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Classic
Electrically Heated Stills
OPERATION MANUAL
AND PARTS LIST
SERIES 495
Model Numbers
A1011 A1015
A1013 A1016
60004 • 5/5/04
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Safety Information ..............................................................................................................................................3
Alert Signals ......................................................................................................................................................3
Warnings ..........................................................................................................................................................3
Introduction..........................................................................................................................................................5
Evaporator ........................................................................................................................................................5
Condenser ........................................................................................................................................................6
Features Provided ............................................................................................................................................6
Electric Heat......................................................................................................................................................6
Low Water Cut-Off ............................................................................................................................................6
Still Heat Control ..............................................................................................................................................7
Unpacking ..........................................................................................................................................................8
Installation ..........................................................................................................................................................9
Siting ................................................................................................................................................................9
Accessories ......................................................................................................................................................9
Plumbing Connections ......................................................................................................................................9
Electrical Connections ....................................................................................................................................11
Operation ..........................................................................................................................................................13
Initial Startup ..................................................................................................................................................13
Initial Operation ..............................................................................................................................................13
Deconcentrator Adjustment ............................................................................................................................14
Normal Operation............................................................................................................................................15
Maintenance and Servicing ..............................................................................................................................17
Cleaning Methods ..........................................................................................................................................17
Disassembly for Cleaning ..............................................................................................................................18
Theory of Operation ..........................................................................................................................................21
Troubleshooting ................................................................................................................................................22
Tests for Condenser Leaks ............................................................................................................................22
Condenser Test for Scale. ..............................................................................................................................23
Heating Element Test and Replacement ........................................................................................................24
Heating Elements............................................................................................................................................26
Troubleshooting Chart ......................................................................................................................................27
Parts List ..........................................................................................................................................................28
Accessories for Electric Stills ............................................................................................................................37
Ordering Procedures ........................................................................................................................................39
Warranty............................................................................................................................................................40
Table of Contents
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This manual contains important operating and
safety information. The user must carefully
read and understand the contents of this manual prior to the use of this equipment.
Water purification technology employs one or
more of the following: chemicals, electrical
devices, mercury vapor lamps, steam and heated vessels. Care should be taken when
installing, operating or servicing Barnstead
products. The specific safety notes pertinent to
the Barnstead Electrically Heated Stills are listed in safety information section.
Your Barnstead Electrically Heated Still has
been designed with function, reliability, and
safety in mind. It is the user’s responsibility to
install it in conformance with local electrical
codes. For safe operation, please pay attention
to the alert signals throughout the manual.
Warnings
To avoid 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 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.
Safety Information
Alert Signals
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.
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2. Use this device with water feed only.
Sanitizing/cleaning agents must be used
in compliance with the instructions in
this manual. Failure to comply with the
above could result in explosion and personal injury.
3. Avoid splashing disinfecting solutions on
clothing or skin.
4. Ensure all piping connections are tight
to avoid leakage of chemicals.
5. Always depressurize chemical lines
before disassembly.
6. Ensure adequate ventilation.
7. Follow carefully the manufacturers’ safety instructions on labels of chemical
containers and Material Safety Data
Sheets (M.S.D.S.).
8. “Caution: Hot Surface. Avoid Contact.”
9. Refer servicing to qualified personnel.
S
AFETY INFORMATION
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Introduction
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
designed 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 Installation
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 disengaging 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 polished 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.
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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
delivery tube of block tin is provided to connect
the distillate outlet of the condenser to a storage
tank or other suitable container.
Features Provided
All stills are equipped with a deconcentrator to
continuously 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 prevent 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 efficiency.
Low Water Cut-Off
Electric current to the still heating elements is
controlled by an ON/OFF switch and a selfresetting low water cutoff. The solid state low
water cutoff is designed to prevent damage
caused by low water conditions in the still
evaporator.
Figure 1
Electrically Heated Still
INTRODUCTION
Note
Heater life may be reduced
when operated 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
Inlet Tube
Constant Level
Device
Preheated
Feedwater Tube
Q-Baffle
Deconcentrator
Valve
Evaporator
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When the water level is at a safe level in the still
evaporator (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 circuit (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 installation
on Barnstead stills, and still heat control (contactor).
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 cutoff
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.
I
NTRODUCTION
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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.
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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 assembled 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
accessory piping and connect the water and
waste service to the still as shown in the installation diagram.
Installation
Bench Dimensions in Inches
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
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. If 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.
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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 electrically heated stills.
DO: Distillate outlet.
WA: Waste line must be atmospherically vented and
gravity flow.
