TSI Instruments DustTrak 8540 Operation And Service Manual
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TSI Instruments DustTrak 8540 Operation And Service Manual

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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

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  • 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 3 Copyright © TSI Incorporated / 2015-2021 / All rights reserved. Address TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA Fax No. (651) 490-3824 Limitation of Warranty and Liability (effective February 2015) (For country-specific terms and conditions outside of the USA, please visit www.tsi.com.) Seller warrants the goods, excluding software sold hereunder, under normal use and service as described in the operator's manual, shall be free from defects in workmanship and material for twenty-four (24) months, or if less, the length of time specified in the...
  • Page 4 GOODS. IN THE CASE OF SOFTWARE, SELLER WILL REPAIR OR REPLACE DEFECTIVE SOFTWARE OR IF UNABLE TO DO SO, WILL REFUND THE PURCHASE PRICE OF THE SOFTWARE. IN NO EVENT SHALL SELLER BE LIABLE FOR LOST PROFITS, BUSINESS INTERRUPTION OR ANY SPECIAL, INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES.

  • Page 5: Table Of Contents

    CONTENTS SAFETY INFORMATION ..............V Laser Safety ..................v Labels ....................vi Description of Caution/Warning Symbols .......... vii Caution ..................vii Warning ..................vii Caution and Warning Symbols ............vii Reusing and Recycling ............... viii CHAPTER 1 PRODUCT OVERVIEW ..........1 DustTrak™...
  • Page 6 Downloading Data ............... 32 Viewing, Graphing and Exporting Data ........33 Local Analog/Alarm Output ..............33 Wiring the Analog Output ............34 Wiring the Alarm ................34 Using TrakPro™ Software to Program the Analog Output ..35 Using TrakPro™ Software to Program Alarm Setpoints ..... 36 CHAPTER 5 MAINTENANCE ............

  • Page 7: Safety Information

    Safety Information Laser Safety • Models 8540 / 8543 / 8540-M / 8542-M / 8543-M DustTrak™ Environmental Monitors are Class I laser-based instruments. • During normal operation, you WILL NOT be exposed to laser radiation. • Precaution should be taken to avoid exposure to hazardous radiation in the form of intense, focused, visible light.

  • Page 8: Labels

    Labels Advisory labels and identification labels are attached to the instrument. 1. Serial Number Label (back) 2. Laser Radiation Label DANGER! (internal) VISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO BEAM WARNING: NO USER SERVICABLE PARTS INSIDE. REFER SERVICING TO QUALIFIED PERSONNEL 3.

  • Page 9: Description Of Caution/Warning Symbols

    Description of Caution/Warning Symbols Appropriate caution/warning statements are used throughout the manual and on the instrument that require you to take cautionary measures when working with the instrument. Caution C A U T I O N Failure to follow the procedures prescribed in this manual might result in irreparable equipment damage.

  • Page 10: Reusing And Recycling

    Reusing and Recycling Incorporated’s effort to have a ® As part of TSI 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.

  • Page 11: Chapter 1 Product Overview

    Chapter 1 Product Overview DustTrak™ Environmental Models 8540, 8540-M, and 8542-M and DustTrak™ DRX Environmental Models 8543 and 8543-M Monitors are data-logging, light-scattering laser photometers that provide real- time mass concentration readings for aerosol contaminants such as dust, smoke, fumes and mist. These instruments use a sheath air system that isolates the aerosol in the optics chamber to keep the optics clean for improved reliability and low maintenance.

  • Page 12: Models 8540-M, 8542-M, And 8543-M Mcerts Certified Monitors

    Models 8540-M, 8542-M, and 8543-M MCERTS Certified Monitors DustTrak™ Environmental Monitor Models 854201-M1, 854001-M1 or 854301-M1, have been designed to meet the UK’s MCERTS (Monitoring Certification Scheme) for indicative instruments. The following must be installed for these models to meet the MCERTS Indicative Certification: 854201-M1: MCERTS PM10 Indicative Certification ❑...

  • Page 13: 854301-M1: Mcerts Pm10 And Pm2.5 Indicative Certification

    854301-M1: MCERTS PM10 and PM2.5 Indicative Certification ❑ 8543-M Photometer ❑ 854038 Environmental Enclosure ❑ 854041 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.
  • Page 14 (This page intentionally left blank) Chapter 1...

