Thermo Scientific MEGA-PURE 680 D440046 Series User manual

Barnstead MEGA-PURE®
Automatic Deionizer
OPERATION MANUAL
AND PARTS LIST
D440046 Series 680
Single Cartridge Deionizer (D1)
D440066 Series 681
Dual Cartridge Deionizer (D2)
Model # Voltage
D440046 120
D440066 120
927854 • 3/28/08 Serial Number__________________

IMPORTANT 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.
Safety Information ..............................................................................................................................................3
Alert Boxes..........................................................................................................................................................3
Warnings ............................................................................................................................................................3
Introduction..........................................................................................................................................................5
System Characteristics ................................................................................................................................5
Dimensions ..................................................................................................................................................5
Deionization Cartridge Data..........................................................................................................................5
Unpackaging ......................................................................................................................................................5
Package Contents Checklist ........................................................................................................................8
Setup and Assembly ..........................................................................................................................................8
Unit Location ................................................................................................................................................9
Bench Mounting ....................................................................................................................................9
Wall Mounting ........................................................................................................................................9
System Drain ..............................................................................................................................................10
Product Water Output ................................................................................................................................10
Power and Plumbing Requirements ..........................................................................................................10
Electrical ..............................................................................................................................................10
Water Supply........................................................................................................................................10
Assembly Instructions ................................................................................................................................11
Tube itting Instructions ............................................................................................................................14
inal Assembly Instructions ........................................................................................................................14
Cartridge Installation ..................................................................................................................................15
Operation ..........................................................................................................................................................16
Maintenance and Servicing ..............................................................................................................................17
Cartridge Replacement ..............................................................................................................................17
Replacement Parts and Cartridges Listing ......................................................................................................20
Optional Accessories ........................................................................................................................................20
Ordering Procedures ........................................................................................................................................21
Warranty ............................................................................................................................................................24
2
Table of Contents

Your Thermo Scientific Barnstead MEGA-PURE®
automatic deionizer has been designed with function,
reliability, and safety in mind. It is the userʼs responsi-
bility to install it in conformance with local electrical
codes. or safe operation, please pay attention to the
alert boxes throughout the manual.
Warnings
To avoid electrical shock, always:
1. Use a properly grounded electrical outlet of
correct voltage and current handling capacity.
2. Disconnect from the power supply prior to
maintenance and servicing.
3. Ensure that the equipment is connected to
electrical service according to local and
national standards. ailure to properly con-
nect may create a fire or shock hazard.
4. Do not mount Your MEGA-PURE® deionizer
directly over equipment that requires electri-
cal service. Routine maintenance of this unit
may involve water spillage and subsequent
electrical shock hazard if improperly located.
5. Do not connect unit to electrical service until
instructed to do so.
To avoid 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. Refer servicing to qualified personnel.
To ensure sa e mounting:
1. Wall composition and construction, as well as
fastener type, must be considered when
mounting this unit. The mounting surface and
3
Safety Information
Warning
Warnings alert you to a possibility of
personal injury.
Caution
Cautions alert you to a possibility of
damage to the equipment.
Note
Notes alert you to pertinent facts and
conditions.
Alert Signals

fasteners selected must be capable of support-
ing a minimum of 41 lbs.; inadequate support
and/or fasteners may result in damage to
mounting surface and/or equipment. If you are
unsure of mounting surface composition, condi-
tion and construction, or correct fasteners, con-
sult your building maintenance group or contrac-
tor.
4
SAFETY INFORMATION

Barnstead MEGA-PURE® Deionization Systems are
designed to remove dissolved inorganic and/or organic
materials from your water supply depending upon your
deionizer and cartridge selection.
Resistivity is continuously monitored. A green light will
indicate that the resistivity of the output water is greater
than 50K ohm-cm. A red light comes on when the deion-
ization cartridge requires changing.
The low Control Valve in this system is a precision nee-
dle valve for precise output flow rate control.
The improved drain system will drain cartridges fast and
efficiently for no-spill cartridge replacement.
The optional Solenoid Valve Accessory (Barnstead Part
No. 440375) will provide automatic shut-off of your water
supply when the resistivity of the output water falls below
50K ohm-cm.
Another option, the Still Adapter Kit (Barnstead Part No.
440376), connects the MEGA-PURE® Deionization
System to any Barnstead MEGA-PURE® Automatic Water
Still. This kit allows the Deionization System to function
automatically with the Water Still.
System Characteristics
The Barnstead MEGA-PURE® Model D1 Deionization
System is a single cartridge deionizer designed to provide
economic removal of inorganic contaminants from most
water supplies. This system has been preset to a resistivi-
ty of 50K ohm-cm. A green light will be lit as long as the
output water has a resistivity greater than 50K. The green
light will go out and a red light will come on if resistivity
falls below 50K. The D1 was primarily designed to utilize
the Barnstead High Capacity Cartridge to provide Reagent
Grade water for general laboratory use or as a water sup-
ply pretreatment to feed any Barnstead MEGA-PURE®
Water Still.
The Barnstead MEGA-PURE® Model D2 Deionization
System is a dual cartridge unit that provides all the fea-
tures of the Model D1 with the addition of organic
removal. The Model D2 is designed to use the Barnstead
5
Introduction

