TSI Instruments DustTrak 8520 Operation manual

Exposure Monitoring
Model 8520
DUSTTRAK™ Aerosol Monitor
TRAKPRO™ Data Analysis Software enclosed
Operation and Service Manual
1980198, Revision S
June 2010

Exposure Monitoring
Model 8520
DUSTTRAK™ Aerosol Monitor
Operation and Service Manual
1980198, Revision S
June 2010
SHIP/MAIL TO:
TSI Incorporated
500 Cardigan Road
Shoreview, MN 55126-3996
USA
U.S.
Technical Support:
[phone]/[phone]
Fax:
[phone]
E-mail address:
[e-mail]
Website:
http://www.tsi.com
INTERNATIONAL
Technical Support:
(001 651) 490-2811
Fax:
(001 651) 490-3824

Copyright ©
TSI Incorporated / 1994–2010 / All rights reserved.
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA
Fax No.
[phone]
Limitation of Warranty and Liability (effective July 2000)
Seller warrants the goods sold hereunder, under normal use and service as described in the
operator's manual, shall be free from defects in workmanship and material for twenty-four (24)
months, or the length of time specified in the operator's manual, from the date of shipment to the
customer. This warranty period is inclusive of any statutory warranty. This limited warranty is
subject to the following exclusions:
a. Hot-wire or hot-film sensors used with research anemometers, and certain other components
when indicated in specifications, are warranted for 90 days from the date of shipment.
b. Parts repaired or replaced as a result of repair services are warranted to be free from defects
in workmanship and material, under normal use, for 90 days from the date of shipment.
c. Seller does not provide any warranty on finished goods manufactured by others or on any
fuses, batteries or other consumable materials. Only the original manufacturer's warranty
applies.
d. Unless specifically authorized in a separate writing by Seller, Seller makes no warranty with
respect to, and shall have no liability in connection with, goods which are incorporated into
other products or equipment, or which are modified by any person other than Seller.
The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated
herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR
PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE.
TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR
BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES,
INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS BASED
ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE) SHALL
BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE
PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE
GOODS. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY SPECIAL,
CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER SHALL NOT BE
RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS
OR CHARGES. No Action, regardless of form, may be brought against Seller more than 12
months after a cause of action has accrued. The goods 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.
Service Policy
Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our
customers, our service policy is designed to give prompt attention to any problems. If any
malfunction is discovered, please contact your nearest sales office or representative, or call TSI
at [phone] (USA) or (001 651) 490-2811 (International).

i
CONTENTS
SAFETY INFORMATION .................................................................... V
1 UNPACKING AND PARTS IDENTIFICATION ............................ 1
Unpacking the DUSTTRAK Aerosol Monitor.................................... 1
Parts Identification for the DUSTTRAK Aerosol Monitor.................. 2
2 SETTING-UP................................................................................. 5
Supplying Power to the DUSTTRAK Aerosol Monitor ..................... 5
Installing the Batteries............................................................. 5
Using the AC Adapter............................................................. 5
Instrument Setup........................................................................... 6
Setting-up TRAKPRO Data Analysis Software......................... 6
Connecting the DUSTTRAK Aerosol Monitor to the
Computer............................................................................. 6
Set-Up the Communications Port........................................... 6
Setting the Real-Time Clock................................................... 7
Programming the Date/Time Using TRAKPRO Software ......... 8
Manually Setting the Real-Time Clock ................................... 8
Connecting the Optional Portable Printer...................................... 8
Connecting/Wiring the Analog/Alarm Output Connector...............9
3 OPERATION............................................................................... 11
Overview...................................................................................... 11
DUSTTRAK Aerosol Monitor Keypad Functions............................ 11
ON/OFF Key................................................................................ 11
SAMPLE Key............................................................................... 12
TIME CONSTANT Key................................................................ 12
Programming the Available Time Constants............................... 13
STATISTICS Key......................................................................... 13
PRINT Key................................................................................... 14
SAMPLING MODE Key............................................................... 14
Survey Mode......................................................................... 14
LOG Modes........................................................................... 15
CLEAR MEMORY Key................................................................ 15
LOGGING INTERVAL Key.......................................................... 15
Programming the Logging Intervals using TRAKPRO Software ...16
and Keys............................................................................. 17
CALIBRATE Key ......................................................................... 17
Display/Keypad Lockout Switch.................................................. 17
Remote Sampling........................................................................ 17
Respirable Mass Sampling with the Cyclone.............................. 18
Using the Cyclone....................................................................... 18
Using the 1.0 or 2.5 µm Inlet Conditioners.................................. 19
Using the 10 µm Nozzle.............................................................. 20
Analog Output.............................................................................. 21

