TSI Instruments DUSTTRAK 854060 User manual

DUSTTRAK™AEROSOL MONITOR
SOLAR POWER KIT
MODEL 854060
(FOR DUSTTRAK™ II AND DRX AEROSOL MONITOR
MODELS 8540 AND 8543)
OPERATION AND MAINTENANCE MANUAL
P/N 6008416, REVISION B
JUNE 2016

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Copyright©
TSI Incorporated / 2015–2016 / All rights reserved.
Part Number
6008416A / Revision B / June 2016
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 internal pump for Models 8530 and 8533 is warranted for two (2) years or
4000 hours, whichever comes first;
c. DustTrak External pump for Models 8530EP and 8533EP is warranted for two (2)
years or 8760 hours, whichever comes first;
d. Environmental DustTrak pump for Models 8540 and 8543 is warranted for two (2)
years or 8760 hours, whichever comes first;
e. 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;
f. 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;
g. 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;
h. 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;
i. 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.

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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 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) 490-2811 (International) or visit www.tsi.com.
Trademarks
DustTrak™ and TrakPro™ are trademarks of TSI Incorporated. Netronix is a trademark
of Netronix Inc. Velcro is a registered trademark of Velcro Industries B.V.

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Contents
Contents.............................................................................................. 1
Safety Information ............................................................................. 1
Description of Caution/Warning Symbols ................................................ 3
Caution and Warning Symbols................................................................ 3
Reusing and Recycling............................................................................ 4
Product Overview .............................................................................. 4
Setting Up ...........................................................................................4
Operation ..........................................................................................16
Overview ............................................................................................... 16
Specifications................................................................................... 17

2 DustTrak Aerosol Monitor Solar Power Kit Model 854060
Safety Information
W A R N I N G S
Use of components other than those specified by
TSI may impair the safety features provided by
the equipment.
The instrument has been design to be used with
batteries supplied by TSI. Do not use a substitute
Old batteries must be properly recycled in
accordance with the local environmental
regulations.
Do not use non-rechargeable batteries in this
instrument. Fire, explosions, or other hazards
may result.
If the solar power kit is used in a manner not
specified by the manufacturer, the protection
provided by the equipment may be impaired.
Do not connect the Solar Cells directly to the
854030 Environmental Enclosure as this may
result in damage. The Solar Cells must be
connected to the Solar Battery Enclosure Box so
they can be regulated by the Solar Charge
Controller.
C a u t i o n
The enclosure is designed to be water resistant
to rain or spray. It has a NEMA rating of 3R. It is
not designed to be waterproof when immersed.
Setting it in a pool of water will result in flooding
the inner compartment with water. This will
severely damage both your battery pack.
Do NOT set the Environmental Enclosure in
water!

Operation and Maintenance Manual 3
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.
Product Overview
The solar power kit provides power to allow continuous monitoring of
Model 854030 Environmental Enclosure.
Setting Up
W A R N I N G
Refer to Solar charger manual for further installation
and operation instructions.
The setup of the Environmental Enclosure is an important part in
allowing reliable and accurate sampling of aerosols in a wide range of
conditions. TSI cannot ensure accurate measurements if any of the
components are set up incorrectly. Failure to follow these procedures
could result in damage to the enclosure or its components.
Note
Prior to using the Battery Pack for the first time, a full
recharge is recommended. Recharging Battery Pack(s)
immediately after use (within one hour maximum) is
critical to obtaining optimal recharge time, battery
health, and battery life.

Operation and Maintenance Manual 5
The full Solar Cell Power System is shown in Figure 1. The following
section details the setup of this system.
I m p o r t a n t
Make all Solar Cell Power System electrical connections
in the order outlined below. Damage to the system can
occur if connections are not made in this order.
Figure 1: Solar Cell Power System
1. Remove the Solar Battery from its packaging and place it in the
Solar Battery Enclosure box. Make sure that the battery positive
(+) terminal is on the left (the positive terminal is noted on the
battery with a RED marking). Remove the battery terminals using
an adjustable wrench and connect the ring terminal ended wires
from the solar charge controller to the battery terminals (see
Figure 2).
Note
There are two wires coming from the charge controller:
one is BLACK and is labeled (+); the other is WHITE and
is labeled (–).
The BLACK (+) wire should be connected to the battery
positive (+) terminal, which has a red marking on the top
of the battery.
The WHITE (–)wire should be connected to the battery
negative (–)terminal.

