TSI Instruments AeroTrak 8240 Service Manual
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TSI Instruments AeroTrak 8240 Service Manual

Portable airborne/particle counters
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AeroTrak
Portable Airborne
Particle Counters
Models 8240/8260/9310/9350/
9510/9550/9500
Service Manual – Cleaning and Repair
P/N 6007705, Revision E
August 2022
www.tsi.com

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  • Page 1 ® AeroTrak Portable Airborne Particle Counters Models 8240/8260/9310/9350/ 9510/9550/9500 Service Manual – Cleaning and Repair P/N 6007705, Revision E August 2022 www.tsi.com...
  • Page 2 Start Seeing the Benefits of Registering Today! ® ® Thank you for your TSI instrument purchase. Occasionally, TSI releases information on software updates, product enhancements and new products. ® By registering your instrument, TSI will be able to send this important information to you.

  • Page 3: Manual History

    M a n u a l H i s t o r y ® The following is a manual history of the AeroTrak Portable Airborne Particle Counters (Models 8240/8260/9310/9350/9510/9550/9500) Service Manual – Cleaning and Repair (P/N 6007705). Revision Date March 2014 November 2014 April 2015 March 2020...
  • Page 4 (This page intentionally left blank) ® AeroTrak Portable Airborne Particle Counters...

  • Page 5: Warranty

    W a r r a n t y Part Number 6007705 / Revision E / August 2022 Copyright ©TSI Incorporated / 2014-2022 / All rights reserved. Address TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA E-mail Address answers@tsi.com Limitation of Warranty and (For country-specific terms and conditions outside of the USA, please visit www.tsi.com.)
  • Page 6 returned under warranty to Seller's factory shall be at Buyer'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.

  • Page 7: Table Of Contents

    C o n t e n t s Manual History ..................... i Warranty ..................... iii Contents ...................... v Safety Information ..................vii Laser Safety ..................vii Labels ....................viii Description of Caution/Warning Symbols ..........ix Caution ....................ix Warning ....................ix Caution or Warning Symbols .............
  • Page 8 Outlet Replacement ................4-8 Inlet Replacement ................4-8 Optics Block Replacement–Removal ..........4-9 Optics Block Replacement–Verify Alignment ........4-10 Optics Block Replacement–Repackage Old Block ......4-11 Main Board Replacement ..............4-11 Blower Replacement ................. 4-13 Battery Board Replacement .............. 4-15 Mirror Replacement ................

  • Page 9: Safety Information

    S a f e t y I n f o r m a t i o n This section gives instructions to promote safe and proper handling of the ® AeroTrak Portable Airborne Particle Counters (Models 8240/8260/ 9310/9350/9510/9550/9500). I M P O R T A N T All maintenance and repair information in this manual is included for use by a qualified, factory-authorized, technician trained in the safe handling of laser and electrostatic sensitive components.

  • Page 10: Labels

    L a b e l s Advisory labels and identification labels are attached to the outside of the particle counter housing and to the optics housing on the inside of the instrument. 1. Serial number label (back panel) 2. Laser radiation label (internal) 3.

  • Page 11: Description Of Caution/Warning Symbols

    D e s c r i p t i o n o f C a u t i o n / W a r n i n g S y m b o l s 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.

  • Page 12: Getting Help

    G e t t i n g H e l p To obtain assistance with this product or to submit suggestions, please contact Customer Service: TSI Incorporated 500 Cardigan Road Shoreview, MN 55126 U.S.A. Fax: (651) 490-3824 (USA) Fax: 001 651 490 3824 (International) Telephone: 1-800-874-2811 (USA) or (651) 490-2811 International: 001 651 490 2811 E-mail Address:...
  • Page 13 C H A P T E R 1 I n t r o d u c t i o n ® This manual contains cleaning and repair process steps for AeroTrak Portable Airborne Particle Counters. N O T I C E Calibration process steps for As Found Verification and As Left ®...
  • Page 14 (This page intentionally left blank) ® AeroTrak Portable Airborne Particle Counters...

