Stuart A4000, A4000D, A8000 Assembly and operating instructions

Aquatron

Automatic Water Stills

A4000 A4000D & A8000

Assembly and
operating instructions

Version 2.3

Contents

Location and Services 3

A4000 - Components, Assembly, Operation & Spares 4

A4000D - Components, Assembly, Operation & Spares 9

A8000 - Components, Assembly, Operation & Spares 14

Distillate Collection & Reservoir System 19

Connection of Aquatron Stills to Deionised and Pre-treated Water Supplies 20

Cleaning 22

Fault Finding 23

Circuit & Wiring Diagrams 24

The Aquatron Water Still complies with the
following European Directives:
89/336/EEC - E.M.C. DIRECTIVE
Amended by 92/31/EEC and 93/68/EEC
73/23/EEC - L.V.D. Amended by 93/68/EEC

Limitations of use

This product meets the applicable E.C. harmonised
standards for radio frequency interference and may
be expected not to interfere with, or be affected by
other equipment with similar qualifications. We
cannot be sure that other equipment used in its
vicinity will meet these standards and we cannot
guarantee that interference will not occur in practice.
Where there is a possibility that injury, damage or loss
might occur if equipment malfunctions due to radio
frequency interference, or for general advice before
use, please contact the Technical Service Department
of Bibby Scientific Ltd.

Location & Services

In order to obtain the optimum performance from your new
Aquatron careful consideration should be given to the intended
location and the availability of services such as water, electricity
and drain.

Please study the following notes before commencing installation.

Before Use

If the equipment is not used in the manner described in this
manual then its performance and operation will be impaired.

Aquatron water stills are designed to operate 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 Mounting
Aquatron models A4000 and A8000 can be either bench or

wall mounted and a bracket is provided for the latter purpose.
A gap of at least 50cm should be left at the right hand end of
the unit to allow access to the heating elements.

For reasons of weight, models A4000D and A8000 are best

bench mounted, but if it is desired to elevate the unit then a
stout shelf should be used.

2. Electricity Supply
N.B. The Aquatron Water Still is classified as

“Permanently Connected Equipment” and should be
connected to the electricity supply by a qualified
electrician in the manner described in the electrical
installation section of this manual.

The Aquatron stills are available in three models, A4000,

A4000D & A8000.

A suitable supply for the A4000 is rated at 3kW, 220-240v,

50/60Hz~ single phase. A suitable supply for the A4000D &
A8000 is rated at 6kW, 220-240v, 50/60Hz~ single phase.

A4000 units should be connected to the mains supply via a

double pole 30mA Residual Current Breaker with over current
protection (RCBO) isolating circuit breaker rated at 15A.

A4000D and A8000 units should be connected to the mains

supply via a double pole 30mA Residual Current Breaker with
over current protection (RCBO) isolating circuit breaker rated at
32A.

If you have any doubts about the suitability of your supply,

consult a qualified electrician before installing your Aquatron
still.

4. Drain
A waste water drain is required. It is important that the

distance between the drain and the water still is kept as short
as possible to reduce the possibility of pressure build-up.
Similarly, the drain pipe from the still should fall straight,
without any kinks or bends, to allow an unimpeded flow. It is
also recommended that the unit is connected to properly earth
bonded water supplies and drainage systems.

5. Storage Tank
A suitable reservoir, the WR20 for instance, is required for the

collection of the distillate. This should be positioned beneath
the still ensuring that the distillate can flow into the reservoir
without hindrance.

6. Maintenance
The location of the still should facilitate easy access for routine

cleaning and maintenance. With regards to the latter, it is
recommended that a space of at least 50cm be provided on the
right hand side of the water still cabinet. This is to allow the
removal of the side cover and replacement of the heating
element.

7. Warranty
Bibby Scientific Ltd warrants this instrument to be free from

defects in material and workmanship, when used under normal
laboratory conditions, for a period of three (3) years. In the
event of a justified claim Bibby Scientific will replace any
defective component or replace the unit free of charge.

