Lighthouse solair 3100 User manual

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Lighthouse Worldwide Solutions
S3100/S5100/Boulder Counter Gen E
Operating Manual

Copyright © 2012 - 201by Lighthouse Worldwide Solutions. All rights reserved. No part of this
document may be reproduced by any means except as permitted in writing by Lighthouse
Worldwide Solutions.
The information contained herein constitutes valuable trade secrets of Lighthouse Worldwide
Solutions. You are not permitted to disclose or allow to be disclosed such information except as
permitted in writing by Lighthouse Worldwide Solutions.
The information contained herein is subject to change without notice. Lighthouse Worldwide
Solutions is not responsible for any damages arising out of your use of the LMS program.
SOLAIR™ and LMS™ are trademarks of Lighthouse Worldwide Solutions.
Microsoft®, Microsoft Windows©, and Excel©are trademarks of Microsoft Corporation.
Lantronix®, DeviceInstaller®are trademarks or Lantronix Incorporated.
Manufactured by:
Lighthouse Worldwide Solutions
1221 Disk Drive
Medford, Oregon 97501
LWS Part Number: 248083389-1 Rev 

EU DECLARATION OF CONFORMITY
Manufacturer’s Name Lighthouse Worldwide Solutions, Inc.
Manufacturer’s Address: Lighthouse Worldwide Solutions, Inc.
1221 Disk Drive
Medford, OR 97501
Declares that the product:
Product Name: Solair Airborne Particle Counter
Model Number(s): Solair 3100, 5100, Boulder Counter
Conforms to the following Product Specifications:
SAFETY EN61010-1:2001 Safety Requirements for Electrical Equipment for
Measurement, Control, and Laboratory Use Part I:
General Requirements IEC 61010-1:2000
CAN/CSA C22.2 Safety Requirements for Electrical
No. 1010.1-1992 Equipment for Measurement, Control, and Laboratory
Use, Part1: General Requirements
LASER SAFETY IEC 60825-1 Am. 2 Guidance on Laser Products: Conforms to
IEC 60601-2-22 FDA 21 CFR Chapter 1 Subchapter J
(Laser Notice 50)
EMC EN61326 Electrical Equipment for Measurement, Control and
Laboratory Use EMC Requirements Part 1: General
Requirements Includes Amendment A1:1998;IEC
61326:1997 + A1:1998
UL 61010A-1 – UL Standard for Safety Electrical Equipment for Laboratory Use; Part 1: General Requirements.
Replaces UL 3101-1
Supplementary information: The product herewith complies with the requirements of the Low Voltage
Directive 73/23/EEC amended by Directive 93/68/EEC and the EMC Directive 89/336/EEC amended by Directive
93/68/EEC, and carries the CE marking accordingly.
Fremont, CA, May 15, 2007 William L. Shade – V.P. Engineering

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248083389-1 Rev t-i
Table of Contents
About this Manual
Text Conventions ........................................................................................................................... i
Additional Help .............................................................................................................................. i
Chapter 1 General Safety
Safety Considerations .................................................................................................... 1-1
LASER Safety Information ........................................................................................... 1-1
Port-Connect Warning ................................................................................................... 1-2
Electrostatic Safety Information .................................................................................... 1-2
Chapter 2 Introduction
Overview ........................................................................................................................ 2-1
SOLAIR Specifications ................................................................................................. 2-4
Chapter 3 Unpacking, Inspecting and Installing
Initial Inspection ............................................................................................................ 3-1
Unpacking ...................................................................................................................... 3-1
Verify Package Contents ............................................................................................... 3-1
Shipping Instructions ..................................................................................................... 3-2
Accessories .................................................................................................................... 3-3
Installation ..................................................................................................................... 3-5
Connecting Power .............................................................................................. 3-5
Installing the Battery .......................................................................................... 3-5
Removing the Battery ........................................................................................ 3-6
Connecting Isokinetic Probe .............................................................................. 3-7
Direct Mount ISO Probe & ISP Filter Cap ........................................................ 3-8
Loading Printer Paper ...................................................................................... 3-10
Connecting Analog Sensors ............................................................................ 3-12
Connecting an External Peripheral Device ...................................................... 3-13
Connecting to an External Computer or Facility Management System .......... 3-13
Chapter 4 Setting up the Counter
Overview ........................................................................................................................ 4-1