  • Page 15: Battery Replacement

    C H A P T E R 2 G e n e r a l M a i n t e n a n c e – M o d e l s 8 2 4 0 , 8 2 6 0 , 9 3 1 0 - 0 1 , 9 5 1 0 - 0 1 , 9 3 5 0 - 0 1 , 9 5 5 0 - 0 1 This section explains how to disassemble Models 8240, 8260, 9310-01, 9510-01, 9350-01, and 9550-01 for general maintenance and/or repair.
  • Page 16 W A R N I N G DO NOT use non-rechargeable batteries in this instrument. Fire, explosions, or other hazards may result. These particle counters may be powered using a rechargeable lithium-ion battery or through an AC power cord. NOTICES When using AC power, the battery (if installed) charges when the instrument is on, but not while actively sampling.

  • Page 17: Opening The Case

    O p e n i n g t h e C a s e Supplies Needed: • Small ratchet, 5/16 socket outside diameter has been ground away for clearance • Medium screw driver • Long Phillips-head screw driver • Tweezers •...

  • Page 18: Closing The Case

    3. Lift the cover just far enough to remove the wires and ribbon cable indicated below. (For 8240/8260 there will be one more connection.) C l o s i n g t h e C a s e 1. Attach ribbon cable and printer cables.

  • Page 19: Filter And Flowmeter Replacement

    4. Install four screws located on the back of the unit (6-32 1/4). F i l t e r a n d F l o w m e t e r R e p l a c e m e n t 1.
  • Page 20 4. On the back is the flowmeter outlet. Models 9310-01, 9350-01, 9510-01, 9550-01: Unscrew the Phillips screw that holds it in place. Models 8240, 8260: The flowmeter outlet is held in place by O-rings. Pull outlet straight off. Old Style Add O-rings to outlet.
  • Page 21 6. Remove the filter by pulling straight out. 7. Install a new filter. Smaller opening will go into the block. 8. Reinstall flowmeter by flexing back chassis and tilting to one side. Once it’s straight, push it into the filter. 9.

  • Page 22: Flowmeter Outlet Replacement

    10. Reinstall ribbon cable. 11. Close the unit. F l o w m e t e r O u t l e t R e p l a c e m e n t For 9310-01, 9350-01, 9510-01, and 9550-01 On the back is the flowmeter outlet.

  • Page 23: Power Board Replacement

    P o w e r B o a r d R e p l a c e m e n t To replace the power board, open the case and remove main board per above procedures. C A U T I O N The electronic circuits within this instrument are susceptible to electro- static discharge (ESD) damage.

  • Page 24: Blower Replacement

    B l o w e r R e p l a c e m e n t 1. Open case and remove main board and power supply board per above procedures. Locate the blower. 2. Remove blower bracket by taking out two screws (each side of bracket, 6-32 3/16).
  • Page 25 5. Pull out blower and replace with new one. 6. Remove screen from block and clean. Install back into block. 7. Push wires as shown. General Maintenance–Models 8240, 8260, 9310-01, 9510-01, 9350-01, 9550-01 2-11...
  • Page 26 8. Tighten nut. 9. Untwist wires by turning pump while screwing feed through in block. 10. Press blower completely into block. Verify the Flat side on blower points toward beam stop. 11. Push wires through cap. 12. Screw cap on feed through. Verify insert bulges out when tightened.
  • Page 27 13. Cut wires. 14. Strip connector wires 1/2 inch. 15. Twist each wire end and tin. 16. Place shrink tubing on wires. 17. Solder same colored wires by twisting tined ends together. 18. Place shrink tubing over solder connection. 19. Use a heat gun to active the shrink tubing.

