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Type A1007Electrically Heated

Portable StillOPERATION MANUAL

AND PARTS LISTSERIES 919

LT919X1 • 6/6/96

BARNSTEAD|THERMOLYNE CORPORATION

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Table of Contents

Table of Contents ............................................................................................................................................... 2Safety Information .............................................................................................................................................. 3

Alert Boxes ..................................................................................................................................................... 3Important Information ...................................................................................................................................... 3Warnings ......................................................................................................................................................... 3

Introduction ........................................................................................................................................................ 5Principles of Operation ................................................................................................................................... 5Technical Specifications ................................................................................................................................. 6

Installation .......................................................................................................................................................... 7Unpacking ....................................................................................................................................................... 7Choosing a Site .............................................................................................................................................. 7Plumbing Connections .................................................................................................................................... 7Electrical Connection ...................................................................................................................................... 7Initial Startup ................................................................................................................................................... 8

Operation ........................................................................................................................................................... 9Startup ............................................................................................................................................................ 9Stopping .......................................................................................................................................................... 9

Maintenance and Servicing .............................................................................................................................. 10Disassembly for Cleaning ............................................................................................................................. 10Cleaning Methods ......................................................................................................................................... 11Testing for Condenser Leaks ........................................................................................................................ 12Condenser Scale Test .................................................................................................................................. 13Heating Element Testing and Replacement ................................................................................................. 14Troubleshooting Guide ................................................................................................................................. 17

Wiring Diagram ................................................................................................................................................ 18Exploded View ................................................................................................................................................. 19Replacement Parts Listing ............................................................................................................................... 20Ordering Procedures ........................................................................................................................................ 21One Year Limited Warranty .............................................................................................................................. 23

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Safety Information

Your Barnstead electrically-heated portable still hasbeen designed with function, reliability, and safety inmind. It is your responsibility to install it inconformance with local electrical codes. This manualcontains important operating and safety information.You must carefully read and understand the contentsof this manual prior to the use of this equipment. Forsafe operation, please pay attention to the alertsignals throughout the manual.

Important Information

Water purification technology employs one or moreof the following: chemicals, electrical devices,mercury vapor lamps, steam and heated vessels.Care should be taken when installing, operating orservicing Barnstead products. The specific safetynotes pertinent to this Barnstead product are listed onthe next page.

Warnings

To avoid electrical shock, always:1. Use a properly grounded electrical outlet of

correct voltage and current handlingcapacity.

2. Ensure that the equipment is connected toelectrical service according to local andnational standards. Failure to properlyconnect may create a fire or shock hazard.

3. Do not mount this portable still directly overequipment that requires electrical service.Routine maintenance of this unit may involvewater spillage and subsequent electricalshock hazard if improperly located.

WarningWarnings alert you to apossibility of personalinjury.

CautionCautions alert you to apossibility of damage to theequipment.

NoteNotes alert you to pertinentfacts and conditions.

Alert Signals

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4. Disconnect from the power supply beforeservicing.

To avoid personal injury:1. Do not use in the presence of flammable

or combustible materials; fire or explosionmay result. This device containscomponents which may ignite suchmaterials.

2. This device is to be used with water feedsonly. Sanitizing/cleaning agents must beused in compliance with instructions in thismanual. Failure to comply with the abovecould result in explosion and personalinjury.

3. Wear eye and hand protection when usingacid for cleaning, as acid spattering mayoccur.

4. Avoid splashing disinfecting solutions onclothing or skin.

5. Carefully follow manufacturer’s safetyinstructions on labels of chemicalcontainers and material safety datasheets.

6. Do not add the acid cleaning solutionrapidly — if any bicarbonate scale ispresent, gas will be released inconsiderable amounts.

7. “Caution - Hot Surface. Avoid Contact.”The exterior of the still becomes hot duringoperation and will remain hot for sometime after the still has been turned off.

8. Refer servicing to qualified personnel.

SAFETY INFORMATION

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Introduction

The Barnstead Electrically Heated Portable Stillprovides high quality distilled water at the rate of1.8 liters/hour. The still is designed to useapproximately 14.4 liters of cooling water and feedwater combined for each 1.8 liters of distilled waterproduced. Two electrically powered, immersion-type heaters are used to give complete heattransfer and maximum heating efficiency. Anautomatic low water cut-off device is incorporatedto protect the heaters against a low water condition.

