Universal Pump Cat. Nos XR, 224-PCXR4, and 224-PCXR8

Transcription

1 Universal Pump Cat. Nos XR, 224-PCXR4, and 224-PCXR8 Service Manual SKC Inc. 863 Valley View Road Eighty Four, PA Publication #1377 Rev 0910

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3 Table of Contents Introduction... 1 Performance Profile... 1 Universal XR Sample Pump Functional Components... 3 Pump Stack Assembly... 3 Pulsation Dampener Assembly... 3 Regulator Assembly... 3 Flowmeter Assembly... 3 Filter Assembly... 3 Universal XR Sample Pump Operational Components... 3 On/Off Switch... 3 Keypad... 3 LCD... 4 Flow Adjust Potentiometer (pot)... 4 Universal XR Sample Pump Electrical System... 4 Battery Pack... 4 Keypad and LCD... 4 Motor Control Circuitry... 4 Functional iii Testing... 5 Initial Leak Check... 5 Pump Flow Rate Spot Check... 5 Testing Flow Range Compensation... 6 Testing the Pressure Regulator... 6 iii Pump iii Disassembly... 7 Removing the Battery Pack... 7 Removing the Back Pump Case... 7 Locating and Correcting Leaks... 7 Checking Pumping Operation... 8 Setting the Regulator... 8 Disassembling the Stack... 9 Checking the Motor Disassembling the Filter Housing Removing the Control Board and Keypad Pump Reassembly Reassembling and Replacing the Stack Setting the Flow Compensation iii Replacing the Back Pump Case Reassembling and Replacing the Filter Housing Replacing the Battery Pack Troubleshooting Figures Addenda Indicates a caution or warning. iii

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5 Introduction Universal XR Sample Pumps Universal XR Sample Pumps are pneumatic constant flow samplers that contain a fully electronic system built for a broad range of applications. Flow is compensated to within ± 5% accuracy over the full range of flows and back pressure. There are three Universal XR pump models: XR 224-PCXR4 224-PCXR8 No additional features LCD and 2-bu on keypad for built-in timer and flow fault/ba ery check LCD and 6-bu on keypad for programming delayed start time, automatic shutdown time, and intermi ent sampling plus flow fault/ba ery check Models 44XR, PCXR4, and PCXR8 are RFI/EMI-shielded and UL Listed for intrinsic safety. Performance Profile Operating Range: 1000 to 5000 ml/min (5 to 500 ml/min requires adjustable low flow holder) Weight: Dimensions: 1 Compensation Range: 1 1 Flow Control: Run Time: Flow Indicator: Power Supply: Charging Time: (with SKC approved charger) 34 oz (964 gm) 5.1 x 4.7 x 1.9 inches; (13 x 11.9 x 4.8 cm) 1000 ml/min up to 40 inches water back pressure 2000 ml/min up to 40 inches water back pressure 2500 ml/min up to 40 inches water back pressure 3000 ml/min up to 35 inches water back pressure 4000 ml/min up to 20 inches water back pressure 5000 ml/min up to 10 inches water back pressure Holds constant flow to ± 5% of the set point 8 hrs minimum at 4000 ml/min and 20 in water back pressure, dependent on media used Built-in rotameter with 250 ml division; scale marked at 1, 2, 3, 4, and 5 L/min Plug-in ba ery pack, rechargeable NiCad 2.0-Ah capacity, 6.0 V, UL Listed 6 to 8.5 hrs with PowerFlex Charger Operating Temp: 1 32 to 113 F (0 to 45 C) Storage Temp: -40 to 113 F (-40 to 45 C) Charging Temp: 50 to 113 F (10 to 45 C) Operating Humidity: Multiple Sampling: RFI-shielding Performance: 0 to 95% non-condensing Built-in constant pressure regulator allows user to take up to four simultaneous samples at different flow rates up to 500 ml/min each using optional adjustable low flow holder. Complies with requirements of EN 55022, FCC Part 15 Class B, EN ; frequency range of the radiated susceptibility test was 27 MHz to 1000 MHz, CE marked. Intrinsic Safety: UL Listed for: Class I, Division 1 and 2, Groups A, B, C, D; Class II, Division 1 and 2, Groups E, F, G; and Class III, Temp Code T3C. 1

6 Performance Profile (cont.) Use only SKC-approved parts to ensure reliable performance. Failure to do so voids UL Listing for intrinsic safety and any warranty. These additional features are found on the PCXR4 and the PCXR8 Flow and Low Ba ery Fault: Ba ery Test: Time Display: Timing Accuracy: Sampling Pause: Fault shutdown at excessive back pressure or low ba ery with LCD indicator and time display retention. LCD shows ba ery condition prior to sampling. LCD shows sampler run time in minutes for sampler period elapsed time, pump run-time or total elapsed time including delayed start time. ± 0.05% (± 45 seconds/day) Allows user to temporarily halt sampling without loss of timing data. Restart does not require rese ing time. These additional features are found on the PCXR8 Timed Shutdown: 2 Delay On: Intermi ent Sampling: 2 2 Allows user to select minutes of operation before automatic shutdown. Allows user to select minutes to delay of test up to 9999 minutes (7 days). Programmable to allow user to extend short term samples over an extended period of time to meet Time Weighted Average (TWA) requirements with a reduced number of samples. Elapsed time maximum is 9999 minutes (7 days). 2 2

