CASELLA CEL TUFF Series User manual

TUFF™
PERSONAL AIR SAMPLING PUMPS
& ‘INSIGHT’ PUMP MANAGEMENT SOFTWARE
(I.S. and Non I.S. Versions)
Go to Contact Details
OPERATOR’S MANUAL
HB3343-05
PRINTED IN ENGLAND

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CONTACT DETAILS
CASELLA CEL
Regent House,
Wolseley Road,
Kempston,
Bedford,
MK42 7JY, U.K.
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.casellameasurement.com
To find your local distributor please visit www.casellameasurement.com
Go to Index

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TABLE OF CONTENTS
PLEASE READ WARNINGS and SAFETY PRECAUTIONS BEFORE ATTEMPTING TO
OPERATE THIS INSTRUMENT.
SECTION TITLE PAGE
1 Introduction 6
2 Charging the Tuff Unit / Batteries 7
3 Operation Symbols 8
4 Operation 9
5 Configuration 14
6 Calibration 17
7 Renew Inlet Adapter Filter 19
8 Servicing 20
9 Fault Finding 21
10 Pump Management Software 22
11 Technical Information/Certification 23

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WARNINGS and SAFETY PRECAUTIONS
The TUFFTM series of air sampling pumps are designed to be robust, however they should
not be dropped or subjected to mechanical shock. Do not suck in water, or highly saturated
or corrosive gases. Failure to comply will render the warranty invalid.
The air sampling pumps contain no user serviceable parts and if a fault is suspected the
instrument must be returned immediately to Casella CEL or to a Casella CEL Approved
Agency for repair.
The warranty does not extend to cleaning or general servicing of the instrument.
Pumps which are not in regular use, or those which have been left on the shelf for several
days, when switched on, may not display a true indication of the current battery charge
status. To ensure accurate battery condition monitoring and charge status displays, it is
advisable to perform one or two complete charge and discharge cycles prior to use.
Warnings for Intrinsically Safe Versions:
The following warnings should be observed for intrinsically safe versions of the TUFF
Pump:-
•DO NOT attempt to download data via the I.R port in a hazardous area.
•Use only the following CASELLA APPROVED Intrinsically Safe battery packs:-
Part No 197140B (4.8 V, 1.7Ah Nickel Metal-Hydride IECEX & ATEX Mining
M1, MASC)
Part No 197141B (4.8 V, 2.7Ah Nickel Metal-Hydride IECEX & ATEX Mining
M1, MASC)
Part No 197150B (4.8 V, 1.7Ah Nickel Metal-Hydride IECEX and ATEX)
Part No 197151B (4.8 V, 2.7Ah Nickel Metal-Hydride IECEX and ATEX)
•DO NOT use Non-intrinsically safe battery pack versions within a Hazardous area.
•DO NOT Connect or Remove battery packs in a hazardous area.
•DO NOT use the battery charger in a hazardous area.
•DO NOT use the equipment if the outer case of the instrument or the battery pack is
cracked as this invalidates the intrinsically safe certification.
•The user MUST ENSURE that the I.S. rating of the pump to be used is suitable for
the I.S. rating of the intended hazardous area.
•DO NOT service while in a hazardous area.

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Repair of this equipment shall only be carried out by the manufacturer or an authorised
representative in accordance with the applicable code of practice.
The certification of this equipment relies on the following materials used in its construction:-
High Impact PC- ABS/ Clear Polycarbonate/Acrylic.
If the equipment is likely to come into contact with aggressive substances, then it is the
responsibility of the user to take suitable precautions that prevent it from being adversely
affected, thus ensuring that the type of protection is not compromised. (Aggressive
substances e.g. solvents that may affect polymeric materials.) Suitable precautions e.g.
regular checks as part of routine inspections or establishing from the material’s data sheet
that it is resistant to specific chemicals.
Instructions specific to hazardous area installations:-
•The equipment may be used with flammable gases and vapours with apparatus Groups
IIA, IIB and with temperature classes T1, T2 and T3.
•The equipment is certified only for use in ambient temperatures in the range -20oC to
+41oC and should not be used outside this range.
•The certification marking and classification is displayed on the battery pack label.
NOTE:
FOR I.S. MINING OPERATION, USE ONLY CERTIFIED BATTERY PACKS Prt. No
197140B or 197141B IN CONJUCTION WITH A PUMP BODY BEARING A LABEL
IDENTIFYING THESE I.S. CERTIFIED BATTERY PACKS.
FOR NON-MNING I.S. OPERATION, USE ONLY CERTIFIED BATTERY PACKS Prt. No:
197150B or 197151B IN CONJUCTION WITH A PUMP BODY BEARING A LABEL
IDENTIFYING THESE I.S. CERTIFIED BATTERY PACKS.
Back to Index

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1. INTRODUCTION
The TUFFTM air sampling pump is produced in three models, the TUFF Standard, TUFF Plus
and TUFF Pro.
This handbook covers the entire range of TUFFTM air sampling pumps.
The TUFFTM was developed to provide sampling capabilities between 5 ml/min and 4.5 l/min
(free air), suitable for a wide range of applications including solvent fumes, asbestos
clearance and personal sampling of dusts. TUFFTM pumps are ideally suited to many of the
“Total” and “Respirable” dust sampling techniques detailed in the U.K. Health and Safety
Executive’s publication MDHS14, and in other international reference methods.
The information contained in this handbook relates only to the operation of Casella CEL
sampling equipment and is not intended to advise or influence your adopted sampling
strategy. For advice on appropriate sampling methods, refer to local legislation and
guidelines as dictated by the relevant national and regional health and safety organisations.
Please make sure the TUFFTM and associated equipment supplied by Casella are not
damaged and the Inlet Nozzle is not restricted before attempting to use this instrument.
Figure 1 TUFFTM Air Sampling Pump
Back to Index

