TSI Instruments Dusttrak II 8530, Dusttrak II 8530EP, Dusttrak II 8532 Operation And Service Manual

DUSTTRAK™ II

AEROSOL MONITOR

MODEL 8530/8530EP/8532

OPERATION AND SERVICE MANUAL

P/N 6001893, REVISION S

DustTrak II 8530 Desktop and 8532 Handheld

JANUARY 2019

DustTrak II 8530EP Monitor

Copyright ©
TSI Incorporated / 2008–2019 / All rights reserved.

Address

TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA

Fax No.

[phone]
Limitation of Warranty and Liability (effective April 2014)

(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. DustTrak internal pump for Models 8530 and 8533 is warranted for operation within

ambient temperatures between 5–45°C. Warranty is void when the internal pump is
operating outside of this temperature range;

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.

i

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) 490-2860 (International) or visit www.tsi.com.

ii

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 .............................................................................. vii

CHAPTER 1 UNPACKING AND PARTS IDENTIFICATION ....................... 1

Unpacking the DustTrak II Aerosol Monitor ................................................. 2

Optional Accessories ............................................................................... 7

Parts Identification for the DustTrak II Desktop Aerosol Monitor

Models 8530 ............................................................................................ 8

Parts Identification for the DustTrak II Desktop Aerosol Monitor

Model 8530EP ......................................................................................... 9

External Pump Module (8530EP only) ........................................................ 9

Parts Identification for the DustTrak II Handheld Aerosol Monitor

Model 8532 ............................................................................................ 10

CHAPTER 2 SETTING UP ......................................................................... 11

Supplying Power to the DustTrak II Aerosol Monitor ................................. 11

Installing the Batteries in Model 8530/8530EP Desktop ........................ 11

Installing the Batteries in Model 8532 Handheld.................................... 12

Connecting the External Pump to DustTrak Model 8530EP .................. 12

Using the AC Adapter to Run Instrument .............................................. 14

Battery Charging .................................................................................... 14

Inlet Cap ................................................................................................ 15

Size-Selective Impactors ....................................................................... 15

Dorr-Oliver Cyclone ............................................................................... 16

Instrument Setup ....................................................................................... 16

Connecting to the Computer .................................................................. 16

Installing TrakProTM Data Analysis Software ......................................... 16

Connecting Analog/Alarm Output .......................................................... 17

Wiring the Analog Output .......................................................................... 18

Wiring the Alarm ........................................................................................ 18

CHAPTER 3 OPERATION ......................................................................... 19

Getting Started .......................................................................................... 19

For Model DustTrak 8530EP only ............................................................. 19

Setup Menu ............................................................................................... 22

Zero Cal ................................................................................................. 23

Flow Cal ................................................................................................ 24

User Cal ................................................................................................ 25

Alarm ..................................................................................................... 30

Analog ................................................................................................... 32

Settings ................................................................................................. 33

Run Mode .............................................................................................. 35

Survey Mode ......................................................................................... 36

Manual Mode ......................................................................................... 37

iii

Log Mode (1–5) ...................................................................................... 38

Locking Feature ......................................................................................... 39

Taking Mass Concentration Measurements ............................................... 41

Screen Regions ...................................................................................... 42

Stats ....................................................................................................... 43

Graphing ................................................................................................ 43

Viewing Data .............................................................................................. 45

Title Bar ..................................................................................................... 46

CHAPTER 4 MAINTENANCE ..................................................................... 47

Maintenance Schedule .............................................................................. 47

Zeroing Instrument ..................................................................................... 48

Cleaning the Inlet ....................................................................................... 48

Cleaning and Oiling Impactors ................................................................... 49

Replacing the Internal Filters ..................................................................... 50

Replacing the Filters in the External Pump Module ................................... 54

Storage Precautions .................................................................................. 54

CHAPTER 5 TROUBLESHOOTING ................................ ........................... 55

APPENDIX A SPECIFICATIONS .............................................................. 61

APPENDIX B ZERO MODULE .................................................................. 63

INDEX ........................................................................................................... 65

These Application Notes can also be found on TSI’s web site:

http://www.tsi.com

EXPMN-001 DustTrak II Theory of Operation.pdf
EXPMN-003 DustTrak II Impactor.pdf

iv

Safety Information

I M P O R T A N T

There are no user serviceable parts inside the instrument. Refer all repair
and maintenance to a qualified factory-authorized technician. All
maintenance and repair information in this manual is included for use by a
qualified factory-authorized technician.

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

There are no user-serviceable parts inside this instrument.
The instrument should only be opened by TSI or a TSI
approved service technician.

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.

Laser Safety

 The Model 8530/8532 DustTrak II monitor is a Class I laser-based

instrument.

 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 II monitor unless you are

specifically told to do so in this manual

 DO NOT remove the housing or covers. There are no serviceable

components inside the housing.

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.

v

Labels

1. Serial Number Label

(bottom)

2. Laser Radiation Label
(internal)

DANGER!

VISIBLE LASER RADIATION WHEN
OPEN. AVOID DIRECT EXPOSURE

TO BEAM

WARNING: NO USER SERVICEABLE

PARTS INSIDE. REFER SERVICING

TO QUALIFIED PERSONNEL

3. Battery label

or

4. European symbol for
non-disposable item.
Item must be recycled.

Advisory labels and identification labels are attached to the instrument.

vi

Description of Caution/Warning Symbols

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.

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.

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.

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

Warning

Caution and Warning Symbols

The following symbols may accompany cautions and warnings to indicate the
nature and consequences of hazards:

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.

vii

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viii

Note

If you purchased a DustTrak II Model 8530-NA (no accessories)
Aerosol Monitor, it only comes with the following items:

 DustTrak II Model 8530 Aerosol Monitor
 Operations manual
 TrakPro™ Data Analysis Software CD
 One-year calibration certificate
 Service paperwork
 2-year warranty

All accessories for the DustTrak II Model 8530 Aerosol Monitor
are sold separately. Contact TSI at [phone] for
information on accessories and how to purchase them through a
TSI sales representative.

Chapter 1

Unpacking and Parts Identification

Carefully unpack the Model 8530/8532 DustTrak™ II 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.

(continued on next page)

1

2

Unpacking the DustTrak II Aerosol Monitor

Item

Qty

Part Number

Description

or

1

8530

Desktop II

8532

Handheld II

1

801670

Desktop II
Carrying
Case

801669

Handheld II
Carrying
Case

1

1090014

Data Analysis
Software
CD-ROM

1

800663

Zero Filter

Compare all the components you received with those listed in the table
below. If any parts are missing, contact TSI.

Chapter 1

3

Item

Qty

Part Number

Description

or

1

801680

7800 mAH
Lithium Ion
Rechargeable
Battery
(Desktop)

801681

Rechargeable
lithium ion
battery
(Handheld)

1

1303740

USB cable
1

801652

Analog/alarm
output cable
(Desktop
models only)

1

6001893

Operation
and Service
Manual

1

N/A

Calibration
Certificate

Unpacking and Parts Identification

4

Item

Qty

Part Number

Description

1

801688

Conductive
Tubing

1

801668

Filter removal
tool (Spanner
Driver)

4

801673

Spare
Internal Filter
Elements
Desktop
Model Only

2

37-mm filter
includes:

Filter body
top

Filter body
bottom

Mesh screen

1

Comes with
37-mm
cartridge
opening tool

8

801666

Spare
Internal
Filters

Handheld
Model Only

1

801667

Impactor Kit

PM

2.5

assembled
Top
Bottom
Impaction Plate
PM

1.0

Top

PM

4.0

Top
PM10 Top
Extra Impaction Plate

1

801691

Dorr-Oliver
Cyclone

Chapter 1

5

Item

Qty

Part Number

Description

1

801684

Power Supply
– Desktop

801694

Power Supply
– Handheld

2

N/A

Stylus

When shipped, one stylus
will be in the accessory bag,
the second stylus attached to
instrument.

1

3012094

Screwdriver,
dual ended.
(For
Handheld
Models only)

1

801674

Impactor Oil

2

801698

Inlet cap

When shipped, one inlet will
be in the accessory bag, the
second inlet attached to
instrument.