This warranty does NOT apply if damage is caused by fire,

accident, misuse, neglect, incorrect adjustment or repair,
damage caused by incorrect installation, adaptation,
modification, fitting of non approved parts or repair by
unauthorised personnel.

This Warranty does not include the heater element which

is only guaranteed for 1 year.

3. Water Supply
A cold water supply is required for coolant and feed purposes.

This may be from the mains supply or a header tank having a
flow capacity of at least 1 litre/min. for the A4000 and 2 litres/
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 and likely to contain particulate

matter, such as rust or silt, it is advisable to fit a pre-filter unit
before the still.

3

A4000

Fig. 1

5

4

6

7

Lid

8

9

10

3

1

2

20

22 21

24

23

19

18

End

Plate

11

12

13

14

15

16

17

List of Major Components – A4000

Item Description Part
no. number

1 Perspex Screen M484

2 Boiler WBA

3 Funnel WF48

4 Condenser WC48/M2

5 Wall Mounting Bracket M510G

6 Green ‘Mains On’ Indicator 700691 (S)

7 White ‘On/Off’ Switch 700988 (S)

8 Amber ‘Reservoir Full’ Indicator 700987

9 White ‘Clean’ Switch 700988 (S)

10 Reservoir Pressure Switch WPS

11 Heaters Connector Terminal A4000/HTB

12 Water Flow Sensor Assembly I/A4000HK/1

Item Description Part
no. number

13 Solenoid Assembly A4000/SA

14 Mains Water Mini Valve Assembly 7001059 (S)

15 Reservoir Water Level Sensor WLS

16 Distillate Outlet Pipe (Bench Mounted) –

17 Cooling Water Pipe to Drain (16mm) –

18 Heater Assembly A4000/HA

19 Thermostat WT4

20 Rotaflo Stopcock A4000/RCOCK

21 Distillate Outlet (Wall Mounted) –

22 Boiler Level Control WL48

23 Boiler Plastic Coupling WBC1

24 Boiler Retaining Spring 700007

4

A4000 Assembly

Your Aquatron A4000 has been designed with ease of assembly
specifically in mind. Please study the installation diagram and the
enclosed DVD before commencing the installation. Follow the
sequence of instructions and do not connect the mains electricity
supply until directed.

1. From the outer packaging remove all the components including
the metal cabinet containing the glass boiler.

2. Before unpacking the individual components, identify them on
the check list below:

A4000 Unit containing boiler.

Condenser – WC48/M2

Heater – W48H

Boiler Level Control – WL48

Funnel – WF48

Reservoir Water Level Sensor – WLS

Output Hose Assembly – I/A4000HK/2

Hose Kit – I/WH48/1/B

Wall Mounting Bracket – M510G

3. Remove the perspex viewing screen (Fig. 1, item 1) from the
unit by lifting it up using the finger recess. Remove the internal
packaging carefully. Snip the temporary ties holding the boiler
retaining springs (Item 24).

4. Remove the end plate and lid by removing the retaining screws.

5. Ensure that the sealing O ring and the stabilising O ring are
correctly positioned on the vapour tube of the boiler. Fit the
condenser (Fig. 1, item 4) to the vapour tube ensuring that the
distillate outlet faces the front and the two water connections
are parallel to the unit Fig 1a. When slight resistance is felt
when fitting the condenser, press down slightly on the top
of the condenser until a gap of approximately 19mm exists
between the condenser and the boiler.

Cooling water outlet

Condenser

Sealing o-ring

7. Take the boiler level control WL48 (Fig. 1, item 22). Remove the
end split nut and central part of the boiler plastic coupling (Item

23) leaving the other split nut in place, and the internal seal
in the boiler level control. Ensure the Rotaflo stopcock is fully
closed (screwed down).

8. Take the 16mm earth spigot located inside the A4000 and
place the 16mm tubing part of it into a beaker of hot water for
approximately 20 – 30 seconds; this will make the tubing more
supple. Connect the 16mm tubing to the boiler level control
(Item 22) drain connection (below the Rotaflo stopcock). Secure
with a tie wrap.

