AUTOMATED SPECIALTY GAS FILL SYSTEM

Produce Mixtures From % Down to PPB Concentrations, Including EPA Protocol Gases

 

GAIN PRODUCTIVITY AND ACCURACY

Easy to Use Touch Screen Technology Guides You Through the Filling Process

 

NEW ADMIN TOOLS FOR OPERATIONS AND SALES

Integrated with Asterisk's Specialty Gas Manager Software Program

 

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gas types available

Inert Model
Designed for Inert Gas Service. Source Gas Mixtures that contain over 23% of Oxidizer are limited to 500 PSI. 580 and 590 CGA connections are used with this unit.

Flammable Model
Designed for Flammable Gas Service. 580 and 350 CGA connections are used with this unit. The included Sartorius 150 kg x 0.1g Gravimetric Scale and 0-4000 PSIG Pressure Transmitter are rated (explosion proof) for this model. Features a purge assembly designed specifically for putting an inert gas purge into the electrical enclosure, which is mounted on the cabinet, in order to prevent the possibility of a fire hazard. Please note, with this model, the console must be rated in order to be in the same room.


Oxidizer Model

Designed for Oxygen Gas Service. 580 and 590 CGA connections are used with this unit. All processed filling components such as valves, check valves, etc. are made out of either brass or Monel. All process piping is made out of Monel. Brass and/or Monel is used due to its great compatibility with high pressure oxygen.

Reactive Model
Designed for Reactive Gas Service. 580, 350 and 660 CGA connections are used with this unit. The included Sartorius 150 kg x 0.1g Gravimetric Scale and 0-4000 PSIG Pressure Transmitter are rated (explosion proof) for this model. Features a purge assembly designed specifically for putting an inert gas purge into the electrical enclosure, which is mounted on the cabinet, in order to prevent the possibility of a fire hazard. The hood on this model has an extension on the sides od the cabinet, PVC curtain strips along the entire edge of the hood and a 10" vent port for an exhaust duct with fan to be connected to (duct and fan not included). All these design features are to ensure that any possible gas leaks are safely contained, directed and released through the duct above the hood. Please note, with this model, the console must be rated in order to be in the same room.

 

every system includes:

  • Operator Console with HMI Touch Screen, Keyboard and Mouse, Printer and Audible Speaker
  • Powder-coated Steel Reference Enclosure With Load Centering Sartorius 150 kg x 0.1g Gravimetric Scale
  • Source Gas Cylinder Storage Rack Built into Base
  • 6 or 10 Cylinder 316 Stainless Steel Orbital Manifold
  • All units with CGA 580 Fittings Supplied for Connecting to Target Cylinders
  • Up to (10) Supply Gases With Double Block & Bleed
  • Max. Service Pressure 3045 PSIG MAWP
  • Pirani Vacuum Gauge With O-ring Flange Connection For Micron Readings
  • 1/4" or 1/8" Rigid Stainless Steel Leads
  • Individual Pneumatically Operated Cylinder Isolation Valves on Leads
  • Static or Dynamic Vacuum

additional options:

  • Source Gas Cylinder Storage Rack for Small Cylinders
  • A vacuum pump, stand, and a vacuum pump starter control box are also available options. All sold separately.

SUR-FILL IQ-S™ AUTOMATED GRAVIMETRIC FILL SYSTEM

For Specialty Gas Applications

The Sur-Fill iQ-s™ Automatic Specialty Gas Gravimetric Fill System puts automated technology at your fingertips. This easy to use system has touch screen technology that guides you through the specialty gas filling process, providing greater productivity and accuracy.  The Sur-Fill iQ-s is capable of producing mixtures (from up to 10 gases) from percent down to ppb concentrations, including EPA Protocol Gases. Our system is integrated with AsteRisk's Specialty Gas Manager software program.

 

