 1 Hour V3 closes.

Reservoir starts to fill

Reservoir reaches >2 liters, P1 turns on

Reservoir reaches >3 liters, UV turns on

Reservoir reaches 7 liters, V1 closes

Recirculates for 30 minutes then checks

for water purity

Is water purity is above user set point?

Commissioning Complete Timer reads 30 minutes

Checks purity every 5 minutes until it
reaches quality

Commissioning Complete

Section 1 – Process Description Issue 3 Page 7 of 52

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

press accept

V1 and V3 open
System displays estimated
commissioning 1:30:00

After 10 minutes V3 closes.

Reservoir starts to fill

Reservoir reaches >2 liters, P1 turns on

Reservoir reaches >3 liters, UV turns on

Reservoir reaches 7 liters, V1 closes

Recirculates for 60 minutes then checks

for water purity

Is water purity is above user set point?

Commissioning Complete Timer reads 30 minutes

Checks purity every 5 minutes until it
reaches quality

Commissioning Complete

Section 1 – Process Description Issue 3 Page 8 of 52

PURELAB flex 3 & 4

PURELAB flex
Sanitization
Hold down PF4 to P1 turns on for 6
access the menu minutes

P1 turns off for

Highlight 60 minutes
sanitization and
press accept
P1 turns on for
24 minutes
Place a 1 liter
container under
the dispense Place a 10 liter
nozzle and press container under
accept the dispense
nozzle and press
the dispense
button
V1 closes and V2
opens to release
pressure from
the system V2 opens and
dispenses the
contents of the
reservoir

Remove the
purification pack
and insert the The reservoir
sanitization pack reaches 0 liters,
V2 closes and P1
turns off
Press accept to
start the
sanitization Remove the
sanitization pack
and insert the
purification pack
The reservoir
level is checked,
if it is <7 liters,
Sanitization
V1 will open and
complete
fill the reservoir
System returns
to normal
operation

A timer will start

to count down on
the screen
1:30:00

Section 1 – Process Description Issue 3 Page 9 of 52

 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  
LC197 Point of Use – Biofilter  
LC217 RO Assembly  

LC216 –
Composite Vent
Filter

LC217 – RO
LC209 –
Assembly
Sanitization Pack

LC145 – POU 0.2µ LC197 - POU

Micro filter Biofilter

Section 2 – Parts Identification Issue 3 Page 10 of 52

PURELAB flex 3 & 4

Accessories

PURELAB PURELAB
Part Number Description
flex 3 flex 4
LA732 Foot Switch  
LA734 Leak Detector  
LA735 Wall Mounting Kit  
LA652 Pressure Regulator  
LA728 Bypass Pack  
LA736 BMS Kit  

LA732 – Foot
Switch

LA652 – Pressure
LA735 – Wall Regulator
Mounting Kit

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 11 of 52

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 1 1
ADAP32798 ADAPTOR STRAIGHT 8mm OD TUBE 2 2
ADAP32800 ADAPTOR STEM 8mm-1/4"BSP" 1 1
ADAP39228 ADAPTOR STAINER 1" BSP 1 1
ADAP39230 ADAPTOR NR VALVE BULKHEAD 1 1
ADAP39406 ADAPTOR STEM 6mm-1/4” BSP 1 1
BALL38832 UV BALLAST BOX ASSY 1 1
BALL38877 BALLAST - BL 14W 24V 1 1
BALL39247 POLYPROPYLENE BALL 8MM 1 2
BASE39105 BAE MOULDING FLEX 3-4 1 1
BEND30108 BEND FLOW CLIP-ON 5/16"OD 7 7
BRAC39233 SOLENOID VALVE BRACKET 1 1
BUSH38879 BUSH FILTER BULKHEAD 1 1
CAPS32084 CAP END PVC 185nm UV HOUSING 1 1
CLIP39255 COMPONENT CLIP - VM-1010 1 1
CONN32791 CONNECTOR BULKHEAD 8mm TUBE 2 2
CONN38836 CONNECTOR SHORT CARTRIDGE 3 3
CONN39229 NRV BULKHEAD CONNECTOR 1 1
CONN39258 TWO-WAY DIVIDER 8mm TUBE 1
CORD39210 FLEX DOOR MECHANISM CORD 2 2
COUP39046 FILTER BULKHEAD COUPLING 1 1
COVR38811 COVER CENTRAL TOP 1 1
COVR39021 USB PROTECTIVE COVER 1 1
COVR39117 REAR COVER FLEX 3 1 1
COVR39252 VALVE ACCESS COVER 1 1
COVR39290 PLASTIC COVER FOR CAPACITOR 1 1
COVR39394 COVER REAR FILLER FLEX 3-4 1 1
DISC32086 DISC SEALING 185nm UV HOUSING 1 1
ELBW35604 ELBOW STEM 6mm OD x 6mm OD 2
ELBW35960 ELBOW REDUCING 8mm OD TUBE x 2 1
ELBW36122 ELBOW SWIVEL 8mm OD TUBE x 2 2
ELBW38317 ELBOW EQUAL - 8mm OD 3 4
ELBW38327 ELBOW STEM - 8mm OD STEM x 8mm 5 4
ELBW39259 JG TUBE TO HOSE ELBW 2 2
EXTR39116 EXTRUSION REAR TOWER FLEX 3-4 2 2
FANM39062 FAN MOUNT BREAKAWAY STYLE 4 4
FILT36123 FILTER 1/2" ST/ST WASHER 1 1
FILT39250 FILTER WASHER REF 4370250.950 1 1
FOOT39251 BARBED RIVET FOOT - FBR-1 4 4
GROM31309 GROMMET QUICK FIT 1 1
GROM38806 GROMMET CABLE 1 1
HOUS36124 HOUSING FLOW RESTRICTOR DRAIN 1 1
HOUS38855 2" UV HOUSING WELD ASSY 1 1

