Classic Electrically Heated Stills - Davis classic stills.pdf · 1 BARNSTEAD THERMOLYNE CORPORATION...

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BARNSTEAD THERMOLYNE CORPORATION

ClassicElectrically Heated Stills

OPERATION MANUALAND PARTS LIST

SERIES 495

Model NumbersA1011 A1015A1013 A1016

60004 • 10/4/99

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Safety Information .............................................................................................................................................. 3 Alert Signals ..................................................................................................................................................... 3 Warnings .......................................................................................................................................................... 3Introduction ........................................................................................................................................................ 5 Evaporator ........................................................................................................................................................ 5 Condenser........................................................................................................................................................ 6 Features Provided ............................................................................................................................................ 6 Electric Heat ..................................................................................................................................................... 7 Low Water Cut-Off ............................................................................................................................................ 7 Still Heat Control .............................................................................................................................................. 8Unpacking .......................................................................................................................................................... 9Installation ........................................................................................................................................................ 10 Siting .............................................................................................................................................................. 10 Accessories .................................................................................................................................................... 10 Plumbing Connections ................................................................................................................................... 10 Electrical Connections.................................................................................................................................... 12Operation ......................................................................................................................................................... 14 Initial Startup .................................................................................................................................................. 14 Initial Operation .............................................................................................................................................. 14 Deconcentrator Adjustment ............................................................................................................................ 15 Normal Operation ........................................................................................................................................... 16Maintenance and Servicing .............................................................................................................................. 18 Cleaning Methods .......................................................................................................................................... 18 Disassembly for Cleaning .............................................................................................................................. 19Theory of Operation ......................................................................................................................................... 22Troubleshooting ............................................................................................................................................... 23 Tests for Condenser Leaks ............................................................................................................................ 23 Condenser Test for Scale. .............................................................................................................................. 24 Heating Element Test and Replacement ........................................................................................................ 25 Heating Elements ........................................................................................................................................... 27Troubleshooting Chart ...................................................................................................................................... 28Parts List .......................................................................................................................................................... 29Accessories for Electric Stills ........................................................................................................................... 37Ordering Procedures ........................................................................................................................................ 39Warranty ........................................................................................................................................................... 40

Table of Contents

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This manual contains important operating andsafety information. The user must carefullyread and understand the contents of thismanual prior to the use of this equipment.Water purification technology employs one ormore of the following: chemicals, electricaldevices, mercury vapor lamps, steam andheated vessels. Care should be taken wheninstalling, operating or servicing Barnsteadproducts. The specific safety notes pertinent tothe Barnstead Electrically Heated Stills arelisted in safety information section.

Your Barnstead Electrically Heated Still hasbeen designed with function, reliability, andsafety in mind. It is the user’s responsibility toinstall it in conformance with local electricalcodes. For safe operation, please pay attentionto the alert signals throughout the manual.

WarningsTo avoid electrical shock, always:

1. Ensure that the equipment is con-nected to electrical service accordingto local and national standards. Failureto properly connect may create a fireor shock hazard.

2. Do not connect unit to electrical ser-vice until instructed to do so.

3. Disconnect from the power supplyprior to maintenance and servicing.

To avoid personal injury:1. Do not use in the presence of flam-

mable or combustible materials; fire orexplosion may result. This devicecontains components which may ignitesuch materials.

Safety Information

Alert Signals

WarningWarnings alert you to apossibility of personal injury.

CautionCautions alert you to a possibilityof damage to the equipment.

NoteNotes alert you to pertinent factsand conditions.

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2. Use this device with water feed only.Sanitizing/cleaning agents must be usedin compliance with the instructions in thismanual. Failure to comply with theabove could result in explosion andpersonal injury.

3. Avoid splashing disinfecting solutions onclothing or skin.

4. Ensure all piping connections are tight toavoid leakage of chemicals.

5. Always depressurize chemical linesbefore disassembly.

6. Ensure adequate ventilation.

7. Follow carefully the manufacturers’safety instructions on labels of chemicalcontainers and Material Safety DataSheets (M.S.D.S.).

8. “Caution: Hot Surface. Avoid Contact.”

9. Refer servicing to qualified personnel.

SAFETY INFORMATION

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Introduction

Barnstead electrically heated water stills areavailable in four sizes; 1, 2, 5 and 10 gallonsper hour of distilled water. The distilled waterproduced by the stills contains not more than1.0 ppm total solids, with a pH value of 5.4 to7.2 and an electrical resistance of not less than300,000 ohms at 25°C when the stills areoperated on most potable water. The stills aredesigned to use not more than 9 gallons ofcooling water and feedwater combined, foreach gallon of distilled water produced. The stillconsists of: an evaporator with its heat supply, acondenser, and devices to control the waterlevel and salt concentration in the evaporator, aQ baffle for pyrogen removal and a low watercutoff control. The operating characteristics foreach size still are shown in the InstallationDiagram.

EvaporatorStill evaporators are the vertical, cylindricaldouble-wall type with air-insulating space. Theevaporators are built sufficiently high and wideto provide ample vapor disengaging space andoperation at low velocity.

The evaporator shell is of polished stainlesssteel. The inner shell (boiler) is fabricated ofcopper, brass and bronze. The evaporatorcover is brass, finished in polished nickel and isprovided with a Q baffle. All surfaces thatcontact the vapor and distillate are coated with

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pure tin to prevent metallic contamination. Awater level sight glass is provided on all 5 and 10gph stills.

CondenserStill condensers are the horizontal type, slightlyinclined and atmospherically vented for finalelimination of volatiles. The condensers arefabricated of copper and brass and are finished inpolished nickel. All surfaces that contact thevapor and distillate are coated with pure tin toprevent metallic contamination. A distillatedelivery tube of block tin is provided to connectthe distillate outlet of the condenser to a storagetank or other suitable container.