Figure 3
Front View
INSTALLATION
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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 accordance 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 terminals 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 evaporator casing.
3. Connect the still heat control contactor coil
to terminals 6 and 11.
4. Connect a 3-wire, 115-VAC, 60-hertz electrical service 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
I
NSTALLATION
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water cutoff controls and the contactor
coil (see See Figure 9).
5. Connect the heater electrical service
to the contactor (see Figure 9). See
the still wiring diagram when connecting the still heating elements to the
contactor - the heater electrical service requirements will be indicated on
the nameplate decal at the base of the
still evaporator.
6. Install the front panel on the low water
cutoff cabinet and install the cover on
the contactor cabinet.
I
NSTALLATION
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Initial Startup
The first time that the still is started, or after
cleaning, operate 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 supply.
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.
Initial 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
lighted 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 started 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. If these were not
purchased with the still, they
must be installed in the cooling
water inlet line by the customer
to ensure proper operation.
Caution
Ensure that the water level in
the evaporator 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
Ideally, 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 Thermolyne PM20700
Digital Pyrometer, inserted into
the vent.
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Deconcentrator Adjustment
The function of the deconcentrator is to maintain
a minimum concentration of dissolved impurities
in the evaporator, thus reducing scale formation
and tendency to foam to a minimum. The deconcentrator is adjusted as follows:
1. Permanent Hard Water or Softened
Water (Softened feed is not
recommended). The deconcentrator
valve should be left open at all times to
bleed water from the evaporator at approximately 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,
disassembled and cleaned with a brush
or scraper.
2. Temporary Hard Water. If 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
deconcentrator valve opened, a larger
quantity of feedwater passes through the
evaporator, precipitating out
bicarbonates, increasing the amount of
scale formed. Keeping the to 150°
deconcentrator closed will result in an increased concentration 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. Demineralized Water
When demineralized water is used as
feedwater the deconcentrator valve may
be kept closed.
O
PERATION
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Normal Operation
Starting - Start the still as follows:
1. Close the drain valve.
2. Open the deconcentrator valve slightly,
if not adjusted.
3. Open the cooling water inlet valve.
4. When water begins to issue steadily
from the deconcentrator valve, turn on
the still heat supply.
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 distribution 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. If necessary, adjust the cooling water
throttling valve until a puff of steam
issues from the condenser 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 completely.
O
PERATION
Caution
Ensure that the water level in
the evaporator 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
Ideally, 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 Thermolyne PM20700
Digital Pyrometer, inserted into
the vent.
Note
Do not change the setting of the
cooling water throttling valve
and deconcentrator valve.
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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
Inlet Valve
Deconcentrator
Valve
Drain Valve
Electrical Terminal
Connection Box
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Cleaning Methods
Cleaning requirements fall into two classes, scale
removal 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 particles should be flushed out with water.
Hard Scale Removal. Hard scale may be removed by using a 10% solution of inhibited HCI.
This acid cleaner is available commercially or
may be prepared using 20 parts water and 6
parts 30% HCI. When using the acid, do not
allow the acid to remain in contact with the part
for more than 20 minutes. Flush the part thoroughly after using the acid cleaner. A 5% Sodium
Bicarbonate solution may be used to remove any
acid left on the part.
Organic Scale and Sludge Removal. If 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. It 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. It is best removed with a blunt instrument.
Maintenance and Servicing
Note
If desired, 10% solutions of sulfamic or acetic acids may be
used instead of the HCI.
Sulfamic and acetic acids have
an advantage over hydrochloric
acid in that they will not corrode
the metal parts being cleaned.
Under no circumstances
should any concentrated acid
be allowed to come in contact
with tinned surfaces.
Warning
Always wear protective clothing
and eye shields when handling
acid. Disconnect from the power
supply prior to maintenance and
servicing. Refer servicing to
qualified personnel.
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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 biological contamination
from the affected part. This may be accomplished
as follows:
1. Immerse 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 intervals until cleaning intervals are
determined. Disassemble, inspect, and clean the
still as follows:
M
AINTENANCE AND SERVICING
Warning
Avoid splashing the isopropyl
alcohol solution on open cuts.
Caution
Do not use chlorine bleach for
biological cleaning. The chlorine
will interact with and damage the
tinned surfaces.
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1. Shut off and drain the still.
2. Shut off the water supply to the still.
3. Remove the condenser from the still.
Inspect the cooling water side of the
condenser for scale and clean as required. If required, clean the distilled
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 removed
as a unit and the interior of the evaporator will be visible. Inspect the interior
of the evaporator for scale. Remove
as much scale as possible manually.
