Low Flow Sample Pump 222-3 Operating Instructions 3707 PDF

Low Flow Sample Pump 222-3 Operating Instructions 3707 PDF
Low Flow Sample Pump
222 Series
Operating Instructions
SKC Inc.
863 Valley View Road
Eighty Four, PA 15330 USA
Form #3707—Rev 0606
13
Table of Contents
Description .................................................................................... 1
Performance Profile ...................................................................... 2
Operation (with sorbent tube) ....................................................... 3
Setting the Sampling Rate ...................................................... 3
Operation Using a Stroke Counter .......................................... 3
Measuring Pump Flow Rate .................................................... 3
Determining the Pump Factor ................................................. 4
Other Sampling Applications ........................................................ 4
Sampling with Long-duration Color Detector Tubes ............... 4
Sampling with Bags ................................................................ 5
Maintenance ................................................................................. 6
NiCad Battery Notes and Technical Note ..................................... 8
Replacement Parts and Accessories ............................................ 9
Service Policy ............................................................................. 10
SKC Inc. Warranty ...................................................................... 11
UL Certificate .............................................................................. 12
Notice: This operating instruction may not address all safety concerns (if any) associated
with this product and its use. The user is responsible for determining and following the
appropriate safety and health practices and regulatory limitations (if any) before using the
product. The information contained in this document should not be construed as legal
advice, opinion, or as a final authority on legal or regulatory procedures.
Description
SKC 222 Series Low Flow Pumps are miniature diaphragm-type pumps
for personal or area sampling of gases and vapors in air. These reliable
lightweight pumps are motor-operated and powered by a rechargeable
battery pack. Featuring reliable stroke counter technology, the pump's
stroke counter indicates the number of times the pump's diaphragm
has pulsed (or stroked) during the sampling period. By multiplying this
stroke number by the volume of air per stroke, an accurate determination
of air volume can be made. SKC sample pumps have special patented
valves that close positively; ensuring "zero leaks." All working parts are
housed in a sturdy, shock-resistant case with belt clip.
Stroke Counter
Dial
Belt Clip
(not shown)
On/Off Switch
Charging Jack
222 Series Low Flow Pump
Model
Description
Flow Range
222-3
For use with sorbent tubes or sample bags
50 to 200 ml/min
222-4
For use with sample bags, sorbent tubes, or
long-duration color detector tubes
20 to 80 ml/min
1
Performance Profile
Flow rate:
222-3:
222-4:
50 - 200 ml/min
20 - 80 ml/min
Operation time:
10 hours per battery charge
Case:
Sturdy, lightweight plastic
Battery:
Rechargeable NiCad
Intrinsic safety is invalid without SKC-approved battery.
Battery regulator:
Holds voltage constant
Counter readout:
Shows pump strokes up to six digits.
Valves:
“Zero-leak” valves
Pumping Action:
Diaphragm
Temperature Ranges:
Operating: 32 to 113 F (0 to 45 C)
Charging: 32 to 113 F (0 to 45 C)
Storing:
-4 to 113 F (-20 to 45 C)
Protect sample pump from weather when in use outdoors.
Size:
5.1 x 2.5 x 1.25 inches (13 x 6.4 x 3.2 cm)
Weight:
12 oz (340 gm)
Intrinsic safety:
UL listed for Class I, Groups A, B, C, and D
Intrinsic safety and other approvals may be void if SKC pumps
are not repaired by SKC or authorized SKC repair centers. In
addition, replacing parts with non-SKC parts can void intrinsic
safety approvals and the manufacturer warranty.
2
Operation with Sorbent Tube
Setting the Sampling Rate
1.
2.
3.
Using a screwdriver, remove the metal plate on the front of the
pump.
The dial with an arbitrary scale is used to set the sampling rate.
Turning the dial clockwise increases the sampling rate, turning it
counterclockwise decreases it.
Adjust the dial to the desired position. Select the minimum setting
(position #0 on the dial) for sampling rates at the low end of the
pump's flow range. Select the maximum setting (position #10) for
sampling rates at the high end of the pump's flow range.
Operation Using a Stroke Counter
1.
2.
3.
4.
5.
6.
7.
Record the initial counter reading.
Break open the ends of a sample tube.
Using flexible tubing, connect the inlet of the pump to the outlet of
the sample tube.
Turn the pump on, using the on/off switch next to the counter,
and sample for the desired time period.
When finished sampling, turn the pump off.
Disconnect and seal the sample tube.
Record the final counter reading and calculate the air volume using the following equation. To determine the pump factor, see
page 4.