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Analog Sensors .............................................................................................................. 4-1
Analog Setup ...................................................................................................... 4-2
Peripheral Interface Connector ...................................................................................... 4-6
Using Report Parameters ............................................................................................... 4-6
Basic Requirements ....................................................................................................... 4-7
Fed Std ft3 .......................................................................................................... 4-7
ISO 14644-1 ....................................................................................................... 4-8
EU GMP 2009 ................................................................................................... 4-9
Ethernet Configuration .................................................................................................. 4-9
Ethernet Adapter .......................................................................................................... 4-10
Definitions of Terms Used ........................................................................................... 4-15
Preparing for Network Installation .............................................................................. 4-16
Equipment Required: ....................................................................................... 4-16
Software Required: .......................................................................................... 4-16
Additional Requirements: ................................................................................ 4-16
Configure Device ......................................................................................................... 4-17
Ethernet Port Configuration ............................................................................. 4-17
Straight-through Cat5 Setup: ............................................................... 4-17
Cross-over Cat5 Setup: ........................................................................ 4-18
Program the Interface ................................................................................................... 4-18
Windows Telnet Programming: ....................................................................... 4-18
Connect SOLAIR to Ethernet LAN ............................................................................. 4-23
Connect Ethernet Cable to Instrument ............................................................. 4-23
Chapter 5 Communications
SOLAIR Communication Mode .................................................................................... 5-1
Overview ............................................................................................................ 5-1
Ethernet Communications .................................................................................. 5-2
RJ-45 Comm Port .............................................................................................. 5-2
RS485 Communications .................................................................................... 5-3
RS232 Communications .................................................................................... 5-3
USB Communications ....................................................................................... 5-3
Using the USB Port to connect to a PC ................................................. 5-3
USB Flash Drive .................................................................................... 5-5
Chapter 6 Operating Counter
Using the Instrument for the First Time ........................................................................ 6-1
Touch Screen Overview ................................................................................................. 6-3
Menu Map .......................................................................................................... 6-3
MAIN Screen ................................................................................................................. 6-4
LOCATION Selection ....................................................................................... 6-8
Changing Locations ............................................................................... 6-8
Locations in AUTO Mode ..................................................................... 6-8

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248083389-1 Rev t-iii
Zoomed Data View ............................................................................................ 6-9
Viewing Two Columns of Data ........................................................... 6-11
CONFIG (Configuration) Screen ................................................................................. 6-14
DATA SETUP ............................................................................................................. 6-15
Particle Channels ............................................................................................. 6-15
Analog Channels .............................................................................................. 6-17
Analog Data Display ............................................................................ 6-20
Zoomed Analog Data Display ............................................................. 6-21
SAMPLE .......................................................................................................... 6-21
SETTING ......................................................................................................... 6-24
COUNT MODE ................................................................................... 6-24
Geiger Counter Mode .......................................................................... 6-25
PARTICLE DISPLAY ........................................................................ 6-26
ALARM ........................................................................................................... 6-27
Alarm Threshold .................................................................................. 6-27
CLEAR BUFFER ............................................................................................ 6-29
DEVICE SETUP .......................................................................................................... 6-29
CLOCK ............................................................................................................ 6-30
OPTIONS ......................................................................................................... 6-32
CONTRAST ADJUST ........................................................................ 6-32
AUDIBLE BEEP ADJUST ................................................................. 6-32
ALIGN TOUCH SCREEN .................................................................. 6-32
SCAN Mode .................................................................................................... 6-36
AUTOSTART MODE ......................................................................... 6-37
DiffCuml on Zoom .............................................................................. 6-37
ONE CHANNEL ................................................................................. 6-37
ONE SECOND REALTIME MODBUS OUTPUT ............................ 6-38
Pump Startup ........................................................................................ 6-38
Language .......................................................................................................... 6-39
COMM ADDRESS .......................................................................................... 6-40
Output Setup .................................................................................................... 6-41
Trouble Shooting the Printer ........................................................................................ 6-45
Nothing Prints .................................................................................................. 6-45
Printing is Not Straight .................................................................................... 6-45
SECURITY ...................................................................................................... 6-46
POWER ON PASSWORD .................................................................. 6-47
CONFIGURATION PASSWORD ...................................................... 6-48
SERVICE ......................................................................................................... 6-48
STATUS ...................................................................................................................... 6-48
RECIPE ........................................................................................................................ 6-50
LOCATION ................................................................................................................. 6-53
Data View Buffer Screen ............................................................................................. 6-56
Printing Data View Buffer Reports ............................................................................. 6-58
Print Record ......................................................................................... 6-59
Print Range ...................................................................................................... 6-60
PRINT RANGE (BUFFER Report) ................................................................ 6-61

