TSI Instruments DustTrak 8540 Operation And Service Manual Download

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DUSTTRAK

™

ENVIRONMENTAL

MONITOR

MODELS 8540, 8543

8540-M, 8542-M, 8543-M

OPERATION AND SERVICE MANUAL

P/N 6008408, REVISION K

FEBRUARY 2021

Summary of Contents for DustTrak 8540

Page 1: ...DUSTTRAK ENVIRONMENTAL MONITOR MODELS 8540 8543 8540 M 8542 M 8543 M OPERATION AND SERVICE MANUAL P N 6008408 REVISION K FEBRUARY 2021 ...

Page 2: ......

Page 3: ...e of its manufacture Instruments returned for calibration are not covered by this warranty f This warranty is VOID if the instrument is opened by anyone other than a factory authorized service center with the one exception where requirements set forth in the manual allow an operator to replace consumables or perform recommended cleaning g This warranty is VOID if the product has been misused negle...

Page 4: ...s risk of loss and will be returned if at all at Seller s risk of loss Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND LIABILITY which contains the complete and exclusive limited warranty of Seller This LIMITATION OF WARRANTY AND LIABILITY may not be amended modified or its terms waived except by writing signed by an Officer of Seller Service Policy Knowing that ino...

Page 5: ...5 Unpacking the DustTrak Monitor 5 User Replaceable Internal Parts 6 Optional Accessories 7 Parts Identification for the DustTrak Environmental Models 8540 8540 M 8542 M 8543 8543 M 8 CHAPTER 3 SETTING UP 11 Environmental Enclosure 11 Supplying Power to the DustTrak Environmental Monitor 12 Omni directional Inlet Column 13 Optional accessory 854040 13 Zero Calibration of Instrument 13 Instrument S...

Page 6: ...Internal Sheath Air HEPA Filter 43 Replacing Pump 45 Replacing Internal 37 mm Sampling Cassette 48 Return Shipping to TSI Incorporated 51 CHAPTER 6 TROUBLESHOOTING 53 APPENDIX A SPECIFICATIONS 55 APPENDIX B INSTRUMENT COMMAND SET 57 Connecting to the Instrument 57 NIDS Communication Method 57 APPENDIX C DRX ADVANCED CALIBRATION 59 Option 1 Serial Gravimetric Calibration 59 Step 1 PCF Calibration 5...

Page 7: ...ecifically told to do so in this manual W A R N I N G The use of controls adjustments or procedures other than those specified in this manual may result in exposure to hazardous optical radiation W A R N I N G If the DustTrak monitor is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired When operated according to the manufacturer s instructi...

Page 8: ... symbol for non disposable item Item must be recycled 6 MCERTS Certification Label s 854201 M1 854001 M1 854301 M1 DANGER VISIBLE LASER RADIATION WHEN OPEN AVOID DIRECT EXPOSURE TO BEAM WARNING NO USER SERVICABLE PARTS INSIDE REFER SERVICING TO QUALIFIED PERSONNEL Calibrated Customer Service 1 800 874 2811 Outside US 001 651 490 2811 www tsi com Date January 2015 USB IP Address 199 254 130 225 ...

Page 9: ...ning W A R N I N G Warning means that unsafe use of the instrument could result in serious injury to you or cause damage to the instrument Follow the procedures prescribed Caution and Warning Symbols The following symbols may accompany cautions and warnings to indicate the nature and consequences of hazards Warns that the instrument contains a laser and that important information about its safe op...

Page 10: ... minimal negative impact on the communities in which its products are manufactured and used DO NOT dispose of used batteries in the trash Follow local environmental requirements for battery recycling If instrument becomes obsolete return to TSI for disassembly and recycling ...

Page 11: ...r the use of a variety of size selective inlet conditioners to measure aerosol concentrations corresponding to PM10 or PM2 5 DustTrak DRX Environmental Monitors Model 8543 and 8543 M The DustTrak DRX Environmental Monitors are continuous real time light scattering laser photometers that simultaneously measure size segregated mass fraction concentrations corresponding to PM1 PM2 5 and PM10 somethin...