Section 2 – Parts Identification Issue 3 Page 12 of 52

PURELAB flex 3 & 4

PURELAB PURELAB
Part Number Description
flex 3 flex 4
LA728 BYPASS CARTRIDGE FLEX 1 1
LATC39253 QUARTER LATCH TURN 4 4
LC210 UV LAMP - PURELAB FLEX 1 1
LC217 RO CARTRIDGE FLEX 3 & 4 1
MAGN39132 FLEX DOOR MAGNET 2 2
MOUN38647 MOUNTING CLIP - 1 1
MOUN39237 FLAT CABLE TIE HOLDER 2
MOUN39288 MOUNT FLEX 3-4 3 3
NUTS20865 NUT M4 HEX FULL 6 6
NUTS39276 COUPLING NUT 1/2" BSP 2 2
PCBS38875 CONTROLLER BOARD FLEX 1 1
PLAT38815 CARTRIDGE MOTION PLATE 1 1
PLAT39108 PUMP MOUNTING PLATE 1 1
PLAT39212 TANK DRIP PLATE 1 1
PLAT39226 PCB AND FAN MOUNTING PLATE 1 1
PLAT39227 PLATE BASE COVER 1 1
PLAT39231 TANK LOCATING PLATE 1 1
PLAT39242 BULKHEAD MOUNTING PLATE 1 1
PLUG32802 PLUG BLANKING 8mm OD STEM 3 3
PLUG38882 BLANKING PLUG CODE 466929 1 1
POWE38971 POWER SUPPLY FLEX 1 1
PU010418 CONNECTOR 8-8MM PM0408E 1 1
PUMP38824 PUMP DIAPHRAGM 88-ELG-38824 1 1
RING32087 RING O" BS115 RED SILICON" 1 1
RING32088 RING O" BS119 RED SILICON" 1 1
RING39248 O RING BS 014 12.5 ID X 1.78 1 1
RING39249 O RING BS 125 - 33ID X 2.62 1 1
RIVT10328 RIVET POP 1/8" DIA SHORT" 2 2
RIVT39296 SNAP RIVET BLACK 2 2
SCRW11946 SCREW M4 x 6mm POZI PAN HEAD 4 4
SCRW22008 SCREW SET M4x16mm PAN HEAD 2 2
SCRW22187 SCREW M4 x 20mm POZI CSK HEAD 2 2
SCRW31311 SCREW No 8 x 1/2" PAN HEAD" 2
SCRW31313 SCREW No.4 x 3/8" PAN HEAD" 4 4
SCRW32690 SCREW M5x12mm POZI PAN HEAD 4 4
SCRW36845 SCREW M4x10mm POSIDRV PAN 4 4
SCRW36895 SCREW M3x8mm POSIDRV PAN HEAD 3 3
SCRW37566 SCREW SELF-TAPPING NO6 x 3/8" 2 2
SCRW38040 SCREW 3.5MM DIA X 38MM LONG 2 2
SCRW38888 DELTA SCREW M2.5 X 8LG 6 6
SCRW38890 SCREW FLEX PUMP 9 9
SCRW38963 POZI HEAD TAPTIE SCREW C'SK 4 4
SCRW38964 POZI HEAD TAPTIE SCREW 6 6
SENS39131 CONTINUOUS LEVEL SENSOR 1 1
SP919 CARTRIDGE BULKHEAD ASSY 1 1
SP925 LINE CELL 3 3
SP926P FLOW SENSOR 1 1
SP929P FLEX DOOR ASSY RIGHT HAND 1 1

Section 2 – Parts Identification Issue 3 Page 13 of 52

PURELAB flex 3 & 4

PURELAB PURELAB
Part Number Description
flex 3 flex 4
SP930P FLEX DOOR ASSY LEFT HAND 1 1
SP940P FAN ASSY PURELAB FLEX 2 2
SP947 PURELAB FLEX 3 & 4 WIRING ASSY 1 1
SP950P PISTON CARTRIDGE ASSY - FLEX 1 1
SP954P DISPENSER ARM ASSY FLEX 3 & 4 1 1
SP963 DISPENSER NRV ASSY FLEX 3 & 4 1 1
SP965 DISPENSER ASSEMBLY GREEN 1 1
SPAC38978 SPACER - NYLON M3 X 37 1 1
SPAC39211 CIRCUIT BOARD SPACER 4 4
TANK39114 RESERVOIR TANK FLEX 3 1 1
TEES38261 TEE EQUAL - 8mm OD 1 1
TUBE10285 TUBE 8mm ID x 11mm OD PVC 0.37 0.37
TUBE31957 TUBE HIPURE 8mm OD x 5mm ID 8.5 8.5
TUBE35949 TUBE 6mm LDPE NATURAL 0.25 0.25
TUBE38870 QUARTZ THIMBLE FLEX 1 1
VALV32039 VALVE SHUT-OFF JG 8mm 1 1
VALV38199 VALVE 3-WAY SOLENOID 1 1
VALV39016 JG SINGLE CHECK VALVE 1 1
VALV39254 SOLENIOD VALVE TYPE 6240 24VDC 1
VALV39261 SINGLE CHECK VALVE 6MM TUBE 1
VALV39286 SOLENOID VALVE FLEX BURKERT 1
WASH10534 WASHER 19mm OD x 11mm ID x 1 1
WASH12250 WASHER M3 PLAIN 4 4
WASH20879 WASHER M4 SPRING 6 6
WASH20884 WASHER M4 PLAIN 2 2
WASH22186 WASHER M4 SHAKEPROOF INTERNAL 3 3
WASH31246 WASHER M5 PLAIN 6 6
WASH39037 WASHER M3 SPRING A2 2 2