9. Take the 1m length of 16mm hose from hose kit I/WH48/1/B.
Place one end into a beaker of hot water for approximately
20 – 30 seconds. Thread the tube through hole (Fig. 1, item

17) until approximately 300mm of tubing is inside the cabinet.
Connect to the 16mm earth spigot and secure with a tie wrap.

10. Pull the 16mm hose back out of the cabinet until a gap of
approximately 5mm exists between the boiler level control and
the boiler connection.

11. Place the boiler plastic coupling split nut and central part onto
the boiler connection. Connect the boiler level control to
the boiler, ensuring that the internal seal of the boiler plastic
coupling is fitted inside the boiler connection and the boiler
level control connection. Tighten the boiler plastic coupling.

12. Loosen the black cap on top of the boiler level control. Fit the
funnel into the top of the boiler level control and tighten the
black cap.

13. Take the hose assembly I/A4000HK/2 and connect the end
marked ‘2’ to the top connection of the condenser. Connect
the other end marked ‘3’ to the boiler level control.

14. Identify the water flow sensor assembly (Fig. 1, item 12) inside
the cabinet. Connect the red connector marked ‘1’ to the
bottom connection of the condenser. It may be necessary to
slightly twist the condenser to release any kinks in the water
sensor assembly.

15. Remove the heater black cap and rubber ring from the boiler.
Place the black cap onto the heater until it is approximately
25mm from the electrical connectors end. Push the rubber ring
onto the heater and into the black cap.

16. Fit the heater into the boiler and screw on the black cap. When
the black cap is tight push the heater through the black cap
until the end of the heater sits in the nodule at the end of the
boiler.

Do not overtighten the screw cap as this may cause the

boiler to break, or push the heater in too far as this may
break the nodule.

Vapour tube

Distillate
Outlet

Stabilising o-ring

Fig. 1a

6. Take the 1m length of 8mm hose from hose kit I/WH48/1/B
and connect one end to the distillate outlet of the condenser
(Fig. 1a). Secure with a tie wrap. Pass the other end of the tube
through the cabinet hole, Fig. 1, item 21 if to be wall mounted,
or hole, Item 16 if bench mounted.

Relay

Fig. 1b

PCB

Thermostat

Heater
Terminal
Blocks

N

E

L

Heater
lead

5

17. Thread the two heater connectors through the hole into the

I/A4000HK/1

I/A4000HK/2

I/WH48/1/B

16mm tubing x 1m - I/WH48/1/B

Solenoid

Condenser

Thermostat &

Thermostat Glass

Heater

Boiler

Level

Control

Funnel

Rotaflo Stopcock

1

2

3

Water Flow Switch

A4000 Installation Diagram

Boiler

Mains Water
Inlet Mini
Valve

Electrics

Reservoir
Water Level
Sensor

8mm Earth Spigot

16mm Earth Spigot

To Distillate

Reservoir

To Drain

electrical control compartment and connect to the heater
terminal block. Brown to Brown, Blue to Blue, (Fig. 1b).

SAFETY: It could be possible to mis-locate the heater
crimps on to the heater terminal block tags. Ensure
that the heater crimps are properly located onto
the heater terminal block tags and fully locked on.
Attempt to pull the crimp off the tag to ensure full
attachment.

18. Refit the end plate and lid.

19. Move the unit to its working location. If it is to be wall
mounted use the mounting bracket (Fig. 1, item 5). Ensure a
space of at least 50cm to the right of the unit to allow access.

20. Connect the cold water supply to the mains water inlet. The
tubing selected should have a safe working pressure of at
least equal to the pressure of the water supply and should be
adequately secured with hose clips.

DO NOT TURN ON WATER SUPPLY

21. THIS EQUIPMENT MUST BE EARTHED!

Carry out the electrical installation. This should only be carried

out by a suitably qualified electrician.

The A4000 is classed as permanently connected equipment. The

earth spigots should pass a high current (ie. >200mA).

