`SMOOTHFLOW FUMEFLUSH` Fume Cupboard USER MANUAL
Contents
1. a power restore alarm see operating instructions Press the red button to reset the controller and start the fume cupboard as normal Page 10 MAINTENANCE BEFORE undertaking any maintenance of the fume cupboard obtain a summary of chemical or other hazards from the laboratory supervisor BEFORE undertaking any maintenance of the duct or fan isolate the power supply and tag the fume cupboard system under maintenance do not use Daily Maintenance Inspect the scrubber spray pattern Refer Page 12 Monthly Maintenance Clean the fume chamber thoroughly Wear appropriate PPE Remove all chemicals and equipment from the fume chamber Remove the rear baffles Refer Pages 4 5 Clean the fume chamber with dilute detergent Do not use abrasives Wash down the fume chamber using the hand held shower head attached to the water spout Irrigate under the glass work top to dilute any spills The glass work top can be removed but with caution as tempered glass is sensitive to edge shock Replace the baffles Test the RCD earth leakage circuit breaker Refer to Pages 2 3 for location of the RCD Press the blue Test button The breaker should immediately trip off Reset the breaker to the on position Isolate the scrubber water supply and clean the strainer Refer Page 13 Six Monthly Maintenance In addition to monthly tasks clean the fluorescent light tube and the light panel in the roof of the fume chamber Inspec2. button The fan and light turn on The TEMPERATURE LED will be green The controller waits 7 seconds for airflow The AIRFLOW LED turns green The PRE PURGE LED will be amber for 50 seconds then flash for another 10 seconds then go out The READY LED turns green Four beeps sound Press the yellow button The POWER amp GAS LED turns green The fume cupboard is now operational power amp gas can be used Press the red button Power amp Gas turn off automatically The POWER amp GAS LED goes out The fan and light continue to operate The POST PURGE LED will be amber for 15 minutes then flash for another 5 minutes then go out The light and fan turn off automatically Press the green button to return from post purge to pre purge Page 8 Operation of FUMEFLUSH SCRUBBER Start Scrubber When the PRE PURGE LED is amber Press the green button again The SCRUBBER LED turns green The scrubber turns on and remains on until the end of the post purge cycle Inspect the scrubber spray pattern FAULT ALARMS If the Power is cut an alarm will sound a slow beep The READY LED will flash red Press the red button to mute the alarm A long beep will sound as the controller shuts down When the Power is restored The fan will automatically turn on for 20 minutes then turn off An alarm will sound for 30 seconds then turn off The LED s will keep flashing Press the red button to reset the controller and stop the fan Press the green butt
3. designed aerodynamically for the safety of the operator It will not work properly if it is cluttered up with excess equipment or vessels which affect the air flow Before starting work clean out the fume cupboard Remove everything which is not needed All chemicals from the fume cupboard should be removed to a suitable store Cleaning the internal surfaces will reduce the risk of contamination It will also reduce the risk of mixing incompatible substances Before starting work refer to the Laboratory Supervisor s risk analysis and schedule of chemical quantities permitted in the fume cupboard Make sure that the fume cupboard is suitable for the intended use and has enough space to do the work safely Adopt work methods that minimise the release of fumes Consider appropriate quantities of substances involved the rate of reaction and design of apparatus Make sure the fume cupboard is working Start up the fume cupboard see operating instructions and check the status of all alarms especially air flow Look around the room and close any windows or doors which could cause cross draughts Make sure that the scrubber is working if required Inspect the viewing panel in the front of the scrubber and carefully observe the spray output of every nozzle Every nozzle must exhibit a fully developed conical spray and the viewing panel will be uniformly irrigated for the scrubber to work properly Set up all the equipment required for
4. taking care to avoid cross threading Page 12 Scrubber Water Supply The scrubber water supply manifold is located In the ceiling above the fume cupboard It is provided to ensure constant spray conditions in the scrubber It comprises an isolating valve strainer black and grey solenoid valve flow switch and pressure regulator To access the water supply it is necessary to remove the adjacent ceiling tile To isolate the scrubber water supply turn the ball valve clockwise turn Place a towel on the ceiling to absorb water spilled from the strainer bowl Unscrew the strainer bowl anticlockwise and remove the wire mesh tube Rinse the bowl and mesh in clean water and re fit Open the ball valve turn anticlockwise Page 13
