Thermo Scientific 2112 Series User manual

Fully Automatic Controls for
Thermo Scientific Barnstead
Electrically Heated Classic Stills
Series 2112
Operating Manual and Parts List LT2112X6 Rev. 1
_________________________________________________________________________________
Part of Thermo Fisher Scientific

Thermo Scientific
MANUAL NUMBER LT2112X6 (7002100)
1 147769/SI-10360 9/7/10 Updates - pgs ccs
0 -- 7/7/10 Transfer to Marietta (was LT2112X6 3/18/10) ccs
REV ECR/ECN DATE DESCRIPTION By
Preface
Fully Automatic Controls i
Models covered in this manual
Model Number Size
G2100 (315958) 1 & 2 gallon/hour 1 phase
G2101 (315959) 2 gallon/hour, 3 phase
G2110 (316960) 5 gallon/hour, 1 & 3 phase
G2125 (315961) 10 gallon/hour, 3 phase

Thermo Scientificii Fully Automatic Controls
Preface
Important Read his ins ruc ion manual. Failure o read, unders and and follow he ins ruc ions in his manual
may resul in damage o he uni , injury o opera ing personnel, and poor equipmen performance. 
Caution All in ernal adjus men s and main enance mus be performed by qualified service personnel. 
Ma erial in his manual is for informa ion purposes only. The con en s and he produc i describes are subjec o
change wi hou no ice. Thermo Fisher Scien ific makes no represen a ions or warran ies wi h respec o his
manual. In no even shall Thermo be held liable for any damages, direc or inciden al, arising ou of or rela ed o
he use of his manual.
©2010 Thermo Fisher Scien ific. All righ s reserved.

Thermo Scientific Fully Automatic Controls iii
Preface
Important operating and/or maintenan e instru tions. Read the a ompanying text arefully.
Potential ele tri al hazards. Only qualified persons should perform pro edures asso iated with this
symbol.
Equipment being maintained or servi ed must be turned off and lo ked off to prevent possible injury.
Hot surfa e(s) present whi h may ause burns to unprote ted skin, or to materials whi h may be
damaged by elevated temperatures.
Marking of ele tri al and ele troni equipment, whi h applies to ele tri al and ele troni equipment
falling under the Dire tive 2002/96/EC (WEEE) and the equipment that has been put on the market
after 13 August 2005.
This produ t is required to omply with the European Union’s Waste Ele tri al & Ele troni
Equipment (WEEE) Dire tive 2002/96/EC. It is marked with the WEEE symbol. Thermo Fisher
S ientifi has ontra ted with one or more re y ling/disposal ompanies in ea h EU Member State
European Country, and this produ t should be disposed of or re y led through them. Further
information on Thermo’s omplian e with this dire tive, the re y lers in your ountry and
information on Thermo produ ts will be available at www.thermofisher. om.
Always use the proper prote tive equipment ( lothing, gloves, goggles, et .)
Always dissipate extreme old or heat and wear prote tive lothing.
Always follow good hygiene pra ti es.
Ea h individual is responsible for his or her own safety.

Thermo Scientificiv Fully Automatic Controls
Preface
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Fully Automatic Controls vThermo Scientific
Table of Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Automatic D ain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Automatic Wate Shut-off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Level Monito . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Unpacking and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Facto y Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Siting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Field Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Initial Ope ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Level Monito . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Automatic D ain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Automatic Wate Shut-off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
No mal Ope ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Section 1
Section 2
Section 3
Section 4

vi Fully Automatic Controls Thermo Scientific
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Solenoid Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Solenoid Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Solenoid Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Automatic Water and Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Valve Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Level Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Timer Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Interval Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Low Water Cut-off Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Probe Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Water Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Ordering Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Wiring Diagrams/Sc ematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Table of Contents
Section 5
Section 6
Section 7

Fully Automatic Controls 1-1Thermo Scientific
Section 1 Safety Information
This manual contains important operating and safety information. The
user must carefully read and understand the contents of this manual prior
to the use of this equipment.
Water purification technology employs one or more of the following:
chemicals, electrical devices, mercury vapor lamps, steam and heated
vessels. Care should be ta en when installing, operating or servicing
Thermo Scientific products. The specific safety notes pertinent to the
Electrically Heated Stills Automatic Controls follow.
Your Thermo Scientific Barnstead Electrically Heated Stills Controls has
been designed with function, reliability, and safety in mind. It is the user’s
responsibility to install it in conformance with local electrical codes. For
safe operation, pay attention to Notes, Cautions, and Warnings
throughout the manual.
Warnings
To avoid electrical shoc , always:
1. Ensure that the equipment is connected to electrical service according
to local and national standards. Failure to properly connect may create
a fire or shoc hazard.
2. Replace fuses only with the same type and rating of fuse for continued
protection against electric shoc .
3. Do not mount Electrically Heated Still Controls directly over
equipment that requires electrical service. Routine maintenance of this
unit may involve water spillage and subsequent electrical shoc hazard
if improperly located.
4. Disconnect from the power supply prior to maintenance and servicing.

