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Thermo Scientific 3600 PDM Manual

Thermo Scientific 3600 PDM Manual

Personal dust monitor
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Model 3600 PDM
Personal Dust Monitor
Part Number 42-009904
8Oct2013

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  • Page 1 Model 3600 PDM Personal Dust Monitor Part Number 42-009904 8Oct2013...
  • Page 2 © 2008 Thermo Fisher Scientific. All rights reserved. Specifications, terms and pricing are subject to change. Not all products are available in all countries. Please consult your local sales representative for details. ® TEOM is a registered trademark of Thermo Fisher Scientific. Other trademarks are the property of their respective holders.
  • Page 3 Warranty Seller warrants that the Products will operate or perform substantially in conformance with Seller's published specifications and be free from defects in material and workmanship, when subjected to normal, proper and intended usage by properly trained personnel, for the period of time set forth in the product documentation, published specifications or package inserts.
  • Page 4 covered by the warranty hereunder, Buyer shall pay or reimburse Seller for all costs of investigating and responding to such request at Seller's then prevailing time and materials rates. If Seller provides repair services or replacement parts that are not covered by the warranty provided in this warranty, Buyer shall pay Seller therefor at Seller's then prevailing time and materials rates.
  • Page 5 WEEE Compliance This product is required to comply with the European Union’s Waste Electrical & Electronic Equipment (WEEE) Directive 2002/96/EC. It is marked with the following symbol: Thermo Fisher Scientific has contracted with one or more recycling/disposal companies in each EU Member State, and this product should be disposed of or recycled through them.
  • Page 6 There are several safety hazards that the general operator and service technician must be aware of when operating and servicing the TEOM 3600 PDM. The hazards include: burn hazards, moving parts and pinch hazards, and voltage hazards. The seller cannot foresee all possible modes of operation in which the user may attempt to utilize this instrumentation.
  • Page 7 Electrical Safety and Conformity Safety and Equipment Damage Alerts Electrical Safety and Conformity Charger Thermo Fisher Scientific certifies that the charger for the PDM 3600 complies with all safety requirements as described below: ANSI/UL 1012 Standard for Power Units Other Than Class 2’ 7 edition 04/29/05 Product Model...
  • Page 8 Electrical Safety and Conformity Safety and Equipment Damage Alerts Sub-Test Test Parameter Voltage Dips and Dropouts EN 61000-4-11:2004 -100% for 0.5 cycles -100% for 1 cycle -30% for 25 cycles -100% for 250 cycles PDM 3600 Instruction Manual Thermo Fisher Scientific...
  • Page 9 Equipment Rating Safety and Equipment Damage Alerts Equipment Rating The following information can be used to determine the power service requirements of this product: Line Voltage 120 V ~ 60 Hz 20 Amp 240 V ~ 50 Hz 10 Amp Charger Fuse Part Number Current Rating...
  • Page 10 Misusing or mishandling the battery packs can lead to ▲ fluid leakage, heat generation, fire or an explosion WARNING Do not operate the TEOM 3600 PDM if its case is damaged or otherwise compromised. ▲ WARNING Whenever the PDM case is opened for maintenance, you must perform a case leak check after reassembling the case.
  • Page 11 About This Manual Safety and Equipment Damage Alerts Alert Description DO NOT use acetone to clean any parts of the PDM. ▲ Equipment Damage Equipment Damage When moving the battery pack to access the wire connections, be sure to minimize stress on the wires and connectors.
  • Page 12 NIOSH Certification Label Safety and Equipment Damage Alerts NIOSH Certification Label This label is affixed to the back of the instrument. Only the parts listed should be used in order to maintain certifications. viii PDM 3600 Instruction Manual Thermo Fisher Scientific...

  • Page 13: Table Of Contents

    Contents Chapter 1 Introduction......................1-1 Advanced Features ................1-4 Organization of Manual ..............1-5 Operating Parameters................1-6 Battery Safety ..................1-7 Safety Test Criteria................1-7 Battery Warnings ................1-7 Chapter 2 Basic Operation ....................2-1 Basic Components ................2-2 Operational Requirements ............... 2-2 Connecting to The Charger ..............
  • Page 14 Contents Viewing Errors After A Sample Run..........2-23 Status Codes..................2-23 Errors When Sampling..............2-24 Status Codes (Errors) List............... 2-24 Downloading Data................2-25 Chapter 3 Using the WinPDM Software................3-1 Installing WinPDM ................3-1 Starting WinPDM ................3-3 Exiting the WinPDM Software Application ........3-5 Starting a Programmed Sample Run ...........
  • Page 15 Contents Repairing/Rebuilding the Cap Lamp..........5-36 Performing a Flow Calibration ............5-38 Chapter 6 Troubleshooting ....................6-1 Start Up Diagnostics ................6-1 Instrument Diagnostics ............... 6-2 Leak Testing..................6-4 Sample Path – Instrument Plumbing ..........6-4 Case – Battery Compartment ............6-6 Appendix A Parts and Consumables ..................