5. the work inside the fume cupboard with sufficient quantity of reagents Position apparatus and materials near the centre and rear of the work space Ignition sources are not to be placed within the sump of the fume cupboard Check that a suitable fire extinguisher is at hand The fume cupboard is now ready for use Wear protective equipment appropriate to the task Keep the sash lowered as much as practical during use In the event of a spill or fire ISOLATE the fume cupboard Press the red fume cupboard emergency isolator button on the keypad This will immediately shut off the power and flammable gas outlets The fan will keep going Refer operating instructions After use dispose of waste substances with due regard for their potential to create hazards and within the rules of the local water authority Refer also to the Laboratory Supervisor and the laboratory risk analysis Maintain the fume chamber in clean condition to avoid chemical contamination and damage to the fume cupboard Remove unused chemicals to a suitable store Do not use a fume cupboard for storage of chemicals Lower the sash Page 7 rp Calibre Y Plastics Manual Scrubber FUME CUPBOARD EMERGENCY ISOLATOR PRE PURGE o POST PURGE AIRFLOW TEMPERATURE SCRUBBER READY YELLOW POWER amp GAS SPRAY BAR OPERATING THE FUME CUPBOARD Start up Pre purge Ready Active Shut down Post purge Re start Press the green
6. AEA Fume Cupboard Serial No XXX Calibre Plastics Ltd Auckland The label located at the bottom right corner of the sash has important user information 1 The spill containment volume of this fume cupboard is stated on the label The Supervisor may use this volume to limit quantities of chemicals permitted in the fume cupboard 2 BEFORE the fume cupboard is used the Supervisor is responsible for carrying out a RISK ANALYSIS of the work Consider the nature of chemicals and processes to be used to determine limiting quantities of hazardous flammable oxidizing and corrosive substances allowed within the fume cupboard Remember that all liquids within the fume cupboard including water may displace other substances during an incident The supervisor is to make a list of chemical quantity limits which is to be readily accessible to all persons using the fume cupboard 3 Ignition sources are not to be placed within the sump of the fume cupboard 4 In the event of a spill or fire ISOLATE the fume cupboard Press the red fume cupboard emergency isolator button on the keypad This will immediately shut off the power and flammable gas outlets The fan will keep going Refer operating instructions 5 The serial number of this fume cupboard may be requested when seeking technical support available Toll Free in New Zealand 0800 422 542 Page 6 GUIDELINES FOR USING FUME CUPBOARDS The fume cupboard is a ventilated work space
7. Control keypad input keys to start stop and activate the fume cupboard displays the fume cupboard status and alarms refer operating instructions located on the right above the sash opening Power outlet double socket for electrical appliances availability of power strictly controlled refer operating instructions located on the right front pillar Label important user information spillage capacity warning notice fume cupboard serial number located on the right corner of the sash Water valve controls water flow to water spout inside the fume cupboard located under the sill Gas valve controls gas flow to gas spout inside the fume cupboard flammable gases have push turn mechanism availability of flammable gases strictly controlled refer operating instructions located under the sill Scrubber contains bed of plastic packing irrigated by spray nozzles drains through pipe behind baffles located above the fume chamber Viewing panel allows inspection of scrubber spray pattern All nozzles must have full cone spray Must be inspected DAILY Scrubber water supply isolating valve strainer solenoid valve flow switch and pressure regulator located beside the fume cupboard Page 3 SASH STOP The sash stop is located on the left front pillar The sash stop limits the sash opening height to about 480mm With the opening restricted less air flow is required to achieve fume capture The sash can be released for maximum opening for