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Printing Buffer Report ......................................................................... 6-62
REPORTS .................................................................................................................... 6-64
Setting up Counter to Run Reports .................................................................. 6-73
Report Output Setup ........................................................................................ 6-74
Printing a Report .............................................................................................. 6-75
Report Requirements ....................................................................................... 6-75
Fed Std ft3 ............................................................................................ 6-75
ISO 14644-1 ......................................................................................... 6-76
EU GMP 2009 ..................................................................................... 6-76
Sample Printouts of Standard Reports ................................................. 6-77
Power Shutdown Levels .............................................................................................. 6-80
Chapter 7 Programming
General Information ....................................................................................................... 7-1
Communicating with the Instrument ............................................................................. 7-1
RJ-45 Comm Port .............................................................................................. 7-2
RS485 Communications .................................................................................... 7-2
RS232 Communications .................................................................................... 7-2
USB Communications ....................................................................................... 7-3
Using the USB Port to connect to a PC ................................................. 7-3
Configuring with the MODBUS Protocol ..................................................................... 7-4
Setting the Real Time Clock .............................................................................. 7-5
Changing the Default Instrument Parameters .................................................... 7-5
Running the Instrument ................................................................................................. 7-7
MANUAL Counting Mode ................................................................................ 7-8
AUTOMATIC Counting Mode ......................................................................... 7-8
Chapter 8 Maintenance Procedures
Introduction .................................................................................................................... 8-1
Safety ............................................................................................................................. 8-1
Maintenance ................................................................................................................... 8-1
Calibration ......................................................................................................... 8-1
Purge Count Test ............................................................................................... 8-1
Troubleshooting ................................................................................................. 8-2
Appendix A Default Settings
Default Settings for SOLAIR Particle Counters ........................................................... A-1
Appendix B MODBUS Register v1.48
COMM Settings ............................................................................................................. B-1

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248083389-1 Rev t-v
Supported MODBUS Commands .................................................................................. B-1
Sensor Settings Registers ................................................................................... B-2
Device Status ..................................................................................................... B-7
Data Registers ................................................................................................................ B-9
Data Status Byte (30007 - 30008) .................................................................... B-11
Alarm Flags in Channels (30076) .................................................................... B-12
Data Type Registers ......................................................................................... B-12
Data Units Registers ........................................................................................ B-13
Data and Alarm Registers ............................................................................................ B-14
Data and Alarm Enable Registers .................................................................... B-14
Enable Alarming for a Channel ....................................................................... B-16
Threshold Setup Registers ............................................................................... B-17
Setting the Alarm Threshold Value ..................................................... B-18
Appendix C Real Time Flow and Laser Current via MODBUS
Required Equipment and Software ................................................................................ C-1
Procedure for Computer to Instrument only ...................................................... C-1
Appendix D Limited Warranty
Limitation Of Warranties: ............................................................................................. D-1
Warranty Of Repairs After Initial Two (2) Year Warranty: ......................................... D-1
Index

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248083389-1 Rev i
About this Manual
This manual describes the operation and use of the Lighthouse
SOLAIR Gen E 3100/5100 and Boulder Counter Airborne Particle
Counters. The word SOLAIR, unit or instrument may be used in place
of specific model. Screen examples will vary.
Text
Conventions
The following typefaces have the following meanings:
Note: A note appears in
the sidebar to give extra
information regarding a
feature or suggestion.
italics Represents information not to be typed
or interpreted literally. For example, file
represents a file name. Manual titles are
also displayed in italics.
WARNING: A warning
appears in a paragraph
like this and indicates a
condition, which if not
met, could cause serious
personal injury or death,
and damage to the
instrument.
boldface Introduces or emphasizes a term.
Courier font Indicates command syntax or text
displayed by the diagnostic terminal.
Bold Courier Indicates commands and information that
you type. You can use uppercase or
lowercase letters; in this manual,
commands are shown in uppercase.
Helvetica Italics Indicates a comment on a command or
text output.
Hexadecimal numbers are shown with the word “hex” or with a small
“h” following the digits. For example:
hex 0D
0Dh
Additional
Help
For more information about the Lighthouse SOLAIR Airborne Particle
Counter, contact Lighthouse Worldwide Solutions:
Service and Support
Tel: [phone] (USA Toll Free)
Tel: [phone] (Outside of USA)
[email protected]

