ATI Technologies TDA-110P Manual

OPERATION &
MAINTENANCE
MANUAL
TDA-110P
Aerosol Penetrometer
Air Techniques International
Division of Hamilton Associates, Inc
11403 Cronridge Drive
Owings Mills, MD 21117 USA
TEL [phone]
FAX [phone]
www.atitest.com

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Table of Contents
1.Utility Requirements ...................................................................................................... 1
2.Specifications................................................................................................................. 2
2.1.Physical Characteristics.........................................................................................................................2
2.2.Operational Requirements.....................................................................................................................2
2.3.Aerosol Generation................................................................................................................................2
2.4.Aerosol Detection...................................................................................................................................2
2.5.Filter Test Flow Measurement ...............................................................................................................2
2.6.Pressure Measurement..........................................................................................................................2
2.7.Efficiency Measurement.........................................................................................................................2
2.8.Communications Port.............................................................................................................................3
3.Control Location and Functions ................................................................................... 4
4.Features and Options................................................................................................... 10
4.1.Test Types ...........................................................................................................................................10
4.2.Alarm Parameters................................................................................................................................10
4.3.Alarm (audible).....................................................................................................................................10
4.4.Usage Timer.........................................................................................................................................10
4.5.Data Output..........................................................................................................................................10
4.6.User Interface Port...............................................................................................................................10
5.Installation .................................................................................................................... 11
5.1.Input Air................................................................................................................................................11
5.2.Exhaust Connection.............................................................................................................................11
5.3.Communications Port...........................................................................................................................11
5.4.User Interface Port...............................................................................................................................11
6.Initial Setup................................................................................................................... 12
7.Filling Methods............................................................................................................. 13
7.1.Proper Fill Level...................................................................................................................................13
7.2.Generator Regulator Pressure.............................................................................................................13
7.3.Generator Fill .......................................................................................................................................13
8.Machine Startup Sequence.......................................................................................... 14
8.1.Power On.............................................................................................................................................14
8.2.System Initialization.............................................................................................................................14
8.3.System Version....................................................................................................................................14
8.4.Input Air................................................................................................................................................14
8.5.System Vacuum...................................................................................................................................14
8.6.Check Liquid Level...............................................................................................................................14
8.7.System Warm up .................................................................................................................................14
8.8.Initial Calibration ..................................................................................................................................14
9.Test Menu...................................................................................................................... 15
9.1.Start Cycle............................................................................................................................................15
9.2.Test Loading ........................................................................................................................................15
9.3.Testing .................................................................................................................................................15
9.4.Test End...............................................................................................................................................15
9.5.Failed Check........................................................................................................................................15
9.6.Calibration Prompt...............................................................................................................................15
9.7.....................................................................................................................................................................15
10.Standby Mode............................................................................................................... 16
11.Calibration Sequence................................................................................................... 17
11.1.Test Flow Setup Menu.........................................................................................................................17
11.2.Test Flow Setting .................................................................................................................................17
11.3.Penetration Setup Menu......................................................................................................................17
12.Setup Menu................................................................................................................... 19
12.1.Select Pressure Units ..........................................................................................................................19
12.2.Maximum Percent Penetration Variable (Alarm Point)........................................................................19
12.3.Minimum Percent Penetration Variable (Alarm Point).........................................................................19