Principles of Operation

The water to be purified enters the condenser at thewater inlet. As the water flows around the outside ofthe condenser tube, it becomes preheated almostto boiling. The preheated water leaves thecondenser through the discharge tube and is fedinto the constant level device. The constant leveldevice maintains a constant water level in theevaporator. The excess hot water (which may beused elsewhere as plain hot water) flows to drain.In the evaporator the water is converted into steamwhich passes up through the vapor pipe to thecondenser tube where it is cooled to form distilledwater.

By reducing the flow of water so that a littlesteam escapes through the condenser vent, highefficiency is assured, entrance of air becomesimpossible, and any trace gases cannot redissolvein the hot distillate but leave with the wisp of steam.The vent also makes the system an open systemso that no pressure can build up within the still.

The low water cutoff is designed to preventdamage caused by low water conditions in theevaporator. In use, the cutoff probe is in contactwith the water in the still evaporator. The watercompletes an electrical circuit when the water is at

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a safe level (above the heating elements). Whenthe water level drops below the probe, the circuitopens and de-energizes the heating elements.

Technical Specifications

INTRODUCTION

1 A hose nipple is provided for a 1/2" hose connection if a

permanent connection is not desired.

NoteA properly regulated watersupply is important foroptimum distillate quality andmaximum distillate output.Ensure that your feedwatersupply meets therequirements at right.

Distillate capacity 1.8 liters/hour (1/2 GPH)Maximum water pressure 90 psigMinimum water pressure 40 psigPlumbing connections

Water inlet 1/ 4 NPT1

Waste 1/ 2" hoseElectrical requirements The still is rated at 1300-watts

and operates on 120 volts AC.The still will draw 12-amperesof current at 120 volts.

Overall dimensionsWidth 19 7/8 in.Depth 9 1/2 in.Height 20 1/2 in.Shipping weight 65 lbs.

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Installation

Unpacking

Unpack the still carefully to prevent damage.Ensure that all parts are removed from thecontainer before discarding the packing materials.

Choosing a Site

Move the still evaporator to the operating locationand install the evaporator so that it is level andplumb.

Plumbing Connections

Connect the water and waste service lines to thestill. Ensure that the waste service line at the still isatmospherically vented and gravity flow. A shut-offvalve and throttling valve should be installed in thewater supply line, just before the still, if the still is tobe permanently piped. If the still is not to bepermanently piped, a hose may be connectedbetween the inlet hose nipple connection and awater faucet. The water faucet may be used as awater throttling valve. The distillate delivery tubingshould be connected to the point of distribution orstorage.

Electrical Connection

The still is connected electrically by connecting thecord to a dedicated 120 volt AC grounded electricalcircuit. See the specifications plate on the stillevaporator for the electrical requirements.

Do not mount this portablestill directly over equipmentthat requires electricalservice. Routinemaintenance of this unit mayinvolve water spillage andsubsequent electrical shockhazard if improperly located.

Warning

NoteEnsure that the servicepiping is adequatelysupported. The still is notdesigned to support theservice piping.

The still should be connectedto a dedicated electrical line.

Note

WarningUse a properly groundedelectrical outlet of correctvoltage and current handlingcapacity.

Ensure that the equipment isconnected to electricalservice according to localand national standards.Failure to properly connectmay create a fire or shockhazard.

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Initial Startup

The first time that the still is started, or aftercleaning, operate the still as follows:

1. Close the drain valve.

2. Open the water shut-off valve.

3. Open the water throttling valve about 1/2

turn.

4. When the water level in the evaporatorreaches a sufficient level, as indicated bya steady overflow to waste, connect thestill to the electrical service, and turn onpower switch. Check to see that the heaterlight is on. (Heater light will only turn onwhen water is above low water cutoffprobe.)

5. When the still begins to produce distilledwater, adjust the water throttling valve untiljust a puff of steam issues from thecondenser vent. Discard the first 2 hoursof distillate production to allow the still toclean itself out.