Features ProvidedAll stills are equipped with a deconcentrator tocontinuously deconcentrate impurities from theevaporator and retard scale formation. A constantlevel device with hot well arrangement is providedfor evaporator water level control and for primaryelimination of volatile impurities. All stills areequipped with a drain valve. Cooling waterdischarge piping is provided between the coolingwater outlet of the condenser and the constantlevel device. Self-resetting solid state low watercutoff controls prevent the heating elements fromburning out in a low water situation.

Figure 1Electrically Heated Still

INTRODUCTION

NoteHeater life may be reducedwhen operated above maximumstated voltage. Operation of stillat a voltage less than the statedvoltages will cause a drop in stilloutput. Electrically heated stillswired for 240 volts AC, 2 or 3wire, will operate on 208 volts, 2or 3 wire respectively withresultant 25 percent drop indistillate capacity. Specialheaters for 208 volts are neededto obtain rated still output. Theelectric heaters will burn out ifoperated in air. To eliminate thepossibility of heating elementburnout, a solid state low watercutoff control is provided.

Condenser

Distillate

Outlet

Cooling Water/Feedwater

Inlet Tube

Constant Level

Device

Preheated

Feedwater Tube

Q-Baffle

Deconcentrator

Valve

Evaporator

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Electric HeatElectrically powered, immersion type heatersare used to give complete heat transfer andmaximum heating efficiency.

Low Water Cut-OffElectric current to the still heating elements iscontrolled by an ON/OFF switch and aself-resetting low water cutoff. The solid statelow water cutoff is designed to prevent damagecaused by low water conditions in the stillevaporator.

When the water level is at a safe level in the stillevaporator (the water level is above theimmersion type heaters and makes contact withthe probe), the circuit across probe terminals 1and 2 at the terminal board (TB1) is completed.The completion of this circuit, after atwo-second delay to prevent contactor chatter,will start the contactor to energize the contactorcoil to connect the heater service to the still.Opening of the probe circuit (water no longermakes contact with the probe) will stop thecontactor without delay.

The Barnstead solid state low water cutoff isdesigned to prevent damage caused by lowwater conditions in the evaporator of Barnsteadelectrically heated water stills. The low watercutoff consists of the Barnstead Solid State LowWater Control, a probe assembly for installationon Barnstead stills, and still heat control(contactor).

INTRODUCTION

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Still Heat ControlThe heat control consists of a cabinetized contactordesigned for wall mounting. The contactor cabinethas a removable cover and knockouts for conduitconnections. The contactor is provided to controlthe heat supply to the still heating elements, asdetermined by the low water cutoff controller. Thecontactor coil operates from a 115 VAC, 50/60hertz, single phase electrical service and derives itscontrol voltage at terminals 6 and 11 at the terminalboard in the low water cutoff control cabinet. SeeFigure 8 for information on the contactor sizerequired for a given size still and the availableheating service.

INTRODUCTION

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Unpacking

Unpack the still carefully so as not to damageany of the parts. Ensure that all parts areremoved from the container before discardingthe packing materials.

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SitingMove the still evaporator to the operating locationand install the evaporator so that it is level andplumb.

AccessoriesAll operating and convenience accessoriespurchased with the still should be installed afterthe still has been assembled on its mounting andbefore connecting the service lines to the still.

Plumbing ConnectionsEnsure that all fittings are tight in the still and stillaccessory piping and connect the water andwaste service to the still as shown in theinstallation diagram.

Installation

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Figure 2Top View

* Overall height includes enoughclearance to facilitate condenserremoval.

NoteThe still is not designed tosupport the service piping.Ensure that the service piping isadequately supported. If nocontrol valves were purchasedwith the still, a shutoff valve andthrottling valve should beinstalled in the cooling watersupply line, just before the still.

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NotesCW-1: Cooling water inlet connection 1, 2 and GPH stills(water supply pressure - 40 to 90 psi.)

CW-2: Cooling water inlet connection on 10 GPH still(water supply pressure - 40 to 90 psi.

CB: Channel base, supplied on 10 GPH stills.

J: Junction box for heating element connections onelectrically heated stills.

DO: Distillate outlet.

WA: Waste line must be atmospherically vented andgravity flow.

Figure 3Front View

INSTALLATION

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Electrical ConnectionsConnect the electrical heating service to the still asshown in Figure 14. The heating service terminalboard is located inside the junction box at the baseof the still. Customer must supply adequate on-offcontrol for electrical heating service.

Make the electrical connection to the terminal boardin the low water cutoff control cabinet as shown inFigure 9 and in accordance with the followinginstructions:

1. Remove the low water cutoff cabinet frontpanel. To remove the panel, remove thetwo lower screws in the front of the cabinetand press firmly down at the bottom centerof the panel to free the panel from thecabinet. The panel fits tightly in thecabinet. Do not attempt to pry the panelfrom the cabinet.

2. Connect the low water cutoff probe wiresto terminals 1 and 2 with #18 AWGstranded wire. Connect the outer shieldwire of the probe to terminal #1 and thecenter wire of the probe to terminal #2.Solder and tape the connections. At theevaporator both wires should protrudethrough the grommet in the probe shieldwhich is secured in place with 2 screwsover the cutoff access hole in theevaporator casing.

3. Connect the still heat control contactor coilto terminals 6 and 11.

4. Connect a 3-wire, 115-VAC, 60-hertzelectrical service to terminals 9 (AC high),7 (AC low), and the ground screw justbelow the terminal board. This electrical

INSTALLATION

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service will provide control voltage forthe low water cutoff controls and thecontactor coil (see See Figure 9).