Notes:

Section 2 – Parts Identification Issue 3 Page 14 of 52

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

N/A Main body assembly – External 16
N/A Main body assembly – Internal 17
N/A Main body assembly – Internal (tank removed) 18
N/A Base moulding 19
N/A Manual drain assembly 22
SP919 Cartridge bulkhead assembly 23
SP923 UV assembly 25
SP945 Tank assembly 20
SP951 Bulk head assembly 26
SP954 Dispenser arm assembly 24

PURELAB flex 4

Sub Assembly Description Page Number

N/A Main body assembly – External 16
N/A Main body assembly – Internal 17
N/A Main body assembly – Internal (tank removed) 18
N/A Base moulding 19
N/A Manual drain assembly 22
SP919 Cartridge bulkhead assembly 23
SP923 UV assembly 25
SP951 Bulk head assembly 26
SP954 Dispenser arm assembly 24
SP958 Tank assembly 21

Section 2 – Parts Identification Issue 3 Page 15 of 52

PURELAB flex 3 & 4

Main Body – External Parts

4 3

2
5

Item Part Number Description

1 SP919 Cartridge Bulkhead Assembly (see page 23 for a breakdown of parts)
2 SP923 UV Assembly (see page 25 for a breakdown of parts)
3 SP929 Right hand door
4 SP930 Left Hand Door
5 SP950 Piston Assembly
6 SP954 Dispenser Arm Assembly (see page 24 for a breakdown of parts)
7 SP965 Dispenser Assembly

Section 2 – Parts Identification Issue 3 Page 16 of 52

PURELAB flex 3 & 4

Main Body – Internal Parts

2 3

4 5

Item Part Number Description

1 SP951 Bulkhead Assembly (see page 26 for a breakdown of parts)
2 SP945 PURELAB flex 3 Tank Assembly (see page 20 for a breakdown of
parts)
3 SP958 PURELAB flex 4 Tank Assembly (see page 21 for a breakdown of
parts)
4 VALV39254 PURELAB flex 4 Inlet Solenoid Valve
5 VALV39286 PURELAB flex 3 Inlet Solenoid Valve

Section 2 – Parts Identification Issue 3 Page 17 of 52

PURELAB flex 3 & 4

Main Body – Internal Parts Tank Removed

Item Part Number Description

1 PU010418 Connector 8mm OD tube x 8mm OD tube
2 PCBS38875 Flex Control Board
3 PUMP38824 Recirculation Pump
4 SP925 Line Cell
5 SP963 Dispenser NRV Assembly

Section 2 – Parts Identification Issue 3 Page 18 of 52

PURELAB flex 3 & 4

Base Moulding - Bottom

Item Part Number Description

1 ELBW38327 Elbow 8mm Stem x 8mm OD Tube
2 SP940 Fan Assembly
3 TEE38261 Tee Equal 8mm OD Tube

Section 2 – Parts Identification Issue 3 Page 19 of 52

PURELAB flex 3 & 4
5 2

SP945 Tank Assembly

9
6

11 12

6 8

10 13

Item Part Number Description

1 ADAP31299 Adaptor 8mm OD tube x 1/8” BSPT male
2 ADAP32800 Adaptor Stem 8mm OD tube x ¼” BSPT male
3 CONN39258 Two way divider 8mm OD tube
4 ELBW35604 Elbow stem 6mm OD tube x 6mm OD tube
5 ELBW35960 Elbow reducing 8mm OD tube x 6mm OD tube
6 ELBW38317 Elbow equal 8mm OD tube
7 ELBW38327 Elbow stem 8mm x 8mm OD tube
8 HOUS36124 Housing flow restrictor
9 SENS39131 Level Sensor
10 TANK39114 7 liter Reservoir
11 VALV38199 3 way solenoid valve
12 VALV39016 Non return valve 5/16
13 VALV39261 Non return valve 6mm OD tube

Section 2 – Parts Identification Issue 3 Page 20 of 52

PURELAB flex 3 & 4

SP958 Tank Assembly

5

1
3

7
8

2
3

Item Part Number Description

1 ADAP32800 Adaptor Stem 8mm OD tube x ¼” BSPT male
2 ELBW35960 Elbow reducing 8mm OD tube x 6mm OD tube
3 ELBW38317 Elbow equal 8mm OD tube
4 ELBW38327 Elbow stem 8mm x 8mm OD tube
5 SENS39131 Level Sensor
6 TANK39114 7 liter Reservoir
7 VALV38199 3 way solenoid valve
8 VALV39016 Non return valve 5/16