The equipment is supplied with 1.5m of flexible, triple

core, circular cable to the following specification:

1.5mm², to BS 6500 or equivalent and <HAR> or BASEC
approved.

Connection to the mains electrical supply should be via a

double pole 30mA Residual Current Breaker with Overcurrent
protection (RCBO) isolating circuit breaker switch with a
continuous current carrying capacity of 15A at 250V and
overcurrent of 15A.

DO NOT SWITCH ON ELECTRICAL SUPPLY.

22. Connect the reservoir water level sensor WLS (Fig. 1, item 15) to
the A4000 and secure with a tie wrap.

Place the glass pressure bell in the collection reservoir, following

the instructions given on page 19.

23. Operate the A4000 Waterstill as per Operating Instructions and
check for leaks.

24. Fit the Perspex viewing screen

A4000 Installation Diagram

6

A4000 Operation

The following instructions apply to the A4000 water still where the
water feed to the boiler is via the mains supply or a header tank.

1. Before switching on either the mains electricity or water supply,
identify the control switches and indicator lights on the front of
the cabinet.

Green Light – When illuminated this shows that there is mains

supply voltage to the unit. Under no circumstances should the
cabinet end-panel be removed when this light is illuminated.

White ‘On/Off’ Switch – This is the primary switch for

controlling water and electricity inside the still. The switch
illuminates when pressed in the ON position.

Amber Light – When illuminated, this indicates that the

distillate collection reservoir is full as detected by the level
control.

White ‘Clean’ Light – This shuts off the heating element but

allows water to flow into the boiler when the still is being
commissioned or cleaned. When pressed in the CLEAN position
the switch illuminates.

2. Carefully check the following:

The appropriate electricity, water and drain services have been

provided. If in doubt, consult the LOCATION & SERVICES
SECTION of this manual.

The ON/OFF switch on the control panel is in the OFF position.

The CLEAN switch is pressed in the CLEAN position.

The Rotaflo stopcock on the boiler level control is closed.

The reservoir water level sensor is fitted to the distillate

collection vessel.

The dummy shorting plug is fitted to the boiler level control DIN

socket on the cabinet.

3. Ensure all earth leads are connected to the earth point.

4. Check all glassware for any damage.

5. Switch on the electricity supply – the green light illuminates.

6. Press the ON/OFF switch to the ON position – the switch will
illuminate.

7. Recheck that the CLEAN switch is in the CLEAN position and
illuminated.

8. Turn on the mains water supply and using the mini valve
assembly, adjust the flow rate to approximately 1 litre/min. This
can be achieved by observing the drain water from the boiler
level control and adjusting the mini valve assembly accordingly.

9. Check for water leaks.

10. Observe the boiler now filling with water to cover the heating
element. When water has reached the pre-set limit, the excess
will discharge to drain. Check the water drains freely and does
not back up into the boiler level control.

11. Switch the CLEAN button off by pressing it a second time. The
switch light goes out.

12. The heater will now warm up and eventually run at a red glow.
If the flow rate is insufficient, the heater will not switch on. This
will require adjustment of the mini valve assembly to be opened
further. After about 2 – 3 minutes of operation distilled water
will emerge from the outlet pipe falling into the collection
reservoir.

13. To avoid excess wastage of coolant water, make further
adjustments to the mini valve assembly. Slowly reduce the flow
rate until the flow control switch switches off the heater, then
increase the flow until the power is restored.

14. Refit the Perspex screen.

15. Safety Cut-Outs – All Aquatron water stills are protected by
the following safety devices.

Flow Control Switch – Monitors the flow of coolant water

into the still and shuts off the heating element if the flow is
insufficient.

Thermostat Cut-Out – In normal operation the water within

the glass will be at 100°C. In single fault conditions, i.e. in
the event of water supply failure, the content will increase
to 112°C where upon a resettable thermostat will operate.
Once switched, the thermostat has to be manually reset. This
is achieved by unscrewing the black knob located inside the
cabinet and pressing the reset button.