  • Page 17: Chapter 1 Introduction

    Thermo Fisher Scientific, incorporates a real-time particulate monitor that measures respirable coal dust mass concentration, shift exposure, and accumulated exposure in real time. The TEOM 3600 PDM (Figure 1–1) has a cap-lamp assembly, power takeoff (PTO) connector and two battery packs.
  • Page 18 The high contrast display provides basic data and statistics for the system, including status conditions. An additional PC-based user interface is provided through Thermo Scientific’s WinPDM communication software. The TEOM 3600 PDM is powered by two internal lithium-ion battery assemblies. See Table 1–1 Table 1–2...
  • Page 19 Introduction Advanced Features The PDM battery charger (Figure 1–2) is a separate unit that connects to the PDM and provides a charging station as well as communication functions. A separate external power cord and communication/charge cable must be installed to operate the charger (Chapter 2). Figure 1–2.

  • Page 20: Advanced Features

    Introduction Advanced Features Advanced The TEOM 3600 PDM offers a number of features to provide superior data quality, ease of use, and flexibility for the user. The following is a Features partial list of the instrument’s advanced features: 30-minute mass concentration measurement in the range of 0.1 to 10 ●...

  • Page 21: Organization Of Manual

    Manual explain the advanced features of the TEOM 3600 PDM. Users should read and understand earlier sections before attempting procedures described later in the manual. The following list provides an overview of the topics handled in each section of this manual: Chapter 1 “Introduction”...

  • Page 22: Operating Parameters

    The air stream then exits the system. The TEOM 3600 PDM maintains a constant volumetric flow rate, and reports sampled volumes (m3) in volumetric terms (based on the ambient temperature as measured near the cyclone).

  • Page 23: Battery Safety

    Pump Mass Transducer Figure 1–3. TEOM 3600 flow path Battery Safety The TEOM 3600 PDM is powered by two internal lithium-ion battery pack assemblies. The batteries can be charged daily through the communication/charge cable and charging unit (Figure 1–2). Be sure to charge the PDM unit in a fresh-air environment.
  • Page 24 ● preferable, contact Thermo Fisher Scientific for further information). Do not dispose of the battery packs in fire or heat. WARNING Do not operate the TEOM 3600 PDM if its case is damaged or otherwise compromised. ▲ PDM 3600 Instruction Manual...

  • Page 25: Chapter 2 Basic Operation

    6 hours before performing the first sample run. Charging must be completed in a fresh air environment. TEOM filter Figure 2–1. TEOM 3600 PDM mass transducer with filter Thermo Fisher Scientific PDM 3600 Instruction Manual...

  • Page 26: Basic Components

    Basic Operation Basic Components Basic The TEOM 3600 PDM unit has a cap lamp, power takeoff (PTO) connector, and two battery packs. The basic TEOM 3600 PDM package is Components shipped with the following components: PDM unit with cap lamp...

  • Page 27: Connecting To The Charger

    Basic Operation Connecting to The Charger Connecting to The charger base functions as both a battery charger and a communications station. To fully charge the internal lithium-ion batteries, allow the PDM The Charger unit to remain connected to the charger for approximately 6 hours before performing the first sample run.
  • Page 28 Basic Operation Connecting to The Charger 3. Set the alignment post into the hole in the back of the PDM. Turn the handle to tighten the connection screw into the connector (Figure 2–4 Figure 2–5). Figure 2–4. Setting the charger connector onto the unit Figure 2–5.
  • Page 29 Basic Operation Connecting to The Charger 6. If the charger and the PDM are both functioning correctly, the LEDs on the front of the charger will indicate the status of the unit (Figure 2– a) Solid grey (or off): Indicates that the PDM is not properly connected to the charger, or the charger power is off.

  • Page 30: Removing A Teom Filter

    Basic Operation Removing a TEOM Filter Removing a The PDM unit is shipped with a Tapered Element Oscillating Microbalance (TEOM) filter installed on the tapered element (TE), but the TEOM Filter filter must be changed after each shift. 1. Locate the TE handle on the left side of the PDM and slide the handle all the way to the right to unlock the mass transducer and then pull the mass transducer out of the unit (Figure 2–7...
  • Page 31 Basic Operation Removing a TEOM Filter 2. Carefully insert the lower fork of the filter exchange tool under the TEOM filter that is in the mass transducer so that the filter disk is between the lower fork and the upper tab of the filter exchange tool. The tines of the lower fork should straddle the hub of the filter base (Figure 2–9 Figure...

  • Page 32: Installing A Teom Filter

    Basic Operation Installing a TEOM Filter Installing a The PDM unit is shipped with a Tapered Element Oscillating Microbalance (TEOM) filter installed on the tapered element (TE), but the TEOM Filter filter must be changed daily (or with each shift). 1.

  • Page 33: Pdm Display

    PDM display will stay on continuously. The display on the top panel (Figure 2–17) of the TEOM 3600 PDM allows for easy navigation through the instrument’s firmware screens by pressing the “A” or “WAKE UP” button and the “B” or “SCROLL”...
  • Page 34 Basic Operation PDM Display Figure 2–17. PDM display 2-10 PDM 3600 Instruction Manual Thermo Fisher Scientific...
  • Page 35 Basic Operation PDM Display Idle screen Start Sampling Exit screen screen Start Sample Exit screen screen Stop Sampling Warming screen screen Stop Sampling Reset Sample 2 First Sample screen screen Screen #1 View Errors First Sample screen Screen #2 Error First Sample screen Screen #3...