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12.4.Maximum Resistance Variable (Alarm point).......................................................................................19
12.5.Minimum Resistance Variable (Alarm point)........................................................................................20
12.6.Test Flow Tolerance Variable (Alarm Point)........................................................................................20
12.7.Load Time Variable..............................................................................................................................20
12.8.Extended Load Time Variable..............................................................................................................20
12.9.Sample Time Variable..........................................................................................................................20
12.10.Open Time Variable.........................................................................................................................21
12.11.Cycles to Calibration........................................................................................................................21
12.12.Concentration Reference Alarm......................................................................................................21
12.13.Set Date and Time...........................................................................................................................21
13.Maintenance.................................................................................................................. 22
13.1.Initial Setup ..........................................................................................................................................22
13.2.Definitions and Features......................................................................................................................22
13.3.Scheduled Maintenance ......................................................................................................................22
13.4.Spare Parts List ...................................................................................................................................22
14.Maintenance Menu Structure ...................................................................................... 23
14.1.Maintenance Menus.............................................................................................................................23
14.2.Gravimetric...........................................................................................................................................25
14.3.Res Offset............................................................................................................................................26
14.4.Flow Balance........................................................................................................................................27
14.5.LSC Check...........................................................................................................................................27
14.6.LSC Offset............................................................................................................................................28
14.7.View Sensor.........................................................................................................................................29
14.8.Cal Sensor ...........................................................................................................................................31
14.9.Primary (HIGH) Flow Sensor Setup.....................................................................................................33
14.10.Auxiliary (LOW) Flow Sensor Setup................................................................................................34
14.11.ID.....................................................................................................................................................36
14.12.Console............................................................................................................................................37
14.13.Security............................................................................................................................................37
14.14.Setting the Machine ID....................................................................................................................37
15.Console Commands..................................................................................................... 38
16.LSC Maintenance ......................................................................................................... 39
16.1.Photomultiplier Tube Replacement......................................................................................................39
16.2.Cleaning...............................................................................................................................................39
16.3.Aligning ................................................................................................................................................40
Appendix A.Dip Switch Settings.................................................................................... 41
Appendix B.TDA-110P Operating Parameters .............................................................. 42
Appendix C.Default Settings.......................................................................................... 43
Appendix D.Fault and Error Messages.......................................................................... 44
Appendix E.Remote Mode Operation............................................................................ 46
Appendix F.USER INTERFACE Circuit Example.......................................................... 47
Appendix G.4B Lite Aerosol Generator......................................................................... 48
Appendix H.PAO-4 Safety Data Sheet ........................................................................... 49
Appendix I.Blower Motor............................................................................................... 49
Appendix J.Flow Sensor Operation and Service Manual............................................ 56
Appendix K.Manual Revision......................................................................................... 57

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1. Utility Requirements
Control Unit
Compressed Air - Clean, dry, compressed airflow rate of 10 SCFM at 80 psig (283 slpm @ 5.6 kg/cm2)
NOTE: Maintain the compressed air temperature between 60 and 90 degrees Fahrenheit (70 to 75 degrees is
recommended). It is highly recommended that a coalescing filter and pressure regulator be installed between the
plant airline and the air inlet.
Power –
Control Unit - Stable electrical power at 115 VAC, 50/60 Hz (a power line conditioner and surge
protection is recommended). 230 VAC, 50/60 Hz is optional.
NOTE: A dedicated power circuit is recommended for stable machine operation. Consult the manufacturer.
Ambient Conditions - Temperature controlled environment: 68 to 85 degrees Fahrenheit
recommended. Humidity controlled environment: 45 – 75% relative humidity recommended.
Aerosol Unit
Compressed Air - Clean, dry, compressed airflow rate of 10 SCFM at 80 psig (283 slpm @ 5.6 kg/cm2).
Three separate lines required.
NOTE: Maintain the compressed air temperature between 60 and 90 degrees Fahrenheit (70 to 75 degrees is
recommended). It is highly recommended that a coalescing filter and pressure regulator be installed between the
plant airline and the air inlet.
Blower Motor Power - Stable electrical power at 208-230/460 VAC, 3-Phase, 60 Hz.
NOTE: A dedicated power line is recommended for stable machine operation. Consult the manufacturer.
Ventilation - Exhaust the air with a duct capable or directing 500 cubic feet per minute at a resistance of
≤1 inch of water (see Section 5.2 - Exhaust Connection for details).
Ambient Conditions - Temperature controlled environment: 68 to 85 degrees Fahrenheit
recommended. Humidity controlled environment: 45 – 75% relative humidity recommended.
NOTE: High ambient temperatures may create particle instability.