Section 2 – Parts Identification Issue 3 Page 21 of 52

PURELAB flex 3 & 4

Manual Drain Assembly

5
8
9

2
4

10
7

Item Part Number Description

1 ADAP39406 Adaptor stem 6mm OD x ¼” BSPT male
2 ADAP32798 Adaptor straight 8mm OD tube x ¼” BSPT male
3 ADAP39228 Adaptor 1” BSP
4 CONN38836 Connector short cartridge
5 ELBW35960 Elbow 8mm OD tube x 6mm OD tube
6 ELBW38317 Elbow equal 8mm OD tube
7 ELBW39259 Elbow stem x hose
8 FILT39250 Filter washer
9 RING39249 O-ring BS125 33 ID x 2.62
10 VALV32039 Shut off valve 8mm

Section 2 – Parts Identification Issue 3 Page 22 of 52

PURELAB flex 3 & 4

SP919 Cartridge Bulkhead Assembly

3
1

Item Part Number Description

1 ELBW38327 Elbow stem 8mm OD x 8mm OD tube
2 PLAT38815 Cartridge plate
3 SP919 Cartridge bulkhead assembly
4 SP925 Line cell
5 SP926 Flow sensor

Section 2 – Parts Identification Issue 3 Page 23 of 52

PURELAB flex 3 & 4

SP954 Dispenser Arm Assembly

5
2

Item Part Number Description

1 CCAP39125 Arm Lock Cover Cap
2 CLAM39128 Arm Clamp Ring
3 DARM38805 Dispenser Arm
4 HOLS39281 Holster
5 SCRW39126 Arm Button Screw
6 SCRW39209 M6 x 6 Socket Head Set Screw
7 STUD39127 Arm Clamp

Section 2 – Parts Identification Issue 3 Page 24 of 52

PURELAB flex 3 & 4

SP923 UV Assembly

10 5
11

3
4

1 8

6
9

Item Part Number Description

1 BALL38832 Ballast box
2 BALL38877 UV ballast
3 CAPS32084 Cap end 185nm UV housing
4 DISC32084 Sealing disk UV housing
5 HOUS38855 UV housing
6 PU010418 Connector equal 8mm OD tube
7 RING32087 O-ring BS115
8 RING32088 O-ring BS119
9 SP925 Line cell
10 SP940 Fan assembly
11 TUBE38870 Quartz tube

Section 2 – Parts Identification Issue 3 Page 25 of 52

PURELAB flex 3 & 4

SP951 Bulk Head Assembly

8
3

4
7

10 2
1 8

Item Part Number Description

1 ADAP39230 Bulkhead adaptor Non return valve
2 BALL39247 8mm ball
3 CONN32791 Connector bulkhead 8mm OD tube
4 CONN38800 Connector panel mount socket
5 CONN38836 Connector short cartridge
6 CONN38883 Connector DC power
7 CONN39229 Bulkhead connector non return valve
8 COUP39046 Filter bulkhead coupling
9 NUTS39276 Coupling nut ½” BSP
10 RING39248 O-ring BS014 12.5 ID x 1.78

Section 2 – Parts Identification Issue 3 Page 26 of 52

 Section 3 - Electronics
Display Icons
PF1
Dispense
Button

PF2
Auto Volume
Dispense PF3
Up

PF4
Accept PF5
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
optional DI pack is Time
installed
Temperature
Alarm Conditions
Refil Status
Auto Volume Display
Shows the volume of
water that is selected
Volume Display
when using the auto
volume dispense option. Shows the volume of
water that is available to
use from the reservoir.

Section 3 - Electronics Issue 3 Page 27 of 52

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 (QS2)
standard refill cycle

Refill Cycle Purifying – This is displayed at the start of each

The system is in a refill cycle
Message on scroll bar refill cycle for 10 minutes

Refill Timer 00:00 – Estimated time until the The countdown timer is removed
Message on the scroll bar reservoir is full 7.0 liters once the reservoir is full

Release and repress dispense

Trying to dispense water
Dispense water quality – button to dispense water. If no
during the first 10 minutes of
Pop up message on display action is taken then the message
refill
will disappear after 6 seconds

The message will time out after 6

When reservoir reaches 0 seconds. Manual dispense will be
Dispense low water level
liters the manual and auto active once the reservoir reaches
warning – Pop up message
volume dispense is disabled 0.25 liters. Auto Volume dispense
will become active at 0.5 liters.

The system processing, the water

Processing symbol – Mini quality can be low at the beginning
timer symbol is displayed of a refill cycle due to the amount of
Water purity is low
on the screen in place of RO water entering the tank. The
the water purity system does this for 10 minutes to
allow the system achieve quality.

Flashing Reservoir Leave system to fill reservoir,

symbol – the water level in The system is in refill cycle estimated time of fill is displayed in
the symbol is moving scroll bar

Leave system to fill reservoir, this

Flashing red reservoir The reservoir is less than 0
will clear once the reservoir reaches
symbol liters
0.25L

Section 3 - Electronics Issue 3 Page 28 of 52

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
flashing red point in the menu
• Carry out a calibration
• Change line cell
Temperature Alarm – The • Check feed water
The temperature is above the
temperature alarm warning temperature
defined alarm set point in the
is displayed in the scrolling • Carry out calibration
menu
message bar • Change line cell
Over Temperature Alarm • Check feed water
– The system shuts down The temperature is above 50 temperature
and displays temperature degrees • Carry out calibration
warning on screen • Change line cell

