User’s Manual AtmosPure™ Re-Gen Gas Purifier Models Voltage, Frequency Electrical Receptacle Plug Type 5121810 5121831 5121835 5121840 5121845 100-115V, 50/60 Hz 208-230V, 50/60 Hz 208-230V, 50/60 Hz 208-230V, 50/60 Hz 208-230V, 60 Hz only North America British (UK) Schuko China/Australia North America To receive important product updates, complete your product registration card online at register.labconco.
Copyright © 2010, 2012, 2014 Labconco Corporation. All rights reserved. The information contained in this manual and the accompanying products are copyrighted and all rights reserved by Labconco Corporation. Labconco Corporation reserves the right to make periodic design changes without obligation to notify any person or entity of such change. Warranty Labconco provides a warranty on all parts and factory workmanship.
TABLE OF CONTENTS CHAPTER 1: INTRODUCTION General Description Circulation System Purifier System Regeneration Control 1 3 3 3 4 CHAPTER 2: PREREQUISITES Support Requirements Exhaust Requirements for the Regeneration Vent Valve Electrical Requirements Plumbing Requirements for Circulation, 4% Hydrogen/ Inert Gas Mixture, Vacuum, and Exhaust Vent Space Requirements 5 6 6 6 CHAPTER 3: GETTING STARTED Unpacking the Gas Purifier Installing the Gas Purifier on a Supporting Structure & Work Surface Connecting
CHAPTER 6: MAINTAINING YOUR GAS PURIFIER Routine Maintenance Schedule Initial Certification Recertification Solenoid Valve Replacement Catalyst Replacement 34 34 34 35 35 35 CHAPTER 7: ACCESSORIZING YOUR GAS PURIFIER 37 CHAPTER 8: TROUBLESHOOTING 41 APPENDIX A: REPLACEMENT PARTS 42 APPENDIX B: DIMENSIONS 44 APPENDIX C: SPECIFICATIONS 45 APPENDIX D: ATMOSPURE RE-GEN GAS PURIFIER OXYGEN & MOISTURE REMOVAL RATES 46 APPENDIX E: CONVERSIONS 54 APPENDIX F: REFERENCES 55
Chapter 1: Introduction The AtmosPure™ Re-Gen Gas Purifier reduces the levels of oxygen and moisture inside the controlled atmosphere glove box. The Gas Purifier enables the user to work in an inert gas environment with materials that are sensitive to oxygen and moisture. The Gas Purifier comes fully regenerated and ready to use after the main chamber oxygen and moisture levels are reduced to 3000-5000ppm using evacuation and re-fills of an inert gas.
Chapter 1: Introduction The Gas Purifier has the capacity to remove up to 5 liters of oxygen (13,500ppm) and 660 grams of moisture (18 million ppm) at standard temperature and pressure (STP). Depending on the application, glove box liner material chosen, and frequency of use, regeneration may be necessary only once every 1-3 months and take only 13 hours to complete the process.
Chapter 1: Introduction General Description The AtmosPure Re-Gen Gas Purifier consists of three distinct systems: A. Circulation System B. Purifier System C. Regeneration Control Circulation System The circulation blower continually circulates the inert gas inside the glove box through the Gas Purifier to remove oxygen and moisture. As the blower circulates the glove box inert atmosphere through the purifier column, water molecules are adsorbed by the molecular sieve.
Chapter 1: Introduction Regeneration Control Regeneration is controlled by a microprocessor which automatically sequences the solenoid valves during the regeneration cycle. The regeneration cycle restores the molecular sieve and copper catalyst. It is programmed for the following time functions: Initial 2 minute purge to allow adjustment of 4% hydrogen/inert gas mixture flow rate to 10-25 CFH. (10 CFH Helium/4% Hydrogen, 20 CFH Nitrogen/4% Hydrogen, 25 CFH Argon/4% Hydrogen). Heat cycle – 3 hours.
Chapter 2: Prerequisites Before you install the Gas Purifier to the controlled atmosphere glove box, you need to prepare your site for installation. You must be certain that the area is level and of solid construction. In addition, a dedicated source of electrical power should be located near the installation site to power the glove box and the Gas Purifier.
