Low Flow Sample Pump 222 3 Operating Instructions 3707 PDF SKC User Manual
User Manual: SKC 222-3 Sample Pump User Manual
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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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