5. Connect the heater electrical serviceto the contactor (see Figure 9). Seethe still wiring diagram when connect-ing the still heating elements to thecontactor - the heater electrical servicerequirements will be indicated on thenameplate decal at the base of the stillevaporator.

6. Install the front panel on the low watercutoff cabinet and install the cover onthe contactor cabinet.

INSTALLATION

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Initial StartupThe first time that the still is started, or aftercleaning, operate the still as follows:

1. Close the drain valve.

2. Open the deconcentrator valve slightly.

3. Open the cooling water inlet valve.

4. Open the cooling water throttling valveabout 1/2 turn.

5. When water begins to issue steadilyfrom the deconcentrator valve, turn onthe still heat supply.

6. When the still begins to produce distilledwater, close the deconcentrator valveand adjust the cooling water throttlingvalve until a puff of steam issues fromthe condenser vent. Discard the first twohours production of distillate to allow thestill to clean itself out.

7. Adjust the deconcentrator as describedbelow.

Initial OperationThe first time the still is operated, or aftercleaning, set the low water cutoff control “ON/OFF” toggle switch to ON position, open themanual drain valve and operate the still accordingto the basic still operating instructions. Thelighted switch will remain lit as long as the switchis in the ON position. The “Still On” lamp will lightwhen the water in the evaporator makes contactwith the probe. The still is started and stoppedwith the “ON/OFF” toggle switch.

Operation

WarningA fire hazard may result if thestill is used with a flammableliquid. “Caution: Hot Surface.Avoid Contact.”

NoteDuring the procedures listedbelow, check all connections forleaks and tighten as required.

NoteThe cooling water inlet andthrottling valves are shown indotted lines. If these were notpurchased with the still, theymust be installed in the coolingwater inlet line by the customerto ensure proper operation.

CautionEnsure that the water level in theevaporator is above the heatingelements before turning on thestill. The heaters are theimmersion type and will burn outif operated in air. The water levelshould be safe when waterissues steadily from thedeconcentrator valve.

NoteIdeally, the temperature of thesteam and gases escaping thevent should be 70°C or higher.To measure the venttemperature, use athermocouple probe, such asthe Thermolyne PM20700Digital Pyrometer, inserted intothe vent.

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Deconcentrator AdjustmentThe function of the deconcentrator is to maintain aminimum concentration of dissolved impurities inthe evaporator, thus reducing scale formation andtendency to foam to a minimum. Thedeconcentrator is adjusted as follows:

1. Permanent Hard Water or SoftenedWater (Softened feed is notrecommended). The deconcentratorvalve should be left open at all times tobleed water from the evaporator atapproximately 1-1/2 times the capacity ofthe still. This valve should be left openpermanently at the required setting.Care should be exercised to see that it isnever clogged. The valve should beinspected periodically and if required,disassembled and cleaned with a brushor scraper.

2. Temporary Hard Water. If the feedwaterto the evaporator is high in temporaryhardness, i.e., high in bicarbonates, thedeconcentrator valve should be closed.The reason for this is that bicarbonatesin solution tend to precipitate out attemperatures exceeding 150°F. With thedeconcentrator valve opened, a largerquantity of feedwater passes through theevaporator, precipitating outbicarbonates, increasing the amount ofscale formed. Keeping the to 150°deconcentrator closed will result in anincreased concentration of solids in theevaporator as time goes on, thuscreating a tendency to foam. Thiscondition is corrected by draining the stillthrough the drain valve at frequentintervals.

3. Demineralized WaterWhen demineralized water is used asfeedwater the deconcentrator valve maybe kept closed.

OPERATION

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Normal OperationStarting - Start the still as follows:

1. Close the drain valve.

2. Open the deconcentrator valve slightly, ifnot adjusted.

3. Open the cooling water inlet valve.

4. When water begins to issue steadilyfrom the deconcentrator valve, turn onthe still heat supply.

As long as the low water cutoff control “ON/OFF”toggle switch is in the ON position, the still willstart and stop automatically, depending on thestored distilled water distribution requirementsand the operating cycle of the interval drain timer.To stop the still, set the low water cutoff control“ON/OFF” toggle switch to the OFF position.When this is done, the still will drainautomatically.

5. If necessary, adjust the cooling waterthrottling valve until a puff of steamissues from the condenser vent.

Stopping - Stop the still as follows:

1. Shut off the still heat supply.

2. Close the cooling water inlet valve.

3. Open the drain valve and let the stilldrain completely.

OPERATION

CautionEnsure that the water level in theevaporator is above the heatingelements before turning on thestill. The heaters are theimmersion type and will burn outif operated in air. The water levelshould be safe when waterissues steadily from thedeconcentrator valve.

NoteIdeally, the temperature of thesteam and gases escaping thevent should be 70°C or higher.To measure the venttemperature, use athermocouple probe, such asthe Thermolyne PM20700Digital Pyrometer, inserted intothe vent.

NoteDo not change the setting of thecooling water throttling valveand deconcentrator valve.

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Figure 4Operating Controls

OPERATION

NoteValves shown in dotted linesmust be installed by customer.Available as optional equipment.

CondenserVent

DistillateTube Cooling Water

Throttling Valve

Cooling WaterInlet Valve

DeconcentratorValve

Drain Valve

Electrical TerminalConnection Box

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Cleaning MethodsCleaning requirements fall into two classes, scaleremoval and biological cleaning. Scale removalmay be accomplished chemically or mechanically.Biological cleaning is accomplished with anisopropyl alcohol solution. For best results allsolutions and water should be heated. The vari-ous methods of cleaning are described below:

Soft Scale Removal. Soft scale may be removedwith a stiff bristle brush. After cleaning, all scaleparticles should be flushed out with water.