Chapter 2: Prerequisites Support Requirements In the preparation of installing the Gas Purifier at the glove box site, please consider the following: A bench or stand that rests on the floor or fixed to the wall, but not both, may be appropriate. 35" to 40" (889mm to 1,016mm) is typical for standing height (Labconco stands offered in Chapter 7 vary from 33" to 40" or 838mm to 1,016mm).
Chapter 2: Prerequisites Plumbing Requirements for Circulation, 4% Hydrogen/Inert Gas Mixture, Vacuum, and Exhaust Vent The Gas Purifier has two 3/4" compression fittings for connecting the inlet/outlet of the circulation system of the Gas Purifier to the glove box inert gas and three solenoid valves with 3/8" compression fittings for connection to the regeneration system (Regeneration Control).
Chapter 3: Getting Started Once the site for your Gas Purifier is properly prepared, you are ready to unpack, inspect, and install your system. Read this chapter to learn how to: Unpack and move the Gas Purifier. Set up the Gas Purifier with the proper supporting structure. Connect the electrical supply. Connect the plumbing lines for circulation, 4% hydrogen/inert gas mixture, vacuum, and exhaust vent. Start-up the Gas Purifier for removal of oxygen and moisture.
Chapter 3: Getting Started THE UNITED STATES INTERSTATE COMMERCE COMMISSION RULES REQUIRE THAT CLAIMS BE FILED WITH THE DELIVERY CARRIER WITHIN FIFTEEN (15) DAYS OF DELIVERY. DO NOT RETURN GOODS WITHOUT THE PRIOR AUTHORIZATION OF LABCONCO. UNAUTHORIZED RETURNS WILL NOT BE ACCEPTED. IF GAS PURIFIER WAS DAMAGED IN TRANSIT, YOU MUST FILE A CLAIM DIRECTLY WITH THE FREIGHT CARRIER. LABCONCO CORPORATION AND ITS DEALERS ARE NOT RESPONSIBLE FOR SHIPPING DAMAGES.
Chapter 3: Getting Started Connect the Plumbing Lines for Circulation, 4% Hydrogen/Inert Gas Mixture, Vacuum, and Exhaust Vent All the plumbing lines to the Gas Purifier must be connected properly. Carefully follow the instructions that follow and refer to Figure 3-1 and Figure 3-8 that depict views of the rear of the Gas Purifier where all the plumbing connections are made.
Chapter 3: Getting Started C.A. COM Port (6-pin) on back of Gas Purifier for shared vacuum pump operation with glove boxes configured with Auto Pressure Control feature. Auto Mode Moisture/Oxygen (9-pin) connector for connection to oxygen or moisture monitor. Only used for auto blower control. Vacuum Pump Outlet for glove boxes without auto pressure control. Used for a dedicated vacuum pump. 3/4" Inlet/Outlet Compression Fittings for Inert Gas Circulation from the Glove Box.
Chapter 3: Getting Started 3/4" Inlet/Outlet Compression Fittings for Connection to Gas Purifier. See Chapter 7: Accessories to order AtmosPure 3/4" to 3/8" Adapter Kits for attachment to glove boxes with 3/8" inlet/outlet. The adapter kits allow for a tube size transition so 3/4" tubing can be run to the Gas Purifier.
Chapter 3: Getting Started Connecting the Circulation Plumbing The circulation plumbing continuously circulates the inert gas atmosphere from the controlled atmosphere glove box and purifies it by removing oxygen and moisture. The connections from the 3/4" inlet/outlet compression fittings must be made to the glove box. Depending on the neoprene lined tubing kit or stainless steel tubing kit selected, route one line from the inlet of the Gas Purifier to the outlet of the glove box.
Chapter 3: Getting Started Isolation Valves (manually operated) Closed initially and upon regeneration only. Opened for normal mode circulation when inert gas atmosphere is below 5000 ppm.
Chapter 3: Getting Started Connecting the Regeneration Plumbing The Regeneration Plumbing allows the copper catalyst and molecular sieve to be regenerated as needed. The regeneration process takes 13 hours and may be completed overnight. Refer to Figures 3-1, 3-3, and 3-8. First, locate the tank of 4% hydrogen/inert gas mixture. Using the AtmosPure Regeneration Tubing Kit, route the tubing from the 4% hydrogen gas mixture pressure regulator to the valve inlet per Figures 3-1 and 3-8.