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 concentrated acid (see “Hard
Scale Removal”) or detergent solution
(see “Organic Scale and Sludge Removal”) or detergent solution (see
“Organic Scale and Sludge Removal”)
as required.
M
AINTENANCE AND SERVICING
Note
Stills equipped with a high purity
chamber or preheater should
not be cleaned with acid unless
the high purity chamber can be
removed. The fumes given off
by the acid may damage the tin
coating used in these
accessories.
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7. Inspect the constant level device and
drain line. Clean as required.
8. If 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 “Initial
Startup.”
12. Lower the cooling water flow rate (with
the cooling water throttling valve) until
steam spouts out of the condenser vent
at least 12 inches. Operate in this
manner for 30-60 minutes to sterilize
and clean out the still.
13. Adjust the still as described in “Initial
Operation.”
M
AINTENANCE AND SERVICING
Caution
Ventilate the room during this
operation.
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The still consists primarily of a boiler or evaporator which holds the water during the evaporation
process; electric heating elements of the
immersion type inserted in the evaporator to boil
the water; and a condenser which condenses the
steam from the boiler to form the distillate.
The water to be purified enters the condenser
where it is heated by the steam passing through
the evaporator. 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 atmosphere 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
Inclined
Condenser
Cooling Water/
Feedwater
Inlet
Q Baffle
Double Walled
Evaporator
Immersion Heaters
(For Electric Stills)
Drain Valve
Constant Level
Device
Deconcentrator
Valve
Preheated
Feedwater
Distillate
Outlet
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This section contains troubleshooting, testing
and repair instructions. A troubleshooting chart is
included to help the repair specialist find the difficulty quickly.
Tests for Condenser Leaks
Visual Test. A simple test for condenser leaks
may be performed as follows:
1. Shut off the still heating elements.
2. Let the cooling water flow through the
condenser until the condenser is cold.
3. Note whether there is a flow, even in
drop quantities, from the distillate outlet.
If there is a continuous flow, it is possible that there is a leak from the cooling
water side to the distillate side. If this is
the case, the condenser must be replaced.
Pressure Test. If a more positive test is required, proceed as follows:
1. Remove the condenser from the still.
2. Remove the cooling water discharge
tubing. Plug the discharge connection
on the condenser with a plug or stopper.
3. Attach a hose to the cooling water inlet
connection on the condenser and apply
about 5 psi air pressure to condenser.
Ensure that the plugs used to seal the
condenser do not leak air.
4. Submerge the entire condenser in a
tank of water.
Troubleshooting
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5. If any air bubbles come from the condenser, replacement is necessary.
Condenser Test for Scale
Test the cooling water side of the condenser for
scale as follows:
1. Adjust the cooling water throttling valve
so that just a puff of steam issues from
the condenser vent.
A. In extreme cases of scale, steam will
always blow from the condenser vent,
even when the cooling water throttling
valve is wide open.
B. Ensure that a minimum cooling water
pressure of 30 psi is maintained. A drop
in cooling water pressure will cause
steam to blow from the condenser
because of inadequate cooling.
2. Remove the condenser if the discharge
pipe is cool enough to hold. Inspect the
interior of the condenser for scale. If
scale is present, pour the acid cleaning
solution (see “Hard Scale Removal”) into
the condenser through one of the cooling
water connections.
3. Let the solution remain in the condenser
for 15-20 minutes, then drain. Repeat if
necessary until scale is removed.
4. Wash the interior of the condenser thoroughly after using acid solution.
5. Install the condenser on the still.
T
ROUBLESHOOTING
Note
The condenser cannot be
repaired and must be replaced
as a unit.
Caution
Do not add the acid cleaning
solution rapidly for if any
bicarbonate scale is present,
gas will be released in considerable amounts. Do not use the
acid cleaning solution on the
tinned (Distilled Water) side of
the condenser.
Page 24
24
Heating Element Test and
Replacement
Whenever a heating element is suspected of not
operating properly, test and if necessary, replace
the heating element as follows:
1. Shut off the still. Close the water supply
valves to the still. Open the drain valve
and let the still drain completely.
2. Disconnect the electrical heat supply to
the still terminal block.
3. Remove the bottom plate from the still
evaporator. Disconnect the electrical
leads and bus bars from the heating element terminals. Tag the leads to facilitate
reassembly.
4. To test each heating element for open
circuit, apply a current across the
terminals. Use a test light in series with
the applied current. If the test light does
not light, the heating element is burned
out. Mark all damaged heating
elements.