Flood Protection Alarm –

The flood protection alarm • Check inlet solenoid valve
Water is above 7.0 liters in
warning is displayed on the • Check for signs of manual
the reservoir
scrolling message bar and filling
V3 is active
• Check the correct DI pack is
DI Pack Alarm – The
installed
system shuts down and DI pack data tag not
• Check data tag connections
displays DI pack alarm on recognized
• Clean the tag and connections
screen
• Replace DI pack (faulty tags)
Level Sensor Fault – The The level sensor is an open • Check connections
system shuts down and circuit for greater than 15 • Check diagnostics display for
displays level sensor alarm seconds level sensor failure
UV Lamp Failure – The UV
failure alarm is displayed on No current is detected in the • Check connections
the scrolling message bar circuit after 3 attempts to • Check UV lamp
and the UV lamp is start the lamp • Check UV ballast
deactivated
Pump Fault – The system
The pump current draw is
shuts down and displays • Replace pump
greater than 2 amps
pump fault alarm on screen
• Check valve V4 is closed
• Check inlet pressure and flow
Low Permeate flow – The • Check inlet strainer and
system shuts down and Reservoir fill rate is less than valves V1 and V3
displays low permeate flow 4 l/hour. • Check pressure regulator if
alarm on screen fitted
• Check level sensor float is
moving freely

Section 3 - Electronics Issue 3 Page 29 of 52

PURELAB flex 3 & 4

Software History

PURELAB flex 3 & 4

Software Version Date Released Modifications

V1.2.0 10th 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. Please find below details of the part numbers for these boards and where they
are used (part number listed include the firmware / software).

Product type PCB Part Number

PURELAB flex 3 & 4 PCBS38875

Software Installation Instructions

The PCB part number above is for a blank board, this will need software installing on it when initially
installed. This process should also be used when installing a new dispense handset.
Please see below instructions on how to install software onto a blank board.

The first step is to ensure that the PCB is set to “default”, once it is set to default then it will allow you
to upload the software onto the board using a USB data stick.

• Power down the PURELAB flex

• Press the [Down key PF5] and [Auto Volume
Dispense key PF2] Figure 1
• Power up the PURELAB flex
• Wait a few minutes until the Controller starts
re-programming itself, do not let go of the
buttons
• You will notice that the light on the dispense
button is flashing (See Figure 1); wait for this
to stop flashing and for the light to go out
before letting go of the buttons. (See Figure 1)
• The PCB has now been set to “Default”
• Visit www.purelabflex.com and download
newest version of firmware and customized
settings onto a USB stick Figure 2
• Insert the USB stick into the flex
• Highlight “Firmware update” and press accept
(See figure 2)
• Wait a few minutes for the firmware to load
• PURELAB flex will return to process mode and
the firmware update is complete

Section 3 - Electronics Issue 3 Page 30 of 52

 PURELAB flex 3 & 4

Section 3 - Electronics Issue 3 Page 31 of 52

 PURELAB flex 3 & 4

TH1
Dispense Handset

TH2
Recirculation Pump
JH2
TH3 Line Cell
Inlet Valve

TH5
UV Ballast

TH5A
UV and PCB Fans
JH3
Temperature Sensor
TH6
Power Supply
JH7
TH7 Level Sensor
Drain Valve
JH4
Flow Sensor

JH5
Data tag and
Footswitch

FUSE39145 – Quick blow 3A

FUSE39146 – Quick blow 2A

Section 3 - Electronics Issue 3 Page 32 of 52

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. Battery
part number BATT38038

Battery replacement instructions

Enter the system menu and make a note of all FIG 1

user settings.

Isolate the power to the system

Ensure that there is no water in the reservoir,

remove the back cover and undo all of the
connections on the PCB.

Lay the PURELAB flex on its side and unscrew the FIG 2
base plate.

Undo the two screws on the PCB base plate. (Fig

1)

Carefully pull the PCB out of the system, you do

not need to remove it completely for this
procedure. (Fig 2)

Remove the battery gently. Please take care not

to cause any damage to the board.

Insert the new battery with the positive side

facing away from the board (fig 3).

Gently push the PCB back into place and secure

with the screws.
FIG 3
Replace the base plate and stand the system up.

Reconnect the PCB and replace the back cover.

Switch on the power to the system

Proceed through the menu to correct the time,

date and other user settings.

Section 3 - Electronics Issue 3 Page 33 of 52

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.
Please use caution when working on systems connected to a main
! power supply. If in doubt do not atempt any work on a product unless
the power supply is isolated.

The electrical parameters detailed in this section of the manual are to be used as a guide to help assist
with general maintenance and troubleshooting. The values below can be measured using a multimeter.

Electrical Supply nominal variance

AC Voltage Input to power supply 100-240 vac ±10%
DC Voltage output from power supply 24 vdc ±2%

Only the power supply supplied with the product should be used. Failure to use the correct power
supply will invalidate all regulatory compliance and warranty claims.

Section 3 - Electronics Issue 3 Page 34 of 52

 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.

After completing the assessment, discuss with the client how the unit has been performing and any
issues that may have occurred since the last visit.

• Before commencing the service, go through the operating procedures of the system and write
down set points and alarm settings so all parameters can be returned to normal at the end of
the service.
• A feed water check should now be performed to ensure the system is being fed by water within
the feed water guidelines detailed in the specifications section of this manual.
• Check the outlet water quality and temperature using the diagnostic screen within the
calibration menu. Please see page 39 for details.
• Press Process and record the product water quality and temperature
• Measure the flow rate from the dispense handset, the flow rates can vary depending on what
type of feed you have to the system, please see the operational parameters section for more
details.
• Check Auto Volume, calibrate if necessary.
• Calibrate the unit by following the work instructions in this service manual. All settings should
be recorded on the service report.
• Check the consumables and replace parts if necessary. Consult client first.
• Perform sanitization if required by the customer.