7 Universal XR Pump Functional Components The Universal XR Pump systems consists of five basic assemblies: Pump Stack Assembly The pump stack contains two silicone diaphragms driven by a DC motor and low-pressure positive-acting valves. The pump mechanism is sealed to protect it from dust. The motor operates from a rechargeable Nickel Cadmium (NiCad) ba ery. The stack consists of two halves. The top half contains the pulsation dampener and pressure regulator. The bo om half holds the pump and motor. Pulsation Dampener Assembly The pulsation dampener assembly maintains a pulsation-free flow. This assembly consists of a pair of diaphragms and is located directly below the regulator assembly (Figure 2, #2). There are two dampeners in each universal pump. Regulator Assembly The regulator assembly is used for low flow sampling in the 5 to 500 ml/min flow range (Figure 2, #1). The assembly consists of a sensing diaphragm with a pre-loaded spring that automatically opens or closes an air inlet valve to recycle the air within the pump to maintain 20 inches of water across a control restrictor. The regulator is not used in high flow applications above 500 ml/min. A manual valve located below the small round protective cap screw on top of the pump (Figure 1, #14) can be opened to activate the regulator. The regulator can be controlled by turning the screw under the cap screw (clockwise closes it, counterclockwise opens it). 3 The regulator is factory preset at 20 inches water back pressure and should not be adjusted for normal use. Flowmeter Assembly 3 This rotameter-style flowmeter is mounted vertically in the case and is used to monitor pump flow (Figure 1, #13). While rotameters 3 are very repeatable, they are not high-precision instruments and should be verified to a primary standard flowmeter. Filter Assembly The pump inlet consists of a see-through housing and a filter membrane held in place by an O-ring (Figure 1, #9, 10, 11, and 12). All incoming air passes through the filter assembly. The transparent housing permits the user to determine if the pump filter needs to be changed. A clogged filter can affect back pressure and reduce ba ery run time. Universal XR Sample Pump Operational Components 3 The on/off switch (Figure 1, #4), keypad, and flow adjust potentiometer (pot) (Figure 1, #7) is under the anti-tamper keypad cover. Use a flat-head screwdriver to remove the anti-tamper cover (Figure 1, #5). On/Off Switch Use a ballpoint pen or small screwdriver to slide the switch up and turn on the pump. Keypad Each model has different features, therefore, the keypad bu ons on each are different. The 44XR model does not have a keypad. The keypad functions and features indicated below are for the PCXR8 model only. For more detailed information about pump operation, see the pump operating instructions. 3

8 Start/Hold - toggles between Start and Hold Flow and Ba ery Check - sets flow without affecting elapsed time and displays ba ery status. Bat OK displays if just off the charger Bat displays if the pump can be run Bat Lo displays if the pump cannot sustain itself Set-up - sets a delayed start, pump period, and sample period. Mode - steps across delayed start, sample period, and pump period modes once the pump is in setup. Digit Select - steps across to le to set next time digit (keep pressing to return to original position). Total Elapsed Time (in minutes) - press and hold bu on for display on LCD. Digit Set - allows user to enter time to start. Keep pressing until desired number appears (0 to 9). Pump Run Time (in minutes) - press and hold bu on for display on LCD. All programmed sequences are lost when pump is switched off. Use 4 a small screwdriver to adjust flow. Gently turn the pot clockwise to increase flow and counterclockwise to decrease flow. Observe flow indication on the built-in rotameter (not a primary standard flowmeter). 4 4 To repeat a timed cycle, press the Set-up bu on and Start/Hold. LCD Displays ba ery status, pump mode, pump run time, total elapsed time, and flow fault (Figure 1, #1). When pump enters flow fault, the timer does not reset. Flow Adjust Potentiometer (pot) There are two cap screws on the top of the pump. The larger one covers the discharge (exhaust) port. The smaller screw covers the regulator valve for selecting low flow mode (Figure 1, #15 and 16). Universal XR Sample Pump Electrical System Battery Pack The ba ery pack contains five Nickel Cadmium (NiCad) cells in series that provide power to the pump motor. The ba ery pack is intrinsically safe and should be replaced only with a UL-Listed ba ery pack manufactured specifically for Universal XR sample pumps. Do not charge in hazardous locations. Use only an SKC-approved charger designated for this model to ensure reliable performance. Failure to do so voids any warranty. 4 Use of a repaired or rebuilt battery pack voids any warranty and the UL Listing for intrinsic safety. Failure to follow warnings and cautions voids any warranty XRM, PCXR4M, and PCXR8M (MSHA models) contain 4-cell ba ery packs. Keypad and LCD Both are powered by the ba ery pack. If the LCD does not light up when the pump is turned on, there may be a problem with the ba ery. See Troubleshooting. Motor Control Circuitry This is a fully electronic system where the voltage applied to the pump motor and the current flowing through the motor windings are both sampled and controlled by the analog driving circuit. The circuit is calibrated by adjusting two pots such that flow compensation to within ± 5% accuracy is achieved over the full range of flows and back pressures. 4