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2. Specifications
2.1.Physical Characteristics
Control Unit Size 24 in wide x 30 in deep x 72 in high
Weight 210 lbs.
Aerosol Unit Size 120 in wide x 44 deep in x 54 in high
Weight 750 lbs.
System Blower Size 22 in wide x 28 in deep x 17 in high
Weight 150 lbs.
2.2.Operational Requirements
Control Unit Power 115 VAC, 60 Hz, 2.5A
220 VAC, 50 HZ, 1.25A (Optional)
Compressed Air Input 10 SCFM @ 80 psig (283 slpm @ 5.6 kg/cm
2
), 1 supply line required
System Blower Power 208-230 VAC-3 Phase, 50/60 Hz or 460 VAC – 3 Phase, 50/60 Hz
System Exhaust Aerosol is exhausted from the system, while not operating in the Test Mode, at a rate
of approximately 400 cfm (cubic feet per minute)
2.3.Aerosol Generation
Technique Pneumatic nebulization with impaction using “Cold” 4 centistokes PAO
Compressed Air Input 10 SCFM @ 80 psig (283 slpm @ 5.6 kg/cm
2
), 2 supply lines required
Reagent PAO-4 (poly alpha olefin – 4 centistokes) (See Appendix I)
Diameter 0.185 ± .020 micrometer CMD (meets 42 CFR Part 84)
Geo Std Deviation < 1.6 (meets 42 CFR Part 84)
Concentration 20 to 30 milligrams per cubic meter (mg/m
3
) minimum.
2.4.Aerosol Detection
Technique Near forward light scattering
Dynamic Range 0.0001 to 200 milligrams per cubic meter (mg/m
3
)
Accuracy ± 1%
Sample Flow Rate Partial flow through detector, 45 LPM (liters per minute)
2.5.Filter Test Flow Measurement
Technique NIST traceable flow meter
Accuracy ± 1.0%
Range 40 to 400 cfm (cubic feet per minute) @ 21.1°C, 760 mm Hg Standard, other flow
ranges upon request
2.6.Pressure Measurement
Technique Electronic pressure transducer
Accuracy ± 1.0% of full scale
Range 0 to 100 mm water column (0 to 3.94 inches water column) Standard, other pressure
ranges upon request
2.7.Efficiency Measurement
Media Test Flow 40 – 400 cfm (cubic feet per minute) @ 21.1°C, 760 mm Hg
Operating Range Efficiencies to 99.9995%

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2.8.Communications Port
Serial Port RS-232
Data Bits 8
Baud Rate 9600
Parity None
Stop Bit 1
Flow Control Xon/Xoff
Cable required Null modem configuration (shown below)

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3. Control Location and Functions
Before operating this unit, familiarize yourself with its features and functions. Each number in the photo is keyed
to the list below.
8 READY Indicator light
9 FAULT Indicator light
10 FAIL Indicator light
7 VF Display window
6 Function keys
5 Chuck Close Switches
11 % Penetration window
12 Resistance window
13 Test Flow window

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1 Power ON
2 Power indicator
3 Power OFF
4 Emergency Stop
17 Exhaust Damper meter
15 Test Flow Rate meter
16 Exhaust Damper adjustment
14 Test Flow Rate adjustment
19 Aerosol Generator ON/OFF
Switch
Pneumatic Tubing Connections-Enclosure Lower Right-side (SN 27098)
(34) Chuck Pilot (36) Aerosol DWN Stream (35) Aerosol UP Stream (32) Resistance
UPStream
(39) Generator Pilot (31) Chuck Supply (37) Damper Open (38) Damper Close (33) Resistance
DWNStream

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1. Power ON – Green push button turns system power and air on
2. Power Indicator – Indicates that the power is on when lit
3. Power OFF – Red push button turns system power and air off
4. Emergency Stop – Push to turn off system power and air. Rotate clockwise to re-set.
5. Chuck Close Switches – Used to actuate test chuck movement. Press simultaneously to close the test
chuck. Pressing either switch will stop the function being performed and open the Test Chuck
6. Function Keys – Four function keys, labeled A through D, used to select or change options. The display
window shows the function of each key.
7. VF Display Window – Displays system information and function key options
8. Ready Indicator – Green light indicates the unit is ready to start a new test
9. Fault Indicator – Yellow light indicates a pre-calibration condition or system fault (see Table 3 – System
Faults)
10. Fail Indicator – Red light indicates a failed test parameter
11. % Penetration Window – Displays the % penetration readings during testing and displays set points
when in Setup mode
12. Resistance Window – Displays the resistance (pressure drop) during testing in units of inches H2O
13. Flow Rate Window – Displays the flow rate during testing in cfm
14. Test Flow Damper Adjustment – pneumatic control of flow control damper. Used in conjunction with
the exhaust damper for flow rate adjustment
15. Test Flow Damper Meter – displays the position of the flow control damper in 0-100 % open.
16. Exhaust Damper Adjustment – controls opening and closing of the exhaust damper. Used in with the
test flow damper for flow rate adjustment
20 AC Power Input
29 User Interface port28 RS232 Communication Port

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17. Exhaust Damper % Open Meter – displays position of exhaust damper in 0 -100 % open
19. Aerosol Generator ON/OFF switch – Turns on the aerosol generator pilot air pressure to enable the
aerosol generators.
20. AC Power Input – Recessed 3-prong, AC power inlet connector for control unit
21. Generator compressed air supply – Regulated compressed air supply for system aerosol generator
30 Main compressed air inlet port
22 Electronic Enclosure
25 AC line Filter
23 Main PCBA
24 Main Power Relay

