User’s Manual FilterMate™ Portable Exhausters Models 3970000 3970001 3970002 3970003 3970004 3970020 3970021 3970022 3970023 3970024 To receive important product updates, complete your product registration card online at register.labconco.com Labconco Corporation 8811 Prospect Avenue Kansas City, MO 64132-2696 800-821-5525, 816-333-8811 FAX 816-363-0130 E-MAIL labconco@labconco.com HOME PAGE www.labconco.com Please read the User’s Manual before operating the equipment.
Copyright © 2004, 2006, 2007, 2008, 2009, 2010 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 About This Manual Typographical Conventions 1 3 4 CHAPTER 2: PREREQUISITES Electrical Requirements Ground Fault Interrupter Exhaust Requirements for the FilterMate Location and Preparation Requirements Your Next Step 5 5 6 6 7 8 CHAPTER 3: GETTING STARTED Unpacking Your FilterMate Setting Up Your FilterMate Initial Installation of HEPA Filters and Carbon Filters Carbon Filters Combination HEPA/Carbon Filters Dual Carbon Connect the Electrical Supply Source to Fi
CHAPTER 5: MAINTAINING YOUR FILTERMATE Monthly Determination of when to Replace Carbon Filters Determination of when to Replace HEPA Filters Install New HEPA Filter with Bag-In/Bag-Out Procedure FilterMate HEPA Filter Leak Test Motorized Impeller Replacement Speed Control Replacement 29 29 30 32 32 34 36 36 CHAPTER 6 MODIFYING YOUR FILTERMATE Converting a Room Exhaust HEPA FilterMate to Outside Exhaust Converting a Combination HEPA/Carbon FilterMate to a Dual Carbon FilterMate Converting a HEPA FilterMate
CHAPTER 1 INTRODUCTION Congratulations on your purchase of a FilterMate™ Portable Exhauster, which exhausts filtered air. Labconco manufactures ten models of the FilterMate. These ten models consist of variations of HEPA filtration, carbon filtration, HEPA filtration to outside exhaust, combination HEPA/Carbon filtration and combination carbon/carbon filtration. All of these units are offered in 115V, 50/60 Hz operations or 230V, 50/60 Hz operations.
Chapter 1: Introduction they are mixed with and diluted by room air. This contaminated air is then drawn into the FilterMate where HEPA filters remove particulates. Vapors are adsorbed in activated or impregnated carbon filters. For applications requiring carbon filtration, it is recommended that the FilterMate be allowed to operate at lower speeds of 60 to 80 feet per minute to allow adsorption of volatiles and prevent material breakthrough back into the air.
Chapter 1: Introduction About This Manual This manual is designed to help you learn how to install, use, and maintain your FilterMate. Instructions for performing routine maintenance and making minor modifications to your FilterMate are also included. Chapter 1: Introduction provides a brief overview of the FilterMate, explains the organization of the manual, and defines the typographical conventions used in the manual.
Chapter 1: Introduction Typographical Conventions Recognizing the following typographical conventions will help you understand and use this manual: • • • ! ) HEPA CARBON HEPA SYSTEM COMBO 4 • • Book, chapter, and section titles are shown in italic type (e.g., Chapter 3: Getting Started). Steps required to perform a task are presented in a numbered format. Comments located in the margins provide suggestions, reminders, and references.
CHAPTER 2 PREREQUISITES Before you install your FilterMate and XPert or XVS Enclosure, you need to prepare your site for installation. Carefully examine the location where you intend to install your FilterMate and enclosure. You must be certain that the area is reasonably level and of solid construction. An electrical source must be located near the installation site. Carefully read this chapter to learn: • • • the electrical supply requirements. the exhaust requirements.
