Automatic Water Stills - Stuart Equipment1).pdf · 3 Boiler WB4 4 Funnel WF48 5 Condenser WC48/M2 6 Cabinet Roof – 7Wall Mounting Bracket – 8 Dummy Shorting Plug – 9Green ‘Mains

A4000 A8000 & A4000D

AquatronAutomatic Water Stills

Assembly and operating instructions

Contents

Location and Services required for A4000, A8000 and A4000D 1

A4000 Aquatron (4 litre/hr, single distillation) 2Assembly 3Operation 5

A8000 Aquatron (8 litre/hr, single distillation) 6Assembly 7Operation 9

A4000D Aquatron (4 litre/hr, double distillation) 10Assembly 11Operation 13

Distillate collection and reservoir system 14

Connection of Stills to deionisers and pre-treated water supplies 15

Cleaning Instructions 16

Fault Finding 17

List of Spares 18

Circuit & Wiring Diagrams 19

Limitations of use

This product meets the applicable E.C. harmonisedstandards for radio frequency interference and maybe expected not to interfere with, or be affected byother equipment with similar qualifications. Wecannot be sure that other equipment used in itsvicinity will meet these standards and we cannotguarantee that interference will not occur in practice.Where there is a possibility that injury, damage or lossmight occur if equipment malfunctions due to radiofrequency interference, or for general advice beforeuse, please contact the Technical Service Departmentof Bibby Scientific Ltd.

The Aquatron Water Still complies with the following European Directives:89/336/EEC - E.M.C. DIRECTIVEAmended by 92/31/EEC and 93/68/EEC73/23/EEC - L.V.D. Amended by 93/68/EEC

1

In order to obtain the optimumperformance from your new Aquatroncareful consideration should be given tothe intended location and the availabilityof services such as water, electricity anddrain.

Please study the following notes beforecommencing installation.

Before UseIf the equipment is not used in the mannerdescribed in this manual then itsperformance and operation will beimpaired.

Aquatron water stills are designed tooperate under the following conditions:

❖ For indoor use only.❖ Ambient temperature +5°C to +40°C.❖ Altitude up to 2000M.❖ Relative humidity not exceeding 80%.❖ Mains supply voltage fluctuates not

greater than ±10% of normal.❖ Over voltage Category II IEC60364-4-443.❖ Polluting degree 2 IEC664.

1 Bench Wall MountingAquatron models A4000 and A8000can be either bench or wall mountedand a bracket is provided for the latterpurpose. A gap of at least 50cm shouldbe left at the right hand end of the unitto allow access to the heatingelements.

For reasons of weight, model A4000Dis best bench mounted, but if it isdesired to elevate the unit then a stoutshelf should be used.

2 Electricity SupplyN.B. The Aquatron Water Still isclassified as “PermanentlyConnected Equipment” and shouldbe connected to the electricitysupply by a qualified electrician inthe manner described in theelectrical installation section of thismanual.

The Aquatron stills are available in threemodels, A4000, A4000D & A8000.

A suitable supply for the A4000 is ratedat 3kW, 220-240v, 50/60Hz~ singlephase. A suitable supply for theA4000D & A8000 is rated at 6kW, 220-240v, 50/60Hz~ single phase.

If you have any doubts about thesuitability of your supply, consult aqualified electrician before installingyour Aquatron still.

3 Water SupplyA cold water supply is required forcoolant and feed purposes. This may befrom the mains supply or a header tankhaving a flow capacity of at least 1litre/min. for the A4000 and 2litres/min. for the A8000 and A4000D.The pressure range should be within 3-100 p.s.i. (0.2–7 x 105Nm-2).

If the feed water quality is poor andlikely to contain particulate matter, suchas rust or silt, it is advisable to fit a pre-filter unit before the still.

4 DrainA waste water drain is required. It isimportant that the distance betweenthe drain and the water still is kept asshort as possible to reduce thepossibility of pressure build-up. Similarly,the drain pipe from the still should fallstraight, without any kinks or bends, toallow an unimpeded flow.

5 Storage TankA suitable reservoir, the WR20 forinstance, is required for the collectionof the distillate. This should bepositioned beneath the still ensuringthat the distillate can flow into thereservoir without hindrance.

6 MaintenanceThe location of the still should facilitateeasy access for routine cleaning andmaintenance. With regards to the latter,it is recommended that a space of atleast 50cm be provided on the righthand side of the water still cabinet. Thisis to allow the removal of the side coverand replacement of the heatingelement.

7 WarrantyBibby Scientific Ltd warrants thisinstrument to be free from defects inmaterial and workmanship, when usedunder normal laboratory conditions, fora period of three (3) years. In the eventof a justified claim Bibby Scientific willreplace any defective component orreplace the unit free of charge.

This warranty does NOT apply ifdamage is caused by fire, accident,misuse, neglect, incorrect adjustment orrepair, damage caused by incorrectinstallation, adaptation, modification,fitting of non approved parts or repairby unauthorised personnel.

This Warranty does not include theheater element which is onlygaranteed for up to 1000 hours inuse.

Location & ServicesA4000, A8000, A4000D

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Item Description Catalogueno. number

1 Perspex Screen –

2 Cabinet –

3 Boiler WB4

4 Funnel WF48

5 Condenser WC48/M2

6 Cabinet Roof –

7 Wall Mounting Bracket –

8 Dummy Shorting Plug –

9 Green ‘Mains On’ Indicator –

10 White ‘On/Off’ Switch –

11 Amber ‘Reservoir Full’ Indicator –

12 White ‘Clean’ Switch –

13 Reservoir Pressure Switch Connection –

14 Terminal Strip for Heater Connection 700670(S)


15 Water Flow Control Switch WS48/1

16 Reservoir Level Control WLS

17 Cabinet End Plate –

18 Mains Water Inlet with Needle Valve –

19 Distillate Outlet Pipe (Bench Mounted) –

20 Cooling Water Pipe to Drain –

21 Thermostat Glass Tube WTT48

22 Thermostat WT4

23 Thermostat Re-set Button –

24 Distillate Outlet (Wall Mounted) –

25 Boiler Level Control WL48

26 Boiler Plastic Coupling WBC1

27 Heating Element W48H

28 Boiler Retaining Springs –

List of Major Components – A4000

Fig 1: Major component parts A4000

3

A4000 Assembly

3 Remove the perspex viewing screen,item 1 fig. 1 by using the finger recessto lift the screen out of the lowercabinet groove, then remove theinternal packaging which hasprotected the glass boiler duringtransit. Also sever the temporary tieholding the two boiler retainingsprings, item 28 in place.

4 Remove the cabinet end plate, item17 by unscrewing the six retainingscrews and ‘shake proof washers’.Similarly, unscrew the six countersunkscrews to remove the cabinet roof.

5 Position the condenser WC48/M2 bymounting it onto the vapour tube ofthe boiler with the distillate outlettube of the condenser facing to thefront. See fig. 2.

6 From the bag of hoses take the 1metre length of 9mm diameter vinyltubing and connect it to the distillateoutlet tube of the condenser. Securewith a tie strap.

7 Pass the free end of the vinyl tubingthrough the orifice in:–i) the cabinet base, item 24, if the

A4000 is to be wall mounted.ii) the cabinet side, item 19, if bench

mounted.

8 Take the 1 metre length of 16mmtubing and push through the larger ofthe three holes, item 20, on the sideof the cabinet. This may be easier ifthe tubing is lubricated by wetting itwith water. Continue until the tubeextends approximately 250mm intothe main chamber, roughly level withthe outlet of the condenser.

9 Connect the tubing to the outlet ofthe level control WL48 and securewith a tie-strap.

Ensure that the Rotaflo PTFE stopcockof the WL48 is closed.

10 Couple the WL48 to the boilerconnection arm with the plasticcoupling and rubber sleeve item 26.Ensure there are no stresses from the16mm tubing on the connection.