1

801675

External
Pump Kit for
8530EP only

Unpacking and Parts Identification

6

Item

Qty

Part Number

Description

1

801797

External
Pump Power
Cable (to
DustTrak
monitor) for
8530EP only

1

801798

External
Pump Flow
Tube (to
DustTrak
monitor) for
8530EP only

1

Exhaust
Adapter,
DustTrak
monitor for
8530EP only

Chapter 1

7

Optional Accessories

Accessories

Qty

Part
Number

Description

1

801675

External Pump
Kit

2

801795

DustTrak II/DRX
External Pump
Service Kit for
8530EP only.
Contains two
filters for
External Pump

1

801685

Battery Charger,
2-Bay, Battery
801680 for
Desktop DustTrak
monitor

1

801686

Battery Charger,
Battery 801681
for Handheld
DustTrak monitor

The following photos and table list optional accessories. If you ordered
optional accessories, make certain they have been received and are in
working order.

Unpacking and Parts Identification

8

Parts Identification for the DustTrak II Desktop

Touchscreen

On/Off

Inlet

Stylus

Power

Analog/Alarm

Output

USB Host

USB Device

Ethernet

Filter Access

Zero Module
Connector

Battery Access

Aerosol Monitor Models 8530

Figure 1-1: Features on Desktop Model 8530

Chapter 1

9

Parts Identification for the DustTrak II Desktop

Exhaust Adapter External Pump

External Pump
Power Connection

External Pump
Flow Tubing

Pump Suction End

Pump Exhaust End

Pump Power Connection

User Replaceable HEPA Filters

Pump

Aerosol Monitor Model 8530EP

External Pump Module (8530EP only)

Unpacking and Parts Identification

Figure 1-2: Features on Desktop Model 8530EP

10

Parts Identification for the DustTrak II Handheld

On/Off

Inlet

Stylus

Touchscreen

Port Cover

Power

USB Device

USB Host

Filter Access

Battery Access

(Screw Lockdown)

Aerosol Monitor Model 8532

Figure 1-3: Features on Handheld Model

Chapter 1

W A R N I N G

The instrument has been design to be used with batteries
supplied by TSI. DO NOT use a substitute.

Disposing of old batteries must be recycled in accordance
with the local environmental regulations.

W A R N I N G

DO NOT use non-rechargeable batteries in this instrument.

Fire, explosions, or other hazards may result.

Chapter 2

Setting Up

Supplying Power to the DustTrak II Aerosol Monitor

The DustTrak II Aerosol Monitor must be powered by either batteries or using
the external AC adapter.

Installing the Batteries in Model 8530/8530EP Desktop

Remove the battery cover and slide one or two batteries into the battery slots.
A single battery can be put into either slot. Orient the batteries with the label
side facing up (see Figure 2-1).

Figure 2-1: Batteries into Desktop Unit

11

12

Installing the Batteries in Model 8532 Handheld

W A R N I N G

Turn the DustTrak monitor OFF before connecting the
external pump. Turn the DustTrak monitor ON only after
connecting the External Module.

Remove the battery cover by loosening captured screw on the bottom of the
unit. Orient battery with brass connectors facing forward. Insert battery into
cavity and slide forward to engage into pins. Replace the battery cover and
secure by tightening screw (see Figure 2-2).

Figure 2-2: Batteries into Handheld Unit

Connecting the External Pump to DustTrak Model 8530EP

The Model 8530EP is a Desktop DustTrak monitor with an external pump.
This DustTrak has no internal pump and will not work with any other external
pump other than the one provided by TSI (P/N 801675). The Model 8530EP
is intended for applications where the DustTrak is operated continuously over
extended periods (several days to months) under wide temperature
fluctuations (0 to 50°C). The external pump is designed to be more robust for
24/7 operation of the DustTrak monitor and is warranted to operate
continuously for one full year or 8760 hours. The Model 8530EP is ideal for
fugitive dust monitoring.

The pump and the DustTrak monitor come separately and require assembly.
Follow the steps below to connect the pump with the Model 8530EP
DustTrak monitor.

Chapter 2

13

1. Connect the pump end of the quick connect to the pump module (see

2. Likewise, plug one end of the power
connector to the pump module as
shown above. Turn the power
connector until it clicks and locks in
place. This prevents the connector
from disconnecting due to vibration
or movement.

3. Connect the exhaust adapter to the
exhaust of the DustTrak monitor
(see Figure 2-4).

Figure 2-4: Connect Exhaust

Adapter to Exhaust of

DustTrak Monitor

Figure 2-3).

Figure 2-3: Connect Pump End of Quick Connect to Pump Module

4. Connect the other end of the flow tubing to the exhaust adapter of the
DustTrak monitor.

5. Connect the other end of the power connector to the DustTrak monitor
(see Figure 2-5).

Setting Up

Figure 2-5: Connect Power Connector to DustTrak Monitor

14

W A R N I N G

The Pump module design does not allow for installation
outdoors without any protection from the elements. Always
operate it within an enclosure.

Notes

1. The power connector and the flow quick connect “click” when securely
connected. The power connector must be rotated clockwise past the
locking pin.

2. Do not hot-plug the External Pump Module when the DustTrak monitor
is turned ON. Always connect the External Pump module first and then
turn the DustTrak monitor ON.

3. TSI recommends that the DustTrak monitor with the external pump be
operated in the Model 8535 Environmental Enclosure.

4. TSI recommends that the pump module be operated when mounted on
its feet and avoid operating at other orientations as much as possible.

5. Pump module and the DustTrak monitor should be at the same
electrical potential.

6. The additional port on the external pump module is where the pump
exhausts the flow. For applications where the DustTrak monitor is
sampling from a chamber or a duct at pressures significantly different
from the ambient, TSI recommends plumbing the exhaust of the
external pump back in to the chamber/duct.

W A R N I N G

When Charging Battery the ambient temp MUST NOT
exceed 42°C.

The DustTrak external pump module does not require an A/C adapter. It is
always powered off the DustTrak monitor.

Using the AC Adapter to Run Instrument

The AC adapter allows you to power the DustTrak monitor from an AC wall
outlet. When using the AC adapter, the batteries (if installed) are bypassed.

Battery Charging

This instrument will charge the Lithium Ion battery packs. Insert the batteries
into the battery compartment, plug the instrument into AC power, and turn the
instrument on. Batteries will charge only when the instrument is on and in
stand-by mode. Batteries will not charge if the instrument is turned off or is
actively taken measurements. Charging will stop when the batteries are fully
charged.

Chapter 2

15

Inlet Cap

The size-selective impactor is
composed of three parts; the cap,
impaction plate and bottom. Selection
of the cap will determine cut size of
the impactor. Each cap is labeled with
the particle cut size (1 µm, 2.5 µm,

4.0 µm or 10 µm). The same

impaction plate and bottom are used
on all impactor sizes.

The impactor assembly is attached to
the instrument in place of the inlet cap.
The inlet cap does not need to be used
if an impactor is being used. See

Chapter 4, "Maintenance," for

instructions on how to add oil to the
impaction plate.

Figure 2-7:

Size-Selective Impactor

Impaction Plate

Cap (1 µm,

2.5 µm, 4 µm
or 10 µm)

Bottom

When using the DustTrak monitor to sample environmental air, the inlet cap
should be put over the instrument. This cap will keep large objects from
dropping into and plugging the inlet. The cap will also keep direct light from
shinning into the chamber and skewing the results.

The inlet cap can simply be pressed onto the instruments inlet.

Figure 2-6: Putting on Inlet Cap

Size-Selective Impactors

Size-selective impactors can be attached to the inlet of the DustTrak II
instruments. Size-selective impactors can be used to pre-condition the size
range of the particles entering the instrument. PM1, PM
and PM10 impactors are available. The instrument must run at the

factory default setting of 3.0 L/min for the impactors to achieve the
correct cut points.

, PM4 (Respirable)

2.5

Setting Up

16

Dorr-Oliver Cyclone

Note

To use TrakPro software with the DustTrak Aerosol Monitor, the
PC must be running Microsoft Windows® and the computer must
have an available Universal Serial Bus (USB) port.

A Dorr-Oliver cyclone is shipped with the instrument. The Dorr-Oliver cyclone
removes particles over 4.0 µm in size. The Dorr-Oliver cyclone is attached to
the instrument by sliding the cyclone clip over the protruding catch. The tube
from the Dorr-Oliver cyclone needs to be routed to the inlet of the instrument.