Hard Scale Removal. Hard scale may be re-moved by using a 10% solution of inhibited HCI.This acid cleaner is available commercially ormay be prepared using 20 parts water and 6parts 30% HCI. When using the acid, do not allowthe acid to remain in contact with the part formore than 20 minutes. Flush the part thoroughlyafter using the acid cleaner. A 5% Sodium Bicar-bonate solution may be used to remove any acidleft on the part.

Organic Scale and Sludge Removal. If thescale has a dark brown or black color, it may beformed from organic impurities present in thefeedwater. This type of scale may be removedwith a strong detergent solution. The detergentsolution should be allowed to be in contact withthe scale or sludge for 24 hours. Rinse off theparts with water after cleaning.

Silica Scale Removal. Silica scale is usuallyclear and shiny and hard to detect visually. It isvery hard and cannot be removed with an acidsolution. Silica scale formation can be reduced bycontrolling the quality of the feedwater by routingit through a mixed bed deionizer. It is best re-moved with a blunt instrument.

Maintenance and Servicing

NoteIf desired, 10% solutions ofsulfamic or acetic acids may beused instead of the HCI.Sulfamic and acetic acids havean advantage over hydrochloricacid in that they will not corrodethe metal parts being cleaned.Under no circumstancesshould any concentrated acidbe allowed to come in contactwith tinned surfaces.

WarningAlways wear protective clothingand eye shields when handlingacid. Disconnect from the powersupply prior to maintenance andservicing. Refer servicing toqualified personnel.

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Biological Cleaning. Biological cleaning is usedon the parts that come in contact with thedistillate (such as, the distilled water side of thecondenser, or the distilled water transmissiontubing) to remove any biological contaminationfrom the affected part. This may be accomplishedas follows:

1. Immerse the part in an isopropyl alcoholor a mild detergent (not containingbleach) solution overnight. Do not rinsethe part with water after cleaning. Drainparts before reassembly.

2. After the still is reassembled and hasoperated for 30 minutes to flush, reducethe cooling water flow rate with thecooling water throttling valve until steamissues from the condenser vent at least12 inches. Operate the still in thismanner for 30-60 minutes. Ventilate theroom during this operation.

Disassembly for CleaningThe frequency of cleaning will depend upon thepurity of the water being used. For example, theevaporator should require infrequent cleaning if itis fed partially purified water; however, thecooling water side of the condenser will have tobe cleaned at more frequent intervals due to thefact that raw water is flowing through it and it willscale up sooner. The still should be inspected atfrequent intervals until cleaning intervals aredetermined. Disassemble, inspect, and clean thestill as follows:

1. Shut off and drain the still.

MAINTENANCE AND SERVICING

WarningAvoid splashing the isopropylalcohol solution on open cuts.

CautionDo not use chlorine bleach forbiological cleaning. The chlorinewill interact with and damage thetinned surfaces.

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2. Shut off the water supply to the still.

3. Remove the condenser from the still.Inspect the cooling water side of thecondenser for scale and clean asrequired. If required, clean the distilledwater side of the condenser asdescribed under “Biological Cleaning.”

4. Disassemble until the interior of theevaporator is visible. The evaporatorcover, high purity chamber andpreheater (if supplied) may beremoved as a unit and the interior ofthe evaporator will be visible. Inspectthe interior of the evaporator for scale.Remove as much scale as possiblemanually.

5. Disassemble the drain line and cleanas required. Ensure that the drain lineis clear (including the drain opening inthe evaporator) before using detergentor acid cleaners. Reassemble thedrain line.

6. Soft scale may be removed asdescribed under “Soft Scale Removal.”Silica scale may be removed asdescribed under “Silica ScaleRemoval.” To remove hard scale ororganic scale, fill the evaporator withconcentrated acid (see “Hard ScaleRemoval”) or detergent solution (see“Organic Scale and Sludge Removal”)or detergent solution (see “OrganicScale and Sludge Removal”) asrequired.

7. Inspect the constant level device anddrain line. Clean as required.


NoteStills equipped with a high puritychamber or preheater shouldnot be cleaned with acid unlessthe high purity chamber can beremoved. The fumes given offby the acid may damage the tincoating used in theseaccessories.

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8. If the still is equipped with a gaugeglass, remove and clean the gaugeglass cocks and gauge glass:

a. Unscrew the nuts that hold the gaugeglass in place.

b. Lift the gauge glass up into the topgauge glass cock about 1/2 inch.

c. After the bottom of the gauge glass isclear of the bottom gauge glass cock,move it away from the still and removeit from the upper gauge glass cock.

d. Remove and clean the gauge glasscocks and clean the gauge glass.

9. Reassemble the still. Assembly isessentially the reverse of disassembly.

10. Connect the water, waste and distillatelines.

11. Start the still as described under “InitialStartup.”

12. Lower the cooling water flow rate (withthe cooling water throttling valve) untilsteam spouts out of the condenser ventat least 12 inches. Operate in thismanner for 30-60 minutes to sterilizeand clean out the still.

13. Adjust the still as described in “InitialOperation.”


CautionVentilate the room during thisoperation.

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The still consists primarily of a boiler or evapora-tor which holds the water during the evaporationprocess; electric heating elements of theimmersion type inserted in the evaporator to boilthe water; and a condenser which condenses thesteam from the boiler to form the distillate.

The water to be purified enters the condenserwhere it is heated by the steam passing throughthe evaporator. The preheated water is fed to theevaporator as required by the constant leveldevice which maintains the proper water level inthe evaporator. An overflow connected to thedrain is provided for the excess cooling water.

Water in the evaporator is vaporized by theelectric heating elements. The steam passes upthrough the vapor pipe into the condenser whereit is condensed to distilled water. The condenseris vented to atmosphere to eliminate the gaseousimpurities. All stills are equipped with adeconcentrator and an extra high evaporator topermit operating a still from hard water supplies.The deconcentrator automatically maintains aminimum concentration of dissolved impurities inthe evaporator, thus reducing to a minimum thescale formation and tendency to foam.

