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SKC 224-44XR, Service Manual

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Universal Pump Service Manual

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Table of Contents

Introduction .................................................................................................................................................................... 1

Performance Profi le ...................................................................................................................................................... 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 Testing ......................................................................................................................................................... 5

Initial Leak Check .................................................................................................................................................. 5
Pump Flow Rate Spot Check ................................................................................................................................. 5
Testing Flow Range Compensation ....................................................................................................................... 6
Testing the Pressure Regulator ............................................................................................................................. 6

Pump 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 .............................................................................................................................................. 10
Disassembling the Filter Housing ........................................................................................................................ 10
Removing the Control Board and Keypad ........................................................................................................... 10

Pump Reassembly....................................................................................................................................................... 11

Reassembling and Replacing the Stack .............................................................................................................. 11
Setting the Flow Compensation ........................................................................................................................... 12
Replacing the Back Pump Case .......................................................................................................................... 13
Reassembling and Replacing the Filter Housing ................................................................................................. 13
Replacing the Battery Pack ................................................................................................................................. 13

Troubleshooting .......................................................................................................................................................... 14

Figures..................................................................................................................................................................... 16-24

Addenda ....................................................................................................................................................................... 25

Indicates a caution or warning.

Summary of Contents for 224-44XR

Page 1: ...Universal Pump Cat Nos 224 44XR 224 PCXR4 and 224 PCXR8 Service Manual SKC Inc 863 Valley View Road Eighty Four PA 15330 8619 Publication 1377 Rev 0910 ...

Page 2: ......

Page 3: ...l Testing 5 Initial Leak Check 5 Pump Flow Rate Spot Check 5 Testing Flow Range Compensation 6 Testing the Pressure Regulator 6 Pump 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 10 Disassembling the Filter Housing 10 Removing the Control Board...

Page 4: ......

Page 5: ...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 Flow Control Holds constant flow to 5 of the set point Run Time 8 hrs minimum at 4000 ml min and 20 in water back pressure dependent on media used Flow Indicator Built in rotameter with 250 ml division scale marked at 1 2 3 4 and 5 L min Power...

Page 6: ...sampler period elapsed time pump run time or total elapsed time including delayed start time Timing Accuracy 0 05 45 seconds day Sampling Pause 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 Allows user to select minutes of operation before automatic shutdown Delay On Allows...

Page 7: ...opened to activate the regulator The regulator can be controlled by turning the screw under the cap screw clockwise closes it counterclockwise opens it The regulator is factory preset at 20 inches water back pressure and should not be adjusted for normal use Flowmeter Assembly This rotameter style flowmeter is mounted vertically in the case and is used to monitor pump flow Figure 1 13 While rotamete...

Page 8: ... a primary standard flowmeter 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 intri...

Page 9: ...ng and Correcting Leaks If the water column does not drop it indicates that there are no leaks in the system If there 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 SKC recommends periodically testing a water manometer for leaks before performing any leak checks Pump Flow Rate Spot Check Ensure that ...

Page 10: ...se 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 r...

Page 11: ...ck Steps 1 through 3 2 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 th...

Page 12: ...g 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 valve 3 Apply vacuum pressure and observe the yoke diaphragm assembly for movement The yoke will move toward the leaking inlet valve 4 Ensure that the pump exhaust port fi ing Figure 1 22 is...

Page 13: ... Stack 1 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 Wires attach the stack to the control board Avoid excessive strain on wires 3 Remove the short black tubing on the flowme...

Page 14: ...ve 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 the Filter Housing 1 Remove the four screws from...

Page 15: ...late assembly Ensure that the components are aligned properly 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...

Page 16: ...et flow compensation unless the ba ery voltage is at least 6 1 volts 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 2 Connect the filter housing inlet Figure 1 9 to the magnehelic gauge outlet and ensure minimum back pressure 3 Turn on the pump 4 Using a small flat head screwdr...

Page 17: ...ting 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 P2240901 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 filt...

Page 18: ...esolder 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 j...

Page 19: ...leshooting 224 PCXR4 and PCXR8 Pump LCD lights when pump is turned on but the motor will not run Turn the flow 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 flow adjust pot counterclockwise If the pot cannot be adjusted clockwise it may have separated from the contr...

Page 20: ...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...

Page 21: ...Universal Pump Service Manual 17 17 17 17 17 Figure 1 1 2 3 4 5 6 7 8 9 10 11 12 13 18 18 17 17 20 19 21 16 15 14 9 22 ...

Page 22: ...p Valve Plate only P22417F P213301 6 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...

Page 23: ...22433U Control Board PCXR4 P22433T Control Board 224 44XR P22433Q 5 Battery Pack P21661 6 Pump Stack with Pressure Switch Assembly PCXR4 PCXR8 P22433RS2 Pump Stack without Pressure Switch Assembly 224 44XR P22433RS1 7 Back Cover Case Parts P21411 8 Belt Clip with Screws P22417BC 9 Battery Connector pkg 10 P2243001 Not Shown Replacement Filter Kit P22409 Exhaust Port Fitting P22417C Anti tamper Cov...

Page 24: ...Description 1 Screws with washers in place 2 Battery Connector with screw 3 V Jumper voltage 4 I Jumper current 5 Negative battery connector pin Figure 5 Pump Stack Bottom View 224 PCXR4 and PCXR8 only Wires to Stack Brown Orange Red Yellow Wires to Stack Red or Yellow Brown or Orange 4 1 3 1 4 2 5 I V I V 3 Shown PCXR8 control board Shown 44XR control board ...

Page 25: ...P MODE FLOW ADJ ON 5 4 3 2 1 AIRCHEK SAMPLER MODEL 224 PCXR8 UL LISTED 124U SERIAL NO SKC INC EIGHTY FOUR PA 15330 WARNING SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRIN SIC SAFETY USE ONLY UL LISTED PORTABLE AIR SAMPLING PUMP BATTERY PACK MODEL P21661 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 TEMPERAT...

Page 26: ...n 1 Pump inlet 2 Filter housing including O ring and filter 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...

Page 27: ... Service Manual 23 23 23 23 23 Figure 9 Power Adapters 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 P8001 ...

Page 28: ...Universal Pump Service Manual 24 24 24 24 24 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 ...

Page 29: ...800 4200 4000 20 3800 4200 3000 0 3000 3000 3000 10 2850 3150 3000 20 2850 3150 3000 30 2850 3150 3000 35 2850 3150 2500 0 2500 2500 2500 10 2375 2625 2500 20 2375 2625 2500 30 2375 2625 2500 40 2375 2625 2000 0 2000 2000 2000 10 1900 2100 2000 20 1900 2100 2000 30 1900 2100 2000 40 1900 2100 1000 0 1000 1000 1000 10 950 1050 1000 20 950 1050 1000 30 950 1050 1000 40 950 1050 Check Points ü Maximu...

Page 30: ... 4000 8 3800 4200 3000 0 3000 3000 3000 10 2850 3150 3000 15 2850 3150 3000 22 2850 3150 2500 0 2500 2500 2500 15 2375 2625 2500 25 2375 2625 2500 30 2375 2625 2000 0 2000 2000 2000 15 1900 2100 2000 30 1900 2100 2000 35 1900 2100 2000 40 1900 2100 1000 0 1000 1000 1000 15 950 1050 1000 30 950 1050 1000 35 950 1050 1000 40 950 1050 Check Points ü Maximum Flow ____ Set Regulator 20 ____ Keypad ____...

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