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Escort Elf® PumpInstruction Manual
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL HAVE THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece of complex equipment, this product will perform as designed only if it is used and serviced in accordance with the manufacturer’s instructions. OTHERWISE, IT COULD FAIL TO PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR THEIR SAFETY COULD SUSTAIN SEVERE PERSONAL INJURY OR DEATH.
The warranties made by Zefon International Inc. with respect to the product are voided if the product is not used and serviced in accordance with the instructions in this manual. Please protect yourself and others by following them. We encourage our customers to write or call regarding this equipment prior to use or for any additional information relative to use or repairs.
In the U.S., contact Zefon at 1-800-282-0073. To contact Zefon outside the U.S., dial +1 (352) 854-8080 or email at [email protected].© Zefon International, Inc. 2011 - All Rights Reserved
PRODUCT OF U.S.Zefon International, Inc.5350 SW 1st Lane • Ocala, FL 34474
(L) Rev 8 IMZ001-034 813549
WARNING
1. Do not charge the battery pack in areas that may contain a flammablemixtureofcombustiblegases,vapors,ordust andair;otherwise,anexplosionmayoccurbecausea sourceofignitionexistsduringcharging.
2.Donotoperatethepumpinoxygen-enrichedatmospheres (morethan21%oxygen)containingcombustiblegases, vapors,orothermaterials.Fireorexplosioncanresult fromoperatingintheseatmospheres.
3.OperatethepumpwithZefon/MSAP/N497702or 10087242batterypackonly.Donotuseotherbatteriesor powersources.
4.Whenusingthepumpinahazardousarea(withrespectto fireorexplosion)asspecifiedintheNationalElectricCode (NEC)Article500-Hazardous(Classified)Locations,the pumpmustbelabeledstatingthatitmeetsthedesign criteriaofthespecificClass,DivisionandGroup.Users mustoperatethepumpinaccordancewiththe instructionsforthatClass,Division,andGroup.Acopyof theNECCodecanbeobtainedfromtheNationalFire ProtectionAssociation,BatterymarchPark,Quincy,MA 02269.
5.UseonlygenuineZefonreplacementpartswhen performingmaintenanceproceduresdescribedinthis manual;failuretodosomayseriouslyimpairtheESCORT ELFPumpperformance.Repairoralterationbeyondthe scopeofthesemaintenanceinstructionsorbyanyone otherthanauthorizedZefonservicepersonnelcouldcause theproducttofailtoperformasdesigned,andpersons whorelyonthisproductfortheirsafetycouldsustain severepersonalinjuryordeath.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNINGS
Sécurité Intrinséque
Avertissement: La Substitution de Composants Peut Compromettre La Sécurité Intrinséque
1.Donotusethepumpwithorganicfluidsinan impingerwithoutanabsorbertrap;otherwise,the pumpwillbedamaged.
2.UseonlyaZefonorMSAOmega™ (Ω)Chargerto chargethepump.
3.If,afterthoroughlyreadingthismanual,youare uncertainoftheinstallation,operation,or maintenanceprocedures,call1-800-282-0073for assistance.
CAUTIONS
DONOTCHANGETHISMANUALWITHOUTMSHAAPPROVAL
Table of Contents
Section 1General Information...........................1-1
Introduction.....................................1-1 OperatingSpecifications........................1-2
Section 2Theory of Operation..........................2-1
Introduction.....................................2-1 FunctionalDescriptionofOperation.........2-1 Figure2-1.Flow-FeedbackControlSystem..2-2 LEDIndicatorOperation................2-3
Section 3Operation...................................3-1
ChargingtheBatteryPack..........................3-1 YWARNING................................3-1 YCAUTION.................................3-1 OperatingTime...................................3-1 Personal/AreaSampling............................3-2 Figure3-1.TypicalOperatingTimeGraph..3-2 OperatingthePump...............................3-3
Section 4Routine Maintenance..........................4-1
PeriodicMaintenance..............................4-1 CheckingtheInletFilter........................4-1 Figure4-1.CheckingtheInletFilter..............4-1 FilterReplacement............................4-2 FritReplacement..............................4-2 BatteryPackMaintenance..............4-2 BatteryPackReplacement..........................4-3 Figure4-2.ReplacingtheBatteryPack...........4-3
Section 5ELF Sensor Calibration.......................5-1
Section 6ELF Sensor Calibrationfor Pumps used in the U.S. Government Mine Safetyand Health Administration (MSHA) Coal Mine DustSampling Program............................6-1
Section 7Repairs and Replacement Parts................7-1
Troubleshooting...................................7-1 YWARNING................................7-1 CorrectiveMaintenance............................7-1 Table7-1.TroubleshootingGuidelines......7-2 Unplugging the Electrical Connectors . . . 7-3 ReattachingtheElectricalConnectors......7-3 Pump&DriveAssembly,OutletDampener,or PressureSensorReplacement . . . . . . . . . 7-4 PrintedCircuitControlBoardReplacement..7-4 ObtainingReplacementParts...................7-5 Figure7-1.ReplacementParts..................7-6 Table7-2.ReplacementPartsList...............7-7 Figure7-2.ReplacementParts(cont.)...........7-8 Section 8Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Section 9ATEX Declaration and Markings................9-1
ATEXDeclaration.....................................9-1 ATEXMarkings.....................................9-2
Section 1, General Information
1-1 ESCORT ELF Pump Instruction Manual
Section 1General Information
IntroductionTheESCORTELFPumpintroducesatotallynew,patented conceptofflowcontrolandflowreadout(U.S.Patent5,295,790).Theheartofthisnewsystemistheelectroniclaminarflowsensor.TheELFsensorcombinesalaminarflowelementandadifferentialpressuresensortomeasuresamplevolumeflowrate.Thismeasureofflowrateisnotaffectedbychangesinsampleloadingortheotherfactorsthataffectrotameter-typeindicatorsusedinotherpumps.TheELFsensorprovidesanelectronicsignalwhichislinearlyrelatedtoflowrate.Thissignalisusedinthepumpcontrolcircuittomaintainthechosenflowrateconstanttowithin±2.5%andisusedinthereadoutcircuittoallowthedigitaldisplayoftheactualflowratetowithin±0.1litersperminute(LPM).