Page 12: ...0 53 preset at the factory It is recommended that the instrument is run with a Photometric Correction Factor PCF of 0 53 However the application of a site specific correction factor may be used if a significant decrease in the expanded uncertainty can be demonstrated 854001 M1 MCERTS PM2 5 Indicative Certification 8540 M Photometer 854038 Environmental Enclosure 854021 PM2 5 Impactor 854041 Heated...

Page 13: ... Heated Inlet PCF PM2 5 set at 0 47 PM10 set at 0 53 preset at the factory It is recommended that the instrument is run with a Photometric Correction Factor PCF of 0 53 However the application of a site specific correction factor may be used if a significant decrease in the expanded uncertainty can be demonstrated ...

Page 14: ...4 Chapter 1 This page intentionally left blank ...

Page 15: ...ssing components Contact TSI immediately if anything is missing or damaged Unpacking the DustTrak Monitor Compare all the components you received with those listed in the table below If any parts are missing contact TSI Item Qty Part Number Description 1 8540 8540 M 8542 M 8543 8543 M DustTrak Environmental Monitor DustTrak DRX Environmental Monitor 1 1090014 Data Analysis Software CD ROM 1 130374...

Page 16: ...laceable Internal Parts Item Part Number Description 854044 Sheath Air Filter 854043 Pump NA 37 mm 2 piece static conductive cassette Blank replacement cassettes or media can be ordered from www zefon com 37 mm 2 piece blank cassette product 37MMH 2 CF Zefon can also supply pre weighed filter media for gravimetric sampling ...

Page 17: ...fication 7 Optional Accessories Item Part Number Description 854038 Environmental Enclosure 801905 Netronix Thiamis 1000 Communication Node 854040 Omni directional Inlet w Water Trap Bottle 854041 Heated Inlet Sample Conditioner ...

Page 18: ...ure Power Supply 854042 Water Trap Bottle 854020 PM10 Impactor 854021 PM2 5 Impactor 854022 PM1 0 Impactor Parts Identification for the DustTrak Environmental Models 8540 8540 M 8542 M 8543 8543 M Figure 1 Features on Models 8540 8540 M 8542 M 8543 8543 M ...

Page 19: ... holes shown Holes are pre drilled in the back of the photometer to enable users to develop their own mounting bracket for attaching the photometer into an alternate enclosure Mounting the photometer using these holes will need quantity four 4 6 32 screws that penetrate no deeper than 0 230 into the back panel of the photometer ...

Page 20: ...Chapter 2 10 This page intentionally left blank ...

Page 21: ...4038 Environmental Enclosure has been designed specifically to protect the DustTrak Environmental Monitor and its accessories See Environmental Enclosure Model 854038 Operation and Maintenance Manual P N 6012377 for more details and installation instructions Figure 4 Environmental Enclosure as shown with optional accessories Omni directional inlet and solar shield ...

Page 22: ... a region specific power cord and is mainly used to power the instrument when it is not mounted inside of the enclosure and communication is required for diagnostics and programming Figure 5 Instrument power connection If the instrument is installed into the 854038 Environmental Enclosure power options include AC Power Supply 854039 AC power supply included with enclosure heater 854054 Rechargeabl...

Page 23: ...ument resets the photo detector to a signal that represents no particles flowing through the optics Over time photometric light scattering instrument readings can drift due to changes in temperature and aerosol build up in the optics Programming regular Zero events corrects the photometric signal to account for these changes The DustTrak Environmental Monitor automatically performs a zero calibrat...

Page 24: ...he instrument status program instrument and activate instrument programmed runs The DustTrak instrument can be setup and controlled using one of three options Use TrakPro Data Analysis Software to configure instrument run instrument and download data Quick start information for using TrakPro software is shown in the section below Use a Netronix Thiamis Communication Node and web based application ...

Page 25: ...s not being used or a web accessed device is not immediately available during field installation Open DustTrak Checkout executable file and follow the steps to run the installation wizard NOTES The DustTrak Checkout Application can also be downloaded from the TSI website Visit http www tsi com Software Firmware and click on the Software and Firmware Wizard link Follow the on screen instructions to...

Page 26: ...d click the Connect button The USB IP address and instrument information will appear when connected Figure 9 Checkout Application Connect tab Click the Data tab to access the current instrument readings Clicking the green arrow will start the instrument pump to begin sampling in Survey Mode No data will be logged onto the instruments memory while running in Survey Mode Figure 10 Checkout Applicati...