  • Page 28: Fan Replacement

    F a n R e p l a c e m e n t 1. Remove four nuts, fan, and fan guard (6-32 lock nuts). 2. Replace Fan with Fan User Service kit S7000073 Portables Fan. 3. Place fan with Fan Guard on Power Supply, verify the orientation.
  • Page 29 4. Install four nuts (6-32 lock nuts). 5. Test fan operation by plugging in fan, power supply, and display cable, and powering on the instrument with line power. 6. Close unit. I n l e t R e p l a c e m e n t f o r 9 3 1 0 - 0 1 , 9 3 5 0 - 0 1 , 9 5 1 0 - 0 1 a n d 9 5 5 0 - 0 1 1.

  • Page 30: Printer Replacement

    P r i n t e r R e p l a c e m e n t 1. Place a screwdriver underneath the plastic rivets and pry up. Take a side cutter to clip off the head. 2. Remove the printer.
  • Page 31 P r i n t e r T e s t f o r 9 3 1 0 - 0 1 , 9 3 5 0 - 0 1 , 9 5 1 0 - 0 1 , a n d 9 5 5 0 - 0 1 1.

  • Page 32: Display And Display Board Replacement

    D i s p l a y a n d D i s p l a y B o a r d R e p l a c e m e n t The display assembly is very sensitive to dust particles and other impurities.
  • Page 33 3. Open cover and unplug cables. Unplug cables 4. Remove four screws from display board (4-40 3/16). 5. Remove two screws and High Voltage board (4-40 3/16). 6. Unscrew four screws from the LCD bracket (4-40). General Maintenance–Models 8240, 8260, 9310-01, 9510-01, 9350-01, 9550-01 2-19...
  • Page 34 7. Remove LCD screen. Replace with new LCD Service kit S7000258 CC Portables Display. 8. Screw bracket onto LCD. C A U T I O N The electronic circuits within this instrument are susceptible to electro- static discharge (ESD) damage. Use ESD precautions to avoid damage.
  • Page 35 12. Reinstall display board with four screws (4-40 3/16). Service kit S7000074 Portables Display 13. Plug in cables. Verify as shown Verify white side up Verify blue side up 14. Fold cover and put “risk of shock” sticker on box to hold it shut.
  • Page 36 D i s p l a y C a l i b r a t i o n f o r 9 3 1 0 - 0 1 , 9 3 5 0 - 0 1 , 9 5 1 0 - 0 1 , a n d 9 5 5 0 - 0 1 The touch screen display needs to be calibrated only once at time of installation.

  • Page 37: Fuse Replacement

    F u s e R e p l a c e m e n t User Service Kit Fuse 1.0A SLOBLO 5 mm x 20 mm GDC S7000066 Portables Fuse (10) Kit. O p t i c s B l o c k C l e a n i n g P r o c e d u r e 1.
  • Page 38 3. Remove four screws (6-32 3/8). 4. Remove mirror from housing. Note orientation of Note orientation of lines on mirror lines on mirror and brewster. and brewster. 5. Inspect mirror surface. If dirty, blow off with clean compressed air. If further cleaning is needed, wipe gently with lens cleaning CLEAN...
  • Page 39 6. Clean chamber with a lint- free wipe and isopropyl alcohol. Particular attention should be shown to the nozzle area. CLEAN 7. Remove four screws and eight washers holding the beam block in place (2-56 3/4 and #4 nylon washers). Verify line orientation Verify line orientation 8.
  • Page 40 10. Replace O-ring with Buna 34-306 O-ring (TSI P/N 2501907 from Verify lens is clean S7000065), and under a microscope or grease it with a magnifying glass. vacuum grease. 11. Replace beam block, make sure orientation is correct (two 2-56 3/4 and eight #4 nylon washers).