  • Page 15: Chapter 2 Unpacking And Parts Identification

    Chapter 2 Unpacking and Parts Identification Carefully unpack the Model 8540 / 8540-M / 8542-M / 8543 / 8543-M DustTrak™ Environmental Monitor from the shipping container. Use the tables and illustrations below to make certain that there are no ® missing components.

  • Page 16: User Replaceable Internal Parts

    Item Part Number Description 6008408 Operation and Service Manual Calibration Certificate User Replaceable Internal Parts Item Part Number Description 854044 Sheath Air Filter 854043 Pump 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: Optional Accessories

    Optional Accessories Item Part Number Description 854038 Environmental Enclosure Netronix™ 801905 Thiamis™ 1000 Communication Node 854040 Omni-directional Inlet w/Water Trap Bottle Heated Inlet 854041 Sample Conditioner Unpacking and Parts Identification...

  • Page 18: Parts Identification For The Dusttrak™ Environmental Models 8540 / 8540-M / 8542-M / 8543 / 8543-M

    Item Part Number Description 854039 Enclosure Power Supply 854042 Water Trap Bottle 854020 Impactor 854021 Impactor 854022 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 Chapter 2...
  • Page 19 Figure 2: Back panel interface control dimensions Figure 3: View of back panel with mounting 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.
  • Page 20 (This page intentionally left blank) Chapter 2...

  • Page 21: Chapter 3 Setting Up

    Chapter 3 Setting Up Environmental Enclosure The DustTrak™ Environmental Monitor is designed to be mounted inside in the environmental ® enclosure. TSI part number 854038 Environmental Enclosure has been designed specifically to protect the DustTrak™ Environmental Monitor and its accessories. See Environmental Enclosure Model 854038 Operation and...

  • Page 22: Supplying Power To The Dusttrak™ Environmental Monitor

    Supplying Power to the DustTrak™ Environmental Monitor One method for supplying power to the instrument is to use the 12V ® power supply (TSI P/N 854052). Fasten the barrel connector to the instrument as shown in Figure 5. This power supply comes with 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.

  • Page 23: Omni-Directional Inlet Column

    Omni-directional Inlet Column Optional accessory 854040 See the Quick Start Guide installing impactors PM (854020), PM (854021), PM (854022) onto the omni-directional inlet for details. Figure 6: Inlet, water trap and base with connection rings Zero Calibration of Instrument The DustTrak™ Environmental Monitor has the ability to automatically “Zero”...

  • Page 24: Instrument Setup And Operation Options

    Instrument Setup and Operation Options Figure 7: Setting up instrument and operating options Press the power button to turn on instrument. The button will turn blue, indicating the instrument has power and is turned on. To turn instrument off, hold the power button for 10 seconds and then release.

  • Page 25: Dusttrak™ Checkout Application

    DustTrak™ Checkout Application • DustTrak™ Checkout Application enables a “virtual screen” for the DustTrak™ monitor. Instrument data, flow calibration, zero calibration, instrument diagnostics, etc., can be viewed or performed through the use of the checkout software. • This software can be used as part of your field installation process to ensure the instrument is functioning properly, when Netronix™...

  • Page 26: Dusttrak™ Checkout Application

    DustTrak™ Checkout Application After installing the application, plug the provided USB cable into the “USB B” port on the instrument and plug the other end into your computer. Power on the instrument and click the Connect button. The USB IP address and instrument information will appear when connected.
  • Page 27 Click on the Flow tab to adjust the pump flow rate. Figure 11: Checkout Application – Flow tab Click the green arrow to start the pump, allowing for a change to the flow setpoint. The flow setpoint is factory set to 3 L/min total flow. 2 L/min of the total flow is measured aerosol flow.
  • Page 28 NO T E – Models 8543, 8543-M The flow rate can be adjusted from approximately 1.5 to 4.0 L/min. This feature allows you to re-adjust the flow rate, if needed, to 3.0 L/min. The flow rate for the DRX models should remain fixed at 3.0 L/min.
  • Page 29 The Diagnostics tab opens a command window that can be used to send instructions to the instrument. Click Send or press the Enter key to send the command to the instrument. See the Communication Settings in Appendix Figure 13: Checkout Application – Diagnostics tab The IP Label tab opens a printer connection box and displays the instrument IP address.
  • Page 30 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 Chapter 3...

