MEGA-PURE One Liter Water Still
MEGA-PURE One Liter Water StillOPERATION MANUALAND PARTS LISTSERIES 798Model NumberA440266A440267A7981A7982LT798X1 7/31/02Voltage120V120V240V240VWithout BottleWith BottleWithout BottleWith Bottle
Important InformationThis manual contains important operating and safety information. You must carefully read and understand thecontents of this manual prior to the use of this equipment.Water purification technology employes one or more of the following: chemicals, electrical devices, mercuryvapor lamps, steam and heated vessels. Care should be taken when installing, operating or servicingBarnstead products. The specific safety notes pertinent to this Barnstead product are listed on page 4.Figure 1 MEGA-PURE One Liter Still2
Table of ContentsImportant Information.2Table of Contents.3Safety Information .4Alert Boxes .4Warnings .4Introduction .6Unpacking .7Installation and Service Requirements .8Location of Unit .8Service Requirements .8Power .9Water Supply Requirements .9Drain .10Initial Assembly .10Feedwater Connections .11Tap Water Boiler Feed.11Pretreated Boiler Feed .12Demineralizer Treated Boiler Feed .13In-House Treated Boiler Feed .14Still Output Connections .16Storage Bottle Installation .16Automatic Collection System Installation .17Operation .18High Temperature Cut-off Switch .19Maintenance and Servicing .20Cleaning .20Troubleshooting.21General .21Electrical .23Still Troubleshooting .23Automatic Collection System Troubleshooting .24Parts List .25Parts arranged by Exploded View key number.25Exploded View .26Wiring Diagram .27Ordering Procedures .28One Year Limited Warranty .323
Safety InformationYour Barnstead MEGA-PURE One Liter Water Still has beendesigned with function, reliability, and safety in mind. It is yourresponsibility to install it in conformance with local electricalcodes. For safe operation, please pay attention to the alertsignals throughout the manual.Alert SignalsWarningWarnings alert you to a possibility ofpersonal injury.WarningsTo avoid electrical shock, always:1. Use a properly grounded electrical outlet of correctvoltage and current handling capacity.2.Ensure that the equipment is connected to electrical service according to local and national standards. Failure to properly connect may create afire or shock hazard.3.Do not mount the MEGA-PURE One Liter WaterStill directly over equipment that requires electricalservice. Routine maintenance of this unit mayinvolve water spillage and subsequent electricalshock hazard if improperly located.4.Replace fuses with those of the same type and rating.5.Disconnect from power supply before servicing.6.Do not connect unit to electrical service untilinstructed to do so.CautionCautions alert you to a possibility ofdamage to the equipment.NoteNotes alert you to pertinent factsand conditions.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 ignitesuch materials.42.Wear eye and hand protection when using acid forcleaning, as acid spattering may occur.3.Use this device with water feed only. Failure tocomply with the above could result in explosionand personal injury.4.Ensure all piping connections are tight to avoidleakage of chemicals.