5. To test each heating element for short
circuit, connect one test lead to the boiler
bottom and the other to each terminal
(one at a time). If the heating element is
short circuited, the test light will light.
Mark all damaged heating elements.
6. Remove the evaporator cover from the
still and inspect the heating elements
from the inside of the evaporator.
Warped or split elements should be
T
ROUBLESHOOTING
Warning
To avoid electrical shock, this
product must be disconnected
from the power supply prior to
performing the following
maintenance and servicing.
Page 25
25
replaced.
7. To remove an inoperative or damaged
heater, loosen the screw under the
heater and push out the heater. If the
heater is badly scaled, remove the
retaining nut and rock the heater back
and forth (from inside the evaporator) to
break the scale.
8. Install a new heater in place of the old
heater. Tighten the screw only enough
to hold the heater in place. This will
allow you to rotate the heater when
installing the bus bars.
9. Install the bus bars and wiring between
heater terminals. Retighten the heater
retaining screws to eliminate the
possibility of leakage.
10. Add water to the evaporator and ensure
that none of the heating elements are
leaking.
11. Reassemble the still and connect the
electrical heating service to the heating
element.
T
ROUBLESHOOTING
Page 26
26
Heating Elements
Listed below are the heating elements available.
The heating elements now have compression
nuts. These are directly interchangeable with the
older threaded types. Heating elements are
shipped complete as shown in Figure 6.
Figure 6 Heating Element Replacement
TROUBLESHOOTING
Note
Heater replacement data
stamped inside still junction box
cover.
Note
Replacement heating elements
are furnished with O-ring,
retaining nut, socket head screw
and two round head screws.
These parts are listed in the
event that only these parts need
replacement.
Tee handle wrench (P/N 06287)
available for removing socket
head screw. May be ordered
with replacement heating
elements.
Bottom of
Evaporator
O-Ring (P/N 06289)
Retaining Nut
(P/N 10246)
Heating Element
Socket head screw
1/4-20 x 3/8”
P/N 10248
Round head screw,
brass 8-32 x 3/8”
(P/N 10194)
.oNgolataCllitS
)yticapaC(
)HPG1(1101A13070056U4
)HPG2(3101A330700001Y6
)HPG5(5101A920700612P6
)HPG01(6101A820700612O21
)HPG01(300X6101A920700612P21
golataCretaeH
.oN
egattaWretaeHepyTretaeH
ytitnauQ
deriuqeR
Page 27
27
Troubleshooting Chart
motpmySesuaCelbaborPydemeRdnatseT
.llitsytriD
.ytirupniporD
.retawdeefniseitirupmielitaloV
.llitsytriD
cinagrorocinegoryP
fonoitanimatnoc
.etallitsid
etallitsidniporD
.yticapac
morfgniwolbmaetS
.resnednoc
.resnednocnikaeL
.retawdellitsidnihtworglacigoloiretcaB
.tinugnitaehnoelacsssecxE
.egatlovwoL
.evlavniardnikaeL
.sretaehevitareponidegamaD
.etarwolfretawgniloocwoL
.erusserpretawgniloocwoL
.resnednocnielacsssecxE
.deriuqer
HN,
OCrofetallitsidtseT
2
,3
.resnednocmorf
.deriuqersa
.deriuqer
)".gninaelC
.gnikael
.evlavgnilttorhttsujdaeR
.isp03tsael
.elacsrofresnednoctcepsnI
sanaelc,elacsrofrotaropavetcepsnI
ecudeR.cte
selitalovetanimileplehotwolfretawgnilooc
naelc,elacsssecxerofrotaropavetcepsnI
saecalperroskaelrofresnednoctseT
htiwnaelC.strapdetcepsusehttcepsnI
lacigoloiB"eeS(.deriuqerfilohocla
.deriuqersanaelcdnatcepsnI
nideificepsnahtsselfI.egatlovkcehC
.naicirtceleyfiton,margaidgniriw
tondnadesolcsievlavniarderusnE
tseT.cte,snoitcennoc,gniriwkcehC
.yrassecenfiecalperdnasretaeh
taebdluohS.erusserpretawgniloockcehC