TheESCORTELFsensorandcontrolcircuitryareverystablebothinstorageanduse.Togethertheyformasecondary standardtomaintainthecalibrationaccuracyforatleast200hoursofpumpusage.Abuilt-inoperatingtimetotalizerhelpsremindtheuserofthetotaloperatinghourssincethelast calibrationcheckwasperformedagainstaprimaryflow standard.Thistotalizerautomaticallyresetsto0whena calibrationisperformed.Ifthepumpisusedinthecoalminedustsamplingprogram,thesecalibrationchecksshouldbedoneaftereach200hoursofuse.Ifthepumpisusedfor OSHAcompliancesampling,therecalibrationshouldbe performedmonthly.
Section 1, General Information
ESCORT ELF Pump Instruction Manual 1-2
Operating Specifications
ELECTRICAL CHARACTERISTICS
POWER SUPPLY 4.8-voltbatterypackoffourNiMHcells BatterypacksMFGbefore10/2011containNiCdcells
BATTERY PACKCAPACITY
2.8amperehour(NiMH) Priorto10/2011maycontain2.4or1.8amperehour(NiCd)
BATTERY PACKRECHARGE TIME
16hours(overnight)withrecommendedchargers
CHARGINGTEMPERATURE
10oto30oC(50oto86oF)
TYPICAL BATTERYPACK LIFE
300ormorechargingcycles
OPERATING AND PHYSICAL CHARACTERISTICS
FLOW CONTROLVolumetricflowrateiscontrolledattheset-pointwithautomaticcompensationforbatteryvoltage,altitude,temperature,andsampleloadchanges
OPERATINGRANGE
0.5TO3.0LPM
5to30incheswaterloadupto1.0LPM;upto30inchesofwaterloadupto2.0LPM;upto20inchesofwaterloadupto2.5LPM;andupto10inchesofwaterloadupto3.0LPM
FLOW BLOCKAGEDETECTION
WhenflowisblockedtheFLOWFAULTLEDindicatorlightsandstayslighteduntilthecauseofflowblockageisremoved.Ifblockedforlongerthan1.5minutes,thepumpshutsdown.Pumpsmaybeorderedthatarenotfactoryprogrammedtoshutdownuponblockage,howeverpumpsconfiguredthiswayareNOTsuitableforcoalminedustsamplingbymineoperators.
FLOW READOUT
Liquidcrystaldigitaldisplaywith0.01LPMresolutionfrom0.5to3.0LPM
Accuracy±2.5%from1.0to3.0LPM,0oto45oC±5%from1.0to3.0LPM,-20oto0oCand45o to 65oC±5%from0.5to0.9LPM,0oto45oC
Section 1, General Information
1-3 ESCORT ELF Pump Instruction Manual
Operating Specifications
ELAPSED TIMEREADOUT
Quartzcontrolledtimerreadsoutto999minutesin1-minutesteps.Holdslastreadingaftereitherflowfaultorlowbatteryshut-down,andwhenpumpisOFForinHOLDmode;resetstozeroautomaticallywhenpumpisturnedON.TimerdoesnotcounttimewhenFLOWFAULTLEDislighted.
SCHEDULEDCALIBRATION
Thepumphasanoperatinghourstotalizertohelpreminduseroftheneedforperiodiccalibrationchecks.
OPERATING TIME
Varieswithflowrate,samplingdeviceloadingandtemperature.Minimumtwelve-houroperationat2.5LPMwith20-inchwaterloadandwithnewfullychargedbattery.(SeeFIGURE3-1.)
LOW BATTERYFUNCTION
ThepumpshutsdownandlightstheLOWBATTLEDwhenbatteryvoltagedropsbelow4.1volts
TEMPERATURECOMPENSATION
0oto45oC(32o to 113oF)±2.5%accuracy-20oto0oCand45oto65oC(-4oto+149oFand112oto148oF)±5.0%accuracy
ALTITUDECOMPENSATION
Belowsea-leveltoatleast10,000ft.