9 PCXR4 and PCXR8 Models: If the pump can no longer compensate due to excessive back pressure or the pump s ba ery pack runs low on voltage during sampling, the motor control circuitry will automatically read the voltage fluctuations, the pump LCD will indicate a flow fault, and the pump will go into Hold mode. Functional Testing SKC recommends that a procedure for tracking pump problems and ba ery life be established as good preventive maintenance practice. Before beginning functional testing, visually inspect the pump for missing or damaged parts and replace as necessary (see Pump Disassembly and Pump Reassembly). Initial Leak Check Tools Universal XR Series pump (fully assembled) Water manometer Large syringe Pump exhaust port fi tting 1. Connect the pump inlet to a water manometer (Figure 6). 2. Leak check the water manometer. Use a large syringe to apply pressure and pinch off tubing a ached to the pump. If there is no drop in the water column, proceed with leak checking the pump. If the water column drops by one-half inch in 10 seconds, disassemble and reconnect the train. Replace tubing or manometer if necessary. 3. Ensure that there is an O-ring seated in the exhaust port. Insert the exhaust port fi ing (Figure 1, #22) into the exhaust port on the pump and seal it off with a finger. 4. Using a large syringe, apply pressure up to 20 inches Observe the water column. If the water column drops within 10 seconds, there is a leak in the pump stack. See Pump Disassembly, Locating and Correcting Leaks. If the water column does not drop, it indicates that there are no leaks in the system. If there 5 is a drop in the water column, quickly verify that it is not the water manometer leaking and replace with a known leak-free manometer if necessary. 5 SKC recommends periodically testing a water manometer for leaks before performing any leak checks. Pump Flow Rate Spot Check Ensure that the ba ery is fully charged before performing the flow rate spot check. SKC recommends performing preventive maintenance and repair while the pump is on a power supply. Power adapter cables (Cat. Nos. P8000, P8001, and P8005) and ba ery adapter cables (Cat. Nos. P8010 and P8013) are available from SKC. See Figures 9 and 10 and contact SKC to order. Tools Universal XR Series pump (fully assembled) Small fl at-head screwdriver 5 1Dual-ball rotameter, 2valve, 3magnehelic gauge connected with tubing in line and in order 1. Ensure that the pump is in the high flow mode (regulator shut-off screw [Figure 1, #16] turned four full turns clockwise). 2. A ach the inlet of the pump to the outlet of the magnehelic gauge. 3. Turn on the pump. 4. Ensure the magnehelic gauge reads minimum back pressure. 5. Using a small screwdriver, adjust the flow adjust pot on the front of the pump counterclockwise until the dual-ball rotameter reads 1000 ml. 6. Observe the dual-ball rotameter. The balls should be fairly steady. If they are bouncing turbulently, see Pump Disassembly, Locating and Correcting Leaks and Checking Pumping Operation. 7. Using a small screwdriver, turn the flow adjust pot until the rotameter reads 5000 ml and repeat Step 6. If the pump will not reach 5000 ml, see Pump Disassembly, Locating and Correcting Leaks and Checking Pumping Operation. 5

10 Testing Flow Range Compensation The Calibration Sheet Addenda in this manual can be used to document this testing. Compensation is factory preset. SKC recommends that compensation be checked periodically during routine maintenance to assure pump accuracy. Flow compensation will need to be reset if non-factory repairs have been made (see Pump Reassembly, Se ing Flow Compensation). Do not perform a compensation check unless the ba ery voltage is at least 6.1 volts. When checking battery voltage, ensure tester probes are oriented properly to avoid short-circuiting the battery. Universal XR Sample Pumps should be able to maintain flow at: 1000 to 2500 ml/min at 40 inches water back pressure 3000 ml/min up to 35 inches water back pressure 4000 ml/min up to 20 inches water back pressure 5000 ml/min up to 10 inches water back pressure Tools Universal XR Series pump (fully assembled) Small fl at-head screwdriver Calibration Sheet 1Dual-ball rotameter, 2valve, 3magnehelic gauge connected with tubing in line and in order 1. Turn on the pump With the pump inlet a ached to the magnehelic gauge outlet and at minimum back pressure, adjust the flow adjust pot on the front of the pump until the dual-ball rotameter reads 1000 ml/min. 3. Slowly increase back pressure up to 40 inches. The dual-ball rotameter should remain stable at 1000 ml/min. If the balls deviate by more than ± 5% during the back pressure increase, it is out of tolerance (see Pump Reassembly, 6 Se ing Flow Compensation) Release back pressure and repeat Steps 2 and 3 at 3000 ml/min and 35 inches water back pressure. If the reading stays within ± 5% at both 1000 ml/min and 3000 ml/min, the pump should be in spec at any other flow point. If readings deviate by more than ± 5%, see Pump Reassembly, Se ing Flow Compensation. Testing the Pressure Regulator This is only required if the low flow mode is used frequently. Check the pressure regulator periodically during routine maintenance to assure pump accuracy. The pressure regulator is factory preset to 20 inches water back pressure at 1500 ml/min. It will need to be reset if non-factory repairs have been made (see Pump Disassembly, Se ing the Regulator). Tools Universal XR Series pump (fully assembled) Small fl at-head screwdriver 1Dual-ball rotameter, 2valve, 3magnehelic gauge connected with tubing in line and in order 1. 6 Remove the two cap screws from the top of the pump (Figure 1, #15 and 16) and turn on the pump. 2. Place the pump in the low flow mode by turning the smaller screw counterclockwise (Figure 1, #16). This is the regulator shut-off screw. Turning this screw counterclockwise opens the regulator isolation valve allowing air to enter the regulator. This screw should be turned four full turns to be sure the valve is fully open. 3. With the pump inlet a ached to the magnehelic gauge outlet and at minimum back pressure, set pump flow to 1500 ml/min. Turn the flow adjust pot on the pump until the dual-ball rotameter reads 1500 ml. 4. Close off the inlet to the dual-ball rotameter. 5. Observe the magnehelic gauge. It should indicate 20 inches water back pressure (± 1 inch). If it does not, see Pump Disassembly, Se ing the Regulator. If pump passes all functional testing successfully, no further service is required. 6