Organic Removal Cartridge and the High Capacity
Cartridge for economical removal of both organic and
inorganic matter from most water supplies.
Dimensions
The Model D1 is 10 1/2" wide x 7 1/2" deep x 25 1/2"
high and has an operational weight of 26 Ibs.
The Model D2 is 16 3/4" wide x 7 1/2" deep x 25 1/2"
high and has an operational weight of 41 Ibs.
Deionization Cartridge Data
Barnstead High Purity Cartridge
Barnstead High Purity Cartridges are designed for use in
applications requiring extremely high resistivity and low
organic product water. Barnstead High Purity Cartridges
are manufactured using only the highest quality, nuclear
grade, mixed bed resins. The result is a deionization car-
tridge that will remove 790 grains* of dissolved solids,
most organics, and produce water with a resistivity
greater than 16 megohm-cm. This cartridge may be used
in any Barnstead MEGA-PURE® Deionization System,
but in the D1 and D2 we recommend that an external
resistivity monitor be used to take full advantage of the
High Purity Cartridge and its high resistivity capability.
Barnstead High Capacity Cartridge
Barnstead High Capacity Cartridges are designed for effi-
cient and economical removal of dissolved inorganic mat-
ter from most water supplies. The output from this car-
tridge may be used in most laboratory procedures or as
the input for a Barnstead MEGA-PURE® Water Still. This
cartridge is recommended for use in the Barnstead
MEGA-PURE® D1 or D2 Deionization Systems.
Approximate cartridge life (50K-ohm end point) can be
calculated by using 1530 grain capacity in the formula list-
ed below.
Barnstead Organic Removal Cartridge
Barnstead Organic Removal Cartridges are designed to
remove most organic impurities from water supplies. It will
remove free chlorine and most color,odor, products of
6
INTRODUCTION

vegetable decay and weak organic acids. Cartridge life is about 1500-
1800 gallons for most water supplies. Periodic testing is recommended
to determine life cycle for your application.
Cartridge Capacity of 790 grains*
Approx. Cartridge Life = (for output above 16 megohm-cm)
Total dissolved solids in supply water
(expressed in grains*/gallon)
*Expressed as CaCO3 equivalent.
7
INTRODUCTION

Package Contents Checklist
MEGA-PURE® Deionizer Instruction Manual
Warranty Card
eedwater Tube itting (1/4" O.D. X 1/8" N.P.T.)
Self Adhesive Operation Label
Rubber Gaskets (2 pcs. D1) (4 pcs. D2)
Inspect package contents. If any of the above items are
damaged or missing, contact your dealer for replacement.
8
Unpackaging

Unit Location
Bench Mounting
Units may be placed on any flat surface providing the
space and weight requirements listed above.
Wall Mounting
The back braces have keyhole slots for wall mounting.
Choose wall anchors suitable for your wall construction
and the unit operating weight. Allow 4-6 inches on the
right side of unit for tubing and valve operation. See
igure 1 for mounting dimensions.
9
Setup and Assembly
Warning
Wall composition and construction, as
well as fastener type, must be consid-
ered when mounting this unit. The
mounting surface and fasteners select-
ed must be capable of supporting a
minimum of 41 lbs.; inadequate sup-
port and/or fasteners may result in
damage to mounting surface and/or
equipment. If you are unsure of mount-
ing surface composition, condition and
construction, or correct fasteners, con-
sult your building maintenance group
or contractor.