ii
Alarm Output................................................................................22
Alarm Output Specifications..................................................23
Programming the Alarm Setpoint..........................................24
Upgrading the DUSTTRAK Aerosol Monitor to Add Analog and
Alarm Functions .......................................................................24
Identifying an Instrument with Analog/Alarm Functions........24
Identifying an Instrument that may be Upgraded to Add
Analog/Alarm Functions.....................................................25
Identifying an Instrument That May Not Be Upgraded..........25
Programming Advanced Modes: LOG 2 and LOG 3...................26
Sample Protocol for LOG 2 and LOG 3 Modes...........................29
Things You Should Know About Taking Pre-Programmed
Samples....................................................................................30
Memory Considerations...............................................................31
Custom Calibrations....................................................................31
Determining the Calibration Factor for a Specific Aerosol ..........32
Setting Custom Calibration Factor from Keypad.........................33
Setting Custom Calibration Factors using TRAKPRO Software....34
Converting Stored Data to Calibrated Data.................................35
4 MAINTENANCE..........................................................................37
Maintenance Schedule................................................................37
Zero Checking/Re-Zeroing..........................................................38
Cleaning the 1.0 µm and 2.5 µm Inlet Conditioners....................39
Cleaning the 10 µm Inlet and Sample Tube................................40
Replacing the Internal Filters.......................................................41
Setting the Flow Rate..................................................................43
Cleaning the Cyclone ..................................................................44
Storage Precautions....................................................................44
5 TROUBLESHOOTING................................................................45
A SPECIFICATIONS.......................................................................49
B MODEL 8520-1 DUSTTRAK ENVIRONMENTAL ENCLOSURE
OPERATION AND MAINTENANCE MANUAL..........................51
Unpacking the DUSTTRAK Environmental Enclosure...................51
Spare Parts..................................................................................51
Parts Identification: Environmental Enclosure.............................52
SETTING-UP...............................................................................54
Installing the Aerosol or Respirable Aerosol Inlet .......................54
Install Water Trap Bottle..............................................................56
Correct Placement of Velcro Straps............................................57
Install DUSTTRAK Monitor into Environmental Enclosure.............57
Connecting Tubing ......................................................................59
Supplying Power to the DUSTTRAK Aerosol Monitor....................59
Using the External Battery Pack...........................................60
Install External Battery Pack.................................................60

iii
Mounting to a Surveyor Tripod.................................................... 61
Downloading a Data File............................................................. 62
Real-Time Monitoring.................................................................. 62
Setting-up TRAKPROTM Data Analysis Software ..........................62
Transporting the Environmental Enclosure................................. 63
Wiring the Analog/Alarm Cable in the Enclosure........................63
OPERATION............................................................................... 64
Overview...................................................................................... 64
How to Properly Orient the Environmental Enclosure................. 64
Changing and Re-charging the Battery Packs............................64
Receiving Data from the DUSTTRAK Aerosol Monitor.................. 64
Zeroing the DUSTTRAK Aerosol Monitor ...................................... 65
Setting the Flow Rate.................................................................. 65
Locking the Environmental Enclosure......................................... 65
Checklist for Sampling with the Environmental Enclosure..........66
MAINTENANCE.......................................................................... 67
Daily Maintenance Checks.......................................................... 67
Cleaning the Aerosol Inlet........................................................... 67
Cleaning the Respirable Aerosol Inlet......................................... 67
When to Change the Battery....................................................... 67
Replacing the Battery Pack......................................................... 67
Recharging the Battery Packs..................................................... 68
Battery Pack Life ......................................................................... 68
Emptying the Water Trap ............................................................ 68
Storage Precautions.................................................................... 69
TROUBLESHOOTING THE ENVIRONMENTAL
ENCLOSURE.............................................................................. 70
SPECIFICATIONS: ENVIRONMENTAL ENCLOSURE............. 73
INDEX................................................................................................ 75
AVAILABLE APPLICATION NOTES
DUSTTRAK, Theory of Operation...........................................ITI-036
Frequently Asked Questions: DUSTTRAK Aerosol
Monitor ..............................................................................ITI-039
Serial Interface Commands and Connections:
Model 8520 .......................................................................ITI-044
DUSTTRAK Analog Output.....................................................ITI-073
DUSTTRAK Alarm Output.......................................................ITI-074