DIMENSIONS
2-1/4inchesdeepx4-1/4incheshighx4incheswide(5.7centimetersdeepx10.8centimetershighx10.2centimeterswide).Dimensionsincludeswitchcoverbutexcludehosebarbandbeltclip.
WEIGHT 23oz.(652grams)
CASE
Caseplasticiselectricallyconductivetoreduceradiofrequencyinterference;anoptionalleathercaseisavailableforpumpprotectionduringroughusagesuchasundergroundminingorconstructionanddemolitionworkareas
SERIAL NUMBERIDENTIFICATION
Locatedonthesideofthecaseunderthebatterypack(includenumberincorrespondencewithZefon)
Section 2, Theory of Operation
ESCORT ELF Pump Instruction Manual 2-1
Section 2Theory of OperationIntroductionThissectiondescribestheoperationofthesampleflowcontrolandreadoutcircuitryoftheESCORTELFPump.
Functional Description of Operation
TheESCORTELFPumpcontainsarechargeablebatterypack,amotor-drivenpump,theELFsensor,andtheelectroniccircuittocontrolanddisplaytheflowrate.
Thebatterypackconsistsoffourrechargeablecells.Thecellsareconnectedinserieswithacurrentlimitingresistortoallowuseinhazardousatmospheres(see“Warnings”).ThepackalsohasaPTCresistorwhichfunctionsasaself-resettingcircuitbreakertopreventdamagetothepackiftheoutputterminalsareaccidentallyshorted.AthermalcutoffprotectsagainstdamagefromhightemperatureconditionsintheNiMHbatterypack.
Themotor-drivenpumpconsistsofaninletpulsationdampener,adiaphragmpump,andsiliconerubberinletandexhaustvalves.Thediaphragmisdrivenbythemotortomakeonepumpstrokewitheachrevolution.Thepulsationdampeneractsasanelasticstoragechambertosmooththeindividualpumppulsestominimizetheireffectonthesamplingdevicesconnectedtothepumpinlet.
TheELFsensorconsistsofalaminarflowelementanda pressuresensor.Alloftheairflowthroughthepumppassesfromtheexhaustportofthepumpandthroughthelaminarflowelement.Theelementisahollowcylinderofporousstainlesssteel.Theairflowingthroughthenarrowpassagesinthecylinderproducesanairpressuredifferencebetweentheouterand
Section 2, Theory of Operation
2-2 ESCORT ELF Pump Instruction Manual
innerwallsofthecylinder.Thisdifferenceismonitoredbyconnectionstothehighandlowpressuretapsofasensitivedifferentialpressuresensor.Theelectricalsignalfromthesensorisalinearvoltage,whichisdirectlyrelatedtotheairflowthroughthelaminarelement.Thissignaliscomparedtotheflowsetpointintheelectroniccircuitandisusedtocontroltheflowatthesetpoint.Anydeviationinflowrateissensedandthemotorpowerisadjustedtomaintainthepresetflowrate.Inthecaseofablockedfloworoperationbeyondthepumpcapacitywheretheflowcannotbebroughttowithin±0.1LPMofthesetpoint,theflowfaultLEDwillbelighted.
Figure 2-1. Flow-Feedback Control System
Section 2, Theory of Operation
ESCORT ELF Pump Instruction Manual 2-3
LED Indicator Operation
• TheRUN/HOLDLEDassurestheuserthattheunitis operating,eveninpoorlylit,noisyenvironments.
• TheRUN/HOLDLEDalsoindicatestheHOLD function.IfthepumpisswitchedtoHOLD,thepump shutsdown,thetimerstops,andtheLEDisswitched toablinkingmode.WhentheRUN/HOLDswitchis pressedagain,thepumpwillrestartandthetimerwill continuefromits“hold”value.
• TheLOWBATTLEDindicatesoperationofthelow batterydetectioncircuit.Whenthebatterypackdrops to4.1volts,thecircuitcausesthepumptoshutdown, thetimertostop,andtheLOWBATTLEDtolight. Thislimitsfurtherbatterydraintojustafew milliamperes,which,inturn,helpspreventdeep dischargingandbatterypackdamageupon recharging.Italsohelpspreventtheinvalidationofthe samplebeingtaken,becausethetimerstoresthe actualsampletimeandtheflowrateiscontrolledup tothetimeofshut-down.
• TheFLOWFAULTLEDindicatesoperationoftheflow blockagedetectioncircuit.Ifthesampleinlet(orthe samplingdeviceconnectedtothepump)isblocked, theFLOWFAULTLEDlightsuntilthecauseoftheflow faultisremoved.
• Thepumpisnormallyfactory-programmedsothata faultlongerthan1.5minuteswillshutdownthepump. Thepumpmayberestartedfromaflowfault shutdownbypressingtheRUN/HOLDswitch. Restartinginthismannerallowscontinuationofthe sampleperiodwithouthavingthetimerresettozero. • TheFlowFaultLEDislightedwheneverthepumpflow rateismorethan±0.1LPMdifferentfromtheset- point.Itisnormalforittobelightedbrieflywhilethe pumpisstartedorwhenanewset-pointisselected.