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Figure 2: Install the Solar Battery and Connect to Controller
2. The next step is to attach the provided power cables with
waterproof connectors to each Solar Cell.
Remove the Solar Cell from its packaging and access the junction
box on the end of the panel. Remove the screws and sealing strip
from inside the box and set aside. Remove the center of one of
the access holes which is labeled ½”. Pass the power cable
through that access hole while attaching the individual pieces of
the cable strain relief, as shown in Figure 3.
Figure 3: Strain Relief and Power Cable through Access Hole

Operation and Maintenance Manual 7
3. Next, attach the power cable to the Solar Cell screw terminals as
shown in Figure 4 and Figure 5.
Note
Make sure the wires are connected as shown below.
Connecting the wires incorrectly can cause severe
damage to the Solar Power System. Refer to the Solar
Cell manufacturer’s specification sheet for additional
details.
BLACK power cable wire connected to RED Solar Term.
This is the POSITIVE (+) connection.
WHITE power cable wire connected to GREY Solar Term.
This is the NEGATIVE (-) connection.
Figure 4: Power Cable
Connection to Solar Cell
Terminals (Supplier part
number 485J and 490J.
See solar panel
instructions for details.)
Figure 5: Power Cable
Connection to Solar Cell
Terminals. (Supplier part
number 90J. See solar
panel instructions for
details).
Negative (-) Positive (+))
Negative (-) Positive (+))

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4. With the wires
tightened,
secure the
terminal block
in its retaining
clips, and
tighten the
strain relief
connections
to the power
cable as
shown in
Figure 6.
Figure 6: Secure Terminal Block and Tighten
Strain Relief
5. Next, attach
the sealing
strip to the
inside of the
junction box
cover, as
shown in
Figure 7.
Figure 7: Apply Sealing Strip to Junction
Box Cover

Operation and Maintenance Manual 9
6. Then attach
the cover to
the junction
box using the
supplied
screws, as
shown in
Figure 8.
Figure 8: Attach Junction Box Cover
7. Now attach the two Solar Cells to the adjustable angle Mounting
Frame using the supplied bolts, as shown in Figure 9.
Figure 9: Assemble the Solar Cells on the Mounting Frame

10 DustTrak Aerosol Monitor Solar Power Kit Model 854060
8. The support bar may also be attached to each side of the
Mounting Frame, as shown in Figure 10.
Figure 10: Assemble the Support Bar to the Mounting Frame
For best results, mount the Solar Cells at an angle directly
pointed at the path of the sun, allowing the maximum power to be
collected by the Solar Cells.
To secure the Mounting Frame to the ground, use the bolt
locations at the end of each frame arm, or add sandbags or other
weights to the support bar.
9. Connect the Solar Cell cables to the Solar Battery Enclosure box
as shown in Figure 11. The Green LED on the Solar Charge
Controller will illuminate when sunlight power is available, and the
Solar Battery is charging.
W A R N I N G
Do not connect the Solar Cells directly to the
854030 Environmental Enclosure as this may result
in damage. The Solar Cells must be connected to
the Solar Battery Enclosure Box so they can be
regulated by the Solar Charge Controller.

Operation and Maintenance Manual 11
Figure 11: Connect Solar Cells to Battery Enclosure Box
10. Connect the Solar Battery Enclosure to the provided outdoor DC
power cable with weatherproof connectors, as shown in
Figure 12.
Figure 12: Connect Power from the Solar Cell Power System
to the Environmental Enclosure

12 DustTrak Aerosol Monitor Solar Power Kit Model 854060
11. Insert the cable into the cable assembly as shown in Figure 13.
Figure 13: DC Cable Preparation
12. Remove bottom left plastic plug from the DustTrak Environment
Enclosure and insert the cable through the hole as shown in
Figure 14.
Figure 14: DC Cable Preparation

Operation and Maintenance Manual 13
13. Using a small
screwdriver, connect
the bare wires to the
front panel connector
outside of the
enclosure as shown
in Figure 15. The blue
wire to terminal “N”
and the brown wire to
terminal “L”.
Figure 15: DC Cable Preparation
14. Rotate connector to
align tab on the
connector to the notch
in the enclosure hole.
Figure 16.
Figure 16: DC Cable Connector

14 DustTrak Aerosol Monitor Solar Power Kit Model 854060
15. While holding the
connecter in the
enclosure notch,
tighten the back-
shell onto the
connector as
shown in
Figure 17.
Figure 17: DC Cable Backshell
16. Tighten the gland
nut into the back-
shell as shown in
Figure 18.
Figure 18: DC Cable Gland Nut

Operation and Maintenance Manual 15
17. Connect phoenix grey connector to the power input on the DIN
rail as shown in Figure 19.
Figure 19: DC Cable to DIN rail
18. Affix DC label next to DC input connector as shown in Figure 20.
Figure 20:DC Power Label

16 DustTrak Aerosol Monitor Solar Power Kit Model 854060
19. Connect DC power cord from solar enclosure as shown in
Figure 21.
Figure 21: DC Cable from Solar Battery to
Environmental Enclosure
Operation
Overview
Prior to using the Solar Cell Power System for the first time, a full
recharge of the Solar Battery is recommended. Simply allow the Solar
Battery to charge for a day with sunlight power from the connected
Solar Cells.
The Solar Charge Controller has built-in low voltage cutout protection
for the Solar Battery. If extended non-sunlight conditions occur,
causing the Solar Battery to become deeply discharged, the Solar
Charge Controller temporarily cuts off output power. The Red LED on
the Solar Charge Controller will illuminate when this condition occurs.
Once sunlight returns, and the Solar Battery has been recharged to
an appropriate level, the Red LED will turn off and the Solar Charge
Controller will re-enable the power output.
The Green LED on the Solar Charge Controller will illuminate when
sunlight power is available, and the Solar Battery is charging.