  • Page 31: Chapter 4 Trakpro™ Software Quick Reference

    Chapter 4 TrakPro™ Software Quick Reference Connecting to the Computer The TrakPro™ software can be used to preprogram the instrument, download data, view and create raw data and statistical reports, ® create graphs, and combine graphs with data from other TSI instruments that use TrakPro™...

  • Page 32: Trakpro™ Software Steps

    TrakPro™ Software Steps Establishing 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. Chapter 4...
  • Page 33 This will open a dialog allowing for the configuration of the different instrument run modes. The sampling mode options include Survey mode, Manual Mode and Program Logs 1-5. Survey Survey Mode runs a real time, continuous active sample, but does not log data. Manual Manual Log sets the instrument to log data for a specified run time.
  • Page 34 Survey Mode Options Time Constant Time Constant can be set from 1 to 60 seconds. When set to “Yes”, unit will start a Auto Start on Power Up measurement upon being powered on, if the unit was set to “Survey” when it was turned off. When set to “No”, the unit will be in idle when it is powered on.
  • Page 35 Program Log Options Auto Zero Interval between re-zeroing the instrument Interval using the built in autozero 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.

  • Page 36: Setting User Calibration Factors

    Setting User Calibration Factors In most cases, a user calibration factor of 1 for photometric and size cal (DRX only) will be sufficient. Use the following instructions to change the instruments User Cal, if an improved calibration factor is required. Set User Calibration Factor allows you to store and use 10 different calibration factors.
  • Page 37 Click the Set User Calibration Factor 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 Four variables can be set for each user calibration. Name User can input a custom description for the custom User Calibration. Photometric Changes the factory calibration of particle Calibration signal, based on Arizona Road Dust, to actual Factor aerosol being measured. Size Calibration Changes the factory calibration of the Factor...
  • Page 39 calibration factor for a specific aerosol. Using the value of 1.00 will always revert back to the factory calibration. To determine a new calibration factor you need some way of accurately measuring the concentration of aerosol, hereafter referred to as the reference instrument. A gravimetric analysis is often the best choice, though it is limited to nonvolatile aerosols.

  • Page 40: Starting A Dusttrak™ Sample Run

    NO T ES • If you installed a gravimetric filter into the DustTrak™ monitor and are; therefore, using the DustTrak™ monitor to obtain a gravimetric sample, the flow rate used to compute the concentration should be 2 L/min, not 3 L/min since only 2 L/min of aerosol flow reaches the filter.
  • Page 41 Next, establish communication with the instrument Press the Discover Instrument button. Select your desired log mode from the Logging Program drop- down menu. TrakPro™ Software Quick Reference...

  • Page 42: Downloading Data

    Press Start Logging to begin the logging. NO T E If a start date and start time 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™...

  • Page 43: Viewing, Graphing And Exporting Data

    This will allow for the downloading of some or all of the data stored on the insturment. Viewing, Graphing and Exporting Data Read the TrakPro™ software help files for information on how to view, graph and export the DustTrak™ data. Local Analog/Alarm Output The DustTrak™...

  • Page 44: Wiring The Analog Output

    Wiring the Analog Output System specifications: • Output voltage: 0 to 5 VDC. With a maximum output of 15 mA. • Output Current 4 mA to 20 mA with a maximum load impendence of 250 ohms. • Correct polarity must be observed (see pin-outs above). Wiring the Alarm System specifications: •...

  • Page 45: Using Trakpro™ Software To Program The Analog Output

    Using TrakPro™ Software to Program the Analog Output Use TrakPro™ software to configure the Analog output. Select Instrument Setup -> Parameters -> Analog Output… to get to the Analog output dialog. This dialog will allow for the turning on/off and configuring of the analog output.

  • Page 46: Using Trakpro™ Software To Program Alarm Setpoints

    Using TrakPro™ Software to Program Alarm Setpoints Use TrakPro™ software to setup the Alarm Setpoints. Select Instrument Setup -> Parameters -> Alarm Setpoint… to get to the alarm settings dialog. NO T E The Alarm is dependent on the logging interval. For the DustTrak™...
  • Page 47 Alarms can be set of each mass channel for the DRX Models 8543 / 8543-M (PM , PM , Resp, PM and Total). Alarms can only be set for the Total channel for the standard DustTrak™ Models 8540 / 8540-M / 8542-M.
  • Page 48 STEL Alarm STEL stands for Short Term Exposure Limit. When a STEL alarm is selected, the instrument will inspect the data on a second by second basis, independent from the selected logging interval. If the mass exceeds the STEL limit, a STEL event triggers and the following actions will be taken.