SAFETY INFORMATION5.Always depressurize chemical lines before disassembly.6.To avoid exposure to chemical fumes, ensure adequate ventilation when using chemicals for cleaning.7.Follow carefully the manufacturers’ safety instructions on labels of chemical containers and MaterialSafety Data Sheets (M.S.D.S.).8.“Caution - Hot Surface. Avoid Contact.” Glass portions of still become hot when still is operating. Toavoid burns, do not touch hot glass.9.Refer servicing to qualified personnel.C. To ensure safe mounting:1. Wall composition and construction, as well as fastener type, must be considered when mountingthis unit. The mounting surface and fastenersselected must be capable of supporting a minimumof 60 lbs.; inadequate support and/or fastenersmay result in damage to mounting surface and/orequipment. If you are unsure of mounting surfacecomposition, condition and construction, or correctfasteners, consult your building maintenance groupor contractor.5
IntroductionWarningUse a properly grounded electrical outletof correct voltage and current handlingcapacity.Ensure that the equipment is connectedto electrical service according to localand national standards. Failure to properly connect may create a fire or shockhazard.Do not mount the MEGA-PURE OneLiter Water Still directly over equipmentthat requires electrical service. Routinemaintenance of this unit may involvewater spillage and subsequent electricalshock hazard if improperly located.Do not connect unit to electrical serviceuntil instructed to do so.NoteOperation of the still at a voltageless than the stated voltage willcause a drop in still output.6Your Barnstead MEGA-PURE One Liter Water Still is a compact, all glass unit with Teflon connectors designed to provide 1.4 liter per hour of high purity distilled water. The product water is non-pyrogenic per USP XIX. Resistivity will begreater than 1.0 megohm-cm at the condenser outlet usingmost tap water as feed. This water still can be used as a discrete unit or with customer supplied pretreated water. It canalso be connected to the Barnstead Automatic CollectionSystem for completely automatic operation.Your MEGA-PURE One Liter Water Still allows you toreplace tap water boiler feed with demineralized, distilled orR.O. water for low maintenance operation and high purity distillate. Distilled water storage can be easily handled in theoptional 6-liter polyethylene or 9-liter Pyrex brand storagebottle. Either fits conveniently inside the water still cabinetand dispenses distilled water through a valve which is accessible at the front of the still.Choice of a location for your MEGA-PURE One Liter WaterStill is primarily a matter of convenience. This unit may belocated on a bench or wall mounted.Your MEGA-PURE One Liter Water Still is rated at either120 volts, 50/60 Hz, 1000 watts, single phase or 240 volts,50/60 Hz, 1000 watts, single phase. This unit requiresapproximately 11 to 15 liters per hour of cooling water.The cabinet and glassware are protected against damagefrom overheating by a thermal switch.
UnpackingTools required: Diagonal cutting pliers.1.Remove parts box and still from shipping cartonand place on workbench.2.Check glassware inside the main cabinet fordamage. Check parts in the accessory box fordamage. Identify any broken or damaged partsand report them to your dealer immediately.Refer to Figure 1 (page 2) for the following step:3. Using diagonal cutting pliers, cut and removethe five (5) plastic shipping ties. The shippingtie locations are: Two (2) on the condenser "B",two (2) on the boiler "I", and one (1) on the trap"N."7
Installation and ServiceRequirementsLocation of UnitWarningDo not mount the MEGA-PURE OneLiter Water Still directly over equipment that requires electrical service.Routine maintenance of this unitmay involve water spillage and subsequent electrical shock hazard ifimproperly located.Wall composition and construction,as well as fastener type, must beconsidered when mounting thisunit. The mounting surface andfasteners selected must be capable of supporting a minimum of60 lbs.; inadequate supportand/or fasteners may result indamage to mounting surfaceand/or equipment. If you areunsure of mounting surface composition, condition and construction, or correct fasteners, consultyour building maintenance groupor contractor.WarningEnsure 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.Do not connect unit to electrical service until instructed to do so.8Choice of location for the MEGA-PURE One Liter Water Stillis primarily a matter of convenience as long as the servicerequirements, listed on the next page, are met.A. The still may be bench or wall mounted. Allow 4"6" clearance at the sides and top for circulation ofambient air to prevent buildup of heat in the cabinet.B.Unit Dimensions: 18" wide x 10" deep x 34" high.C.Wall Mounting: The still is supplied with slottedmounting holes located 16" on center in the rear ofthe cabinet and22 7/8" from the bottom. The weight of the unitwith a full storage bottle is 45-60 lbs.Service RequirementsPowerYour water still is supplied with a power cord (5 feet long) andplug. The plug on the 120V unit requires a standard NorthAmerican 120V, 15A, 3-prong receptacle. The plug on the240V unit requires a standard European 240 volt receptacle.(See Figure 2.) If you do not have the required receptacleavailable within 5 feet of your still, a certified electricianshould install one in accordance with local and national standards. As an alternate method of power supply for a 240 voltunit, your electrician may remove the supplied plug and wirethe cord to a 15A-250V breaker box.(See Figure 3.)Water Supply RequirementsBarnstead recommends one of the following options for supplying water to operate your MEGA-PURE One Liter WaterStill.OPTION #1A single, untreated cold water supply. The supply must becapable of providing a minimum of 4 gallons (15 liters) perhour at a pressure of 20-100 psi and be located within 4 feet(1.2 meters) of the MEGA-PURE One Liter Water Still. Youmust provide a shut off valve and reducer as shown in Figure4.