Page 27: ...ach a flow calibrator reference flowmeter to inlet port You may use a bubble buret mass flowmeter dry piston or rotameter as flow measurement devices 2 Click on the up or down arrows to achieve desired flow on the reference flowmeter Each click of the up or down arrow will change the flow about 1 Allow time between button presses to let pump change to the new flow rate 3 Click Save once the desire...

Page 28: ...e Zero tab to manually perform a zero calibration for the instrument Click Start Zero to start the zeroing process The Last Zero and New Zero values do not represent particle count or aerosol mass These values are associated with the signal received by the photometric sensor when no particles are passing through the optics Figure 12 Checkout Application Zero tab The Laser tab is only accessible in...

Page 29: ...nstrument Click Send or press the Enter key to send the command to the instrument See the Communication Settings in Appendix B Figure 13 Checkout Application Diagnostics tab The IP Label tab opens a printer connection box and displays the instrument IP address Figure 14 Checkout Application IP Label tab ...

Page 30: ...3 20 The IP Addressing tab can be used to change the settings for the instruments Ethernet IP address After making changes click Save for the settings to take effect Figure 15 Checkout Application IP Addressing ...

Page 31: ...s and the computer must have an available Universal Serial Bus USB port 1 Insert the TrakPro Data Analysis Software CD into the CD ROM drive The install screen starts automatically NOTE If the software does not start automatically after a few minutes manually run the program listed on the label of the CD using the Run command on the Windows Start Menu 2 Follow the directions to install TrakPro sof...

Page 32: ...Communications with the Instrument Open up TrakPro software and select Instrument Setup Communications The software will automatically find the instrument as shown in the dialog Configuring the Logging Parameters Select Instrument Setup Logging Setup ...

Page 33: ...ive sample but does not log data Manual Manual Log sets the instrument to log data for a specified run time Log Modes Log Mode starts and stops the instrument at specified times run for a specified test length and perform multiple tests of the same length with a specified time period between tests Press the Read button to get the current log modes from the instrument Update the log modes to meet l...

Page 34: ...sed for the 8540 8540 M 8542 M 8543 8543 M models Program Log Options Log Name Enter descriptive name for the log mode Start Date Select the date and the test will start Select the check box to use Start Date option to use programmed start date or bypass programmed start date Start Time Select the time the test will start Select the check box to use Start Time option to use programmed start time o...

Page 35: ... functionality Use the check box to enable use of autozeroings Once the log modes have been updated press the Send button to send the new log modes to the instrument If using a programmed start time and start date update the instrument date and time to ensure the logging starts as planned Select Instrument Setup Parameters Clock to set the time ...

Page 36: ...Ambient Cal and the other is the Factory Cal 8540 M 8542 M and 8543 M also have an MCERTS cal The Ambient Cal is appropriate for outdoor ambient dust or fugitive dust monitoring The Factory Cal is the calibration to ISO 12103 1 A1 Arizona test dust for which a calibration certificate is provided with the instrument The Factory Cal is appropriate for most workplace aerosol monitoring Factory Cal ca...

Page 37: ... button to access the instrument calibration settings In this dialog you can select the factory ambient cal or customizable user cals 1 through 10 1 through 9 for MCERTS models 8540 M 8542 M and 8543 M User Cals 1 through 10 can be used to set custom user calibration factors ...

Page 38: ... 12103 1 A1 test dust is fairly representative of a wide variety of workplace aerosols Because optical mass measurements are dependent upon particle size and material properties there may be times in which a custom calibration would improve your accuracy for a specific aerosol Determining an aerosol specific photometric calibration requires that you determine a true mass concentration e g gravimet...

Page 39: ...te i e 01 00 is often a good choice 4 Co locate the DustTrak monitor and the reference sampler together so that they are measuring from the same area 5 Start sampling aerosol with both instruments at the same time NOTE Greater accuracy will be obtained with longer samples The time you permit for sampling often depends on the reference instrument and characteristics of the measured aerosol It may t...

Page 40: ...s using conductive polypropylene 2 piece 37 mm cassette housings 9 Compute the new calibration constant NewCal using the following formula NewCal Reference Concentration DustTrak Concentration CurrentCal 10 Enter the new value into one of the custom user cals and turn that cal on using the radio button Starting a DustTrak Sample Run Once a log mode is set and a calibration mode selected the DustTr...