Chapter 2: Prerequisites ! CAUTION: This equipment must be grounded (earthed). Ground Fault Interrupter ) WHEN CONNECTING THE FILTERMATE TO A GROUND FAULT INTERRUPTER CIRCUIT (GFIC), ENSURE THAT THE CIRCUIT IS RATED FOR 15-AMP LOAD AND IS FUNCTIONING CORRECTLY. CONNECTION OF THE FILTERING SYSTEM TO A LOWER CAPACITY OR DEFECTIVE GFIC MAY RESULT IN EXCESSIVE ACTIVATION OF THE GFIC, CUTTING POWER TO THE FILTERMATE WHILE IT IS OPERATING.
Chapter 2: Prerequisites If the FilterMate exhaust is to be connected to the house exhaust system, it is recommended that 3970002 (115 Volt) or 3970022 (230 Volt) be ordered with thimble connections. The 6" diameter thimble connection allows you to easily balance the exhaust airflow. HEPA Filter Part #3707900 is 99.99% efficient on particles 0.3 micron. Normal life expectancy is two to five years. See Chapter 5 for filter changing procedure.
Chapter 2: Prerequisites device that could disrupt its airflow patterns. All windows in the room adjacent to the enclosure should be closed. The FilterMate may be placed anywhere close to the enclosure. It may be bench mounted, placed on the floor or suspended on a shelf nearby.
CHAPTER 3 GETTING STARTED Now that the site for your FilterMate is properly prepared, you are ready to unpack, inspect, install, and test your FilterMate. Read this chapter to learn how to: • • • • • • unpack and move your FilterMate. set up your FilterMate. connect 5" hose and exhaust transition. install filters. connect the electrical supply source to your FilterMate. set the face velocity with the speed control adjustment.
Chapter 3: Getting Started ) IF YOUR FILTERMATE 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. Do not discard the carton or packing material for your FilterMate until you have checked all of the components, installed, and tested the FilterMate. Setting Up Your FilterMate, Installing 5" Hose and Exhaust Transition Move the FilterMate to the location where you want to install it.
Chapter 3: Getting Started (Monitor moved forward) 3908800, 01 3944700, 01 Figure 3-1 Enclosure & FilterMate Top Exhaust Product Service 1-800-522-7658 11
Chapter 3: Getting Started (Monitor moved forward) 3908800, 01 3944700, 01 Figure 3-2 Enclosure & FilterMate Concealed Exhaust Ducted to the Outside 12 Product Service 1-800-522-7658
Chapter 3: Getting Started Initial Installation of HEPA Filters and Carbon Filters HEPA Filters (For Models 3970000, 3970002, 3970020, 3970022) HEPA HEPA filters are shipped installed with the gasket on the downstream side. The HEPA filters are leak checked at the Labconco factory. A second leak check is recommended before using the FilterMate and at least annually thereafter. Consult your Safety Officer and Chapter 5 for the HEPA Filter Leak Test and HEPA Filter Bag-In/Bag-Out Procedure.
Chapter 3: Getting Started e. Re-install the perforated plenum exhaust cover. See Figures 3-5, 3-6 and 3-7 for combination HEPA/Carbon installation. CARBON Dual Carbon (For Models 3970003, 3970004, 3970023, 3970024) For added carbon capacity or for adsorption of mixed vapors two carbon filters may be installed. Use two carbon filters on dual carbon FilterMate models 3970004 and 3970024. Replace the HEPA filter with a carbon filter on the combination FilterMate models 3970003 and 3970023.
Chapter 3: Getting Started Figure 3-3 FilterMate Rear Isometric View Product Service 1-800-522-7658 15
Chapter 3: Getting Started Figure 3-4 Rear Isometric View with Bag Cover Removed 16 Product Service 1-800-522-7658
Chapter 3: Getting Started Figure 3-5 Rear View Product Service 1-800-522-7658 17
Chapter 3: Getting Started Figure 3-6 Combination HEPA/Carbon or Dual Carbon 18 Product Service 1-800-522-7658
Chapter 3: Getting Started Figure 3-7 Combination HEPA/Carbon or Dual Carbon with Exhaust Cover Removed Product Service 1-800-522-7658 19
Chapter 3: Getting Started Connect the Electrical Supply Source to the FilterMate 115V Simply connect the 115V power cord supplied to the IEC electrical supply plug on the back of the unit. If using 50 Hz operation, blower performance maximum airflow will be reduced by 17%. Refer to Chapter 2 for setting up the building electrical supply. Locate the switched auxiliary outlet on the back for plugging in the airflow monitor.