Lighthouse S3100/S5100/Boulder Counter Operating Manual
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1General Safety
Safety
Considerations
Warnings and cautions are used throughout this manual and the reader
should become familiar with the meaning of a warning before
operating the particle counter. Many warnings will appear in the left
margin of the page next to the subject or step to which it applies or they
can appear in the body of text. Take care when performing any
procedures preceded by or containing a warning. The classifications of
warnings are defined as follows:
WARNING: There are
no user-serviceable
components inside the
particle counter.
• LASER - pertaining to exposure to visible or invisible laser
radiation
• Electrostatic - pertaining to electrostatic discharge
• Network Connect - pertaining to communication ports and
instrument damage
LASER Safety
Information
This product contains a laser-based sensor that is a Class 1 product (as
defined by FDA 21 CFR, Chapter 1, Sub-Chapter J) when used under
normal operation and maintenance. Performing service on the sensor
can result in exposure to invisible radiation.
The particle counter has been evaluated and tested in accordance with
EN 61010-1, “Safety Requirements For Electrical Equipment for
Measurement, Control and Laboratory Use” and IEC 60825-1, “Safety
of Laser Products”.
WARNING: The use of controls, adjustments or procedures
other than those specified within this manual may result in
personal injury and/or damage to this instrument. Attempts
by untrained personnel to disassemble, alter, modify or
adjust the electronics or optics may result in personal injury
and damage to the instrument and will void its warranty.
There are no user-serviceable components inside the
particle counter. Only factory authorized service personnel
should repair or service this instrument and its optical
system.

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1-2 248083389-1 Rev 
If replacement of the power supply AC power cord is
required, replace it only with a cord having as good as or
better rating than the cord provided by Lighthouse
Worldwide Solutions. Attempting to use an under-rated
cord can expose the instrument power supply, adjacent
equipment or the user to dangerous shock and fire hazards.
Failure to heed this warning can result in personal injury or
death.
For further technical assistance, contact Lighthouse at 1-800-945-5905
(USA Toll Free) or 1-541-770-5905 (Outside of USA).
The international Caution symbol is located on the rear of the
instrument next to the RS-485 IN port. The symbol will be
accompanied in this manual with a warning about +24VDC being
present on the connector pin-7 when instrument power is applied.
WARNING: +24VDC is
present on RS-232/485 IN
port pin 7 when
instrument power is
applied.
Port-Connect
Warning
WARNING: Connect to the SOLAIR 1 CFM instrument using
the Ethernet port (top RJ45), RS485 port (2nd RJ45) or USB
port. The instrument will determine which port should be
active and configure it accordingly. Only one interface can
be active at a time. Do NOT attempt to use two or more of
these connectors at one time.
It is suggested that power to the instrument be removed
before changing from one port to another then power the
instrument ON. This warning does NOT apply to the USB
Flash Drive.
Electrostatic
Safety
Information
Electrostatic discharge (ESD) can damage or destroy electronic
components. Therefore, any service or maintenance work should be
done at a static-safe work station. A static-safe work station requires an
ESD consultant to evaluate the work environment and propose the
equipment and apparel needed for just such a work station to be
successful.