INSTALLATION AND SERVICE REQUIREMENTSNoteThe double solenoid valve kit is not neededif you are using a MEGA-PURE D1 or D2deionizer for pretreatment.GroundLineLineDrainAn open or atmospherically vented drain located lower thanthe still is necessary to allow for gravity flow. Barnstead supplies a 5 foot length of 1/2" I.D. vinyl tubing for the drain.Additional tubing may be purchased from your laboratorydealer.Figure 2 240 Volt ReceptacleLine GroundWith Option #1, approximately 4 gallons of untreated waterwill be used per hour in the cooling section of the still, 1 gallon of this water will be used as boiler feed. Water connections are discussed on pages 13-14.OPTION #2An untreated cold water supply plus a source of RO, demineralized or previously distilled water. The untreated supplymust be capable of providing a minimum of 4 gallons (15liters) per hour at a pressure of 20-100 psi and be locatedwithin 4 feet (1.2 meters) of the water still. The treated supplymust be capable of providing 1 gallon (3.75 liters) per hourand be located within 4 feet of the water still. You must provide a shut-off valve and reducer at each water supply (seeFigure 4). In addition you will require the optional double solenoid valve kit (Catalog No. RY798X2A (120V) or 440236(240V)).With Option #2, approximately 4 gallons of untreated waterwill be used each hour for cooling. The second (treated)water supply of 1 gallon per hour will be used as boiler feed.Water connections are discussed on pages 14-18.LineWaterSupplyLoad(Brown Wire)ReducerLoad Ground(Green Wire)Figure 3 15A - 250V Breaker BoxLoad(Blue Wire)2"-3"Lengthofpipewith1/8"N.P.T.Figure 4 Shut-offValve9
Initial AssemblyTools required for assembly: 7/16" open end wrench, diagonalcutting pliers, common screwdriver.1. Unwrap the condenser “B” and thoroughly flush allof the salt out.Solenoid PowerReceptacleHeater igure 5 Control Bottom Connections102.Reattach the condenser “B” to the still and thenattach the two Teflon connectors “D” and “P” to thecondenser “B” as shown in Figure 1.3.Check orientation of trap "N." If it is not level or tilted back toward the boiler as shown in Figure 1,move the condenser "B" up in its bracket. This willtilt trap as shown in Figure 1.4.Remove the packing material and rotate tube "L"into the constant level chamber of boiler "I" asshown in Figure 1.5.Unpack the Vycor immersion heater "M" andcheck the voltage rating on the top cap. It shouldagree with the voltage of your power supply. If itdoes not, contact your dealer and order the correctheater.6.Insert the immersion heater into the top opening ofboiler "I" as shown in Figure 1.7.Thread the heater plug and cord through the largehole above the boiler "I," then back through thehole below the control box "H." Plug heater pluginto the receptacle on the bottom of the controlbox. The plug is twist-lock type and requires 1/4clockwise turn to lock in place.ACS ControlReceptacle
Feedwater ConnectionsNoteBarnstead strongly recommends thatyou install the optional flowmeter(Catalog Number 440092) into yourfeedwater line(s). This will allow youto control the flow of water to yourstill easily and precisely.This still always uses tap water for cooling the steam in thecondenser. However, you have the option of feeding yourboiler with higher purity pretreated water, thereby reducingthe need to drain and clean your boiler.If you will be using tap water as your boiler feedwater, proceed to the Tap Water Boiler Feed section. If you will beusing a supply of distilled, deionized or reverse osmosiswater as your boiler feed, proceed to the Pretreated BoilerFeed section.Tap Water Boiler FeedSee Figure 61. Install a customer supplied shutoff valve onto yourtap water source. Thread the solenoid valve ontoyour customer supplied shutoff, with the sidemarked “in" toward the shutoff.2.Install the supplied fitting to the “out” side of thesolenoid valve. Connect the 5/16" I.D. tubing (fromthe condenser) to this fitting.3.Route 3/8" I.D. vinyl drain tubing to an atmospherically vented drain.Figure 6 Tap Water Feed Only11