CHAPTER 4 USING YOUR FILTERMATE Now that the installation of your FilterMate and enclosure is completed, you are ready to use your FilterMate.
Chapter 4: Using FilterMate Applications for the FilterMate when attached to an Enclosure • • • • • Release of low concentrations of vapors effectively adsorbed or treated in carbon-based filters, or release of particulates for HEPA filter only and release of vapors and particulates for combination HEPA and carbon filters. Weighing of powders using a HEPA filter. Treatment of specific chemicals that are carcinogens or suspected carcinogens. See section on carcinogens in Chapter 4.
Chapter 4: Using Your FilterMate TWA - Recommended Exposure Limits expressed as a Time Weighted Average. The exposure limit for that chemical for up to a 10-hour workday, 40 hours a week. Odor Threshold - The value in parts per million for which one might expect to smell a chemical’s presence in the air. This value is very subjective and detection will vary with the sensitivity of one’s nose.
Chapter 4: Using FilterMate Chemicals must have a detectable odor at concentrations below the TWA for the chemical. Chemicals must be designated by NIOSH guidelines as acceptable for use with chemical cartridge type respirators (the exception is formaldehyde). Chemicals not listed by NIOSH in the Pocket Guide must be approved by Labconco’s Product Specialist (or Engineering). Inlet concentration must never exceed the IDLH (Immediately Dangerous to Life and Health) concentrations.
Chapter 4: Using Your FilterMate The FilterMate Chemical Guide chart provides estimated saturation times up to the TWA concentration for the Chemical. In addition to the above, all other guidelines for chemical use in the FilterMate apply. Acids Must Not Be Used The FilterMate blower cannot be exposed to acids. Where applications require the use of acids, the enclosure must be vented to the outside by a remote blower without the use of the FilterMate.
Chapter 4: Using FilterMate 26 • Use in areas where only trained users have access to the enclosure. Any new users must be trained and should also read this Instruction Manual. • Do not use the FilterMate in a poorly ventilated area. If the FilterMate is to be used in a confined space, make sure the space is well ventilated and the concentration of toxic contaminants cannot accumulate greater than the TWA.
Chapter 4: Using Your FilterMate • If a chemical is spilled on the work surface DO NOT switch off the blower until all traces of the chemical have been removed. • Make sure carbon based filters or HEPA filters are installed prior to each use. • If the blower fails during use, chemical processes should cease and the area should be vacated, and ventilated. • Always refer to the NIOSH Pocket Guide to Chemical Hazards before proceeding.
Chapter 4: Using FilterMate The rate of accumulation will depend upon the cleanliness of the room air, the amount of time the enclosure is operating, and the nature of work being done. With normal usage, the HEPA filters will last two to five years before requiring replacement. Each HEPA FilterMate is provided with a disposal bag for proper disposal. Follow the HEPA Filter Bag-In/Bag-Out procedure in Chapter 5 for disposal instructions.
CHAPTER 5 MAINTAINING YOUR FILTERMATE Monitoring and changing the filters is the primary maintenance required. The following maintenance schedule is recommended: Monthly (or more often as required) Test filter condition on carbon filtered models using a gas detector tube at intervals of 20% of the total estimated time. The exception to the 20% recommendation is formaldehyde or any carcinogen or suspected carcinogen. These hazardous chemicals must be checked at least every 10% of the total estimated time.
Chapter 5: Maintaining Your FilterMate CARBON Determination of When to Replace Carbon Filters The carbon filters MUST be replaced when any one of the following two conditions are met: 1. The FilterMate outlet (exhaust) concentration approaches the inlet concentration, indicating filter saturation. 2. The odor in the work area becomes intolerable or the concentration of the chemical in the work area is greater than the TWA.