Section 3, Operation
3-1 ESCORT ELF Pump Instruction Manual
Section 3Operation
Charging the Battery PackUseanyZefon/MSAOmegaTMcharger(forexample:P/N494716,495965or801759)forchargingthebatterypack.Removetheprotectiverubberplugandchargethebatterypackfor16hours.(Notethatchargingforlongerperiodswillnotreducebatterylife,providedthechargingisperformedatroomtemperature.)Thebatterypackcanbechargedwiththepackremovedfromthepump.Alwaysreplacetherubberplugafterchargingandbeforeusingthepumptopreventwaterentryintothejack.
Do not charge the battery pack in areas that may contain a flammable mixture of combustible gases, vapors, or dust and air; otherwise, an explosion may occur because a source of ignition exists during charging.
Use only a Zefon/MSA Omega™ (Ω) charger from Zefon/MSA to charge the pump.
Operating TimeThemaximumexpectedoperatingtimeforapumpwithafullychargedbatterypackdependson: 1.Theselectedflowrate. 2.Thevacuumloadimposedbythesamplingdevice. 3.Thetemperature. 4.Theageofthebatterypack.
WARNING
CAUTION
Section 3, Operation
ESCORT ELF Pump Instruction Manual 3-2
SeeFIGURE3-1forapproximateoperatingtimes.Theshadedareashowsoperatingloadsandflowrateswithinthepumpspecifications.Theexampleshownwithdashedlinesisforapumpsetfor2.0LPMwithasamplingloadof15”;theexpectedmaximumoperatingtimewouldbe18.5hours.Thisfigureisbasedonroomtemperatureoperationwithanewpack.At0degreesCentigrade,theoperatingtimewillbereducedby10%,20%at-20oC.Afterseveralhundredcharge/dischargecycles,thepackcapacitymaybereducedby20%.
Personal/Area SamplingTheESCORTELFPumpisdesignedforeitherpersonalorareasamplingofambientair.Itautomaticallyprovidesaconstantvolumetricflowrateofthesampleairthroughthesamplingdevice(filterdisc,impinger,orabsorbenttube)tomeasuretheconcentrationofairbornemists,dusts,particulates,gases,andvaporsintheworkplace.
Figure 3-1. Typical Operating Time Graph
Section 3, Operation
3-3 ESCORT ELF Pump Instruction Manual
Operating the Pump1. Chargethebatterypackfor16hoursusingtheZefon/MSA Omega™ (Ω)Charger. • ReadtheWARNINGonthebatterypack.
2. Connectthedesiredsamplingdevicetotheinletfitting.
3. PressON/OFFbuttonuntiltheRUN/HOLDLEDlights. • TheFlowFaultandLowBatLEDswillthenlight. DuringthetimetheseLEDsarelighting,anumber from0to999willbedisplayed.Thisisthetotalofthe pump’soperatinghourssinceitslastcalibration. • WhenallthreeLEDsarelighted,thedisplaychanges to 8.88 LPM/MINS,toshowallsegmentsarefunctional. • Thepumpwillthenbeginoperation.TheLOWBAT LEDwillbedarkifthebatteryvoltageisabove4.1 volts.TheFlowFaultLEDwillbedarkwhentheflow rateiswithin0.1LPMofthesetpoint.
4. Usetheandswitchbuttonstoadjusttheflowsetpointif anewflowrateisdesired.Wheneitherbuttonispressed: • RUN/HOLDLEDwillbedark • Displaywillshowtheflowsetpointbeingsteppedupor steppeddowntothenewsetpoint. 5. TheRUN/HOLDbuttonmaybepressedtointerruptsampling withoutcausingthetimertoresettozero. 6. PresstheON/OFFbuttonattheendofsampling. • Totalsampleminuteswillbeonthedisplayandwill remainuntilthepumpisturnedONagain.
7. Checkcalibrationmonthly(every200hoursofuseforcoal minedustsampling).
8. Operatethepumpwithasamplingdeviceconnectedtothe inlet.Operationwithoutasamplerattachedwillreducethe lifeofthepumpinletfilter.Operationatverylowflowrates maybeunstablewithoutanattachedsamplingdevice, suchasacharcoaltube.
Section 4, Routine Maintenance
ESCORT ELF Pump Instruction Manual 4-1
Section 4Routine Maintenance
Periodic MaintenanceChecking the Inlet Filter
Thepumpinletcontainsdustandwaterfilterstoprotectthepumpfromparticlesandwaterinthesampleair(FIGURE4-1). Ifthefiltersbecomeclogged,thesampleflowmaybeblocked oranextraloadplacedonthepump;therefore,checkthefiltersregularly.
Figure 4-1. Checking the Inlet Filter
Section 4, Routine Maintenance
4-2 ESCORT ELF Pump Instruction Manual
Thefrequencyofthechecksshoulddependontheamountofpumpusageandtheconcentrationofparticlesallowedtoenterthepump.Usually,onlythedustfilterneedstobereplaced.TheTeflon*waterfiltershouldrarelyneedtobereplaced.Thewaterfilterisveryfragileandmustbehandledwithcare.Evenatiny pinholewilldestroyitsfunction.Thefilterfritshouldneverneedtobereplacediftheotherfiltersaremaintained.