  • Page 41: Photodiode Board Replacement

    14. Reattach nozzle using two screws. 15. Perform a complete calibration. P h o t o d i o d e B o a r d R e p l a c e m e n t 1. Remove both connections to the Photodiode Board.
  • Page 42 2. Remove shield from Photodiode Board. 3. Remove two Phillips head screws. 4. Replace old Photodiode PCB with S7000155. Verify surface is clean, if not, clean with alcohol using cotton swab. 5. Install two Phillips head screws. 6. Install shield on photodiode board. ®...
  • Page 43 7. Connect both connections to the Photodiode Board. General Maintenance–Models 8240, 8260, 9310-01, 9510-01, 9350-01, 9550-01 2-29...
  • Page 44 (This page intentionally left blank) ® 2-30 AeroTrak Portable Airborne Particle Counters...
  • Page 45 C H A P T E R 3 S e r v i c e R e p l a c e m e n t K i t s – M o d e l s 8 2 4 0 , 8 2 6 0 , 9 3 1 0 - 0 1 , 9 5 1 0 - 0 1 , 9 3 5 0 - 0 1 , 9 5 5 0 - 0 1 Each contamination control instrument has a few field replaceable units.
  • Page 46 Part Number Description S7000064 CC Portables Hardware Kit (continued) (10) SCR 4-40 x 1/8 PAN HD PHH SS (5036195) (10) SCR 4-40 x 3/16 PAN HD PHH SS (5037090) (10) SCR 4-40 x 3/16 SKT HD SET SS (5037190) (10) SCR 4-40 x 1/4 PAN HD PHH SS (5038090) (10) SCR 4-40 x 7/8 SKT HD CAP SS (5045180) (10) SCR 6-32 x 3/16 PAN HD PHH SS (5067000) (10) SCR 6-32 x 1/4 SKT HD CAP SS (5068180)
  • Page 47 Part Number Description S7000072 CC Portables 9X50 Inlet Kit (1) Inlet Nozzle (1) O-Ring Buna 1.5 x 9 mm DUR 70 (2) SCR 4-40 x 3/16 SKT HD CAP SS S7000073 CC Portables Fan Kit (1) Fan Guard (1) Fan (4) Nut 6-32 Lock "KEP"...
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  • Page 49: Battery Replacement

    C H A P T E R 4 G e n e r a l M a i n t e n a n c e – M o d e l s 9 3 1 0 - 0 2 , 9 3 5 0 - 0 2 , 9 3 5 0 - 0 3 , 9 5 1 0 - 0 2 , 9 5 5 0 - 0 2 , 9 5 0 0 - 0 1 This section explains how to disassemble Models 9310-02, 9350-02,...

  • Page 50: Opening The Case

    O p e n i n g t h e C a s e 1. Remove four screws located on the back of the unit (M4 x 0.7 x 8 mm). 2. Remove two screws located on the bottom of the unit (6-31 1/4).

  • Page 51: Closing The Case

    5. Move internal bracket back and lift out of the case. C l o s i n g t h e C a s e 1. Place inner bracket over studs located on the base of the chassis. 2. Align the bracket as close as possible to the back panel.
  • Page 52 3. Using a socket and ratchet, install four nuts at the base (M-4 nuts). 4. Install the wire and ribbon cable indicated in the picture. 5. Place top cover on. 6. Install two screws at bottom of unit (M4 x 0.7 x 8 mm).

  • Page 53: Display Board Replacement

    D i s p l a y B o a r d R e p l a c e m e n t 1. Remove connectors from the board. 2. Using a long socket remove four M-4 nuts. At that time remove the display from the cover.
  • Page 54 6. Connect the cables to the PCA Board. 7. Before installing the new display clean the outer and inner of the screen with air. If that does not remove all the dirt, use a soft cloth. CLEAN 8. Using a long socket driver install four (4) M-4 Penn Nuts.

  • Page 55: Printer Replacement

    9. Install connectors onto the display board. P r i n t e r R e p l a c e m e n t 1. Place a screwdriver underneath the plastic rivets and pry up. Take a side cutter to clip off the head.

  • Page 56: Outlet Replacement

    O u t l e t R e p l a c e m e n t 1. The outlet is on the top-right corner of the rear of the unit. Use service replacement kit S7000113. To remove loosen two (2) socket head screws (M3 x 0.5 x 35 mm).