Chapter 5: Maintaining Your FilterMate syringe represents a 100-ml sample and corresponds to the number of strokes necessary to give the indicated color changes. Due to the wide variety of organics and varying TWA’s, it is recommended that specific detector tubes be purchased directly from Sensidyne, Draeger or your laboratory supply dealer. Alternate detector pumps can also be purchased from your laboratory supply dealers. The vast majority of detector tubes available start measuring at the TWA.
Chapter 5: Maintaining Your FilterMate HEPA Determination of when to Replace HEPA Filters The HEPA filters in the FilterMate gradually accumulate airborne particulate matter and powders from the enclosure and room. The rate of accumulation will depend upon the cleanliness of the room air, the amount of time the enclosure is operating, and the nature of work being done in the enclosure. In typical installations and usage, the HEPA filters will last two to five years before requiring replacement.
Chapter 5: Maintaining Your FilterMate glove inside out. Double seal this glove and cut off the glove with the contaminated bag stub inside. 8. Carefully install the new HEPA filter and uniformly tighten the two filter clamp bolts until the HEPA filter gasket is compressed 50%. 9. Carefully fold and roll the new bag in four-inch pleats and push the bag into the access port. Turn the FilterMate ON to draw a vacuum on the bag. Reinstall the rear cover panel to protect the bag.
Chapter 5: Maintaining Your FilterMate HEPA FilterMate HEPA Filter Leak Test Purpose After the Bag-In/Bag-Out procedure, the HEPA filter should be leak checked. This test is performed to determine the integrity of the HEPA filter, the filter housing, and the filter mounting frames. Leak test is to be done by qualified technician with calibrated equipment. Remove the exhaust cover by first removing the hole plug and then using a Phillips screw driver to unfasten the (4) captive screws.
Chapter 5: Maintaining Your FilterMate 4. Using the “^” or “v” keypads, respectively, increase or decrease the numerical value until it equals 48 for the FilterMate connected to the enclosure. (36 for the FilterMate by itself). 5. Press the “ENTER” Keypad. The photometer will scan for 15 seconds, and then the “0” keypad will flash. Press the “Enter” keypad. The unit will scan for 5 seconds, the display will read “0000”, and the unit will sound a confirming tone. 6. Set the valve to “DOWNSTREAM”.
Chapter 5: Maintaining Your FilterMate Motorized Impeller Replacement The motorized impeller must be replaced as a complete unit. When the motorized impeller is replaced, the capacitor should also be replaced. See Appendix A for Replacement Parts Diagram. 1. Wear appropriate personal protective equipment to decontaminate the FilterMate and then unplug from the electrical outlet. 2. Remove filter housing and filters. HEPA filter (if so equipped) per Bag-In/Bag-Out procedure. 3.
CHAPTER 6 MODIFYING YOUR FILTERMATE The following procedure may be necessary to modify the FilterMate. Converting a Room Exhaust HEPA FilterMate to Outside Exhaust Refer to Figures 3-2 and 3-3. 1. Remove the perforated exhaust cover and replace it with the FilterMate 6" canopy outside exhaust cover (Catalog #3913600). 2. Next connect the ductwork to the remote blower. Remote blowers available from Labconco are listed below: 3. Remote Blowers (Roof-Mounted) and Dampers. 1/4 hp direct drive.
Chapter 6: Modifying Your FilterMate 4. If the enclosure is connected directly to a house exhaust system, an adjustable damper (or valve) must be installed to control the airflow properly. Converting a Combination HEPA/Carbon FilterMate to a Dual Carbon FilterMate 1. Simply remove the HEPA filter per the Bag-In/Bag-Out Procedure in Chapter 5. 2. Next place the carbon filter in the FilterMate in place of the HEPA filter.
CHAPTER 7 TROUBLESHOOTING YOUR FILTERMATE Refer to the following if your FilterMate fails to operate properly. If the suggested corrective actions do not solve your problem, contact Labconco for additional assistance.