Chapter 3: Getting Started Figure 3-5 Alternate View for Vacuum Connection 16 Product Service 1-800-522-7658
Chapter 3: Getting Started C.A. COM Port (6-pin) on Back of Auto Pressure Control Glove Box. Used for connection to AtmosPure ReGen for single shared vacuum pump operation. Vacuum Pump electrical plug on Auto Pressure Controller for single shared vacuum pump use.
Chapter 3: Getting Started Initial Start-up of the Gas Purifier for Removal of Oxygen and Moisture Do not open the isolation valves (Figure 3-4) until the inert atmosphere in the controlled atmosphere glove box main chamber has been reduced below 5000 ppm for both oxygen and moisture. The Gas Purifier arrives fully regenerated and ready for use. Usually 5000 ppm can be attained through 200 evacuation and fill cycles of inert gas into the glove box.
Chapter 3: Getting Started Start/Stop Regeneration button to start and stop the regeneration process. Vacuum release button used momentarily for less than one second after the regeneration process is complete. Indicator Lights show each step of the 13 hour regeneration process. Main Power ON/OFF Switch Two 3/4" manually operated Isolation Ball Valves to isolate Gas Purifier from the glove box during regeneration.
Chapter 3: Getting Started Regenerating the Gas Purifier Catalysts The AtmosPure Re-Gen Gas Purifier is initially shipped with the copper catalyst and molecular sieve fully regenerated and ready to use. The copper catalyst can last 1-3 months with normal use.
Chapter 3: Getting Started Regeneration Steps: Step 1 – Check to see that the 4% hydrogen/inert gas mixture tank valve is open and its pressure regulator is set between 10-14 psi. At least ½ a tank of 4% hydrogen/inert gas must be available. Also, be sure that the vacuum pump electrical power cord is plugged in. Step 2 – Close both isolation valves. ! CAUTION: Both isolation valves must remain closed until the entire regeneration cycle is completed and vacuum is released.
Chapter 3: Getting Started Step 9 – The regeneration procedure has now been completed. The blower button needs to be turned on to begin circulating the inert gas in the glove box through the Gas Purifier. AUTOMATIC REGENERATION PROGRAMMED FUNCTIONS FUNCTION H2 Set Initial Purge (manual adjustment of 4% hydrogen/inert gas flow rate) HEAT H2 PURGE VACUUM VACUUM RELEASE SOLENOID VALVES 4% HYDROGEN VENT INLET TIME HEATER 2 MIN. ON OPEN OPEN CLOSED 3 HRS. 2 HRS.
Chapter 3: Getting Started Figure 3-8 Connection Diagram for AtmosPure Gas Purifier and Controlled Atmosphere Glove Box Product Service 1-800-522-7658 23
Chapter 3: Getting Started Requirements Note: Refer to Chapter 7 for proper accessories required for set-up. At a minimum, you will require the following from Chapter 7: Adjustable height base stand Regeneration Tubing kit Circulation Tubing kit Gas/Vacuum/Vent Tubing kit Direct drive rotary vane vacuum pump Oxygen or Moisture monitor or both (Recommended) A glove box configured with auto pressure controller facilitates best performance of the AtmosPure Re-Gen Gas Purifier.
Chapter 4: Features and Safety Precautions Labconco has engineered the Gas Purifier to meet the ISO 10648-2 Class 1 atmosphere leak specification when used with Labconco controlled atmosphere glove boxes. The information that follows details performance features so you can get the most out of your Gas Purifier. Refer to Figure 4-1. Gas Purifier Performance Features 1.) 2.) 3.) 4.) 5.) 6.
Chapter 4: Features and Safety Precautions 7.) 8.) 9.) 10.) 26 levels are 1 ppm for stainless steel, 2 ppm for FRP, and 5 ppm for moisture. The vacuum pump outlet on the back is rated at 115V, 8A or 230V, 4.5A. Three solenoid valves control the regeneration of the copper catalyst and molecular sieve. All are located on the back of the Gas Purifier for easy connection to the 4% hydrogen/inert gas mixture, vacuum pump, and vent exhaust.