INSTALLATION

The heaters are immersion-type heaters, and will burnout if operated in air whenthe low water cutoff isdisconnected. Read theOperation section beforeconnecting the still toelectrical service. Watersupply must not beinterrupted before power isturned off.

Caution

NoteDuring the Initial Startupprocedures, check allconnections for leaks andtighten as required.

NoteIdeally, the temperature ofthe steam and gasesescaping the vent should be70°C or higher. To measurethe vent temperature, use athermocouple probe, such asthe Thermolyne PM20700Digital Pyrometer, insertedinto the vent.

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Operation

Startup

Start the still as follows:1. Close the drain valve.

2. Open the water shut-off valve.

3. Turn on main power switch. When waterlevel is above low water cutoff probe,heaters will turn on.

4. Check the cooling water flow and the venttemperature.

StoppingStop the still as follows:

1. Turn main power switch off.

2. Close the water shut-off valve.

3. Open the drain valve to allow the stillevaporator to drain completely while itscontents are hot.

Note

WarningDo not use in the presenceof flammable or combustiblematerials; fire or explosionmay result. This devicecontains components whichmay ignite such materials.

This device is to be usedwith water feeds only.Sanitizing/cleaning agentsmust be used in compliancewith instructions in thismanual. Failure to complywith the above could result inexplosion and personalinjury.

“Caution - Hot Surface.Avoid Contact.” The exteriorof the still becomes hotduring operation and willremain hot for some timeafter the still has been turnedoff.

If the still is operatedcontinuously, it should bestopped and drained onceevery four hours. Drainingthe still at frequent intervalswill help to inhibit theformation of scale in theevaporator.

Do not change the setting ofthe water throttling valve.

CautionAlways turn main power switch off beforeshutting off the water supply.

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Maintenance and Servicing

Disassembly for Cleaning

The frequency of cleaning will depend upon thepurity of the water being used. The still should beinspected at frequent intervals until cleaningintervals are determined. Disassemble, inspect, andclean the still as follows:

1. Stop the still. Turn the still off and allowthe still to cool.

2. Remove the condenser from the still.Inspect the cooling water side of thecondenser for scale and clean as required.

3. Disassemble the evaporator until theinterior of the evaporator is visible. Inspectthe interior of the evaporator for scale.Remove as much scale as possiblemanually.

4. Disassemble the drain line and clean asrequired. Ensure that the drain line is clear(including the drain opening in theevaporator) before using a cleaner.Reassemble the drain line.

5. Soft scale may be removed as describedunder “Soft Scale Removal.” Silica scalemay be removed as described under“Silica Scale Removal.” To remove hardscale or organic scale, fill the evaporatorwith acid cleaner (see “Hard ScaleRemoval”).

6. Inspect the constant level device and drainline and clean as required.

7. Reassemble the still. Assembly isessentially the reverse of disassembly.

WarningTo avoid electrical shock,always disconnect frompower supply beforemaintenance and servicing.

Refer servicing to qualifiedpersonnel.

Carefully followmanufacturer’s safetyinstructions on labels ofchemical containers andmaterial safety data sheets.

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8. Connect the water, waste and distillatelines.

9. Start the still as described under InitialStartup.

10. Lower the water flow rate with the waterthrottling valve until steam spouts out ofthe condenser vent at least 12 inches.Operate in this manner for 30 to 60minutes to sterilize and clean out the still.

11. Readjust the still as described in InitialStartup.

Cleaning MethodsCleaning requirements fall into two classes: scaleremoval and biological cleaning. Scale removalmay be accomplished chemically or mechanically.Biological cleaning is accomplished with anisopropyl alcohol solution. The various methods ofcleaning follow:

Soft Scale Removal Soft scale may be removedwith a stiff bristle brush. After cleaning all scaleparticles should be flushed out with water.

Hard Scale Removal Hard scale can beremoved by using a 10 percent solution of inhibitedhydrochloric acid. This acid solution is availablecommercially or can be prepared using 20 partswater and 6 parts 30 percent hydrochloric acid.Flush the part thoroughly after using the acidsolution. A 5 percent Sodium Bicarbonate Solutioncan be used to remove any acid left on the part.

If inhibited hydrochloric acid is not available, aten percent solution of sulfamic or acetic acid maybe used as a substitute. Exposure time to this acid

MAINTENANCE AND SERVICING

WarningVentilate the room duringthis operation.