11 Pump Disassembly Tools Universal XR Series pump Needle nose pliers 1Dual-ball rotameter, 2valve, Phillips head screwdriver Small fl at-head screwdriver 3magnehelic gauge connected with Small Allen wrench Water manometer tubing in line and in order Pliers Pump exhaust port fi tting Large syringe Removing the Battery Pack 1. Turn the pump over so that the belt clip is facing upward. 2. Using a Phillips head screwdriver, remove the two right-hand screws (Figure 3, #5). 3. Slide the ba ery straight out to the right. Lifting up while disconnecting the battery pack can damage the battery pins. Removing the Back of the Pump Case 1. Using a Phillips head screwdriver, loosen and remove the four screws on the back of the pump case (Figure 3, #7). 2. Holding the filter housing assembly firmly, li the back half of the case (with belt clip) off the front half. Locating and Correcting Leaks 7 If the pump failed functional testing, it could be due to a leak. Locate and correct the leak(s). The ba ery pack, back pump case, and stack must be removed from the front pump case to perform the following steps (see Pump Disassembly, Removing the Ba ery Pack, Removing the Back of the Pump Case, and Disassembling the Stack, Steps 1 through 3). Filter 7 Housing and Flowmeter Assemblies Leak Check 1. Remove the filter housing (Figure 2, #3) and flowmeter assemblies from the stack (Figure 2, #4). See Pump 7 Disassembly, Disassembling the Stack, Steps 1 through A ach the filter housing inlet to a water manometer (Figure 6). 3. Place a finger over the short black tubing on the flowmeter. 4. Apply pressure and observe the water column. If it moves, pinch the long black rubber tubing that connects the filter housing assembly to the flowmeter assembly. 5. Apply pressure and observe the water column. If the water column remains steady, the leak is in the flowmeter. If the column moves during this test, there is a leak in the filter housing assembly. Replace filter housing or flowmeter as indicated by this test and repeat Steps 2 through 5. Regulator and Pulsation Dampener Assemblies Leak Check 1. Remove the regulator assembly (Figure 2, #1) and the two pulsation dampener assemblies (Figure 2, #2) from the stack by loosening the screw beside the pump exhaust port and the screw beside the regulator isolation valve 7 (Figure 2, #11). (See Pump Disassembly, Disassembling the Stack, Step 4.) Ensure there is an O-ring seated at the bottom of the exhaust port. If it is missing, replace it to prevent the port from leaking. 2. A ach the stack (regulator) inlet (Figure 2, #14) to a water manometer (Figure 6). 3. Cover the inlet passage on the bo om of the top half stack (Figure 2, #15) with a finger. 4. Holding the assembly firmly, apply not more than 20 inches of pressure and observe the water column. If there is movement, there is a leak in one of the assemblies. 5. Remove the bo om pulsation dampener assembly (Figure 2, #2) and repeat Steps 3 and 4. If there is no movement, replace the bo om pulsation dampener with a new one and you have fixed the leak. If there is still movement in the water column, see Step 6. 7

12 6. Remove the top pulsation dampener assembly and repeat Steps 3 and 4. If there is no movement, replace the top pulsation dampener assembly and repeat Steps 3 and 4. If there is still movement in the water column, see Step Replace the regulator with a new one and repeat Steps 3 and 4. Throughout this procedure, simply replace the last part removed before the leak went away. 8. Reassemble the stack and retest the pump for leaks (see Functional Testing, Initial Leak Check). 9. Set flow compensation and set regulator (See Pump Reassembly, Se ing the Flow Compensation and Pump Disassembly, Se ing the Regulator). Bo om Half Stack Leak Check Remove the motor/eccentric assembly from the pump housing (see Pump Disassembly, Disassembling the Stack, Steps 5 and 6). Because it is very difficult to determine the source of leaks in the bo om half stack, SKC recommends complete replacement with Cat No. P21251 (does not include a pressure switch assembly). A er replacing the half stack with a new one, perform functional testing (see Functional Testing). Set flow compensation (see Pump Reassembly, Se ing the Flow Compensation). Checking Pumping Operation If the pump failed the flow range compensation testing during functional testing but does not show signs of a leak, there could be a problem with the valves. Before checking the valves, ensure that the two stack halves are assembled and that the motor/eccentric assembly is removed from the pump housing (see Pump Disassembly, Disassembling the Stack, Steps 5 and 6) With the stack assembled but the motor/eccentric assembly removed, a ach the stack (regulator) inlet to a water manometer (Figure 6). 2. Using a finger, gently push the yoke/diaphragm in the pump housing up and down and observe the water column on the manometer. The column should rise evenly and steadily with each stroke. If it does not, there is a leaky 8 valve. 3. Apply vacuum pressure and observe the yoke/diaphragm assembly for movement. The yoke will move toward 8 the leaking inlet valve. 4. Ensure that the pump exhaust port fi ing (Figure 1, #22) is installed on the exhaust port and a ach the pump exhaust port to the water manometer. 5. Apply positive pressure and observe the yoke diaphragm assembly for movement. The yoke will now move away from the leaking outlet valve. 6. Replace the leaking valve plate assembly (see Pump Disassembly and Pump Reassembly) and retest the pump for leaks (see Functional Testing, Initial Leak Check). If the yoke/diaphragm does not move either way, it could mean that both inlet valves are leaky. Perform a visual check for wrinkled valves or dust under the valves. Replace the entire valve plate if necessary. Setting the Regulator 8 This is only required if the low flow mode is used frequently or non-factory repairs have been made. Check the pressure regulator periodically during routine maintenance to assure pump accuracy. The pressure regulator is factory preset to 20 inches water back pressure at 1500 ml/min. To perform the following steps the ba ery pack and back pump case must be removed and the stack partially disassembled (see Pump Disassembly, Disassembling the Stack, Steps 1 and 2). In newer pump models, the 1-1/8 x 1-1/4-inch plate on the top of the pump may need to be removed to access the regulator adjustment screw. This may be done by removing the back cover of the pump. Be careful not to bind internal parts and wires. 1. Remove both cap screws from the top of the pump (Figure 1, #15 and 16). Li the stack out of the case and remove the brown plate from the top of the stack. 8