Chapter 4: Features and Safety Precautions 11.) 12.) 13.) 14.) 15.) 16.) 17.) The Gas Purifier automatically compensates for power outages and restarts the regeneration process if interrupted for 10 minutes or longer. This feature assures complete regeneration of the copper catalyst and molecular sieve as the system would cool and not regenerate properly. Leak tight.
Chapter 4: Features and Safety Precautions Figure 4-1 Features 28 Product Service 1-800-522-7658
Chapter 4: Features and Safety Precautions Safety Precautions 1. It is the responsibility of the user to determine the suitability of this product for the intended applications. Consult your Safety Officer for application review. 2. This product is not designed or intended to be explosion proof. It is the responsibility of the user to determine and avoid the lower explosive limits and flammability of the enclosed gases used within the controlled atmosphere glove box.
Chapter 4: Features and Safety Precautions 11. Ensure only trained operators use the Gas Purifier with the glove box. New users must review the User’s Manual and should be trained by operators familiar with glove box operation. 12. Tag the Gas Purifier and glove box with appropriate warnings, if work inside the glove box is hazardous or needs to remain untouched. Tag the Gas Purifier and glove box if it requires servicing. 13.
Chapter 5: Using Your Gas Purifier Now that the installation of your Gas Purifier and glove box is completed, you are ready to use it. Read this chapter to learn about: Routine Daily Work Procedures. Hazardous Use with Chemicals. Prohibited Materials Use. Routine Daily Work Procedures Planning Thoroughly understand procedures and equipment required before beginning work. Work from a written plan.
Chapter 5: Using Your Gas Purifier Perform evacuation and fill cycle on the transfer chamber of the glove box using the vacuum outlet and gas inlet valves. Depending on the vacuum level achieved, it takes 1-5 cycles to reduce oxygen and moisture levels below 1%. Porous materials being transferred may require longer sustained vacuum evacuations to remove the oxygen and moisture trapped in the materials.
Chapter 5: Using Your Gas Purifier Transferring Materials to the Outside All open chemical weigh vessels or containers must be sealed before removing materials from the glove box main chamber. Objects in contact with previously contaminated internal atmospheres must be surface decontaminated or bagged before removal from the glove box through the transfer chamber.
Chapter 6: Maintaining Your Gas Purifier Review this chapter on maintenance for the following: 1. 2. 3. 4. 5. Routine maintenance. Initial certification. Recertification. Solenoid valve replacement. Catalyst replacement. Routine Maintenance Schedule Weekly Monitor and record oxygen and moisture levels inside the glove box with accessory monitors (see Chapter 7). 1-3 Months Regenerate the catalysts every 1-3 months depending on your application, glove box liner material, and frequency of use.
Chapter 6: Maintaining Your Gas Purifier Recertification Under normal operating conditions, the Gas Purifier and glove box system should be recertified at the time of installation and at least annually thereafter. The certifier should choose and perform one of the following tests. Both tests validate the system Leak Test of the Gas Purifier connected to the glove box. Oxygen Method Leak Test per ISO 10648-2 test methods. See glove box manual. Pressure Change Leak Test per ISO 10648-2 test methods.
Chapter 6: Maintaining Your Gas Purifier 5. Replace the large nut and seal with pipe sealant compound. 6. Install the outer service panel. 7. Follow 13 hour Regeneration procedure from Chapter 3. 8. Once regenerated, the Gas Purifier blower can be run as soon as the glove box inert atmosphere is reduced to 3000-5000 ppm through 100-200 evacuation/fill cycles.
Chapter 7: Accessorizing Your Gas Purifier There are many ways to accessorize the Gas Purifier for your use with the glove box. These include many different accessories listed in this chapter. 1. Adjustable Height Base Stands with Work Surface (Part #5235500 w/casters, Part #5235501 w/adjustable feet) These stands, 60" x 31", with attached black laminate work surfaces have an adjustable height range from 33" to 40" (838mm-1,016mm) and include a lower shelf for supporting accessory equipment. See Figure 1-1.
