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1. VORTEX Standard 2 8 VORTEX Timer 2 October 2000 PERSONAL SAMPLING PUMPS Handbook VORTEX Standard 2 VORTEX Timer 2 SAMPLING PUMPS User Manual HB 3260 06 COPYRIGHT The copyright in this document which contains proprietary information is vested in CASELLA CEL The contents of this document must not be used for purposes other than that for which it has been supplied or reproduced or disclosed wholly or in part without the prior written permission of CASELLA CEL CASELLA CEL CASELLA USA Regent House 17 Old Nashua Road 15 Wolseley Road Amherst Kempston NH 03031 Bedford U S A MK42 7JY United Kingdom Toll Free 1 800 366 2966 Phone 44 0 1234 844 100 Fax 1 603 672 8053 Fax 44 0 1234 841 490 E mail info casellaUSA com E mail info casellagroup com Web www casellaUSA com Web www casellagroup com Contents VORTEX Standard 2 8 VORTEX Timer 2 PERSONAL SAMPLING PUMPS Handbook CONTENTS PAGE 1 INTRODUCTION 2 caca ri a dd Cp ee eG 3 Ze OPERATION tetera a dd ba E a de a 4 2 1 BY ci a e ead ir A 5 2 2 Battery Low Shut Down o 5 2 3 Switching the Pump ON And OFF 5 2 4 Indicator LEDS s s a ee Bee ek Ge ne e Es 5 2 5 Setting the FlowiRate 4 2 2 ak ea dee Sle es 6 2 6 Flow Compensation 6 2 6 1 Adjustment Technique 4 7 2 7 Flow Shut Down Adjustment 7 2 8 Timer Timer 2 only
2. 7 OPTIONAL ACCESSORIES 158045B 158046B 158047D 158051A Spare Battery Single way Battery charger 5 way Battery charger Pump Calibration Kit Alteration Without Notice Please note that the contents of this manual are subject to change without Page 14 of 16 prior notice
3. a letter giving full details with your packing list Send to CASELLA CEL LIMITED Service Department Regent House Wolseley Road Kempston Bedford MK42 7JY United Kingdom If purchased outside the United Kingdom please return to your distributor Page 11 of 16 VORTEX Standard 2 8 VORTEX Timer 2 PERSONAL SAMPLING PUMPS Handbook Fault Finding 5 FAULT FINDING Typical problems are shown on the following table Symptom Possible Cause Service Hint Pump does not switch ON or run Green LED not lit Battery fully discharged or unserviceable Recharge for 14 hours Wiring loom disconnected at some point Fault on joint Locate amp resolder Circuit Keypad failure Return for repair Pump does not run Green LED lit Pump or motor seizure Replace pump motor Broken wire or worn brushes Repair connection Pump runs but no air drawn Diaphragm rubber split Replace Tubes between pump and outlet split or disconnected Replace Pump runs but cannot achieve desired flow rate Leak on pump assembly Locate amp Correct Dirty or damaged valves Clean Replace Inlet filter clogged Remove amp Clean Excessive pressure drop Check sample filter Red error LED lit or flashing plus audible alarm Battery voltage too low Recharge battery Excessive pressure drop or high pump cur
4. not left in a fully discharged condition for extended periods of time Excessive over charging should also be avoided 2 2 Battery Low Shut Down A battery low cut off facility will turn the pump off once the internal battery pack becomes fully discharged This will prevent deep discharge damage and ensures maximum life of the battery pack Should the pump be switched on with a discharged battery battery low warning bleeps will be given prior to the pump shutting itself down 2 3 Switching the Pump ON and OFF To switch the pump ON press the FLOW and RESET keys at the same time The buzzer will bleep twice and the green LED will switch on indicating PUMP ON To switch the pump OFF press the FLOW and RESET keys at the same time 2 4 Indicator LEDs There are two light emitting diodes LEDs located on the front panel of the instrument PUMP ON Green indicator used to indicate that the pump is switched ON and is running The LED flashes when in flow adjustment mode BATTERY LIMIT Red indicator used to identify one of two potential error conditions Battery Low Warning When the battery approaches a discharged condition the red BATTERY LIMIT LED flashes slowly and the audible alarm sounds Sampling should be terminated and the battery recharged Page 5 of 16 Operation VORTEX Standard 2 8 VORTEX Timer 2 PERSONAL SAMPLING PUMPS Handbook Flow Fault Shut Down
5. The red BATTERY LIMIT LED flashes rapidly and the audible alarm sounds whenever the pump s loading exceeds a pre set value This may be due to excessive back pressure from a tube restriction filter blockage or pump fault Should the fault condition remain for 8 seconds the pump will be automatically shut down and the BATTERY LIMIT LED remain lit Pressing both keys will cancel the error warning and switch the pump off Re start the pump as normal 2 5 Setting the Flow Rate Adjust the pump flow to the desired rate while the pump is running 1 Press the FLOW key for 3 seconds the green PUMP ON LED will flash 2 Temporarily release the key the green LED will continue to flash while the pump is in this mode 3 Adjust the flow rate either up or down by holding down the appropriate key the adjustment is slow to start then picks up speed 4 If there is no key press after 4 seconds the pump will return to normal run mode and the green PUMP ON LED will stop flashing For optimum stability of flow it may be necessary to allow the pump to run for a few minutes before use 2 6 Flow Compensation The VORTEX Standard 2 and VORTEX Timer 2 control circuitry is designed to maintain a stable inlet flow rate over varying pressure drop conditions Small increases in back pressure may occur during sampling due to the gradual increase in filter contamination All personal samplers are factory calibrated to su