  • Page 36: Idle Screen

    Basic Operation Idle Screen Idle Screen When the PDM is turned on and not sampling, the unit will briefly display the Thermo Fisher Scientific Splash screen (Figure 2–19) followed by the Idle screen. Press the “A” (WAKE UP) button (Figure 2–17) located on the top panel of the PDM unit, the Idle screen (Figure...

  • Page 37: Start Sampling Screen

    Basic Operation Start Sampling Screen All screen displays and functions described in this chapter apply to both types of sample runs, except that a programmed sample run cannot be stopped from the instrument keypad. Start Sampling While the WinPDM program (Chapter 3) allows users to access advanced features of the unit, including programmed sample runs, the user can Screen initiate a manual sample run using the instrument’s display and buttons.

  • Page 38: Start Sample Screen

    Basic Operation Start Sample Screen (B) more options... This field contains directions on how to display the Start Sampling screen, Hours Used, or the View Errors screen. Refer to the appropriate section for more information on these screens. Start Sample The user can initiate a manual sample run through the Start Sample screen.

  • Page 39: Starting A Second Sample Run

    Basic Operation Starting a Manual Sample Figure 2–24. Warming screen Figure 2–25. First Sample Screen #1 Starting a Second While sampling, a second sample may be started, for example if the conditions change or the employees moves to a different area, a second Sample Run manual sample run can be started running concurrently with the first sample run.

  • Page 40: Dynamic Warm Up

    Basic Operation Dynamic Warm Up (“Sample 2”). This screen will display immediately after the start of a second manual sample run. Figure 2–27. Second Sample screen The Second Sample Screen #1 contains the following information: 15 MIN. This field contains the averaged mass concentration value ●...

  • Page 41: Stopping A Sample Run

    Basic Operation Stopping a Sample Run Idle screen Start Sampling Exit screen screen Start Sample Exit screen screen Stop Sampling Warming screen screen Stop Sampling Reset Sample 2 First Sample screen screen Screen #1 View Errors Second Sample screen Screen #1 Error First Sample screen...

  • Page 42: Stopping During Warm Up

    Basic Operation Stopping a Sample Run (B) more options... This field contains directions on how to display the ● various operating screen. When in the Stop Sampling screen, press the “B” button to display either the Exit screen, View Errors screen, or the Reset Sample 2 screen, depending on the screen from which you have accessed the Stop Sampling screen.
  • Page 43 Basic Operation Sample Run Screens Sample Run The TEOM 3600 PDM displays several screens during a sample run. Information includes cumulative exposure and other data, as well as Screens whether the instrument is operating properly (refer to the “System Status”...

  • Page 44: First Sample - Screen #2

    Basic Operation Sample Run Screens 30 MIN CONC. This field contains the mass concentration value (mg) ● averaged during the previous 30-minute period. CUM1 CONC. This field contains the cumulative mass concentration ● value (mg/m ) measured from the beginning of the first primary sample run.

  • Page 45: First Sample - Screen #4

    Refer to “Starting a Second Sample Run” earlier in this chapter for more information on the Second Sample screen. Sample Complete The TEOM 3600 PDM displays several screens following a sample run. Information includes cumulative exposure and other data, as well as any Screens errors logged during the sample run(s).

  • Page 46: Status Conditions

    PDM will turn off its LED display. Press the “A” button to reactivate the LED display. Status The TEOM 3600 PDM monitors its performance during a sample run and registers any status conditions (errors) logged during the sample run(s). The Conditions unit displays a blinking “E”...

  • Page 47: Viewing Errors During A Sample Run

    Basic Operation Status Codes The View Errors screen contains the following information: (A) View Errors. This field contains directions on how to display any ● errors that may have occurred during the primary sample run. Press A to view system errors/status codes. (B) more options...

  • Page 48: Errors When Sampling

    Basic Operation Status Codes Figure 2–38. Errors screen If the PDM unit has encountered more than one status condition, pressing the “B” button repeatedly allows viewing of all the error conditions that occurred during the primary sample run. The current screen number and number of screens is displayed in the lower right corner.

  • Page 49: Downloading Data

    Basic Operation Downloading Data The TEOM 3600 PDM status codes (“error conditions”) are as follows: TE not detected. This error is reported when the PDM unit senses that ● the mass transducer has been removed from the unit. High filter load. This error is reported when the PDM unit senses that ●...
  • Page 50 Basic Operation Downloading Data 3. When in the Download Data screen, select the sampling event that you want to download. 4. Select the “Download” button. If you have selected the “Auto” downloading function, the Download Data screen may display a “downloading progress bar”...
  • Page 51 Basic Operation Downloading Data Note The WinPDM software automatically names the saved data file with the PDM unit's serial number (“0104”) and the date of the sample run (“08-13-08”). ▲ Note If two samples are run in a 24-hour period, both files will have the same name.