1-2 Fully Automatic Controls Thermo Scientific
Section 1
Safety Information
To avoid personal injury:
1. Avoid splashing disinfecting solutions on clothing or skin.
2. Ensure all piping connections are tight to avoid leakage of chemicals.
3. Use this device with water feed only. Sanitizing/cleaning agents must
be used in compliance with the instructions in this manual. Failure to
comply could result in explosion and personal in ury.
4. Always depressurize chemical lines before disassembly.
5. Wear eye and hand protection when using acid for cleaning, as
spattering may occur.
6. Ensure adequate ventilation.
7. Follow carefully the manufacturers' safety instructions on labels of
chemical containers and Material Safety Data Sheets (M.S.D.S.).
8. Refer servicing to qualified personnel.

Fully Automatic Controls 2-1Thermo Scientific
Section 2 Introduction
This publication comprises installation, operation, maintenance, and parts
lists with appropriate illustrations for Barnstead Automatic Start, Stop, and
Drain Controls for Barnstead Electrically Heated Stills. The automatic
controls start the still when the stored distilled water drops to a
predetermined level, shut off the still when the stored distilled water
returns to the full level, drain the still periodically, shut off the current to
the heatin elements when the water in the still drops to an unsafe
operatin level, and turn on the current to the heatin elements when the
water returns to a safe operatin level. The controls are desi ned to be used
with 1, 2, 5, and 10 allon-per-hour stills (Electrically Heated Stills
Catalo No. A1011, A1013, A1015 and A1016, respectively). The
automatic controls (see Fi ure 2-1) consist of: an automatic water shut-off
valve, an automatic drain valve, a level monitor, a probe assembly for
installation in the still evaporator and associated pipin and wirin .
This solenoid valve is located in the water inlet pipin as shown in Fi ure
1 and is wired to the low water cutoff control cabinet. The valve
automatically controls the water supply to the still in response to the level
monitor and the interval drain timer.
The 1, 2, and 5 ph stills use 1/4-inch valves, and the 10 ph stills use
1/2-inch valves. These valves are packless, two-way, normally closed,
solenoid valves that open when their solenoids are ener ized and close
when they are de-ener ized. The valves have brass bodies and resilient
seats.
In addition to the automatic shut-off valve, the water inlet pipin is
provided with a strainer, a manual throttlin valve, and a pressure au e.
This solenoid valve is located in the drain pipin as shown in Fi ure 2-1
and is wired to the low water cutoff control cabinet. The valve
automatically drains the still in response to the interval drain timer.
The 1, 2, and 5 ph stills use 1/2-inch valves, and the 10 ph stills use
3/4-inch valves. These valves are packless, two-way, normally open,
solenoid valves that close when their solenoids are ener ized and open
when they are deener ized. The valves have brass bodies and resilient seats.
In addition to the automatic drain valve, the drain pipin is provided with
a manual shut-off valve.
Automatic Water
Shut-off Valve
Automatic Drain
Valve

2-2 Fully Automatic Controls Thermo Scientific
Section 2
Introduction
The level monitor is mounted on the distilled water storage tank and is
wired to the control cabinet. This device monitors the level of distilled
water and turns the still off when the storage tank is full, and on when the
water level drops.
The level monitor consists of a dustproof switch that is actuated by a
stainless steel diaphragm to make or break the circuit to the interval drain
timer, and thus to the automatic water drain valves. All adjustments are
made externally (see MAINTENANCE section).
Level Monitor
Automatic
Controls
Still Cat.
No. Still Capacity
Heating
Service
Phase
Contractor
SI English
G2100 A1011 3.79 l/hr 1 gph 1 27 amp, 2 pole
A1013 7.57 l/hr 2 gph 1 27 amp, 2 pole
G2101 A1013 7.57 l/hr 2 gph 3 27 amp, 2 pole
G2110 A1015 18.9 l/hr 5 gph 1 or 3 60 amp, 3 pole
G2125 A1016 37.9 l/hr 10 gph 3 100 amp, 3 pole

Fully Automatic Controls 2-3Thermo Scientific
Section 2
Introduction
Level Monitor
Figure 2-1. Automatic Controls
Note Automatic controls include equipment shown solid. 