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2. CHARGING THE TUFF PUMPS / BATTERIES
There are two methods of charging the battery.
1. When the battery is attached to the pump.
2. The battery on its own.
This section details both methods.
Figure 2 Fit Battery to Pump and then to the Charger
•Insert pump into charging cradle as shown above.
•Fast charge starts and the red LED on the pump flashes.
•When fully charged the blue LED will illuminate. The pump can be left in the cradle
on trickle charge or may be removed.
•Individual battery packs can also be charged / stored in the cradle. The battery
pack’s own red LED will indicate that charging is in progress.
Battery Charge Mode
Note: Make sure all pumps are fully charged before use.

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Figure 3 Insert Battery in Charger
•Insert battery into the charging cradle.
•Slow charge (>8-14 hours) starts. Red LED on battery illuminates.
•Battery fully charged. LED on battery holds steady illumination. The battery can be
left in cradle on trickle charge or removed.The battery charger will power down after
5 seconds.
3. SYMBOLS DISPLAYED DURING OPERATION
During a sampling run symbols are displayed on the screen to indicate the pump Running
/Stopped status.
The symbol in the top left hand corner of the screen displays the pump mode.
Pump Running.
Pump Stopped.
Pump Paused.
The operating keys can be set in a Partial Lock Mode or Locked Mode.
Partial Lock Mode. This can be activated in Stop Mode and Run Mode. In this
mode the pump can only be started and stopped. Press the ON/OFF key three
times within 3 seconds to enter Partial Lock Mode. Repeat once to unlock in
Stop Mode, repeat twice to unlock in Run mode.
Fully Locked Mode. This can only be activated in Run Mode. In this mode all
keys are disabled. From Partial Lock Mode press the ON/OFF key three times
within 3 seconds to enter Locked Mode. Repeat to unlock.
BATTERY GAUGE
TUFF Standard models – Battery gauge shows approximate estimate of
available battery capacity.
TUFF Plus Model- Here the battery status bar indicates approximate %
remaining.
PRO only - This screen shows the estimated life remaining based on the
current battery loading.
ERROR MESSAGES
The pump stops and an error condition is indicated by a
flashing ‘!’ and red LED. Low Battery and Flow Blockage are
shown here. After 1 minute stoppage the pump will try restart.
All error messages are displayed for 4 hours before the pump
turns off.
This symbol is displayed if the Run Time exceeds 2500hrs or
exceeds 600 charge cycles.
Back to Index

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4. OPERATION
A. POWER ON
Note: To Set Language go to Configuration Chapter 5.
To start the pump, press and release the ON/OFF Key. The Firmware will run through the
initialisation screens and then automatically go to the Main Menu.
Figure 4 Power ON Screens
B. MAIN MENU (Fig. 5)
When on the Sampler will scroll through the Main Menu Options. The information displayed
on the screens will be the saved data from the last time the pump was used. Press the
ENTER key on any screen to start the pump. (Volume and Flow not displayed on
Standard Model.)
Figure 5 Main Menu
C. RUN MODE MAIN MENU (Fig. 6)
When the pump is running the Sampler will scroll through the Run Mode Menu options and
the blue led will be flashing. Current run data will be displayed. To stop the pump, press and
hold the ENTER key on any screen until the countdown is complete.
Note: PRO Model Only - Screen (Z) is the remaining run time available based on the
current flow and pressure loading. The Plus model displays the % of remaining battery
capacity only. Standard model only displays battery status bar and elapsed run time only.
No flow rate or sampled volume are displayed.
Figure 6 Run Mode Main Menu
D. STOPPED MODE MENU OPTIONS (Fig. 7)
Use the UP/DOWN keys to step through the Menu Options. Press ENTER to access a Menu
Option when it is displayed. Menu option not available in partial lock mode.
Figure 7 Menu Options

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E.TIME WEIGHTED AVERAGE (TWA) PRO ONLY (Fig. 8) (Only activated when advanced
mode is selected-see configuration chapter)
This mode allows the user to allow a known volume of sample to be taken over a selectable
time period (for example 120L over 8 hours.). In this instance if the pump was set to 2l/min
flow rate, it would only need to sample for 60 minutes over the whole 8 hour sampling
duration. The pump will automatically switch on/off spreading the sample on time over the
whole duration evenly.
Use the UP/DOWN keys to step through the Menu Options until the TWA screen is
displayed.
Press ENTER to continue to the TWA Run screen. Use the UP/DOWN keys to set the total
sampling duration, e. g 8 hours.
Press ENTER to continue to the Exposure time setting. Use the UP/DOWN keys to set the
Exposure Time, e. g 1 hour.
The settings entered will provide 1 hours exposure time evenly spaced over the 8 hours
running time.
Press ENTER to Start.
Figure 8 Time Weighted Average
To exit the program at any time press and hold ENTER. The display will count down 3, 2, 1
and default to the Main Menu.
F. RUN DURATION (PRO and PLUS ONLY) (Fig. 9)
Allows a pre set sampling duration time to be set e.g 6 hours.
Press ENTER to access Run Duration setup screen.
Use the UP/DOWN keys to set run duration in hours and minutes.
Press ENTER again to start the pump. The duration will be counted down and indicate time
remaining. The pump will stop when the duration end time is reached.
Figure 9 Run Duration