iv
To obtain any of the listed Application Notes, contact TSI at:
U.S. [phone]/[phone], Fax: [phone]
International (001 651) 490-2811, Fax: [phone]
These Application Notes can also be found under TSI’s web site:
http://www.tsi.com

v
Safety Information
When operated according to the manufacturer’s instruction, this device is a
Class I laser product as defined by U.S. Department of Health and Human
Services standards under the Radiation Control for Health and Safety Act of
1968. A certification and identification label like the one shown below is
affixed to each instrument.
There are no user-serviceable parts inside this instrument. Performing
services other than those described in this manual may result in exposure to
harmful (invisible) laser radiation. A warning label like the one shown
below is affixed to the internal laser device.
DANGER: INVISIBLE LASER
RADIATION WHEN OPEN. AVOID
DIRECT EXPOSURE TO BEAM.
WARNING: NO USER SERVICEABLE
PARTS INSIDE. REFER SERVICING
TO QUALIFIED PERSONNEL.
!
WARNING
The DUSTTRAK monitor Alarm Output function should not
be used to detect hazardous conditions or to provide an
alarm for protecting human life, health, or safety.

vi

1
Chapter 1
Unpacking and Parts Identification
Carefully unpack the Model 8520 DUSTTRAKTM Aerosol Monitor from the
shipping container. Use the tables and illustrations below to make certain
that there are no missing components. Contact TSI immediately if anything
is missing or damaged.
Unpacking the DUSTTRAK Aerosol Monitor
Compare all the components you received with those listed in the table
below. If any parts are missing, contact TSI.
Quantity
Item Description
Part/Model
1
Model 8520 Aerosol Monitor
8520
1
Carrying Case
800686
4
C-size Alkaline Batteries
1208018
1
AC adapter
115 V, NEMA-1-15
230 V, Eur., CEE 7/16
230 V, Great Britain
240 V, Australian
2613033
2613078
800169
2613105
1
Data Analysis Software CD-ROM
800700
1
Zero Filter
800663
1 Computer Cable, 9-pin to RJ-45 800563
1 25-Pin to 9-Pin Serial Cable Adapter 962003
1 Model 8520 DUSTTRAK Aerosol Monitor
Operation and Service Manual
1980198
1
Calibration Certificate
—
1
10 mm Nylon Dorr-Oliver Cyclone
800665
1
Flowmeter, 0–2.5 L/min
800669
4 feet
Plastic Tubing, 1/4 in I.D.
800668
1 Small Screwdriver 800661
1 Sample Nozzle Removal Tool 800662
8 Spare Internal Filter Element 1602188
1 Wrist Strap 2913028
1 Shoulder Strap 2913120
1 Sample Nozzle Cleaning Brush 800699
10 Cotton Swab —
1 Inlet Nozzle, 2.5 µm 1508112
1 Inlet Nozzle, 1.0 µm 1508113
1 Impactor Plate 1508114
1 Tube, Grease 801163
1 Analog Output/Alarm:connector, with cable 801652