Fully Automatic Controls 3-1Thermo Scientific
Section 3 Unpacking and Installation
Unpack th automatic controls car fully so that non of th parts will b
damag d. Ensur that all parts ar r mov d from th contain rs b for
discarding th packing mat rial.
Th locations of th automatic wat r and drain valv s ar d t rmin d by
th location of th still, and th location of th l v l monitor is d t rmin d
by th location of th distill d wat r storag tank. Th l ngth of wir runs
r quir d should b a main consid ration wh n conn cting th l ctrical
s rvic and th automatic controls. Mak sur that ad quat room is
provid d for op ration of th control switch and r plac m nt of th fus .
Also, room should b provid d for th l ctrical conduits that nt r th
low wat r cutoff cabin t.
Th automatic controls can b install d at th factory or at th custom r's
facility.
Wh n th still and storag tank hav b n ord r d from th factory with
automatic controls, mak th n c ssary plumbing and l ctrical
conn ctions as follows:
1. Th l v l monitor may b install d on an xisting distill d wat r
storag tank or a n w tank from th factory as follows:
a. Install a 3/8-inch NPT tin-lin d spud 610 mm (24 inch s) from
th top of th tank as shown in Figur 3-1. If th spud cannot b
locat d 610 mm (24 inch s) from th top of th tank b caus th
tank is too shallow, or for som oth r r ason, locat th spud as
clos to 610 mm (24 inch s) as possibl .
b. Install th U-tub ass mbly in th spud and th l v l monitor in
th U-Tub using T flon® ribbon tap on th pip conn ctions.
T flon tap may b purchas d by calling T chnical S rvic s and
sp cifying Part No. 06078.
c. Adjust th l v l monitor as d scrib d in th MAINTENANCE
s ction of this manual.
Siting
Assembly
Factory Installation

2. Connec he wa er inle piping and he drain piping o he service
lines. The loca ion of hese connec ions is shown in Figure 2-1, and he
sizes of he connec ions are lis ed in Table 3-1:
3. Make he elec rical connec ions o he erminal board in he low wa er
cu off con rol cabine as shown in he Wiring Diagram a he end of
his manual and in accordance wi h he following ins ruc ions:
a. Remove he low wa er cu off cabine fron panel. To remove he
panel, remove he wo lower screws in he fron of he cabine , and
press firmly down a he bo om cen er of he panel o free he
panel from he cabine .
3-2 Fully Automatic Controls Thermo Scientific
Section 3
Unpacking and Installation
Figure 3-1. Level Monitor Installation
Still Cat. No. Still Capacity Water Inlet NPT Drain NPT
SI English
A1011 3.79 l/hr 1 gph 1/4 1/2
A1013 7.57 l/hr 2 gph 1/4 1/2
A1015 18.9 l/hr 5 gph 1/4 3/4
A1016 37.9 l/hr 10 gph 3/8 3/4
Table 3-1. Connections Sizes

Caution The panel fits tightly in the cabinet - o not attempt to pry the
panel from the cabinet. 
b. Connect the solenoi s of the automatic water shut-off valve an
the automatic rain valve to terminals 5 an 12.
c. Remove the jumper between terminals 8 an 10, an connect the
level monitor to these two terminals.
. Connect the low water cutoff probe wires to terminals 1 an 2
with #18 AWG stran e wire (observe lea number on probe an
attach to correspon ing number on terminal). Connect the outer
shiel wire of the probe to terminal #1 an the center wire of the
probe to terminal #2. Sol er an tape the connections. At the
evaporator, both wires shoul protru e through the grommet in
the probe shiel which clips in place over the cutoff access hole in
the evaporator casing.
Note Ensure that the service lines are supporte in epen ently an not by
the still piping.
Install a manual shut-off valve in the water supply line. 
Ensure that the waste line to which the rain is connecte is
atmospherically vente an gravity flow. 
5. Connect the still heat control contactor coil to terminals 6 an 11.
6. Connect a 3-wire, 120VAC, 60-Hz electrical service to terminals 9
(AC high), 7 (AC low), an the groun screw just below the terminal
boar . This electrical service will provi e control voltage for the low
water cutoff controls an the contactor coil (see Wiring Diagram at the
en of this manual). (120V only, not for use on 208V or 240V.)
7. Connect the heater electrical service to the contactor (see Wiring
Diagram at the en of this manual). See the still wiring iagram when
connecting the still heating elements to the contactor the heater
electrical service requirements will be in icate on the nameplate ecal
at the base of the still evaporator.
8. Install the front panel on the low water cutoff cabinet an install the
cover on the contactor cabinet.
Fully Automatic Controls 3-3Thermo Scientific
Section 3
Unpacking and Installation