FEEDWATER CONNECTIONS4.Plug the solenoid valve power cord (not shown)into the receptacle on the bottom of the control box"H." (See Figure 5.)5.Go to the Still Output Connections section to complete your still's setup.Pretreated Boiler FeedWhen a supply of distilled, deionized or reverse osmosiswater is to be used as boiler feed, first revise the still connections as follows:1. Remove boiler fill tube "O" from still and set aside.2.Locate the 3/8" I.D. x 44" long vinyl tubing and onebarbed tee (3/8" I.D. x 3/8" I.D. x 3/8" I.D.) in theparts box.3.Install one end of the vinyl tubing to the coolingwater outlet located on the top right of the condenser "B" (where boiler fill tube "O" wasattached). Route the other end through the cabinetand down the back as shown in Figure 7.4.Cut the 3/8" I.D. vinyl drain tubing and install thebarbed tee. Connect the 3/8" I.D. vinyl tubing fromcondenser to the barbed tee. Push the vinyl tubingall the way onto the tee to assure a leak free seal.5.Route the drain tubing to an atmospherically vented drain.If you will be using a MEGA-PURE D1 or D2 demineralizer toprovide pretreated boiler feed, go to the DemineralizerTreated Boiler Feed section. If you will be using an "in-house"source of pretreated water for boiler feed, go to the In-HouseTreated Boiler Feed section.Figure 7 Tubing Connections12
FEEDWATER CONNECTIONSDemineralizer Treated Boiler FeedSee Figure 8. (Must have optional still adapter kit: CatalogNo. 440376)1. Install a customer supplied shutoff valve onto yourtap water source. Thread the solenoid valve ontoyour customer supplied shutoff, with the sidemarked “in" toward the shutoff.NoteIf using the optional flowmeter,install it at this point instead of theadapter.2.Install the fitting supplied with the still adapter kitinto the “out” side of the solenoid valve. Connectthe 1/4" O.D. tubing (from the demineralizer) tothis fitting.3.Cut the 1/4" O.D. tubing (from last step) at a convenient point and install the tee from the stilladapter kit (Catalog No. 440376).4.Connect a length of 1/4" O.D. tubing to the thirdarm of the tee. Connect the 1/4" O.D. to 3/8" I.D.adapter to the free end of this length of 1/4" O.D.tubing. Connect the5/16" I.D. tubing (from the condenser) to thisadapter.5.Locate boiler fill tube "L." Connect 7/16" I.D. vinyltubing from demineralizer output to end of boiler filltube. Route as shown and install clip "S" to support the tubing.Figure 8 Deionizer Feed13
FEEDWATER CONNECTIONS6.Route 3/8" I.D. vinyl drain tubing to atmospherically vented drain.7.Plug solenoid valve power cord (not shown) intoreceptacle in control box "H."8.Plug still adapter kit cable into right side of demineralizer and receptacle in control box "H."9.Go to the Still Output Connections section on page19 to complete the setup of your still.In-House Treated Boiler FeedSee Figure 9. (Must have optional double solenoid valves:Catalog No. 440236 (240V), RY798X2A (120V))1. Install customer supplied shutoff valves onto yourtap water source and your in-house treated watersource. Thread the solenoid valves onto your customer supplied shutoffs, with the sides marked “in"toward the shutoffs.2.Figure 9 In-house Treated Feed14Install the supplied 5/16" fitting to the “out” side ofthe solenoid valve on your tap water source.Connect the 5/16" I.D. tubing (from the condenser)to this fitting.