Page 41: ...TrakPro Software Quick Reference 31 Next establish communication with the instrument Press the Discover Instrument button Select your desired log mode from the Logging Program drop down menu ...

Page 42: ...is selected the instrument will not immediately start with the logging and will remain in idle unit the targeted date and time Downloading Data Once the data has been logged to the instrument it can be down loaded into TrakPro software Select File Receive to download data from the instrument ...

Page 43: ...nformation on how to view graph and export the DustTrak data Local Analog Alarm Output The DustTrak Environmental Monitor has an Analog Alarm Output connection on the side of the instrument The pin outs for wiring are shown below 4 pin miniDIN connector Cable Wiring Diagram Brown Wire Analog Ground Orange Wire Analog Out Red Wire Alarm White Wire Alarm Black Wire Shield Figure 16 Cable Wiring Diag...

Page 44: ...ated inside the DustTrak monitor must be located on the ground side of the alarm system W A R N I N G The Alarm Output function SHOULD NOT be used to detect hazardous conditions or to provide an alarm for protecting human life health or safety When connected to the analog out and alarm out connector you MUST use safety certified equipment and or power sources C A U T I O N The alarm switch MUST NO...

Page 45: ...he turning on off and configuring of the analog output Analog out On Off Turns analog out port on Size Fraction Selects the size channel that will drive the analog out DRX Models 8543 or 8543 M only Output Setting V mA Select 0 5 V or 4 20 mA Lower Limit mg m3 Mass concentration reading of the selected channel that will correspond to 0 V or 4 mA Upper Limit mg m3 Mass concentration reading of the ...

Page 46: ...Environmental Monitor to alarm as soon as the Alarm Setpoint is exceeded the logging interval must be set as low as possible i e 1 second or 2 seconds If a long test duration does not permit setting such a short logging interval use the STEL alarm instead The STEL is always based on 1 second concentrations and is independent of the logging interval For more details on the STEL alarm see section be...

Page 47: ...ned on unit will close its local relay switch when Alarm level is surpassed Relay alarm can only be linked to one mass channel at a time for the DRX models 8543 8543 M STEL On Off When the STEL alarm is turned on STEL data will be collected when Alarm level is surpassed STEL alarm can only be linked to one mass channel at a time for the DRX models 8543 8543 M See following STEL Note Audible On Off...

Page 48: ...channel at a 1 minute logging interval for 15 minutes This data will be stored in a separate file named STEL_XXX where XXX will be matched to the logged data file The instrument will also continue to log the mass concentration data at the logging interval selected STEL Alarm repeat If the instrument remains over the STEL limit after the 15 minute interval or if the instrument exceeds the STEL limi...

Page 49: ...ment case should only be opened by TSI or a TSI approved service technician NOTE To maintain the MCERTS certification it is required that the MCERTS model photometers 8540 M 8542 M 8543 M be recalibrated on a yearly cycle Maintenance Schedule The DustTrak Environmental Monitor requires maintenance on a regular basis Table 1 lists the factory recommended maintenance schedule Some maintenance items ...

Page 50: ...ated amount of aerosol drawn through it since its last cleaning Cleaning the Inlet The inlet should be cleaned based on the schedule in Table 1 1 Turn the DustTrak monitor off 2 Remove the 4 screws and the inlet mounting ring 3 Unscrew the black inlet nozzle from the instrument Figure 17 Figure 17 Unscrew Inlet Nozzle 4 Use a cotton swab to clean the outside of the inlet nozzle body You may dampen...

Page 51: ...Maintenance 41 NOTE Be careful not to blow particles into the DustTrak monitor inlet port Figure 18 DO NOT Blow into Instrument 5 Screw hand tighten inlet nozzle back into instrument ...

Page 52: ... frequently Average dust concentration mg m3 Impactor maintenance interval 0 015 97 days 0 025 60 days 0 035 42 days 0 050 30 days 0 100 16 days 0 150 10 days 0 250 6 days 0 400 4 days 1 Unscrew Impactor Check O ring on the impactor base 2 Clean outside and inside of Impactor and the impactor plate using a clean brush and a light solvent Dry impactor parts by blowing it out with compressed air or ...