WarningWear eye and handprotection when using acidfor cleaning, as acidspattering may occur.

To avoid electrical shock,always disconnect frompower supply beforemaintenance and servicing.

Do not use in the presenceof flammable or combustiblematerials; fire or explosionmay result. This devicecontains components whichmay ignite such materials.

Caution

When using the acidsolution, do not allow theacid to remain in contact withthe part for more than 20minutes. Under nocircumstances should anyacid cleaner be allowed tocome in contact with tinnedsurfaces (such as thedistilled water side of thecondenser or the distilledwater transmission tubing).

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is 2 to 3 hours. Sulfamic and acetic acids have anadvantage over hydrochloric acid ; they will notcorrode the metal parts being cleaned.

Organic Scale and Sludge Removal If thescale has a dark brown or black color, it may beformed from organic impurities present in the feedwater. This type of scale may be removed with astrong detergent solution. The detergent solutionshould be allowed to be in contact with the scale orsludge for 24 hours. Rinse off the parts with waterafter cleaning.

Silica Scale Removal Silica scale is usuallyclear and shiny and hard to detect visually. It is veryhard and cannot be removed with an acid solution.Silica scale formation can be reduced by controllingthe quality of the feed water by routing it through amixed-bed deionizer less than 10 megohm/cm. It isbest removed with a blunt instrument.

Biological Cleaning Biological cleaning is usedon the parts that come in contact with the distillate(such as the distilled water side of the condenser ordistilled water transmission tubing) to removebiological contamination from the affected part.Parts that come in contact with the steam vapors(such as distilled water transmission tubing) may bebiologically cleaned by removing them from the stilland immersing them in a one-percent solution byweight of isopropyl alcohol overnight. After therequired amount of exposure to the isopropylalcohol solution, reinstall the cleaned parts onto thestill without rinsing them. Start the still and use thedistillate output to rinse any remaining isopropylalcohol solution to waste.

Testing for Condenser Leaks

Visual Test for Leaks A simple test for condenserleaks may be performed as follows:

MAINTENANCE AND SERVICING

NoteFor best results, heat acidsolutions and detergentsolutions.

NoteIf your still developssignificant sludge and scaleon an ongoing basis, you willprobably benefit frompretreatment of yourfeedwater.Barnstead|Thermolyne'sCustomer Service will helpyou ascertain the bestpretreatment for yourfeedwater supply.

WarningDo not add isopropyl alcoholto boiler. A fire may result.

Avoid splashing disinfectingsolutions on clothing or skin.

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1. Disconnect the still from the electricalservice.

2. Let the water flow through the condenseruntil the condenser is cold.

3. Note whether there is a flow, even in dropquantities, from the distillate outlet. If thereis, it is possible that there is a leak fromthe cooling water side to the distillate side.If this is the case, the condenser must bereplaced.

Pressure Test for Leaks If a more positive test isrequired, proceed as follows:

1. Remove the condenser from the still.

2. Remove the water discharge tubing. Plugthe discharge connection on thecondenser with a plug or stopper.

3. Attach a hose to the water inlet connectionon the condenser and apply no more than5-psi of air pressure to the condenser.

4. Submerge the entire condenser in a tankof water.

5. If any air bubbles come from thecondenser, replacement is necessary.

Condenser Scale Test

Test the condenser for scale as follows:1. Adjust the water throttling valve until just a

puff of steam issues from the condenservent. The volume of water required to coolthe condenser to this point gives a generalindication of the amount of scale that has

MAINTENANCE AND SERVICING

NoteThe condenser cannot berepaired and must bereplaced as a unit.

NoteWhen conducting thecondenser scale test, ensurethat a minimum inlet waterpressure of 40 psi ismaintained. A drop in waterpressure will also causesteam to blow from thecondenser because ofinadequate cooling.

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built up inside the condenser's coolingwater tubing; the greater the scaling, thegreater the volume of water required. Inextreme cases of scale, steam will alwaysblow from the condenser vent, even whenthe water throttling valve is completelyopen.

