TSI Instruments DustTrak 8540 Operation manual

DUSTTRAK™
ENVIRONMENTAL
MONITOR
MODELS 8540, 8543
8540-M, 8542-M, 8543-M
OPERATION AND SERVICE MANUAL
P/N 6008408, REVISION K
FEBRUARY 2021

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Copyright ©
TSI Incorporated / 2015-2021 / All rights reserved.
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA
Fax No.
[phone]
Limitation of Warranty and Liability (effective February 2015)
(For country-specific terms and conditions outside of the USA, please visit www.tsi.com.)
Seller warrants the goods, excluding software 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 if less, 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 and exceptions:
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. DustTrak Environmental pump for Models 8540, 8543, 8540-M, 8542-M, and 8543-M
is warranted for two (2) years or 8760 hours, whichever comes first.
c. 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;
d. 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;
e. This warranty does not cover calibration requirements, and seller warrants only that
the instrument or product is properly calibrated at the time of its manufacture.
Instruments returned for calibration are not covered by this warranty;
f. This warranty is VOID if the instrument is opened by anyone other than a factory
authorized service center with the one exception where requirements set forth in the
manual allow an operator to replace consumables or perform recommended
cleaning;
g. This warranty is VOID if the product has been misused, neglected, subjected to
accidental or intentional damage, or is not properly installed, maintained, or cleaned
according to the requirements of the manual. 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. WITH RESPECT TO
SELLER’S BREACH OF THE IMPLIED WARRANTY AGAINST INFRINGEMENT, SAID
WARRANTY IS LIMITED TO CLAIMS OF DIRECT INFRINGEMENT AND EXCLUDES
CLAIMS OF CONTRIBUTORY OR INDUCED INFRINGEMENTS. BUYER’S
EXCLUSIVE REMEDY SHALL BE THE RETURN OF THE PURCHASE PRICE
DISCOUNTED FOR REASONABLE WEAR AND TEAR OR AT SELLER’S OPTION
REPLACEMENT OF THE GOODS WITH NON-INFRINGING GOODS.
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

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GOODS. IN THE CASE OF SOFTWARE, SELLER WILL REPAIR OR REPLACE
DEFECTIVE SOFTWARE OR IF UNABLE TO DO SO, WILL REFUND THE PURCHASE
PRICE OF THE SOFTWARE. IN NO EVENT SHALL SELLER BE LIABLE FOR LOST
PROFITS, BUSINESS INTERRUPTION OR ANY SPECIAL, INDIRECT,
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's Customer Service department at [phone] (USA) or
(001 651) 490-2860 (International) or visit www.tsi.com.

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CONTENTS
SAFETY INFORMATION ....................................................................V
Laser Safety..........................................................................................v
Labels...................................................................................................vi
Description of Caution/Warning Symbols .......................................... vii
Caution.........................................................................................vii
Warning........................................................................................vii
Caution and Warning Symbols........................................................... vii
Reusing and Recycling.......................................................................viii
CHAPTER 1 PRODUCT OVERVIEW ...............................................1
DustTrak™ Environmental Monitors (Model 8540, 8540-M,
and 8542-M).......................................................................................1
DustTrak™ DRX Environmental Monitors (Model 8543
and 8543-M).......................................................................................1
Models 8540-M, 8542-M, and 8543-M MCERTS Certified Monitors..2
854201-M1: MCERTS PM10 Indicative Certification....................2
854001-M1: MCERTS PM2.5 Indicative Certification...................2
854301-M1: MCERTS PM10 and PM2.5 Indicative Certification..3
CHAPTER 2 UNPACKING AND PARTS IDENTIFICATION............5
Unpacking the DustTrak™ Monitor......................................................5
User Replaceable Internal Parts ..........................................................6
Optional Accessories............................................................................7
Parts Identification for the DustTrak™ Environmental
Models 8540/8540-M/8542-M/8543/8543-M................................8
CHAPTER 3 SETTING UP..............................................................11
Environmental Enclosure....................................................................11
Supplying Power to the DustTrak™ Environmental Monitor.............12
Omni-directional Inlet Column............................................................13
Optional accessory 854040.........................................................13
Zero Calibration of Instrument.....................................................13
Instrument Setup and Operation Options ..........................................14
DustTrak™ Checkout Application ...............................................15
DustTrak™ Checkout Application ...............................................16
CHAPTER 4 TRAKPRO™SOFTWARE QUICK REFERENCE ....21
Connecting to the Computer...............................................................21
Installing TrakPro™Data Analysis Software.....................................21
TrakPro™Software Steps..................................................................22
Establishing Communications with the Instrument......................22
Configuring the Logging Parameters...........................................22
Setting User Calibration Factors .................................................26
Starting a DustTrak™ Sample Run .............................................30