11 Unscrew the black plastic screwcapform the WL48 and assemble theglass funnel WF48 – item 4.

12 Looking inside the cabinet, identifythe vinyl tubing assembly fitted with 3numbered screwthread connectors.Referring to illustration fig. 2 makethe following connections:–Connector No. 1 to lower water inletof the condenser.Connector No. 2 to upper wateroutlet of the condenser.Connector No. 3 to boiler level controlWL48.

13 Unscrew the black plastic screwcap,and rubber ring, form the boiler. Slideboth onto the heating element(W48H, item 27). Insert the heaterinto the boiler ensuring that the end issupported in the glass nodule of theboiler.

Do not over-tighten the screwcapas this may cause the boiler tobreak or push the heater in too faras this may break the nodule.

14 Pass the electric cable of the heaterup into the electrical controlcompartment via the available orifice.Push the spade terminals onto thecorrect pins of the connecting strip(refer to fig. 3).

Fig 3 Termination for A4000

Blue - neutralBrown - liveEarth - yellow/green

Fig 2

Screw threadconnections

To distillatereservoir

To drainLevel controlWL48

Condenserdistillate outlet tube

Boilercoupling

Vent pipe

PCB

Thermostat

Relay

N E

L

Heaterlead

Rubber sleeve

Your Aquatron A4000 has been designedwith ease of assembly specifically in mind,but before commencing assembly pleasestudy the illustration, fig. 1 on page 2 tofamiliarise yourself with the general lay-out. During assembly, follow the sequenceof instructions and do not connect themains electricity supply until directed.

1 From the outer packaging remove allthe components including the metalcabinet containing the glass boiler.

2 Before unpacking the individualcomponents, identify them on thecheck-list below.

Item No. Description Catalogue No. Qty.

5 Condenser WC48/M2 127 Heater W48H 125 Boiler Level Control WL48 14 Funnel WF48 1

16 Reservoir Level Control WLS 17 Wall Mounting Bracket – 1– Bag of plastic hoses & tie straps – 1

4

15 Refit the cabinet end panel with all sixscrews and washers and the cabinetroof with all six counter sunk screws.Replace the perspex viewing screen.

You have now assembled yourAquatron Water Still. Move theassembled A4000 to its workinglocation - using the mounting bracket,item 7 if the unit is to be wallmounted. Ensure there is a space of atleast 50cm to the right of the unit toallow access to the heating element.

16 Connect the cold water supply to themains water inlet, item 18, fig. 1.Note the tubing selected should havea safe working pressure of at leastequal to the pressure of the watersupply and should be adequatelysecured by hose clips.

DO NOT TURN ON WATER SUPPLY.

17 Electrical Installation

THIS EQUIPMENT MUST BEEARTHED!

The electrical installation should onlybe carried out by a qualifiedelectrician.

The A4000 is classed as permanentlyconnected equipment.

The equipment is supplied with 1.5mof flexible, triple core, circular cable tothe following specification:- 1.5mm2,to BS 6500 or equivalent and <HAR>or BASEC approved.

Connection to the mains electricalsupply, should be via a double poleisolation switch with a continuouscurrent carrying capacity of 15A at250V and overcurrent protectionshould be provided by a double poleapproved fuse rated at 15A.

These devices should be sited near tothe equipment and clearly marked –“Disconnect device for AquatronWater Still“

The colour code for the mains cableis:–

Brown – LiveBlue – NeutralYellow/Green – Earth

Mains Cable ReplacementIf the mains cable requiresreplacement, only specially preparedspare mains lead obtained from BibbyScientific should be used.

DO NOT SWITCH ON ELECTRICITYSUPPLY.

18 Connect the reservoir level controlWLS as detailed on page 14 of themanual.

19 Refer to page 5 for operatinginstructions.

5

A4000 Operation

The following instructions apply to theA4000 water still where the water feed tothe boiler is via the mains supply, or aheader tank.

If the boiler is to be fed with either de-ionised or pre-treated water, please followthe instructions on page 15.

1 Before switching on either the mainselectricity or water supply, identify thecontrol switches and indicator lightson the front of the cabinet.

Green LightWhen illuminated this shows thatthere is mains supply voltage to theunit. Under no circumstances shouldthe cabinet end-panel be removedwhen this light is illuminated.

White “On Off” SwitchThis is the primary switch forcontrolling water and electricity insidethe still. The switch illuminates whenpressed in the ON position.

Amber LightWhen illuminated, this indicates thatthe distillate collection reservoir is fullas detected by the level control.

White “Clean” SwitchThis shuts off the heating element butallows water to flow into the boilerwhen the still is being commissionedor cleaned. When pressed in theCLEAN position the switch illuminates.

2 Carefully check the following:–

– the appropriate electricity, waterand drain services have beenprovided. If in doubt, consult theLOCATION & SERVICES section onpage 1.

– the ON/OFF switch on the controlpanel is in the OFF position.

– the CLEAN switch is pressed in theCLEAN position.

– the Rotaflo stopcock on the boilerlevel control WL48 is closed.

– the Reservoir pressure switch isfitted to the distillate collectionvessel.

– the dummy shorting plug is fittedto socket item 8, fig. 1.

3 Switch on the electricity supply – thegreen indicator light will illuminate.

4 Press the ON/OFF switch to the ONposition – the switch will illuminate.

5 Recheck that the CLEAN switch is inthe CLEAN position and illuminated.

6 Turn on the mains water supply andusing the needle valve item 18 fig. 1on the side of the cabinet, adjust theflow rate to approximately 1 litre/min.

Check that there are no water leaksfrom the hose connections.

7 Observe that the boiler is now fillingwith water to cover the heatingelement. When the water has reachedthe pre-set level, the excess will bedischarged to drain. Check that thedrain water flows freely and does not“back-up” into the level control.

8 Switch the CLEAN button off bypressing it for a second time – theswitch light goes out.

The heater will start to warm up andeventually run at a red glow. If theflow rate is insufficient, then theheater will not switch on – this willrequire the control needle valve to beopened further. After about 2 to 3mins. of operation distilled water willemerge from the outlet pipe, fallinginto the collection reservoir.

9 To avoid excessive wastage of coolantwater, make further adjustments tothe needle valve. Slowly reduce theflow-rate until the flow control switch,item 15, switches off the heaters –then increase the flow until the poweris restored.

10 Refit the perspex viewing screen.

11 Safety Cut-OutsAll Aquatron water stills are protectedby the following safety devices.

Flow Control Switch (item 15)monitors the flow of coolant waterinto the still and shuts off the heatingelement, if the flow is insufficient.

Thermostat Cut-Out (item 22)In normal operation the water withinthe glass will be at 100°C. In singlefault conditions, i.e. in the event ofwater supply failure, the content willincrease to 110°C where upon aresettable thermostat will operate.Once switched, the thermostat has tobe manually reset. This is achieved byunscrewing the black knob, fig. 1,item 23, located inside the cabinetand pressing the reset button.

Reservoir Control (fig. 11)is positioned on the collectionreservoir and switches off both theelectricity and water supply when thereservoir is full of distilled water. Thewater supply is only shut off around 7minutes after the reservoir is full toallow the heating element to cool.

It is recommended that the operationof the flow switch and reservoircontrol be checked on a regular basis.

a) Simulation of Mains WaterSupply FailureTurn off the mains water supply atthe tap. This should switch off theheating element. Turning the tap onagain will switch the heater on.

b) Simulation of Reservoir FullConditionLower the glass pressure bell WPB,(fig. 11), into the distillate to adepth of 150mm. This will switchoff the heating elementimmediately and the cooling waterafter 7 minutes. Raising the bell willcause both to be re-supplied.

12 Switching OffPush the CLEAN switch to the ONposition. Wait until the residual heatcontained in the heating element hasdispersed and no boiling is evident.Turn off water supply. Push ON/OFFswitch to OFF position. Isolate frommains electricity supply.