Chapter 7: Accessorizing Your Gas Purifier 6. AtmosPure 3/4" to 3/8" Adapter Kit (See Part #’s below) Fittings permit 3/4" ID neoprene hose included with 5441800 and 5441801 Kits (sold separately) to attach to glove box’s 3/8" inlet/outlets. Two fittings included with each kit. Not required on current Protector Glove Boxes (manufactured after November 2010) Part # 5441900 5441901 Description Elbows Reducers Used On Precise Glove Boxes Pre-2011 Protector Glove Boxes 7.
Chapter 7: Accessorizing Your Gas Purifier 11. Oxygen Monitors Oxygen monitors allow the user to continuously monitor oxygen levels inside the glove box. Monitors are normally placed inside the main chamber to provide the best performance. Never operate a transfer chamber vacuum evacuation on sensitive oxygen monitors as damage can occur.
Chapter 7: Accessorizing Your Gas Purifier the evacuation/fill cycles up to 499 cycles for the main chamber and up to 199 cycles on the transfer chamber. The vacuum and pressure can be automatically regulated between -5 to +5 inches of water gauge in the main chamber and between 0 to -29 inches of mercury gauge in the transfer chamber. See illustration below and figures in Chapter 3.
Chapter 8: Troubleshooting Refer to the following table if your Gas Purifier box fails to operate properly. If the suggested corrective actions do not solve your problem, contact Labconco for additional assistance. PROBLEM CAUSE CORRECTIVE ACTION Control panel lights won’t operate. Unit not plugged into outlet. Plug unit into appropriate electrical service and turn main power switch on. Circuit breaker(s) tripped. Reset or replace circuit breaker. Switch is defective. Replace switch.
Appendix A: Replacement Parts The components that are available for your Gas Purifier are listed. The parts shown are the most commonly requested. If other parts are required, please contact Product Service. Item Qty.
Appendix A: Replacement Parts Figure A-1 Replacement Parts for AtmosPure Re-Gen Gas Purifier Product Service 1-800-522-7658 43
Appendix B: Dimensions The following dimensions are for all the Gas Purifiers. All dimensions in inches and metric.
Appendix C: Specifications This Appendix contains technical information about all the Gas Purifiers including electrical specifications and environmental operating conditions. 10 Amps, 100-115V or 5 Amps, 230V, 50/60 Hz AtmosPure Re-Gen Gas Purifier. Environmental Conditions Indoor use only. Maximum altitude: 12,000 feet (3,657 meters). Ambient temperature range: 41° to 104°F (5° to 40°C).
Appendix D: AtmosPure Re-Gen Gas Purifier Oxygen and Moisture Removal Rates Protector CA (Stainless Steel) Oxygen Removal with AtmosPure Re-Gen Gas Purifier 1000000 210000 100000 42000 10000 10000 653.6, 220 cycles stop and AtmosPure circulation blower starts and isolation valves are opened. Oxygen (PPM) 3300 1000 100 55.7 26.2 14.1 7.7 10 4.2 2.4 1.5 1.1 0.8 0.7 1 0 50 100 150 200 0.1 Time (Minutes) This chart shows oxygen level decrease from 210,000 ppm at atmospheric conditions to 0.
Appendix D: Oxygen & Moisture Removal Rates Protector CA (Stainless Steel) Moisture Removal with AtmosPure Re-Gen Gas Purifier 100000 11253, 40% RH 10000 1560 Moisture (PPM) 696 1000 167.5, 220 cycles stop and AtmosPure circulation blower starts and isolation valves are opened. 445 100 87.5 15.9 10 8.5 3.5 2.4 1.8 1.0 1 1 10 100 1000 10000 Time (Minutes) This chart shows moisture level decrease from 11,253 ppm (40% relative humidity) to 1.0 ppm after 8965 minutes.
Appendix D: Oxygen & Moisture Removal Rates Protector CA (Stainless Steel) Oxygen Removal with AtmosPure Re-Gen Gas Purifier 1000 753.6 100 55.7 Oxygen (PPM) 26.2 14.1 10 7.7 4.2 2.4 1.1 1.5 1 0 20 40 60 80 100 120 140 0.8 0.1 Time (Minutes) This chart shows oxygen level decrease from 753.6 ppm to 0.7 ppm after 150 minutes. Two separate calibrated oxygen monitors confirmed results.* * Results were attained at Labconco Corporation under controlled conditions. Actual results may vary.