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Downloading Data .......................................................................32
Viewing, Graphing and Exporting Data .......................................33
Local Analog/Alarm Output................................................................33
Wiring the Analog Output ............................................................34
Wiring the Alarm..........................................................................34
Using TrakPro™Software to Program the Analog Output..........35
Using TrakPro™Software to Program Alarm Setpoints.............36
CHAPTER 5 MAINTENANCE.........................................................39
Maintenance Schedule....................................................................... 39
Cleaning the Inlet................................................................................40
Cleaning and Oiling Impactors........................................................... 42
Replacing the Internal Sheath Air (HEPA) Filter ...............................43
Replacing Pump.................................................................................45
Replacing Internal 37-mm Sampling Cassette.................................. 48
Return Shipping to TSI® Incorporated................................................ 51
CHAPTER 6 TROUBLESHOOTING...............................................53
APPENDIX A SPECIFICATIONS....................................................55
APPENDIX B INSTRUMENT COMMAND SET.............................57
Connecting to the Instrument............................................................. 57
NIDS Communication Method........................................................... 57
APPENDIX C DRX ADVANCED CALIBRATION..........................59
Option 1: Serial Gravimetric Calibration............................................59
Step 1: PCF Calibration...............................................................59
Step 2: SCF Calibration...............................................................59
Option 2: Parallel Gravimetric Calibration .........................................60
INDEX ................................................................................................63
Application Notes can also be found on TSI®Incorporated’s web site:
https://www.tsi.com

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Safety Information
Laser Safety
•Models 8540/8543/8540-M/8542-M/8543-M DustTrak™
Environmental Monitors are Class I laser-based instruments.
•During normal operation, you WILL NOT be exposed to
laser radiation.
•Precaution should be taken to avoid exposure to hazardous
radiation in the form of intense, focused, visible light.
•Exposure to this light may cause blindness.
Take these precautions:
•DO NOT remove any parts from the DustTrak™Environmental
Monitor unless you are specifically told to do so in this manual.
W A R N I N G
The use of controls, adjustments, or procedures other
than those specified in this manual may result in
exposure to hazardous optical radiation.
W A R N I N G
If the DustTrak™monitor is used in a manner not
specified by the manufacturer, the protection
provided by the equipment may be impaired.
When operated according to the manufacturer’s instructions, 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.

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Labels
Advisory labels and identification labels are attached to the instrument.
1. Serial Number Label (back)
2. Laser Radiation Label
(internal)
3. Calibration Label (back)
4. IP Label (back)
5. European symbol for non-
disposable item. Item must
be recycled.
6. MCERTS Certification Label(s)
854201-M1
854001-M1
854301-M1
DANGER!
VISIBLE LASER RADIATION WHEN
OPEN. AVOID DIRECT EXPOSURE
TO BEAM
WARNING: NO USER SERVICABLE
PARTS INSIDE. REFER SERVICING
TO QUALIFIED PERSONNEL
Calibrated
Customer Service 1-800-874-2811
Outside US 001-651-490-2811
www.tsi.com
Date: January 2015
USB IP Address:
199.254.130.225

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Description of Caution/Warning Symbols
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.
Caution
C A U T I O N
Failure to follow the procedures prescribed in this
manual might result in irreparable equipment
damage. Important information about the operation
and maintenance of this instrument is included in
this manual.
Warning
W A R N I N G
Warning means that unsafe use of the instrument
could result in serious injury to you or cause damage
to the instrument. Follow the procedures prescribed.
Caution and Warning Symbols
The following symbols may accompany cautions and warnings to
indicate the nature and consequences of hazards:
Warns that the instrument contains a laser and that
important information about its safe operation and
maintenance is included in the manual.
Warns that the instrument is susceptible to electro-
static discharge (ESD) and ESD protection should be
followed to avoid damage.
Indicates the connector is connected to earth ground
and cabinet ground.

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Reusing and Recycling
As part of TSI®Incorporated’s effort to have a
minimal negative impact on the communities in which
its products are manufactured and used:
DO NOT dispose of used batteries in the trash.
Follow local environmental requirements for
battery recycling.
If instrument becomes obsolete, return to TSI®for
disassembly and recycling.

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Chapter 1
Product Overview
DustTrak™ Environmental Models 8540, 8540-M, and 8542-M and
DustTrak™DRX Environmental Models 8543 and 8543-M Monitors
are data-logging, light-scattering laser photometers that provide real-
time mass concentration readings for aerosol contaminants such as
dust, smoke, fumes and mist. These instruments use a sheath air
system that isolates the aerosol in the optics chamber to keep the
optics clean for improved reliability and low maintenance. These
monitors offer a suitable solution for long-term outdoor monitoring,
construction and environmental clean-up sites.
DustTrak™Environmental Monitors (Model 8540,
8540-M, and 8542-M)
The DustTrak™Environmental Monitors are continuous, real-time,
single-channel, 90° light-scattering laser photometers that are used to
determine the mass concentration of aerosols. A robust, long-life
pump allows for the use of a variety of size-selective inlet conditioners
to measure aerosol concentrations corresponding to PM10, or PM2.5.
DustTrak™DRX Environmental Monitors (Model 8543
and 8543-M)
The DustTrak™DRX Environmental Monitors are continuous, real-
time light-scattering laser photometers that simultaneously measure
size-segregated mass fraction concentrations corresponding to PM1,
PM2.5, and PM10—something no other monitor can do. The instrument
combines both particle cloud (total area of scattered light) and single
particle detection to achieve mass fraction measurements. This size-
segregated mass fraction measurement technique is superior to either
a basic photometer or optical particle counter (OPC). It delivers the
mass concentration of a photometer and the size resolution of
an OPC.
The DustTrak™Environmental Monitors are designed to operate
inside the TSI®Environmental Enclosure (Model 854038) which has
an International Protection Marking of IP44. The DustTrak™
Environmental Monitor should not be used outdoors without an
appropriate weather-proof enclosure.