  • Page 53: Chapter 3 Using The Winpdm Software

    WinPDM will not communicate with PDM 3600 firmware versions 7.1 and higher. 1. Exit all Windows programs currently running on your PC. To install WinPDM onto a PC: 2. Place the TEOM 3600 PDM software CD-ROM in the CD-ROM drive. Thermo Fisher Scientific PDM 3600 Instruction Manual...
  • Page 54 Using the WinPDM Software Installing WinPDM 3. Open the “Software” folder on the TEOM 3600 PDM software CD- ROM, then open the “WinPDM Setup.exe” file located in the Software folder. 4. The InstallShield Wizard screen (Figure 3–1) will post several temporary installation messages while WinPDM prepares the installation program.

  • Page 55: Starting Winpdm

    Starting WinPDM The TEOM 3600 PDM must be connected to the charger and a PC to use the WinPDM program. Refer to Chapter 2 for information on connecting the PDM unit to the charger and establishing communications.
  • Page 56 Using the WinPDM Software Starting WinPDM Note You also can display the PDM-New Connection screen by selecting File > Connect from the drop-down menu, or by selecting the new connection icon in the top, left-hand corner of the toolbar. ▲ 5.

  • Page 57: Exiting The Winpdm Software Application

    Using the WinPDM Software Starting WinPDM Figure 3–4. WinPDM showing "Not Connected" Note If the cable connections are secure, and the PDM is functioning correctly, but you still cannot make a successful connection between the PDM and PC, contact Thermo Fisher Scientific.▲ Exiting the WinPDM When the programming is complete, users can disconnect the PDM and exit the WinPDM software.

  • Page 58: Starting A Programmed Sample Run

    Using the WinPDM Software Starting a Programmed Sample Run Starting a You must use the WinPDM communications software to start and stop a programmed sample run. When you use the WinPDM communications Programmed software application to set up a programmed sample run, you can not stop Sample Run or change the sample run duration by pressing the “A”...
  • Page 59 Using the WinPDM Software Starting a Programmed Sample Run screen will display. Refer to Configuring a Program Shift later in this chapter for more information on correcting programming errors. Figure 3–6. Programmed You can now exit from the WinPDM software application and disconnect the PDM unit from its charger.
  • Page 60 Using the WinPDM Software Starting a Programmed Sample Run Figure 3–7. Warming Figure 3–8. Running PDM 3600 Instruction Manual Thermo Fisher Scientific...

  • Page 61: Stopping A Programmed Run

    Using the WinPDM Software Stopping a Programmed Run When the sample run has completed, the WinPDM PDM - COM1 screen will display a “STOP” message on the screen. The PDM unit will display the appropriate completed sample screens (Chapter 2) until you download the data from the PDM unit, or until you start another primary or programmed sample run.

  • Page 62: Pdm Display

    Using the WinPDM Software PDM Display PDM Display The display on the top panel of the TEOM 3600 PDM allows users to navigate through the instrument’s firmware screens by pressing the “A” and During Programmed “B” buttons. But when the WinPDM communications software is used to...

  • Page 63: Configuring A Program Shift

    Using the WinPDM Software Configuring a Program Shift Figure 3–11. Reset Sample 2 screen 2. In the Reset Sample 2 screen, press the “A” button to begin a second primary sample run. The second primary sample run will begin immediately after pressing the “A” button. The PDM unit will not perform another 35-minute warmup period before beginning the second primary sample run, and the Second Sample screen will display.
  • Page 64 Using the WinPDM Software Configuring a Program Shift All shift setup fields must have an entry (Figure 3–13). For example, N/A can be used if a field is not required. Figure 3–13. Field Entry Error screen The instrument stores the field information from the last programmed shift.
  • Page 65 Using the WinPDM Software Configuring a Program Shift The Program Shift screen contains the following information: 1. Wearer ID. This field contains the identification number (8 digits) ● of the person who is wearing the PDM unit. 2. Mine ID. This field contains the identification number of the mine ●...

  • Page 66: Setting Up Programmed Sample Parameters

    Mining Research Establishment (MRE) of the National Coal Board, England or its equivalent. Setting Up Users can set up the TEOM 3600 PDM’s sample run parameters, including identifying the mine information and setting up the sample start Programmed time, duration and type.
  • Page 67 Using the WinPDM Software Setting Up Programmed Sample Parameters Figure 3–15. Selecting sample type 6. Enter the 4-digit mechanized mining unit (MMU) identification code and the 4-digit designated area/designated work position (DA/SA) for the MMU that will be using the PDM unit, if necessary, in the box under “10.

  • Page 68: Program Shift Setup Problems

    Using the WinPDM Software Program Shift Setup Problems the screen will light up (refer to Starting a Programmed Sample Run earlier in this chapter for more information). If you have not correctly set up the sampling parameters, a Warning/Confirmation screen will display.

  • Page 69: Correcting Shift Setup Problems

    Using the WinPDM Software Correcting Shift Setup Problems Figure 3–18. Ambient Temperature Warning screen Correcting Shift The automatic warning screens force the user to correct the time or temperature errors before proceeding with the programming and sample Setup Problems run. 1.