Page 53: ...trument Service Panel Figure 20 3 Disconnect and remove old sheath air filter from the instrument Figure 21 Figure 20 Open instrument service panel Figure 21 Disconnect and remove old sheath air filter 4 Replace with new filter PN 854044 Ensure tubing coming from the Y connects to the inlet side of the filter as indicated by the Flow arrow Figure 22 Figure 22 Replace with new filter ...

Page 54: ...setting the filter concentration may clear the filter error condition shown in the Data tab of DustTrak Checkout Software Reset the date and concentration by performing the following Figure 23 Replace cover a Power the instrument b Open the DustTrak Checkout software c Connect the provided USB cable to the instrument and your personal computer d Click Connect e Click Reset Filter Date and Concentr...

Page 55: ...lacing Pump If the pump stops working it can be removed and replaced in the field See Quick Start Guide included with Replacement Pump 854043 for additional details Figure 24 First remove Photometer from the Environmental Enclosure following the applicable steps 1 Disconnect all cabling from photometer Figure 24 Replacement pump 854043 2 Remove inlet column If inlet column includes a heated inlet ...

Page 56: ...r down and out of enclosure Figure 25 a Heated inlet cable b remove retainer ring and lower photometer 5 Have a replacement pump P N 854043 available 6 Open instrument service panel Figure 26 Figure 26 Open instrument service panel ...

Page 57: ... remove any screws with heads flush to the surface Figure 27 Remove screws from left side panel 8 Pull the pump from the enclosure and detach tubing muffler and cable Figure 28 Pull pump from enclosure and detach tubing muffler and cable 9 Attach the muffler to P tubing to V and cable to the new pump Figure 29 Figure 29 Attach muffler ...

Page 58: ... instrument comes with a blank cassette containing a mesh sieve to keep large particulate out of the instrument pump Save this cassette and the filter The DustTrak Environmental Monitor is designed to have this cassette in place The flow path will be compromised without this cassette On occasion this cassette should be removed and the mesh screen cleaned by blowing with compressed air or rinsing u...

Page 59: ...uctive plastic cassette to ensure proper fit inside the DustTrak monitor 1 To remove cassette open instrument service panel to access the sampling cassette Internal sampling cassette is located in the upper right opening Figure 32 Remove sampling cassette 2 Pinch the blue clip to release the bottom cassette holder and remove cassette from the holder Figure 33 Release and remove cassette holder ...

Page 60: ...ssette with the appropriate filter media for the analysis to be performed Figure 34 Inspect top inlet fitting and blue cassette holder 5 Make sure the Cassette snaps securely into the inlet port on the top of the cassette holder and the bottom clip snaps securely into place If the connection is loose air will leak resulting in inaccurate sampling results Figure 35 Figure 35 Snap cassette securely ...

Page 61: ...nt The model number will be needed for the Service Request form o For 8540 M use 8540 o For 8543 M use 8543 Package the instrument in the original shipping container NOTE If original shipping container is not available pack instrument securely in a durable shipping carton to prevent damage during shipment Consult with courier for packing guidance Include printed copy of Service Request form inside...

Page 62: ...Chapter 5 52 This page intentionally left blank ...

Page 63: ... properly Replace internal filters if necessary DustTrak reading negative concentrations Zero Drift Increase autozero frequency Analog output does not work Cable connector not correctly installed Make sure cable connector is fully seated Output wired with reverse polarity Make sure analog out and analog ground are wired correctly to data logger Alarm output does not work Alarm function not turned ...

Page 64: ...te See the maintenance section of the manual Laser Error indicated in data set of on Environet Laser background is too high Remove and clean inlet nozzle Pay close attention to the tip of the nozzle that is inserted into the instrument to ensure it is clear of any contamination Laser is failing Factory service may be required Filter Error indicated in data set or on Environet Internal sheath air H...

Page 65: ...ls 8543 8543 M Resolution 0 1 of reading or 0 001 mg m3 whichever is greater Zero Stability 0 002 mg m3 24 hours at 10 sec time constant Particle Size Range Approximately 0 1 to 10 µm 8540 8540 M 8542 M 0 1 to 15 µm 8543 8543 M Flow Rate 3 0 L min set at factory Flow Accuracy 5 factory setpoint Internal flow controlled Temperature Coefficient 0 001 mg m3 per C Operational Temp 0 to 50 C Storage Te...