.egatlovhgiH
.naicirtcele
.kaelresnednoC
morfgniwolbretaW
.resnednoc
tonlliwtubstratsllitS
.etallitsidecudorp
.eniletallitsiddepparT
.rotaropavenisdilosfonoitartnecnochgiH
.tiucricretaehotrewoplacirtceleoN
.deriuqersa
.gnippart
.netfoeromllitsniarddna
.tuo
.denrub
.snoitcurtsni
,egatlovdetarehtrevofI.egatlovkcehC
yfitoN.yletaidemmillitsnwodtuhs
ecalperroriapeR.skaelrofresnednoctseT
rosnoitcirtserynarofseniletallitsidtcepsnI
ylreporpdetsujdasirotartnecnocederusnE
denrubfiecalperdnaliocrotcatnockcehC
yldabfiecalperdnastnioprotcatnockcehC
sieborpffotucretawwoltahtkcehC
htiwecnadroccanidellatsniylreporp
Page 28
28
Parts List
xednI
.oN.oN
.oN.oN
.oN
1resnednoC8501206012260124601246012
2
3
4
5
6revoCrotaropavE5911279112991125351253512
7tuNdelrunK9173091730964309643096430
8
9rotaropavE3211272112131120031200312
01eciveDleveLtnatsnoC0231212312761121031210312
11evlaVrotartnecnoceD2721227212340123401234012
21lennuFrotartnecnoceD1821228212140129161291612
31evlaVniarD6902069020690206053060530
noitpircseD
ebuTyrevileDetallitsiD226024260242602)"63(40912)"63(40912
yrevileDetallitsiD"84
retpadAO/WebuT
retpadAebuTetallitsiD
nwohStoN-)dnE(
retaWgnilooC
ebuTegrahcsiD
retaWgnilooC
woblEegrahcsiD
teksaGepiPropaV
)ylno300X-6101A(
revoCrotaropavE
teksaG
1101A
)HPG1()HPG1(
)HPG1()HPG1(
)HPG1(
136023360233602----------
944100541005410----------
188122881238812----------
2073020730624301143011430
1726017260272602726027260
3101A
)HPG2()HPG2(
)HPG2()HPG2(
)HPG2(
----------2511225112
5101A
)HPG5()HPG5(
)HPG5()HPG5(
)HPG5(
6101A
)HPG01()HPG01(
)HPG01()HPG01(
)HPG01(
300X6101A
)HPG01()HPG01(
)HPG01()HPG01(
)HPG01(
)xoB()nwohS
eeS(stnemelEgnitaeH
)nwohStoN()1etoN
)nwohStoN(elffaBQ
toN(ffO-tuCretaWwoL
1307033070920708207092070
0561G
B1X566SC
0561G
B1X566SC
1561G
B1X566SC
1561G
B1X566SC
1561G
B1X566SC
Page 29
29
PARTS LIST
1
2
3
4
5
6
7
8
9
10
11
12
13
Figure 7
Note
Junction box includes terminal
block segments (04205 or
04150) and terminal block ends.
Note
For more details on heating elements, refer to “Heating
Element Replacement.”
detartsullItoNstraPrehtO.oNtraP
)HPG2-1()HPG01-5(
stnemgeSkcolBlanimreT5024005140
sdnEkcolBlanimreT6024015140
skcoCssalGeguaG-----20020
ssalGeguaG-----83060
)ssalGeguaG(sgniR-O-----14060
Page 30
30
Figure 8
Still Heat Control Contactor
PARTS LIST
1
1
xednI
.oN
noitpircseD.oNgolataC
yticapaCetallitsiDllitSHPG2&HPG1HPG2HPG5HPG01HPG01
esahP-eciveSgnitaeH133&113
elop2,pma7270110--------------------
elop3,pma71-----73410---------------
rotcatnoC
elop3,pma06----------73410----------
elop4,pma06--------------54410-----
elop3,pma59--------------------53410
Page 31
31
1. Heater life may be reduced when operated above maximum stated voltage. Operation of still at a
voltage less than the above stated voltages will cause a drop in still output.
2. Customer external connections and circuit protection must be capable of carrying the full load current in accordance with the national electrical code and local practice.
3. Still evaporator must be grounded.
4. O denotes terminal in junction box.
5. At 208 volts, the output is reduced by 25% of rated capacity. Special heaters for 208 volts are
needed to obtain rated still output.
6. This nonstandard voltage will cause a 16% drop in still output capacity in a standard still. Special
heaters may be ordered as an option to achieve rated capacity.
PARTS LIST
Terminal Block
1 Gallon Still
Terminal Block
2 and 5 Gallon Still
Terminal Block
10 Gallon Still
Catalog
No.
A1011
A1013
A1015
A1016
G.P.H.