2. Remove the condenser if the dischargepipe is cool enough to hold. Inspect theinterior of the condenser for scale. If scaleis present, pour the acid cleaning solution(see “Hard Scale Removal”) into thecondenser as follows:

Connect funnel to top (Water outlet)of condenser. Connect tubing withclamp to bottom connection (waterinlet) of condenser. Pour acid solutioninto funnel and let sit in condenser for10-15 minutes. Open drain clamp andlet acid solution flow to drain. Rinsecondenser with distilled water afteracid cleaning.

3. Reinstall the condenser on the still.

Heating Element Testing andReplacement

Whenever a heating element is suspected of notoperating properly, test and — if necessary —replace the heating element as follows:

1. Drain and cool the still.

2. Remove the bottom cover from the stillevaporator. This may be done byremoving the 2 screws from the bottom.

MAINTENANCE AND SERVICING

WarningTo avoid electrical shock,always disconnect frompower supply beforemaintenance and servicing.Refer servicing to qualifiedpersonnel.

Warning

Do not add the acid cleaningsolution rapidly — if anybicarbonate scale is present,gas will be released inconsiderable amounts.

Do not pour any acid solutioninto the distillant side of thecondenser — the acid willdestroy the tin coating.

Caution

Top Connector

Bottom Connector

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Disconnect the electrical leads and busbars from the heating element terminals.Tag the leads to facilitate reassembly.

3. To test each heating element for an opencircuit, apply a current across theterminals. Use a test light in series with theapplied current. If the test light does notlight, the heating element is burned out.Mark the damaged heating elements.

4. To test each element for a short circuit,take an ohm reading on each elementwhile bus bars are disconnected. Theproper reading should be approximately21 ohms.

5. Remove the evaporator cover from the stilland inspect the heating elements from theinside of the evaporator. Warped or splitelements should be replaced.

6. To remove an inoperative or damagedheater, loosen the screw under the heaterand push out the heater. If the heater isbadly scaled, remove the retaining nut androck the heater back and forth (from insidethe evaporator) to break the scale.

7. Install a new heater in place of the oldheater. Tighten the screw only enough tohold the heater in place. This will allow youto rotate the heater when installing the busbars.

8. Install the bus bars and wiring betweenheater terminals. Retighten the heaterretaining screws to eliminate the possibilityof leakage.

MAINTENANCE AND SERVICING

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9. Add water to the evaporator and ensurethat none of the heating elements areleaking. Allow to sit for 30 minutes. If noleaking occurs, reattach bottom cover tostill.

10. Reassemble the still and connect the stillto the electrical service.

MAINTENANCE AND SERVICING

Heating Element Replacement

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Problem Possible Causes Solutions

Drop in purity • Dirty still

• Volatile impurities in feedwater

• Inspect evaporator for excessscale and clean as required

• Test distillate for CO2, NH3,etc. Reduce water flow rate tohelp eliminate volatiles fromcondenser

Pyrogenic or organiccontamination of distillate

• Dirty still

• Leak in condenser

• Bacteriological growth indistilled water

• Inspect evaporator for excessscale and clean as required

• Test condenser for leaks andreplace if required

• Inspect the suspected parts.Clean with an isopropylalcohol solution if required(see “Biological Cleaning”under Cleaning Methods)

Drop in distillate capacity • Excess scale on heating unit

• Low voltage

• Leak in drain valve

• Damaged or inoperativeheaters

• Inspect and clean as required

• Check voltage. If less thanfive percent of the ratedvoltage, notify electrician

• Ensure drain valve is closedand not leaking

• Check wiring, connections,etc. Test heaters and replaceif necessary

Steam blowing from condenser • Low water flow rate

• Low water pressure

• Excess scale in condenser

• Readjust throttling valve

• Check water pressure — itshould be at least 40 psi

• Inspect condenser for scale

Water blowing from condenser • Condenser leak

• Trapped distillate line

• Test condenser for leaks;repair or replace as required

• Inspect distillate line for anyrestrictions or trapping

Troubleshooting Guide

MAINTENANCE AND SERVICING

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Wiring Diagram

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Exploded View

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Replacement Parts Listing

*See the Heating Element Replacement illustration in the Maintenance and Servicing section of this instruction.