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2 Cabinet –

3 Boiler WB8

4 Funnel WF48

5 Condenser (2 off) WC48/M2

6 Cabinet Roof –

7 Wall Mounting Bracket –

8 Dummy Shorting Plug –












19 Distillate Outlet Pipe (Bench Mounted) –

20 Cooling Water Pipe to Drain (9mm) –



23 Thermostat WT8


25 Distillate Outlet Pipe (Wall Mounted) –

26 Boiler Level Control WL48


28 Heating Element (2 off) W48H


List of Major Components – A8000

Fig 4: Major component parts A8000

7

A8000 Assembly

3 Remove the perspex viewing screen,item 1 fig. 4 by using the finger recessto lift the screen out of the lowercabinet groove, then remove theinternal packaging which hasprotected the glass boiler duringtransit. Also sever the temporary tieholding the two boiler retainingsprings, item 29 in place.

4 Remove the cabinet end plate, item17 by unscrewing the six retainingscrews and ‘shake proof washers’.Similarly, unscrew the six countersunkscrews to remove the cabinet roof.

5 Position one of the condensersWC48/M2 onto the left hand vapourtube of the boiler with the distillateoutlet tube facing the front. See fig.5.

6 Looking inside the cabinet, identifythe vinyl tubing assembly fitted with 5numbered screwthread connectors.Referring to fig. 5 make the followingconnections to the assembledcondenser:–

Connect No. 2 to lower water inlet.

Connect No. 4 to upper water outlet.

7 Position the second condenserWC48/M2 onto the right hand vapourtube of the boiler with the distillateoutlet tube facing the front and makethe following tube connections:–

Connect No. 1 to lower water inlet.

Connect No. 3 to upper water outlet.

8 From the bag of hoses, take the 1metre length of 9mm diameter vinyltubing fitted with a ‘T’ piece.

Connect the 180mm length of tubingfrom the ‘T’ piece to the distillateoutlet of the condenser on the left-hand side. Secure with a tie strap andtrim off excess strap length. Connectthe 100mm length of tubing from the‘T’ piece to the distillate outlet of thecondenser on the right-hand side.Secure with a tie strap.

9 Pass the free end of the vinyl tubingthrough

i) the cabinet base, item 25, if theA8000 is to be wall mounted.

ii) the cabinet side, item 19, if benchmounted.

10 Take the 1 metre length of 16mmtubing and push through the larger ofthe three holes, item 21, on the sideof the cabinet. This may be easier ifthe tubing is lubricated by wetting itwith water. Continue until the tubeextends approximately 250mm intothe main chamber.

11 Connect the tubing to the outlet ofthe level control WL48 and securewith a tie strap.

Ensure that the Rotaflo PTFE stopcockof the WL48 is closed.

12 Couple the WL48 to the boilerconnection arm with the plasticcoupling and rubber sleeve item 27.

Ensure there are no stresses from the16mm tubing on the connection.

13 Unscrew the black plastic screwcapfrom the WL48 and assemble theglass funnel WF48 – item 4.

14 Identify the tubing connection No. 5and make the final connection to theboiler level control WL48, see fig. 5.This tubing assembly is also fitted witha 1 metre length of 9mm vinyl tubing.Feed the free end of this tube throughthe orifice, item 20, in the side of thecabinet.

15 The tubing assembly is also fitted witha 1 metre length of 9mm diametervinyl tubing. Feed the free end of thistubing through the orifice, item 20, inthe side of the cabinet.

16 Unscrew the two black plasticscrewcaps, and rubber rings, from theboiler. Slide both onto the heatingelements, W48H, item 28. Insert theheaters into the boiler ensuring thatthe ends are supported in the glassnodules of the boiler.

Do not over-tighten the screwcapsas this may cause the boiler tobreak or push the heaters in toofar as this may break the nodule.

Your Aquatron A8000 has been designedwith ease of assembly specifically in mind,but before commencing assembly pleasestudy the illustration, fig. 4 on page 6 tofamiliarise yourself with the general lay-out. During assembly, follow the sequenceof instructions and do not connect themains electricity supply until directed.



Item No. Description Catalogue No. Qty.

5 Condenser WC48/M2 228 Heater W48H 226 Boiler Level Control WL48 14 Funnel WF48 1

16 Reservoir Level Control WLS 17 Wall Mounting Bracket – 1– Bag of plastic hoses & tie straps – 1

Fig 5

To distillatereservoir

To drainLevel controlWL48

Condenserdistillate outlet tube

Boilercoupling

Vent pipe

2

4

3

1

5

Rubber sleeve

8

17 Pass the electric cables of the heatersup into the electrical controlcompartment via the available orifice.Push the spade terminals onto thecorrect pins of the connecting strip(refer to fig. 6).

18 Refit the cabinet end panel with all sixscrews and washers and the cabinetroof with all six countersunk screws.Replace the perspex viewing screen.

You have now assembled yourAquatron Water Still. Move theassembled A8000 to its workinglocation – using the mountingbracket, item 7 if the unit is to be wallmounted. Ensure there is a space of atleast 50cm to the right of the unit toallow access to the heating elements.

19 Connect the cold water supply toconnection 18 fig. 4. Note the tubingselected should have a safe workingpressure of at least equal to thepressure of the water supply andshould be adequately secured by hoseclips.

DO NOT TURN ON WATER SUPPLY.




The A8000 is classed as permanentlyconnected equipment.


Connection to the mains electricalsupply, should be via a double poleisolation switch with a continuouscurrent carrying capacity of 30A at250v and overcurrent protectionshould be provided by a double poleapproved fuse rated at 30A.




Fig 6 Terminations for A8000






PCB

Thermostat

Relay

Relay

N E

L

Heaterlead(front)

Heaterlead(back)

9

The following instructions apply to theA8000 Aquatron water still where thewater feed to the boiler is via the mainssupply, or a header tank.

If the boiler is to be fed with either de-ionised or pre-treated water, please followthe instructions on page 15.


Green LightWhen illuminated this shows thatthere is mains supply voltage to theunit. Under no circumstances shouldthe cabinet end-panel be removedwhen this light is illuminated.

White “On Off” SwitchThis is the primary switch forcontrolling water and electricity insidethe still. The switch illuminates whenpressed in the ON position.

Amber LightWhen illuminated, this indicates thatthe distillate collection reservoir is fullas detected by the level control.

White “Clean” SwitchThis shuts off the heating element butallows water to flow into the boilerwhen the still is being commissionedor cleaned. When pressed in theCLEAN position the switch illuminates.


– the appropriate electricity, waterand drain services have beenprovided. If in doubt, consult theLOCATION & SERVICES section onpage 1.



– the Rotaflo stopcock on the boilerlevel control WL48 is closed.


– the dummy shorting plug is fittedto socket item 8, fig. 4.




6 Turn on the mains water supply andusing the needle valve item 18, fig. 4,on the side of the cabinet, adjust theflow rate to approximately 2litres/min.

Check that there are no water leaksfrom the hose connections.

7 Observe that the boiler is now fillingwith water to cover the heatingelements. When the water hasreached the pre-set level, the excesswill be discharged to drain. Checkthat the drain water flows freely anddoes not “back-up” into the levelcontrol.

8 Switch the CLEAN button off bypressing it for a second time – theswitch light goes out.

The heaters will start to warm up andeventually run at a red glow. If theflow rate is insufficient, the heaterswill not switch on – this will requirethe needle valve to be opened further.After about 2 to 3 mins. of operationdistilled water will emerge from theoutlet pipe, falling into the collectionreservoir.

9 To avoid excessive wastage of coolantwater, make further adjustments tothe needle valve. Slowly reduce theflowrate until the flow control switch,item 15, switches off the heaters –then increase the flow until the poweris restored.