Theory of Operation

Figure 5

AtmosphericVent

InclinedCondenser

Cooling Water/Feedwater

InletQ Baffle

Double WalledEvaporator

Immersion Heaters(For Electric Stills)

Drain Valve

Constant LevelDevice

DeconcentratorValve

PreheatedFeedwater

DistillateOutlet

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This section contains troubleshooting, testing andrepair instructions. A troubleshooting chart isincluded to help the repair specialist find thedifficulty quickly.

Tests for Condenser Leaks

Visual Test . A simple test for condenser leaksmay be performed as follows:

1. Shut off the still heating elements.

2. Let the cooling water flow through thecondenser until the condenser is cold.

3. Note whether there is a flow, even indrop quantities, from the distillate outlet.If there is a continuous flow, it is possiblethat there is a leak from the coolingwater side to the distillate side. If this isthe case, the condenser must bereplaced.

Pressure Test. If a more positive test is required,proceed as follows:

1. Remove the condenser from the still.

2. Remove the cooling water dischargetubing. Plug the discharge connectionon the condenser with a plug or stopper.

3. Attach a hose to the cooling water inletconnection on the condenser and applyabout 5 psi air pressure to condenser.Ensure that the plugs used to seal thecondenser do not leak air.

4. Submerge the entire condenser in atank of water.

Troubleshooting

24

5. If any air bubbles come from the con-denser, replacement is necessary.

Condenser Test for ScaleTest the cooling water side of the condenser forscale as follows:

1. Adjust the cooling water throttling valveso that just a puff of steam issues fromthe condenser vent.

A. In extreme cases of scale, steam willalways blow from the condenser vent,even when the cooling water throttlingvalve is wide open.

B. Ensure that a minimum cooling waterpressure of 30 psi is maintained. A dropin cooling water pressure will causesteam to blow from the condenserbecause of inadequate cooling.

2. Remove the condenser if the dischargepipe is cool enough to hold. Inspect theinterior of the condenser for scale. Ifscale is present, pour the acid cleaningsolution (see “Hard Scale Removal”) intothe condenser through one of thecooling water connections.

3. Let the solution remain in the condenserfor 15-20 minutes, then drain. Repeat ifnecessary until scale is removed.

4. Wash the interior of the condenserthoroughly after using acid solution.

5. Install the condenser on the still.

TROUBLESHOOTING

NoteThe condenser cannot berepaired and must be replacedas a unit.

CautionDo not add the acid cleaningsolution rapidly for if anybicarbonate scale is present, gaswill be released in considerableamounts. Do not use the acidcleaning solution on the tinned(Distilled Water) side of thecondenser.

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Heating Element Testand ReplacementWhenever a heating element is suspected of notoperating properly, test and if necessary, replacethe heating element as follows:

1. Shut off the still. Close the water supplyvalves to the still. Open the drain valveand let the still drain completely.

2. Disconnect the electrical heat supply tothe still terminal block.

3. Remove the bottom plate from the stillevaporator. Disconnect the electricalleads and bus bars from the heatingelement terminals. Tag the leads tofacilitate reassembly.

4. To test each heating element for opencircuit, apply a current across theterminals. Use a test light in series withthe applied current. If the test light doesnot light, the heating element is burnedout. Mark all damaged heatingelements.

5. To test each heating element for shortcircuit, connect one test lead to theboiler bottom and the other to eachterminal (one at a time). If the heatingelement is short circuited, the test lightwill light. Mark all damaged heatingelements.

6. Remove the evaporator cover from thestill and inspect the heating elementsfrom the inside of the evaporator.Warped or split elements should bereplaced.

TROUBLESHOOTING

WarningTo avoid electrical shock, thisproduct must be disconnectedfrom the power supply prior toperforming the followingmaintenance and servicing.

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7. To remove an inoperative or damagedheater, loosen the screw under theheater and push out the heater. If theheater is badly scaled, remove theretaining nut and rock the heater backand forth (from inside the evaporator) tobreak the scale.

8. Install a new heater in place of the oldheater. Tighten the screw only enough tohold the heater in place. This will allowyou to rotate the heater when installingthe bus bars.

9. Install the bus bars and wiring betweenheater terminals. Retighten the heaterretaining screws to eliminate thepossibility of leakage.

10. Add water to the evaporator and ensurethat none of the heating elements areleaking.

11. Reassemble the still and connect theelectrical heating service to the heatingelement.

TROUBLESHOOTING

27

Heating ElementsListed below are the heating elements available.The heating elements now have compressionnuts. These are directly interchangeable with theolder threaded types. Heating elements areshipped complete as shown in Figure 6.

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TROUBLESHOOTING

NoteHeater replacement datastamped inside still junction boxcover.

Bottom ofEvaporator

Heating Element

O-Ring (P/N 06289)

Socket head screw1/4-20 x 3/8”P/N 10248

Round head screw,brass 8-32 x 3/8”

(P/N 10194)

Retaining Nut(P/N 10246)

NoteReplacement heating elementsare furnished with O-ring,retaining nut, socket head screwand two round head screws.These parts are listed in theevent that only these parts needreplacement.

Tee handle wrench (P/N 06287)available for removing sockethead screw. May be orderedwith replacement heatingelements.