Reservoir Control – Is positioned in the collection reservoir

and switches off both the electricity and water supplies when
the reservoir is full of distillate water. The water supply is shut
off after around 7 minutes after the reservoir is full to allow the
heating element to cool.

It is recommended that the operation of the flow switch and

reservoir control is checked on a regular basis.

a. Simulation of Mains Water Supply Failure

Turn off the mains water supply at the tap. This should switch

off the heating element. Turning the tap on again will switch
the heater on.

b. Simulation of Reservoir Full Condition

Lower the glass pressure bell of the reservoir water level sensor

into the distillate to a depth of 150mm. This will switch off the
heating element immediately and the cooling water after 7
minutes. Raising the bell will cause both to be switched back
on.

16. Switching Off – Push the CLEAN switch to the ON position.
Wait until the residual heat contained in the heating element
has dispersed and no boiling is evident. Turn off water supply.
Push ON/OFF switch to OFF position. Isolate from mains
electricity supply.

7

A4000 Spares

Boiler WB4

Funnel WF48

Condenser WC48/M2

‘Mains On’ Green Indicator 700691(S)

‘On/Off’ White Switch 700988(S)

‘Reservoir Full’ Amber Indicator 700987

‘Clean’ White Switch 700988(S)

Reservoir Pressure Switch WPS

Heater Terminal Block A4000/HTB

Solenoid Assembly A4000/SA

Water Flow Sensor Assembly and Hoses I/A4000HK/1

Condenser to Boiler level control Hose (Output Hose Assembly) I/A4000HK/2

Reservoir Water Level Sensor WLS

Mains Water Mini Valve Assembly 7001059(S)

Thermostat Glass Tube WTT48

Thermostat WT4

Boiler Level Control WL48

Boiler Plastic Coupling WBC1

Heater Assembly A4000/HA

Heater Assembly 220V A4000/HA220

Boiler Retaining Spring 700007

Rotaflow Stop Cock Assembly A4000/RCOCK

6 Way Electrical Terminal Block A4000/ETB

Ceramic Terminal Block A4000/CTB

5 DIN Socket Assembly A4000/DIN

Boiler Vapour Tube Sealing O Ring I/M502

Boiler Vapour Tube Stabilising O Ring I/QR38/24

Relay Assembly A4000/RA

PCB 700804(ES)

Distillate Output and Boiler Level Control Drain Hose Kit I/WH48/1/B

Wall Mounting Bracket M510G

Black Phenolic Screw Cap I/QC38/25

8

A4000D

Fig. 2

Lid

5

6

7

8

9

3

2

1

25

24

4

23 22 21

19

20

17

18

10

11

12

13

14

End

Plate

15

16

List of Major Components – A4000D

Item Description Catalogue
no. number

1 Perspex Screen M484

2 Boiler (2 off) WB4

3 Funnel WF48

4 Condenser (2 off) WC48/M2

5 Green ‘Mains On’ Indicator 700691(S)

6 White ‘On/Off’ Switch 700988(S)

7 Amber ‘Reservoir Full’ Indicator 700987

8 White ‘Clean’ Switch 700988(S)

9 Reservoir Pressure Switch WPS

10 Terminal Strip for Heaters A4000/HTB

11 Water Flow Sensor Assembly I/A4000DHK/1

12 Solenoid Assembly A4000/SA

13 Mains Water Inlet Valve Assembly 7001059(S)

Item Description Catalogue
no. number

14 Reservoir Water Level Sensor WLS

15 Distillate Outlet Pipe –

16 Drain Pipe from W4L2A –

17 Cooling Water Pipe to Drain (8mm) –

18 Cooling Water Pipe to Drain (16mm) –

19 Thermostat (2 required) WT4

20 Heater Assembly (2 required) A4000/HA

21 Boiler Level Control (rear) W4L2A

22 Rotaflo Stopcock A4000/RCOCK

23 Boiler Level Control (front) WL48

24 Boiler Plastic Coupling WBC1

25 Retaining Springs 7000007

9