10 Refit the perspex viewing screen.


Flow Control Switch (item 15)monitors the flow of coolant waterinto the still and shuts off the heatingelements, if the flow is insufficient.


Reservoir Control (fig. 11)is positioned on the collectionreservoir and switches off both theelectricity and water supply when thereservoir is full of distilled water. Thewater supply is only shut off around 7mins. after the reservoir is full to allowthe heating element to cool.


a) Simulation of Mains WaterSupply FailureTurn off the mains water supply atthe tap. This should switch off theheating element. Turning the tap onagain will switch the heater on.

b) Simulation of Reservoir FullConditionLower the glass pressure bell WFB,fig. 11, into the distillate to a depthof 150mm. This will switch off theheating element immediately andthe cooling water after 7 minutes.Raising the bell will cause both tobe re-supplied.

12 Switching OffPush the CLEAN switch to the ONposition. Wait until the residual heatcontained in the heating elements hasdispersed and no boiling is evident.Turn off water supply. Push ON/OFFswitch to OFF position. Isolate frommains electricity supply.

A8000 Operation

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2 Cabinet –

3 Boiler (2 off) WB4

4 Funnel WF48

5 Condenser (2 off) WC48/M2

6 Cabinet Roof –

7 Dummy Plug –

8 Boiler Level Socket for W4L2A –












19 Distillate Outlet Pipe –

20 Drain Pipe from W4L2A –




24 Thermostat WT4

25 Boiler Level Control (rear) W4L2A


27 Boiler Level Control (front) WL48


29 Heating Element (2 off) W48H


List of Major Components – A4000D

Fig 7: Major component parts A4000D

11

Rubber sleeve

Condenser distillateoutlet tube

Ventpipe

To W4L2Alevel control

WL48

To drain

4

2

5

A4000D Assembly

Your Aquatron A4000D has been designedwith ease of assembly specifically in mind,but before commencing assembly pleasestudy the illustration, fig. 7 on page 10 tofamiliarise yourself with the general lay-out. During assembly, follow the sequenceof instructions and do not connect themains electricity supply until directed.



3 Remove the perspex viewing screen,item 1 fig. 7 by using the finger recessto lift the screen out of the lowercabinet groove, then remove theinternal packing which has protectedthe glass boilers during transit. Alsosever the temporary ties holding theboiler retaining springs, item 30, inplace.

4 Remove the cabinet end plate, item17 by unscrewing the six retainingscrews and ’shake proof washers‘.Similarly, unscrew the six countersunkscrews to remove the cabinet roof.

5 Withdraw the metal thermostatprobe, fig. 7. item 24, from the glasstube inside the front boiler.

6 Remove the front boiler from thecabinet by releasing the retainingsprings, item 30.

7 Mount one of the condensersWC48/M2 onto the vapour tube ofthe rear boiler with the distillate outletfacing the front. See fig. 8a.

8 Select one of the 1metre lengths of9mm vinyl tubing and connect to theupper distillate outlet tube of thecondenser. Secure with tie strap. Passthe free end of the vinyl tubingthrough hole, item 19 in the cabinetside.

9 Take the Level Control, W4L2A, item25 and the other metre length of9mm tubing. Connect the tubing tothe lower drain outlet of the W4L2Aand secure with tie strap. Feed thefree end of the tubing through theopening, item 20 in the side of thecabinet.

10 From the hose pack, take the 300mmlength of vinyl tubing and connect tothe side arm of the W4L2A, securingwith a tie strap. Direct the free end ofthe tubing to the front of the cabinet.

11 Using the plastic coupling and rubbersleeve, item 28, couple the W4L2A tothe boiler connection arm. Ensure thatthe Rotaflo Stopcock on the W4L2A isclosed.

12 Connect the 4 pin DIN plug from thefloat switch of the W4L2A to the DINsocket, item 8, fig.7, situated insidethe main chamber of the cabinet.

13 Refit the front boiler into the cabinetand secure with retaining springs.

14 Fit the remaining condenser onto theboiler with the distillate outlet at thefront. See fig. 8b.

15 Connect the free end of the 320mmvinyl tubing (instruction 10 refers) tothe distillate outlet of the frontcondenser. Secure with a tie strap.

Fig 8a: Rear

Fig 8a: Front

Vent pipe

W4L2A

From distillate of first condenser

From distillate of first condenser

To drain

To boilerlevelsocket

Item No. Description Cat. No. Qty

5 Condenser WC48/M2 229 Heater W48H 227 Boiler Level Control (front) WL48 125 Boiler Level Control (rear) W4L2A 14 Funnel WF48 1

16 Reservoir Level Control WLS 1– Bag of plastic hoses & tie straps – 1

To drain

12


Fig 9 Terminations for A4000D

PCB

Thermostat(Rear)

Thermostat(Front)

Relay

Relay

N E

L

Heaterlead(front)

Heaterlead(back)

16 Refit the metal thermostat probe intoglass tube of the boiler.

17 Take the one metre length of 16mmtubing and insert through the hole,item 22 in the cabinet side. Thetubing should extend approximately250mm into the cabinet, roughly levelwith the outlet of the condenser.

18 Identify the front boiler level controlWL48, item 27, fig.7, and connect theoutlet to the tubing. Secure with a tiestrap. Ensure that the RotafloStopcock of the WL48 is closed.

19 Couple the WL48 to the boilerconnection arm with the plasticcoupling and rubber sleeve, item 28.Ensure there are no stresses from the16mm tubing on the connection.

20 Looking inside the cabinet, identifythe vinyl tubing assembly fitted with 5numbered screwthread connectors.Referring to illustration fig. 8 makethe following connections:–

Connector no. 1 to lower water inletof rear condenser.Connector no. 2 to lower water inletof front condenser.Connector no. 3 to upper wateroutlet of rear condenser.Connector no. 4 to upper wateroutlet of front condenser.Connector no. 5 to front boiler levelcontrol WL48.

21 The tubing assembly is also fitted witha 1 metre length of 9mm diametervinyl tubing. Feed the free end of thistubing through the opening, item 21,in the side of the cabinet.

22 Unscrew the black plastic screwcapfrom the WL48 and assemble theglass funnel WF48 – item 4.

23 Unscrew the black plastic screwcapand rubber ring from the rear boiler.Slide both onto heating elementW48H – item 29.

24 Assemble the heater into the boilerensuring that the far end is supportedin the glass nodule of the boiler.

Note: It is not necessary to overtighten the screwcap and riskbreaking the glass boiler.

25 Pass the electric cable of the heaterup into the electrical controlcompartment via the orifice available. Push the spade terminalsonto the CORRECT PINS of theconnecting strip (refer to fig. 9).

26 Repeat the operation to fit the secondheating element for the front boiler.

27 Refit the cabinet end panel with all sixscrews and washers. Refit cabinet roofwith the six countersunk screws.

28 Refit the perspex viewing panel.

29 Move assembled A4000D to desiredworking location. ensure there is aspace of at least 50cm to the right ofthe unit to allow access to the heatingelements.

30 Connect the cold water supply toconnection 18 fig. 7.

Note: The tubing selected shouldhave a safe working pressure at leastequal to the pressure of the watersupply. The tubing should beadequately secured by hose clips.

DO NOT SWITCH ON.




The A4000D is classed as permanentlyconnected equipment.


Connection to the mains electricalsupply, should be via a double poleisolation switch with a continuouscurrent carrying capacity of 30A at250v and overcurrent protectionshould be provided by a double poleapproved fuse rated at 30A.








Fig 10W4L2ALevel Control

To boiler levelsocket

Guidetube

Float switch

Distillate feedfrom front still

To drain

15 - 20mm

13

The following instructions apply to theA4000D double distillation stills where thewater feed to the first stage boiler is eithervia the mains supply or a header tank.

If it is desired to feed the first stage boilerwith deionised or pre-treated water toobviate cleaning, then the instructions onpage 15 should be followed.

