Molecular Devices Sofnolime HiCap CO2 User manual

Molecular Products Limited
Mill End, Thaxted, Essex T+44 (0)1371 830676 E[email protected]
CM6 2LT United Kingdom F+44 (0)1371 830998 W www.molecularproducts.com
HiCap
TM
CO2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma nu fa ct ur er :
Car b on Dioxi d e
Abs o rbe r C ar t rid g e
USER MANUAL
HiCap™CO2
Sofnolime®Carbon Dioxide Large Absorber Cartridge.
The data provided is intended for general guidance and does not necessarily cover all the
operational aspects of the cartridges. Each individual case needs to be properly assessed for safe
operation by the facility managers.
Further advice and help in producing your own operational procedures for the safe deployment of
the large absorber cartridges is available on request from the manufacturer.
Version 4, 29/10/10 MCL, JS
Page 1 of 9

• The cartridge is designed to remove carbon dioxide from
an enclosed environment as part of a life support system.
Consideration needs to be given to any oxygen supply
requirements.
• This unit is for professional use only and will therefore require
operators to be suitable trained.
A user manual is supplied, but it is the responsibility of the facility
operators to supply an operating procedure and training for the end
users appropriate for the intended location and conditions.
It is suggested that the supplied user manual should be used to form
the basis of the local operating procedure and basic training to the
end users.This procedure and training will be specific to a location
and depend on the end users requirements.
HiCap™CO2
Sofnolime®Carbon Dioxide Large Absorber Cartridge.
H i C a p
T M
C O 2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma n u f a c t u r e r :
C a r b o n D i o x i d e
A b s o r b e r C a r t r i d g e
Important note
to operators
Version 4, 29/10/10 MCL, JS
Page 2 of 9

Introduction
The large scale absorber cartridges are available in two formats one for the removal and control of carbon dioxide
(CO2) and the other for the removal and control of the much more toxic carbon monoxide (CO). Both cartridges
use the same crate design to hold the active constituents and are the same physical size (Figure 1).The cartridges are
differentiated by labelling and require different operating conditions to produce the specified performance. The
cartridges are designed to seal against the base plate cut-out of fan driven air supply equipment.
Figure 1 – dimensions
Length (mm): 400
Width (mm): 300
Height (mm): 170
Total weight (kg): 14
Base cut out (mm) 270 x 370
The performance and normal running conditions for each type of cartridge is described below.The carbon dioxide
cartridges are normally required to remove CO2that is being continuously produced by people exhaling CO2at a steady
rate for extended periods of time; hours or days.Whereas the carbon monoxide cartridges are normally required to
remove an initial high concentration of carbon monoxide to low levels as fast as is practical; usually within minutes.
Each cartridge is supplied in a sealed gas and water resistant barrier foil packaging to ensure the cartridges are
protected from contamination and remain active during storage.
Each cartridge is provided with a seal round the base which provides a gas tight seal when deformed by the weight of the
cartridge against a cut-out in a base unit designed to accommodate the cartridge.The size of the base cut-out needs to be
270 x 370 mm (+/- 1 mm).The air stream is normally passed up through the cartridge (base to top) but the cartridges will
operate with the flow reversed. However the flow should not be reversed during operation as this will reduce the
usable capacity.
It is important the procedures are in place to allow safe deployment of the cartridges before they are required.It is the
responsibility of the facility operators to ensure these procedures are adequate for the intended purpose and that
training is provided to all personnel who may need to use the cartridges before they are required to use them.
The descriptions assume the cartridges are deployed in an enclosed volume that allows free circulation and good mixing
of air to and from the cartridges.
H i C a p
T M
C O 2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma n u f a c t u r e r :
C a r b o n D i o x i d e
A b s o r b e r C a r t r i d g e
HiCap™CO2
Sofnolime®Carbon Dioxide Large Absorber Cartridge.
Version 4, 29/10/10 MCL, JS
Page 3 of 9

