Thermo Scientific 495 Series User manual

1
Classic
Electrically Heated Stills
OPERAT ON MANUAL
AND PARTS L ST
SER ES 495
Mo el Numbers
A1011 A1015
A1013 A1016
60004B • 5/23/07

2
Safety nformation ..............................................................................................................................................3
Alert Signals ......................................................................................................................................................3
Warnings ..........................................................................................................................................................3
ntroduction..........................................................................................................................................................5
Evaporator ........................................................................................................................................................5
Condenser ........................................................................................................................................................5
Features Provided ............................................................................................................................................6
Electric Heat......................................................................................................................................................6
Low Water Cut-Off ............................................................................................................................................6
Still Heat Control ..............................................................................................................................................7
Unpacking ..........................................................................................................................................................8
nstallation ..........................................................................................................................................................9
Siting ................................................................................................................................................................9
Accessories ......................................................................................................................................................9
Plumbing Connections ......................................................................................................................................9
Electrical Connections ....................................................................................................................................11
Operation ..........................................................................................................................................................12
nitial Startup ..................................................................................................................................................12
nitial Operation ..............................................................................................................................................12
Deconcentrator Adjustment ............................................................................................................................13
Normal Operation............................................................................................................................................14
Maintenance and Servicing ..............................................................................................................................16
Cleaning Methods ..........................................................................................................................................16
Disassembly for Cleaning ..............................................................................................................................19
Theory of Operation ..........................................................................................................................................20
Troubleshooting ................................................................................................................................................21
Tests for Condenser Leaks ............................................................................................................................21
Condenser Test for Scale. ..............................................................................................................................22
Heating Element Test and Replacement ........................................................................................................23
Heating Elements............................................................................................................................................25
Troubleshooting Chart ......................................................................................................................................26
Parts List ..........................................................................................................................................................27
Accessories for Electric Stills ............................................................................................................................36
Ordering Procedures ........................................................................................................................................38
Warranty ............................................................................................................................................................40
Table of Contents

3
This manual contains important operating and safety
information. The user must carefully read and under-
stand 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
taken when installing, operating or servicing Barnstead
products. The specific safety notes pertinent to the
Thermo Scientific Barnstead Electrically Heated Stills are
listed in safety information section.
Your Barnstead Electrically Heated Still has been de-
signed with function, reliability, and safety in mind. t is
the userʼs responsibility to install it in conformance with
local electrical codes. For safe operation, please pay
attention to the alert signals throughout the manual.
Warnings
To avoi electrical shock, 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 shock hazard.
2. Do not connect unit to electrical service until
instructed to do so.
3. Disconnect from the power supply prior to
maintenance and servicing.
To avoi personal injury:
1. Do not use in the presence of flammable or
combustible materials; fire or explosion may
result. This device contains components
which may ignite such materials.
2. Use this device with water feed only. Sanitiz-
ing/cleaning agents must be used in compli-
ance with the instructions in this manual.
Failure to comply with the above could result
in explosion and personal injury.
Safety nformation
Alert Signals
Warning
Warnings alert you to a possibili-
ty of personal injury.
Caution
Cautions alert you to a possibili-
ty of damage to the equipment.
Note
Notes alert you to pertinent
facts and conditions.

4
3. Avoid splashing disinfecting solutions on cloth-
ing or skin.
4. Ensure all piping connections are tight to avoid
leakage of chemicals.
5. Always depressurize chemical lines before dis-
assembly.
6. Ensure adequate ventilation.
7. Follow carefully the manufacturersʼ safety in-
structions on labels of chemical containers and
Material Safety Data Sheets (M.S.D.S.).
8. “Caution: Hot Surface. Avoid Contact.”
9. Refer servicing to qualified personnel.
SAFETY INFORMATION

5
ntroduction
Thermo Scientific Barnstead electrically heated water
stills are available in four sizes; 1, 2, 5 and 10 gallons
per hour of distilled water. The distilled water produced
by the stills contains not more than 1.0 ppm total solids,
with a pH value of 5.4 to 7.2 and an electrical resistance
of not less than 300,000 ohms at 25°C when the stills
are operated on most potable water. The stills are de-
signed to use not more than 9 gallons of cooling water
and feedwater combined, for each gallon of distilled
water produced. The still consists of: an evaporator with
its heat supply, a condenser, and devices to control the
water level and salt concentration in the evaporator, a Q
baffle for pyrogen removal and a low water cutoff control.
The operating characteristics for each size still are
shown in the nstallation Diagram.
Evaporator
Still evaporators are the vertical, cylindrical double-wall
type with air-insulating space. The evaporators are built
sufficiently high and wide to provide ample vapor disen-
gaging space and operation at low velocity.
The evaporator shell is of polished stainless steel. The
inner shell (boiler) is fabricated of copper, brass and
bronze. The evaporator cover is brass, finished in pol-
ished nickel and is provided with a Q baffle. All surfaces
that contact the vapor and distillate are coated with pure
tin to prevent metallic contamination. A water level sight
glass is provided on all 5 and 10 gph stills.
Condenser
Still condensers are the horizontal type, slightly inclined
and atmospherically vented for final elimination of
volatiles. The condensers are fabricated of copper and
brass and are finished in polished nickel. All surfaces
that contact the vapor and distillate are coated with pure
tin to prevent metallic contamination. A distillate de-
livery tube of block tin is provided to connect the distillate
outlet of the condenser to a storage tank or other suit-
able container.