FEEDWATER CONNECTIONS3.Connect the 3/8" fitting and 3/8" I.D. vinyl tubingfrom the double solenoid valve kit to the “out” sideof the solenoid valve on your treated water supply.4.Locate the boiler fill tube "L." Connect 3/8" I.D.from treated water supply solenoid to the end ofthe boiler fill tube. Route as shown and install clip"S" to support the tubing.5.Route the 3/8" I.D. vinyl drain tubing to an atmospherically vented drain.6.Plug the solenoid valve power cord (not shown)into the receptacle in control box "H" (See Figure5.)7.Go to the Still Output Connections section on page19 to complete the setup of your still.15
Still Output ConnectionsIf you are using one of the optional Storage Bottles, go to theStorage Bottle Installation section. If you are connecting yourstill to an Automatic Collection System, go to the AutomaticCollection System Installation section.NoteThe storage bottles do not automatically control the still.Figure 10 Storage Bottle Installation16Storage Bottle InstallationTo install the optional 6 or 9 liter storage bottle inside the oneliter still cabinet, first locate the following parts in the storagebottle parts box:Product delivery tube "F"Teflon Connector "E"20" length of 1/2" vinyl tubingPlastic tee (1/2 X 1/2 X 1/2)1.Place storage bottle (with product delivery tube "F"installed) inside still cabinet below condenser "B."Connect product delivery tube to condenser withTeflon connector "E."2.Locate plastic tee (1/2 x 1/2 X 1/2) and 20" lengthof 1/2" vinyl tubing in parts box. Connect to bottleoverflow tubulation and drain as shown in Figure10 below.
STILL OUTPUT CONNECTIONSAutomatic Collection SystemInstallationBefore connecting your MEGA-PURE One Liter Water Still tothe Barnstead Automatic Collection System, move the still toits final location.1. Locate ACS tube "Q" and Teflon connector "E" inthe ACS parts box. Locate distillate outlet tube(TU798X1) in the still parts box. Assemble to tubing from collection system as shown in Figure 11.2.Plug input jack from ACS into ACS receptacle onbottom of still control box "H." (See Figure 5)Figure 11 Complete System Layout (Not to scale)17
OperationWarningUse a properly grounded electricaloutlet of correct voltage and currenthandling capacity.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.Do not use in the presence of flammable or combustible materials; fireor explosion may result. This devicecontains components which mayignite such materials.Plug electrical power cord into appropriate receptacle.Refer to Figure 1, page 2 for referenced locations.1. Close drain clamp "G" on bottom of boiler "I."2.Open valve at tap water source and treated watersource if so installed.3.Switch on the main power breaker on control atcustomer power source.4.Push “Water” switch on control box "H". Greenindicator will light and solenoid will open. Allowboiler to fill.5.Push “OPERATE” switch. Indicator will light andheaters will come on.6.Allow the still to operate for 15-20 minutes. Formaximum volume of distillate, increase the flow ofcooling water to the point where only a slight wispof steam is visible at the condenser vent "A." If youare using a separate source of pretreated water foryour boiler feed, adjust the boiler feed flow so thata constant overflow from the boiler is maintained.7.Your MEGA-PURE One Liter Water Still shouldnow be operational. Run the still for 4-5 hours tocleanse itself before collecting water for use.8.To shut your water still off push the OFF switch.This will shut the water supply and the heaters off.Use this device with water feed only.Failure to comply with the abovecould result in explosion and personal injury.“Caution - Hot Surface. AvoidContact.” Glass portions of stillbecome hot when still is operating.To avoid burns, do not touch hotglass.If any difficulties are encountered in operating this water still,check all operating and assembly steps to be sure the stillwas assembled and is being operated correctly. If the difficulty still exists, consult the Troubleshooting section of this manual.18