Page 66: ...utput 0 to 5 V or 4 to 20 mA User selectable scaling Alarm Out 8540 8540 M 8542 M 8543 8543 M Relay or sound buzzer Relay No latching MOSFET User selectable setpoint 5 deadband Connector 4 pin Mini DIN connectors Internal Sampling Cassette Removable 37 mm 2 piece static conductive cassette Contact AIHA Accredited Analytical Lab for guidance on selecting the proper filter media for your desired ana...

Page 67: ... modems and other dataloggers Contact TSI for a copy of the communication manual P N 6002481 Connecting to the Instrument USB and Ethernet instrument connections use the NDIS communication method port 3602 NIDS Communication Method This method communicates with the instruments via USB and Ethernet connections This method uses windows sockets ...

Page 68: ...58 Appendix B This page intentionally left blank ...

Page 69: ... Figure 36a The calibration steps are outlined below Step 1 PCF Calibration Install a PM2 5 impactor at the inlet of the external gravimetric filter Co locate and run the gravimetric sample and DustTrak DRX monitor simultaneously to collect enough mass on the gravimetric filter Calculate the PM2 5 mass concentration PM2 5_Grav from the gravimetric filter based on the net mass collected on the filt...

Page 70: ...es the DustTrak DRX monitor advanced calibration can be performed in the parallel configuration as shown in Figure 36b The calibration steps are outlined below 1 Install a PM2 5 and a PM10 impactor at the inlet of the two external gravimetric filters respectively 2 Co locate and run the gravimetric samples and DustTrak DRX monitor simultaneously to collect enough mass on the gravimetric filters 3 ...

Page 71: ...DRX Advanced Calibration 61 6 Update the new SCF and PCF in the user calibration settings a b Figure 36 Experimental Setup for a Serial and b Parallel Gravimetric Calibration ...

Page 72: ...62 Appendix C This page intentionally left blank ...

Page 73: ...ck panel interface control dimensions 9 back panel with mounting holes 9 base 13 battery power 12 bubble buret 17 C cable detaching 47 cable wiring diagram 33 calibration certificate 6 calibration factor for specific aerosol 28 calibration label vi cassette holder removing 49 caution description vii caution and warning symbols vii cellular 56 checkout application 16 connect tab 16 data tab 16 diag...

Page 74: ... analysis 28 gravimetric sampling 29 H heated inlet cable 46 heated inlet sample conditioner 7 heater enclosure 12 humidity 55 I J K inlet 13 inlet conditioner cleaning 40 inlet nozzle 40 instrument calibration user calibration name 27 instrument command set 57 connecting to instrument 57 NIDS communication method 57 instrument not storing new data 54 instrument setup 14 calibration 26 logging con...

Page 75: ...3 output setting 35 P Q parallel gravimetric calibration 60 particle size range 55 parts identification 5 8 PCF calibration 59 photometric calibration factor 28 PM1 0 impactor 8 PM10 and PM2 5 indicative certification 3 PM10 impactor 8 PM10 indicative certification 2 PM2 5 impactor 8 PM2 5 indicative certification 2 power 56 power button 14 power connector pin out 12 power supply 5 8 12 product ov...

Page 76: ... time constant 24 T temperature coefficient 55 test length 24 time between tests 24 time constant 24 55 TrakPro software 13 communicating with instrument 22 configuring logging parameters 22 installation 21 TrakPro software continued program alarm setpoints 36 program analog output 35 quick reference 21 steps 22 troubleshooting 53 tubing detaching 47 U unpacking 5 upper limit 35 USB 56 USB cable 5...

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Page 78: ...ions DustTrak and TrakPro are trademarks of TSI Incorporated TSI Incorporated Visit our website www tsi com for more information USA Tel 1 800 680 1220 UK Tel 44 149 4 459200 France Tel 33 1 41 19 21 99 Germany Tel 49 241 523030 India Tel 91 80 67877200 China Tel 86 10 8219 7688 Singapore Tel 65 6595 6388 P N 6008408 Rev K 2021 TSI Incorporated Printed in U S A ...

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