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Troubleshooting Chart

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.retawdeefniseitirupmielitaloV

sanaelc,elacsrofrotaropavetcepsnI.deriuqer

OCrofetallitsidtseT 2 HN, ,3 ecudeR.cteselitalovetanimileplehotwolfretawgnilooc

.resnednocmorf

cinagrorocinegoryPfonoitanimatnoc

.etallitsid

.llitsytriD

.resnednocnikaeL

.retawdellitsidnihtworglacigoloiretcaB

naelc,elacsssecxerofrotaropavetcepsnI.deriuqersa

saecalperroskaelrofresnednoctseT.deriuqer

htiwnaelC.strapdetcepsusehttcepsnIlacigoloiB"eeS(.deriuqerfilohocla

)".gninaelC

etallitsidniporD.yticapac

.tinugnitaehnoelacsssecxE

.egatlovwoL

.evlavniardnikaeL

.sretaehevitareponidegamaD

.deriuqersanaelcdnatcepsnI

nideificepsnahtsselfI.egatlovkcehC.naicirtceleyfiton,margaidgniriw

tondnadesolcsievlavniarderusnE.gnikael

tseT.cte,snoitcennoc,gniriwkcehC.yrassecenfiecalperdnasretaeh

morfgniwolbmaetS.resnednoc

.etarwolfretawgniloocwoL

.erusserpretawgniloocwoL

.resnednocnielacsssecxE

.egatlovhgiH

.evlavgnilttorhttsujdaeR

taebdluohS.erusserpretawgniloockcehC.isp03tsael

.elacsrofresnednoctcepsnI

,egatlovdetarehtrevofI.egatlovkcehCyfitoN.yletaidemmillitsnwodtuhs

.naicirtcele

morfgniwolbretaW.resnednoc

.kaelresnednoC

.eniletallitsiddepparT

.rotaropavenisdilosfonoitartnecnochgiH

ecalperroriapeR.skaelrofresnednoctseT.deriuqersa

rosnoitcirtserynarofseniletallitsidtcepsnI.gnippart

ylreporpdetsujdasirotartnecnocederusnE.netfoeromllitsniarddna

tonlliwtubstratsllitS.etallitsidecudorp

.tiucricretaehotrewoplacirtceleoN

denrubfiecalperdnaliocrotcatnockcehC.tuo

yldabfiecalperdnastnioprotcatnockcehC.denrub

sieborpffotucretawwoltahtkcehChtiwecnadroccanidellatsniylreporp

.snoitcurtsni

29

Parts List

xednI.oN .oN .oN .oN .oN

noitpircseD1101A

)HPG1( )HPG1( )HPG1( )HPG1( )HPG1(3101A



)HPG01( )HPG01( )HPG01( )HPG01( )HPG01(300X6101A

)HPG01( )HPG01( )HPG01( )HPG01( )HPG01(

1 resnednoC 85012 06012 26012 46012 46012

2

ebuTyrevileDetallitsiD 22602 42602 42602 )"63(40912 )"63(40912

yrevileDetallitsiD"84retpadAO/WebuT

13602 33602 33602 ----- -----

retpadAebuTetallitsiDnwohStoN-)dnE(

94410 05410 05410 ----- -----

3retaWgnilooCebuTegrahcsiD

18812 28812 38812 ----- -----

4retaWgnilooC

woblEegrahcsiD20730 20730 62430 11430 11430

5teksaGepiPropaV)ylno300X-6101A(

----- ----- 25112 25112

6 revoCrotaropavE 59112 79112 99112 53512 53512

7 tuNdelrunK 91730 91730 96430 96430 96430

8revoCrotaropavE

teksaG17260 17260 27260 27260 27260

9 rotaropavE 32112 72112 13112 00312 00312

01 eciveDleveLtnatsnoC 02312 12312 76112 10312 10312

11 evlaVrotartnecnoceD 27212 27212 34012 34012 34012

21 lennuFrotartnecnoceD 18212 28212 14012 91612 91612

31 evlaVniarD 69020 69020 69020 60530 60530

eeS(stnemelEgnitaeH)nwohStoN()1etoN

13070 33070 92070 82070 92070

)nwohStoN(elffaBQ

toN(ffO-tuCretaWwoL)xoB()nwohS

0561G

B1X566SC

0561G

B1X566SC

1561G

B1X566SC

1561G

B1X566SC

1561G

B1X566SC

30

NoteFor more details on heatingelements, refer to “HeatingElement Replacement.”

NoteJunction box includes terminalblock segments (04205 or04150) and terminal block ends.

PARTS LIST

1

2

3

45

67

8

9

10

11

12

13

Figure 7

detartsullItoNstraPrehtO .oNtraP

)HPG2-1( )HPG01-5(

stnemgeSkcolBlanimreT 50240 05140

sdnEkcolBlanimreT 60240 15140

skcoCssalGeguaG ----- 20020

ssalGeguaG ----- 83060

)ssalGeguaG(sgniR-O ----- 14060

31

xednI.oN

noitpircseD .oNgolataC

yticapaCetallitsiDllitS HPG2&HPG1 HPG2 HPG5 HPG01 HPG01

esahP-eciveSgnitaeH 1 3 3&1 1 3

1

rotcatnoC

elop2,pma72 70110 ----- ----- ----- -----

elop3,pma71 ----- 73410 ----- ----- -----

elop3,pma06 ----- ----- 73410 ----- -----

elop4,pma06 ----- ----- ---- 54410 -----

elop3,pma59 ----- ----- ----- ----- 53410

Figure 8Still Heat Control Contactor

PARTS LIST

1

32

1. Heater life may be reduced when operated above maximum stated voltage. Operation of still at avoltage less than the above stated voltages will cause a drop in still output.

2. Customer external connections and circuit protection must be capable of carrying the full loadcurrent in accordance with the national electrical code and local practice.

3. Still evaporator must be grounded.

4. O denotes terminal in junction box.

5. At 208 volts, the output is reduced by 25% of rated capacity. Special heaters for 208 volts areneeded to obtain rated still output.