13 2. A ach the filter housing inlet (Figure 1, #9) to the outlet of the magnehelic gauge. Ensure magnehelic gauge reads minimum back pressure. 3. Turn on the pump and adjust the flow adjust pot on the pump (Figure 1, #7) until the dual-ball rotameter reads 1500 ml. 4. Using a flat-head screwdriver, turn the regulator shut-off screw (Figure 1, #16) counterclockwise four or five turns. This will open the regulator isolation valve and allow it to work. 5. With the regulator isolation valve open, close off the inlet to the dual-ball rotameter. 6. If the magnehelic gauge reads 20 inches back pressure, no adjustment is needed. If the gauge reads over or under 20 inches, slowly adjust the regulator adjustment screw (Figure 1, #14) until the magnehelic gauge reads 20 inches Remove the two cap screws from the top of the pump (Figure 1, #15 and 16). 2. Carefully li the stack and filter housing assembly straight up and lay on top of the control board to the right or onto a surface to the le of the pump. Remove the brown plate from the top of the pump. 9 Turn the regulator adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure. If you exceed 20 inches while turning the regulator adjustment screw, release block on the dual-ball rotameter inlet, turn the regulator adjustment screw counterclockwise, close off inlet to dual-ball rotameter, and slowly turn the regulator adjustment screw until the gauge reads 20 inches. To double-check adjustment, release block on rotameter inlet, then reapply. The gauge should still read 20 inches. 7. When the pump is set at 20 inches back pressure, reinsert the cap screw, and release all back pressure. The pump is now set for low flow operation between 5 and 500 ml/min. To return the pump to high flow operation, turn the regulator shut-off screw (Figure 1, #16) clockwise until it is in the closed (down) position. Replace the cap screw. Disassembling the Stack Wires attach the stack to the control board. Avoid excessive strain on wires Remove the short black tubing on the flowmeter from the stack (regulator) inlet and pull the flowmeter away from the pump (the filter housing assembly will come away with it). 4. Remove the top half of the stack by loosening the screw beside the exhaust port and the screw beside the regulator isolation valve on top of the stack (Figure 2, #1 and 11). The stack will fall into two halves. The top half stack contains the regulator and pulsation dampener assemblies. The bo om half stack contains the valve, yoke/ diaphragm, and motor assemblies. Leave the two long screws loosened, but in place in the top half stack. This will help to hold all the components of the top half stack together. Also note the position of O-rings. Ensure that they do not drop out of place during troubleshooting. 5. Using a small Allen wrench, loosen the set screw on each side of the pump housing in the bo om half stack (Figure 8, #14). 6. Gently remove the motor assembly by gripping it with suitable pliers and slowly twisting it while withdrawing it 9 from the pump housing. When removing the motor, be careful with the pliers. Do not let them slip and damage the motor. Do not pull the wires soldered onto the motor. 7. Remove the five screws on the bo om valve plate (Figure 2, #6 and 5). One screw is shorter than the rest and must be replaced in the same hole from which it was removed so that the motor is not damaged. Keep this screw and its counterpart from the top valve plate separate from the rest of the screws (Figure 2, #13). 9

14 8. Separate the bo om valve plate from the pump housing. 9. Remove the five screws on the top valve plate (Figure 2, #6 and 5). One screw is shorter than the rest and must be replaced in the same hole from which it was removed (Figure 2, #13). 10. Separate the top valve plate from the pump housing. 11. Remove the bu on cap from the side of the pump housing. 12. Remove the yoke/diaphragm assembly by gently pushing the yoke/diaphragm to one side (Figure 2, #8) of the pump housing and pulling it out of the other side. Checking the Motor 1. Remove the pump stack (Figure 3, #6) from the case and the motor/eccentric assembly (Figure 2, #9) from the pump housing (see Pump Disassembly, Disassembling the Stack, Steps 1, 2, 5, and 6). 2. Spin the motor sha by hand and observe its movement. If it does not turn smoothly, does not turn at all, or makes a grating noise, it needs to be replaced. See Pump Reassembly. 4. With the pump plugged into a DC power supply, carefully apply the positive voltmeter probe to the solder connection of the yellow wire on the motor (Figure 5) and the negative probe to the negative ba ery connector pin (Figure 4, #5). This should indicate a reading of > 1 volt. 5. Repeat this procedure with the solder connection of the orange wire on the motor (Figure 5). This should indicate a reading of < 1 volt. For PCXR4 and PCXR8 models: If there is voltage > 5 volts on both solder connections, the pump is in HOLD mode. Disassembling 10 the Filter Housing 1. Remove the four screws from around the filter housing intake (Figure 1, #10). 2. Remove and discard the filter (Figure 1, #12). 3. Remove the O-ring (Figure 1, #11). 10 Removing 10 the Control Board and Keypad The control board is covered with adhesive foam padding. Once removed, do not set foam facedown on a surface. Try to keep it out of dusty environments. 1. Remove foam padding and carefully set it aside for reuse. 2. Remove the two screws (one screw in 44XR model) on the back of the board (Figure 4, #1). Do not lose the washers beneath the screws. 3. Remove the screw holding the ba ery connector (Figure 4, #2). 4. Carefully li board up and push on the back of the window in the front case to separate the keypad from the front of the pump case (Figure 3, #1). Not applicable to 44XR model. 5. Gently pull the old keypad interface ribbon from the board. Not applicable to 44XR model. 10 Note how the keypad ribbon connector is inserted before disconnecting it. 10