Air
Volume
=
(
Final Counter
Reading
–
Initial Counter
Reading
)
x
Pump
Factor
Measuring Flow Rate with a Calibrator
1.
2.
3.
4.
Using flexible tubing, attach the outlet of a representative sample
tube to the pump inlet.
Attach the inlet of the sample tube to a film flowmeter or electronic calibrator.
Turn the pump on, using the on/off switch next to the counter,
and measure the flow rate following the calibrator instructions.
Adjust the flow by using a screwdriver to turn the dial clockwise to
increase or counterclockwise to decrease flow.
When ready to sample, break the ends off a new tube, insert the
tube into the tubing, and sample for the desired sampling period.
Protect sample pump from weather when in use outdoors.
3
Determining the Pump Factor
To determine the relation between the counter to the pump volume:
1.
2.
3.
4.
5.
6.
7.
8.
Using flexible tubing, connect the pump inlet to the outlet of a
film flowmeter.
Turn the pump on, using the on/off switch next to the counter.
Calibrate the pump to 100 ml/min. Turn the dial to adjust the flow.
Turn the pump off.
Record the counter reading, then turn the pump on and allow the
pump to run for one minute.
Turn the pump off and record the counter reading.
Subtract the first counter reading from the second reading. This
yields the number of counts per 100 ml.
Calculate the pump factor (ml per count) using the following
equation:
Pump Factor (ml per count) = 100
Number of Counts per 100 ml
The pump factor should be checked periodically. SKC recommends this procedure after every 40 hours of operation.
Other Sampling Applications
Sampling with Long-duration Color Detector Tubes
Long-duration color detector tube samples should be taken at a rate of
approximately 10-20 ml/min. The 222-4 pump is the appropriate
pump for this application. Set the pump rate at the minimum setting
(position #0 on the dial) on the 222-4 pump. The flow rate of the pump
can be measured with a calibrator or the stroke factor can be used to
calculate the air volume.
Long-duration Color Detector Tubes require a special tube
cover that accommodates an in-line trap tube. The trap tube
protects the pump from caustic fumes that are often released
from detector tubes. Please read closely all precautions when
using these tubes. Failure to use the necessary traps will
damage the pump and void the warranty.
1.
2.
Insert the outlet of a long-duration color detector tube into a tube
holder attached to flexible tubing.
To protect the pump from chemicals that may off-gas from the
color detector tube, connect the other end of the tubing to the inlet
of a trap tube. Use a trap tube (SKC Cat. No. 222-3D-2) and holder
(Cat. No. 222-3D-1) in line. The trap tube should be closest to the
pump.
4
3.
4.
Record the initial counter reading.
Turn the pump on, using the on/off switch next to the counter,
and sample for the desired time period.
Protect sample pump from weather when in use outdoors.
5.
6.
7.
Turn the pump off.
Record the final counter reading and the color band result from
the detector tube. Each tube is calibrated for a specific volume.
Calculate and correct the data as follows:
a.
Determine the air volume using a stroke counter:
Air Volume (liters) =
[(Pump Factor) x (Final Count Reading - Initial Count Reading)]
1000
b.
Correct detector tube reading:
Corrected Detector Tube Reading =
(Absolute Detector Tube Reading)
(Air Volume in Liters)
Sampling with Bags
The SKC 222 Series Low Flow samplers are also designed for sampling
with bags. It is important that precautions be taken to prevent contamination of the pump when performing bag sampling.
Protect sample pump from weather when in use outdoors.
1.
2.
3.
4.
Loosen the setscrew on the outlet fitting at the top end of the
pump.
Remove the fitting by unscrewing counterclockwise.
Attach Teflon® tubing to the exposed special fitting. Attach the
other end of the tubing to the inlet valve on the sample bag.
See the bag operating instructions for details on the operation of
the bag fitting(s).
When collecting bag samples, the contaminant passes
through the interior of the pump. The pump should be
purged after bag sampling to remove any remaining
contaminant. To purge the pump, run it for several minutes
in a clean air environment. If the contaminant is hazardous,
take all necessary safety precautions.
5
Maintenance
Checking for Leaks
To function properly and provide correct pumping volume, the
diaphragm must be free from leaks and close positively. Remove cover
plate and check as follows:
Intake Valves
1.
To check the intake valves for leaks, connect a water manometer
and a “T” connection to the pump inlet as shown below:
Open end of T
Inlet
Outlet
(exhaust)
Pump
2.
3.
Water manometer
On the open end of the "T," draw vacuum by mouth until 4 to
5 inches of water vacuum register on the manometer.
Seal off the open end of the "T" and watch the manometer. The
water level should drop less than one-half inch in ten seconds.
Diaphragm and Valve System Integrity
1.