  • Page 71: Chapter 4 Viewing And Saving Data

    Chapter 4 Viewing and Saving Data This chapter describes how to configure the data downloading process, download data from the TEOM 3600 PDM, and how to view those data files using the buttons in the PDM-COM1 screen (Figure 4–1). When running a primary sample run, the PDM unit will log data points based on a pre-programmed logging template.

  • Page 72: Configuring Data Downloading

    Viewing and Saving Data Configuring Data Downloading Configuring Data The Download Data screen allows users to choose which sample data will be downloaded, and then download the data from this screen. When in the Downloading PDM - COM1 screen, select the “Download Sample” button to display the Download Data screen (Figure 4–2).

  • Page 73: Downloading Data

    Viewing and Saving Data Downloading Data Downloading Data User can view, download and store several different types of information at the end of a primary or programmed sample run. 1. Following a primary or programmed sample run, connect the PDM To download data from the PDM unit: unit to its charger and the charger to the PC.
  • Page 74 Viewing and Saving Data Downloading Data Figure 4–4. Download Data screen with progress bar 5. If the PDM unit encountered any status conditions (“errors”) during the sample run, the “Error List” screen will display (Figure 4–5). Figure 4–5. Errors screen PDM 3600 Instruction Manual Thermo Fisher Scientific...
  • Page 75 Viewing and Saving Data Downloading Data 6. If the error screen displays, select the “Save As” button. The “Save As” screen will display. Accept the data file name that the software provides for the data file or you can change the data file name, if necessary. Select the “Save”...
  • Page 76 Viewing and Saving Data Downloading Data 10. Select the “Print” button to print a paper record of the sample run. This hard-copy record will display the data entered when the sample run was first programmed and the data results that were recorded. Figure 4–7.

  • Page 77: Download Graph Screen

    Viewing and Saving Data Download Graph Screen Select the “Save” button. The “Save As” screen will display. Accept the data file name that the software provides for the data file or you can change the data file name, if necessary. Select the “Save” button. Note The WinPDM software automatically names the saved data file with the PDM unit's serial number (“0104”) and the date of the sample run (“08-13-08”).

  • Page 78: Dust Data Card Screen

    Viewing and Saving Data Dust Data Card Screen When in the Download Graph screen, you can select the data parameter you want to view from a drop-down menu. When in the Downloaded Logging Parameters drop-down menu, select the downloaded logging parameter that you want to display on the graph (Figure 4-9).

  • Page 79: Viewing Data Files

    Viewing and Saving Data Viewing Data Files Viewing Data After you have downloaded the data file (and error file, if necessary), you can view the data file by using a spreadsheet program such as Microsoft Files Excel. The data file format is a comma-separated value (“.csv”) text file format. The WinPDM software application allows the data files to be stored where needed by browsing to the desired folder.

  • Page 80: Viewing An Error File

    Viewing and Saving Data Viewing an Error File Program shift information Header/footer information Data values of logging parameters Figure 4–11. Excel file with downloaded data Viewing an Locate the error file that was downloaded in the WinPDM folder. The error file format is a comma-separated value (“.csv”) text file format. Error File Using a spreadsheet program (such as Microsoft Excel), open the error file (Figure...

  • Page 81: Viewing Status Codes

    Viewing and Saving Data Viewing Status Codes Figure 4–12. Error file Viewing Status Locate the error file that was downloaded in the WinPDM folder. The error file format is a comma-separated value (“.csv”) text file format. Codes Using a spreadsheet program (such as Microsoft Excel), open the data file (Figure 4–13).
  • Page 82 Viewing and Saving Data Viewing Status Codes Figure 4–13. Data file with status codes 4-12 PDM 3600 Instruction Manual Thermo Fisher Scientific...

  • Page 83: Chapter 5 Maintenance And Calibration

    Maintenance and Calibration This section describes the procedures involved in verifying the calibration of the TEOM 3600 PDM Monitor and maintaining the consistent operation of the hardware. In addition to regularly scheduled maintenance, the unit may require other maintenance as necessary, including replacing the batteries, changing the cap lamp or other procedures.

  • Page 84: Removing The Mass Transducer

    Maintenance and Calibration Removing the Mass Transducer Removing the Several maintenance procedure, including changing the filter, cleaning the grit pot and cleaning the sample lines, require the mass transducer to be Mass Transducer removed from the unit. 1. Locate the TE handle on the left side of the PDM and slide it all the To remove the mass transducer: way to the right to unlock the mass transducer...

  • Page 85: Cleaning The Grit Pot

    Maintenance and Calibration Cleaning the Grit Pot 3. When ready, reinstall the mass transducer into the PDM by aligning the flat side of the transducer toward the center of the PDM and pushing it in until it seats firmly in place (Figure 5–3 Figure 5–4).
  • Page 86 Maintenance and Calibration Cleaning the Grit Pot 1. Remove the mass transducer. To clean the grit pot 2. Locate the grit pot on the right-hand side of the PDM unit (Figure 5– Figure 5–5. Remove the grit pot retaining ring 3.