Figure 2-8: Installing Door-Oliver Cyclone

Do not use Inlet attachments (impactors or inlet cap) when using the Dorr­Oliver Cyclone. The instrument flow rate must be changed to 1.7 L/min

when using the Dorr-Oliver Cyclone in order to achieve a 4 µm
(respirable) cut-point. See the Flow Cal instructions in the Operations

chapter for instructions on how to change the instruments flow rate.

Instrument Setup

The DustTrak II monitor can be connected to a computer to download data
and upload sampling programs.

Connecting to the Computer

Connect the USB host port of a Microsoft Windows®-based computer to the
USB device port on the side of the DustTrak monitor.

Installing TrakProTM Data Analysis Software

TrakPro software can preprogram the DustTrak monitor, download data, view
and create raw data and statistical reports, create graphs, and combine
graphs with data from other TSI instruments that use TrakPro software. The
following sections describe how to install the software and set up the
computer.

®

Windows is a registered trademark of Microsoft Corporation.

®

Microsoft and Windows are registered trademarks of Microsoft Corporation.

Chapter 2

17

1. Insert the TrakPro Data Analysis Software CD into the CD-ROM drive.

Note

If the software does not start automatically after a few minutes,
manually run the program listed on the label of the CD using the

Run command on the Windows Start Menu.

Cable Wiring Diagram

Brown Wire

Analog Ground

Orange Wire

Analog Out

Red Wire

Alarm (+)

White Wire

Alarm (-)

Black Wire

Shield

Alarm Positive (+)

Alarm Ground (–)

Analog Output (+)

Analog Ground (–)

The install screen starts automatically.

2. Follow the directions to install TrakPro software.
TrakPro software contains a comprehensive installation guide. TSI

recommends printing out this guide prior to starting the TrakPro software
installation on your computer, so it may be consulted during the installation.
The TrakPro Software manual is located in the “Help” file in TrakPro
software. There is no separately printed TrakPro Data Analysis software
manual.

Connecting Analog/Alarm Output

The Analog/Alarm Output Cable plugs into the alarm connection on the side
of the instrument. This feature is on the desktop model 8530 only.

The cable contains a 4-pin, mini-DIN connector. The pin-outs for the
connector and the wiring for the cable are shown below.

4-pin miniDIN connector

Figure 2-9: Cable Wiring Diagram

Setting Up

18

Wiring the Analog Output

W A R N I N G

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.

C a u t i o n

The alarm switch MUST NOT be wired to AC power! Failure

to install the user alarm properly could damage the DustTrak
instrument and/or void the instrument warranty! Please read
and follow all instructions before wiring or operating the user
alarm.

W A R N I N G

When connected to the analog out and alarm out connector,
you MUST use safety certified equipment and/or power
sources.

System specifications:

 Output voltage: 0 to 5 VDC. With a maximum output of 15 mA.
 Output Current 4 mA to 20 mA with a maximum load impendence of

250 ohms.

 Correct polarity must be observed (see pin-outs above).

The output cable supplied by TSI (P/N 801652) is labeled with the pin-out
wiring diagram. Additional equipment may be needed for making connections
to the system that TSI does not supply. It is your responsibility to specify and
supply all additional equipment.

Wiring the Alarm

System specifications:

 Maximum voltage: 15 VDC (DO NOT USE AC POWER)
 Maximum current: 1 Amp
 Correct polarity must be observed (see pin-outs above)
 The alarm switch, located inside the DustTrak monitor must be located

on the ground side of the alarm system.

Chapter 2

W A R N I N G

Always setup and operate the DustTrak monitor with External
Pump Module with the External Pump Module connected to
the DustTrak monitor. Failure to do so will result in
communication errors.

Chapter 3

Operation

Getting Started

The START UP screen is displayed initially when the instrument is turned on,
following the initial TSI logo splash screen.

Use a stylus or fingertip, touch the “buttons” on the screen to activate
different menus.

For Model DustTrak 8530EP only

19

20

Communication errors take place under four different scenarios as follows:

Note

“No Pump is Connected” is a sticky error. Even after the warning
message, if the External Pump Module is connected to the
DustTrak, the error will not disappear until the screen is
refreshed. Refresh the screen by going into a different menu and
returning to the Main menu.

1. When the unit is idle and is not connected to the External Pump Module,
a warning displays on the Main screen.

2. When the unit is not connected to the External Pump Module and an
attempt is made to start a run by selecting “Start”, an error appears on
the Main screen.

Chapter 3

21

3. If the pump is not connected while attempting to perform a Zero Cal, an
error appears on the Setup screen.

4. If the pump is not connected while attempting to perform a Flow Cal, an
error appears on the Setup screen.

Operation

22

Setup Menu

Serial Number

The instruments serial number.

Model Number

The instruments model number.

Firmware Version

Instruments current version of firmware.

Calibration Date

Date of the last factory calibration.

Pump Run Time

Pump running time in hours.

Cum Mass Conc

Amount of mass run through instrument over life.

Cum Filter Conc

Amount of mass run through instrument since last
filter change.

Filter Time

Date of last filter change.

Pressing Setup activates the Setup Menu touchscreen buttons along the left
edge of the screen. Setup is not accessible when the instrument is sampling.

The main screen of the Setup screen displays the following information:

Chapter 3

23

Zero Cal

NEVER perform a zero cal without attaching a zero filter.

Run Zero Cal the first time the instrument is used and repeat prior to every
use. Zero Cal requires that the zero filter be attached prior to running. Zero
Cal must also be performed if the unit is reading negative concentrations. It is
not possible for the DustTrak to read negative concentrations. Negative
concentrations are a symptom of zero drift.

1. Press Zero Cal Button

2. Attach Zero Filter

3. Press the Start button to start Zeroing process.

4. A count-down clock will appear indicating the time remaining. The screen
with indicate “Zero Cal Complete” when done.

Remove filter after zeroing has been completed. The instrument is now zero
calibrated and ready for use.

Operation

24

Flow Cal

Note

The flow rate can be adjusted from approximately 1.5 to

4.0 L/min. If needed, this feature can be used to adjust the flow
rate to a value other than the factory set point, allowing for the
use with the provided Dorr-Oliver Cyclone (1.7 L/min required) or
3rd party size selective inlets (cyclones or impactors) that may
require a different flow rate.

Run Flow Cal to change the flow set point. The flow set point is factory set to
3 L/min total flow. 2 L/min of the total flow is measured aerosol flow. 1 L/min
of total flow is split off, filtered, and used for sheath flow. There is an internal
P flowmeter in the DustTrak II instrument that controls flow rate to ±5% of
the factory setpoint. TSI recommends checking the flow with an external flow
reference meter, especially when collecting data. The pump will automatically
start when entering the Flow Cal screen.

1. Attach a flow calibrator (reference flow meter) to inlet port. You may use
a bubble buret, mass flow meter, dry piston or rotameter as flow
measurement devices.

2. Move the arrows up or down to achieve desired flow rate on the
reference flowmeter. Each up or down arrow will change the flow about
1%. Allow time between button presses to let pump change to the new
flow rate.

Select Save once the desired flow rate is achieved. Select Undo to
return to the factory set point.

Chapter 3

25

User Cal

User Cal allows you to store and use 10 different calibration factors. In

addition, there are two factory defaults, one is the “Ambient Cal” and the
other is the “Factory Cal”. The “Ambient Cal” is appropriate for outdoor

ambient dust or fugitive dust monitoring. The “Factory Cal” is the calibration to
ISO 12103-1, A1 Arizona test dust for which a calibration certificate is
provided with the instrument. The “Factory Cal” is appropriate for most
workplace aerosol monitoring. The currently active user calibration is
highlighted with an asterisk “*”.

Four variables can be set for each user calibration.

Operation

26

Name

User can rename calibration to a description name.

Photometric

Changes the factory calibration of particle signal,
based on Arizona Road Dust, to actual aerosol being
measured. See below for sets to set this calibration.

User Cal [on,off]

Selecting On will activate current user calibration and
deactivate the previously selected user calibration.