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22. Electronics Enclosure – contains the control relays and PCBA (printed circuit board assemblies)
23. Main PCBA – microprocessor circuit board. Location of operating program E-Prom and 8 bit
microprocessor
24. Main Power Relay (CR1) – maintains power to the control unit circuits, relays and valves after actuation
by the main Power ON switch
25. AC Line Filter –power input line conditioner to remove transient voltage fluctuations
26. Upstream Pressure Transducer Port P2 - Used to determine the filter pressure differential
27. Downstream Pressure Transducer Port P1 - Used to determine the filter pressure differential
28. Communication Port – A DB-9 female connector for RS-232 computer interface used for connection to a
PC serial port
29. User Interface Port - Used to interface with external control equipment
30. Main Pressure Input Port - Input for system compressed air supply
31. Chuck Supply– Compressed air used to raise test chuck to its open position
32. Resistance UP Stream - Used to determine the filter pressure differential
33. Resistance DWN Stream - Used to determine the filter pressure differential
34. Chuck Pilot - Compressed air used to lower test chuck to its closed position
35. Aerosol UP Stream – Sample line for measuring 100% aerosol challenge used for testing
36. Aerosol DWN Stream – Sample line for measuring aerosol challenge level penetrating through the filter
under test
26 Upstream Pressure
Transducer port - P2
27 Downstream
Pressure transducer
port - P1

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37. Damper Open – Opens the aerosol damper.
38. Damper Close – Closes the aerosol damper.
39. Generator Pilot – Provides air pilot signal to turn on aerosol generators.
40. Aerosol Generator - Cold nebulization aerosol generator. Two units included.
41. Virtual Impactor – Impactor to control aerosol particle size output by removing large particles. Two units
included.
42. Flow Sensor Control Unit – Contains the control electronic and adjustments for the flow sensor signal to
the control unit.
43. Flow Sensor – Measures the air speed for the flow measurement.
43 Flow Sensor
41 Virtual Impactor
40 Aerosol Generator
21 Generator Supply
42 Flow Sensor Control Unit

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4. Features and Options
4.1.Test Types
Percent Penetration
Resistance (available units of measure are mm
water column, inches of water, Pascals, or
kilopascals)
Test Flow Rate (CFM)
4.2.Alarm Parameters
Alarm points can be set and enabled by the user (see
Setup Menu beginning at Section 12.5 for details). If
an enabled alarm point is reached, the test fails, the
display flashes, and the audible alarm sounds.
4.3.Alarm (audible)
The alarm is used for prompting the operator and
indicating system actions and faults. The time
interval during which the audible alarm functions is
set by adjusting the “Open Time” variable.
4.4.Usage Timer
When the unit is first turned on, the penetration
display shows the total time, in hours, that the unit
has been in an energized state.
4.5.Data Output
Outputs test data through the RS-232
communications port. Port settings are 9600, N, 8, 1
4.6.User Interface Port
The port allows the user to interface with ancillary
equipment for controlling or monitoring the unit. (See
Section 5.4 – User Interface Port & Appendix F –
Remote Mode Operation)

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5. Installation
5.1.Input Air
Before connecting the compressed air line,
check the line for any fluids or unwanted
contaminants.
NOTE: Pre-filtering is recommended.
Connect the compressed air sample line to the
Main Pressure Input Port shown in the Figure
on page 7, Item No. 30 and the two TDA-4Blite
generators.
CAUTION: For the user’s safety, make sure all the
connections are secure.
5.2.Exhaust Connection
Connect each of the two 6–inch exhaust hoses
(user supplied) to the system exhaust ducts.
Exhaust draw should be as minimal as
possible.
WARNING: Excessive exhaust draw will cause
unstable aerosol concentration resulting in
faulty and/or inconsistent results.
5.3.Communications Port
The communications port is a standard 9-pin
male (DTE configuration).
Using a standard RS-232 null modem cable,
connect the unit to your PC serial port.
Configure your serial port to the following
settings:
Baud 9600
Data Bits 8
Parity None
Stop Bit 1
Flow Control Xon/Xoff
5.4.User Interface Port
The outputs are an open collector type capable
of sinking 50 mA for a non-inductive load (see
Table 1 & Appendix G & H for connection
details).
Ready (Output) – Indicates that the unit is ready to
start a new test
Pass (Output) – Indicates a passed test
Fail (Output) – Indicates a failed test
Fault (Output) – Indicates a system fault (See
Appendix D –Fault & Error Messages)
In Cal (Output) – Indicates when the unit is in
penetration calibration
External Start (Input) – The signal used to start a
test cycle from an external source. A pulse of 5-
24V DC for a minimum 0.100 seconds will start a
test cycle.
NOTE: This port is isolated from the unit to protect
against external damage.
Table 1 – Connector Pins & Functions
Connector Pin Function
1 External Start
2 NC
3 Fault
4 Pass
5 NC
6 Ground
7 Ready
8 Fail
9 In Cal / Busy