6
Features Provided
All stills are equipped with a deconcentrator to continu-
ously deconcentrate impurities from the evaporator and
retard scale formation. A constant level device with hot
well arrangement is provided for evaporator water level
control and for primary elimination of volatile impurities.
All stills are equipped with a drain valve. Cooling water
discharge piping is provided between the cooling water
outlet of the condenser and the constant level device.
Self-resetting solid state low water cutoff controls pre-
vent the heating elements from burning out in a low
water situation.
Electric Heat
Electrically powered, immersion type heaters are used to
give complete heat transfer and maximum heating effi-
ciency.
Low Water Cut-Off
Electric current to the still heating elements is controlled
by an ON/OFF switch and a self-resetting low water cut-
off. The solid state low water cutoff is designed to pre-
vent damage caused by low water conditions in the still
evaporator.
When the water level is at a safe level in the still evapo-
rator (the water level is above the immersion type
heaters and makes contact with the probe), the circuit
across probe terminals 1 and 2 at the terminal board
(TB1) is completed. The completion of this circuit, after a
two-second delay to prevent contactor chatter, will start
the contactor to energize the contactor coil to connect
the heater service to the still. Opening of the probe cir-
cuit (water no longer makes contact with the probe) will
stop the contactor without delay.
The Barnstead solid state low water cutoff is designed to
prevent damage caused by low water conditions in the
evaporator of Barnstead electrically heated water stills.
The low water cutoff consists of the Barnstead Solid
State Low Water Control, a probe assembly for installa-
tion on Barnstead stills, and still heat control (contactor).
Figure 1
Electrically Heated Still
INTRODUCTION
Note
Heater life may be reduced when oper-
ated above maximum stated voltage.
Operation of still at a voltage less than
the stated voltages will cause a drop in
still output. Electrically heated stills
wired for 240 volts AC, 2 or 3 wire, will
operate on 208 volts, 2 or 3 wire
respectively with resultant 25 percent
drop in distillate capacity. Special
heaters for 208 volts are needed to
obtain rated still output. The electric
heaters will burn out if operated in air.
To eliminate the possibility of heating
element burnout, a solid state low
water cutoff control is provided.
Condenser
Distillate
Outlet
Cooling Water/
Feedwater
nlet Tube
Constant Level
Device
Preheated
Feedwater Tube
Q-Baffle
Deconcentrator
Valve
Evaporator

7
Still Heat Control
The heat control consists of a cabinetized contactor
designed for wall mounting. The contactor cabinet has a
removable cover and knockouts for conduit connections.
The contactor is provided to control the heat supply to the
still heating elements, as determined by the low water cut-
off controller. The contactor coil operates from a 115 VAC,
50/60 hertz, single phase electrical service and derives its
control voltage at terminals 6 and 11 at the terminal board
in the low water cutoff control cabinet. See Figure 8 for
information on the contactor size required for a given size
still and the available heating service. Unpack the still
carefully so as not to damage any of the parts. Ensure that
all parts are removed from the container before discarding
the packing materials.
INTRODUCTION

8
Unpacking
Unpack the still carefully so as not to damage any of the
parts. Ensure that all parts are removed from the container
befoer discarding the packing materials.

9
Siting
Move the still evaporator to the operating location and
install the evaporator so that it is level and plumb.
Accessories
All operating and convenience accessories purchased with
the still should be installed after the still has been assem-
bled on its mounting and before connecting the service
lines to the still.
Plumbing Connections
Ensure that all fittings are tight in the still and still accesso-
ry piping and connect the water and waste service to the
still as shown in the installation diagram.
nstallation
Figure 2
Top View
* Overall height includes enough
clearance to facilitate condenser
removal.
Note
The still is not designed to support the
service piping. Ensure that the service
piping is adequately supported. f no
control valves were purchased with
the still, a shutoff valve and throttling
valve should be installed in the cooling
water supply line, just before the still.
Bench Dimensions in nches
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

10
ledoM
rebmuN
llitS
yticapaC WK
taspmA
V021
eriW2
esahP1
taspmA
V042/V021
eriW3
esahP1
taspmA
V8o2/021
eriW4
esahP3
taspmA
V042
eriW3
esahP3
taspmA
V084
eriW3
esahP3
1101A HPG1 6.2 32 21 AN AN AN
3101A HPG2 6 AN 62 71 AN AN
5101A HPG5 31 AN 75 63 33 AN
6101A HPG01 62 AN AN 37 66 33
Electric Heat Requirements
gnilooC
retaW
tnemeriuqeR
rh/L03
HPG8
rh/L16
HPG61
rh/L151
HPG04
rh/L303
HPG08
retaWtelnI
erusserP
isp09-04
3.6-8.2
mc/gk
2
isp09-04
3.6-8.2
mc/gk
2
isp09-04
3.6-8.2
mc/gk
2
isp09-04
3.6-8.2
mc/gk
2
Cooling Water and Inlet Pressure Requirement
Still
Capacity 1 GPH 2 GPH 5 GPH 10 GPH
sehcnIniseziSeniLecivreS
)HPG(yticapaCllitS12501
ylppuSretaWgnilooC-WC4/14/14/18/3
etsaW-AW2/12/14/34/3
gnittifretawdeeftnemtaerterP
)ylnosllitstnemtaerterprof( 8/38/38/38/3
Notes
CW-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 on elec-
trically heated stills.
DO: Distillate outlet.
WA: Waste line must be atmospherically vented and
gravity flow.
Figure 3
Front View
INSTALLATION