Chapter 1
2
Parts Identification for the DUSTTRAK Aerosol Monitor
Figures 1–1 and 1–2 identify the parts of the Model 8520 DUSTTRAK
Aerosol Monitor. Become familiar with these components before
proceeding.
Figure 1–1: Top and Front of the DUSTTRAK Monitor
1. Display
7. External Power Socket
2. Keypad
8. Sample Inlet Nozzle and Port
3. Battery Cover
9. Flow Adjustment Screw
4. Battery Cover
Thumb Screw
10. Analog Output/Alarm
Connector
5. Data Port
11. Cyclone Holder Clip
6. Display/Keypad
Lockout Switch
12. Exhaust Port
2
1
3 4
5 6 7
8
9
11
12
10

Unpacking and Parts Identification
3
Figure 1–2: DUSTTRAK Aerosol Monitor Accessories
1. Zero Filter
9. AC Adapter
2. Flowmeter
10. Cyclone
3. Wrist Strap
11. 25-Pin to 9-Pin Adapter
4. 2.5 µm Inlet Nozzle
12. Shoulder Strap
5. 1.0 µm Inlet Nozzle
13. Sample Tube Cleaning Brush
6. Impactor Plate
14. Sample Tube Removal Tool
7. Grease
15. Internal Filter Elements
8. Computer Cable 16. Analog/Alarm Cable (not
shown)
1
2
3
8
9 10
11
12
13 14
15
4 5
6
7

Chapter 1
4

5
Chapter 2
Setting-Up
Supplying Power to the DUSTTRAK Aerosol Monitor
The Model 8520 DUSTTRAKTM Aerosol Monitor must be powered in one of
two ways: four size C batteries or the supplied AC adapter.
Installing the Batteries
Remove the battery cover and slide the battery holder out of the battery
compartment and insert four size C batteries.
Hold the wires out of the way and slide the battery holder back into the
battery compartment. Tuck the wires in and then re-install the battery
cover (see Figure 2–1).
Figure 2–1: Tuck the Wires In and Close the Cover
Using the AC Adapter
The AC adapter allows you to power the DUSTTRAK monitor from an
AC wall outlet. When using the AC adapter, the batteries (if installed)
will be bypassed. The AC adapter will not charge the batteries.
The DUSTTRAK monitor has an internal, non-user accessible battery that
is used to keep logged data intact when power is turned off. Changing
the C-size batteries or disconnecting the AC adapter will not cause data
to be lost. This battery will last for years. TSI will install a new battery,
if necessary, when the unit is returned to the factory for service.

Chapter 2
6
Instrument Setup
The DUSTTRAK monitor comes with special software called TRAKPROTM
Data Analysis Software, which is designed to provide you with maximum
flexibility and power when using the DUSTTRAK monitor. The following
sections describe how to install the software and set up the computer.
Setting-up TRAKPRO Data Analysis Software
TRAKPRO software contains a very comprehensive Help Function. This
utility provides all the necessary information to guide you in all aspects
of software operation.
Connecting the DUSTTRAK Aerosol Monitor to the Computer
Each DUSTTRAK monitor comes equipped with an RS-232 cable and a
25-pin to 9-pin serial cable adapter. One end of the cable is a 25-pin D
subminiature connector labeled COMPUTER; the other end is an RJ-45
modular connector that connects with the logging instrument. Serial port
connectors always have pins (male) on the computer side.
1. Locate an available serial port on your computer: COM1, COM2,
COM3, or COM4.
2. If the port has a 25-pin connector, you do not need the adapter. If
the port has a 9-pin connector, plug the 25-pin end of the adapter
into the RS-232 cable.
3. Connect the RS-232 cable to the available serial port on your
computer.
4. Connect the RJ-45 connector to the DUSTTRAK monitor.
Set-Up the Communications Port
To communicate with the DUSTTRAK monitor, the software must be
configured for the proper COM port. The TRAKPRO software can be
manually set to operate on a specific COM port, or it can automatically
find a DUSTTRAK monitor that is attached to any COM port. To set up
the COM port, do the following:
1. Turn on the DUSTTRAK monitor and start the TRAKPRO software.
2. Select Communications from the Instrument Setup menu. The
following dialog is displayed:

