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Classic Electrically Heated Stills

OPERATION MANUALAND PARTS LIST

SERIES 495

Model NumbersA1011 A1015A1013 A1016

60004 • 1/30/03

Barnstead International Classic Electrically Heated Stills Operation Manual- Authorized Distributor Clarkson Laboratory & Supply Inc. www.clarksonlab.com E-mail: [email protected] Phone: 619-425-1932 Fax: 619-425-7917 Please visit our website for current prices

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Safety Information ..............................................................................................................................................3Alert Signals ......................................................................................................................................................3Warnings ..........................................................................................................................................................3

Introduction..........................................................................................................................................................5Evaporator ........................................................................................................................................................5Condenser ........................................................................................................................................................6Features Provided ............................................................................................................................................6Electric Heat......................................................................................................................................................6Low Water Cut-Off ............................................................................................................................................6Still Heat Control ..............................................................................................................................................7

Unpacking ..........................................................................................................................................................8Installation ..........................................................................................................................................................9

Siting ................................................................................................................................................................9Accessories ......................................................................................................................................................9Plumbing Connections ......................................................................................................................................9Electrical Connections ....................................................................................................................................11

Operation ..........................................................................................................................................................13Initial Startup ..................................................................................................................................................13Initial Operation ..............................................................................................................................................13Deconcentrator Adjustment ............................................................................................................................14Normal Operation............................................................................................................................................15

Maintenance and Servicing ..............................................................................................................................17Cleaning Methods ..........................................................................................................................................17Disassembly for Cleaning ..............................................................................................................................18

Theory of Operation ..........................................................................................................................................21Troubleshooting ................................................................................................................................................22

Tests for Condenser Leaks ............................................................................................................................22Condenser Test for Scale. ..............................................................................................................................23Heating Element Test and Replacement ........................................................................................................24Heating Elements............................................................................................................................................26

Troubleshooting Chart ......................................................................................................................................27Parts List ..........................................................................................................................................................28Accessories for Electric Stills ............................................................................................................................37Ordering Procedures ........................................................................................................................................39Warranty ............................................................................................................................................................40

Table of Contents


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This manual contains important operating andsafety information. The user must carefully read and understand the contents of this manu-al prior to the use of this equipment.Water purification technology employs one ormore of the following: chemicals, electricaldevices, mercury vapor lamps, steam and heat-ed vessels. Care should be taken wheninstalling, operating or servicing Barnsteadproducts. The specific safety notes pertinent tothe Barnstead Electrically Heated Stills are list-ed 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 connect-ed to electrical service according tolocal 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 flamma-

ble or combustible materials; fire orexplosion may result. This device con-tains components which may ignitesuch materials.

Safety Information

Alert Signals

WarningWarnings alert you to a possibili-ty of personal injury.

CautionCautions alert you to a possibili-ty of damage to the equipment.

NoteNotes alert you to pertinentfacts and conditions.


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2. Use this device with water feed only.Sanitizing/cleaning agents must be usedin compliance with the instructions inthis manual. Failure to comply with theabove could result in explosion and per-sonal injury.

3. Avoid splashing disinfecting solutions onclothing or skin.

4. Ensure all piping connections are tightto avoid leakage of chemicals.

5. Always depressurize chemical linesbefore disassembly.

6. Ensure adequate ventilation.

7. Follow carefully the manufacturers’ safe-ty 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,a condenser, 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 withpure tin to prevent metallic contamination. Awater level sight glass is provided on all 5 and10 gph stills.


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CondenserStill condensers are the horizontal type, slightlyinclined and atmospherically vented for finalelimination of volatiles. The condensers are fab-ricated 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 con-stant level device with hot well arrangement isprovided for evaporator water level control andfor primary elimination of volatile impurities. Allstills are equipped with a drain valve. Coolingwater discharge piping is provided betweenthe cooling water outlet of the condenser andthe constant level device. Self-resetting solidstate low water cutoff controls prevent the heat-ing elements from burning out in a low water sit-uation.

Electric HeatElectrically powered, immersion type heaters areused to give complete heat transfer and maxi-mum heating efficiency.

Low Water Cut-Off Electric current to the still heating elements iscontrolled by an ON/OFF switch and a self-resetting low water cutoff. The solid state lowwater cutoff is designed to prevent damagecaused by low water conditions in the stillevaporator.