Filter Replacement
1. RemovethefourscrewsholdingthefiltercoverandO-ring.
2. Replacethefilterwithanewone.
3. Re-assembletheO-ringandcover.
Frit Replacement
1. Stabthefritcenterwithasmallscrewdriver,andliftitout.
2. Pressinanewfrit.
3. Re-assembletheTeflonanddustfilters,O-ring,andcover.
Battery Pack MaintenanceTheNiMHbatterypackisexpectedtohaveaservicelifeof300ormorechargingcycles.Actualbatterypacklifewillvarydependingontheconditionsofuseandstorage.Hightemperaturescancauseacceleratedaging.Asthebatterygoesthroughcharge/dischargecyclesandages,itscapacitywilldiminishovertime.Ifyouexperienceruntimesthatarenoticeablyshorterevenwithafullychargedbattery,ithasreacheditsendoflifeandshouldbereplaced.
Allbatterieswillself-dischargebythemselvesovertime,evenwhennotinuse.Allowingbatteriestofullydischargeandremainfullydischargedmaydamagethebatterypack.Tomaintainthebatterypackintopworkingcondition,itisrecommendedthatitbefullychargedatleastonceevery30daysevenifnotused.
* Teflon is a trademark of the du Pont Company
Section 4, Routine Maintenance
ESCORT ELF Pump Instruction Manual 4-3
Figure 4-2. Replacing the Battery Pack
Battery Pack Replacement(FIGURE 4-2 illustrates the battery pack.)
1. Removethetwoscrewssecuringthebatterypacktothecase.
2. Separatethepackfromthecase.
3.MakesurethattheO-ringisinplaceonthereplacement pack.Then,slidethepackintothepumpcasewhile pressingthecasefrontandbacktomakesurethecase edgesgoinsidetheedgesofthepack.
4. Insertthetwoscrewsandtighten.
Section 5, ELF Sensor Calibration
5-1 ESCORT ELF Pump Instruction Manual
Section 5ELF Sensor Calibration 1. Checkpumpinletfilterfordust;replaceifheavilyloaded.
2. TurnONthepumpandallowittoreachitsflowratesetting.
3. Ifthepumpisnotsetfor2.50LPM,setitto2.50.
4. Allowthepumptooperatefor10to15minutesat2.50LPM. Tocheckforleaks,temporarilyblockthepumpinlet;0.02 LPMorlessshouldbedisplayed.Ifnot,checktheinlet filtercoverando-ringforcorrectassembly.
5. Leavethepumpsetfor2.50LPMandturnOFFthepump.
6. Connectaprimarycalibrationstandardtothepump.
7. TurnONthepump;asthepumpgoesthroughits self-checksequence,pressandholdtheON/OFFand RUN/HOLDswitchessimultaneouslyuntilthedisplay readsCAL.Immediatelyreleasebothbuttons. NOTE:FailuretoreleasebothbuttonswillturnOFFthepump. • ThedisplaywillshowCALandacountdown sequenceofnumbersfrom9through0;thereafter,it willalternatelydisplayCALand2.50LPM.
8. Operatethecalibrationstandardandobtainatleastsix readingswhichareveryclosetooneanother.
9. Usetheandswitchbuttonstostepthepumpdisplayup ordownuntilitagreesexactlywiththeaverageofthesixreadings. 10.TurnOFFthepump;theELFsensorisnowcalibrated. Repeatmonthlyorevery200hoursofuse.
11. WhenyounextturnONthepump,theoperatinghours willberesetto0andbedisplayedduringthelightingof theFLOWFAULTandLOWBATLEDs.
Section 5, ELF Sensor Calibration
ESCORT ELF Pump Instruction Manual 5-2
TheBiosDryCalorBiosDefendershouldbeusedtocalibrateorchecktheflowrateofanZefonEscortELFpumponlyifanisolatingflowrestrictor(e.g.,afilteroranorificesuchasP/N632646)providingatleast10”WCisplacedinlinebetweenthepumpandthecalibrator.Failuretousesuchanisolationtechniquecancauseacalibrationinaccuracyontheorderof2%andisnotrecommended.
6-1 ESCORT ELF Pump Instruction Manual
Section 6, ELF Sensor Calibration for Pumps Used inMSHA Coal Mine Dust Sampling Program
Section 6ELF Sensor Calibration for Pumps Used in the U.S. Government Mine Safety and Health Administration (MSHA) Coal Mine Dust Sampling Program
1.Checkpumpinletfilterfordust;replaceifheavilyloaded.
2.TurnONthepumpandallowittoreachitsflowratesetting.
3. Ifthepumpisnotsetfor2.00LPM,setitto2.00.
4.Allowthepumptooperatefor10to15minutesat2.00LPM. Tocheckforleaks,temporarilyblockthepumpinlet;0.02 LPMorlessshouldbedisplayed.Ifnot,checktheinlet filtercoverando-ringforcorrectassembly.
5.Leavethepumpsetfor2.00LPMandturnOFFthepump.
6.Connectaprimarycalibrationstandardtothepump.
7.TurnONthepump;asthepumpgoesthroughitsself-check sequence,pressandholdtheON/OFFandRUN/HOLD switchessimultaneouslyuntilthedisplayreadsCAL. Immediatelyreleasebothbuttons.