  • Page 57: Optics Block Replacement-Removal

    4. If needed, clean new inlet with pressurized air. Grease O-ring with vacuum grease. 5. Replace inlet. 6. Install two Phillips head screws (M3 x 6). 7. Replace hose. Verify that it is clean and fits snug on the nozzle. O p t i c s B l o c k R e p l a c e m e n t –...

  • Page 58: Optics Block Replacement-Verify Alignment

    5. Place new s-kit Laser Block Assembly on Block and insert screws to hold in place. Verify that connector is close to top of the block and next to other board. O p t i c s B l o c k R e p l a c e m e n t – V e r i f y A l i g n m e n t 1.

  • Page 59: Optics Block Replacement-Repackage Old Block

    O p t i c s B l o c k R e p l a c e m e n t – R e p a c k a g e O l d B l o c k Repackage old block to send back to TSI for refurbishing.
  • Page 60 3. Remove eight (8) Phillips head screws from the Main Board (M3 x 6). 4. Remove Microboard by unscrewing two (2) M3 x 6 Phillips head screws. 5. Replace main board with S7000119 Service Kit. 6. Install Microboard then screw in place. Verify “+”...

  • Page 61: Blower Replacement

    7. Mount the new board in the base of the unit. Verify that the plug-ins face the back of the unit. 8. Install eight (8) Phillips head screws. 9. Plug in blower and ribbon cables. 10. Reinstall cover. B l o w e r R e p l a c e m e n t 1.
  • Page 62 3. Using a long socket driver remove four (4) M-4 Nuts. 4. Install new tubing and filter to inlet from S7000120 service kit. 5. Secure tubing with hose clamps from S7000310 service kit. 6. Install new blower from S7000120 service kit. Using a long socket driver install four (4) M-4 Nuts.

  • Page 63: Battery Board Replacement

    9. Plug in blower cable. B a t t e r y B o a r d R e p l a c e m e n t 1. Remove one M3 x 6 screw. Replace board with S7000118 service kit. M i r r o r R e p l a c e m e n t 1.

  • Page 64: Photodiode Replacement

    3. Remove screws from mirror and screw them in to S7000121 service kit. Use vacuum grease on the O-ring. 4. Insert mirror. Verify all three notches match the notches on the block. And screw it in to place. P h o t o d i o d e R e p l a c e m e n t 1.

  • Page 65: Cleaning Requirements

    4. Replace O-ring using S7000112 Service kit (O-ring BUNA 2.5 x 19 mm Dur 70). 5. Hold the board above the block and start one screw at a time. BE VERY CAREFUL NOT TO SMEAR THE MIRROR ON THE O-RING. After all four screws have been started go back and tighten them each a little at a time.
  • Page 66 7. Clean inlet with pressurized air. Grease O-ring with vacuum grease. 8. Locate the Mirror on the Optics Block in the back of the unit. 9. Remove two M3 x 6 screws and screw them into the holes on the mirror. 10.
  • Page 67 14. Clean Beam Dump with compressed air and a cotton swab. If it is still dirty, use alcohol on the end of the cotton swab. Blow dry. 15. Clean Optics Block with compressed air and a cotton swab with a little alcohol applied to the tip.
  • Page 68 22. Turn on the unit. 23. Place power meter probe over Beam Dump hole and turn on meter. Adjust the Meter so that it reads zero. 24. Start the unit. This will turn on the laser. 25. Locate the potentiometer on the laser board.