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2Introduction
Overview This operating manual describes how to use the Lighthouse SOLAIR
1.0 CFM, Gen E portable particle counters, such as the SOLAIR 3100
and 5100 and the Boulder Counter.
The model number (except in the case of the Boulder Counter) signifies
the minimum particle size measured by the instrument. The number
“3100” indicates a 0.3 μm minimum channel size at 1.0 CFM. The
number “5100” indicates a 0.5 μm minimum channel size at 1.0 CFM.
The Boulder Counter, due to its large-particle counting ability starting
at 5.0 m, does not use a model number, per sè.
All models discussed in this manual have a color touchscreen, may
have the thermal printer option installed, may have the battery option
installed and can store up to 3000 records. The Boulder Counter is an
exception because it includes all of the features.
SOLAIR 3100 and 5100 instruments support up to eight particle-size
channels, four 4-20mA analog sensors, built-in thermal printer and a
rechargeable, removable Li-Ion battery. The Boulder Counter supports
only six particle-size channels.
Note: For lists of the
standard channel sizes
available for each SOLAIR
model, see the SOLAIR
Specifications section in
this chapter.
All SOLAIR instruments contain a microprocessor that controls all of
the instruments’ functions. Count data is displayed in cumulative or
differential mode as raw data or normalized in particles per cubic foot
or per cubic meter.
SOLAIRs use the Extreme Life Laser Diode Technology for a laser life
span of greater than 20 years and collection optics for particle
detection. Particles are directed through the laser’s beam and scatter its
light. The collection optics collect and focus that light onto a photo
diode that converts it into electrical pulses. The pulse height is a
measure of particle size. Pulses are counted and their amplitude is
measured for particle sizing. Results are displayed as particle counts in
the specified size channel.
Utilizing a large touch screen interface, SOLAIR instruments are easy
to configure and operate.

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Each SOLAIR can store 3,000 records from up to 8 particle count
channels and up to four 4-20mA analog sensors, including location
information. All data can be quickly and reliably downloaded to a
computer, stored on a Flash Drive or printed on an optional printer.
Instruments in the SOLAIR family allow users to:
• Set sampling and hold times;
• Configure the number of samples taken in a single location;
• Connect up to four analog 4-20mA sensors;
• Connect an external alarm light, buzzer, or external remote control
to a relay output;
• Print reports based on Federal Standard 209E (ft3), EU GMP Annex
1 (if unit has 0.5 and 5.0 channels) and ISO 146441-1 if the printer
option is installed;
• Save data for historical data review;
• Print data tables using the included data transfer software; export
data to ExcelTM to build graphs or charts;
• Store data in *CSV and *LSD format to a USB Flash Drive.

Introduction
248083389-1 Rev 2-3
Figure 2-1 SOLAIR Dimensions
Side Dimensions
Top Dimensions

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SOLAIR
Specifications
3100 Size Ranges 0.3 - 25.0μm
Channel Thresholds Standard and Optional, 6 & 8 Channels:
0.3, 0.5, 0.7, 1.0, 2.0, 3.0, 5.0, 7.0, 10.0,
25.0μm
5100 Size Ranges 0.5 - 25.0μm
Channel Thresholds Standard and optional, 6 and 8 channels:
0.5, 0.7, 1.0, 2.0, 3.0, 5.0, 7.0, 10.0, 25.0μm
Boulder Counter Size
Range
5.0 - 100.0m
Channel Thresholds 5.0, 10.0, 25.0, 40.0, 50.0, 100.0 μm
Flow Rate 1.0 CFM (28.3 LPM)
Counting Efficiency 3100: 50% @ 0.3 m; 100% for particles >
0.45 m (per ISO 21501-4)
5100: 50% @ 0.5 m; 100% for particles >
0.75 m (per ISO 21501-4)
Laser Source Extreme Life Laser diode
Zero Count Level <1 count/5 minutes (per ISO 21501-4)
Concentration Limits 500,000 Particles/ft3@ 5% Coincidence Loss
Calibration NIST Traceable
Count Modes Concentration, manual, automatic, beep
Data Storage Stores up to 3000 sample records of particle &
environmental data, plus location and time
Communication Modes Ethernet TCP/IP, RS485/Modbus, RS232 via
RJ-45 to PC, USB, USB Flash Drive
Supporting Software LMS XChange Data Transfer Software
Optional: LMS Express/RT, LMSNet
External Connections PIC connector; USB-B and Flash Drive USB-
A; Ethernet RJ45, RS485 RJ45, Calibration
port, 4-20 Analog ports, AC IN.
Analog Inputs Up to four optional 4-20mA analog sensors
Touch Screen Display 5.7" (14.47 cm), 320x240 pixels
Printer Thermal printer, optional, specify at time of
order
Table 2-1 Solair Specifications