HiCap™ CO2- Sofnolime®Carbon Dioxide Large Absorber Cartridge
This cartridge uses Sofnolime®as the absorbent which chemically reacts with the carbon dioxide to remove it from
the air stream.The carbon dioxide is chemically removed and cannot be regenerated from the cartridge.The cartridge
is designed to remove CO2produced by respiration of personnel in an enclosed sealed space. The time each
cartridge will last depends on the gas flow rate through the cartridge,the volume of the enclosed space and the number
of people present - see Table 1 for operational performance. Multiple cartridges should be used simultaneously when
the enclosure volume or number of people require it. Each cartridge is designed to be incorporated into a fan driven,
purpose built ventilation system designed to run with a nominal airflow of 400 litres per minute gas flow through each
cartridge. Gas flows below 200 litres per minute will not damage the cartridges but will reduce the CO2removal rate
substantially from the figures used in Table 1. Gas flow rates above 600 litres per minute will reduce the time that the
CO2levels can be maintained at low levels and may reduce the effective CO2removal capacity under normal operating
conditions.
The cartridges can be deployed immediately on sealing the refuge or space in which they operate or they can be deployed
when the CO2level reaches a predefined level.There is usually not a great urgency to deploy the cartridges in the first
minutes as the CO2level can safely be allowed to rise slightly (up to 1 -2 % CO2) without significant physiological effects
on the occupants of the space.
Sufficient cartridges need to be available to provide CO2control to the required level for the specified duration that
the space will be occupied.
Operating instructions: carbon dioxide (CO2) removal
1. Remove outer foil barrier film (a safety blade is provided with each cartridge)
2. Check that the bases seal is in place and intact, then place the cartridge onto the base unit aperture
3. Warning - all the base (fan) unit apertures must have cartridges installed for correct operation - If the base unit
has more than one aperture ensure all the apertures are covered with installed cartridges – use an exhausted
cartridge if there are no fresh cartridges available
4. Start the airflow through the cartridge(s) – refer to the OEM base unit operating procedure
5. Exhausted cartridges should be removed and replaced with fresh cartridges once they are incapable of removing the
CO2at the rate it is being produced
6. In a multi-aperture base unit, if the some cartridges are exhausted and fresh ones are not available the
exhausted cartridges should be left in place
7. Exhausted cartridges can be left in place – used HiCap™ CO2cartridges will continue to remove CO2for some time
after the specified performance but at much lower rates. Warning – the enclosure CO2concentration will start to
increase once the CO2removal rate falls below the production rate irrespective of the remaining capacity
H i C a p
T M
C O 2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma n u f a c t u r e r :
C a r b o n D i o x i d e
A b s o r b e r C a r t r i d g e
Version 4, 29/10/10 MCL, JS
Page 4 of 9