6. This nonstandard voltage will cause a 16% drop in still output capacity in a standard still. Specialheaters may be ordered as an option to achieve rated capacity.

PARTS LIST

Terminal Block

1 Gallon StillTerminal Block

2 and 5 Gallon StillTerminal Block

10 Gallon Still

Catalog

No.

A1011

A1013

A1015

A1016

G.P.H.

5

10

Single Phase Three Phase120 V (2 wire) 120/240 V (3 wire) 240 V (2 wire)

(See Notes)

480 V (2 wire) 120/208 V (4 wire) 240 V (3 wire)

(See Notes)

380/220 V (4 wire)

(See Notes)

480 V (3 wire)

.oNgolataCfoepyT&ytitnauQ

tnemelEegatloV egattaW sttaWlatoT

1101A UepyT4 021 056 0062

3101A YepyT6 021 0001 0006

5101A PepyT6 021 0612 00031

6101A OepyT21 021 0612 00062

300X-6101A PepyT21 021 0612 00062

Figure 9

2

1

Notes:

33

Floorstand for Classic StillsThe floorstands are crafted of sheet metaland are provided with adjustable levelers.

Enclosed in this package: Floorstand.

.oNledoM noitpircseD

0001G sllitSHPG01dna5rofdnatsroolF

1001G sllitSHPG2dna1rofdnatsroolF .oNledoM noitpircseD

1273GdeefotsllitsHPG01dna5

llitsotretawdetaerterp

tAtnerruCdaoLlluF

.oNgolataCCAV021esahP1

CAV042/021esahP1

CAV802/021esahP3

CAV042esahP3

CAV084esahP3

1101A 32 21 --- --- ---

3101A --- 62 71 --- ---

5101A --- 75 63 33 ---

6101A --- --- 37 66 33

300X-6101A --- --- 37 --- ---

Float Feeder for Classic StillsUsed for pretreated water conservation. Thefloat mechanism controls the flow of pretreatedwater to boiler, eliminating waste. All surfacescoming in contact with purified water are puretin.

Enclosed in this package: Assembled floatfeeder valve, cooling water discharge pipe(which accompanies only the 5 PGH still); anadapter, 3524 (to be used for 10 GPH still);Steam still only) and 2 nipples, 3435 (to beused for 10 GPH Steam Still only) and 3436 (tobe used for 10 GPH Electric Still only).

Figure 10Electric Still Mounted on a Floorstand

Figure 11Electric Still with Float Feeder, Automatic FeedwaterShutoff and Floorstand

PARTS LIST

Floorstand

Float Feeder

Automatic

Feedwater Shut-Off

Valve

Pretreated

Water InletFloorstand

34

Flow Automatic ControlsAllows for completely unattended 24-houroperation when still is attached to tank.Adjustable drain timer/cycler 2-, 4-, 8- or 16- hourdrain allows reduced still cleaning frequency.

Figure 13Steam Still with Automatic Controls mounted on Floorstand

Figure 12Electric Still with Automatic Feedwater ShutoffValve

PARTS LIST

.oNledoM desUerehW

0192G slortnoccitamotuayllufhtiwylnO

.oNledoM egatloV desUerehW

0012G zh06,V021,HPG2dna1

llitsesahp1

1012G zh06,V021 llitsesahp3,HPG2

0112G zh06,V021 llitsesahp3dna1,HPG5



Automatic FeedwaterShutoff Valve for ClassicStillsFor the conservation of water and auto-matic operation. This is to be used withfloat feeder (G3721) to interruptfeedwater to float feeder when still isturned off.

Enclosed in this package: AssembledAutomatic Solenoid Valve, brass elbow(03415) used to connect feedwater inletto the Assembled Automatic SolenoidValve and a brass bushing (03407) usedto attach Assembled Automatic SolenoidValve to the Float Feeder Shutoff Valve.

Enclosed with the package: AutomaticSolenoid Valve, Brass Elbow (03415)and a brass bushing.

Floorstand

Float Feeder

Automatic

Feedwater Shut-oof

Valve

Pretreated

Water Inlet

Water Drain

Distillate

Outlet

Automatic

Controls

Cooling Water Inlet

Floorstand Water Drain

35

.oNledoM rewoP

0333G zH06/05-CAV511


0523G llitSHPG1roftekcarBllaW




Puramatic Diverter forClassic StillsDivert substandard distilled water to drain.All of the piping is constructed of inertpure tin. The automatic temperaturecompensated purity meter.

Enclosed in this package: AssembledPuramatic Diverter piping; Drain Cupassembly; Purity Meter/Controller; 2clamps (used to hang the PuramaticDiverter on the Cooling Water Inlet pipingto the condenser); 10 1- inch plastic tubes(TU495X64), used to protect the piping onthe Puramatic Diverter from beingscratched); 2 brass elbows(PM495X134A, used to run the pipingfrom the Puramatic Diverter to the DrainCup); 3 brass tubings (TU495X53A, usedto run the overflow to the Drain Cup); 1tubing (not numbers, runs from PuramaticDiverter to the storage tank).

Wall Brackets for Classic StillThe wall brackets are made of aluminum cast-ing (G3275 is made of steel).

Enclosed in this package: Wall Bracket

Figure 14Electric Still with Automatic Controls, PuramaticDiverter, Float Feeder and Automatic FeedwaterShutoff Valve, mounted on Floorstand.

PARTS LIST

Distillate

Outlet

Puramatic

Diverter

Automatic

Controls

Floorstand

Water

Drain

Pretreated

Water Inlet

Float Feeder

Automatic Feedwater

Shut-off Valve

36

Cartridge Pretreatment Kit forClassic StillsThe pretreatment kit removes scale-formingimpurities from the feedwater to the stillevaporator (boiler) while improving the distillatepurity. Each pretreatment kit has a scaleeliminator cartridge, Cat. No. D8921, containingion-exchange resin to remove scale-formingimpurities and activated carbon to removechlorine and volatile organic impurities. Thecapacity of the cartridge is 750 grains as NaCI.