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 with resul-tant 25 percent drop in distillatecapacity. Special heaters for208 volts are needed to obtainrated still output. The electricheaters will burn out if operatedin air. To eliminate the possibilityof heating element burnout, asolid state low water cutoff con-trol is provided.

Condenser

Distillate

Outlet

Cooling Water/

Feedwater

Inlet TubeConstant Level

Device

Preheated

Feedwater Tube

Q-Baffle

Deconcentrator

Valve

Evaporator


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When the water level is at a safe level in the stillevaporator (the water level is above the immer-sion type heaters and makes contact with theprobe), the circuit across probe terminals 1 and2 at the terminal board (TB1) is completed. Thecompletion of this circuit, after a two-seconddelay to prevent contactor chatter, will start thecontactor to energize the contactor coil to con-nect the heater service to the still. Opening ofthe probe circuit (water no longer makes contactwith the probe) will stop the contactor withoutdelay.

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 water cut-off consists of the Barnstead Solid State LowWater Control, a probe assembly for installationon Barnstead stills, and still heat control (contac-tor).

Still Heat ControlThe heat control consists of a cabinetized con-tactor designed for wall mounting. The contactorcabinet has a removable cover and knockoutsfor conduit connections. The contactor is provid-ed to control the heat supply to the still heatingelements, as determined by the low water cutoffcontroller. The contactor coil operates from a 115VAC, 50/60 hertz, single phase electrical serviceand derives its control voltage at terminals 6 and11 at the terminal board in the low water cutoffcontrol cabinet. See Figure 8 for information onthe contactor size required for a given size stilland the available heating service. Unpack thestill carefully so as not to damage any of theparts. Ensure that all parts are removed from thecontainer before discarding the packing materi-als.

INTRODUCTION


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Unpacking

Unpack the still carefully so as not to damage anyof the parts. Ensure that all parts are removedfrom the container befoer discarding the packingmaterials.


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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 the installa-tion diagram.

Installation

Bench Dimensions in Inches

Electric Heat

Still Cap (GPH) 1 2 5 10

Dimension A* 20 35 45 58

Dimension B 22 23 35 43

Dimension C 10 11 14 14

Figure 2Top View

* Overall height includes enoughclearance to facilitate condenserremoval.

NoteThe still is not designed to sup-port the service piping. Ensurethat the service piping is ade-quately supported. If no controlvalves were purchased with thestill, a shutoff valve and throt-tling valve should be installed inthe cooling water supply line,just before the still.


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NotesCW-1: Cooling water inlet connection 1, 2 and GPHstills (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 on elec-trically 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 terminalboard in the low water cutoff control cabinet asshown in Figure 9 and in accordance with the fol-lowing instructions:

1. Remove the low water cutoff cabinet frontpanel. To remove the panel, remove thetwo lower screws in the front of the cabi-net and press firmly down at the bottomcenter of the panel to free the panel fromthe cabinet. 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 AWG strand-ed wire. Connect the outer shield wire ofthe probe to terminal #1 and the centerwire of the probe to terminal #2. Solderand tape the connections. At the evapora-tor both wires should protrude through thegrommet in the probe shield which issecured in place with 2 screws over thecutoff access hole in the evaporator cas-ing.

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

4. Connect a 3-wire, 115-VAC, 60-hertz elec-trical service to terminals 9 (AC high), 7(AC low), and the ground screw just belowthe terminal board. This electrical servicewill provide control voltage for the low

INSTALLATION


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water cutoff controls and the contactorcoil (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 ser-vice requirements will be indicated onthe nameplate decal at the base of thestill evaporator.

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 accord-ing to 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 flammable liq-uid. “Caution: Hot Surface. AvoidContact.”

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 inthe evaporator is above theheating elements before turningon the still. The heaters are theimmersion type and will burn outif operated in air. The water levelshould be safe when waterissues steadily from the decon-centrator 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 maintaina minimum concentration of dissolved impuritiesin the evaporator, thus reducing scale formationand tendency to foam to a minimum. The decon-centrator 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 at ap-proximately 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 itis never 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 at tem-peratures 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 an in-creased 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,if not 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 inthe evaporator is above theheating elements before turningon the still. The heaters are theimmersion type and will burn outif operated in air. The water levelshould be safe when waterissues steadily from the decon-centrator 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 equip-ment.