1 Before switching ON either mainselectricity or water supply, identify thecontrol switches and indicator lightson the front of the cabinet.

Green LightWhen illuminated this shows there ismains supply voltage within the unit.In no circumstances should thecabinet end-panel be removed whenthis light is illuminated.

White “On/Off” SwitchThe primary switch for controllingwater and electricity inside the still.The switch illuminates when pressedin the ON position.

Amber LightWhen illuminated, this indicates thatthe distillate collection reservoir is full,as detected by the level control.

White “Clean” SwitchThis shuts off the heating elementsbut allows water to flow into theboiler. Used for filling the boiler oncommissioning and cleaning purposes.The switch illuminates when pressedin the ‘ON’ position.


– That the appropriate electricity,water and drain services have beenprovided. If in doubt,– consult the“Location and Services” notes onpage 1.

– Water still ON/OFF switch is in theOFF position.

i.e. – switch should not be pressedand should not illuminate.

– Water still CLEAN switch is in theON position.

– The Rotaflo stopcock on the frontboiler level control WL48 is closed.

– The float switch on the secondstage boiler level control W4L2A isset at the factory. However, checkthat this has not been disturbedduring transit. A rough check is thatthe distance from the top of thelarge screw cap of the W4L2A tothe top of the glass guide tubeshould be approximately 15-20mmsee fig. 10.

– The dummy shorting plug is fittedto socket item 7, fig. 7.

3 Switch on the electricity supply.(Note: the green indicator light willilluminate).

4 Press the ON/OFF switch to the ONposition (switch will illuminate).

5 Re-check that the Clean switch is inthe ‘ON’ position (switch willilluminate).

6 Turn on the mains water supply andusing the needle valve, item 18, fig. 7,on the side of the cabinet, adjust theflow rate to approximately 2litres/minute.

Check there are no water leaks fromthe hose connectors.

7 Observe that the front boiler is nowfilling with water to cover the heatingelements. When the water hasreached the pre-set level excess will bedischarged to drain. Check that thedrain water flows freely and does not“back-up” into the level control.

8 Press the Clean button to ‘OFF’position. (Switch light should go out).

The heater on the front boiler shouldstart to warm up and eventually runwith a red glow. After a short timedistilled water will emerge from theoutlet pipe item. This should feed intothe empty rear boiler via the levelcontrol W4L2A.

9 Allow the rear boiler to fill with singledistilled water (for approx. 20 to 30minutes), keeping an eye on the level.Note that the heater of the secondstage only comes on when the level ofsingle distilled water in the rear boileris at about the equator. It may benecessary to adjust the level of thefloat switch of the WL42A to achievethis condition. Refer to fig. 10.

Lifting the guide tube increases thelevel at which the heating elementwill switch on.

Lowering the guide tube decreasesthe level at which the element willswitch on.

Double distilled water ultimately flowsfrom outlet pipe, item 19. This shouldfall away from the still with no kinks,restrictions or U bends.

10 To avoid excessive wastage of coolantwater, make further adjustments tothe needle valve, item 18. Slowlyreduce the flowrate until the flowcontrol, item 15, switches off theheaters - then increase the flow untilthe power is restored.


Flow Control Switch (item 15)monitors the flow of coolant waterinto the still and shuts off the heatingelements, if the flow is insufficient.


Reservoir Control (fig. 11)is positioned on the collectionreservoir and switches off both theelectricity and water supply when thereservoir is full of distilled water. Thewater supply is only shut off around 7mins. after the reservoir is full to allowthe heating elements to cool.


a) Simulation of Mains WaterSupply FailureTurn off the mains water supply atthe tap. This should switch off theheating element. Turning the tap onagain will switch the heaters on.

b) Simulation of Reservoir FullConditionLower the glass pressure bell WFB,fig. 11, into the distillate to a depthof 150mm. This will switch off theheating element immediately andthe cooling water after 7 minutes.Raising the bell will cause both tobe re-supplied.

12 Switching OffPush the CLEAN switch to the ONposition. Wait until the residual heatcontained in the heating elements hasdispersed and no boiling is evident.Turn off water supply. Push ON/OFFswitch to OFF position. Isolate frommains electricity supply.

A4000D Operation

14

Each Aquatron water still is supplied with aRESERVOIR LEVEL CONTROL, WLS, fig. 11.This automatically switches off the heatingelements and coolant water supply whenthe distillate collection reservoir is filledwith distilled water.

Note that, the control is fitted with a‘delay timer’ which switches off thecoolant water supply approximately 7minutes after the heating elements. This isto allow time for the heaters to cool andfor boiling to cease.

The control also automatically switches onthe heating elements and coolant watersupply when the level of distillate in thecollection reservoir falls.

It is possible to fit the glass pressure bell ofthe control to most types of reservoir andcontainer by means of a metal clip WFC/1which is provided.

Alternatively, Bibby Scientific offer apurpose designed reservoir collectionsystem WR20 fitted with a special adapterto hold the bell, see fig. 12.

Fitting the Reservoir Control WLS toCollection Vessels

1 Position the distillate collectionreservoir in a suitable location. Thisshould be below the water still so thatthe vinyl rubber tubing transportingthe distilled water from the still canfall down to the reservoir withoutrestrictions, kinks or U bends.

2 Take the Reservoir Level Control WLSand connect the free end of therubber tubing to the nozzle, item 13,of the reservoir pressure switchlocated on the side of the cabinet.

3 Use the metal clip to fit the glasspressure bell inside the distillatecollection reservoir. Refer to fig. 11.

4 Position the bell so that the open endis 140mm below the desired distillatelevel.

Bibby Scientific offer a purpose designedreservoir system for the collection ofdistilled water from your Aquatron. This comprises:–

WR20 – 20 litre Pyrex glass reservoircomplete with Rotaflo stop-cockand special lid.

WS20 – Reservoir stand, 43cm high foruse with WR20.

The lid of the reservoir has a side arm forconnection to the distillate feed from theAquatron and a vent fitted with abacteriological filter to maintain the purityof the water. A screwthread fitting is alsoprovided to support the Reservoir LevelControl WLS.

Location & Assembly

1 Locate the reservoir in a positionwhich is below the level of the waterstill.

2 Fit the Rotaflo drain cock to thelower ground glass socket of thereservoir and secure with the plasticjoint clip.

3 Take the bacteriological filter andconnect this to the top of the glassfeed-pipe using the vinyl tubingprovided. Fit the feed pipe and filterinto the reservoir lid via the largescrewcap fitting.

4 Fit the Reservoir Level Control WLS tothe lid via the small screwcap fitting.Note that the stem of the glasspressure bell should extendapproximately 50mm above thescrewcap (see illustration).

5 Place the assembled lid into thesocket of the reservoir.

6 Take the rubber tubing from thereservoir level control WLS andconnect to the small plastic nozzle,item 13, on the side of the water stillcabinet.

7 Take the vinyl plastic tubing from thedistillate outlet of the water still andconnect to the side-arm of the feedpipe on the reservoir lid. Ensure thatthe tubing falls down to the reservoirwithout any restrictions, kinks or Ubends.

Distillate CollectionA4000, A8000,A4000D

Reservoir SystemWR20 & WS20

Fig 11 WLS Reservoir level control

140mm

Fig 12 Reservoir WR20 and Stand WS20

To pressure switch(Item 13 on Aquatron)

DistillatefromAquatron

50mm

WLS

15

Connection ofAquatron stills todeionised andpre-treated watersupplies

Many laboratories prefer to feed theirwater stills with deionised or pre-treatedwater to obviate the need for boilercleaning and de-scaling.

Your new Aquatron can be easilyconverted to deionised water-feed by useof a simple accessory – the WATER FEEDCONVERSION KIT, Catalogue No. WCK/N.This kit permits the still to operate withmost types of deioniser and also pipedsupplies of pre-treated water. Pleasecontact Bibby Scientific or your laboratorytrade house for ordering and priceinformation.