NOTE:FailuretoreleasebothbuttonswillturnOFFthepump. • ThedisplaywillshowCALandacountdownsequence ofnumbersfrom9through0;thereafter,itwill alternatelydisplayCALand2.00LPM.
Section 6, ELF Sensor Calibration for Pumps Used inMSHA Coal Mine Dust Sampling Program
ESCORT ELF Pump Instruction Manual 6-2
8. Operatethecalibrationstandardandobtainatleastsix readingswhichareveryclosetooneanother.
9. Usetheandswitchbuttonstostepthepumpdisplay upordownuntilitagreesexactlywiththeaverageofthe sixreadings.
10.TurnOFFthepump;theELFsensorisnowcalibrated. Repeatevery200hoursofuse.
11.WhenyounextturnONthepump,theoperatinghourswill be reset to 0andwillbedisplayedduringthelightingof theFLOWFAULTandLOWBATLEDs.
Section 7, Repairs and Replacement Parts
7-1 ESCORT ELF Pump Instruction Manual
Section 7Repairs and Replacement Parts
TroubleshootingTABLE7-1,“TroubleshootingGuidelines”,liststhesymptomsofthemostcommonproblems;italsoliststheirprobablecause(s)andtheactionrequiredtocorrecteachproblem.Usethe guidelinesifyoucannotcalibratetheESCORTELFPumporif thepumpdoesnotoperateproperly.Ifyoucannotresolveaproblembyusingtheguidelines,call1-800-282-0073tolocate alocalZefonRepairCenter.
Use only genuine Zefon replacement parts when perform-ing the maintenance procedures described in this manual. Failure to do so may seriously impair instrument performance. Repair or alteration beyond the scope of these maintenance instructions or by anyone other than a Zefon-trained service person could cause the product to fail to perform as designed, and persons who rely on this product for their safety could sustain severe personal injury or death.
Sécurité Intrinséque
Avertissement: La Substitution de Composants Peut Compromettre La Sécurité Intrinséque
Corrective MaintenanceWhenaninoperativepartislocatedbyusingTABLE7-1,TroubleshootingGuidelines,replaceitaccordingtooneofthereplacementprocedureslaterinthissection.Alsoreferto “ObtainingReplacementParts”laterinthissectionfor informationonhowtoorderthenecessarypartfromZefon.
WARNING
Section 7, Repairs and Replacement Parts
ESCORT ELF Pump Instruction Manual 7-2
Table 7-1. Troubleshooting Guidelines
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
ON/HOLDLEDindicatorturnsOFFprematurely;FLOWFAULTLEDIndicatormaybeONorOFFandLOWBATTLEDisturnedON
1.Inletfiltercloggedor blockedwithwater
1.Replacefilter accordingto“Checking theInletFilter”
2.Batterypackisdegraded 2.Installnewpackon pumpbyperformingproceduredescribedunder“BatteryPackReplacement”
3.Operationbeyondflow andloadlimits
3.Reducefloworreplace samplerwithlowerload device
ON/HOLDLEDandFLOWFAULTLEDindicatorsturnedON,andpumpwillnotrunor,ifitdoesrun,noflowisdisplayedonreadout
1.Pumpmotorconnector improperlypluggedinto PCboard
1.Checkconnector
2.Pressuresensor connectorfault
2.Checkconnector.Verifyfivepinsarepluggedin
3.Pumpmotorinoperative 3.Replacepumpand motordriveassembly accordingtoprocedure under“Replacingthe PumpandDriveAssembly
4.PressuresensororPCboardinoperative
4.ReplacesensororPCboard
Wheninletisblocked,theflowindicationisnot0.02LPMorless
1.Sampleflowleaks 1.CheckforleakingtubeconnectionorO-ringsealattheinletfiltercover
LEDindicatoronchargerdoesnotturnONwhenplugon-linecordisinsertedin115VACoutletandplugonchargingcordisinsertedinjackonbatterypack
1.Powersourceinactive 1.Checkandcorrectcause ofpowerloss
2.Chargerfailure 2.Replacecharger
3.Batterypackfailure 3.Replacebatterypackby performingprocedureunder“ReplacingtheBatteryPack”
Desiredflowratecannot beobtainedunderheavysamplingdeviceloadswithinregimeofFIGURE3-1
1.Inletfilterpartiallyclogged 1.Replacefilteraccordingtoinstructionsunder“CheckingtheInletFilter”
2.Leakexistsinsampleflow system
2.CheckforleakingtubeconnectionorO-ringattheinletfiltercover
Section 7, Repairs and Replacement Parts
7-3 ESCORT ELF Pump Instruction Manual
Unplugging the Electrical Connectors
ServiceprocedureswhichrequireopeningtheELFpumpcaserequiretheunpluggingoftwoelectricalconnectors: 1.Pullonthemotorelectricalconnectortoremovethe motorwiresfromtheprintedcircuitboard.
2.Pullonthe5-pinribboncabletoremovetheconnector fromtheELFsensor.