15 Pump Reassembly Tools Universal XR Series pump (disassembled) Pliers 1Dual-ball rotameter, 2valve, Phillips head screwdriver Needle nose pliers 3magnehelic gauge connected Small fl at-head screwdriver Thin wooden stick with tubing in line and in order Small Allen wrench (popsicle stick) Reassembling and Replacing the Stack 1. Insert the yoke/diaphragm into the pump housing. Ensure that the opening in the yoke is properly placed to allow the motor to be installed (Figure 7) and that the oval-shaped O-rings are still in place at the air passages (Figure 2, #12). 2. Gently push the motor with the soldered wires facing outward into the pump housing until it is bo omed. 11 Ensure the motor is centered in the yoke/diaphragm before pushing it in (Figure 7). 3. Set the top valve plate assembly on top of the pump housing ensuring that the diaphragm fits into the recessed area in the valve plate. This will help keep the diaphragm centered. 4. Gently press the yoke/diaphragm parallel against the motor counterweight (Figure 7). Once the yoke/diaphragm has aligned itself with the face of the motor counterweight, press down on the valve plate, replace the short screw in the top screw hole first, and then replace remaining 4 screws. Tighten the screws in an alternating fashion. Ensure that the short screw is placed in the top screw hole (Figure 2, #13). The yoke/diaphragm assembly must be perfectly parallel to the motor counterweight. If it is not, it can cause the motor to bind (Figure 7) Replace the bo om valve plate assembly. Ensure that the components are aligned properly. 11 Ensure that the diaphragm is fi ed into the recessed area in the valve plate.. 6. Replace the short screw in the top screw hole first, and then replace the remaining four screws on the bo om valve plate. Tighten in an alternating fashion. Ensure that the short screw is placed in the top screw hole (Figure 2, #13). 7. Reassemble the top half stack (two pulsation dampener assemblies and regulator assembly). Ensure that components are aligned properly (Figure 2). Do not assemble components O-ring to O-ring Using a small Allen wrench, tighten the set screw on each side of the pump housing (Figure 8, #14). Turn on the pump to ensure that the motor runs properly. If it does not, loosen the set screw on each side of the pump housing and use pliers to carefully back the motor out slightly. Also check that the valve plates are installed properly. Retest the motor. If it still does not run, ensure the set screws are loosened and remove it. Turn on the pump and slowly reinsert the running motor until it stops. This will help to determine where the motor is binding. 9. Align the two long screws (Figure 2, #11) in the top half stack with screw holes on top of the bo om half stack. 10. Tighten screws. 11. Using needle nose pliers, grip the cable connector on the new keypad interface ribbon and insert it into the plug on the board. Not applicable to 44XR model. 12. From inside the case, insert the top of the keypad through the slot at the bo om of the front case (Figure 3). Not applicable to 44XR model. 13. Reseat the control board, reinsert screws (one screw in 44XR model) into the back of the control board, and tighten (Figure 4). Ensure that a washer is underneath each screw head before tightening them. 11

16 14. Replace screw holding the ba ery connector (Figure 4, #2) and tighten. 15. Reinsert the ba ery, turn on the pump, and test the keypad (if applicable). 16. If the keypad is working properly, peel off the keypad backing to expose the adhesive, align it with the indentations on the front of the pump, and adhere it to the pump case. Not applicable to 44XR model. 17. Align and re-adhere the foam padding on top of the control board (Figure 8). 18. Replace the bu on cap on the side of the pump housing. 19. Align the control board wires with the right side of the stack (Figure 8). 20. Look for the original bend in the wiring and fold accordingly. 21. Loop the wiring around the bo om of the stack toward the le. 22. Fit the flowmeter assembly under the orange and yellow wires a ached to the motor and place the flowmeter so that it faces the window in the front case of the pump (Figure 1, #13). 23. A ach the short section of black rubber tubing on the flowmeter to the stack (regulator) inlet (Figure 2, #14). 24. Loop the longer black rubber tubing that a aches the flowmeter to the filter housing assembly under the yellow and orange wires and over the motor. Slide the filter housing assembly into place (Figure 8). 25. Ensure that the stack is seated firmly and that it is level before replacing the back pump cover. 26. Recheck the pump for leaks (see Functional Testing, Initial Leak Check). If it leaks, see Pump Disassembly, Locating and Correcting Leaks. 27. Set the flow compensation (see Reassembly, Se ing Flow Compensation). Setting Flow Compensation Compensation is factory preset. SKC recommends that compensation be checked periodically during routine maintenance to assure pump accuracy. Flow compensation will need to be reset if non-factory repairs have been made. Do not set flow compensation unless the ba ery voltage is at least 6.1 volts. 12 Completely reassemble the pump before se ing flow compensation (see Pump Reassembly). 1. Remove the compensation pot access screws from the le side of the pump (Figure 1, #2 and 3) Connect the filter housing inlet (Figure 1, #9) to the magnehelic gauge outlet and ensure minimum back pressure. 3. Turn on the pump Using a small flat-head screwdriver, carefully adjust the high compensation pot (Figure 1, #3) for minimum flow. 12 The high compensation pot is also known as pot B. This is a 3/4-turn pot. It needs only a slight turn to affect the pump flow. Consistently turning it too far can cause damage to the pot. 5. Turn the flow adjust pot on the front of the pump (Figure 1, #7) until the dual-ball rotameter reads 2000 ml/min. 6. Adjust the high compensation pot until the dual-ball rotameter reads 2100 ml/min. 7. Turn the flow adjust pot until the dual-ball rotameter reads 1000 ml/min. 8. Apply forty inches of water back pressure. 9. Adjust the low compensation pot (Figure 1, #2) to correct any deviation from 1000 ml/min. The low compensation pot is also known as pot A. This is a 3/4-turn pot. It needs only a slight turn to affect the pump flow. Consistently turning it too far can cause damage to the pot. 10. Turn the flow adjust pot until the dual-ball rotameter reads 2000 ml/min. 11. Apply 40 inches of water back pressure and note the flow. 12. If the flow does not change by more than 5%, check the flow and back pressure as indicated on the calibration sheet found at the back of this manual. If all measurements are found to be within 5% of the nominal value, the compensation has been set correctly. 13. If the flow noted in Step 11 changed by more than 5%, note the amount of increase or decrease. Release the back pressure, and adjust the high compensation pot to cause the flow to change in the same direction and amount as noted in 11. Repeat Steps 11 through 13 until the flow remains within 5%. Go back to Step 7 and repeat each step up to Step