2 Chapter 1
Models 8540-M, 8542-M, and 8543-M MCERTS
Certified Monitors
DustTrak™ Environmental Monitor Models 854201-M1, 854001-M1 or
854301-M1, have been designed to meet the UK’s MCERTS
(Monitoring Certification Scheme) for indicative instruments. The
following must be installed for these models to meet the
MCERTS Indicative Certification:
854201-M1: MCERTS PM10 Indicative Certification
❑8542-M Photometer
❑854038 Environmental Enclosure
❑854020 PM10 Impactor
❑854041 Heated Inlet
❑PCF set at 0.53 (preset at the factory). It is recommended that the
instrument is run with a Photometric Correction Factor (PCF) of
0.53. However, the application of a site specific correction factor
may be used if a significant decrease in the expanded uncertainty
can be demonstrated.
854001-M1: MCERTS PM2.5 Indicative Certification
❑8540-M Photometer
❑854038 Environmental Enclosure
❑854021 PM2.5 Impactor
❑854041 Heated Inlet
❑PCF set at 0.33 (preset at the factory). It is recommended that the
instrument is run with a Photometric Correction Factor (PCF) of
0.33. However, the application of a site specific correction factor
may be used if a significant decrease in the expanded uncertainty
can be demonstrated.

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854301-M1: MCERTS PM10 and PM2.5 Indicative Certification
❑8543-M Photometer
❑854038 Environmental Enclosure
❑854041 Heated Inlet
❑PCF PM2.5 set at 0.47, PM10 set at 0.53 (preset
at the factory). It is recommended that the
instrument is run with a Photometric Correction Factor (PCF) of
0.53. However, the application of a site specific correction factor
may be used if a significant decrease in the expanded uncertainty
can be demonstrated.

4 Chapter 1
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Chapter 2
Unpacking and Parts Identification
Carefully unpack the Model 8540/8540-M/8542-M/8543/8543-M
DustTrak™Environmental 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™Monitor
Compare all the components you received with those listed in the
table below. If any parts are missing, contact TSI®.
Item
Qty
Part Number
Description
1
8540
8540-M
8542-M
8543
8543-M
DustTrak™
Environmental
Monitor
DustTrak™DRX
Environmental
Monitor
1
1090014
Data Analysis
Software CD-ROM
1
1303740
USB cable
1
854052
12 VDC power
supply

Chapter 2
6
Item
Qty
Part Number
Description
1
6008408
Operation and
Service Manual
1
N/A
Calibration
Certificate
User Replaceable Internal Parts
Item
Part Number
Description
854044
Sheath Air Filter
854043
Pump
NA
37-mm, 2-piece,
static conductive
cassette
Blank replacement cassettes or media can be ordered from
www.zefon.com.
37-mm 2-piece blank cassette product # 37MMH-2-CF
Zefon can also supply pre-weighed filter media for gravimetric sampling.

Unpacking and Parts Identification
7
Optional Accessories
Item
Part Number
Description
854038
Environmental
Enclosure
801905
Netronix™
Thiamis™1000
Communication
Node
854040
Omni-directional
Inlet w/Water Trap
Bottle
854041
Heated Inlet
Sample Conditioner

Chapter 2
8
Item
Part Number
Description
854039
Enclosure Power
Supply
854042
Water Trap Bottle
854020
PM10 Impactor
854021
PM2.5 Impactor
854022
PM1.0 Impactor
Parts Identification for the DustTrak™Environmental
Models 8540/ 8540-M/ 8542-M/8543/8543-M
Figure 1: Features on Models 8540/8540-M/8542-M/8543/8543-M

Unpacking and Parts Identification
9
Figure 2: Back panel interface control dimensions
Figure 3: View of back panel with mounting holes shown
Holes are pre-drilled in the back of the photometer to enable users to
develop their own mounting bracket for attaching the photometer into
an alternate enclosure.
Mounting the photometer using these holes will need quantity four (4)
#6-32 screws that penetrate no deeper than 0.230” into the back
panel of the photometer.

Chapter 2
10
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