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Yamato WG 1000, Instruction Manual

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Yamato WG 1000 Instruction Manual Download Page 40

 

 

37

 

Maintenance Method 

Replacement of Heater 

 

•

  If the heater should be disconnected or damaged due to deposit of scale, replace it by the 

procedure below. (Also refer to Page 33 "Washing of Distiller" in working.) 

1.  Turn "OFF" the earth leakage breaker of this unit. 
2.  Close the tap. 
3.  Turn "OFF" earth leakage breaker, and when more than 30 minutes has passed, open the front door 

of this unit, and open the boiler water drain cock. 

4.  Open the left side plate of the body, loosen the four screws on the right of the terminal block, and 

disconnect the heater lead terminal. 

5.  Pull the heater lead out of the grommet. 
6.  Remove the cap nut of heater, and pull out the heater. 
7.  Remove the packing and cap nut from the damaged heater. 
8.  Install the packing and cap nut on the new heater. At that time, do not touch with bare hand in order 

to prevent soiling by hand. 

Packing

 

 

9.  Install on the boiler so that "YK-W-3" mark of the heater is faced up. 
10. Feed the heater lead wire through the grommet, check the heater lead wire attaching position, and 

secure to the terminal block. 

11. Mount the left side plate. 
12. Close the boiler water drain cock. 
13. Close the front door, and then open the tap. 
14. Turn on the earth leakage breaker. 
15. The standby screen appears at the display window of the control panel. 
16. 

Perform calibrations by pressing POWER key while holding down PURE WATER key and 
DISTILLED WATER key. (Refer to page 21.) 
(Calibration is performed for storing the standard temperature of the sensors in each heater under 
normal operation in the inner controller. Performing calibration detects errors when the temperature 
rises higher than the standard tempe 20

℃

.) 

17. During calibration, a message is displayed at the message window of the control panel. 
18. After approx. 5 minutes passed after starting calibration, normal operation starts automatically. 

 

Summary of Contents for WG 1000

Page 1: ...k you for purchasing Auto Still WG series of Yamato Scientific Co Ltd z To use this unit properly read this Instruction Manual thoroughly before using this unit Keep this instruction manual around this unit for referring at anytime WARNING Carefully read and thoroughly understand the important warning items described in this manual before using this unit ...

Page 2: ......

Page 3: ...n of Measured Amount of Pure Water 24 Collection of Measured Amount of Distilled Water 25 Display of Water Quality 27 Setting Display of Submenu 29 Handling Precautions 31 Maintenance Method 32 Daily Inspection and Maintenance 32 Washing of Distiller 33 Replacement of Heater 37 Washing of Water Supply Hose Filter 38 Replacement of Hose 38 Long storage and disposal 39 When not using this unit for l...

Page 4: ...nger of a problem that may cause a serious accident or even fatality CAUTION If the caution is ignored there is the danger of a problem that may cause injury damage to property or the unit itself Meaning of Symbols This symbol indicates items that urge the warning including the caution A detailed warning message is shown adjacent to the symbol This symbol indicates items that are strictly prohibit...

Page 5: ...aution electrical shock Caution scald Caution no road heating Caution not to drench Caution water only Caution deadly poison Prohibit Prohibit generally Prohibit inflammable Prohibit to disassemble Prohibit to touch Compulsion Compulsion generally Compulsion connect to the grounding terminal Compulsion install on a flat surface Compulsion disconnect the power plug Compulsion periodical inspection ...

Page 6: ... Do not use the power cord if it is bundled or tangled If it is used in this manner it can overheat and fire may be caused Do not process bend wring or stretch the power cord forcibly Do not process bend wring or stretch the power cord forcibly Fire or electrical shock may result Do not disassemble or modify this unit Do not disassemble or modify this unit Fire or electrical shock or failure may b...

Page 7: ...sive gas is generated Ambient temperature 35 C and above or 5 C and below Ambient temperature fluctuates violently There is direct sunlight There is excessive humidity and dust There is a constant vibration Not horizontal surface The power source is instable Keep space around each product above the range shown below Install units within sink equipment if possible 10cm or more Front side 10cm or mo...

Page 8: ...r greater When power capacity is insufficient sampling of distilled water goes short and normal control is disabled by fall of power voltage Connect to power equipment having sufficient power capacity Electric capacity WG250 100V AC Single phase 15A WG1000 200V AC Single phase 20A 7 Handling of power code Do not entangle the power cord This will cause overheating and possibly a fire Do not bend or...