Taking a Gravimetric Sample Using the DustTrak Monitor

Note

Use only the conductive plastic filter cassette holder (SKC
Part# 225-308).

When sampling with the DustTrak monitor, you can simultaneously take a
gravimetric sample either for custom calibration of the DustTrak monitor or for
collecting the sample on to the gravimetric filter downstream of the DustTrak
monitor without a need for additional gravimetric sampling pump and filter
assembly. To accomplish this, follow the instructions given below:

1. Setup the DustTrak monitor to sample how long you want the sample run
time to be. The following example shows a sample for 8 hours.

2. Under RunMode menu, put the instrument in Manual Log (Manual
Logging is reviewed later in this section), which will enable you to start
and stop the pump at any time you choose.

3. Set the logging interval. One minute (i.e., “01:00”) is a good choice.

4. Make sure you have a preweighed 37-mm gravimetric filter cassette
loaded into the DustTrak monitor. See Chapter 4, “Replacing the Internal

Filters” on how to access the filter (see figure 4-8) and replace it.

5. Under the Setup Menu, make sure the DustTrak monitor is set to the
desired flow rate. For DustTrak II Model 8530, the flow can be varied
from 1.7 to 4 L/min for use with various inlet conditioners. For
DustTrak DRX Model 8533, the flow cannot be changed. The flows for
DustTrak II monitor can be changed by changing the default flow
calibration setpoint from 1.0 to any value between 0.5 to 1.5 in the span
adjustment. An external flowmeter is needed to measure the total flow.
Flow can be changed by clicking on the UP or DOWN arrow keys shown
below:

Chapter 3

27

Note

The flow rate used for gravimetric analysis is only 2/3 the total
flow since 1/3 of the flow is used as sheath flow.

6. Conduct a preflow calibration on the DustTrak monitor using the same
kind of sample media you will sample with. Now, attach the sample
media you intend to sample with and start sampling aerosol for the
desired time. After the desired run time, stop the sampling. Remove the
filter from the DustTrak monitor and follow your laboratory’s criteria for
filter post weight. Conduct a post-flow calibration with the same sample
media done with the pre-flow calibration and determine if these flow
calibrations are within ±5% of each other. If they are, use the following to
calculate the actual flow rate for the DustTrak monitor. The laboratory will
need the following information to calculate mass concentration in mg/m3:

 Total sample time in minutes.
 Flow rate—flow rate of the DustTrak monitor used for gravimetric

analysis is only 2/3 the total flow since 1/3 of the flow is used as
sheath flow.

 Total liters of air sampled = total sample time x flow rate.

7. Using this information the laboratory can determine the concentration
using the following formula:







 



󰇛󰇜 󰇛󰇜

󰇛













󰇜

 󰇛󰇜

8. For instructions on how to calibrate the DustTrak monitor using this data,

see section below on “Determining the Calibration Factor for a Specific

Aerosol”.

Operation

28

Photometric Calibration Factor

In most situations, the DustTrak monitor with its built-in data logging capability
can provide very good information on how the concentration of an aerosol
changes for different processes over time. Factory calibration to the
respirable fraction of standard ISO 12103-1, A1 test dust is fairly
representative of a wide variety of workplace aerosols. Because optical mass
measurements are dependent upon particle size and material properties,
there may be times in which a custom calibration would improve your
accuracy for a specific aerosol.

Determining an aerosol specific photometric calibration requires that you
determine a true mass concentration (e.g., gravimetric analysis) for the
aerosol you want to measure. The true mass concentration is used to
calculate the custom calibration factor for that aerosol. Once you have a
custom calibration factor, you can reuse it each time you make
measurements in the same aerosol environment.

Determining the Calibration Factor for a Specific Aerosol

The DustTrak II monitor is factory calibrated to the respirable fraction of
standard ISO 12103-1, A1 test dust. The DustTrak monitor can be easily
calibrated to any arbitrary aerosol by adjusting the custom calibration factor.
The DustTrak monitor’s custom calibration factor is assigned the value of

1.00 for the factory calibration to standard ISO test dust. This procedure
describes how to determine the calibration factor for a specific aerosol. Using
the value of 1.00 will always revert back to the factory calibration.

To determine a new calibration factor you need some way of accurately
measuring the concentration of aerosol, hereafter referred to as the reference
instrument. A gravimetric analysis is often the best choice, though it is limited
to nonvolatile aerosols. The internal 37 mm filter cartridge, in the desktop
units, can be used to collect the reference gravimetric reference sample.

To make an accurate calibration you must simultaneously measure the
aerosol concentration with the DustTrak monitor and your reference
instrument.

1. Zero the DustTrak II monitor.

2. Put the instrument in Manual Log (Manual Logging is reviewed later in
this section).

3. Set the logging interval. One minute (i.e., “01:00”) is often a good choice.

4. Co-locate the DustTrak II monitor and the reference sampler together so
that they are measuring from the same area. The 37-mm filter cartridge
in the desktop unit can be used to collect the particles to be weighed for
the gravimetric reference.

5. Start sampling aerosol with both instruments at the same time.

Chapter 3

29

Note

Greater accuracy will be obtained with longer samples. The time
you permit for sampling often depends on the reference
instrument and characteristics of the measured aerosol. It may
take some time to collect sufficient aerosol onto a filter cassette
for accurate gravimetric analysis. Refer to instructions of your
reference instrument for sampling times.

6. Stop sampling with both instruments at the same time.

Note

If you used the internal gravimetric filter in the DustTrak Model
8530, the flow rate used to compute the concentration should be
2 L/min, not 3 L/min since only 2 L/min of aerosol flow reaches
the filter.

CurrentCal

ionConcentrat DustTrak

ionConcentrat Reference

NewCal 













7. Record the DustTrak monitor average concentration by viewing the
sample average in the Data screen. (Data Screen is reviewed later in this
chapter.)

8. Determine the mass concentration in mg/m3 from your reference
instrument. For gravimetric sampling this means weighing the gravimetric
sample.

9. Compute the new calibration constant, NewCal, using the following
formula:

10. Select Photometric from the User Cal drop down selection and enter the
NewCal factor using the onscreen controls.

Operation

30

Alarm

Note

The Alarm is dependent on the logging interval. For the DustTrak
to alarm as soon as the Alarm Setpoint is exceeded, the logging
interval must be set as low as possible (i.e., 1 second or
2 seconds). If a long test duration does not permit setting such a
short logging interval, use the STEL alarm instead. The STEL is
always based on 1 second concentrations and is independent of
the logging interval. For more details on the STEL alarm, see
section below on STEL.

In Survey mode, the alarm is dependent on the time constant.

Alarm allows you to set an alarm level that will be triggered if the instrument’s
reading goes above the setpoint. However, the alarm functioning is
determined by the logging interval. The alarm will turn ON only if the average
concentration over the logging interval exceeds the set point. If the logging
interval is too long and the concentration exceeds the set point and stays at
that level, the alarm will not turn ON until after the logging interval has
passed. Likewise, the alarm will not stop until after the concentration has
dropped below 5% of the threshold and after the logging interval has passed.

Chapter 3

31

Alarm1 Setpoint [mg/m3]

The alarm1 setpoint is the mass
concentration level upon which the alarm1 is
triggered.

Alarm will trigger if the mass concentration,
taken at the logging interval, rises above the
setpoint.

Note

Alarm 2 must be lower than Alarm 1 when
both alarms are enabled.

Alarm1 Relay [On, Off]

When the relay alarm is turned on, unit will
close relay switch when Alarm1 level is
surpassed.

Relay selection is available on the 8530
desktop model only.

Alarm1 STEL [On, Off]

When the STEL alarm is turned on, STEL
data will be collected when Alarm1 level is
surpassed.

STEL selection is available on the 8530
desktop model only.

See STEL Note below.

Alarm2 Setpoint [mg/m3]

The alarm2 setpoint is the mass
concentration level upon which the alarm2
triggers.

Alarm triggers if the mass concentration,
taken at the logging interval, rises above the
setpoint.

Note

Alarm 2 must be lower than Alarm 1 when
both alarms are enabled.

Alarm2 Enable [On, Off]

Enables Alarm2 to be logged and will
activate the Audible or Visible alarms if they
are enabled.

Alarm Audible [On, Off]

When the audible alarm is turned on, the
instrument will activate internal beeper when
Alarm1 or Alarm2 level is surpassed.