The sequence of operations to fit theWCK/N is detailed below:–

1 Assemble the Aquatron as describedunder the relevant ASSEMBLYinstructions.

A4000 refer to page 3A8000 refer to page 7A4000D refer to page 11

2 Ensure the unit is isolated from themains electricity supply.

3 Remove the perspex viewing screen,the cabinet end-panel and the cabinetroof.

4 Lift out the front switch panel fromthe cabinet groove by unscrewing thecounter sunk screw at the top of thepanel. This will allow better access tothe plumbing system.

5 Identify the length of 9mm vinyltubing which connects the side arm ofthe Boiler Level Control WL48 and theoutlet of the Water Flow ControlSwitch (WS48/1 or WS48/2). Removethe tubing by unscrewing the plasticscrewthread connector from theWL48 and then severing the tie strapon the Flow Switch.

6 From the Water Feed Conversion KitWCK/N, take the 1 metre length of9mm vinyl tubing. Push one end ofthe tubing onto the OUTLET of theWater Flow Control Switch, andsecure with a tie-strap.

7 Push the free end of the tubingthrough the vacant orifice in the sideof the cabinet and lead to the drain.

8 Take the 220mm length of reinforcedplastic tubing from the WCK/N kit.Connect the free-end to the nozzle ofthe solenoid valve, item 1, fig 13.Secure with metal hose clip. Fit theother end of the tubing to the sidearm of the Level Control WL48, item3, using the screwthread connector.

9 Refit the front switch panel andsecure with screw.

10 Take the plastic screwcap, hoseconnector and rubber ring from theWCK/N kit. Fit to the deionised waterinlet, item 2, fig. 13, having firstremoved the red protective cap.

11 Unscrew the screwcap, item 4, fig. 13,from the Level Control WL48. Removethe glass funnel WF48 and the rubberring which are no longer required.

12 Take the glass float, guide tube andwasher assembly, item 5, and pass theelectric lead and plug through thehole in the screwcap. Carefully pushthe washer into the cap.

13 Refit the screwcap and float assemblyto the Level Control WL48 ensuringthat the end of the guide tube locatesin the well at the base.

14 Remove the dummy shorting plugfrom the socket item, 6, fig. 13, andfit the plug from the Float Switch.

15 Replace the cabinet end-plate androof.

16 Connect the hose connector, item 2,of the deionised water inlet to theoutlet of the deioniser or pre-treatedwater supply. Note the tubing selectedshould have a safe working pressureof at least equal to the pressure of thewater supply and should beadequately secured with hose clips.


Green LightWhen illuminated this shows thatthere is mains supply voltage to theunit. Under no circumstances shouldthe cabinet end-panel be removed thislight is illuminated.

White ‘ON/Off’ SwitchThis is the primary switch forcontrolling water and electricity insidethe still. The switch illuminates whenpressed in the ON position.

Amber LightWhen illuminated this indicates thatthe distillate collection reservoir is fullas detected by the level control.

White ‘Clean’ SwitchThis shuts off the heating element butallows water to flow into the boilerwhen the still is being commissionedor cleaned. When pressed in theCLEAN position the switch illuminates.


– the appropriate electricity, waterand drain services have beenprovided. If in doubt, consult theLOCATION AND SERVICES sectionon page 1.



– the Rotaflo Stopcock on the boilerlevel control WL48 is closed.


– the dummy shorting plug has beenremoved from it’s socket andreplaced with the lead from theWCK/N.

Operation

Fig 13 Conversion to deionised or pre-treated water supply

Deioniser orpre-treated water supply

3

2

1

6

4 5

16




6 Turn on the mains water supply andusing the needle valve on the side ofthe cabinet, adjust the flow rate toapproximately 1 Litre/Min. for A4000and 2 Litres/Min. for A8000 andA4000D. Ensure that the mains waterflows to drain without any restriction.

7 Turn on the supply of deionised orpre-treated water. Observe thatdeionised water enters the boiler viathe float system of the WCK/N.

8 Allow deionised water to flow intothe boiler until the heating element(s)is covered by approximately 10mm. Atthis level the flow of deionised waterinto the boiler should be automaticallycut off by the WCK/N float system.

9 Switch off the CLEAN button bypressing it for a second time – theswitch light goes out.

The heater(s) will start to warm upand eventually run at a red glow. (Ifheater fails to glow, check that theflow of mains water is adequate).

10 Allow distillation to commence andobserve that the WCK/N float systemallows fresh deionised water to enterthe boiler and maintain a satisfactoryoperating level.

If the deionised supply fails then theWCK/N will switch off the heater untilit is restored.

11 Replace the perspex viewing screen.

When any of the Aquatron stills have beenused to produce distilled water directlyfrom a mains water supply, there willinevitably be a build-up of scale in theboiler and on the heating element(s). Toobtain optimum performance from the stillthe scale should be removed on a regularbasis. The time span between cleaningdepends entirely upon the hardness of thewater supply. In very hard water areas itmay be necessary to clean the still once aweek, whereas in soft water areas severalweeks may elapse before cleaning isnecessary.

It should not, of course, be necessary tode-scale the second stage boiler on theA4000D or when the stills have beenoperated from a de-ioniser.

Cleaning the still involves the use ofconcentrated hydrochloric acid. As a safetyprecaution protective clothing, gloves,mask and goggles should be worn duringcleaning.

Note:The cabinet and perspex screen should becleaned using a dilute detergent solutiononly.

It is possible to descale the AquatronWater Still without dismantling theglassware by following these instructionsin conjunction with Control of SubstancesHazardous to Health regulations (COSHH)1988.

Method1 Push the CLEAN switch to the CLEAN

position – the switch illuminates.

2 Observe that the heating element/shas switched off. Allow boiling to stopand water to cool.

3 Push ON/OFF switch to OFF position.

4 Remove perspex screen.

5 Open the Rotaflo stopcock on thelevel control WL48, allow the boiler toempty to 3/4’s of its full capacity, andclose stopcock.

6 Carefully add about 100ml. ofconcentrated hydrochloric acid intothe glass funnel of the WL48.

7 Push the ON/OFF switch to the ONposition, the boiler will refill to itsoperating level.

8 Push the ON/OFF switch to the OFFposition.

9 Allow the chemical reaction within theboiler to continue until all the depositshave been removed.

Note – if scale has built up above theoperating level, the boiler may becompletely filled by either lifting thedrain pipe or restricting the flow ofwater to drain. This operation must becarefully controlled so that the boilerdoes not over-fill and cause water tobe forced over the funnel top.

10 Open Rotaflo stopcock and allowcontents of the boiler to draincompletely.

Note:If the acid added to the boiler has notbeen completely neutralised, theliquid flowing to drain may bestrongly acid. Necessary safetyprecautions should be observedaround the drain position, and anyeffluent control procedures followed.

11 Close Rotaflo stopcock.

12 Push ON/OFF switch to ON positionand allow boiler to fill with water.Again the boiler may be completelyfilled by following procedure detailedin step 8.

13 Push ON/OFF switch to OFF position.

14 Drain the boiler by opening theRotaflo stopcock.

15 Repeat steps 11-14 two or three timesuntil the boiler has been thoroughlyflushed through.

16 The still is re-started by finishing thecleaning cycle at step 12, and thenpushing the CLEAN switch to the OFFposition. (Switch is not illuminated).

Before collecting the distillate the stillshould be allowed to run for about 10minutes with the distillate running todrain, this will ensure that any residualacid is removed.

Note:The amount of acid required willdepend upon the degree of scaling. If after performing the cleaning cycledeposits are left in the boiler, it maybe necessary to repeat the cleaningcycle using a fresh quantity of acid.

The benefits gained from regularcleaning cannot be over emphasised.