6. ing pressure An accessory kit is available to provide adjustable inlet pressure loading Please contact Casella CEL sales for further information 2 7 Flow Shut Down Adjustment The flow shut down is factory set to a level ensuring the sampler shuts down if operated with an inlet blockage or beyond its designed operating envelope Adjustment of the shut down threshold may be required for operation at higher flowrate or pressure drop conditions for example when the sampler is used in conjunction with a low flow constant pressure regulator Page 7 of 16 Operation VORTEX Standard 2 8 VORTEX Timer 2 PERSONAL SAMPLING PUMPS Handbook Adjust the shut down threshold value as follows 1 6 2 8 Loosen the four screws on the face of the sampler and carefully remove the lid The shut down control is located on the rear of the circuit board as shown below Flow Shut Down adjustment potentiometer blue Diagram showing the location of the flow shut down potentiometer Adjust the potentiometer fully clockwise until it clicks Connect the pump via the appropriate sampling head and filter to a flowmeter and adjust to the required flow rate using the front panel keys With the pump running and the filter head connected adjust the potentiometer anti clockwise until the BATTERY LIMIT LED flashes then back the adjustment off half a turn Replace the sampler lid Timer Timer 2 o
7. it the majority of monitoring applications and should require no further adjustments If however the sampler is used over a large range of flow rates or pressure drops then for optimum stability of a given flow rate adjustment of the sampler s feedback control may be necessary The feedback control is located on the side of the pump under a sealed label For adjustment of the feedback control it is necessary to remove this label Page 6 of 16 VORTEX Standard 2 8 VORTEX Timer 2 Operation PERSONAL SAMPLING PUMPS Handbook ul Feedback Control Used during Setup L Diagram showing the location of the flow compensation control potentiometer An alternative label design is provided should frequent access to the control be desired 2 6 1 Adjustment Technique If the sample flow rate drops due to an increase in pressure loading adjust the feedback control with a trimming tool and increase the flow to slightly above the desired flow rate Reduce the flow back to the desired flow rate using the front panel keys If an increase in the applied pressure loading causes the sample flow rate to increase decrease the flow to below the desired flow rate using the feedback control Increase the flow back to the desired flow rate using the front panel keys Repeat the feedback adjustment procedure until the sample flow rate remains constant over changes in the operat
8. ng appropriate sampling methods reference should be made to local legislation and guidelines as dictated by the relevant national health and safety organisations CASELLA CEL are able to offer a wide range of training courses and analytical services specifically suited to users of air sampling equipment Please contact CASELLA CEL for further information e Page 3 of 16 Operation VORTEX Standard 2 8 VORTEX Timer 2 PERSONAL SAMPLING PUMPS Handbook 2 OPERATION These samplers are based upon an efficient diaphragm pump whose flow rate is precisely maintained by automatic flow control circuitry With the exception of the ELAPSED TIME display the layout of both VORTEX pumps is identical as shown below E Z Charging Socket Elapsed Time Indicator Timer 2 only Keys for On Off i Flow Adjustment oo amp Elapsed Time Reset Timer 2 only Page 4 of 16 VORTEX Standard 2 8 VORTEX Timer 2 Operation PERSONAL SAMPLING PUMPS Handbook 2 1 Battery A rechargeable nickel cadmium battery provides typically in excess of 8 hours continuous operation The battery charging socket is located on the side of the pump Using the standard charger the battery will be fully charged in 14 hours To ensure maximum cycle life expectancy of the battery pack it is recom mended that the battery is