Deployment (for carbon dioxide removal)
The number of cartridges required is determined primarily by the number of people present but also by the volume
of the enclosed sealed space.The number of people determines the required CO2removal capacity and the volume of
the enclosed space determines the minimum required removal rate.The total CO2removal rate needs to be greater
than the production rate or the CO2level will continually increase.The deployed CO2capacity will determine the time
interval that the cartridge(s) can run before they need to be changed for fresh cartridges. The CO2production rate will
change with respiration rate or may be set by the relevant legislation.
Table 1 shows typical data for a range of operational conditions for people relaxed and exhaling an average of 0.24 l/
minute (14.4 l/hr) CO2.Table 2 shows the same data for a higher CO2exhalation rate of 0.4 l/minute (24 l/hr) CO2.
The main body of the table (shaded in blue) shows the normal operating range.The red shaded areas show marginal
or non-recommended conditions.
Select the volume of the enclosure in the left column then select the column with the maximum number of people in the
top row.The intersection gives the minimum number of cartridges that should be used to provide an acceptable removal
rate.The value to the right of this gives the expected time the cartridge(s) will run between changes.More cartridges than
this minimum will maintain a lower CO2concentration for a longer time interval.The time interval between changes will
depend on the number of people present and their activity level.The best way of operating the cartridges to ensure
maximum usable capacity is to monitor the CO2level in the enclosed space and change the cartridges when the CO2
concentration reaches a predetermined level – typically 1 or 2 % CO2.
The supplementary information is provided to allow other conditions to be calculated if required.
Table 1 – typical data for a range of normal operating conditions – people at rest (1).
(Assumes: 0.24 l/min CO2per person; 1,500 l/CO2per cartridge; 400 l/min air flow rate per cartridge
and 1% max CO2inlet concentration)
H i C a p
T M
C O 2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma n u f a c t u r e r :
C a r b o n D i o x i d e
A b s o r b e r C a r t r i d g e
Volume No. of run time No. of run time No. of run time No. of run time No. cartridges
of people (hr) people (hr) people (hr) people (hr) for 1air
enclosure 1to 10 11 to 20 21to 30 31to 40 change per hour
min No. min No. min No. min No.
m
3 cartridges cartridges cartridges cartridges
10 110.42 15.2113.47 12.60 0.42
20 110.42 15.2113.47 12.60 0.83
30 2 20.83 2 10.42 2 6.94 2 5.211.25
40 2 20.83 2 10.42 2 6.94 2 5.211.67
50 3 31.25 3 15.63 3 10.42 3 7.812.08
60 3 31.25 3 15.63 3 10.42 3 7.812.50
70 4 41.67 4 20.83 4 13.89 4 10.42 2.92
80 4 41.67 4 20.83 4 13.89 4 10.42 3.33
90 4 41.67 4 20.83 4 13.89 4 10.42 3.75
100 5 52.08 5 26.04 5 17.36 5 13.02 4.17
max no. 10 20 30 40
of people
max 144 288 432 576
CO2l/hr
No. 0.096 0.192 0.288 0.384
cartridges
per hr
1 cartridge 10.42 5.213.47 2.60
lasts (hr)
Normal operating range
Marginal or non
recommended conditions
ref (1) Criteria for the
design of refuge stations
Drake, Fellow & Bates
Version 4, 29/10/10 MCL, JS
Page 5 of 9

Table 2 – typical data for a range of normal operating conditions people Entrapped (1).
(Assumes: 0.4 l/min CO2per person; 1,500 l/CO2per cartridge; 400 l/min air flow rate per cartridge
and 1% max CO2inlet concentration)
H i C a p
T M
C O 2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma n u f a c t u r e r :
C a r b o n D i o x i d e
A b s o r b e r C a r t r i d g e
Volume No. of run time No. of run time No. of run time No. of run time No. cartridges
of people (hr) people (hr) people (hr) people (hr) for 1air
enclosure 1to 10 11 to 20 21to 30 31to 40 change per hour
min No. min No. min No. min No.
m
3 cartridges cartridges cartridges cartridges
10 16.25 13.13 12.08 11.56 0.42
20 16.25 13.13 12.08 11.56 0.83
30 2 12.50 2 6.25 2 4.17 2 3.13 1.25
40 2 12.50 2 6.25 2 4.17 2 3.13 1.67
50 3 18.75 3 9.38 3 6.25 3 4.69 2.08
60 3 18.75 3 9.38 3 6.25 3 4.69 2.50
70 4 25.00 4 12.50 4 8.33 4 6.25 2.92
80 4 25.00 4 12.50 4 8.33 4 6.25 3.33
90 4 25.00 4 12.50 4 8.33 4 6.25 3.75
100 5 31.25 5 15.63 5 10.42 5 7.814.17
max no. 10 20 30 40
of people
max 240 480 720 960
CO2l/hr
No. 0.16 0.32 0.48 0.64
cartridges
per hr
1 cartridge 6.25 3.13 2.08 1.56
lasts (hr)
Normal operating range
Marginal or non
recommended conditions
ref (1) Criteria for the
design of refuge stations
Drake, Fellow & Bates
Version 4, 29/10/10 MCL, JS
Page 6 of 9