CleaningA4000, A8000,A4000D

17

In the event of operating difficulties withyour Aquatron it is suggested that thefollowing basic checks are made. (Pleasenote that these checks should only becarried out by suitably qualifiedpersonnel).

If these checks fail to identify and remedythe problem then you are advised to seekthe help of your supplier or the TechnicalServices Department of Bibby Scientific Ltd.

1 Unit completely inoperative –No mains green indicator light on

Check the electricity supply to theAquatron and ensure that a fuse hasnot blown at the plug or supply fuseboard. (This check should beconducted by a QUALIFIEDELECTRICIAN).

2 Heater(s) not on –Mains green indicator light onwater flowing

a) Check the Aquatron switches are inthe correct mode, i.e.:

ON/OFF switch is in the ONposition.

CLEAN switch is in the OFF position.

Check that the Reservoir indicatorlight is NOT illuminated andindicating a full collection reservoir.

b) Check that the 15 amp fuses,located inside the electricalchamber of the cabinet, have notblown. (This check should beconducted by a QUALIFIEDELECTRICIAN).

c) Check that the flow of coolingwater is sufficient.

A4000 requires a flowrate of atleast 1 litre/min.

A8000, A4000D requires a flowrateof at least 2 litres/min.

If the flowrate is NOT sufficientthen:–

Check the mains water supply isturned on.

Check the needle valve on theright-hand side of the cabinet isopen.

Check the water inlet filter is notblocked (see note 8).

Check the flow of water is notimpeded by blockages orrestrictions.

3 Heater(s) not on –Water not flowingMains green indicator light on

Check that the thermostat has notoperated. Confirm this by pressing thethermostat reset button located insidethe main chamber of the cabinet.

If the thermostat has cut-out then thecause should be identified at once.

Check that the boiler containssufficient water.

Check that the plumbing connectionsare not leaking.

Check that the stopcock on the boilerlevel control WL48 is closed.

4 Heater in second stage boiler ofA4000D not on

Check the setting of the boiler levelcontrol W4L2A. See page 12 fordetails.

Check thermostat has not operated.See notes under 3.

5 Water level in boiler too high –Choking of condenser

Check that the flow of water into theboiler is not excessive. Control flow byadjusting needle valve on right-handside of cabinet.

Check that the coolant water drainpipe falls away from the Aquatronwithout restrictions or U bends.

If level of water in the second stageboiler of model A4000D is too high,then:–

Check setting of the float switch inboiler level control W4L2A. See page12 for details.

6 Distillate quality low –

Check the condition of the boiler andclean if heavily scaled.

7 Distillate collection reservoirfloods –

Check the location of the Reservoirlevel control WLS inside the reservoir.See page 13 for details.

Check that the WLS pipe connectionsbetween the glass bell and Aquatronare secure and air tight.

8 Cleaning blocked water filters

Your Aquatron is fitted with a built-inwater filter to prevent the ingress ofparticulate matter into the plumbingsystem.

The filter can be examined andcleaned if necessary by unscrewingthe black plastic screwcap whichsecures the needle valve, item 18, tothe right-hand side of the cabinet.

A similar filter is also incorporated onthe same side of the cabinet for usewith pre-treated water supplies.Access is via the black screwcap whichsecures the hose nozzle.

Fault FindingA4000, A8000,A4000D

Additional checksfor Aquatrons fedwith deionised orpre-treated water

a) Boiler does not fill –

Check that supply of pre-treatedwater is switched on.

Check input water filter on side ofcabinet is not blocked (see note 8).

Check Water Feed Conversion KitWCK/N is correctly fitted andadjusted. See page 14 for details.

b) Heater(s) not on –

Check water level in boiler is abovethe heating element.

Check Water Feed Conversion KitWCK/N is correctly fitted andadjusted. See page 14 for details.

18

List of Spares

Catalogue no.

Boiler for A4000, A4000D WB4

Boiler for A8000 WB8

Boiler plastic coupling WBC1

Boiler Level Control WL48

Boiler level control for A4000D rear boiler W4L2A

Float switch for W4L2A X/6I/B595264

Condenser WC48/M2

Electric fuse, 15 amp, HRC W15F

Funnel WF48

Heater W48H

Hose assembly for A4000 WH48/1

Hose assembly for A8000 WH48/2

Hose assembly for A4000D WH48/3

Printed circuit board WPCB/M3

O ring (lower) for vapour tube QR38/24

O ring (upper) for vapour tube WB48/01

Reservoir assembly complete WR20

Components:–

20 litre glass reservoir 1569/22

Bacteriological filter WR20/01

Lid/adapter WR20/02

Feed pipe WR20/03

Stopcock WR20/04

Stopcock retaining clip KC29

Reservoir metal stand WS20

Reservoir Level Control WLS

Reservoir pressure switch WPS

Rubber ring for heating element QR38/24

Rubber ring for thermostat QR18/10

Rubber rings for reservoir lid QR18/10 & QR28/18

Screwcap for heating element QC38/25

Screwcap for thermostat QC18/11

Screwcaps for reservoir lid QC18/11 & QC28/21

Screwthread connectors for hose assemblies 4510/02

Solenoid valve WSV

Thermostat for A4000 & A4000D WT4

Thermostat for A8000 WT8

Thermostat glass tube WTT48

Water Feed Conversion kit WCK/N

Float switch for WCK/N WCK/01N

Water Flow Control Switch for A4000 WS48/1

Water Flow Control Switch for A8000 & A4000D WS48/2

19

Circuit diagram for A4000

Wiring diagram for A4000

*NOTE

SKT1 IS USED IN CONJUNCTION WITH THE DE-IONISED FEED CONVERSION KIT, WCK/N.IF THE STILL IS NOT FITTED WITH WCK/N, PINS 1 & 5 ARE CONNECTED TOGETHERWITH THE 'DIN' PLUG SUPPLIED WITH THE STILL.PINS 1 & 5, BOILER WATER LEVEL REED SWITCH.PINS 2 & 4 DE-IONISED FEED SOLENOID REED SWITCH.

(E) DENOTES E.M.C. CRITICAL COMPONENT

(S) DENOTES SAFETY CRITICAL COMPONENT

T1 (S)

MR1C2

33uF16V

C11000uF

25V

IC1

+12

RL2(S)

RL1(S)

D3

1N4007

D2

1N4007

D11N4007

TR1

R168K

R21K

C32200uF

16V

3,6,9

2,5,7,8,1

1

10

12 - WAYSOCKET

ON/OFF(WHITE)

CLEAN(WHITE)

RESERVOIRFULL

(AMBER)

CLEANPRESSURESWITCH

(S)

FLOWSWITCH

(S)(SEE

NOTE)*4 2 3 1

ON/OFF(S)

SKT1/1 (SEE NOTE)*

L

N

E

MAINS ON(GREEN)

(S)

THERMOSTAT

(S)

RL3/1 (E)(S)

HEATERSV2 (S)DE - IONISED

WATERSOLENOID

SV1 (S)COOLINGWATER

SOLENOID

12

345

12

345

A4000/PCB (S)

T 125 m AL (S)

WHEN USED WITH WCK/N

1

4 - WAY SOCKET(S)

}

1N4007

RL4(E)(S)

12 - WAYSOCKET

*NOTESKT1 IS USED IN CONJUNCTION WITH THE DE-IONISED FEED CONVERSION KIT,WCK/NIF THE STILL IS NOT FITTED WITH WCK/N, PINS 1 & 5 ARE CONNECTEDTOGETHER WITH THE 'DIN' PLUG SUPPLIED WITH THE STILL.PINS 1 & 5, BOILER WATER LEVEL REED SWITCHPINS 2 & 4, DE-IONISED FEED SOLENOID