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6. Initial Setup
1) Verify that all the input compressed air supplies are connected.
2) Plug the unit into the proper power source.
3) Fill both the 4Blite generators to the fill line (middle) with the oil specified in the
Factory Settings sheet (see Section 7 - Filling Methods).
NOTE: Over or under filling the generator will result in an unstable aerosol
source.
WARNING: If any liquids are used other than that which is specified on the
Factory Settings sheet, the generator will not function to specification.
4) Follow the Machine Startup Sequence (Section 8) until the Test menu (Section 9) is
reached. At this point the TDA-4Blite generators should be on and each of the
regulators located at the generators adjusted to 30 psi.
5) Check the system settings against the Factory Settings sheet included with this
manual.
6) Power the unit off by pressing the red push button.
7) Perform the test set up at this time (Section 12 – Setup Menu) to adjust user
specific testing parameters.

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7. Filling Methods
7.1.Proper Fill Level
PAO Moil must always be used with this equipment.
ATI 4Blite Laskin aerosol generators tanks are
marked with a fill line at the center point of the
reservoir. The PAO oil level should always be
maintained within ± 0.25 inches of the fill line.
WARNING: Do not fill generator more than 0.50
inches from the fill line.
7.2.Generator Regulator Pressure
The 4B lite generator regulators must be set at 30 psi
when the regulators are functional. Switch the
Aerosol Generators switch to ON at the control panel
and check to ensure the regulators are set to 30 psi.
7.3.Generator Fill
Remove the generator fill caps from each generator
and fill with PAO oil noting the fill line on the sight
glass. Replace the fill cap.
WARNING: NEVER operate the equipment
without the fill caps in place.
.

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8. Machine Startup Sequence
In this manual, the following conventions are
used:
<Function> indicates the function key that is
pressed. This usually corresponds to
the switch label on the bottom line of
the display. If no label is present, the
switches are designated “A”, “B”, “C”,
and “D”, from left to right.
xx indicates a variable displayed value.
[P] Indicates the penetration display.
[R] Indicates the resistance display.
[F] Indicates the test flow display.
<CLOSE>Indicates that both of the chuck close
switches should be pressed
simultaneously.
<OPEN> Indicates that pressing either chuck
close switch should open the chuck.
NOTE: Pressing either chuck close switch cancels
the function being performed and opens the chuck.
8.1.Power On
Turn on the unit power by pressing the green button
on the control unit then turn on the blower and
aerosol generator using the switches.
8.2.System Initialization
Immediately after power on, the system will
enter an initialization sequence lasting
approximately 15 seconds. The progress of the
initialization is indicated by a series of periods on
the second line of the display.
Initializing System
. . . . . . . . .
8.3.System Version
ATI 110P Ver n.n
UNIT ID 9999
n.n Software Version
9999 The unit id assigned to this unit. (See
Section 15.21 for information on
setting the unit id.)
[P] Hours the unit has been in operation
8.4.Input Air
Awaiting Air
The unit is waiting for the input air.
8.5.System Vacuum
Awaiting Vacuum
The unit is waiting for the system vacuum.
8.6.Check Liquid Level
Check the liquid level in generators and fill if
necessary. Remove any liquid in the drip jars
before continuing.
Check Liquid Level
CONT
<CONT> Continue with Startup
8.7.System Warm up
The system will now enter an eight minute
warm-up to allow the aerosol output to stabilize.
The standard warm-up period is eight minutes.
SYSTEM WARMUP
BYPASS
<BYPASS> Continue with Startup
8.8.Initial Calibration
After a system start the system must perform
the penetration calibration sequence (Section 11).
After this initial calibration is completed, the
machine will be ready for use and will display the
screen shown in Section 9.