Effect of moisture
The Sofnolime®absorbent needs some water vapour to be present to work efficiently.The optimum required amount
of water is incorporated into the material as supplied. High humidity air flow through the cartridges will not harm
the cartridges and indeed will help maintain optimum performance providing liquid water is not allowed to enter the
cartridge. Adding extra liquid water to the cartridge will decrease the capacity by causing local flooding in the
absorber that prevents air flow. High air flow rates of very dry air passed through the cartridge for extended periods
of time can limit the CO2removal rate towards the end of the use period if the cartridge becomes unduly desiccated.
Therefore it is recommended that when cartridges are used in very low humidity conditions (<50% RH) that the
operating procedures design takes the run time into account and limits the operating period of the individual cartridges
to less than about 15 to 20 hours i.e. change out times should be less than this. For volumes greater than 100m3please
consult the manufacturer.
Storage, Maintenance and Condition checks
The cartridges do not require any maintenance in storage but do need to be stored in such a way that the barrier foil
packaging prevents moisture or contamination entering the cartridge.
• Thecartridgesneedtobehandledandstoredunderconditionsthatpreventdamagetothebarrierfoilpackaging
i.e. avoid sharp objects or pressure points puncturing the packaging.
• Thecartridgesshouldbestoredbetween0–35C°,outofdirectsunlightandprotectedfromwetconditions.Thecartridges
will not work if the water, present in the material, is frozen.
• Each cartridge is marked with a label on the outside of the packaging that shows the original packed weight
of the cartridge.
The cartridges can loose moisture if the packaging is damaged therefore the weight change can be used as a measure
of the seal integrity and the condition of the cartridge.
• Iftheweightchangesbymorethantheweightallowedshownonthelabel,thencartridgeshouldbereplaced.
• Thisweightchangeallowanceassumestheweightchangeisduetowaterlossorcontaminationandindicatesthe
point at which the cartridge starts to work less efficiently than documented here.
The cartridges gain weight (approximately 1 kg) in normal use.
Residual risks:
The cartridges produce heat as the reaction of CO2proceeds.Thistemperaturecanreachapproximately50°Catthe
outlet. Consideration of this additional heat load should be incorporated into the design of the system in which it is
to be used. HiCapTM CO2contains Sofnolime®which is an Irritant, a MSDS is available on request.
Disposal of used or time expired cartridges
The cartridges are constructed from polypropylene which can be recycled when emptied and cleaned.The fill can be
disposed of to land fill via a licensed waste disposal contractor. A material safety data sheet for the Sofnolime®
absorbent is available on request. Local legislation may apply to disposal or recycling. Advice on individual cases can
be sought from the manufacturer or your local supplier.
H i C a p
T M
C O 2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma n u f a c t u r e r :
C a r b o n D i o x i d e
A b s o r b e r C a r t r i d g e
Version 4, 29/10/10 MCL, JS
Page 7 of 9