Alarm1 Visible [On, Off]

When the visible alarm is turned on, unit will
show the alarm icon (Alarm1 , Alarm 2

) in title bar when Alarm1 or Alarm2

level is surpassed.

Operation

32

STEL Alarm

STEL indicator

The STEL indicator
will show Red on the main screen.

Data

Data will be taken of the STEL alarm channel at
a 1 minute logging interval for 15 minutes.

This data will be stored in a separate file named
STEL_XXX, where XXX will be matched to the
logged data file.

The instrument will also continue to log the mass
concentration data at the logging interval
selected.

STEL Alarm repeat

If the instrument remains over the STEL limit
after the 15 minute interval, or if the instrument
exceeds the STEL limit later during the sample
period, additional STEL files will be generated.

STEL stands for Short Term Exposure Limit. When a STEL alarm is selected,
the instrument will inspect the data on a second by second basis,
independent from the selected logging interval. If the mass exceeds the STEL
limit, then a STEL event triggers and the following actions will be taken.

Analog

Chapter 3

33

Analog setup screen sets the parameters that will drive the analog out port.

Analog out [On, Off]

Turns analog out port on.

Size Fraction

Selects the size channel that will drive the
analog out.

Output Setting [V, mA]

Select between 0 to 5 V and 4 to 20 mA.

Lower Limit [mg/m3]

Mass concentration reading of the selected
channel that will correspond to 0 V or 4 mA.

Upper Limit [mg/m3]

Mass concentration reading of the selected
channel that will correspond to 5 V or 20 mA.

Date Time

Sets current date, current time and date/time format.
Time can be set in 12 or 24 hour format. Date can be
set in yyyy/dd/mm, yyyy/mm/dd or yyyy/dd/mm.

Applies to the 8530 Desktop model only.

Settings

Settings screen sets basic unit parameters.

Operation

34

Background

Switches between blue and white backgrounds.

Touch Cal

Calibrates the touch cal screen.

IP

USB PORT IP Address:

USB IP is the address assigned to the instrument by
the NDIS driver. It is shown but cannot be changed.

Ethernet Port IP parameters:
(Model 8530 Desktop only.)

IP method can be set to static or dynamic.
For static IP, IP address, default gateway, and subnet

mask can be set.
For Dynamic, The IP assigned by the network is

shown. This cannot be changed.
See Note below.

Chapter 3

35

IP Note

After changing the instrument to Dynamic or Static,
reboot the instrument.

In Dynamic Mode, the unit will show the IP to which is
assigned (after being rebooted).

Language

Switches between display languages. After changing
the display language, reboot the instrument.

Run Mode

Operation

36

The RunMode tab brings up sampling mode options.

Survey

Survey Mode runs a real time, continuous active sample,
but does not log data.

Manual

Manual Log sets the instrument to log data for a
specified run time.

Log Modes

Log Mode starts and stops the instrument at specified
times, run for a specified test length, and perform
multiple tests of the same length with a specified time
period between tests.

Time Constant

Time Constant can be set from 1 to 60
seconds. This will control the update rate of
the main screen. It is the rolling average of
data displayed on the main screen and is not
linked to logged data in either Manual or
Program Log modes.

Auto Start on Power Up

When set to “Yes”, unit will start a
measurement upon being powered on, if the
unit was set to “Survey” when it was turned
off.

When set to “No”, the unit will be in idle when

it is powered on.

Sampling mode options include Survey Mode, Manual Log, and

Log Mode 1-5.

Survey Mode

Chapter 3

37

Manual Mode

Log Interval

The log interval can be set from 1 second to 60
minutes. It is the amount of time between logged data
points.

Test Length

Test length can be set from 1 minute to the limit of the
data storage.

Time Constant

Time Constant can be set from 1 to 60 seconds. This
will control the update rate of the main screen. It is the
rolling average of data displayed on the main screen
and is not linked to logged data in either Manual or
Program Log modes.

In Manual mode, data will be stored to a file named “Manual_XYZ” where
XYZ is an incrementing integer.

Operation

38

Log Mode (1–5)

Log Name

Log Name, brings up a virtual keypad to name the
Logged Data file.

Start Date

Start Date, select the date the test will start.

Start Time

Start Time, select the time the test will start.

Log Interval

The log interval can be set from 1 second to 60
minutes. It is the amount of time between logged
data points.

Auto Zero Interval

Interval between re-zeroing the instrument using
the Auto-Zero accessory. Model 8530 desktop
only.

Test Length

From 1 minute to the limit of the data storage.

Number of Tests

Number of tests, 1 to 999.

Time between Tests

Time between tests, 1 minute to 30 days.

Time Constant

Time Constant can be set from 1 to 60 seconds.
This will control the update rate of the main
screen. It is the rolling average of data displayed
on the main screen and is not linked to logged
data in either Manual or Program Log modes.

Use Start Date

Use Start Date, option to use programmed start
date or by pass programmed start date.

Use Start Time

Use Start Time, option to use programmed start
time or bypass programmed start time.

Chapter 3

39

In Log mode, data will be stored to a file named “LogName_XYZ” where

Note

This feature is only available on Desktop models. It is not
available on Handheld models.

LogName is the user entered log name and XYZ is an incrementing integer.

Locking Feature

The locking feature allows you to lock the screen at any time. This can be
done during mass concentration measurements and while the instrument is
idle.

To enable this feature, touch the Lock button on the main screen.

Next enter the model of the instrument. For 8530EP models, 8530 should be
used. After entering the model number, touch OK.

Operation

40

The screen is now locked.

Note

If you happen to enter the model number incorrectly and touch
OK, you will be given another chance to enter it correctly. There
is no limit to number of chances.

To unlock, touch UNLOCK and re-enter the model number. For 8530EP
models, 8530 should be used. After entering the model number, touch OK.

Chapter 3

41

Taking Mass Concentration Measurements

Measurements are started and controlled from the main screen.
Prior to starting a measurement the instrument should be zeroed from the

Setup screen and the run mode should be configured and selected from the
RunMode screen.

When the instrument is on, but not taking any mass measurements the start
button will be green and instruments pump will not be running. To start taking
a measurement, press the green start button.

For the Model 8530EP DustTrak monitor with external pump, make sure the
external pump is connected to the DustTrak monitor as described in

Chapter 2. If the pump is not connected and the green start button is pressed,

the DustTrak monitor will identify that the pump is not connected and a
warning will be displayed as shown below:

Operation

42

Connect the External Pump Module to the DustTrak monitor and then try

Mass Reading

Shows the instruments mass measurements.

Run Mode Region

Shows the run mode selected from the
RunMode screen.

File Name Region

Displays the file name to which the data is
currently being saved.

Test Progress Region

Shows the time-based progress of the test.

Error Indicator Region

Shows the current stats of the instrument
STEL: Shows if STEL is in progress (desktop

instruments only)
Flow: Status of the flow control
Laser: Status of the Laser
Filter: Status of the Filter
See Chapter 5, "Troubleshooting," to resolve

any of these error conditions.

again. TSI recommends powering down the DustTrak monitor before
connecting the External Pump Module to the DustTrak monitor. Connect the
power cable and the flow tubing between the DustTrak monitor and the
External pump module, as applicable.

While taking a measurement the screen will display the current measured
mass concentration. The various regions of the screen are shown below.

Screen Regions

Chapter 3

43

Stats

Time Display

(live area)

Scale Display

(live area)

Data Region

(live area)

The Stats button shows the statistics of the mass measurement. When the
Stats button is pressed, the main mass reading will reduce in font size, and
the measurement statistics will show on the right side of the screen.

Graphing

During sampling, pressing the Graph button displays current readings in
graphical form.

 During Survey Mode, five (5) minutes of running real-time data is

displayed graphically.

 During Logging Mode, the entire log test time is displayed on the graph.

Operation

44

Time Display

Pressing the Time x-axis label on the graph screen
switches between Time (s), Time (abs), and Time (rel).

Time (s): Elapsed time from first logged point (log
interval) to the last logged point (test length).

Time (rel): Relative time from zero to last logged point
(test length – log interval).

Time (abs): Absolute time from first logged point (test
start + log interval) to last logged point (test stop).