5
10
Single Phase
Three Phase
120 V (2 wire) 120/240 V (3 wire)
240 V (2 wire)
(See Notes)
480 V (2 wire)
120/208 V (4 wire)
240 V (3 wire)
(See Notes)
380/220 V (4 wire)
(See Notes)
480 V (3 wire)
Figure 9
2
1
Notes
:
See
Figure A
.oNgolataC
foepyT&ytitnauQ
tnemelE
egatloVegattaWsttaWlatoT
1101AUepyT40210560062
3101AYepyT602100010006
5101APepyT6021061200031
6101AOepyT21021061200062
300X-6101APepyT21021061200062
Page 32
32
3
1
0
8161513
0
3A
3B
3
L
3
3
C
g
e
a
ox
pp
y
)
r
pp
y
)
Field Connections for Model A1016-X003 Classic Still
This still requires a terminal box connection between the contactor box and the
terminal block connection (located on the side of the still.) The terminal box is
supplied by the customer. (See Fig. A)
The three main power lines and neutral line come into and out of the contactor
box (L1, L2, L3, L4.) From the contactor box, the three main lines and neutral
line run into the terminal box as four lines, exit the other side as two lines each.
(See Fig. A)
The lines are then split into eight lines because of the amperage draw and size
of the inlet power lines needed. The lines coming from the terminal box should
be of ample size in order to handle the current draw and also fit into the terminal
block on the still. (See Fig. B)
NOTE: Wiring should be done by a certified electrician.
Connections for A1016-X003 Stills
Figure B
See Figure B
Still Terminal Block
Figure A
customer
ontacto
lied b
(su
l B
customer
rmin
lied b
T
(su
Shown Dotted
Field Connections
18 20 16
11 13 22 19
21 15 23 17
Catalog No. A1016-X003 GPH 10
G L1A L1B L2A L2B L3A L3B N2 N1
L
L
G 12 14 10
L
L
2
2
191
2
Elements
1
onnections to Heatin
Page 33
33
Float Feeder for Classic Stills
Used for pretreated water conservation. The
float mechanism controls the flow of pretreated
water to boiler, eliminating waste. All surfaces
coming in contact with purified water are pure
tin.
Enclosed in this package: Assembled float
feeder valve, cooling water discharge pipe
(which accompanies only the 5 PGH still); an
adapter, 3524 (to be used for 10 GPH still);
Steam still only) and 2 nipples, 3435 (to be
used for 10 GPH Steam Still only) and 3436 (to
be used for 10 GPH Electric Still only).
Floorstand for Classic Stills
The floorstands are crafted of sheet metal
and are provided with adjustable levelers.
Enclosed in this package: Floorstand.
.oNledoMnoitpircseD
0001GsllitSHPG01dna5rofdnatsroolF
1001GsllitSHPG2dna1rofdnatsroolF
.oNledoMnoitpircseD
1273G
deefotsllitsHPG01dna5
llitsotretawdetaerterp
tAtnerruCdaoLlluF
Figure 10
Electric Still Mounted on a Floorstand
Figure 11
Electric Still with Float Feeder, Automatic Feedwater
Shutoff and Floorstand
PARTS LIST
Floorstand
Floorstand
Pretreated
Water Inlet
Automatic
Feedwater Shut-Off
Valve
Float Feeder
.oNgolataC
1101A3221---------
3101A---6271------
5101A---756333---
6101A------376633
300X-6101A------37------
CAV021
esahP1
CAV042/021
esahP1
CAV802/021
esahP3
CAV042
esahP3
CAV084
esahP3
Page 34
34
Automatic Feedwater
Shutoff Valve for Classic
Stills
For the conservation of water and automatic operation. This is to be used with
float feeder (G3721) to interrupt feedwater to float feeder when still is turned
off.
Enclosed in this package: Assembled
Automatic Solenoid Valve, brass elbow
(03415) used to connect feedwater inlet
to the Assembled Automatic Solenoid
Valve and a brass bushing (03407)
used to attach Assembled Automatic
Solenoid Valve to the Float Feeder
Shutoff Valve.
Enclosed with the package: Automatic
Solenoid Valve, Brass Elbow (03415)
and a brass bushing.
Flow Automatic Controls
Allows for completely unattended 24-hour
operation when still is attached to tank.
Adjustable drain timer/cycler 2-, 4-, 8- or 16- hour
drain allows reduced still cleaning frequency.