Warning All installation described below should be done by a qualified
electrician. 
The still is installed at the custo er's facility. The auto atic controls and
accessory piping are installed on the still at the custo er's facility as
follows:
1. Shut off the water and electrical service. Drain the still and storage
tank.
2. Disconnect the still heating ele ents fro the electrical service.
3. Disconnect all service piping fro the still.
4. Replace the drain valve at the constant level device with the plug
provided.
5. Re ove the low water cutoff cabinet front panel. To re ove the panel
re ove the two lower screws in the front of the cabinet, and press
fir ly down at the botto center of the panel to free the panel fro
the cabinet. The panel fits tightly in the cabinet - do not atte pt to
pry the panel fro the cabinet.
6. Install the level
onitor on the
distilled water
storage tank in
accordance with
the instructions in
Step 1 of "Factory
Installation".
7. Install the water
inlet piping as
shown in Figure 3-
2. Note that unions
are provided to
facilitate asse bly.
3-4 Fully Automatic Controls Thermo Scientific
Section 3
Unpacking and Installation
Field Installation
Figure 3-2. Water Inlet Piping

8. I stall the drai pipi g as
show i Figure 3-3. Note
that u io s are provided i
the pipi g to facilitate
assembly.
9. Co ect the water i let
pipi g a d drai pipi g to
the service li es i
accorda ce with the
i structio s i Step 2 of
"Factory I stallatio ."
10. Make all electrical
co ectio s betwee the
still a d ta k co trol
devices a d the low water
cutoff co trols, betwee
the co tactor a d the low
water cutoff co trols, a d
betwee the heater
electrical service a d still
a d the co tactor i
accorda ce with the
i structio s i Step 3 of
"Factory I stallatio ."
11. Re-i stall the lower fro t pa el to the Low Water Cut-off Co trol.
Fully Automatic Controls 3-5Thermo Scientific
Section 3
Unpacking and Installation
Field Installation
(continued)
Figure 3-3. Drain Piping

Fully Automatic Controls 4-1Thermo Scientific
Section 4 Operation
Water flow to t e still is controlled by t e automatic. water s ut-off valve,
w ic is a solenoid valve t at is closed w en its coil is de-energized. W en
bot t e control switc contacts on t e low water cutoff cabinet and t e
mercury switc contacts in t e level monitor are closed, t e interval timer
relay closes, and t e coil of t e solenoid valve is energized. Energizing t e
coil opens t e valve and allows water to flow to t e still. W en eit er t e
control switc or t e level monitor switc contacts are opened or t e
interval timer relay opens, t e coil is de-energized and t e valve is closed
by spring action, s utting off t e water flow to t e still.
Draining of t e still is controlled by t e automatic drain valve, w ic is a
solenoid valve t at is open w en its coil is de-energized. T is coil is
connected in parallel wit t e coil of t e automatic water s ut-off valve so
t e automatic drain valve opens w en t e water valve closes. Hence, t e
still drains at t e same time t at t e water flow to t e still is s ut off.
As discussed above, water flows to t e still w en t e switc contacts R-B in
t e level monitor are closed, and it is s ut off w en t e switc contacts are
open. T e switc is actuated by t e movement of a diap ragm t at reacts
to t e varying pressure caused by t e c anging level of t e distillate in t e
storage tank. As t e level of t e distillate lowers, t e pressure on t e
diap ragm decreases until at a predetermined setting, t e switc contacts
close and start t e still. As t e tank fills, t e level rises increasing t e
pressure on t e diap ragm until at anot er predetermined (see LEVEL
MONITOR in t e MAINTENANCE section) setting t e switc opens
and s uts off t e still.
T e first time t e still is operated, or after cleaning, set t e low water
cutoff control "ON/OFF" switc to t e ON position, open t e manual
drain valve and operate t e still according to t e basic still operating
instruction. T e "ON/OFF" switc will remain lig ted as long as t e
"ON/OFF" switc is in t e ON position. T e "Still On" lamp will lig t
w en t e water in t e evaporator makes contact wit t e probe. T e still is
started and stopped wit t e "ON/OFF" switc .
Automatic Water
Shut-off Valve
Automatic Drain
Valve
Level Monitor
Initial Operation