Reattaching the Electrical Connectors
1.Whenreattachingthemotorconnector,makesurethe angularrampattheendfacestowardsthelatchprojecting fromtheprintedcircuitboardsocket. NOTE:Thepumpwilloperatewiththeconnector installedtheotherway,buttheabovemethodis encouragedbecausetherampandlatchhelp keeptheconnectorattachedasthepumpis knockedaroundduringuse.
2.WhenreattachingtheconnectortotheELFsensor,make surepins#1through#5arestraightandinline. NOTE: Ifthesepinsarebent,useneedle-nosepliersto straightenandalignthem.Pin#6isintentionally cutoffbecauseitisnotusedintheELFpump.
3.Pullthecablesothattheendoftheconnectorisabout 7/8”abovetheprintedcircuitboard.
4.Holdthepumpfaceintherighthandandpositionyour thumbandforefingeraroundthetoplefthandcornerof thepumpface.
5.Holdtheconnectorwiththesetwofingersandholdthe pumpcasewiththelefthand.
6.Positiontheconnectorsothatanendpinisjustinsidethe funnelopeningofthecorrespondingpinsocket.
7.Graduallytilttheconnectortogetthenextpinjustinside itssocket,andrepeatthisprocessuntilallfivepinsarejust insidetheircorrespondingsockets.
8.Slowlypresstheconnectorontothepinsuntilthey “bottomout.”
Section 7, Repairs and Replacement Parts
ESCORT ELF Pump Instruction Manual 7-4
9. Inspecttheconnectoratthetopandbottomtomakesure allpinsarecorrectlyinserted.
Pump & Drive Assembly,Outlet Dampener, or Pressure Sensor Replacement 1.Removetwoscrewssecuringthebatterypacktothecase. 2.Removethebatterypack. 3.Removethetwoscrewssecuringthepumpcase. 4.Pullthe5-pinribbonconnectorfromthepressuresensor. 5.PullthemotorelectricalconnectorfromthePCboard. 6.Removethetwoscrewssecuringthepumpmounting collartothebackofthecase. 7.Liftoutthepumpanddrivewhileremovingtheinlet dampenerconnectionfromthefitting. NOTE: Adropofsoapsolution(SNOOP*)“workedin”at theendoftherubbertubemakesremovaleasier andwillpreventtearingtherubbertube. 8.Removethetwoscrewssecuringthepressuresensor. 9.Removethepressuresensorandbecarefulnottodropit, eventothetabletop. 10.Removetheoutletdampenerifitistobereplaced. 11.Installthereplacementpumpanddrive,outletdampener orpressuresensorbyreversingthisprocedure. NOTE: Wettingtheendoftheoutletdampenerwillmake slidingitoverthesensorbodyeasier.Makesure bothcuffsarecompletelyinthegrooves. NOTE: Tightentheuppermotorcollarscrewbefore tighteningthelowerscrewwheninstallingthe newpumpanddrive.
Printed Circuit Control Board Replacement 1.Removethetwoscrewssecuringthebatterypack. 2.Removethebatterypack.
*SNOOP is a trademark of Swagelok Company
Section 7, Repairs and Replacement Parts
7-5 ESCORT ELF Pump Instruction Manual
3.Removethetwoscrewssecuringthepumpcase. 4.Pulltheconnectorfromthepressuresensor. 5.Pullthemotorelectricalconnectorfromtheprinted circuitboard. 7.Removeandsavethethreescrews,twowashersand spacersecuringthePCboardtothepumpface. 8. Installthereplacementprintedcircuitboardby reversingthisprocedure. NOTE: Besurethebatteryconnectorismountedwith theblackwiretowardsthetopofthecase.
Obtaining Replacement PartsTheESCORTELFPumppartsandpartnumbersarelistedinTABLE7-2.Toobtainparts,service,orinformationintheU.S.,callZefonInternationalat1-800-282-0073.ToreachZefonoutsidetheU.S.,call+1(352)854-8080.
Section 7, Repairs and Replacement Parts
ESCORT ELF Pump Instruction Manual 7-6
Figure 7-1. Replacement Parts
Section 7, Repairs and Replacement Parts
7-7 ESCORT ELF Pump Instruction Manual
Table 7-2. Replacement Parts ListFIGURE 7-1 ITEM NO. PART/COMPONENT PART NO.
1 PumpandDriveAssembly,Complete 804661
2 Collar 800025
3 PrintedCircuit-BoardAssembly 813551
4 PumpFaceAssembly 813297
5 Screw 636493
6 O-ring 636602
7 Screw 636414
8 BeltClip 636293
9 Screw 636416
10 Screw 636415
11 Spacer 628852
12 Lockwasher 64095
13 SwitchCover 802381
FIGURE 7-2 ITEM NO. PART/COMPONENT PART NO.