  • Page 87: Cleaning The Mass Transducer And Sample Lines

    Maintenance and Calibration Cleaning the Mass Transducer and Sample Lines 5. Direct a burst of canned air into the plastic nozzle to clean the inside of the nozzle. Use an alcohol swab to clean the inside and outside surfaces of the plastic nozzle (Figure 5–7). Figure 5–7.
  • Page 88 Maintenance and Calibration Cleaning the Mass Transducer and Sample Lines 1. Disconnect the sample line from the cap lamp (Figure 5–8). To clean the mass transducer and sample lines: Disconnect Here Figure 5–8. Disconnect the sample line 2. Remove the mass transducer from the PDM unit and remove the TEOM filter from the mass transducer.
  • Page 89 Maintenance and Calibration Cleaning the Mass Transducer and Sample Lines Do Not blow air into this hole, It will damage the pressure sensors. Direct air here. Figure 5–9. Clean the bell-shaped inlet with a swab and air Figure 5–10. Clean the bell-shaped inlet with air Thermo Fisher Scientific PDM 3600 Instruction Manual...
  • Page 90 Maintenance and Calibration Cleaning the Mass Transducer and Sample Lines 5. Direct a stream of air through the end of the sample line removed from the cap lamp and through the sample nozzle on the cap lamp (Figure 5–11 Figure 5–12).

  • Page 91: Performing A Flow Audit

    Maintenance and Calibration Performing a Flow Audit 6. Install a new TEOM filter onto the mass transducer and install the mass transducer into the PDM unit. 7. Install the sample line onto the cap lamp. Performing a Users should perform a flow audit on the unit once per month, or as necessary.
  • Page 92 Maintenance and Calibration Performing a Flow Audit Figure 5–14. Installing the flow/audit/tubing adapter 3. Connect the PDM unit to the charger and make sure the charger is connected to your PC. 4. Open the WinPDM software and connect to the instrument. 5.

  • Page 93: Cleaning The Cyclone And Inlet Tubing

    Maintenance and Calibration Cleaning the Cyclone and Inlet Tubing Cleaning the The cyclone and inlet tubing should be cleaned once per month, or as necessary. Tool/materials needed for this procedure: Cyclone and Canned air ● Inlet Tubing Alcohol swab ● Small flat-head screwdriver ●...
  • Page 94 Maintenance and Calibration Cleaning the Cyclone and Inlet Tubing 5. Remove the top cyclone plate (Figure 5–17) from the cyclone inlet assembly (Figure 5–18). Clean the cyclone inlet with an alcohol swab then direct a stream of air into the inlet. Figure 5–17.
  • Page 95 Maintenance and Calibration Cleaning the Cyclone and Inlet Tubing 6. Locate the red cyclone inlet assembly plate gasket (between the top cyclone plate and the cyclone inlet assembly). 7. Check the cyclone inlet assembly plate gasket for signs of wear or damage, and replace the gasket, if necessary (Seal Replacement Kit: 59- 009961).
  • Page 96 Maintenance and Calibration Cleaning the Cyclone and Inlet Tubing 10. Check the inlet tubing gasket for signs of wear or damage, and replace the gasket, if necessary (Seal Replacement Kit: 59-009961). Using canned air, direct a stream of air up through the inlet tubing (Figure 5–...

  • Page 97: Auditing The K0 Number

    Maintenance and Calibration Auditing the K0 Number Auditing the K0 Once a year, the calibration constant (K0 number) of the unit should be audited. Tool/materials needed for this procedure: Number K0 audit kit (59-010020) ● Alcohol swab ● Small flat-head screwdriver ●...
  • Page 98 Maintenance and Calibration Auditing the K0 Number Figure 5–23. Prompt to add weight 5. The computer will prompt to add four more weights. Add each weight consecutively as shown in (Figure 5–24). Figure 5–24. Add filters 6. After the final weight has been added, a % error will be displayed (Figure 5–25).

  • Page 99: Auditing The Tilt Sensor

    Maintenance and Calibration Auditing the Tilt Sensor Figure 5–25. K0 audit passed prompt The tilt sensor should be audited once a year. ● Auditing the Tilt Sensor 1. Connect the PDM unit to its charger and start the WinPDM software. To perform a tilt sensor audit: 2.
  • Page 100 Maintenance and Calibration Auditing the Tilt Sensor Figure 5–26. Tilt Audit screen 3. The instrument could take up to 45 minutes to stabilize the TE frequency. 4. When stable, the computer will prompt to position the instrument upright as shown in Figure 5–27.
  • Page 101 Maintenance and Calibration Auditing the Tilt Sensor 5. When prompted, position the instrument on the right side (mass transducer) as shown in Figure 5–28. Figure 5–28. Position the instrument on the right side 6. When prompted, position the instrument on its battery connector as shown in Figure 5–29.

  • Page 102: Periodic Maintenance

    Lubricating the mass transducer O-rings ● Performing a flow calibration. ● WARNING Do not operate the TEOM 3600 PDM if its case is damaged or otherwise compromised. ▲ CAUTION TEOM 3600 PDM maintenance should only be performed by trained, authorized personnel.
  • Page 103 Maintenance and Calibration Opening the PDM Case WARNING Whenever the PDM case is opened for maintenance, you must perform a case leak check after reassembling the case. ▲ 1. Remove the mass transducer from the PDM unit and place it on a flat To open the PDM case: surface so that the front is accessible.