Figure 13
Steam Still with Automatic Controls mounted on Floorstand
Figure 12
Electric Still with Automatic Feedwater Shutoff Valve
PARTS LIST
.oNledoMdesUerehW
0192GslortnoccitamotuayllufhtiwylnO
.oNledoMegatloVdesUerehW
0012Gzh06,V021
,HPG2dna1
llitsesahp1
1012Gzh06,V021llitsesahp3,HPG2
0112Gzh06,V021llitsesahp3dna1,HPG5
0212Gzh06,V021llitsesahp1,HPG01
5212Gzh06,V021llitsesahp3,HPG01
Floorstand
Float Feeder
Automatic
Feedwater Shut-oof
Valve
Pretreated
Water Inlet
Water Drain
Distillate
Outlet
Automatic
Controls
Cooling Water Inlet
Floorstand
Water Drain
Page 35
35
Wall Brackets for Classic Still
The wall brackets are made of aluminum casting (G3275 is made of steel).
Enclosed in this package: Wall Bracket
Puramatic Diverter for
Classic Stills
Divert substandard distilled water to
drain. All of the piping is constructed of
inert pure tin. The automatic temperature
compensated purity meter.
Enclosed in this package: Assembled
Puramatic Diverter piping; Drain Cup
assembly; Purity Meter/Controller; 2
clamps (used to hang the Puramatic
Diverter on the Cooling Water Inlet piping
to the condenser); 10 1- inch plastic
tubes (TU495X64), used to protect the
piping on the Puramatic Diverter from
being scratched); 2 brass elbows
(PM495X134A, used to run the piping
from the Puramatic Diverter to the Drain
Cup); 3 brass tubings (TU495X53A, used
to run the overflow to the Drain Cup); 1
tubing (not numbers, runs from Puramatic
Diverter to the storage tank).
.oNledoMrewoP
0333GzH06/05-CAV511
.oNledoMnoitpircseD
0523GllitSHPG1roftekcarBllaW
1523GllitSHPG2roftekcarBllaW
2523GllitSHPG5roftekcarBllaW
5723GllitSHPG01roftekcarBllaW
Figure 14
Electric Still with Automatic Controls, Puramatic
Diverter, Float Feeder and Automatic Feedwater
Shutoff Valve, mounted on Floorstand.
PARTS LIST
Distillate
Outlet
Puramatic
Diverter
Automatic
Controls
Floorstand
Water
Drain
Pretreated
Water Inlet
Float Feeder
Automatic Feedwater
Shut-off Valve
Page 36
3636
Cartridge Pretreatment Kit for
Classic Stills
The pretreatment kit removes scale-forming
impurities from the feedwater to the still
evaporator (boiler) while improving the distillate
purity. Each pretreatment kit has a scale
eliminator cartridge, Cat. No. D8921, containing
ion-exchange resin to remove scale-forming impurities and activated carbon to remove chlorine and volatile organic impurities. The capacity
of the cartridge is 750 grains as NaCI.
Enclosed in this package: Holder for wall
mounting the cartridge, a flow meter for
regulating the water flow through the cartridge,
and the necessary piping and tubing to connect
the scale eliminator cartridge to the still. For use
with 1 and 2 GPH Classic Stills only.
.oNledoMnoitpircseD
8263G
1roftiKtnemtaerterPegdirtraC
1sedulcni(sllitSHPG2dna
)egdirtrac
1298DegdirtraCtnemtaerterPartxE
PARTS LIST
Distillate
Outlet
Pretreat Inlet
Water Drain
Cooling Inlet
Figure 15
Pretreated Cartridge Kit for 1 and 2 GPH
Electric Stills with Automatic controls, mounted
on wall bracket
Page 37
37
Accessory Numbers for Electric Stills
Tin-Coated Vertical Cylindrical Storage Tanks
Accessories for Electric Stills
yrosseccA1101A3101A5101A6101A
tiKtnemtaerterP
8263G
1298D
tekcarBllaW0523G1523G2523G5723G
lortnoCcitamotuAylluF0012G
evlaVdioneloSretawdeeFcitamotuA0192G0192G
redeeFtaolF1273G1273G
dnatsroolF1001G1001G0001G0001G
retreviDcitamaruP0333G0333G0333G0333G
8263G
1298D
0012G
ro
1012G
0112G
0212G
ro
5212G
yrosseccA1101A3101A5101A6101A
knaTegarotSlacirdnilyCnollaG013403B3403B3403B3403B
dnatsroolF0001H0001H0001H0001H
tekcarBllaW0423H0423H0423H0423H
knaTegarotSlacirdnilyCnollaG525403B5403B5403B5403B
dnatsroolF1001H1001H1001H1001H
tekcarBllaW2423H2423H2423H2423H
knaTegarotSlacirdnilyCnollaG056403B6403B6403B6403B
dnatsroolF2001H2001H2001H2001H
knaTegarotSlacirdnilyCnollaG0017403B7403B7403B7403B
dnatsroolF3001H3001H3001H3001H
knaTegarotSlacirdnilyCnollaG0029403B9403B9403B9403B
dnatsroolF0323H0323H0323H0323H
Page 38
38
Tin-Coated Rectangular Storage Tanks
Accessories to Accompany Tin-Coated Rectangular
and Cylindrical Storage Tanks
ACCESSORIES FOR ELECTRIC STILLS
yrosseccA1101A3101A5101A6101A
knaTegarotSralugnatceRnollaG527203B7203B7203B7203B
knaTegarotSralugnatceRnollaG058203B8203B8203B8203B
yrosseccA1101A3101A5101A6101A
dragtneV0213H0213H0213H0213H
laeSretaW0313H0313H0313H0313H
laeSretaWdnadragtneV1113H1113H1113H1113H
dragtneVrofretliFtnemecalpeR10052100521005210052
pmaLteloivartlU5004H5004H5004H5004H
V021rofVUtnemecalpeR14140141401414014140
Page 39
39
Ordering Procedures
Please refer to the Specification Plate for the complete model number, serial number, and
series number when requesting service, replacement parts or in any correspondence concerning this unit.