  • Page 49: Chapter 5 Maintenance

    Chapter 5 Maintenance The DustTrak™ Environmental Monitor can be maintained in the field using the instructions below. ® recommends the DustTrak™ Environmental Monitor be returned ® to the factory for annual calibration. For a reasonable fee, TSI will quickly clean and calibrate the unit and return it to you in “as new” working condition, along with a Certificate of Calibration.

  • Page 50: Cleaning The Inlet

    Table 1. Recommended Maintenance Schedule Item Frequency Clean the inlet nozzle* 350 hr. at 1 mg/m Replace internal HEPA filter Every 6 months Return to factory for cleaning and calibration Annually Remove and clean the 37-mm blank cassette Monthly (see Replacing Internal 37-mm Sampling Cassette section for futher details)
  • Page 51 NO T E 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. Maintenance...

  • Page 52: Cleaning And Oiling Impactors

    Cleaning and Oiling Impactors Follow the recommended Impactor cleaning interval for size selective Impactors as shown below. These impactors are used with models 8540, 8540-M, and 8542-M DustTrak™ Environmental instruments. Recommended impactor maintenance interval is every two months except where the “average dust concentration” level indicated in the table shows the impactor should be cleaned more frequently: Average dust Impactor...

  • Page 53: Replacing The Internal Sheath Air (Hepa) Filter

    Replacing the Internal Sheath Air (HEPA) Filter ® recommends replacing the internal sheath air filter after every six months of use. 1. Turn the instrument off. 2. Open Instrument Service Panel (Figure 20). 3. Disconnect and remove old sheath air filter from the instrument (Figure 21).
  • Page 54 5. Replace cover and return to service (Figure 23). 6. It is important to reset the instruments filter change date and cumulative filter mass concentration after replacing the Sheath air filter. Resetting the filter concentration may clear the filter error condition shown in the Data tab of DustTrak™...

  • Page 55: Replacing Pump

    A Dialog box will appear confirming that you would like to reset the change date and the cumulative filter concentration. Click Yes to reset the cumulative filter concentration to zero. The Checkout Software will now show zero for the Cum Filter Mass and the current date for the Filter Change Date.
  • Page 56 4. Pull photometer 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 Chapter 5...
  • Page 57 7. Remove the four Phillips head screws from the left- side panel (Figure 27). NO T E Remove only the raised-head screws. DO NOT remove any screws with heads flush to the surface. Figure 27: Remove screws from left side panel 8.

  • Page 58: Replacing Internal 37-Mm Sampling Cassette

    10. Orientate pump inside instrument with muffler (port P) located in the lower position (Figure 30). Figure 30: Pump orientation 11. Secure the new pump inside the instrument case with the four Phillips head screws (Figure 31). 12. Replace photometer service panel and reinstall photometer inside Environmental Enclosure...
  • Page 59 ® does not provide the filter media for gravimetric or analytical sampling. When requesting cassette with filter media for gravimetric sampling, ask for a 37-mm, 2-piece, static conductive plastic cassette to ensure proper fit inside the DustTrak™ monitor. 1. To remove cassette, open instrument service panel to access the sampling cassette.
  • Page 60 3. Inspect top inlet fitting and blue cassette holder for broken pieces or missing seals (Figure 34). 4. Install a blank cassette for DustTrak™ monitor operation or a pre- weighed, 37-mm, 2-piece, conductive Figure 34: Inspect top inlet fitting and cassette with the blue cassette holder appropriate filter media...

  • Page 61: Return Shipping To Tsi ® Incorporated

    ® Return Shipping to TSI Incorporated Visit our website at tsi.com/service to initiate a Service Request form: • Disconnect and remove all accessories. Only the photometer can be serviced. • The model number can be found on the label on the back of the instrument.
  • Page 62 (This page intentionally left blank) Chapter 5...

  • Page 63: Chapter 6 Troubleshooting

    Chapter 6 Troubleshooting The table below lists the symptoms, possible causes, and recommended solutions for common problems encountered with the DustTrak™ monitor. Symptom Possible Cause Corrective Action Erratic reading. Leak Check connections for leaks Dirty inlet port and/or Clean inlet port. Clean or sample tube replace tubing Internal filter(s) not...
  • Page 64 Symptom Possible Cause Corrective Action Instrument does Memory is full Delete or transfer historic not store new data data Instrument is in The instrument does not Survey mode store data in survey mode. Can to manual or program log mode Flow Error is Flow obstruction Remove obstruction if still...