Scale Display

Pressing in the Scale Display area will
bring up a dialog that will allow
changing between auto scaling and
user scaling of the Y-axis.

Data Region

Pressing the data region will bring up
a dialog to show TWA or Average
lines.

TWA: Will show a secondary line on
the graph showing the time weighted
average of the data. This line will not
show if test time is less than 15
minutes.

Average: Show a secondary line on
the graph of the running average of
the data.

In Graphing Mode, pressing Main returns the instrument to the Main Screen
display.

Chapter 3

45

Viewing Data

Select File

Press the arrows on the right side of the screen to
scroll up or down to the data file to be viewed.

Data Statistics

Statistics on the selected file

o File Name
o Sample Average
o Sample TWA
o Sample Maximum Reading
o Sample Minimum Reading
o Number of Data Points in the File

Save All Button

Downloads data to a USB thumb drive. The USB
thumb drive must be attached to the USB host port.
Data is saved as a .csv file that can be viewed in
Microsoft® Excel® spreadsheet software.

Delete Button

Deletes the currently highlighted file.

Delete All Button

Deletes all the files stored on the instrument.

Graph Button

Data can also be viewed in graphical form by
pressing the Graph button while the data file is
highlighted.

The Data button opens a list of data files for viewing.

Operation

46

Title Bar

Current Screen

Title of the current screen that is being displayed.

Instrument Lock

Icon shows if the instrument touchscreen is in an
unlocked or locked condition.

Unlocked:
Locked:

To lock the touchscreen controls, touch the “lock”

icon, immediately followed by three (3) quick touches
on the current screen (Main) word along the top tool
bar.

Repeat the process to unlock the screen.

Battery Status

Show the current % life of the battery and show if the
battery is currently being charged:

Charging: (unfilled portion of the icon is filled
yellow as well as animated to indicate that the

charging is in progress)
Not Charging: (unfilled portion of the icon

transparent)

Date and Time

Indicates the instruments current date and time.

Alarm

If the instrument is in an alarm status, an alarm icon

will appear in the title bar.

Current Screen

Date

,

Time

Battery Status

Instrument Lock

The Title Bar shows common instrument information.

Chapter 3

W A R N I N G

There are no user-serviceable parts inside this instrument.
The instrument should only be opened by TSI or a TSI
approved service technician.

Item

Frequency

Perform zero check

Before each use.

Clean inlet

350 hr. at 1 mg/m3*

Clean 2.5 µm calibration impactor

Before every use.

Replace internal filters

350 hr. at 1 mg/m3* or when
indicated by the main screen
filter error indicator.

Return to factory for cleaning and
calibration (For 8530EP, TSI recommends
that both the DustTrak and the External
Pump Module be returned to TSI)

Annually
Replace the internal HEPA filters in the

External Pump module

Annually

Chapter 4

Maintenance

The DustTrak II aerosol monitor can be maintained in the field using the
instructions below. Additionally, TSI recommends that you return your
DustTrak II monitor to the factory for annual calibration. For a reasonable fee,

we will quickly clean and calibrate the unit and return it to you in “as new”

working condition, along with a Certificate of Calibration. This “annual
checkup” helps ensure that the DustTrak II monitor is always in good

operating condition.

Maintenance Schedule

The DustTrak II Aerosol Monitor requires maintenance on a regular basis.
Table 4–1 lists the factory recommended maintenance schedule.

Some maintenance items are required each time the DustTrak monitor is
used or on an annual basis. Other items are scheduled according to how
much aerosol is drawn through the instrument. For example, TSI
recommends cleaning the inlet sample tube after 350 hours of sampling a
1 mg/m3 concentration of aerosol. This recommendation should be pro-rated
according to how the instrument is used. 350 hours at 1 mg/m3 is the same
amount of aerosol as 700 hours at 0.5 mg/m3 or 175 hours at 2 mg/m3, etc.

Table 4–1. Recommended Maintenance Schedule

*Pro-rated, see discussion above.

47

48

The DustTrak monitor keeps track of the accumulated amount of aerosol
drawn through it since its last cleaning. When the internal filter replacement is
due, the filter error indicator will turn from green to red.

TSI recommends you perform a zero check prior to each use for the DustTrak
monitor and certainly before running any extended tests, and after the
instrument experiences a significant environmental change. Examples of
significant environmental changes would be ambient temperature changes
that exceed 15 F (8 °C) or moving from locations with high aerosol
concentrations to low concentrations.

Zeroing Instrument

1. Attach the zero filter to the inlet of the instrument.

Figure 4-1: Attach Zero Filter to Inlet

2. Follow zero calibration instructions detailed in the operations section of
this manual.

Cleaning the Inlet

The inlet should be cleaned based on the schedule in Table 4–1.

1. Turn the DustTrak monitor off.

2. Unscrew the inlet nozzle from the instrument (Figure 4-2).

Figure 4-2: Unscrew Inlet Nozzle

Chapter 4

49

3. Clean the inlet port. Use a cotton swab to clean the outside of the inlet

Note

Be careful not to blow particles into the DustTrak monitor
inlet port.

1. Unscrew Impactor. Check O-ring
on the impactor base.

2. Clean outside and inside of
Impactor and the impactor plate
using a clean brush and a light
solvent. Dry impactor parts by
blowing it out with compressed air,
or let it air-dry thoroughly.

3. Apply 2 drops of oil (included) to
the impactor plate. DO NOT over­fill impaction plate.

4. Screw (hand-tighten) impactor back
together.

Figure 4-4: Apply 2 Drops of

Oil to Impactor Plate

Apply
2 Drops of Oil

port. You may dampen the swabs with water or a light solvent (e.g.,
isopropanol). Clean the inside of the sample tube by using a small brush,
along with a light solvent. Dry the tube by blowing it out with compressed
air, or let it air-dry thoroughly.

Figure 4-3: Do NOT Blow into Instrument

4. Screw (hand-tighten) inlet back into instrument.

Cleaning and Oiling Impactors

The calibration impactor should be cleaned prior to every use, using it to
perform a Standard Calibration (size correction) on the instrument, as
described in the Operations section.

Maintenance

50

Replacing the Internal Filters

Note

Replacement filters were shipped with the new instrument. Order
additional filters from TSI under PN 801666.

Replace the internal filters based on the schedule in Table 4–1 or when the
filter indicator on the main screen changes to red.

1. Turn the instrument off.

2. Remove old filters from the instrument.

Handheld Model

a. Use the enclosed filter removal tool (PN 801668) tool to unscrew the

two filter caps located on the bottom of the instrument.

b. Pull the old filters out of the two filter wells. If filter wells are visibly

dirty, blow out with compressed air.

Figure 4-5: Pull Filters Out of Two Filter Wells (Handheld Model)

c. Put two (2) new filters (P/N 801666) into the filter wells and screw

filter caps back into place.

Desktop Model

a. Open filter access door on the back of the instrument.
b. Use the enclosed filter removal tool (PN 801668) to unscrew

filter cap.

Chapter 4

51

c. Pull out single cylindrical filter from filter well. If filter well is visibly

dirty, blow out with compressed air.

Figure 4-6: Pull out Single Cylindrical Filter from Filter Well

(Desktop Model)

d. Put new filer (P/N 801673) back into filter well and screw filter cap

back into place.

e. Open blue retention clip by pinching ends inward and pushing down.

Figure 4-7: Open Blue Retention Clip

Maintenance

52

f. Remove 37-mm filter cassette by pulling downward and outward.

Figure 4-8: Remove 37-mm Filter Cassette

g. Open filter cassette using enclosed tool PN 7001303.

Figure 4-9: Open Filter using Enclosed Tool

h. Remove screen mesh from filter cassette and blow out using

compressed air. Blow in reverse direction to remove captured
particulate.

i. Replace mesh in filter cassette and press halves together. Make

sure filter has been fully closed. The filter tool PN 7001303 can be
used to ensure the filter is fully closed.

Figure 4-10: Replace Mesh in Filter Holder

j. Place filter cassette back into position and close blue retaining clip.

Make sure retaining clip snaps back into place.

Chapter 4

53

Notes

Replacement filters (HEPA and 37-mm Filter Cassette with mesh
filter) were shipped with the new instrument. Order additional
filters from TSI under PN 801673.