Page 9: ...and water supply hose can be separated There separate the two parts 2 Once loosen the plug from the ring 3 Tighten the 4 mounting screws uniformly while pressing the ring slightly and uniformly to make the packing in flat contact with water tap If the tap is a chemical tap adjust the position so that the mounting screw is located at the bottom valley of tap nipple as shown 4 Turn the plug clockwis...

Page 10: ...n the socket is connected by plug otherwise water is not fed because this valve does not open 13 Connect the water supply hose to the tap provided with sink equipment If the water supply hose is connected to a tap without sink equipment flood damage may be caused when water supply hose is disconnected or damaged therefore be sure to connect to a tap having sink equipment 14 When the sink equipment...

Page 11: ...f the main unit For WG1000 unit be sure to set the hose in the hose holder at the backside plate WG1000 WG250 Hose clamp Drain port hose on the main unit Elbow Drain hose accessory Hose clamp Drain port Drain hose 17 Use care in routing of drain hose Do avoid making bend or projection of drain hose In case that the drain hose is bent and the drain cannot be performed back flow or breakage of the c...

Page 12: ...tube DV RR joint is used for the joint and even if insert socket JIS K6739 is used the water drain trap in the nonstandard options should be used when the control temp cannot be lowered 60 or lower Even if the drain temperature is 60 or lower and if the above mentioned tubes and joint are not used the drain trap in the nonstandard options should be used 19 When drain temperature of sink equipment ...

Page 13: ...Fig 2 5 Remove the rubber cap attached to the inlet and outlet of ion exchange resin cartridge 6 Fit in the coupler marked with IN to the inlet of ion exchange resin cartridge left until click is heard See Fig 3 7 Fit in the coupler marked with OUT to the outlet of ion exchange resin cartridge right until click is heard See Fig 3 Coupler may be hard at first When applying force in inserting do not...

Page 14: ...ont door of this unit is opened connection hose marked IN and OUT is found in the coupler there make connection matching them with IN and OUT on pre treatment cartridge 5 In connecting mate the coupler and port of cartridge while sliding the blue portion of coupler toward the hose push in then release the blue portion 6 When connection is finished place the pre treatment cartridge at the position ...

Page 15: ...ake out two membrane filters and seal tape from among accessories of the main body 2 Pay attention to the direction of arrow mark on the membrane filter Wind the seal tape clockwise as viewed from the tape windind side two to three turns while pulling the tape slightly Remaining tape should be cut away 3 Screw the membrane filter with the seal tape applied side on the top side while taking care no...

Page 16: ...tank Ion exchange resin cartridge CPC S Reset switch Pre treatment cartridge Heater Water sampling table Earth leakage breaker Product number sticker Drain port 2pcs each at right left Control panel Multi purpose distilled water sampling port Distilled water sampling port Ion exchange water sampling port Drain switch for water sampling table ...

Page 17: ...e resin cartridge CPC S Reset switch Leakage detection electrode Water sampling table Boiler Heater Tank Earth leakage breaker Drain port 2pcs each at right left Control panel Multi purpose distilled water sampling port Drain switch for water sampling table Product number sticker Leakage detection electrode ...

Page 18: ... pure water While standby time the breaker is turned on and POWER key is turned off WG250 WG1000 Multi purpose distilled water intake opening The multi purpose distilled water intake opening is located at right side surface of the unit and one touch joint is installed at the opening Distilled water in the tank can be filled by removing the plug stopper and connect the hard tube ofφ8 of outer diame...

Page 19: ...sor 6 Ion exchange resin cartridge CPC S Two pieces are used for WG1000 type 22 Distilled water flow sensor 7 Float cylinder 23 Ion exchange water sampling port 8 Float switch 1 24 Distilled water sampling port 9 Float switch 2 25 Distilled water tank 10 Boiler drain solenoid valve 26 Float switch 3 11 Boiler drain cock 27 Air filter 12 Boiler 28 Distilled water sampling pump 13 Heater 29 Distille...

Page 20: ...e time Drain of the boiler is performed every 5 hours during distillation 2 Boiler Water Supply and Distilling Operation When drain of the boiler is finished both of raw water supply solenoid valve 4 and boiler water supply solenoid valve 17 open at the same time in order to supply water to boiler 12 When float switch 1 8 in float cylinder 7 detects water level heater 13 is turned on and distillat...