  • Page 69: Cleaning The Instrument Inlet

    C l e a n i n g t h e I n s t r u m e n t I n l e t The instrument’s inlet should be cleaned after running the instrument in an environment with high particle concentrations or running the instrument for extended periods of time.
  • Page 70 4. Orient the wide part of the swab parallel with the back of the unit and clean the entire interior of the inlet nozzle while unit is sampling. NO T IC E: The unit’s blower will slow down or stop while cleaning the inlet. W A R N I N G DO NOT attempt to use a cleaning swab without the swab handle.
  • Page 71 C H A P T E R 5 S e r v i c e R e p l a c e m e n t K i t s – M o d e l s 9 3 1 0 - 0 2 , 9 3 5 0 - 0 2 , 9 3 5 0 - 0 3 , 9 5 1 0 - 0 2 , 9 5 5 0 - 0 2 , 9 5 0 0 - 0 1 Each contamination control instrument has a few field replaceable units.
  • Page 72 Part Number Description S7000067 CC Portables Printer Kit (1) Printer, Martel PFF5510 Panel Mount (2) Nylon Snap Lock Rivet #6 S7000113 CC Portables Outlet (1) Outlet Adapter (2) SCR M3 x 6 PAN HD PHH SS S7000117 CC Portables Display Board (1) Display PCB S7000118 CC Portables Battery Board...
  • Page 73 Part Number Description S7000167 CC Portables 50 LPM Nozzle w/adapter (1) 50 LPM Nozzle with 3/8” inlet Barb (1) Ring Buna 1.5 x 9 mm DUR 70 (1) Ring Buna 1 x 7 mm DUR 70(2) SCR M3 X 6 PAN HD PHH SS (1) Collar S7000168...
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  • Page 75 C H A P T E R 6 I n s t r u m e n t T r o u b l e s h o o t i n g Symptom Possible Cause Corrective Action Display jittery or not Unseated cables.
  • Page 76 Symptom Possible Cause Corrective Action Flow error Instrument was unable to control flow rate (if Restart measurement. any tubing is connected to particle counter). Pressure drop across inlet may be too large. Lessen pressure drop across inlet by using larger diameter tubing, less tubing, and/or adding a bleed valve.

  • Page 77: Chapter 6 Instrument Troubleshooting

    Symptom Possible Cause Corrective Action Photodetector Error Photodiode Channel A saturated due to high Clean mirror and beam dump if dirty. See light scatter in the chamber. Optics Block Cleaning. May need to realign laser. Laser has become misaligned due to Photodiode Replacement.

  • Page 78: If Unable To Zero Portables

    I f U n a b l e t o Z e r o P o r t a b l e s 1. An issue with portables that could contribute to failing zero count significantly is setting the 0.3 µm threshold too low. For portables, the threshold (Channel A threshold) cannot be lower than 17.

  • Page 79: Technical Contacts

    TSI ® Customer Service at 1-800-680-1220 (USA) or (651) 490-2860. International Contacts Service TSI Instruments Ltd Stirling Road Cressex Business Park High Wycombe, Buckinghamshire HP12 3ST UNITED KINGDOM Telephone:...
  • Page 80 TSI Instruments Singapore Pte Ltd 150 Kampong Ampat #05-05 KA Centre SINGAPORE 368324 Telephone: +65 6595-6388 Fax: +65 6595-6399 E-mail: tsi-singapore@tsi.com TSI Instrument (Beijing) Co., Ltd. Unit 1201, Pan-Pacific Plaza, No.12 A, Zhongguancun South Avenue Haidian District, Beijing CHINA 100081...

  • Page 81: Returning For Service

    TSI Instrument (Beijing) Co., Ltd. Unit 1201, Pan-Pacific Plaza, No.12 A, Zhongguancun South Avenue Haidian District, Beijing CHINA 100081 Telephone: +86 10 8219 7688 Fax: +86 10 8219 7699 E-mail: tsibeijing@tsi.com R e t u r n i n g f o r S e r v i c e and complete the on-line “Service Visit our website at tsi.com/service...
  • Page 82 (This page intentionally left blank) ® AeroTrak Portable Airborne Particle Counters...
  • Page 84 TSI Incorporated – Visit our website www.tsi.com for more information. Tel: +1 800 680 1220 India Tel: +91 80 67877200 Tel: +44 149 4 459200 China Tel: +86 10 8219 7688 France Tel: +33 1 41 19 21 99 Singapore Tel: +65 6595 6388 Germany Tel: +49 241 523030 P/N 6007705 Rev.

This manual is also suitable for:

Aerotrak 8260Aerotrak 9310Aerotrak 9350Aerotrak 9510Aerotrak 9550Aerotrak 9500

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