Model Type: A1007Product Name: Electrically Heated Portable StillSeries Number: 919 Key Part # (Qty) Description

1 21058 Condenser2 21100 Distillate delivery tube3 21880 Water discharge tube, 10 5/ 8"4 03702 Water discharge elbow5 21195 Steam cover6 03719 Wing nut, brass, #10-24 UNC7 06271 Gasket, evaporator steam cover8 CS670X1A Evaporator9 21319 Constant Level Device

10 02096 Drain faucet11 07031* Heating element12 21414 Dish baffle13 20251 Ring, stand base14 21894 Bottom plate15 CR919X1 Cord set, 120 volt16 03775 Elbow, brass, 1/2 NPT x 1/4 NPT17 FSX191 Screw, phillips head, thread cutter, stainless steel, #8-32 x 3/ 8

18 03717 Hose nipple, brass, 1/ 2" x 1/ 4 NPT19 SRX16 Strain relief, plastic20 03411 Elbow, brass, 3/8 NPT x 90°21 03436 Nipple, brass, 3/ 8 NPT x 2"22 03535 Nipple, close, brass, 3/8 NPT23 SCX58 Triac24 PC670X1A Low Water Control Board25 PLX97 Indicator Light26 BR670X1A Low Water Cut-off Probe Assembly27 CA919X1A Capacitor Assembly28 SWX137 ON/OFF Switch29 SWX129 Circuit Breaker30 CV919X2A Electrical Box Cover31 CV919X1A Heat Sink

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Ordering Procedures

Please refer to the Specification Plate for thecomplete model number, serial number, and seriesnumber when requesting service, replacementparts or in any correspondence concerning this unit.

All parts listed herein may be ordered from theBarnstead|Thermolyne dealer from whom youpurchased this unit or can be obtained promptlyfrom the factory. When service or replacementparts are needed we ask that you check first withyour dealer. If the dealer cannot handle yourrequest, then contact our Customer ServiceDepartment at 319-556-2241 or 800-553-0039.

Prior to returning any materials toBarnstead|Thermolyne Corp ., please contact ourCustomer Service Department for a “Return GoodsAuthorization” number (RGA). Material returnedwithout a RGA number will be refused.

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Barnstead|Thermolyne Corporation warrants that if a product manufactured by Barnstead|Thermolyne andsold by it within the continental United States or Canada proves to be defective in material or construction, itwill provide you, without charge, for a period of ninety (90) days, the labor, and a period of one (1) year, theparts, necessary to remedy any such defect. Outside the continental United States and Canada, the warrantyprovides, for one (1) year, the parts necessary to remedy any such defect. The warranty period shallcommence either six (6) months following the date the product is sold by Barnstead|Thermolyne or on thedate it is purchased by the original retail consumer, whichever date occurs first.

All warranty inspections and repairs must be performed by and parts obtained from an authorizedBarnstead|Thermolyne dealer or Barnstead|Thermolyne (at its own discretion). Heating elements, however,because of their susceptibility to overheating and contamination, must be returned to our factory, and if, uponinspection, it is concluded that failure is not due to excessive high temperature or contamination, warrantyreplacement will be provided by Barnstead|Thermolyne . The name of the authorized Barnstead|Thermolynedealer nearest you may be obtained by calling 1-800-446-6060 (319-556-2241) or writing to:

Barnstead|ThermolyneP.O. Box 797

2555 Kerper BoulevardDubuque, IA 52004-0797

USAFAX: (319) 589-0516

E-MAIL ADDRESS: mkt@barnstead.com

Barnstead|Thermolyne’s sole obligation with respect to its product shall be to repair or (at its own discretion)replace the product. Under no circumstances shall it be liable for incidental or consequential damage.

THE WARRANTY STATED HEREIN IS THE SOLE WARRANTY APPLICABLE TO Barnstead|ThermolynePRODUCTS. Barnstead|Thermolyne EXPRESSLY DISCLAIMS ANY AND ALL OTHER WARRANTIES,EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR USE.

One Year Limited Warranty

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9001ISOREGISTERED

Barnstead|Thermolyne2555 Kerper Blvd.P.O. Box 797Dubuque, IA 52004-2241Phone: 319-556-2241 800-553-0039Fax: 319-589-0516E-Mail Address: mkt@barnstead.com