  • Page 104: Installing The Pdm Cover Panel

    Maintenance and Calibration Installing the PDM Cover Panel Figure 5–33. PDM with cover panel removed Installing the The front panel of the PDM may have to be removed to perform certain maintenance tasks (Figure 5–33). PDM Cover Panel WARNING Whenever the PDM case is opened for maintenance, you must perform a case leak check after reassembling the case.
  • Page 105 Maintenance and Calibration Installing the PDM Cover Panel Figure 5–34. Cover gasket checkpoints 4. Install the screws in locations 1 and 2 until seated (Figure 5–35). Press down on back of cover, aligning holes 3 and 4. Put a screw into either location 3 or 4 and tighten lightly.

  • Page 106: Performing Sample Path And Case Leak Checks

    Maintenance and Calibration Performing Sample Path and Case Leak Checks Performing Sample Periodically, or if the front cover has been removed for maintenance, perform a case leak check on the PDM unit. Tool/materials needed for this Path and Case procedure include the case leak check suction cup and sample line plug. Leak Checks WARNING Whenever the PDM case is opened for maintenance, you must perform a case leak check after reassembling the case.
  • Page 107 Maintenance and Calibration Performing Sample Path and Case Leak Checks 4. A sample path leak check must be performed before a case leak check can be performed. Select the Leak Check Sample Path Routine and follow the instructions on the screen. Remove the sample line from the inlet adapter and plug using the insert inlet plug (Figure 5–37).
  • Page 108 Maintenance and Calibration Performing Sample Path and Case Leak Checks Figure 5–39. Battery compartment vent Figure 5–40. Leak check suction cup installed on battery vent 7. The Calibrate/Audit screen will display with a “Performing case check” message. The PDM unit will perform the case leak check and display a pass or fail message on the Calibrate/Audit screen (Figure 5–41).
  • Page 109 Return to normal operation. If the leak check fails, refer to the Troubleshooting section. WARNING Do not operate the TEOM 3600 PDM if its case is damaged or otherwise compromised. ▲ Thermo Fisher Scientific...

  • Page 110: Replacing The Battery Packs

    Maintenance and Calibration Replacing the Battery Packs Replacing the The TEOM 3600 PDM has two battery pack assemblies that should be replaced when their capacity diminishes. Tool/materials needed for this Battery Packs procedure include a Phillips screwdriver. WARNING Whenever the PDM case is opened for maintenance, you must perform a case leak check after reassembling the case.
  • Page 111 Maintenance and Calibration Replacing the Battery Packs 3. Carefully remove the battery pack “A” from the PDM unit. Press the small tab on the wire connection to disconnect the battery wires (Figure 5–43 Figure 5–44). Equipment Damage When moving the battery pack to access the wire connections, be sure to minimize stress on the wires and connectors.

  • Page 112: Lubricating The Mass Transducer O-Rings

    Maintenance and Calibration Lubricating the Mass Transducer O-rings 10. Press the “A” (“WAKE UP”) button on the top panel of the PDM unit to ensure that the display screen appears. 11. If the display screen does not appear, open the case and double-check the battery connections.

  • Page 113: Replacing The Cap Lamp

    Maintenance and Calibration Replacing the Cap Lamp Figure 5–45. Mass transducer chamber Figure 5–46. Mass transducer O-rings 3. Using the cotton swab, apply the silicone compound to the O-rings. 4. Install the PDM cover plate (refer to the instructions earlier in this chapter for information on opening the case) and perform a leak check.
  • Page 114 Maintenance and Calibration Replacing the Cap Lamp Top cyclone plate Hidden Figure 5–47. Removing screws from top cyclone plate Figure 5–48. Cyclone inlet screws (4) 2. Remove the top cyclone plate from the cyclone inlet assembly. 3. Using the 7/64-inch hex wrench, remove the three remaining hex screws from the bottom cyclone plate (Figure 5–49).
  • Page 115 Maintenance and Calibration Replacing the Cap Lamp 4. Remove the PDM cover plate (refer to the instructions earlier in this chapter for information on opening the case). 5. Locate the red power (supply) wire and open the blue connector on the red power wire by unscrewing it (Figure 5–50).
  • Page 116 Maintenance and Calibration Replacing the Cap Lamp Figure 5–52. Insulation removed to expose wiring 8. Locate the cap lamp assembly's black return wire that is connected to the terminal block (Figure 5–53). Figure 5–53. Terminal block 5-34 PDM 3600 Instruction Manual Thermo Fisher Scientific...
  • Page 117 Screw Maintenance and Calibration Replacing the Cap Lamp 9. Using a small flathead screwdriver, loosen the screw on the terminal block that is toward the bottom of the unit and remove the black return wire from the block (Figure 5–53). 10.