All details of your visit must be logged for future reference and to give the end user confidence in the
equipment. A detailed Routine maintenance report has been created to be used in conjunction with this
document. A copy of this report can be found in the Appendix section of this manual, please feel free to
copy this report and use it during your service visit.

Section 4 - Maintenance Issue 3 Page 35 of 52

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). Water to flex
Ensure that the pressure regulator is installed in
the correct direction using the arrows indicated on
the bottom of the regulator (fig 2).
Turn on the water supply and switch on the power
to the PURELAB flex
Proceed through the commissioning procedure
until it starts flushing to drain (fig 3)
During this dispense stage you should adjust the
Fig 1
pressure regulator to read 4.0 bar (58 psi).

During normal operation

Ensure that the tank is filling, if not initiate a refill
cycle by holding down the Auto volume dispense
button.
Check the pressure regulator and adjust to 4.0 Fig 2
bar (58 psi)
Fig 3

Auto Volume Dispense Settings

Volume
From To Increment
50ml 500ml 50ml
500ml 2000ml 100ml
2000ml 7000ml 250ml

When using Auto Volume Dispense the dispense rate can vary. The PURELAB flex will purposefully
dispense at a lower rate of 1.2 l/min when dispensing less than 500ml, all other volumes will be
dispensed at full flow.

Section 4 - Maintenance Issue 3 Page 36 of 52

PURELAB flex 3 & 4

Calibration

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.

Sub boxes and adaptors required for the calibration of the PURELAB flex:

Adaptors LA738
Sub Box 07 Sub Box 14 Sub Box 15 These are included with Sub
boxes 14 & 15, You do not
BOXS31509C BOXS39060C BOXS39061C need to purchase these
separately.

These substitution boxes must be calibrated annually by ELGA, check the calibration label before use to
make sure they are still in date. Please contact ELGA technical support for more information.

Connecting the calibration boxes

Sub box Adaptor Connection to the PCB

SUB boxes 7, 14 and 15 have a square
4-position connector and require an
adaptor to be able to connect to the
PCB. These adaptors are available from
ELGA, part number LA738

The PCB position for connecting the

quality SUB box adaptor is ‘JH2’.

JH2 The PCB position for connecting the

temperature SUB box adaptor is ‘JH3’.
JH3

Section 4 - Maintenance Issue 3 Page 37 of 52

PURELAB flex 3 & 4

Sub Box Connection to Adaptor

SUB-15 SUB-07
SUB-14 SUB-07 TS1
μS/cm
MΩ.cm TS2 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 – to JH2 on PCB

USB Stick Preparation

When carrying out a calibration a USB stick must be used to access the calibration program, please
find below details of how to prepare the USB stick.

• Insert the USB stick into your PC and

allow the USB stick to be detected by
your PC before trying to accessing the
device.
• Open the USB stick as a window to
enable visibility of the top level contents
of the USB stick.
(Go to ‘My Computer’, look for the
appropriate drive for the USB stick and
double click the drive.)
• Right-click your mouse cursor within the
window, away from any files contained
on the USB stick.
• Select ‘New’ from the menu, and then
select to create a new document, for
example a Word document. This will
create a new file and prompt for the file
name to be edited, as per image.
• The file name and file extension should
be fully over-written as follows:
SERVICE.TST – For Access to the
calibration procedure
PRODUCT.TST – For Access to the test procedure (mainly used when installing a new PCB
or dispense gun.
(the file name and extension must be in capital letters)
• Safely remove the USB stick from the PC
• The USB stick is now prepared for calibration

Section 4 - Maintenance Issue 3 Page 38 of 52

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 &
PF5) Once Service Calibration is highlighted press Accept (PF4)
N/A
to access the calibration procedure

Skip outlet valve adjustment?

Highlight Yes to move on to service calibration
Highlight No to carry out Outlet valve adjustment
Press Accept (PF4)

Test Procedure Diagnostics

This screen is just for information it gives you the readings from
QS1, QS2, QS3, TS1, TS2 and Tank level
Press Accept (PF4)
Skip outlet valve adjustment? N/A
Highlight Yes to move on to service calibration
Highlight No to carry out Outlet valve adjustment
Press Accept (PF4)

Outlet Valve Adjustment

Adjust the outlet valve

Place a container under the dispense nozzle (1 Liter)
Press the up button (PF3) until the dispense valve is open and
you see a small stream of water coming from the dispense
nozzle.
Press the down button (PF5) slowly until the small stream of
water stops dripping, do not over seal the valve.
Press Accept (PF4)
N/A
The system will perform a test sequence on the valve to ensure it
closes correctly. It will dispense small amounts of water opening
and closing the valve approximately 22 times.
Skip service calibration?
Highlight Yes to exit the service calibration
Highlight No to carry out service calibration
Press Accept (PF4)

Section 4 - Maintenance Issue 3 Page 39 of 52

PURELAB flex 3 & 4

Quality and Temperature Sensor Calibration Continued

Service Calibration

Remove the rear cover of the PURELAB flex to expose the PCB
N/A
Connect the calibration boxes using the correct connectors

Set sub box to the required value and wait for the display value 1
to settle and turn white.
SUB Box 14 10
Press Accept (PF4) to save the setting
Press Auto Volume dispense (PF2) to move on to the next screen 18
40
Press Up (PF3) to accept the calibration and move on to the next
N/A
section or press Down (PF5) to repeat the previous section