OPERATIONNoteIf you are feeding an ACS with yourstill, note that when the ACS is full, itwill signal the still to shut down.During this shut-down, the heaterand the water supply will both shutoff and the front panel lights on thestill will be extinguished. This normaloperation can mimic the effects ofan overheating boiler, but does notrepresent any problem with the still.High Temperature Cut-off SwitchYour MEGA-PURE One Liter Water Still is protected againstoverheating by a thermal switch located in the control box atthe right hand side of the boiler. Should the boiler overheat,the switch will open causing the heater and water supply toshut off. When the boiler cools (5-15 minutes), the switch willreset automatically, but the still will have to be restarted bythe operator. When unit has cooled, press the “WATER”switch and then the “OPERATE” switch to restore normaloperation. Check boiler occasionally for proper water level.19
Maintenance and ServicingWarningDisconnect from the power supplybefore servicing.Wear eye and hand protection whenusing acid for cleaning, as acid spattering may occur.Ensure all piping connections aretight to avoid leakage of chemicals.Always depressurize chemical linesbefore disassembly.CleaningFor top performance and efficiency, the MEGA-PURE OneLiter Water Still should be kept clean and free of scale. It isrecommended that the boiler be drained and refilled withfresh water daily to flush the boiler of the concentration ofcontaminants from the previous day’s run.When using untreated boiler feed, cleaning is recommended after every 15-20 hours of operation. The unit should becleaned with a hydrochloric acid solution. This is done as follows:1. Push unit “OFF” switch.2.Disconnect output tubing at condenser "B" fromcollection vessel and temporarily place a beakerunder condenser outlet.3.Drain boiler by opening clamp "G." Close clamp"G" after boiler has completely drained. Refill boiler.4.Use the spare pinch clamp from the parts box toshut off overflow tube from constant level chamber"K" as close as possible to overflow stem.5.Carefully pour approximately 260 ml. of 10%hydrochloric acid solution into top of constant levelchamber "K."6.Wait approximately 10 minutes or until residue disappears. If additional cleaning is required, drainboiler down 1 inch and turn unit on for a few minutes until residue disappears. Do not boil. Turn thestill off.7.Carefully drain the unit, remove clamp from overflow tube and refill with fresh water. Drain boiler,refill with fresh water and operate for 30 minutes.Reconnect tubing from collection vessel to condenser "B."To avoid lung injury or suffocation,ensure adequate ventilation whenusing chemicals for cleaning.Follow carefully the manufacturers’safety instructions on labels ofchemical containers and MaterialSafety Data Sheets (M.S.D.S.).Refer servicing to qualified personnel.20
MAINTENANCE AND SERVICINGTroubleshootingGeneralProblemLeaks.Rough Boiling.Scale Build-up.Heater Failure.Heater failure due to scalebuild-up or alkali attack willnot be replaced underwarranty.CausesThe most common leak is oneoccurring in the vinyl draintubing. Hot water causessoftening and pulling loose atthe plastic barbed connectors.Rough boiling is the result ofalkali attack to the matte finishon the heaters. The mostcommon cause is using waterpretreated with NaCIregenerated water softeners.A brownish-white scale in theboiler indicates that the boilerrequires cleaning.SolutionRuns of vinyl tubing should besupported to reduce the pullon the plastic connectors.Small clamps may be used tofirmly hold the vinyl tubing.Remove heater and lightlyroughen surface with 150 gritsandpaper.Clean boiler per cleaninginstructions. Scale should notbe allowed to accumulate asheaters may be damaged.Short life on Vycor immersion heaters can usuallybe attributed to use of waterpretreated with NaCIregenerated water softenersor excessive scale buildup.Softened water used as aboiler feed causes aconcentration of sodium ionsand alkaline attack of theVycor glass. Rough boilingwill be the first indication ofalkaline attack. At failure, theheaters will us
replace tap water boiler feed with demineralized, distilled or R.O. water for low maintenance operation and high purity dis-tillate. Distilled water storage can be easily handled in the optional 6-liter polyethylene or 9-liter Pyrex brand storage bottle
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