2.
With the water manometer and “T” connected to the inlet, as in
the previous test, seal off the outlet of the pump and introduce
positive pressure through the open end of the “T” to 4 to 5 inches
of water on the manometer.
While maintaining the pressure, seal off the open end of the “T”
and watch the manometer. The water level should drop less than
one-half inch in ten seconds.
Exhaust Valve Seating
1.
2.
3.
Disconnect the “T” and water manometer from the pump inlet
and connect them to the outlet of the pump.
Introduce positive pressure through the open end of the "T" to
4 to 5 inches of water on the manometer.
While holding this pressure, seal off the open end of the “T.”
Watch the manometer. The water level should drop less than onehalf inch in ten seconds.
6
Changing the Battery
1.
2.
3.
Remove the six screws on the back of the pump case.
Gently pull the battery pack from the case.
Grasp both sides of the white connector and pull apart.
Do not pull on red and black wires.
4.
5.
6.
7.
8.
9.
Remove old battery pack and replace with new battery pack.
Push the two sides of the white connector together ensuring that
the two pins on the left side of the connector align with the two
sockets on the right side of the connector. Push firmly until the
connector clicks.
Place the battery pack back in the pump case with the label facing
you.
Ensure that the white connector is seated down into the pump
case.
Place the back plate back onto the pump with the belt clip facing
downward.
Replace and tighten the six screws.
Tampering with the battery pack voids the SKC warranty and
the UL Intrinsic Safety listing.
7
NiCad Battery Notes and Recommended Maintenance
• NiCad batteries self-discharge at an average rate of 18 to 20% per month at
room temperature. The rate of self-discharge increases with temperature. Ultimately, self-discharge results in an increased need for charging.
Recommended Maintenance:
• Cycle battery use on a monthly basis (quarterly for pumps not used on a
regular basis).
• "Exercise" your battery pack! Use an SKC battery conditioning system
(MasterCharger® or PowerFlex®) that automatically exercises batteries. Perform this procedure before storage and monthly (quarterly for pumps not
used on a regular basis).
• Store and charge batteries in the recommended temperature range.
• Discharge and recharge battery packs fully before use and storage.
• Stated battery capacity will not be reached "right out of the box," but only
after the battery is exercised. Often new NiCad battery packs require 5 to 7
cycles to reach the stated capacity.
Recommended Maintenance:
"Exercise" your battery! Use an SKC battery conditioning system (MasterCharger or PowerFlex) that automatically exercises batteries. Perform this
procedure before storage and monthly (quarterly for pumps not used on a
regular basis).
• Battery packs are typically shipped less than fully charged to meet testing and
shipping requirements.
Recommended Maintenance:
Discharge and recharge battery packs fully before use and storage.
• A NiCad battery should not sit on a charger for long periods of time.
Recommended Maintenance:
Remove battery pack from its charger within 24 to 48 hours after charging is
complete.
For further information on Maintaining NiCad Battery Packs, request SKC Publication
1363 (available for download at www.skcinc.com).
Technical Note: Battery Pack Life
• Battery manufacturers typically indicate expected battery life as the number of
usable cycles within an approximate number of years (e.g., 300 charge/discharge
cycles or 3 years).
• The number of usable cycles/years of useful life for a battery pack is determined
by the number of cycles/amount of time it takes for the battery to decline to 80%
of its initial capacity when used under ideal conditions. The battery should be
replaced at this point.
• Battery life ratings are nominal (±5%) and are generally based on ideal conditions of use such as those in which they are tested (for testing criteria, see IEC
61436 and IEC 61951 test methods at www.iec.ch).
• Individual conditions of use, charging procedures, and applications (high versus low current drain, intermittent versus steady current drain) may affect battery life.
• While nickel-metal hydride (NiMH) batteries provide longer run times than NiCad
batteries on a single charge, the user can expect less cycles life from an NiMH
battery when compared to NiCad cycles life.
8
Replacement Parts and Accessories
Part Description
Catalog No.
Motor (Model 222-3)
Motor (Model 222-4)
Battery Pack
Voltage Regulator
Eccentric
Counter
Bearing/Ring/Stem Assembly
Diaphragm Disc Assembly
Switch
Links - Counter/Eccentric
Pump case with Meter,
Switch, Pot, and Window
Potentiometer Control
C-1 Connector
C-2 Connector
Window
Body/Valve Assembly
Neoprene Gasket
Stainless Steel Back Plate
Case Fitting - Inner-Male
Case Fitting - Outer-Female
O-ring (pk/10)
Jack
Angle Bracket
Body Valve Set
P222301
P222402
222-3SR-04
P22231202
P222302
P222304
P222305
P222308
P222310
P222313
Accessories
Catalog No.