TSI does not supply any filter media for the filter cassette. Any
commercially available 37-mm filter media may be used with the
DustTrak II or DRX desktop instruments to collect gravimetric
reference samples.

3. It is important to reset the instruments filter counter after replacing

Touch

filters. Resetting the counter will clear the filter error condition
shown on the main screen. Reset the counters by the following:

a. Turn on the instrument.
b. Press the Setup button to go into the setup screen.
c. Touch the Cum Filter Conc: (live key) to reset the aerosol mass.

d. Replace user serviceable filters? Dialog will appear. Press OK.
e. Reset filter concentration? Dialog will appear. Press Yes to reset the

cumulative filter concentration to zero.

f. The Setup screen will now show zero for the Cum Filter

Concentration and the current date for the Filter Time.

Maintenance

54

Replacing the Filters in the External Pump Module

C a u t i o n

When replacing the HEPA filters, make sure they are
oriented in the correction direction as shown in the picture
above.

User Replaceable HEPA Filters

The external pump module provided with Model 8530EP is designed to run
continuously for about a year (8760 hours). There are two HEPA filters that
protect the pump from contamination—one on the suction side of the pump
and the other on the discharge side of the pump. The discharge side of the
pump collects particles shedding from the vanes of the pump and will turn
black over time. The HEPA filters will have to be replaced once a year.

To access the filters open the top cover of the pump module. The two HEPA
filters are identified in the figure below. The two filters can be replaced by
disconnecting the soft tubing between the filters, pump, and the casing
connectors.

Storage Precautions

When storing the DustTrak monitor for more than 30 days, you should charge
and remove the batteries. This prevents damage due to battery leakage.

This instrument must be stored in a location where the temperature remains
between –20 and 60°C (–4 and 140°F).

Chapter 4

Symptom

Possible Cause

Corrective Action

Erratic zero
reading.

Leak

Check connections for leaks
Replace zero filter

Dirty inlet port and/or
sample tube

Clean inlet port. Clean or
replace tubing

Internal filter(s) not
installed properly
(leaking)

Inspect internal filter wells to
make certain the filters and
O-rings are seated properly.
Replace internal filters if
necessary

DustTrak
reading
negative
concentrations

Zero Drift

Perform Zero Cal

Zero Cal was performed
without the Zero Filter
in-line

Perform Zero Cal again and
make sure the Zero Filter is
attached to the DustTrak inlet

Error
completing
Zero Cal

Too much light scatter
in the optics chamber
due to dust deposits

Clean the inlet nozzle. Attach
the zero filter and sample for
about 2 minutes. During
sampling, pulse the flow going
into the DustTrak monitor by
intermittently plugging the zero
filter. Any dust in the optics
chamber will break loose
during flow pulsations and will
be cleared out by the pump

Perform Zero Cal again. If the
Zero Cal still cannot be
performed, factory service may
be required

Run Mode
Error: The
start time has
passed

The selected Run Mode

program has “Use Start
Date” selected, but the

start date is prior to the
current date

Correct or change the run
mode program

Chapter 5

Troubleshooting

The table below lists the symptoms, possible causes, and recommended
solutions for common problems encountered with the DustTrak II monitor.

55

56

Symptom

Possible Cause

Corrective Action

Run Mode
Error: The
selected log
mode will
exceed the
allowed
number of
samples

The selected Run Mode
program is programmed
to save more samples
then is room in memory

Reduce the number of samples
by reducing the test length or
increasing the logging interval
Instrument
runs slow

Large amount of data in
memory

Large data files or many small
data files will cause instrument
to slow, due to need to read
and display large amounts of
data

No display

Unit not switched on

Switch unit on

Low or dead batteries

Recharge the batteries or plug
in the AC adapter

No touch ­screen
response

Instrument currently
busy

The instrument will take time to
open large data files and save
configuration information.
During this time, the instrument
will not respond to additional
touchscreen touches

Instrument Touchscreen
is locked

If the lock in the title bar is red,
unlock the instrument following
the instructions in the Chapter

3, Operation: Title Bar section

of this manual

Analog output
does not work

Cable/connector not
correctly installed

Make sure cable connector is
fully seated

Output wired with
reverse polarity

Make sure analog out (+) and
analog ground (-) are wired
correctly to data-logger

Analog output
is not in
proportion to
display

Analog output range in
DustTrak monitor may
be set incorrectly

Check analog output setting in
the Setup->Analog screen.
Make sure the channel of
interest is selected. Make sure
that the correct output (0 to 5V,
4 to 20 mA) is selected

Data logger scaling
factor may be set
incorrectly

Review the scaling factor set in
the Setup-Analog screen

Alarm output
does not work

Alarm function not
turned on

Turn the alarm function on in
the Settings->Alarm screen

Chapter 5

57

Symptom

Possible Cause

Corrective Action

Alarm does not
turn on
correctly

Alarm setting incorrect

Check the alarm settings in the

Settings->Alarm screen

Make sure the logging interval
and time constant are set as
short as possible (30 seconds
or lower)

Alarm output wired with
reverse polarity

Alarm wires are polarized.
Voltage input must be wired to
alarm input (+)

Instrument
does not store
new data

Memory is full

Delete or transfer historic data

Instrument is in Survey
mode

The instrument does not store
data in survey mode. Can to
manual or program log mode

Flow Error is
indicated on
front screen

If sampling from a duct,
instrument may have
problems overcoming
pressure differences

Attach both the input and the
exhaust port into the duct

Flow obstruction

Remove obstruction if still
present. Press any key to
bypass

Internal pump failing,
indicated by inability to
adjust flow rate to full
range

Factory service may be
required

Filter Cassette clogged
or has mass loading

Replace the filter cassette. See
the maintenance section of the
manual

Maintenance

58

Symptom

Possible Cause

Corrective Action

Flow Error is
indicated on
front screen

External pump module
(for Model 8530EP only)
is not connected to the
DustTrak monitor

Make sure both the External
Pump cable and the flow tubing
connector are connected to the
DustTrak monitor and the
External pump module. Lock
the External Pump Cable in
place by rotating the connector
clockwise until you hear it snap
in place

Make sure the tubing between
the DustTrak monitor and the
External pump module is not
kinked and is free of any sharp
bends

Make sure the exhaust adapter
is connected to the exhaust of
the DustTrak monitor

Make sure the External Pump
module filters are not clogged.
If found dirty, replace the two
HEPA filters

Laser Error
indicated on
front screen

Laser background is too
high

Remove and clean inlet nozzle.
Pay close attention to the tip of
the nozzle that is inserted into
the instrument to ensure it is
clear of any contamination

Laser is failing

Factory service may be
required

Filter Error
indicated on
front screen

Filters need to be
replaced

Replaced the filters per
instructions in the maintenance
section of this manual. Make
sure to reset the filter mass and
date once the filters have been
changed

Note

This is only a warning. The
unit will continue to operate
normally until the increase in
pressure drop across the
filter is so high that the pump
can no longer maintain the
set flow rate.

Chapter 5

59

Symptom

Possible Cause

Corrective Action

System Error
has Occurred!

The processor did not
receive the input it
expected. This can also
happen if the optics
chamber is saturated
with light, or the
External Pump Cable is
accidentally
disconnected during the
middle of sampling

Reboot the instrument. If the
error does not go away, factory
service is required

Maintenance

60

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Chapter 5

Sensor Type

90° light scattering

Range

8530 Desktop 0.001 to 400 mg/m3
8532 Handheld 0.001 to 150 mg/m3

Resolution

±0.1% of reading or 0.001 mg/m3, whichever is
greater

Zero Stability

±0.002 mg/m3 24 hours at 10 sec time constant

Particle Size Range

Approximately 0.1 to 10 µm

Flow Rate

3.0 L/min set at factory

1.4 to 3.0 L/min adjustable

Flow Accuracy

±5% of factory set point
Internal flow controlled

Temperature
Coefficient

+0.001 mg/m3 per °C

Operational Temp

0 to 50°C

Storage Temp

-20 to 60°C

Operational Humidity

0-95% RH, non-condensing

Time Constant

Adjustable 1 to 60 seconds

Data Logging

45 days at 1 minute samples

Log Interval

1 second to 1 hour

Physical Size (HWD)

Handheld: 4.9 x 4.75 x 12.45 in.
Desktop: 5.3 x 8.5 x 8.8 in.
External Pump: 4.0 x 7.5 x 3.5 in.