Safety Features and Benefits

  • Designed to produce mixtures from percent down to ppb concentrations, including EPA Protocol gases.
  • Unlimited number of recipes can be stored with up to 10 source gas supply stations
  • Intuitive HMI touch screen with self prompting features 
  • Produces ultra-consistent mixtures
  • Uses significantly less labor to produce highly accurate mixtures
  • Runs unattended after the cylinders are connected and the mixture recipe is selected
  • Add-on feature provides remote monitoring capability and support
  • Includes a start-up and power loss recovery validation mode
  • Performs pigtail/lead deflection test prior to producing each mixture
  • Software keeps track of pressure and service cylinder contents
  • All process piping has been hydrostatically tested to 5250 PSIG to ensure quality and safety
  • Self-contained cabinet aids in reducing environmental influences to scale
  • Orbital fill head provides equal flow to each cylinder connected to manifold
  • Every morning, when logged into, the system performs an integrity check prior to starting the unit
  • Relief valves are installed for over pressure protection during the fill process
  • All components are orbital welded and mostly VCR connections. (Oxidizer/Inert model has monel tubing with compression fittings)
  • All piping components manufactured by Weldcoa have been cleaned for oxygen service per: PSGP Oxygen Cleaning Procedure #PSMB-O2 CLEAN. This is to check the entire system, making sure there are no leaks in the common piping.
  • All Gas Flo Products pneumatic valves and check valves have been cleaned by Gas Flo Products per CGA G4.1-2009 (practice for cleaning methods and cleanliness levels for material and equipment used in oxygen-enriched environments)   
  • Valves are high integrity diaphragm type stainless steel (Oxygen model has diaphragm packless monel/brass)     
  • The entire manifold assembly, including the leads, are 100% hydrostatically pressure tested to 1.5 times the MAWP, 100% nitrogen leak tested, 100% oxygen cleaned, dried, bagged to the highest safety standards. 
  • Installation is quick and easy. System is delivered assembled, oxygen cleaned, pressure tested and ready to go. Simply uncrate the unit, position it in place, anchor it to the floor and connected it to the existing plumbing.
  • Made in the USA

 


integrated with SPECIALTY gas manager software

The latest version of AsteRisk’s Specialty Gas Manager Software is downloaded into every iQ-s model. The Specialty Gas Manager assists your operations and sales personnel in... 

Mixture Recipes - 

It applies safe mixture making procedures which have been developed from years of specialty gas mixture experience (vapor pressure limitation, BTU/ LEL limitation, compatibility, etc.) It recommends the CGA outlet, hydrotest frequency and eligibility for 10% overfill. It is also customizable to prohibit certain gases or conditions (fuel/oxidizer, etc.). PPM mixtures are automatically calculated using base (dilution) mixtures. 

Post Fill Mixture Calculator - 

This utility assists you in calculating the concentration of the mixture from the actual grams added on the scale. The data is entered once and available to other modules (Labels, Recipe, etc.). 

Mixture Label Generation - 

You select the gases in the mixture and the Labels Module prints a medical or industrial label with the following: 

  • DOT Shipping Diamonds
  • DOT Proper Shipping Name
  • CAS ID Numbers 
  • UN Number 
  • OSHA, DOT and FDA warnings
  • Your address, logos, etc. 
Sales Quotation Tool - 

This module recommends a mixture price based on: the gases in the mixture, technician labor, cylinder maintenance costs, materials costs, delivery costs, desired margin, etc. It facilitates a consistent pricing strategy which protects your margin. 

System Settings - 

The Specialty Gas Manager is highly configurable to your specific needs. Your preferences are entered into the System Settings. Your company logos, fill procedures, units of measure, cylinder preferences, labor/gas cost assumptions, print preferences, etc. are easily entered and modified. Additionally, system information is displayed: validation certificate, upgrade history, etc. 


REQUIREMENTS NEEDED:

  • Power Requirements:
    • 15 amp 120 VAC
  • Network Connection Requirements:
    • VPN Support  (This is Required for Remote Monitoring and Support)
  • Vacuum Requirements: 
    • Minimum 8 CFM of Free Air to 50 Microns 
  • Pneumatic Requirements: 
    • 100 PSIG Nitrogen, 5 SCFM Minimum 
    • Filtered, Regulated, and Ambient Temperature

What to expect from Weldcoa

All Weldcoa Systems are fully built 100% at Weldcoa. The entire manifold assembly, including the leads, are 100% hydrostatically pressure tested to 1.5 times the MAWP, 100% nitrogen leak tested, 100% oxygen cleaned, dried, bagged to the highest safety standards.  Weldcoa guarantees all of our structures to be free of manufacturing defects for life.

For any questions on what is offered or if you have a specialty application, please feel free to contact us at (630) 806-2000 or email us at solutions@weldcoa.com.

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Deep Industry Experience

From the most basic to the most demanding, we have the products, experience and staff that will support you and your customer’s needs better than anyone in the specialty gas industry.

 

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Weldcoa is a true USA Manufacturer

We are proud to say all of our specialty gas equipment is engineered, designed, programmed, fabricated, wired, assembled and thoroughly tested at our Aurora, Illinois USA facility. 

 

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Top Quality Products and Staff

Weldcoa continually strives to exceed their customers’ expectations. With our vast amount of experience involved with the litany of documentation required, as well as our unmatched depth of knowledge and technical expertise, it will become quite clear that Weldcoa is the partner you are looking for.