P222314UL
P222316
P222317
P222319
P222322
P222323
P222324
P222325
P222326
P222327
P222328
P222331
P222332
P222334
PowerFlex Charger
5-station, 100 - 240 V
Single, 120 V
Single, 100 - 240 V
PowerFlex Charging Cable
for 222 Low Flow Pumps
Tube Holders:
Type A fits tubes 6 mm OD x 70 mm L
Type B fits tubes 8 mm OD x 110 mm L
Type C fits tubes 10 mm OD x 150 mm L
Type D fits tubes 10 mm OD x 220 mm L
Type J fits tubes 8 mm OD x 110 mm L
used with filter cassettes (not included)
Tandem style for color detector tubes
9
223-1000
223-2000
223-2000B
223-1005
222-3-1
222-3L-1
222-3XL-1
222-3XD-1
222-3XJ-1
222-3D-1
Service Policy
To return products to SKC for servicing:
1. Call 800-752-8472 (724-941-9701 for international customers) to obtain a
Return Materials Authorization (RMA) number and Product Decontamination Form.
2. Carefully package the product. Mark the RMA number on any correspondence relating to the return and on the outside of the package.
3. Ship to SKC, freight prepaid, to the following address:
SKC Inc.
National Service Center
863 Valley View Road
Eighty Four, PA 15330
Package product carefully to prevent damage during transit. Include a
contact name, phone number, shipping address, RMA number, and a brief
description of the problem. For nonwarranty repairs, a purchase order
number and billing address are also required. The Service Department will
contact nonwarranty customers with an estimate before proceeding with
repairs.
Intrinsic safety and other approvals may be void if SKC pumps are not
repaired by SKC or authorized SKC repair centers. In addition,
replacing parts with non-SKC parts can void intrinsic safety
approvals and the manufacturer warranty.
10
SKC INC.
LIMITED ONE YEAR WARRANTY
1. SKC warrants that its instruments provided for industrial hygiene, environmental, gas analysis, and safety and health applications are free from defects in workmanship and materials under normal and proper use in accordance with operating instructions provided with said instruments. The term
of this warranty begins on the date the instrument is delivered to the buyer
and continues for a period of one (1) year.
This warranty does not cover claims due to abuse, misuse, neglect, alteration, accident, or use in application for which the instrument was neither
designed nor approved by SKC Inc. This warranty does not cover the buyer’s
failure to provide for normal maintenance, or improper selection or misapplication. This warranty shall further be void if changes or adjustments to the
instrument are made by other than an employee of the seller, or if the operating instructions furnished at the time of installation are not complied with.
2. SKC Inc. hereby disclaims all warranties either expressed or implied, including any implied warranties of merchantability or fitness for a particular
purpose, and neither assumes nor authorizes any other person to assume for
it any liability in connection with the sale of these instruments. No description of the goods being sold has been made a part of the basis of the bargain
or has created or amounted to an express warranty that the goods will conform to any such description. Buyer shall not be entitled to recover from SKC
Inc. any consequential damages, damages to property, damages for loss of
use, loss of time, loss of profits, loss of income, or other incidental damages.
Nor shall buyer be entitled to recover from SKC Inc. any consequential damages resulting from defect of the instrument including, but not limited to, any
recovery under section 402A of the Restatement, Second of Torts.
3. This warranty extends only to the original purchaser of the warranted
instrument during the term of the warranty. The buyer may be required to
present proof of purchase in the form of a paid receipt for the instrument.
4. This warranty covers the instrument purchased and each of its component parts.
5. In the event of a defect, malfunction, or other failure of the instrument
not caused by any misuse or damage to the instrument while in possession of
the buyer, SKC Inc. will remedy the failure or defect without charge to the
buyer. The remedy will consist of service or replacement of the instrument.
SKC Inc. may elect refund of the purchase price if unable to provide replacement and repair is not commercially practicable.
6. (a) To obtain performance of any obligation under this warranty, the buyer
shall return the instrument, freight prepaid, to SKC Inc., at the following address:
SKC Inc., National Service Center
863 Valley View Road
Eighty Four, PA 15330 USA
(b) To obtain return authorization information or for further information on
the warranty performance you may telephone 724-941-9701 at the above address. See Service Policy section in operating manual (if applicable).
7. This warranty shall be construed under the laws of the Commonwealth
of Pennsylvania which shall be deemed to be the situs of the contract for purchase of SKC Inc. instruments.
8.
No other warranty is given by SKC Inc. in conjunction with this sale.
Form #3755 Rev 0207
11
12
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