  • Page 118: Repairing/Rebuilding The Cap Lamp

    Maintenance and Calibration Repairing/Rebuilding the Cap Lamp Figure 5–54. Installing the ferrule and connector 17. Install the blue connectors on the red power wires by screwing them together firmly. 18. Reinstall the black insulating material onto the cyclone area to cover the wiring underneath.
  • Page 119 Maintenance and Calibration Repairing/Rebuilding the Cap Lamp o Assembly, LED o Assembly, PCB 1. Remove the three Allen head screws that are securing the bezel ring to the housing. 2. Remove and replace headpiece lens and/or headpiece gasket as required. 3.

  • Page 120: Performing A Flow Calibration

    Maintenance and Calibration Performing a Flow Calibration Performing a If the monthly flow audit fails, perform a flow calibration. Tool/materials needed for this procedure: Flow Calibration Flow meter ● Tubing adapter ● Flow calibration kit (59-010019) ● o Black (0.028-inch) orifice or red with black stripe o Yellow (0.033-inch) orifice or red 1.
  • Page 121 Maintenance and Calibration Performing a Flow Calibration 6. In the Flow Calibration screen, the Air Heater and TE Heater must stabilize before a flow calibration can be performed. A Warning/Confirmation screen displays the “Connect flow meter to cap lamp tube inlet” message when the flow calibration can begin. 7.
  • Page 122 Maintenance and Calibration Performing a Flow Calibration 10. Increase or decrease the flow rate reading on the flow meter by clicking on the small black triangles located to the right of the “Pump Speed” (Figure 5–59). Adjust pump speed until the flow meter reads 2.2 lpm.
  • Page 123 Maintenance and Calibration Performing a Flow Calibration Figure 5–60. Flow calibration orifices Figure 5–61. Black orifice installed in sample line and flow meter tubing 16. When in the Warning/Confirmation screen with an “Attach orifice” message, select the “OK” button. The Flow Calibration screen will display with the Pump Speed white box active.
  • Page 124 Maintenance and Calibration Performing a Flow Calibration 22. When in the Warning/Confirmation screen with an “Attach yellow or red orifice to the inlet” message, select the “OK” button. The Flow Calibration screen will display with the Pump Speed white box active. 23.

  • Page 125: Chapter 6 Troubleshooting

    Chapter 6 Troubleshooting During instrument warm-up, the PDM 3600 continuously monitors the Start Up operating status for unexpected conditions. If any fault conditions are Diagnostics flagged the screen will flash ‘DIAGNOSTIC FAILURE’. To view the cause of the error, press the A and B buttons, press ‘B’ to scroll until the ‘View Failures’...

  • Page 126: Instrument Diagnostics

    Troubleshooting Instrument Diagnostics Instrument During instrument warm-up, the PDM 3600 continuously monitors the operating status for unexpected conditions. If any fault conditions are Diagnostics flagged the screen will flash ‘DIAGNOSTIC FAILURE’. To view the cause of the error, press the A and B buttons, press ‘B’ to scroll until the ‘View Failures’...
  • Page 127 Troubleshooting Instrument Diagnostics Pump and Heaters OFF Test WinPDM Instrument Diagnostics Cause Solution AIR TEMP Defective/Disconnected Check connection. Sensor AMBIENT PRES Defective Sensor Contact TFS service AMBIENT TEMP Defective/Disconnected Check connection. Sensor CLOCK Defective Component Contact TFS service DIFFERENTIAL PRESSURE Defective Sensor Contact TFS service FREQUENCY...

  • Page 128: Leak Testing

    Troubleshooting Leak Testing FREQUENCY Mass Transducer not Install Mass Transducer installed. Filter not installed Check for filter Mass Transducer damaged Contact TFS service NO MASS TRANSDUCER Mass Transducer not Install Mass Transducer installed RH SENSOR Defective Sensor Contact TFS service RH TEMP Defective Sensor Contact TFS service...
  • Page 129 Troubleshooting Leak Testing Mass transducer o-rings - need grease, torn or damaged Cyclone gasket – screws not tight, gasket damaged, metal plates damaged Top cyclone plate Thermo Fisher Scientific PDM 3600 Instruction Manual...

  • Page 130: Case - Battery Compartment

    Troubleshooting Leak Testing Case – Battery The most common sources of a leaking battery compartment, in order of most likely to cause a leak: Compartment Case screws – screws missing, not tightened to 6-in. lbs per the sequence shown in the following illustration. Front Cover –...

  • Page 131: Appendix A Parts And Consumables

    Appendix A Parts and Consumables Table A–1 lists the replacement parts for the TEOM 3600 PDM. Table A–1. Parts and Consumables Description Part Number PDM Parts Battery assembly, PDM 3600 (1 battery 56-010897-2300 Flow path seal kit, PDM (3 O-rings, 1...
  • Page 132 Parts and Consumables Leak Testing Description Part Number PDM 3600 Training Videos 59-011567 Tools Filter tool assembly, PDM 55-009885 Tool, hex key 7/64” ball end 30-009908 Tool, hex key 2.5 mm ball end 30-009907 K0 audit kit 59-010020 Flow calibration kit (includes orifice set) 59-010019 Leak check kit (suction cup, adapter, 59-010237...

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