Page 21: ...ing of Distilled Water For 10 minutes after starting distillation initial distilled water condensed in condenser 14 is drained by opening initial accumulated water drain solenoid valve 18 Then distilled water is stored in distilled water tank 25 by distilled water quality gauge electrode 16 Distillation stops as the tank is full when float switch 3 26 on the top in the tank operates The stored wat...

Page 22: ... sampled by way of the pressure reducing valve 1 raw water supply solenoid valve 4 pre treatment cartridge 5 ion exchange resin cartridge 6 ion exchange water quality electrode 15 ion exchange water sampling solenoid valve 19 ion exchange water flow sensor 21 ion exchange water sampling port 23 and membrane filter 32 ...

Page 23: ...ring submenu or maintenance mode Also confirms the setting then shifts to the next setting item F key Cancels the setting then returns to the previous setting item Description of WATER LEVEL lamp This lamp indicates the storage amount of distilled water in the tank in five levels When this red lamp lights distilled water cannot be collected for empty drive prevention of the pump When this red lamp...

Page 24: ...st time using this unit refer to page 22 and when changing the heater of the boiler refer to page 37 Press POWER key while holding down PURE WATER key and DISTILLED WATER key Perform calibration operation at the measured values of heater temperature and power supply voltage for about five minutes after then distillation starts automatically Key operation becomes disable while calibration operation...

Page 25: ...ain of the boiler starts Drain of the boiler starts when turning on off the earth leakage breaker and when five hours passed after distillation starts Drain of the boiler does not start if POWER key is not turned on 3 Distillation operation FILL CONDUCTIVITY M F WATER LEVEL MEASURED CONTINUOUS FULL EMPTY POWER PURE WATER DISTILLED WATER In Distillation Tank Empty Distill Water NA Continuous Distil...

Page 26: ... WATER key again Then PURE WATER lamp is turned on After water collection is finished it returns to distillation operation Continuous collection of distilled water FILL CONDUCTIVITY M F WATER LEVEL MEASURED CONTINUOUS FULL EMPTY POWER PURE WATER DISTILLED WATER DW sampling Continuous DISTILLED WATER lamp lights up by pressing DISTILLED WATER key while CONTINUOUS lamp is ON Then distilled water can...

Page 27: ...Set the amount of collecting pure water The same setting screen is used for setting of pure water and distilled water 1 Set the amount of pure water by pressing key Set up to 30 liters for WG250 or up to 100 liters for WG1000 2 After setting pressing PURE WATER key starts water collection 3 Collecting FILL CONDUCTIVITY M F WATER LEVEL MEASURED CONTINUOUS FULL EMPTY POWER PURE WATER DISTILLED WATER...

Page 28: ... amount of collecting distilled water The same setting screen is used for setting of pure water and distilled water 1 Set the amount of distilled water by pressing key Set up to 30 liters for WG250 or up to 100 liters for WG1000 2 After setting pressing DISTILLED WATER key starts water collection 3 Collecting FILL CONDUCTIVITY M F WATER LEVEL MEASURED CONTINUOUS FULL EMPTY POWER PURE WATER DISTILL...

Page 29: ...ft screen is displayed when the tank becomes empty during collecting water and DISTILLED WATER lamp blinks and operation of water collection is suspended 2 Distillation starts 3 In case that EMPTY lamp of WATER LEVEL display does not light up press DISTILLED WATER key again to start collecting water If PURE WATER key is pressed under this condition the holding condition is released 4 After collect...

Page 30: ...ILL CONDUCTIVITY M F WATER LEVEL MEASURED CONTINUOUS FULL EMPTY POWER PURE WATER DISTILLED WATER DW sampling DW Conductivity 0 85 10 4 S m Continuous Switch the conductivity display The conductivity of distilled water is displayed during distillation and the conductivity of pure water is displayed during collecting pure water Pressing CONDUCTIVITY key switches the conductivity display for either o...

Page 31: ...ric conductivity and when the value is the greater the better is purity When obtaining specific resistivity from electric conductivity where specific resistivity is R and electric conductivityρ R Ω m 1 S m ρ or R 10 Ω m 1 10 S m ４ ４ ρ So the theoretical value of pure water is as follows R 18 3 104 Ω m 18 3MΩ cm 25 Take notice that the resistivity is displayed in integer form not in decimal in the ...

Page 32: ...nd alarm buzzer sound 1 Select an item of submenu by pressing key 2 Confirm the item by pressing M key The selection screen appears 3 Specify ON or OFF of each item by pressing key and confirm the setting by pressing M key 4 Pressing F key returns to the submenu screen ON is set to buzzer sound at default setting 2 2 Calendar setting Calendar 2005 year 9 29 month day 12 25 h min To set the calenda...

