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

11
Electrical Connections
Connect the electrical heating service to the still as shown in
Figure 14. The heating service terminal board is located
inside the junction box at the base of the still. Customer must
supply adequate on-off control for electrical heating service.
Make the electrical connection to the terminal board in the low
water cutoff control cabinet as shown in Figure 9 and in ac-
cordance with the following instructions:
1. Remove the low water cutoff cabinet front panel.
To remove the panel, remove the two lower screws
in the front of the cabinet and press firmly down at
the bottom center of the panel to free the panel
from the cabinet. The panel fits tightly in the
cabinet. Do not attempt to pry the panel from the
cabinet.
2. Connect the low water cutoff probe wires to termi-
nals 1 and 2 with #18 AWG stranded wire. Connect
the outer shield wire of the probe to terminal #1
and the center wire of the probe to terminal #2.
Solder and tape the connections. At the evaporator
both wires should protrude through the grommet in
the probe shield which is secured in place with 2
screws over the cutoff access hole in the evapora-
tor casing.
3. Connect the still heat control contactor coil to ter-
minals 6 and 11.
4. Connect a 3-wire, 115-VAC, 60-hertz electrical ser-
vice to terminals 9 (AC high), 7 (AC low), and the
ground screw just below the terminal board. This
electrical service will provide control voltage for the
low water cutoff controls and the contactor coil
(see See Figure 9).
5. Connect the heater electrical service to the contac-
tor (see Figure 9). See the still wiring diagram
when connecting the still heating elements to the
contactor - the heater electrical service require-
ments will be indicated on the nameplate decal at
the base of the still evaporator.
6. nstall the front panel on the low water cutoff cabi-
net and install the cover on the contactor cabinet.
INSTALLATION

12
nitial Startup
The first time that the still is started, or after cleaning, oper-
ate 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 valve about 1/2
turn.
5. When water begins to issue steadily from the
deconcentrator valve, turn on the still heat sup-
ply.
6. When the still begins to produce distilled water,
close the deconcentrator valve and adjust the
cooling water throttling valve until a puff of
steam issues from the condenser vent. Discard
the first two hours production of distillate to
allow the still to clean itself out.
7. Adjust the deconcentrator as described below.
nitial Operation
The first time the still is operated, or after cleaning, set the
low water cutoff control “ON/OFF” toggle switch to ON
position, open the manual drain valve and operate the still
according to the basic still operating instructions. The light-
ed switch will remain lit as long as the switch is in the ON
position. The “Still On” lamp will light when the water in the
evaporator makes contact with the probe. The still is start-
ed and stopped with the “ON/OFF” toggle switch.
Operation
Warning
A fire hazard may result if the still is
used with a flammable liquid. “Caution:
Hot Surface. Avoid Contact.”
Note
During the procedures listed below,
check all connections for leaks and
tighten as required.
Note
The cooling water inlet and throttling
valves are shown in dotted lines. f
these were not purchased with the
still, they must be installed in the cool-
ing water inlet line by the customer to
ensure proper operation.
Caution
Ensure that the water level in the evap-
orator is above the heating elements
before turning on the still. The heaters
are the immersion type and will burn
out if operated in air. The water level
should be safe when water issues
steadily from the deconcentrator valve.
Note
deally, the temperature of the steam
and gases escaping the vent should
be 70°C or higher. To measure the
vent temperature, use a thermocouple
probe, such as the Thermo Scientific
PM20700 Digital Pyrometer, inserted
into the vent.

13
Deconcentrator Adjustment
The function of the deconcentrator is to maintain a mini-
mum concentration of dissolved impurities in the evapora-
tor, thus reducing scale formation and tendency to foam to
a minimum. The deconcentrator is adjusted as follows:
1. Permanent Har Water or Softene Water
(Softene fee is not recommen e ). The
deconcentrator valve should be left open at all
times to bleed water from the evaporator at ap-
proximately 1-1/2 times the capacity of the still.
This valve should be left open permanently at
the required setting. Care should be exercised
to see that it is never clogged. The valve should
be inspected periodically and if required, disas-
sembled and cleaned with a brush or scraper.
2. Temporary Har Water. f the feedwater to the
evaporator is high in temporary hardness, i.e.,
high in bicarbonates, the deconcentrator valve
should be closed. The reason for this is that
bicarbonates in solution tend to precipitate out at
temperatures exceeding 150°F. With the decon-
centrator valve opened, a larger quantity of feed-
water passes through the evaporator, precipitat-
ing out bicarbonates, increasing the amount of
scale formed. Keeping the to 150° deconcentra-
tor closed will result in an increased concentra-
tion of solids in the evaporator as time goes on,
thus creating a tendency to foam. This condition
is corrected by draining the still through the drain
valve at frequent intervals.
3. Demineralize Water
When demineralized water is used as feedwater
the deconcentrator valve may be kept closed.
OPERATION