8. LGA Sy Calibre Solutions Calibre Solutions Ltd 145 Hepburn Rd Waitakere 0602 Freephone 0800 422 542 Phone 64 9 813 1303 Fax 64 9 813 1319 SMOOTHFLOW FUMEFLUSH Fume Cupboard and Fumeflow Fan USER MANUAL CONTENTS PAGE FEATURES 1 Smoothflow Fume Cupboard Features 2 2 Sash Stop 4 3 Baffles 4 PREPARATION 4 Warning 6 Da Guidelines for Safety 7 OPERATION 6 Operating Instructions 8 7 Faults 9 8 Trouble shooting 10 MAINTENANCE 9 Monthly 11 10 Six Monthly 11 11 Annually 11 12 Scrubber Nozzles 12 13 Scrubber Water Supply 13 Smoothflow Fumeflush Fume Cupboard Features N e oS er s SN EN A Ae lee SS os SN a Ss SS SN A viewing panel ie A ee ak a ee A A oe Set ue lt va S he microprocessor controller light RCD pattery N f sash stop control keypad water valve label j power outlet push turn gas valve Microprocessor controller controls all aspects of operation via the control keypad the controller is located on top of the fume cupboard RCD protection device for the power sockets battery energy for the mains power failure alarm refer maintenance instructions Light illuminates the work area the light is located on top of the fume cupboard Sash stop limits the opening height of the sash in normal operation releases the sash to full height for service access located on the left front pillar Page 2 Smoothflow Fume Cupboard Features cont
9. cleaning inside the fume cupboard or setting up equipment before the work starts ALWAYS lower the sash before commencing work NEVER use the fume cupboard with the sash above the stop To release the sash Raise the sash until it reaches the upper stop position 1 Insert a coin or key in the slot of the sash stop 2 Twist the sash stop clockwise about a quarter turn and hold 3 Raise the sash above the stop Release the stop and withdraw the coin or key The stop will automatically reset when the sash is lowered ALWAYS lower the sash before commencing work NEVER use the fume cupboard with the sash above the stop BAFFLES There are two baffles in the fume cupboard The baffles are easily removed to facilitate cleaning of the entire fume chamber This should be done as often as the work requires and at least monthly refer maintenance instructions ALWAYS remove ALL chemicals and equipment from the fume cupboard ALWAYS wear personal protective equipment before handling baffles Protective equipment must be suitable for the chemicals used inside the fume cupboard Refer to Supervisor Minimum requirements are overalls or coat with long sleeves suitable eye protection glasses goggles or mask and suitable gloves Page 4 5 left baffle 10 right baffle Removing amp Replacing Baffles Rear Baffles The rear baffles are sprung between a row of hooks inside the back of the fume cupboard and a corres
10. e spray nozzles through the viewing panel daily If nozzles become blocked they must be cleaned The inside of the scrubber is highly acidic Wear appropriate PPE for hands arms and face Work from a stable step ladder of comfortable height When the fume cupboard and fan are off Remove two M6 stainless steel screws from the top of the viewing panel Slide the viewing panel vertically up out of the slot Place the viewing panel so as to avoid scratching it Unscrew the spray nozzles from the header pipe The nozzles should not be tight but if finger pressure is not enough a small adjustable wrench may be used to loosen half a turn Do not insert any tool inside the spray nozzle Back flush the nozzles with suitable small diameter tubing from a bench spout adjusted to modest pressure High water pressure will squirt Take care to prevent loss of nozzles down the sink drain Surface films can be removed from the nozzles by ultrasonic cleaning in an alkaline bath Domestic dishwasher machine detergent is suitable Rinse in clean water Screw the nozzles into the header pipe Do not use force Take extra care to align the nozzle and avoid cross threading Make sure the thread is fully engaged but Do not over tighten Use only gentle finger pressure Check all nozzles are replaced To replace the viewing panel slide it vertically down into the slot Check alignment of the fixing holes Replace the two M6 stainless steel screws
11. on for normal start up If the Airflow gets low the screen will display FAULT and AIR FAIL An alarm will sound and the red LED will flash Press the red button to mute the alarm The fume cupboard will go into normal post purge but the alarm message and LED will stay on Check out what caused the alarm Get it fixed before using the fume cupboard again If the Temperature inside the fume cupboards gets high The fault LED will flash slowly The screen will display TEMP WARM Turn down the heat inside the fume cupboard If the temperature inside the fume cupboards gets higher The screen will display FAULT and TEMP HIGH An alarm will sound and the red LED will flash Press the red button to mute the alarm The fume cupboard will go into normal post purge but the alarm message and LED will stay on Check out what caused the alarm Get it fixed before using the fume cupboard again The temperature sensor works even when the fume cupboard is turned off Press the red button to mute the alarm If the Scrubber water flow gets low An alarm will sound and the SCRUBBER LED will flash Press the red button to mute the alarm The fume cupboard will go into normal post purge but the SCRUBBER LED will be red Check out what caused the alarm Get it fixed before using the fume cupboard again Page 9 TROUBLE SHOOTING No power at power socket Power is made available to the socket outlet only during Active status Refer operating instructions Af