9. nly The LCD timer display situated on the front panel indicates the sample run elapsed time in whole minutes The timer can be reset to zero by holding down the RESET key for 3 seconds This can be carried out while the pump is on or off Page 8 of 16 VORTEX Standard 2 8 VORTEX Timer 2 Operation PERSONAL SAMPLING PUMPS Handbook 2 9 Table of Functionality Function Required Key LED Buzzer Press Switch ON Press both keys Green PUMP Double bleep together ON LED lit Switch OFF Press both keys No LEDs lit together Flow adjustment Press FLOW Green PUMP mode key for 3 seconds Release key and then adjust flow up or down ON LED flashes Exit flow adjust No key press for 4 Green PUMP ment mode seconds ON LED stops flashing Reset timer Press RESET Timer 2 only key for 3 seconds Page 9 of 16 Sampling VORTEX Standard 2 amp VORTEX Timer 2 PERSONAL SAMPLING PUMPS Handbook 3 SAMPLING The battery must be fully charged to ensure an 8 hour run especially for filters producing a high initial pressure drop The sampler is designed to work at maximum efficiency for flow rates between 0 5 and 3 5 litres min The flow rate is accurately controlled to within 5 for pressure drop variations appropriate to the selected flow rate The pressure drop limits are also related to the selected flow rate T
10. o o 8 2 9 Table of Functionality 0 ae 9 3 SAMPLING 22 ato Bor sic in ine on ers a Les 10 3 1 Check List Before Sampling 10 4 SERVICING stos posi Sire tw Ba ae Wy aed ans a 11 5 FAULT BINDING 4 ce cio ie ar a OP i a 12 6 TECHNICAL SPECIFICATIONS 00 13 6 1 Common Specifications 0 0 0000 eee 13 6 2 Common Additional Features 13 6 3 Timer 2 Additional Features 13 7 OPTIONAL ACCESSORIES o a a 14 Page 2 of 16 VORTEX Standard 2 8 VORTEX Timer 2 Introduction PERSONAL SAMPLING PUMPS Handbook 1 INTRODUCTION This handbook is designed to introduce you to the basic operation and features of the Casella VORTEX Standard 2 and VORTEX Timer 2 personal sampling pumps Both pumps may be used for air sampling applications using flow rates between 0 5 and 3 5 litres min They are ideally suited to many of the Total and Respirable dust sampling techniques as detailed within the Health and Safety Executive s publication MDHS14 The VORTEX Timer 2 includes an LCD display that indicates the sample run time in minutes This facilitates accurate calculation of the sampled volume without the need for a separate clock or timer The information contained in this handbook relates to the operation of Casella sampling equipment only and is not intended to advise or influence your adopted sampling strategy For information regardi
11. rent Remove pressure load Repair pump Flow rate not main tained through full working shift Incomplete charge Re charge Battery below capacity Fully charge amp check voltagewhich should be more than 4 8 V If below this level check the output from the charger Replace battery High current consumption due to mechanical defect in pump Locate amp correct Filter disc clogged Replace Page 12 of 16 VORTEX Standard 2 8 VORTEX Timer 2 Specifications PERSONAL SAMPLING PUMPS Handbook 6 TECHNICAL SPECIFICATIONS 6 1 Common Specifications Flow Range 0 5 to 3 5 litres min Flow Control Accuracy 5 for selected flow Max Pressure Drop 40 cm H20 at 2 litres min 15cm H20 at 3 5 litres min Nominal Battery Voltage 4 8 volt Nominal Battery Capacity 1 2 Ah Run Time In excess of 8 hours Operating Temperature 0 to 40 C Dimensions 120 mm x 74mm x 50 mm Weight 500 g 6 2 Common Additional Features X Low battery shut down X Compact size to cause no significant handicap for the wearer X Low battery indication Visual and audible X Automatic flow fault shut down due to excessive pressure drops or blockages X Digital flow adjustment 6 3 Timer 2 Additional Features X Six digit elapsed time timer with 1 minute resolution Page 13 of 16 VORTEX Standard 2 8 VORTEX Timer 2 PERSONAL SAMPLING PUMPS Handbook
12. ypically 15 cm H20 max at 3 5 litres min and 40 cm H20 at 2 litres minute The sampler is suited to the vast majority of commonly used sampling methods and filter media Note The sampler should never be run without a filter on the inlet 3 1 Check List Before Sampling Ir Make sure the battery has been fully charged 2 Ensure that the sampling head is correctly fitted with no leaks 3 If the flow rate cannot be obtained with similar conditions to previous occasions a leakage may be present Page 10 of 16 VORTEX Standard 2 amp VORTEX Timer 2 Servicing PERSONAL SAMPLING PUMPS Handbook 4 SERVICING CASELLA CEL s in house service department offers a comprehensive range of repair and calibration services designed to effect a fast and efficient back up for all our products The Service Department is operated under the scope of our BSI registration for products manufactured by us We will however undertake the repair of other manufacturers equipment For further information please contact the CASELLA CEL Service Department at our Bedford headquarters We will be happy to provide quotations for individual repairs or provide annual maintenance under contract We recommend factory service by technicians trained and equipped to repair your instrumentation Should you wish factory repair assistance send your equipment in a package equivalent to the original packaging Insure to full value and ship pre paid Include

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