14
Normal Operation
Starting - Start the still as follows:
1. Close the drain valve.
2. Open the deconcentrator valve slightly, if not ad-
justed.
3. Open the cooling water inlet valve.
4. When water begins to issue steadily from the
deconcentrator valve, turn on the still heat sup-
ply.
As long as the low water cutoff control “ON/OFF” toggle
switch is in the ON position, the still will start and stop
automatically, depending on the stored distilled water distri-
bution requirements and 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 drain automatically.
5. f necessary, adjust the cooling water throttling
valve until a puff of steam issues from the con-
denser 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 still drain com-
pletely.
OPERATION
Caution
Ensure that the water level in the evap-
orator is above the heating elements
before turning on the still. The heaters
are the immersion type and will burn
out if operated in air. The water level
should be safe when water issues
steadily from the deconcentrator valve.
Note
deally, the temperature of the steam
and gases escaping the vent should
be 70°C or higher. To measure the
vent temperature, use a thermocouple
probe, such as the Thermo Scientific
PM20700 Digital Pyrometer, inserted
into the vent.
Note
Do not change the setting of the cool-
ing water throttling valve and decon-
centrator valve.

15
Figure 4
Operating Controls
OPERATION
Note
Valves shown in dotted lines must be
installed by customer. Available as
optional equipment.
Condenser
Vent
Distillate
Tube Cooling Water
Throttling Valve
Cooling Water
nlet Valve
Deconcentrator
Valve
Drain Valve
Electrical Terminal
Connection Box

16
Cleaning Methods
Cleaning requirements fall into two classes, scale re-
moval and biological cleaning. Scale removal may be
accomplished chemically or mechanically. Biological
cleaning is accomplished with an isopropyl alcohol
solution. For best results all solutions and water
should be heated. The various methods of cleaning
are described below:
Soft Scale Removal. Soft scale may be removed
with a stiff bristle brush. After cleaning, all scale parti-
cles should be flushed out with water.
Har Scale Removal. Hard scale may be removed
by using a 10% solution of inhibited HC . This acid
cleaner is available commercially or may be prepared
using 20 parts water and 6 parts 30% HC . When
using the acid, do not allow the acid to remain in con-
tact with the part for more than 20 minutes. Flush the
part thoroughly after using the acid cleaner. A 5% So-
dium Bicarbonate solution may be used to remove
any acid left on the part.
Organic Scale an Slu ge Removal. f the scale
has a dark brown or black color, it may be formed
from organic impurities present in the feedwater. This
type of scale may be removed with a strong detergent
solution. The detergent solution should be allowed to
be in contact with the scale or sludge for 24 hours.
Rinse off the parts with water after cleaning.
Silica Scale Removal. Silica scale is usually clear
and shiny and hard to detect visually. t is very hard
and cannot be removed with an acid solution. Silica
scale formation can be reduced by controlling the
quality of the feedwater by routing it through a mixed
bed deionizer. t is best removed with a blunt instru-
ment.
Biological Cleaning. Biological cleaning is used on
the parts that come in contact with the distillate (such
as, the distilled water side of the condenser, or the
distilled water transmission tubing) to remove any
Maintenance and Servicing
Note
f desired, 10% solutions of sulfamic
or acetic acids may be used instead
of the HC . Sulfamic and acetic acids
have an advantage over hydrochloric
acid in that they will not corrode the
metal parts being cleaned. Un er no
circumstances shoul any concen-
trate aci be allowe to come in
contact with tinne surfaces.
Warning
Always wear protective clothing and
eye shields when handling acid. Dis-
connect from the power supply prior to
maintenance and servicing. Refer ser-
vicing to qualified personnel.