Weight

Handheld: 2.9 lb, 3.3 lb with battery
Desktop: 3.45 lb, 4.45 lb – 1 battery,

5.45 lb – 2 batteries

External Pump: 3.0 lb

Communications

8530: USB (Host and Device) and Ethernet.

Stored data accessible using thumb
drive

8532: USB (Host and Device). Stored dada

accessible using thumb drive.

Power—DC

Handheld 12 VDC at 2A
Desktop 24 VDC at 2.5A

Appendix A

Specifications

Specifications are subject to change without notice.

61

62

Battery

8530: Up to 2 Removable Li-Ion
External and Internal charging
Life, 1 battery: >6.5 hours (9 hours

typical for a new battery) for both
internal and external pump Desktop

DustTrak monitors
Life, 2 battery: >13 hours
8532: 1 Removable Li-Ion
External and Internal charging
Life: 5 hours typical

Analog out

8530:
User selectable output 0 to 5 V or 4 to 20 mA
User selectable scaling

Alarm Out

8530:
Relay or sound buzzer
Relay
No latching MOSFET
User selectable set point
5% deadband
Connector 4-pin, Mini-DIN connectors

8532:
Sound buzzer

Screen

8530: 5.7” color touchscreen
8532: 3.5” color touchscreen

Gravimetric Sampling

8530: Removable 37-mm Cartridge

EMI/RF Immunity:

Complies with Emissions Directive Standard:
EN50081-1:1992

Complies with Immunity Directive Standard:
EN50082-1:1992*

*ESD Shock may require instrument reboot

Appendix A

Appendix B

Zero Module

The Zero Module (PN 801690) allows for automatic re-zeroing of the
DustTrak Instrument during long sampling runs. The Zero Module works only
with the 8530 desktop models.

Attach the AutoZero module to the main instrument in two steps.

1. Place the Zero module over the instrument’s inlet and press down. The

Zero module has an O-ring seal that will engage with the instrument’s
inlet.

Figure B-1: Place Zero Module Over Inlet and Press Down

2. Attach the cable from the Zero module to the Zero module connector

located on the back of the instrument.

Figure B-2: Zero Module Connector

63

64

The Zero Module can only be used in a program log mode. The Zero module

Auto Zero Interval

Interval between re-zeroing the instrument using
the Auto-Zero accessory.

Use Auto Zero

Select Yes to use the Zero Module. Select No to
not use the Zero Module.

function is controlled through these two program mode options:

Important points on Zero Module operation:

 The Zero module will take one (1) minute to take a zero reading. The first

45 seconds of that period is used to clear the chamber of particles.
Readings from last 15 second of the period, when the chamber is
cleared of particles, will be averaged to determine the Zero offset.

 The log interval, when the Zero module is activated, must be two (2)

minutes or greater. Data will not be recorded to the log file when the Zero
module is activated.

Appendix B

Index

4

4-pin miniDIN connector, 17

A

AC adapter, 14
accessories

8530-NA, 1

optional, 7
advisory labels, vi
aerosol monitor

maintenance, 47

specifications, 61

troubleshooting, 55
alarm, 30, 46

audible, 31

logging interval, 30

survey mode, 30

wiring, 18
alarm functioning, 30
alarm1

relay, 31

STEL, 31

visible, 31
alarm1 setpoint, 31
alarm2 enable, 31
alarm2 setpoint, 31
analog, 33

lower limit, 33

out, 33

output setting, 33

size fraction, 33

upper limit, 33
analog cable, 3
analog output

wiring, 18
analog/alarm output

connecting, 17
audible, 31
auto start on power up, 36
auto zero interval, 64

B

background, 34
battery

charging, 14

disposal, 11
battery charger, 7

battery installation, 11

desktop unit, 11

handheld unit, 12
battery label, vi
battery status

charging, 46

not charging, 46

C

calibration certificate, 3
calibration date, 22
calibration factor

for specific aerosol, 28
calibration impactor

cleaning and oiling, 49
charging battery, 14
Class I, v
cleaning

inlet conditioner, 48
communication errors, 20
conductive tubing, 4
connect exhaust adapter to exhaust

of DustTrak (8530EP), 13

connect power connector to

DustTrak (8530EP), 13

connect pump end of quick connect

to pump module (8530EP), 13

connecting

analog/alarm output, 17
connecting computer, 16
current screen, 46

D

data, 45

delete, 45

delete all, 45

save all button, 45

select file, 45

statistics, 45
delete, 45
delete all, 45
determining calibration factor for

specific aerosol, 28
Dorr-Oliver cyclone, 4, 16
DustTrak 8530EP, 19
DustTrak 8533EP, 19

65

66

E

error indicator region, 42
error messages, 55
Ethernet port IP parameters, 34
external pump kit, 5, 7
external pump module, 9, 19, 20, 21

connecting, 42

F

file name region, 42
filter cassette, 52, 53

troubleshooting, 57
filter error, 58
filter opening tool, 4
filter removal tool, 4
filter time, 22
filter tool, 52
firmware version, 22
flow cal, 24
flow error, 57

G–H

graph, 43

button, 45

data region, 44

scale display, 44

time display, 44
gravimetric sample, 26

I–J–K

impactor oil, 5
inlet cap, 5, 15
inlet conditioner

cleaning, 48
installing batteries, 11
instrument lock, 46
instrument setup, 16
internal filter, 4

replacing, 50
internal filter element, 4
internal gravimetric filter, 29

L

laser error, 58
laser radiation label, vi
lock button, 39
lock feature, 39, 40
locking feature

unlock, 40
log interval, 37, 38
log mode, 36, 38

auto zero interval, 38
log interval, 38
log name, 38
number of tests, 38
start date, 38
start time, 38
test length, 38
time between tests, 38
time constant, 38
use start date, 38

use start time, 38
log modes, 36
log name, 38

M

maintenance, 47

schedule, 47
manual log, 36
manual mode, 37

log interval, 37

test length, 37

time constant, 37
mass concentration measurements,

41
mass reading, 42
model number, 22

N

name, 26
newcal, 29
number of tests, 38

O

optional accessories, 7

P–Q

packing list, 2
parts identification, 8, 9, 10
photometric, 26, 29
photometric calibration factor, 28
power supply, 5
pump run time, 22

R

relay, 31
replacing filters in the external pump

module (8530EP), 54
replacing internal filter, 50
reusing and recycling, vii
run mode region, 42
runmode, 36

Index

67

S

safety information, v
save all button, 45
screwdriver, 5
select file, 45
serial number, 22
serial number label, vi
service policy, ii
setting up, 11

instrument, 16

settings, 33

background, 34
date time, 33
display, 35
IP, 34, 35
touch cal, 34

setup menu, 22

calibration date, 22
cum filter conc, 22
cum mass conc, 22
filter time, 22
firmware version, 22
model number, 22
pump run time, 22

serial number, 22
size fraction, 33
size-selective impactors, 15
software

installation, 16
spanner driver, 4
specifications, 61
start date, 38
start time, 38
start up, 19
START UP screen, 19
stats, 43
STEL, 31, 32

alarm repeat, 32

data, 32

indicator, 32
storage precautions, 54
stylus, 5
supplying power, 11
survey mode, 36

auto start on power up, 36

time constant, 36
system error, 59

T

test length, 37
test progress region, 42
time between tests, 38
time constant, 36, 37, 38
title bar, 46

alarm, 46
battery status, 46
current screen, 46
date and time, 46

instrument lock, 46
touch cal, 34
TrakPro™ software

installation, 16
troubleshooting, 55

U

unlock, 40
unpacking, 1
USB cable, 3
USB port

connector, 16
USB port IP address, 34
use auto zero, 64
use start date, 38
use start time, 38
user cal, 25, 26

name, 26

photometric, 26
user replaceable HEPA filters

(8530EP), 54

V

visible, 31

W–X–Y

warning, v
warranty, i
wiring alarm, 18
wiring analog output, 18

Z

zero cal, 23

error, 55
zero filter, 2, 48
zero module, 63
zeroing instrument, 48

Index

68

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Index

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