Set sub box to the required value and wait for the display value 150
to settle and turn white.
SUB Box 15
Press Accept (PF4) to save the setting
5
Press Auto Volume dispense (PF2) to move on to the next screen
Press Up (PF3) to accept the calibration and move on to the next
N/A
section or press Down (PF5) to repeat the previous section

Set sub box to the required value and wait for the display value
1
to settle and turn white.
SUB Box 7
Press Accept (PF4) to save the setting
35
Press Auto Volume dispense (PF2) to move on to the next screen
Press Up (PF3) to accept the calibration and move on to the next
N/A
section or press Down (PF5) to repeat the previous section

Set sub box to the required value and wait for the display value
1
to settle and turn white.
SUB Box 7
Press Accept (PF4) to save the setting
35
Press Auto Volume dispense (PF2) to move on to the next screen
Press Up (PF3) to complete the calibration or press Down (PF5) to
N/A
repeat the previous section

Section 4 - Maintenance Issue 3 Page 40 of 52

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
is highlighted press Accept (PF4) to access the procedure
Press the dispense button PF1, the system will now dispense 1000ml of water
Measure the actual amount of water dispensed in the measuring cylinder, empty the cylinder and
replace beneath the dispense outlet
Using PF3 and PF5 set the value on the display to reflect the actual volume dispensed in the measuring
cylinder. Press the dispense button PF1 to confirm
The system will then dispense 1000ml of water
Check the measuring cylinder to ensure that 1000ml has been dispensed
Is the volume correct? Use the Up and Down buttons (PF3 & PF5) to highlight yes or no

If Yes is highlighted – Press Accept to return to the main menu

If No is highlighted – Press Accept to return to the beginning of the Auto volume calibration procedure

Section 4 - Maintenance Issue 3 Page 41 of 52

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. A material safety data sheet conforming to COSHH regulations is provided with
the chemical, please read this carefully before carrying out the sanitization.
Safety goggles and gloves should be worn at all times while handling
! any chemical substance.

Process Table

Action

Press and hold PF4 to access the menu

Using the up and down (PF3 & PF5) buttons highlight sanitization

Press accept (PF4) to enter the sanitization procedure

Place a 10 liter container under the dispense nozzle and press accept to release the pressure in the DI
pack
Remove the DI or Bypass pack from the system and replace with the sanitization pack, the tags on the
pack will be read and the type of pack will display on the screen

Press accept to start the sanitization

The system will then recirculate for 1 hour and 30 minutes

Once the timer has finished, ensure that a 10 liter container is placed under the dispense nozzle and
press the dispense button.
The outlet valve will then open and empty the entire contents of the tank, you can pause this at any
time by pressing the accept button.

Remove the sanitization pack from the system and replace with the DI pack. Please dispose of the
sanitization pack as it cannot be reused.

Press accept

The system will then return to the main menu, exit will be highlighted

Press accept to return to normal operation

Notes:

Section 4 - Maintenance Issue 3 Page 42 of 52

 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 CaCO3 TBC

Free Chlorine <0.05 ppm Cl2 <0.05 ppm Cl2

Chloramine <0.02 ppm Cl2 <0.05 ppm Cl2

Total Chlorine <0.05 ppm Cl2 <0.05 ppm Cl2

Silica <30 ppm SiO2 <2 ppm SiO2

Carbon Dioxide Maximum <30 ppm (recommended <20ppm)

Fouling Index <10 <1

Iron / Manganese <0.05 ppm N/A

Organics (TOC) <2 ppm <50 ppb

Temperature 4-40°C (recommended 10-25°C)

Flowrate (requirement @ 15°C) Up to 75 l/hr Up to 60 l/hr

Drain Requirements (gravity fall with air
>90 l/hr >70 l/hr
gap)

Feedwater Pressure

System Type
Model PURELAB Flex 3 PURELAB Flex 4
Maximum 90psi (6bar) 90psi (6bar)

Minimum 30psi (2bar) 1psi (0.07bar)

Section 6 - Troubleshooting Issue 3 Page 43 of 52

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

Bacteria – Typical (with Biofilter) <1 CFU/10ml

Endotoxin (with Biofilter) <0.001 EU/ml

DNase (with Biofilter) <20 pg/ml

RNase (with Biofilter) <0.002 ng/ml

*Dependant on feed water supply

Dimensions and Weights

System Type
Model PURELAB Flex 3 PURELAB Flex 4
Width 236mm, Depth 470mm, Height Minimum
Dimensions
900mm, Height Maximum 1020mm
Operational Weight 23kg (57.3lb)

Installation Bench / Wall

Electrical Requirements

System Type
Model PURELAB Flex 3 PURELAB Flex 4
Mains Input 100-240V ac, 50—60Hz
System Control Voltage (not including
24V dc / 5 amp
pumps and uv)
Power consumption during Peak Demand 100VA

Noise Level <40dBa

The information in this document is correct at time of print.

*All of the treated water specifications are subject to regular sanitization and routine maintenance.