  • Page 65: Appendix A Specifications

    Appendix A Specifications Specifications are subject to change without notice. 8540 / 8540-M / 8542-M / 8543 / 8543-M DustTrak™ Environmental Monitors are designed to operate inside a weather-proof enclosure, ® like TSI Model 854038 Environmental Enclosure, sold separately. Sensor Type ... 90°...
  • Page 66 Physical Size (HWD) ..... 8.25 x 8.25 x 4.25 in. (20.96 x 20.96 x 10.80 cm) Weight ....5.25 lbs (2.38 kg) ® Communications ... Cellular, Wi-Fi , GPS/GPRS, USB (Host and Device) and Ethernet. Power ...... 12/24 Volts DC 50 Watts Analog Out .....

  • Page 67: Appendix Binstrument Command Set

    Appendix B Instrument Command Set See the DustTrak™ Communication Manual for instrument command instructions for communicating with wireless 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.
  • Page 68 (This page intentionally left blank) Appendix B...

  • Page 69: Appendix Cdrx Advanced Calibration

    Appendix C DRX Advanced Calibration The advanced calibration method is employed to yield high size segregated mass concentration accuracy for PM , PM Respirable, and PM size fractions. It involves two gravimetric measurements to obtain PCF and SCF. The two gravimetric measurements can be done in sequence or in parallel, depending on the gravimetric sampling device availability.

  • Page 70: Option 2: Parallel Gravimetric Calibration

    • Co-locate and run the gravimetric sample and DustTrak™ DRX monitor simultaneously to collect enough mass on the gravimetric filter. • Calculate the PM mass concentration (PM ) from the 10_Grav gravimetric filter based on the net mass collected on the filter, sampling time, flow rate, and total liters of air sampled.
  • Page 71 6. Update the new SCF and PCF in the user calibration settings. Figure 36: Experimental Setup for (a) Serial and (b) Parallel Gravimetric Calibration DRX Advanced Calibration...
  • Page 72 (This page intentionally left blank) Appendix C...

  • Page 73: Index

    Index battery power, 12 bubble buret, 17 4-pin miniDIN connector, 33 cable advanced calibration, 59 detaching, 47 advisory labels, vi cable wiring diagram, 33 alarm calibration certificate, 6 alarm setpoint, 37 calibration factor audible, 37 for specific aerosol, 28 logging interval, 36 calibration label, vi relay, 37 cassette holder...
  • Page 74 determining calibration factor for I-J-K specific aerosol, 28 inlet, 13 diagnositcs tab, 19 inlet conditioner diagnostics tab, 19 cleaning, 40 discover instrument, 31 inlet nozzle, 40 dry piston, 17 instrument calibration DustTrak checkout software, 14 user calibration name, 27 DustTrak DRX Environmental instrument command set, 57 Monitor, 5 connecting to instrument, 57...
  • Page 75 maximum current, 34 parts identification, 5, 8 maximum voltage, 34 PCF calibration, 59 MCERTS certification photometric calibration factor, 28 854001-M1, 2 impactor, 8 854201-M1, 2 PM10 and PM2.5 indicative 854301-M1, 3 certification, 3 MCERTS certification label, vi impactor, 8 Model 8540, 1, 5 PM10 indicative certification, 2 alarm, 37 impactor, 8...
  • Page 76 SCF calibration, 59 TrakPro software (continued) securing pump, 48 program alarm setpoints, 36 sensor type, 55 program analog output, 35 serial gravimetric calibration, 59 quick reference, 21 serial number label, vi steps, 22 service policy, ii troubleshooting, 53 set user calibration factor, 27 tubing setting up, 11 detaching, 47...
  • Page 78 _______________ TSI and TSI logo are registered trademarks of TSI Incorporated in the United States and may be protected under other country’s trademark registrations. DustTrak and TrakPro are trademarks of TSI Incorporated. TSI Incorporated – Visit our website www.tsi.com for more information. Tel: +1 800 680 1220 India Tel: +91 80 67877200...

This manual is also suitable for:

Dusttrak 8543Dusttrak 8540-mDusttrak 8542-mDusttrak 8543-m

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