Setting-Up
7
3. Select the following:
Serial
Port Select the name of the serial port to which the
logging device is connected: COM1, COM2,
COM3, or COM4.
Baud
Rate
Select the baud rate for the port. Higher baud rates
are recommended to transfer data at a faster rate.
Select a lower baud rate only if you are having
trouble communicating at a higher rate.
4. Select Test to verify that you have set up the communications port
properly. The system displays an informative message indicating
whether it was able to establish communications.
5. As an alternate, you can select Find Port, to have the TRAKPRO
software search the available COM ports, looking for an attached
DUSTTRAK monitor.
6. Select OK to accept the setup or Cancel to discard the changes.
Note: Some computers do not communicate reliably at baud rates
above 9600.
Setting the Real-Time Clock
The DUSTTRAK monitor has an internal real-time clock that keeps track
of the time of day (The format is HH:MM where HH is the hour in 24-
hour format and the MM is minutes) and the date. It is very important
for the DUSTTRAK monitor to have the time and date correctly set;
otherwise, date and time stamping of recorded data and calibrations will
not be correct.
There are two ways to set the time and date. The first is to use the
supplied TRAKPROTM Data Analysis Software.

Chapter 2
8
Programming the Date/Time Using TRAKPRO Software
To program the DUSTTRAK monitor date and time:
1. Make sure the DUSTTRAK monitor is connected to the computer
and turned on.
2. Select Parameters, then Clock from the Instrument Setup menu.
The TRAKPRO software retrieves the current date and time settings
from the DUSTTRAK monitor and displays them in the following
dialog:
3. The system date and time (from the computer) can be transferred to
the DUSTTRAK monitor using the “arrows” keys. Alternately, the
date and time can be manually entered into the dialog box.
4. Select Send to reprogram the DUSTTRAK monitor.
Manually Setting the Real-Time Clock
To set the time and date with the keypad, you must press and hold the
SAMPLE key while the DUSTTRAK monitor displays the time of day
during its power-up. Release when the DUSTTRAK monitor “beeps.”
You will have an opportunity to view and/or change the hours, minutes,
year, month, and day of month in sequence. Use the up and down arrow
keys () to change a setting. Use the SAMPLE key to store each
setting and advance to the next one.
Connecting the Optional Portable Printer
To connect the portable printer to the DUSTTRAK monitor, locate Printer
Interface Cable and connect the 9-pin end labeled “PRINTER” to the printer
and the other end to the data port on the DUSTTRAK. monitor Always turn the
DUSTTRAK monitor on BEFORE the printer. If the printer prints question
marks (??????), asterisks (******), or random characters, reset it by turning
05/09/2006 05/09/2006

Setting-Up
9
it off and then on again. If necessary, refer to the Portable Printer Operation
and Service Manual.
Connecting/Wiring the Analog/Alarm Output Connector
The Model 8520 DUSTTRAK Aerosol Monitor is capable of providing an
analog output voltage signal that is proportional to the displayed
concentration. It also contains a switch closure that is tied to an alarm value
(see Chapter 3, “Operation,” for complete specifications and operational
information for these features). The DUSTTRAK monitor is supplied with an
output cable. The cable contains a 4-pin, mini-DIN connector. See
Figure 2-2 below.
1. Analog Ground (-)
3. Alarm Positive (+)
2. Analog Output (+)
4. Alarm Ground (-)
Figure 2–2: Analog/Alarm Connector Pin-Outs
Since every application of this function will have unique requirements, the
customer is responsible for making connections to their own equipment. The
output cable contains a label, showing the wiring diagram/pin-outs.
Please see TSI Application Notes ITI-073 and ITI-074 for complete
information and examples of wiring and using the Analog/Alarm Outputs.
These Application Notes are available at the TSI website,
http://www.tsi.com.
1
2 3
4

Chapter 2
10