17 Replacing the Back Pump Case 1. Carefully align the cut-out in the back pump case with the filter housing assembly. Ensure the stack and wiring sit properly in the front cover (i.e., stack is sitting level, wires are wrapped around the sides and bottom of stack, and wires are not obstructing the case channel or screw holes (Figure 8). 2. Gently push the back half of the case down onto the front half. If there is resistance, stop and check that the stack, filter housing assembly, and wiring are seated properly. 3. Once seated, replace four case screws and tighten in an alternating fashion. If wiring is obstructing the case channel, use a thin wooden stick to push it into place. Reassembling and Replacing the Filter Housing 1. Insert a new filter (SKC Cat. No. P ) and replace the existing O-ring*. 2. Fit two halves back together. 3. Replace four screws and tighten in an alternating fashion. 4. Check for leaks (see Functional Testing, Initial Leak Check). * Replace with new O-ring only as needed (SKC Cat. No. P22409 [3 filters, 3 O-rings]). Replacing the Battery Pack 1. Align ba ery with grooves on case and ba ery connector pins on the control board. 13 Forcing the battery pack when misaligned can damage the battery pins. 2. Carefully push the ba ery to the le toward the belt clip until it clicks into place. 13 It may be necessary to pull up on the belt clip so that the ba ery pack can slide into place Replace two ba ery pack screws and tighten in an alternating fashion

18 Troubleshooting Tools Universal XR Series pump Phillips head screwdriver Small Allen wrench Pliers Needle nose pliers Soldering iron and solder Checking the Control Board (PCXR4 and PCXR8 only) The control board controls all electrical functions. These include flow, compensation, fault protection, and timing. There are three fault conditions that will stop the pump. All three conditions will be indicated by the same flow fault display. If the pump faults, the source of the fault may be determined in the following manner: 1. Remove the ba ery and back pump case (see Pump Disassembly). Remove adhesive foam padding from the control board. Locate the two jumper links at the lower right corner of the control board (Figure 4), and remove them by pulling them straight up from the board. Replace the ba ery. 2. Start the pump. If the pump faults again, the problem is probably the pressure switch. Remove the ba ery, locate the wires that a ach to the pressure switch, and desolder or disconnect either one from the control board (Figure 5). Replace the ba ery. If the pump still faults, replace the control board (Cat. Nos. P22433U [PCXR8] or P22433T [PCXR4]). If the pump does not fault, replace the pressure switch (Cat. No. P22417E). Do not let the loose wire that was removed from the pressure switch touch any other parts. 3. If no fault occurred in Step 2, remove the ba ery, replace the V jumper (Figure 4), replace the ba ery, and turn 14on the pump. If the pump faults and the flow was not adjusted higher than 3 L/min, then the problem is on the control board. SKC recommends replacing the board. Replacement Control Board Cat. Nos. P22433U (PCXR8) or P22433T (PCXR4). 4. If the pump did not fault when the V jumper was replaced, remove the ba ery, replace the I jumper 14 (Figure 4), replace the ba ery, and turn on the pump. If the pump faults and there is minimum back pressure, 14the problem is probably on the control board. Replace the control board. Replacement Control Board Cat. Nos. P22433U (PCXR8) or P22433T (PCXR4). Use only SKC-approved parts to ensure reliable performance. Failure to do so voids the UL Listing for intrinsic safety and any warranty. Failure to follow warnings and cautions voids any warranty

19 Troubleshooting 15 Pump Problem Possible Solution 224-PCXR4 and PCXR8 224-PCXR4 and PCXR8 224-PCXR4 and PCXR8 Pump LCD doesn t light when pump is turned on and the motor will not run. Pump LCD lights when pump is turned on, but the motor will not run. Pump runs when turned on, but the LCD will not light. Check that motor wiring is undamaged and solder joints at the motor and on the board are in good repair. Check the battery for charge and proper voltage. Swap with a known good battery for further troubleshooting. Turn the fl ow adjust pot clockwise a few turns. The pot may have been adjusted to the lowest setting. If the motor still does not respond, follow steps above. If the motor runs at full speed, turn the fl ow adjust pot counterclockwise. If the pot cannot be adjusted clockwise, it may have separated from the control board. Check control board. If pot has separated, resolder pot and test operation (see Functional Testing, Flow Rate Spot Check). If pot doesn't operate properly, replace the control board (Cat. Nos. P22433U [PCXR8] or P22433T [PCXR4]). Check the battery voltage or switch to an alternate power supply to check the LCD. If it still doesn t light, it is either a bad LCD display or a bad diode on the control board. Replace LCD (Cat. No. P72380, see Pump Disassembly and Pump Reassembly) or replace the control board (Cat. Nos. P22433U [PCXR8] or P22433T [PCXR4]) Use a known good control board, stack, and motor when troubleshooting. SKC also recommends that a power supply be used for all testing. Connect it directly to the ba ery connector on the control board a er removing the ba ery pack. Use only SKC-approved parts to ensure reliable performance. Failure to do so voids UL Listing for intrinsic safety and any warranty. Failure to follow warnings and cautions voids any warranty

20 Diagrams/Part Description for Figure 1 Use only SKC-approved parts to ensure reliable performance. Failure to do so voids UL Listing for intrinsic safety and any warranty. No. Description 1 LCD: Displays indicators for all sampler functions. 2 Low Compensation (Pot A): Adjusts factory-set flow compensation. Access screw helps reduce accidental contact or tampering. 3 High Compensation (Pot B): Adjusts factory-set flow compensation. Access screw helps reduce accidental contact or tampering. 4 ON/OFF Switch: Allows the pump to be shut down completely. 5 Anti-tamper Cover: Protects controls from accidental contact or tampering. 6 Cover Screw: Fastens anti-tamper cover. 7 Flow Adjust Potentiometer: Adjusts pump flow from 1000 to 5000 ml/min. 8 Accessory Mounting Screws (2): Secure accessories such as an impinger and trap holder. 9 Filter Housing (intake): Air intake port and trap. 10 Filter Housing Screws (4): Secure filter housing. 11 Filter O-ring: Leak seal for filter in housing. 12 Filter (10 micron, nylon): Filters particulates before airflow enters pump. 13 Built-in Flowmeter: Monitors flow changes (not a primary standard flowmeter). 14 Regulator Pressure Adjustment Cap: Accesses regulator pressure adjust screw. 15 Discharge Air Cap Screw: Accesses exhaust port. 16 Regulator Shutoff Cap Screw: Accesses regulator isolation valve Ba ery Pack Screws (2): Secures pack to front case. 18 Pump Case Screw (4). Secures back case to front case. 19 Ba ery Pack: Provides power to pump. 20 Charging Jack: Connector for ba ery charger Belt Clip: Secures pump to worker Exhaust Port Fi ing 16 16