Page 33: ... history by pressing key 2 Pressing F key returns to the previous screen Up to 20 records are displayed for each change history If it exceeds 20 records the oldest record is deleted 2 7 Water cutoff occurrence history Water Alarm History No 1 05 09 29 12 25 05 09 29 12 30 To display the water cutoff occurrence history 1 Confirm the maintenance history by pressing key 2 Pressing F key returns to th...

Page 34: ...rgent liquid Orgazor 10 is sulfamic acid acidic with pH of water solution approx 1 In handling this detergent liquid use protective tools gloves mask and glasses When it is in contact with human body wash it away with clean water Neutralize the liquid with neutralizer such as sodium hydroxide after washing Ensure neutralization with pH test paper etc Do not use empty container for beverage Do not ...

Page 35: ...in cartridge becomes short Please dispose used cartridge as nonconbustibles When it is sent back to our company fill in the designated invoice attached to a new cartridge and send it with the used cartridge to us Replacement of ion exchange resin cartridge When a cartridge is stored for a long time deterioration of water quality and fall of processing capacity are found therefore prepare a spare c...

Page 36: ... port turn the hose band by use of tool and displace the engaged portion serrated portion Take care in disconnecting because excessive force applied to glass may cause damage Cooling Water Outlet Cooling Water Inlet Boiler Water Supply and Drain Port Distilled Water Outlet 5 Disconnect the hole plug at left plate remove four screws with a screw driver then remove the left plate 6 Loosen 4 screws o...

Page 37: ... washing liquid from spilling 4 Pour in washing liquid through connection port with condenser with heater turned on Most scale is removed in 4 to 5 hours approximately Drain washing liquid in the boiler If much scale is distiller deposited pour in washing liquid newly and repeat washing 1 When scale removing work is finished take the heater out of boiler and wash each of them enough with city wate...

Page 38: ...lizer such as sodium hydroxide In neutralization check that it is neutral by use of pH test paper etc Principal component of scale detergent Sulfamic acid and pH of water solution Acidic approximately 1 3 In storing this detergent seal the agent and store in cold and dark place avoiding high temperature and humidity 4 In handling this detergent be sure to use protective tools gloves mask and glass...

Page 39: ...and secure with the hose band Installation of condenser 1 Place packing in the connection port of boiler with condenser and secure with connecting hardware so that the boiler and condenser are placed in the same direction Inlet Outlet Boiler Condenser Connecting Hardware 2 Connect the hose respectively to the cooling water inlet outlet and distilled water outlet of condenser 3 Close the boiler wat...

Page 40: ...r to prevent soiling by hand Packing 9 Install on the boiler so that YK W 3 mark of the heater is faced up 10 Feed the heater lead wire through the grommet check the heater lead wire attaching position and secure to the terminal block 11 Mount the left side plate 12 Close the boiler water drain cock 13 Close the front door and then open the tap 14 Turn on the earth leakage breaker 15 The standby s...

Page 41: ... hose from the connection port 2 Remove the plug from ring as turning 3 Cleanse filter attached to the packing with water 4 Wash the filter with spray etc 5 Assemble by reversing the procedure Replacement of Hose Be sure to use a hose specified by Yamato Scientific for replacement Connection Port Body Ring Plug Socket Spacer Mounting Screw Packing Filter One touch Joint Tap Sleeve Tap side Water S...

Page 42: ...nerated bacteria or algae Drain water by the procedure below Boiler Water Drain 1 In draining boiler water turn off the earth leakage breaker ensure that the tap is closed then wait for 30 minutes or more and open the front door 2 Open the boiler water drain cock 3 Make sure that all water in the boiler and float cylinder is drained 4 Be sure to close the boiler water drain cock If boiler water dr...

Page 43: ...ame Material Main components of exterior Exterior Made of iron bonded steel plate melamine resin baking finish Exterior rear plate Made of iron bonded steel plate melamine resin baking finish Door Made of iron bonded steel plate melamine resin baking finish Door rear plate Stainless steel plate SUS 304 Mounting plate painted Made of iron bonded steel plate melamine resin baking finish Mounting pla...