Appendix D: Oxygen & Moisture Removal Rates Protector CA (Stainless Steel) Moisture Removal with AtmosPure Re-Gen Gas Purifier 1000 853.2 87.5 Moisture (PPM) 100 15.9 8.5 10 3.5 2.4 1.8 1.0 1 1 10 100 1000 10000 Time (Minutes) This chart shows moisture level decrease from 853.2 ppm to 1.0 ppm after 8905 minutes. Two separate calibrated moisture monitors confirmed results.* * Results were attained at Labconco Corporation under controlled conditions. Actual results may vary.
Appendix D: Oxygen & Moisture Removal Rates Protector CA (Fiberglass) Oxygen Removal with AtmosPure Re-Gen Gas Purifier 1000 969.2 100 63.9 Oxygen (PPM) 28.0 15.3 10 7.9 4.3 2.4 1.2 0.9 1.6 1 0 20 40 60 80 100 1.0 120 0.1 Time (Minutes) This chart shows oxygen level decrease from 969.2 ppm to 0.77 ppm after 150 minutes. Two separate calibrated oxygen monitors confirmed results.* * Results were attained at Labconco Corporation under controlled conditions. Actual results may vary.
Appendix D: Oxygen & Moisture Removal Rates Protector CA (Fiberglass) Moisture Removal with AtmosPure Re-Gen Gas Purifier 1000 600 Moisture (PPM) 100 50.1 10.6 10 6.7 4.6 3.5 2.3 1 1 10 100 1000 10000 Time (Minutes) This chart shows moisture level decrease from 600 ppm to 2.3 ppm after 9875 minutes. Two separate calibrated moisture monitors confirmed results.* * Results were attained at Labconco Corporation under controlled conditions. Actual results may vary.
Appendix D: Oxygen & Moisture Removal Rates Precise CA (polyethylene) Oxygen Removal with AtmosPure Re-Gen Gas Purifier 1000 980.2 100 Oxygen (PPM) 101.0 30.5 15.8 10 7.2 5.0 5.3 4.9 5.6 5.1 1 0 50 100 150 200 250 300 350 400 Time (Minutes) This chart shows oxygen level decrease from 980.2 ppm to 4.9 ppm after 400 minutes. Two separate calibrated oxygen monitors confirmed results.* * Results were attained at Labconco Corporation under controlled conditions. Actual results may vary.
Appendix D: Oxygen & Moisture Removal Rates Precise CA (polyethylene) Moisture Removal with AtmosPure Re-Gen Gas Purifier 1000 660.2 100 Moisture (PPM) 72.4 28.6 16.5 11.7 10.6 10 5.0 1 1 10 100 1000 10000 Time (Minutes) This chart shows moisture level decrease from 660.2 ppm to 5.0 ppm after 8475 minutes. Two separate calibrated moisture monitors confirmed results.* * Results were attained at Labconco Corporation under controlled conditions. Actual results may vary.
Appendix E: Conversions Pressure Conversions To From mmHg in.Hg mmHg in.Hg in.H2O ft.H2O atm lb/in.2 Kg/cm2 kPa bar 1 25.40 .03937 1 .5353 13.60 .04461 1.133 .00132 .03342 .01934 .4912 .00136 .03453 .1333 3.387 .0013 .0339 in.H2O ft.H2O atm lb/in.2 Kg/cm2 kPa 1.868 22.42 760 51.71 735.6 7.500 .07355 .8826 29.92 2.036 28.96 .2953 1 12 406.8 27.69 393.7 4.016 .08333 1 33.90 2.307 32.81 .3347 .00246 .02950 1 .06805 .9678 .00987 .03612 .4334 14.70 1 14.22 .1451 .00254 .03048 1.033 .
Appendix F: References Many excellent reference texts and booklets are currently available. The following is a brief listing: Pharmaceutical Isolators, A Guide to their application design and control. Pharmaceutical Press 2004, Editors: Midcalf, Phillips, Neiger, and Coles. Isolation Technology, A Practical Guide, 2004 CRC Press, 2nd Edition, www.crcpress.com International Standard ISO 10648-2 Containment Enclosures Classification according to leak tightness and associated checking methods.