14 PumpandDriveLessPressureSensor 805285
15 FlowSensorAssemblyLessSensor 805286
16 ReplacementSensorOnly 805284
17 MotorandConnectorAssembly 805296
18 EccentricandBearingAssembly 805046
19 PumpBlockandValvesAssembly 805360
20 InletDampener 803816
21 Screws 637140
22 OutletDampener 804663
FIGURE4-1
Screw 636418
FilterCover 497393
Filter,InletDust(packof5) 808935
O-ring 637009
Filter,Teflon 802897
Filter,Frit 800303
FIGURE4-2
BatteryPack(includesO-ring&Plug) 10087242
O-ringforBatteryPack 636603
ChargeJackPlug 804158
notshown
InstructionManual 813549
Screwdriver 636913
LeatherCase(optional) 811741
UpgradeKit(includesprintedcircuitboardandpumpfaceassemblies)
814029
Section 7, Repairs and Replacement Parts
ESCORT ELF Pump Instruction Manual 7-8
Table 7-2. Replacement Parts List (cont.)
PART/COMPONENT PART NO.
Kit,PumpMaintenanceParts
802922
BeltClips(2)
FilterCover
Screws(filtercover)(4)
O-Rings(batterypack)(2)
Screws(beltclip)(2)
Screws(case)(4)
Filters,Frit(2)
O-Rings(filtercover)(2)
Filters,Teflon(2)
Filters,InletDust(2packsof5)
ChargeJackPlug
HexKey
Figure 7-2. Replacement Parts (cont.)
Section 8, Warranty
8-1 ESCORT ELF Pump Instruction Manual
Zefon Escort Pump Warranty ZefonInternationalwarrantsthat,theEscortELFpersonalsamplingpumpmanufaturedbyandsoldbyZefonInternationalorauthorizeddistributorsofZefonInternationalshallbefreefromalldefectsinworkmanshipandmaterialsundernormaluseandservicewithinthewarrantytimeperiod.
Thewarrantytimeperiodshallbefortwo(2)yearsfromthedateoforiginalinvoicefromZefon.ZefonInternationalwillrepairorreplace,atitssoleoption,anyEscortELFthatisfoundtobedefectivebyZefonInternational.Thiswarrantydoesnotcovernormalreplacementpartssuchasinletfiltersthatareexpectedtobechangedbytheuserundernormalroutinemaintenance.ThewarrantyshallbevoidandZefonreleasedfromallobligationsifthereisdamagefrommisuse,accident,abuse,improperoperationandmaintenance,orthereisevidencethepumphasbeenmodified,alteredorrepairedbysomeoneotherthanZefonorZefonauthorizedrepairpersonnel.
ThiswarrantyconstitutestheonlywarrantymadebyZefonInternationalconcerningtheEscortELFandisinlieuofanyotherwarranties,expressedorimplied,includinganywarrantiesofmerchantabilityorfitnessforuseofaparticularpurpose.UndernocircumstanceshallZefonInternationalbeheldliabletothebuyeroranyuserforanypunitive,incidental,consquential,special,orindirectdamages.
Section 8Warranty
Thefollowing2pagesreferenceapprovalsforuseoutsideoftheUnitedStatesandthusfalloutsidethescopeofapplicableMSHA,NIOSHandPADEPapprovals.
Section 9, ATEX Declaration and Markings
9-1 ESCORT ELF Pump Instruction Manual
Section 9ATEX Declaration and Markings
EC Declaration of Conformity Issued in accordance with the ATEX Directive 94/9/EC
for use in potentially explosive atmospheres.
Document Number: 10063746
Document Name: Sheet, Addendum, Declaration of Conformity, Escort ELF
Revision: 2
Manufacturer: Zefon International, Inc. 5350 SW 1st lane Ocala, FL 34474 USA Product: ESCORT ELF Sampling Pump Markings:
II 2GDI M2
Ex ib IIB T3 GbEx ib IIIC T85oC DbEx ib I Mb
Harmonized Standards: EN 60079-0 : 2009
EN 60079-11 : 2007 EC-Type Examination LOM 11 ATEX 2041 Certificate: Notified Body number: 0163
Laboratorio Oficial J. M. Madariaga Alenza, 1, 28003 Madrid, Spain
Quality Assurance 11 ATEX Q150195 Notification: Notified Body number: 0539
UL International Demko A/S Lyskaer 8, P.O. Box 514
DK-2730 Herlev, Denmark EC Directives: 94/9/EC ATEX Directive 2004/108/EC EMC Directive
Jeffrey Mantz Zefon International, Inc. Vice President April 2013
Section 9, ATEX Declaration and Markings
ESCORT ELF Pump Instruction Manual 9-2
CE marking &number of notifed body responsible for production.
ATEX Markings
Specific Mark for ExplosionProtection Equipment
Group
II=Non-MiningI=Mining
EquipmentCategory
2=High ProtectionM2=De-Energizedin presence ofexplosive atmosphere
Hazard
G=GasD=Dust
EC-Type examinationcertification number
Notified bodyresponsible forEC-TypeExamination(Test House)
YearCertificateIssued
ATEXCertificate Serial
Number
Certification Codes
ExplosionProtectedEquipment
ProtectionConcept
ib=IntrinsicSafety
Gas Group
IIB=EthyleneIIIC-Conductive DustI=Methane (Mining Only)
TemperatureClassification
T3=200°CT85°C=MaximumExternal Surface Temperature
Equipment ProtectionLevel
Gb=Gas Zone 1Db=Dust Zone 21Mb=Mining De-energizedin presence ofexplosive atmosphere