Specification
Carbon dioxide capacity - greater than 1,400 litres (@ 400 l/min to 0.5% CO2at outlet)
Carbon dioxide capacity - greater than 1,500 litres (@ 400 l/min to 1% CO2at outlet)
Normal operating gas flow rate 400 litre per minute per cartridge
Operational flow rates 200 to 600 litres per minute per cartridge
Pressure drop per cartridge – not more than 14 mm H2O gauge at 400 litres per minute flow
Pressure variation between cartridges - not more than 4 mm H2O gauge (provisional)
Dimensions 400 x 300 x 180 mm
Cartridge weight (as delivered) 14 kg
Storage life 5 years (condition can be monitored by weight change)
Conditions of use and limit of liability – HiCap™ CO2- Sofnolime®Filled Large Absorber Cartridge
The cartridges are designed to be used as part of a purpose built air purification system that can operate within the
documented design parameters. No liability or guarantee of performance can be accepted for cartridges operated
outside these conditions.
The performance is guaranteed only if the cartridges are used and stored within the declared operational limits set by
the manufacturer and documented in this user manual.
The cartridges are supplied in a sealed barrier foil bag.The seal must not be broken until the cartridge is required
for use as the cartridge can loose or gain water from the atmosphere that can reduce its CO2removal performance.
The performance of cartridges that have been opened, but not used, for more than a few hours cannot be guaranteed
or predicted.
Cartridges with damage to the sealed packaging should not be used.The cartridges are supplied with a weight check
and weight tolerance label that allows the user to establish if the cartridges have remained sealed prior to use.The use
of cartridges that have failed this weight check requirement or that have damaged packaging cannot be guaranteed by
the manufacturer as the performance may be affected.
The way that the cartridges are used is the responsibility of the user and /or facility operator. It is strongly
recommended that the facility operator should carry out a risk assessment of the way in which the cartridge(s) are to
be used before they are deployed.
The cartridges comply with the essential safety requirements of the EU Mechanical Directive and are
labelled accordingly.
H i C a p
T M
C O 2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma n u f a c t u r e r :
C a r b o n D i o x i d e
A b s o r b e r C a r t r i d g e
Version 4, 29/10/10 MCL, JS
Page 8 of 9

Appendix 1 – air recirculation equipment interface requirements
The cartridges are designed to seal against the base plate cut-out of fan driven air supply equipment.
This base plate cut-out design allows the cartridge’s base seal to provide a gas tight seal under the weight of the
cartridge. In order to achieve this, the base plate needs to be flat with a cut out of the correct size to allow the seal
to function.
The cartridges weigh circa. 15kg – 33lbs each so the base plate must be sufficiently stiff to support the weight and
prevent distortion of the base plate preventing the seal from working. It is recommended that the base plate should be
constructed from flat stainless steel sheet that is sufficiently thick, or stiffened, to prevent distortion in use. A turned
over edge is preferred to prevent sharp edges damaging the seals or the fingers of the operators.The recommended
dimensions are given below.
Base cut-out dimensions: Baseplate details
• Length370mm+/-1mm
• Width270mm+/-1mm
• Maximumradiusofcorners
8 mm (but can be any value less)
• Minimumrecommendedseparation
between cartridges – 50 mm between
inside edges of cut-outs.
If the cartridges need to be secured in position the top edge of the base flange can be used to clamp against.Care should
be exercised to ensure the base seal is not distorted to the point it fails to seal if the cartridges are fastened or clamped
in position.The outside edge of the upper surface can be used to seal against if the cartridges are to be used in a fully
ducted system.
The provision of air flow through the cartridge is the responsibility of the equipment provider but it is advised that the
airflow should beblownfrombaseto topupthroughthecartridges.Thecartridgesshouldnotencounterreversedgasflow
during use as this will reduce the capacity of the cartridges. Please contact the manufacture if advice is required on
non-standard operating conditions. Cartridges must remain sealed until ready for use. Opened, unsealed cartridges left
on the base for extended periods of time may have significantly reduced performance. Only remove the barrier sealing
foil immediately before use.The foil barrier film is a strong material and a safety blade is provided with each cartridge.
The packaging cannot be torn fully open by hand.
50mm
270 +/- 1mm
370 +/- 1mm
Max radius
8mm
Seal
Baseplate
Unit
Cut-outCut-out
Molecular Products Limited
Mill End, Thaxted, Essex T+44 (0)1371 830676 E[email protected]
CM6 2LT United Kingdom F+44 (0)1371 830998 W www.molecularproducts.com Version 4, 29/10/10 MCL, JS
Page 9 of 9
H i C a p
T M
C O 2
Instructions for use:
Use in accordance with refuge
manufacturer’s instructions.
Disposal and the Environment:
Please dispose of responsibly complying
with local legislation.
Contains Soda Lime
Ma n u f a c t u r e r :
C a r b o n D i o x i d e
A b s o r b e r C a r t r i d g e