21 Figure

22 Figure No. Description Cat. No Regulator Assembly P22417J 2 Pulsation Dampener Assembly P22417K 3 Filter Housing Assembly P22417D 4 Flowmeter Assembly P22433L 5 Valve Plate Assemblies (top and bottom) P22417F 18 Top Valve Plate only P Valve plate screws (2 shorter screws must be placed in top holes on top and bottom plates) 7 Pump Housing P22417G 8 Diaphragm/Yoke Assembly P22417H 9 Motor/Eccentric Assembly P22417M 10 Pressure Switch Assembly (PCXR4, PCXR8) P22417E Bottom Plate Assembly (224-44XR) P22417W 11 Screws (2 long screws that hold top half stack to bottom half stack 12 O-rings 13 Short Valve Plate Screws (must be replaced in the exact same holes) 14 Stack (regulator) inlet 15 Inlet air passage 18

23 Figure No. Description Cat. No. 1 Keypad (PCXR8) P22433P Keypad (PCXR4) P22433N 2 Cap Screws (set of 2) (PCXR8, PCXR4, XR) P22417B 3 Case Parts (excluding Battery Case) P Control Board (PCXR8) P22433U Control Board (PCXR4) P22433T 19 Control Board (224-44XR) P22433Q 5 Battery Pack P Pump Stack (with Pressure Switch Assembly) (PCXR4, PCXR8) P22433RS2 Pump Stack (without Pressure Switch Assembly) (224-44XR) P22433RS1 7 Back Cover (Case Parts) P Belt Clip with Screws P22417BC 9 Battery Connector (pkg 10) P Not Shown: Replacement Filter Kit Exhaust Port Fitting Anti-tamper Cover External Screw Pack P22409 P22417C P22433C P22433ES 19

24 Figure 4 - Pump Board in Pump 1 4 Wires to Stack: Brown Orange Red Yellow Wires to Stack Red or Yellow Brown or Orange Shown: 44XR control board 3 I V No. Description 20 Shown: PCXR8 control board Screws with washers in place 2 Battery Connector with screw 3 V Jumper (voltage) 4 I Jumper (current) 5 Negative battery connector pin 20 Figure 5 - Pump Stack - Bottom View (224-PCXR4 and PCXR8 only) 20 Yellow Wire (+) Orange Wire (-) 20 Red Wire Pressure Switch Assembly Shrink Tubing Brown Wire 20

25 Figure 6 - Water Manometer Set-up AIRCHEK SAMPLER SAMPLE PERIOD MINUTES FLOW START AND BATTERY HOLD CHECK U L LISTED 124U INTRINSICALLY SAFE PORTABLE AIR SAMPLING PUMP FOR USE IN HAZARDOUS LOCA TIONS CLASS I, GROUPS A B C D AND CLASS II, GROUPS E F G AND CLASS III, TEMPERATURE CODE T3C SET-UP DIGIT SELECT TOTAL ELAPSED TIME MODE DIGIT SET PUMP RUN TIME AIRCHEK SAMPLER MODEL 224-PCXR8 WARNING - SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRIN SIC SAFETY. USE ONLY UL LISTED PORTABLE AIR SAMPLING PUMP BATTERY PACK MODEL P FLOW ADJ ON SERIAL NO. SKC INC. EIGHTY FOUR PA

26 Figure 7 - Motor and Yoke Assembly 1 4 Movement 5 No. 1 Ensure that the yoke is parallel to motor counterweight 222 Motor/Eccentric assembly 3 Diaphragm/Yoke assembly 4 Valve plate assemblies 5 Set-screws 622 O-rings 22 Description Figure 8 - Pump Stack in Case No. Description 1 Pump inlet 2 Filter housing including O-ring and fi lter 3 Discharge air cap screw covering exhaust port 4 Regulator pressure adjustment cap covering regulator adjust screw 5 Back case cover screws (4) 6 Motor/Eccentric assembly 7 Regulator and pulsation dampener assembly 8 Valve plate assembly and motor/eccentric assembly 9 Jumpers 10 Control Board 11 Battery connector 12 Battery pack screws (2) 13 O-ring 14 Set-screw 9 Not shown: Flowmeter assembly under fi lter housing, set-screw on other side of pump housing, and button cap on right side of pump housing

27 Figure 9 - Power Adapters 23 Universal Power Adapter Cat. No. P8005 (requires Cat. No. P8000) Power Adapter Cat. No. P8000 (required for use with Cat. No. P8005) Multi-purpose Power Adapter Cat. No. P

28 Figure 10 - Battery Adapters Universal Battery Adapter Cat. No. P8013 (requires Cat. No. P8010) Battery Adapter Cat. No. P8010 (required for use with Cat. No. P8013) 24 24

29 Addendum A XR, 224-PCXR4, and 224-PCXR8 (5 Cell) Pump Calibration Model Serial Number Date: Settings Readings Flow BP Minimum Flow Maximum Max Check Points Maximum Flow Set Regulator 20 Keypad Flow Fault 25

30 Addendum B XRM, 224-PCXR4M, and 224-PCXR8M (4 Cell) Pump Calibration Model Serial Number Date: Settings Readings Flow BP Minimum Flow Maximum Max Check Points Maximum Flow Set Regulator 20 Keypad Flow Fault 26