Page 44: ...y hose Vinyl chloride Drain hose Ethylene propyne Hose transparent Vinyl Hose milky transparent Silicon Hose clamp Polyacetal Hose nipple resin black Polyamide Hose nipple resin white Polypropylene Hose nipple metal Brass Main components of electric system Pump Casing Polypropylene Impeller Polypropylene Magnet Ferrite magnet Motor case Iron Rotor Iron Solenoid Valve Made of metal Body brass Made ...

Page 45: ...r till a beep is heard Then the alarm indication is reset Membrane filter for distilled water exchange notification It s time to exchange Distilled Water Membrane Filter When 3 months passed under continuous energizing condition Change the membrane filter for distilled water Press and hold the reset switch on backside of the door till a beep is heard Then the alarm indication is reset Membrane fil...

Page 46: ...perature sensor Change the heater Burnout of heater Heater Error Service Call When temperature of the heater did not rise after certain time passed during distillation Change the heater Tank water level meter error Tank Water Sensor Error Service Call When the condition of the float contacting points in the tank water level meter becomes abnormal Change the float switch Pure water conductivity met...

Page 47: ...lant solenoid valve and the coolant path Water level error of boiler Boiler Water Level Error Service Call When the heater operation water level input kept OFF even if the time for required to evaluate the boiler water level error passed after starting water supply to the boiler Check the feedwater solenoid valve and feedwater path whether manual drain cock is opened or not Water level meter of bo...

Page 48: ...or 5 Turn on the earth breaker and press POWER key Now the defect is repaired and the unit starts normal operation How to remove the lower front panel of WG250 1 Remove the screws at left right positions of the lower front panel 2 Pull the panel frontward Be careful of the cable of the drain switch specially used for water sampling table 3 Disconnect the cable of the drain switch for water samplin...

Page 49: ...accumulated Defect of initial boiled water drain solenoid valve Defect of piping Distilled water is not stored Defect of float switch Water is not sampled Defect of Ion exchanged water Distilled water sampling solenoid valve Defect of distilled water sampling pipe Defect of piping Measures in emergency Error indications causes This unit has a self diagnosis function When a trouble occurs during op...

Page 50: ...ales office Check following items before contact Model Name of Product Production Number Purchase Date About Trouble in detail as possible Minimum Retention Period of Performance Parts for Repair The minimum retention period of performance parts for repair of this unit is 7 years after discontinuance of this unit The performance part for repair is the part that is required to maintain this unit Se...

Page 51: ...rage tank Made of polyethylene 30λ Made of polyethylene 100λ Water sampling table Slide out type Load bearing capacity 10kg For 5λ beaker with handle Slide out type Load bearing capacity 20kg For 10λ tank Multi purpose distilled water sampling port Feedwater connection to WR type at right side of main unit Configuration Water level detection Lead switch Five level detection also used for distillat...

Page 52: ...ite Black White Black Red White Black Green Yellow Blue Symbol Part name Symbol Part name ELB Earth leakage breaker X Main relay T1 T2 Terminal block MV1 Raw water solenoid valve H Heater MV2 Boiler water supply solenoid valve OH Temperature sensor MV3 Cooling water solenoid valve E1 Ion exchange water quality gauge MV4 Initial accumulated water drain solenoid valve E2 Distilled water quality gaug...

Page 53: ...oid valve E2 Distilled water quality gauge MV5 Boiler drain solenoid valve WL1 WL2 WL3 Water leakage detector MV6 Distilled water sampling solenoid valve FL1 Distilled water flow gauge MV7 Ion exchange water sampling solenoid valve FL2 Ion exchange water flow gauge P Distilled water sampling pump Fs1 Control float switch SSR1 Solid state relay Fs2 Control float switch SSR2 Solid state relay Fs3 Wa...

Page 54: ...um perchlorate and other perchlorate Potassium peroxide Sodium peroxide Barium peroxide and other inorganic peroxide Potassium nitrate Sodium nitrate Ammonium nitrate and other nitrate Sodium chlorite and other chlorites OXIDIZING Calcium hypochlorite and other hypochlorites Ethyl ether Gasoline Acetaldehyde Propylene chloride Carbon disulfide and other flammable substances having a flash point of...

Page 55: ......

Page 56: ...ct what this document forbids Unexpected accidents or breakdown may result in Note The contents of this document may be changed in future without notice Any books with missing pages or disorderly binding may be replaced Instruction Manual for Water Purifier Auto Still Model WG250 1000 Fourth Edition Nov 18 2011 Yamato Scientific Co Ltd 2 1 6 Nihonbashi Honcho Chuo ku Tokyo 103 8432 Japan http www ...

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