Condenser

Vent

Distillate

Tube Cooling Water

Throttling Valve

Cooling Water

Inlet Valve

Deconcentrator

Valve

Drain Valve

Electrical Terminal

Connection Box


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Cleaning MethodsCleaning requirements fall into two classes, scaleremoval and biological cleaning. Scale removalmay be accomplished chemically or mechanical-ly. 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 re-moved with a stiff bristle brush. After cleaning, allscale particles 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 notallow the acid to remain in contact with the partfor more than 20 minutes. Flush the part thor-oughly after using the acid cleaner. A 5% SodiumBicarbonate solution may be used to remove anyacid left 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 reducedby controlling the quality of the feedwater by rout-ing it through a mixed bed deionizer. It is best re-moved with a blunt instrument.

Maintenance and Servicing

NoteIf desired, 10% solutions of sul-famic 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 the cool-ing 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:

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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1. Shut off and drain the still.

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 as re-quired. 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 and pre-heater (if supplied) may be removedas a unit and the interior of the evapo-rator will be visible. Inspect the interiorof the evaporator for scale. Removeas much scale as possible manually.

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 ScaleRemoval.” Silica scale may be re-moved as described under “SilicaScale Removal.” To remove hardscale or organic scale, fill the evapora-tor with concentrated acid (see “HardScale Removal”) or detergent solution(see “Organic Scale and Sludge Re-moval”) or detergent solution (see“Organic Scale and Sludge Removal”)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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7. Inspect the constant level device anddrain line. Clean as required.

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 andremove it from the upper gauge glasscock.

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 a decon-centrator and an extra high evaporator to permitoperating a still from hard water supplies. Thedeconcentrator automatically maintains a mini-mum concentration of dissolved impurities in theevaporator, thus reducing to a minimum the scaleformation and tendency to foam.

Theory of Operation

Figure 5

AtmosphericVent

InclinedCondenser

Cooling Water/Feedwater

InletQ Baffle

Double Walled Evaporator

Immersion Heaters(For Electric Stills)

Drain Valve

Constant LevelDevice

DeconcentratorValve

Preheated Feedwater

Distillate Outlet


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This section contains troubleshooting, testingand repair instructions. A troubleshooting chart isincluded to help the repair specialist find the diffi-culty quickly.

Tests for Condenser LeaksVisual 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 possi-ble that there is a leak from the coolingwater side to the distillate side. If this isthe case, the condenser must be re-placed.

Pressure Test. If a more positive test is re-quired, 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 stop-per.

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


23

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 the coolingwater 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 condenser thor-oughly 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,gas will be released in consider-able amounts. Do not use theacid cleaning solution on thetinned (Distilled Water) side ofthe condenser.


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Heating Element Test andReplacementWhenever 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 heating ele-ment terminals. Tag the leads to facilitatereassembly.

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 the boilerbottom and the other to each terminal(one at a time). If the heating element isshort circuited, the test light will light.Mark all damaged heating elements.

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

TROUBLESHOOTING

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


25

replaced.

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 enoughto hold the heater in place. This willallow you to rotate the heater wheninstalling the 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


26

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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)HPG01(300X6101A 92070 0612 P 21

Figure 6 Heating Element Replacement

TROUBLESHOOTING

NoteHeater replacement datastamped inside still junction boxcover.

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.

Bottom of

Evaporator

O-Ring (P/N 06289)

Retaining Nut

(P/N 10246)Heating Element

Socket head screw

1/4-20 x 3/8”

P/N 10248 Round head screw,

brass 8-32 x 3/8”

(P/N 10194)


27

Troubleshooting ChartmotpmyS esuaCelbaborP ydemeRdnatseT

.ytirupniporD

.llitsytriD

.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


28

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


29

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

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

NoteFor more details on heating ele-ments, refer to “HeatingElement Replacement.”


30

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


31

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 load cur-rent 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

:

SeeFigure A


32


33

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).

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 --- ---

Figure 10Electric Still Mounted on a Floorstand

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

PARTS LIST

Floorstand FloorstandPretreated

Water Inlet

Automatic

Feedwater Shut-Off

Valve

Float Feeder


34

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

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

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

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 Shutoff Valve

PARTS LIST

.oNledoM desUerehW

0192G slortnoccitamotuayllufhtiwylnO

.oNledoM egatloV desUerehW

0012G zh06,V021,HPG2dna1

llitsesahp1

1012G zh06,V021 llitsesahp3,HPG2

0112G zh06,V021 llitsesahp3dna1,HPG5



Floorstand

Float Feeder

Automatic

Feedwater Shut-oof

Valve

Pretreated

Water Inlet

Water Drain

Distillate

Outlet

Automatic

Controls

Cooling Water Inlet

Floorstand Water Drain


35

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

Enclosed in this package: Wall Bracket

Puramatic Diverter forClassic StillsDivert substandard distilled water todrain. All of the piping is constructed ofinert pure 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 plastictubes (TU495X64), used to protect thepiping on the Puramatic Diverter frombeing scratched); 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).