System Drain
When the cartridge(s) needs changing, the water in the
system must be drained. A 5 foot length of 1/4" I.D. vinyl
tubing is attached for this purpose. This tubing may be
routed to any open or atmospherically vented drain that is
located such that draining can be accomplished by gravi-
ty. If no convenient drain is available, the tubing may be
cut to an appropriate length for draining into a large bottle
or beaker.
Product Water Output
A 5 foot length of 7/16" I.D. vinyl tubing is supplied to
deliver the deionized water. This tubing may be routed to
any Barnstead MEGA-PURE® Water Still or other suit-
able container. The end of this tube must be at least one
foot higher than the base of the D1 or D2 or air may be
drawn into the system causing degradation of the output
water.
Power and Plumbing
Requirements
Electrical
Barnstead MEGA-PURE® Deionizers will plug into any
standard 3-prong, 120V, grounded receptacle. They oper-
ate on 50/60 HZ and current draw is less than 1/10
ampere. The power cord is 7 feet long.
Water Supply
Demineralizers require a 5 — 100 psig water supply.
Input water temperature must not exceed 40°C. Sodium
(NaCl) regenerated pretreatment systems (water soften-
ers) are not acceptable. The high sodium content will
reduce cartridge life by as much as 80%.
A 5 foot, 1/4" O.D., High Pressure tubing and a 1/8" N.P.T.
fitting are supplied to attach to your water supply.
Customer must supply the Shut-off Valve shown in igure
2, and also the appropriate fittings to match the factory-
supplied 1/8" N.P.T. fitting.
10
SETUP AND ASSEMBLY

Assembly Instructions
Deionizer only setup - igure 3
1. Locate the 1/4" OD x 1/8" NPT. plastic fitting in
the parts box.
2. Install the plastic fitting at your water source.
3. Refer to igure 6 and instructions and install
1/4" O.D. High Pressure tubing to plastic fitting
from step 2.
4. Route the 1/4" I.D. Vinyl tubing to your drain or
shorten for use on appropriate drain vessel.
5. Route the 7/16" I.D. Vinyl tubing to your point of
use. Remember that the end of the tubing must
be at least one foot higher than the base of the
deionizer.
6. Go to inal Assembly Instructions on page 14.
11
SETUP AND ASSEMBLY
Note
Review the setups shown below and
proceed with instructions that fit your
application.

Deionizer with solenoid valve accessory -
igure 4
1. Unpack Part No. 440375 Solenoid Valve
Accessory Kit (ordered separately).
2. Note the "IN" side and connect that side to your
water source.
3. Install the 1/4" N.P.T. plastic fitting from the parts
box to the "OUT" side of the solenoid valve.
4. Refer to igure 6 and instructions and install
1/4" O.D. High Pressure tubing to plastic fitting
from step 3.
5. Go to steps 4, 5 and 6 of DEIONIZER ONLY
SETUP.Deionizer to a Barnstead MEGA-PURE
Still - igure 5
12
SETUP AND ASSEMBLY

Deionizer to a Barnstead MEGA-PURE
Still - igure 5
1. Refer to igure 5 and instructions and install
plastic "T" fitting from Still Adapter Kit into the
source water line now feeding your Still as
shown in igure 5. Locate as desired.
2. Connect the 1/4" O.D. High Pressure tubing to
this "T" fitting as shown in igure 5.
3. Route 1/4" I.D. Vinyl tubing to same drain as
water still.
4. Route 7/16" I.D. Vinyl tubing to constant level
chamber of still as shown. Go to inal Assembly
Instructions on page 14.
13
SETUP AND ASSEMBLY
Note
This setup assumes that your Barnstead
MEGA-PURE Water Still is now con-
nected to your water source and that
you have Part No. 440376 Still Adapter
Kit (purchased separately).

Tube itting Instructions
1. Cut the 1/4" O.D. tubing cleanly, at a slight
angle, to make insertion of end easy.
2. Loosen the nut on the fitting until about three
threads are visible, moisten the tubing and
insert into the nut opening until it stops. (See
igure 6).
3. Tighten the nut by hand; additional tightening
should not be necessary.
14
SETUP AND ASSEMBLY
Figure 6
inal Assembly Instructions
1. Remove "Operation" label from parts box. Peel
off paper backing and apply label at any con-
venient location on Deionizer.
2. If setup is for Deionizer Only, proceed to
Cartridge Installation.
3. Remove the hole plug from the end panel (See
igure 7).
4. Install the rectangular plug from either the
Solenoid Valve or Still Adapter Cord into the rec-
tangular accessory receptacle.
5. Plug the phone jack end of the Still Adapter
Cord into the control box on the MEGA-PURE®
Water Still.