Notes:

Section 5 - Specifications Issue 3 Page 44 of 52

 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.
Check the connections on the PCB

Change the DI pack

Display Quality Low
Calibrate the system

Confirm the inlet temperature

If the system has been recirculating for a long
Temperature High on Display time dispense some water until the refill cycle is
initiated.
Calibrate the system

Dispense dripping Perform a calibration on the dispense valve

Confirm pump operation

Dispense rate low Check POU filter if fitted
Check dispense valve calibration

If a new dispense gun has just been fitted, return

the board to its default settings and reinstall the
Dispense gun fault system software as per the instructions on page
LCD screen faulty 30.
Replace the whole dispense gun assembly (Do not
take the dispense gun assembly apart)

Change the UV lamp

UV lamp fault Ensure the UV ballast is operational
Check fuses

Isolate the system and replace the o’rings in the

UV housing leaking
UV housing

Confirm Voltage to pump

Pump fault
Check fuses

Section 6 - Troubleshooting Issue 3 Page 45 of 52

 Section 7 - Appendix
Appendix Index

Appendix Description Page Number

A Commissioning Report 47
B Routine Service Report 49
C Calibration Certificate 51
D Service Bulletins 52

Section 7 - Appendix Issue 3 Page 46 of 52

PURELAB flex 3 & 4

Appendix A

Commissioning Report
System Settings

Default Default
Function to be set Option Installed? Actual settings
Feature settings

Language Yes Yes No English

Refill Level Yes Yes No 2.5 Liters

Timed Auto Refill No Yes No Disabled

Alarm
Yes 1 MΩ-cm
Dispense Purity
Mandatory Feature
Cannot be removed
Alarm
Yes 35°C
Water Temperature

Time and Date No Yes No Not Set

From: 00:00
Sleep Time No Yes No
To: 00:00

TOC Verification No Yes No N/A

Mandatory Feature
Display Units Yes MΩ-cm
Cannot be removed

Temperature
No Yes No Enabled
Compensation

Auto Volume
Yes Yes No N/A
Calibration

Sanitization Yes Yes No N/A

Change Purification Mandatory Feature

Yes N/A
Pack Cannot be removed

Section 7 - Appendix Issue 3 Page 47 of 52

PURELAB flex 3 & 4

Tests

Feed Water Parameters PURELAB flex 3 PURELAB flex 4 Recorded

Conductivity 2000µs/cm <30 µs/cm
temperature 4°C - 40°C
Fouling Index <10 <1
Chlorine (free) <0.5 ppm < 0.05 ppm
Carbon Dioxide <30 ppm
Organics (TOC) <2 ppm < 50 ppb
Pressure Maximum 90psi (6bar) 90psi (6bar)
Pressure Minimum 30psi (2bar) 1psi (0.07bar)

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

PURELAB flex 3 & 4

Appendix B
Routine Service Report

Site History and Observations:

General Questions - Site Related Yes No Concerns?
Review Service History
Review Customer's Operation Log
Query lab manager/users about unit's operation

VISUAL Check of unit's location/connections Yes No Corrected?

Is the unit clear of obstruction?
Is there space for the front doors to open fully and still have space
to service the unit?
Is there clear access to feed water shut-off valve?
Is there clear access to any pre-treatment components?
Has anything changed since the initial commissioning that is not
documented?

Feed Water Chemistry

Take water chemistry samples from the pre-purified water source, on-site chemistry test can be done
while unit is being sanitized.
Feed Water Parameters PURELAB flex 3 PURELAB flex 4 Recorded
Conductivity 2000µs/cm <30 µs/cm
temperature 4°C - 40°C
Fouling Index <10 <1
Chlorine (free) <0.5 ppm < 0.05 ppm
Carbon Dioxide <30 ppm
Organics (TOC) <2 ppm < 50 ppb

Feed Water:
Feed Water Parameters PURELAB flex 3 PURELAB flex 4 Recorded
Pressure Maximum 90psi (6bar) 90psi (6bar)
Pressure Minimum 30psi (2bar) 1psi (0.07bar)

Outlet Parameters

SERVICE ITEM - Distribution Quality, Temperature nominal recorded adjusted

Product Resistivity (MΩ-cm) measured at dispense outlet
Product Resistivity (MΩ-cm) displayed (QS2)
Product Temperature (°C) measured at dispense outlet
Product Temperature (°C) displayed (TS2)
Product Flow Rate measured at dispense outlet Up to 2 L/min

Section 7 - Appendix Issue 3 Page 49 of 52

PURELAB flex 3 & 4

System Menu

Questions - Settings Yes No Corrected?

Review User System Access Menu Parameters
Have the setting choices changed since commissioning?
Are the setting choices appropriate for the site and user needs?
Visually check for any water drips, puddles, stains, etc.
If found, locate source of leak.
Check dispense valve for leaks, if a leak is observed calibrate
dispense valve

Consumable Change

Consumables Changed Yes No Comments

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

PURELAB flex 3 & 4

Appendix C

Calibration Certificate

Please fill in the sections applicable to the unit that is being calibrated. These are detailed in
the calibration instructions.

The systems covered by this certificate are:

PURELAB flex 3
PURELAB flex 4

System Serial Number

System Serial Number

Calibration substitution boxes:

Sub Box Number Sub Box Serial Number Sub Box Calibration Date
Sub Box 07
Sub Box 14
Sub Box 15

Calibration:

Sub Box Board Position Default Value Recorded Value

0
1
Sub Box 14 JH2 (using adaptor) 10
18
40
150
Sub Box 15 JH2 (using adaptor)
5
1
Sub Box 07 JH3 (using adaptor)
35
1
Sub Box 07 JH3 (using adaptor)
35

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

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
UK

Phone - +44 (0) 1494 887850

Fax - +44 (0) 1494 887505
Email – techsupport@elgalabwater.com

Please also visit our extranet site – www.elgalabnet.net