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Escort Elf ® Pump Instruction 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

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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

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To contact Zefon International, call 1-800-282-0073.© Zefon International Inc. 2011 - All Rights Reserved

PRODUCTOFU.S.ZefonInternational,Inc.•5350SW1stLane•Ocala,FL34474