Chapter 7: Troubleshooting Your FilterMate 40 Product Service 1-800-522-7658
APPENDIX A FILTERMATE COMPONENTS AND REPLACEMENT PARTS The components that are available for your FilterMate are listed. The parts shown are the most commonly requested. If other parts are required, please contact Product Service. Item Qty.
Appendix A: FilterMate Components and Replacement Parts 42 Item Qty.
Appendix A: FilterMate Components and Replacement Parts Figure A-1 Replacement Parts Product Service 1-800-522-7658 43
Appendix A: FilterMate Components and Replacement Parts 44 Product Service 1-800-522-7658
APPENDIX B FILTERMATE SPECIFICATIONS This Appendix contains technical information about the FilterMate including specifications, environmental operating conditions, wiring diagrams, dimensions, and evaporation rates. Electrical Specifications • • FilterMate 10 Amps, 115V, 50/60 Hz. FilterMate, 10 Amps, 230V, 50/60 Hz. Environmental Conditions • • • • • • • Indoor use only. Maximum altitude: 6562 feet (2000 meters). Ambient temperature range: 41° to 104° (5° to 40°C).
Appendix B: FilterMate Specifications HEPA or Carbon FilterMate Dimensions Models: 3970000, 3970001 (115V) 3970020, 3970021 (230V) Figure B-1 46 Product Service 1-800-522-7658
Appendix B: FilterMate Specifications Combination HEPA/Carbon FilterMate and Dual Carbon FilterMate Dimensions Models: 3970003 (115V) HEPA/Carbon 3970023 (230V) HEPA/Carbon 3970004 (115V) Dual Carbon 3970024 (230V) Dual Carbon Figure B-2 Product Service 1-800-522-7658 47
Appendix B: FilterMate Specifications HEPA System FilterMate Dimensions.
Appendix B: FilterMate Specifications Product Service 1-800-522-7658 49
Appendix B: FilterMate Specifications 50 Product Service 1-800-522-7658
APPENDIX C BLOWER CURVES Filtermate Blower Curve 2.8 2.75 Original Manufacturer Blower (Not Installed) 2.6 2.4 2.4 2.2 2.32 FilterMate Blower (*Installed) 2.25 2.1 2 1.9 Pressure (in H2O) 1.8 * FilterMate Portable Exhauster attached 1.75 to an X-Pert Balance Enclosure with an 8' long by 5" diameter hose. 1.6 1.6 1.4 1.3 1.2 1 0.9 0.8 0.6 0.58 0.4 0.2 0.
Appendix C: Blower Curves FilterMate Blower Curve 1.8 1.6 *FilterMate Blower Curve 1.4 Pressure (in H2O) 1.2 1 FilterMate Sound Levels Exhaust CFM 250 200 150 100 70 0.8 0.6 0.4 Noise Pressure dB(A) 63 - 65 56 - 61 51 - 54 45 - 47 < 45 * FilterMate Portable Exhauster attached to an X-Pert Balance Enclosure with an 8' long by 5" diameter hose. 0.
APPENDIX D FILTERMATE RESOURCES The following resources are for you to refer to for your FilterMate. Pocket Guide to Chemical Hazards National Institute for Occupational Safety and Health (NIOSH) (202) 783-3238 National Draeger, Inc. 101 Technology Drive P.O.
Declaration of Conformity DECLARATION OF CONFORMITY Application Council Directive(s): 73/23/EEC, 89/336/EEC, 2002/95/EC (ROHS), 2002/96/EC (WEEE) Standard(s) to which conformity is declared: EN61010-1, EN55022, EN50082-1 Manufacturer’s Name: Labconco Corporation Manufacturer’s Address: 8811 Prospect Avenue Kansas City, MO 64132 USA Importer’s Name: See Shipping/Customs Documents Importer’s Address: See Shipping/Customs Documents for your equipment Type of Equipment: Laboratory Equipment - Safety