17
biological contamination from the affected part. This may
be accomplished as follows:
1. mmerse the part in an isopropyl alcohol or a
mild detergent (not containing bleach) solution
overnight. Do not rinse the part with water after
cleaning. Drain parts before reassembly.
2. After the still is reassembled and has operated
for 30 minutes to flush, reduce the cooling water
flow rate with the cooling water throttling valve
until steam issues from the condenser vent at
least 12 inches. Operate the still in this manner
for 30-60 minutes. Ventilate the room during this
operation.
Disassembly for Cleaning
The frequency of cleaning will depend upon the purity of
the water being used. For example, the evaporator should
require infrequent cleaning if it is fed partially purified
water; however, the cooling water side of the condenser
will have to be cleaned at more frequent intervals due to
the fact that raw water is flowing through it and it will scale
up sooner. The still should be inspected at frequent inter-
vals until cleaning intervals are determined. Disassemble,
inspect, and clean the still as follows:
1. Shut off and drain the still.
2. Shut off the water supply to the still.
3. Remove the condenser from the still. nspect the
cooling water side of the condenser for scale
and clean as required. f required, clean the dis-
tilled water side of the condenser as described
under “Biological Cleaning.”
4. Disassemble until the interior of the evaporator
is visible. The evaporator cover, high purity
chamber and preheater (if supplied) may be re-
moved as a unit and the interior of the evapora-
tor will be visible. nspect the interior of the
evaporator for scale. Remove as much scale as
possible manually.
MAINTENANCE AND SERVICING
Warning
Avoid splashing the isopropyl alcohol
solution on open cuts.
Caution
Do not use chlorine bleach for biologi-
cal cleaning. The chlorine will interact
with and damage the tinned surfaces.
Note
Stills equipped with a high purity
chamber or preheater should not be
cleaned with acid unless the high puri-
ty chamber can be removed. The
fumes given off by the acid may dam-
age the tin coating used in these
accessories.

5. Disassemble the drain line and clean as
required. Ensure that the drain line is clear
(including the drain opening in the evaporator)
before using detergent or acid cleaners.
Reassemble the drain line.
6. Soft scale may be removed as
described under “Soft Scale Removal.” Silica
scale may be removed as described under
“Silica Scale Removal.” To remove hard scale
or organic scale, fill the evaporator with con-
centrated acid (see “Hard Scale Removal”) or
detergent solution (see “Organic Scale and
Sludge Removal”) or detergent solution (see
“Organic Scale and Sludge Removal”) as re-
quired.
7. nspect the constant level device and drain
line. Clean as required.
8. f the still is equipped with a gauge glass,
remove and clean the gauge glass cocks and
gauge glass:
a. Unscrew the nuts that hold the gauge glass
in place.
b. Lift the gauge glass up into the top gauge
glass cock about 1/2 inch.
c. After the bottom of the gauge glass is clear
of the bottom gauge glass cock, move it
away from the still and remove it from the
upper gauge glass cock.
d. Remove and clean the gauge glass cocks
and clean the gauge glass.
9. Reassemble the still. Assembly is essentially
the reverse of disassembly.
10. Connect the water, waste and distillate lines.
11. Start the still as described under “ nitial
Startup.”
12. Lower the cooling water flow rate (with the
cooling water throttling valve) until steam
18
Caution
Ventilate the room during this opera-
tion.
MAINTENANCE AND SERVICING

19
spouts out of the condenser vent at least 12
inches. Operate in this manner for 30-60 min-
utes to sterilize and clean out the still.
13. Adjust the still as described in “ nitial
Operation.”
MAINTENANCE AND SERVICING

20
The still consists primarily of a boiler or evaporator
which holds the water during the evaporation pro-
cess; electric heating elements of the immersion type
inserted in the evaporator to boil the water; and a
condenser which condenses the steam from the boil-
er to form the distillate.
The water to be purified enters the condenser where
it is heated by the steam passing through the evapo-
rator. The preheated water is fed to the evaporator as
required by the constant level device which maintains
the proper water level in the evaporator. An overflow
connected to the drain is provided for the excess
cooling water.
Water in the evaporator is vaporized by the electric
heating elements. The steam passes up through the
vapor pipe into the condenser where it is condensed
to distilled water. The condenser is vented to atmos-
phere to eliminate the gaseous impurities. All stills are
equipped with a deconcentrator and an extra high
evaporator to permit operating a still from hard water
supplies. The deconcentrator automatically maintains
a minimum concentration of dissolved impurities in
the evaporator, thus reducing to a minimum the scale
formation and tendency to foam.
Theory of Operation
Figure 5
Atmospheric
Vent
nclined
Condenser
Cooling Water/
Feedwater
nlet Q Baffle
Double Walled
Evaporator
mmersion Heaters
(For Electric Stills)
Drain Valve
Constant Level
Device
Deconcentrator
Valve
Preheated
Feedwater
Distillate
Outlet