.oNledoM rewoP

0333G zH06/05-CAV511


0523G llitSHPG1roftekcarBllaW




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


3636

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-forming im-purities and activated carbon to remove chlo-rine and volatile organic impurities. The capacityof 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

PARTS LIST

Distillate

Outlet

Pretreat Inlet

Water Drain

Cooling Inlet

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


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 ProceduresPlease refer to the Specification Plate for the complete model number, serial number, andseries number when requesting service, replacement parts or in any correspondence con-cerning this unit.

All parts listed herein may be ordered from the Barnstead International 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 at 563-556-2241 or 800-553-0039.

Prior to returning any materials to Barnstead International, please contact our CustomerService Department for a “Return Goods Authorization” number (RGA). Material Returnedwithout an RGA number will be returned.


4040

One Year Limited Warranty

Barnstead International (“BARNSTEAD”) warrants that if a product manufactured by Barnstead shall be free ofdefects in materials and workmanship for one (1) year from the first to occur of (i) the date the product is sold byBARNSTEAD or (ii) the date the product is purchased by the original retail customer (the “CommencementDate”). Except as expressly stated above, BARNSTEAD MAKES NO OTHER WARRANTY, EXPRESSED ORIMPLIED, WITH RESPECT TO THE PRODUCTS AND EXPRESSLY DISCLAIMS ANY AND ALL WARRANTIES,INCLUDING BUT NOT LIMITED TO, WARRANTIES OF DESIGN, MERCHANT ABILITY AND FITNESS FOR APARTICULAR PURPOSE.

An authorized representative of BARNSTEAD must perform all warranty inspections. In the event of a defectcovered by BARNSTEAD’s warranty, BARNSTEAD shall, as its sole obligation and exclusive remedy, provide freereplacement parts to remedy the defective product. In addition, for products sold by BARNSTEAD within the con-tinental United States or Canada, BARNSTEAD shall provide provide free labor to repair the products with thereplacement parts, but only for a period of ninety (90) days from the Commencement Date.

BARNSTEAD’s warranty provided hereunder shall be null and void and without further force or effect if there isany (i) repair made to the product by a party other than BARNSTEAD or its duly authorized service representa-tive, (ii) misuse (including use inconsistent with written operating instructions for the product), mishandling, conta-mination, overheating, modification or alteration of the product by any customer or third party or (iii) use ofreplacement parts that are obtained from a party who is not an authorized dealer of BARNSTEAD.

Heating elements, because of their susceptibility to overheating and contamination, must be returned to theBARNSTEAD factory and if, upon inspection, it is concluded that failure is due to factors other than excessivehigh temperature or contamination, BARNSTEAD will provide warranty replacement. As a condition to the returnof any product, or any constituent part thereof, to BARNSTEAD’s factory, it shall be sent prepaid and a prior writ-ten authorization from BARNSTEAD assigning a Return Goods Number to the product or part shall be obtained.

IN NO EVENT SHALL BARNSTEAD BE LIABLE TO ANY PARTY FOR ANY DIRECT, INDIRECT, SPECIAL, INCI-DENTAL, OR CONSEQUENTIAL DAMAGES, OR FOR ANY DAMAGES RESULTING FROM LOSS OF USE ORPROFITS, ANTICIPATED OR OTHERWISE, ARISING OUT OF OR IN CONNECTION WITH THE SALE, USEOR PERFORMANCE OF ANY PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, TORT(INCLUDING NEGLIGENCE), ANY THEORY OF STRICT LIABILITY OR REGULATORY ACTION.

The name of the authorized Barnstead International dealer nearest you may be obtained by calling 1-800-446-6060 (563-556-2241) or writing to:

2555 Kerper BoulevardP.O. Box 797Dubuque, Iowa 52001-0797Phone: 563-5-2241 or 800-553-0039Fax: 563-589-0516E-mail: [email protected]


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