All parts listed herein may be ordered from the Barnstead International dealer from whom
you purchased this unit or can be obtained promptly from the factory. When service or
replacement parts are needed we ask that you check first with your dealer. If the dealer
cannot handle your request, then contact our Customer Service Department at
563-556-2241 or 800-553-0039.
Prior to returning any materials to Barnstead International, please contact our Customer
Service Department for a “Return Materials Authorization” number (RMA). Material Returned
without an RMA number will be returned.
Page 40
4040
One Year Limited Warranty
Barnstead International (“BARNSTEAD”) warrants that if a product manufactured by Barnstead shall be free of
defects in materials and workmanship for one (1) year from the first to occur of (i) the date the product is sold by
BARNSTEAD or (ii) the date the product is purchased by the original retail customer (the “Commencement
Date”). Except as expressly stated above, BARNSTEAD MAKES NO OTHER WARRANTY, EXPRESSED OR
IMPLIED, WITH RESPECT TO THE PRODUCTS AND EXPRESSLY DISCLAIMS ANY AND ALL WARRANTIES,
INCLUDING BUT NOT LIMITED TO, WARRANTIES OF DESIGN, MERCHANT ABILITY AND FITNESS FOR A
PARTICULAR PURPOSE.
An authorized representative of BARNSTEAD must perform all warranty inspections. In the event of a defect
covered by BARNSTEAD’s warranty, BARNSTEAD shall, as its sole obligation and exclusive remedy, provide free
replacement parts to remedy the defective product. In addition, for products sold by BARNSTEAD within the continental United States or Canada, BARNSTEAD shall provide provide free labor to repair the products with the
replacement parts, but only for a period of ninety (90) days from the Commencement Date.
BARNSTEAD’s warranty provided hereunder shall be null and void and without further force or effect if there is
any (i) repair made to the product by a party other than BARNSTEAD or its duly authorized service representative, (ii) misuse (including use inconsistent with written operating instructions for the product), mishandling, contamination, overheating, modification or alteration of the product by any customer or third party or (iii) use of
replacement parts that are obtained from a party who is not an authorized dealer of BARNSTEAD.
Heating elements, because of their susceptibility to overheating and contamination, must be returned to the
BARNSTEAD factory and if, upon inspection, it is concluded that failure is due to factors other than excessive
high temperature or contamination, BARNSTEAD will provide warranty replacement. As a condition to the return
of any product, or any constituent part thereof, to BARNSTEAD’s factory, it shall be sent prepaid and a prior written authorization from BARNSTEAD assigning a Return Materials Number to the product or part shall be
obtained.
IN NO EVENT SHALL BARNSTEAD BE LIABLE TO ANY PARTY FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OR FOR ANY DAMAGES RESULTING FROM LOSS OF USE OR
PROFITS, ANTICIPATED OR OTHERWISE, ARISING OUT OF OR IN CONNECTION WITH THE SALE, USE
OR PERFORMANCE OF ANY PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, TORT
(INCLUDING NEGLIGENCE), ANY THEORY OF STRICT LIABILITY OR REGULATORY ACTION.
The name of the authorized Barnstead International dealer nearest you may be obtained by calling
1-800-446-6060 (563-556-2241) or writing to:
2555 Kerper Boulevard
P.O. Box 797
Dubuque, Iowa 52001-0797
Phone: 563-556-2241 or 800-553-0039
Fax: 563-589-0516
E-mail: mkt@barnstead.com
www.barnstead.com
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