12. ponding row of hooks under the roof see drawing The baffle is in two pieces with a vertical join in the centre The join cover strip is attached to the RIGHT hand baffle Remove this baffle first 1 2 3 4 To remove the baffle place both gloved hands palms up under the bottom edge of the baffle Raise the baffle and bring it forward over the hooks Bring the bottom edge of the baffle forward over the sill Disengage the top edge of the baffle from the upper hooks Repeat the action with the left baffle Replace the baffles by reverse action 5 11 Replace the left baffle without cover strip first Hold the baffle with the edge notch at the top left corner and the slots offset towards the centre of the fume cupboard see diagram Lift the baffle into the fume cupboard and engage the top edge of the baffle in the upper hooks Lift the bottom edge of the baffle over the sill Carry the baffle to the back of the fume cupboard and lift the bottom edge onto the rear hooks Check alignment in top and bottom hooks Hold the right baffle with the edge notch at the top right corner and the cover strip towards the centre of the fume cupboard Repeat actions 6 9 above with the right baffle Page 5 WARNING La deveseves cvesesedes Spillage volume XX L Observe chemical limits specified by Supervisor Jananee No ignition sources in sump ISOLATE FUME CUPBOARD C ET in case of spills or fire Smoothflow De
13. t and maintain fans motors drive belts and bearings Check all plastic bolts and replace if UV brittle Perform smoke and velocity tests as AS NZS 2243 8 Appendices F and E Submit a maintenance and test report to the laboratory supervisor Annual Maintenance In addition to six monthly tasks carefully inspect the fume chamber for defects and repair as required Check the sash counterweight cords for wear Ensure that service controls and outlets are in good condition Check operation of controller and automatic isolators Replace 9V battery for power failure alarm Refer to Features Section of this manual for location of the battery Lift and pull the battery drawer on the front of the control box Observe polarity carefully when fitting the new battery Close the battery drawer Page 11 Annual Maintenance cont Inspect the exhaust duct from fume chamber to stack Assess the whole system for compliance with AS NZS 2243 8 Perform smoke and velocity tests as AS NZS 2243 8 Appendices F and E Submit a maintenance audit and test report to the laboratory supervisor Affix a label to the fume cupboard showing date of inspection and overall test result Scrubber Nozzles The scrubber is located above the fume cupboard The larger module contains a bed of plastic packing irrigated by a row of spray nozzles The packed bed promotes contact of the wash water with the fumes and must be uniformly irrigated for best performance Observe th
14. ter the pre purge is complete and Ready status is displayed press the yellow button to activate the power outlet If Active status is displayed and there is still no power check the RCD breaker the blue switch visible in the lid of the control box on top of the fume cupboard If the switch will not latch on there is an electrical fault in the circuit Call an electrician No gas at gas outlet Gas is made available to the outlet only during Active status Refer operating instructions After the pre purge is complete and Ready status is displayed press the yellow button to activate the power outlet If Active status is displayed and there is still no gas check the RCD breaker the blue switch visible in the lid of the control box on top of the fume cupboard If the switch will not latch on there is an electrical fault in the circuit Call an electrician If the power socket is live but there is still no gas the gas mains may be isolated Some laboratories have a master gas isolator Controller does not respond to keypad If the control sequence has become corrupted the controller needs to re load the program from memory which happens automatically on power restore The mains isolator switch is visible in the lid of the control box on the fume cupboard Turn off mains supply to the fume cupboard controller Wait 5 seconds then turn the mains isolator on again The processor will reboot and signal
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