1011

12

7

9

3

1

6

5

2

3241

4 - WAY PLUG

12 - WAY PLUG

PINK

WHITE

YELLOW

RED

WHITE

RED

BLACK

BLACK

YELLOW

ORANGE

BLUE

BROWN

THERMOSTAT (S)

1N4007

RL3 (E)(S)

PINK

BLUE

BROWN

ON/OFF(S)

VIOLET

BLACK

RED

REDCLEANSWITCH

YELLOW

CLEANBLACK

RESERVOIRFULL

WHITE

BLACK

ON/OFF

BLUE

BROWN

BROWN

MAINS ON(S)

BROWN

RL3/1 (E)(S) HEATER

BLUEL

N

BLUE

BLUE

1

2

3

4

56

FLOWSWITCH

(S)

SV2 (S)

SV1 (S)



SKT1 (SEE NOTE)*12

34 5

1 2

34

PRESSURESWITCH

(S)

} WHEN USED WITH WCK/N

20

Circuit diagram for A8000

Wiring diagram for A8000

D3

1N4007

*NOTE

SKT1 IS USED IN CONJUNCTION WITH THE DE-IONISED FEED CONVERSION KIT, WCK/N.IF THE STILL IS NOT FITTED WITH WCK/N, PINS 1 & 5 ARE CONNECTED TOGETHERWITH THE 'DIN' PLUG SUPPLIED WITH THE STILL.PINS 1 & 5, BOILER WATER LEVEL REED SWITCH.PINS 2 & 4 DE-IONISED FEED SOLENOID REED SWITCH.



T1 (S)

MR1C2

33uF16V

C11000uF

25V

IC1

+12

RL2(S)

RL1(S)

D2

1N4007

D11N4007

TR1

R168K

R21K

C32200uF

16V

3,6,9

2,5,7,8,1

1

10

12 - WAYSOCKET

ON/OFF(WHITE)

CLEAN(WHITE)

RESERVOIRFULL

(AMBER)

CLEANPRESSURESWITCH

(S)

1N4007

RL3(E)(S)

1N4007

RL4(E)(S)

FLOWSWITCH

(S)(SEE

NOTE)*4 2 3 1

ON/OFF(S)

SKT1/1 (SEE NOTE)*

L

N

E

MAINS ON(GREEN)

(S)

THERMOSTAT(S)

RL3/1 (E)(S)

RL4/1 (E)(S)

FRONTHEATER

REARHEATER

SV2 (S)DE - IONISED

WATERSOLENOID

SV1 (S)COOLINGWATER

SOLENOID

12

345

12

345

A4000/PCB (S)

T 125 m AL (S)


1

4 - WAY SOCKET(S)

}

12 - WAYSOCKET

RL3 (E)(S)

1N4007

10

11

12

7

9

3

1

6

5

2

3

2

4

1

4 - WAY PLUG

12 - WAY PLUG

PINK

WHITE

YELLOW

RED

WHITE

RED

BLACK

YELLOW

ORANGE

BLUE

BROWN

RL4 (E)(S)

PINK

BLUE

BROWN

ON/OFF(S)

VIOLET

BLACK

RED

REDCLEANSWITCH

YELLOW

CLEANBLACK

RESERVOIRFULL

WHITE

BLACK

ON/OFF

BLUE

BROWN

BROWN

MAINS ON(S)

BROWN

RL3/1 (E)(S) FRONT HEATER

BLUE

L

N

BLUE

BLUE

1

2

3

4

5

6

FLOWSWITCH

(S)

SV2 (S)

SV1 (S)



SKT1 (SEE NOTE)*

BROWN

BROWNBROWN

RL4/1 (E)(S) REAR HEATER

BLUE

8

BLACK PINK

THERMOSTAT (S)

ORANGE

REAR BOILERFLOAT SWITCH

1N4007

PRESSURESWITCH

(S)

123

54

1 2

43

*NOTESKT1 IS USED IN CONJUNCTION WITH THE DE-IONISED FEED CONVERSIONKIT, WCK/N.IF THE STILL IS NOT FITTED WITH WCK/N, PINS 1 & 5 ARE CONNECTEDTOGETHER WITH THE 'DIN' PLUG SUPPLIED WITH THE STILL.PINS 1 & 5, BOILER WATER LEVEL REED SWITCHPINS 2 & 4, DE-IONISED FEED SOLENOID } WHEN USED

WITH WCK/N

*NOTESKT1 IS USED IN CONJUNCTION WITH THE DE-IONISED FEED CONVERSIONKIT, WCK/N.IF THE STILL IS NOT FITTED WITH WCK/N, PINS 1 & 5 ARE CONNECTEDTOGETHER WITH THE 'DIN' PLUG SUPPLIED WITH THE STILL.PINS 1 & 5, FRONT BOILER WATER LEVEL REED SWITCHPINS 2 & 4, DE-IONISED FEED SOLENOID

RL3 (E)(S)

1N4007

10

11

12

7

9

3

1

6

5

2

3

2

4

1

4 - WAY PLUG

12 - WAY PLUG

PINK

WHITE

YELLOW

RED

WHITE

RED

BLACK

YELLOW

ORANGE

BLUE

BROWN

FRONT THERMOSTAT (S)

RL4 (E)(S)

PINK

BLUE

BROWN

ON/OFF(S)

VIOLET

BLACK

RED

REDCLEANSWITCH

YELLOW

CLEANBLACK

RESERVOIRFULL

WHITE

BLACK

ON/OFF

BLUE

BROWN

BROWN

MAINS ON(S)

BROWN

RL3/1 (E)(S) FRONT HEATER

BLUE

L

N

BLUE

BLUE

1

2

3

4

5

6

FLOWSWITCH

(S)

SV2 (S)

SV1 (S)



SKT1 (SEE NOTE)*

BROWN

BROWNBROWN

RL4/1 (E)(S) REAR HEATER

BLUE

8

BLACK PINK

REAR THERMOSTAT (S)

ORANGE

REAR BOILERFLOAT SWITCH

1N4007

PRESSURESWITCH

(S)

123

54

1 2

43

} WHEN USEDWITH WCK/N

Circuit diagram for A4000D

Wiring diagram for A4000D

*NOTE

SKT1 IS USED IN CONJUNCTION WITH THE DE-IONISED FEED CONVERSION KIT, WCK/N.IF THE STILL IS NOT FITTED WITH WCK/N, PINS 1 & 5 ARE CONNECTED TOGETHERWITH THE 'DIN' PLUG SUPPLIED WITH THE STILL.PINS 1 & 5, FRONT BOILER WATER LEVEL REED SWITCH.PINS 2 & 4 DE-IONISED FEED SOLENOID REED SWITCH.



T1(S)

MR1C2

33uF16V

C11000uF

25V

IC1

+12

RL2(S)

RL1(S)

D3

1N4007

D2

1N4007

D11N4007

TR1

R168K

R21K

C32200uF

16V

3,6,9

2,5,7,8,1

1

10

12 - WAYSOCKET

ON/OFF(WHITE)

CLEAN(WHITE)

RESERVOIRFULL

(AMBER)

CLEANPRESSURESWITCH

(S)

1N4007

RL3(E)(S)

1N4007

RL4(E)(S)

REARBOILERFLOAT

SWITCH

FLOWSWITCH

(S)(SEE NOTE)*

SKT1/24 2 3 1

ON/OFF(S)

SKT1/1 (SEE NOTE)*

L

N

E

MAINS ON(GREEN)

(S)

FRONTTHERMOSTAT

REARTHERMOSTAT

TT1(S)

TT2(S)

RL3/1 (E)(S)

RL4/1 (E)(S)

FRONTHEATER

REARHEATER

SV2 (S)DE-IONISED

WATERSOLENOID

SV1 (S)COOLINGWATER

SOLENOID

12

345

12

345

A4000/PCB (S)

T 125 m AL (S)


1

4 - WAY SOCKET(S)

12 WAYSOCKET

}

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