Enclosed in this package: Holder for wallmounting the cartridge, a flow meter forregulating the water flow through the cartridge,and the necessary piping and tubing to connectthe scale eliminator cartridge to the still. For usewith 1 and 2 GPH Classic Stills only.


8263G1roftiKtnemtaerterPegdirtraC

1sedulcni(sllitSHPG2dna)egdirtrac

1298D egdirtraCtnemtaerterPartxE

Figure 15Pretreated Cartridge Kit for 1 and 2 GPHElectric Stills with Automatic controls, mountedon wall bracket

PARTS LIST

Distillate

Outlet

Pretreat Inlet

Water Drain

Cooling Inlet

37

Accessory Numbers for Electric Stills

Tin-Coated Vertical Cylindrical Storage Tanks

Accessories for Electric Stills

yrosseccA 1101A 3101A 5101A 6101A

tiKtnemtaerterP8263G

1298D

8263G

1298D

tekcarBllaW 0523G 1523G 2523G 5723G

lortnoCcitamotuAylluF 0012G0012G

ro1012G

0112G0212G

ro5212G

evlaVdioneloSretawdeeFcitamotuA 0192G 0192G

redeeFtaolF 1273G 1273G

dnatsroolF 1001G 1001G 0001G 0001G

retreviDcitamaruP 0333G 0333G 0333G 0333G

yrosseccA 1101A 3101A 5101A 6101A

knaTegarotSlacirdnilyCnollaG01 3403B 3403B 3403B 3403B

dnatsroolF 0001H 0001H 0001H 0001H

tekcarBllaW 0423H 0423H 0423H 0423H



tekcarBllaW 2423H 2423H 2423H 2423H







38

Tin-Coated Rectangular Storage Tanks

Accessories to Accompany Tin-Coated Rectangularand Cylindrical Storage Tanks

ACCESSORIES FOR ELECTRIC STILLS

yrosseccA 1101A 3101A 5101A 6101A

knaTegarotSralugnatceRnollaG52 7203B 7203B 7203B 7203B

knaTegarotSralugnatceRnollaG05 8203B 8203B 8203B 8203B

yrosseccA 1101A 3101A 5101A 6101A

dragtneV 0213H 0213H 0213H 0213H

laeSretaW 0313H 0313H 0313H 0313H

laeSretaWdnadragtneV 1113H 1113H 1113H 1113H

dragtneVrofretliFtnemecalpeR 10052 10052 10052 10052

pmaLteloivartlU 5004H 5004H 5004H 5004H

V021rofVUtnemecalpeR 14140 14140 14140 14140

39

Ordering Procedures

Please refer to the Specification Plate for the complete model number, serial number, andseries number when requesting service, replacement parts or in any correspondenceconcerning this unit.

All parts listed herein may be ordered from the Barnstead Thermolyne dealer from whomyou purchased this unit or can be obtained promptly from the factory. When service orreplacement parts are needed we ask that you check first with your dealer. If the dealercannot handle your request, then contact our Customer Service Department at319-556-2241 or 800-553-0039.

Prior to returning any materials to Barnstead Thermolyne Corp. , please contact ourCustomer Service Department for a “Return Goods Authorization” number (RGA). MaterialReturned without an RGA number will be returned.

40

Barnstead|Thermolyne Corporation warrants that if a product manufactured byBarnstead|Thermolyne and sold by it within the continental United States or Canadaproves to be defective in material or construction, it will provide you, without charge, for aperiod of ninety (90) days, the labor, and a period of one (1) year, the parts, necessary toremedy any such defect. Outside the continental United States and Canada, the warrantyprovides, for one (1) year, the parts necessary to remedy any such defect. The warrantyperiod shall commence either six (6) months following the date the product is sold byBarnstead|Thermolyne or on the date it is purchased by the original retail consumer,whichever date occurs first.

All warranty inspections and repairs must be performed by and parts obtained froman authorized Barnstead|Thermolyne dealer or Barnstead|Thermolyne (at its owndiscretion). Heating elements, however, because of their susceptibility to overheating andcontamination, must be returned to our factory, and if, upon inspection, it is concluded thatfailure is not due to excessive high temperature or contamination, warranty replacement willbe provided by Barnstead|Thermolyne . The name of the authorizedBarnstead|Thermolyne dealer nearest you may be obtained by calling 1-800-446-6060 orwriting to:

Barnstead|ThermolyneP.O. Box 797

2555 Kerper BoulevardDubuque, IA 52004-0797

USAFAX: (319) 589-0516

E-MAIL ADDRESS: [email protected]|Thermolyne’s sole obligation with respect to its product shall be to repair

or (at its own discretion) replace the product. Under no circumstances shall it be liable forincidental or consequential damage.

THE WARRANTY STATED HEREIN IS THE SOLE WARRANTY APPLICABLE TOBarnstead|Thermolyne PRODUCTS. Barnstead|Thermolyne EXPRESSLY DISCLAIMSANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDINGWARRANTIES OF MERCHANTABILITY OR FITNESS FOR USE.

One Year Limited Warranty

9001ISOREGISTERED

Barnstead|Thermolyne2555 Kerper Blvd.P.O. Box 797Dubuque, IA 52004-2241Phone: 319-556-2241 800-553-0039Fax: 319-589-0516E-Mail Address: [email protected]

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Transcript of Classic Electrically Heated Stills - Davis classic stills.pdf · 1 BARNSTEAD THERMOLYNE CORPORATION...