Cartridge Installation
1. Locate rubber gaskets in parts box. Remove
paper backing and install (sticky side to metal)
in upper and lower recesses in cartridge holder.
2. Remove plastic bag from one organic Cartridge
and place on the lower gasket in the RIGHT-
HAND housing of the Model D2.
3. Turn knob to move cartridge upward until it just
makes contact with the upper gasket. Center
cartridge on upper gasket and tighten knob firm-
ly to seal cartridge in place. DO NOT OVER-
TIGHTEN.
4. Repeat steps 2 & 3 with a High Capacity
Cartridge. Place this in only the LE T housing of
the Model D2
15
SETUP AND ASSEMBLY
Note
Cable to Accessory Receptacle not sup-
plied. Order as an option.
Caution
Always install the organic cartridge in
the right-hand housing of the model D2.
Installation of the organic cartridge in the
D1 or the wrong side of the D2 will
cause red light to be always on.

1. Turn WATER SUPPLY valve to "off" and DRAIN
valve to "closed".
2. Plug power cord into a grounded 110/120V
receptacle. Place OPERATION MODE SWITCH
to the "purge" position. BOTH PURITY LIGHTS
will be on at this time.
3. Open the customer shut-off valve and turn the
WATER SUPPLY valve to "on".
4. Turn the LOW CONTROL 2-3 turns counter-
clockwise and allow the system to run. Discard
the first 3-4 liters of treated water.
5. Turn the MODE SWITCH to "normal." The
"RED" light will go to very dim condition and the
"GREEN" light will remain lit indicating water
purity greater than 50K ohm-cm. When the
water purity has slipped to below 50K ohm-cm,
the “RED” light will be bright. Turn WATER SUP-
PLY valve to "off". Check system for leaks.
System is now ready for use.
16
Operation
Caution
The low Control valve is a precision
needle valve designed to give stable
flow control at low flow rates. Never
use this vale to shut off water to the
system. If clogging occurs in this valve,
we recommend the Barnstead Part No.
D5839 filter housing with a Part No.
440087 prefilter to remove particulate
matter prior to the deionizer.
Note
Pretreatment feedwater-flow rate to be
adjusted so as to “just maintain a full
boiler.” Too fast a flow water will
exhaust pretreatment cartridges pre-
maturely.

Cartridge Replacement
If the system has been idle for a period of time, the red
change cartridge light may have come on. Place the
Mode Switch in the PURGE position and run 1-2 liters of
water through the system. Place the Mode Switch back in
the RUN position. If the red light does not go out, the
deionization cartridge needs to be changed. Replace as
follows:
1. Disconnect power cord.
2. Turn drain valve to "open" then turn water sup-
ply valve to "off".
3. When water stops flowing from the drain hose,
loosen the bottom knob, remove the deioniza-
tion cartridge and discard.
4. Check gaskets and replace if necessary.
5. Replace cartridges per steps 2 & 3 under
Cartridge Installation.
6. Refer to Operation Sequence for start-up.
17
Maintenance and Servicing

18
MAINTENANCE AND SERVICING

19
MAINTENANCE AND SERVICING

Part Number Description
D400377 High Purity Cartridge
D400499 High Capacity Cartridge
D440265 Organic Removal Cartridge
410671 Rubber Gaskets (4/case)
410126 1/4" O.D. High Pressure Tubing (5 foot length)
410228 low Adjust Needle Valve Assembly
410229 Ball Valve (Water supply or Drain)
440119 Resistivity Monitor Assembly (PCB and Cell)
Optional Accessories
Part Number Description
440375 Solenoid Valve Accessory Kit (Solenoid Valve and Cord)
440376 Still Adapter Kit
410535 9-Liter Pyrex®Storage Bottle w/Spigot
413934 13-Liter Pyrex Storage Bottle w/Spigot
410164 45-Liter Pyrex Storage Bottle w/Spigot
or more information on these accessories and other Barnstead MEGA-PURE®products, please contact your
Laboratory Distributor.
MEGA-PURE®is a trademark of Barnstead Thermolyne Corporation.
PYREX®is a registered trademark of Corning, Incorporated.
20
Replacement Parts and
Cartridges