model 8130 tester

Automated Fi l ter Testers

CERTITEST® Model 8127/8130 Automated Filter Tester

Operation and Service Manual

P/N 1980207 Revision J January 2008

Product Overview 1

Unpacking the Tester

2

Tester Components 3

Setting Up the Tester

4

CERTITEST® Model 8127/8130 Automated Filter Tester Operation and Service Manual

Operating the Tester: The Basics

5

Software Reference Guide

6

Checking System Performance

7

Application Notes 8

Maintaining the Tester

9

Troubleshooting and Obtaining Service

10

Appendixes

iii

Manual H is tory

The following is a history of the CERTITEST Model 8127/8130 Automated Filter Tester Instruction Manual, P/N 1980207. Revision Date Revision Date First Release November 1994 Final December 1994 A June 1995 B October 1996 B1 September 1998 C July 2000

D December 2002 E July 2003 F January 2004 G May 2004 H January 2006 J January 2008

The following changes were made in revision A:

❑ More precautions were added to the safety section.

❑ Three paragraphs were added to the end of “Unpacking” in Chapter 2.

❑ Appendix I, “Dismantling and Disposal of Filter Tester,” was added.

❑ In Appendix A, Environmental Conditions and Noise Level were added to Table A-1.

❑ In Chapter 5, two sentences were added: (1) detailing how to dissipate the remaining compressed air and (2) describing how to disconnect electrical power.

The following changes were made in revision B: TSI’s “Limitation of Warranty and Liability” on page iii was updated. Revisions were made throughout the manual for new software version 1.24. Revisions were also made throughout the manual to bring it up-to-date.

In revision B1 TSI’s area code was changed from 612 to 651.

In revision C, TSI’s Limitation of Warranty and Liability was updated.

In revision D, TSI’s phone number and address were updated. Appendix F schematics were updated.

In revision E, changes were made to Appendixes A and D, references were updated for TSI’s portable printer and Model 8118A Oil Generator.

In revision F, references to P/N 1602089 were changed to P/N 813010.

iv CERTITEST® Model 8127/8130 Automated Filter Tester

In revision G, TSI phone numbers were updated, schematics were updated, and outdated references to generator oil suppliers were removed.

In revision H, the section “Removing the Photomoter Module” was added to Chapter 9 and added the section “UNASSIGNED MESSAGE # or USER MEMORY FULL” in Chapter 10.

In revision J, updated “Connecting The Aerosol Exhaust” section in Chapter 4 and added Figure 4-8b. Updated front and back cover with new TSI logo. Added hyperlinks to referenced sections. Replaced 2306671 schematic with updated Rev. C version.

v

Warranty

Part Number 1980207 / Revision J / January 2008

Copyright ©TSI Incorporated /October 1993–2008 / All rights reserved.

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

Fax No. (651) 490-3824

E-mail Address [email protected]

Limitation of Warranty and Liability (effective July 2000)

Seller warrants the goods sold hereunder, under normal use and service as described in the operator's manual, shall be free from defects in workmanship and material for (12) months, or the length of time specified in the operator's manual, from the date of shipment to the customer. This warranty period is inclusive of any statutory warranty. This limited warranty is subject to the following exclusions:

a. Hot-wire or hot-film sensors used with research anemometers, and certain other components when indicated in specifications, are warranted for 90 days from the date of shipment.

b. Parts repaired or replaced as a result of repair services are warranted to be free from defects in workmanship and material, under normal use, for 90 days from the date of shipment.

c. Seller does not provide any warranty on finished goods manufactured by others or on any fuses, batteries or other consumable materials. Only the original manufacturer's warranty applies.

d. Unless specifically authorized in a separate writing by Seller, Seller makes no warranty with respect to, and shall have no liability in connection with, goods which are incorporated into other products or equipment, or which are modified by any person other than Seller.

The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE.

TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES, INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS BASED ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE) SHALL BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE GOODS. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER SHALL NOT BE RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS OR CHARGES. No Action, regardless of form, may be brought against Seller more than 12 months after a cause of action has accrued. The goods returned under warranty to Seller's factory shall be at Buyer's risk of loss, and will be returned, if at all, at Seller's risk of loss.

Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND LIABILITY, which contains the complete and exclusive limited warranty of Seller. This LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its terms waived, except by writing signed by an Officer of Seller.

Service Policy Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our customers, our service policy is designed to give prompt attention to any problems. If any malfunction is discovered, please contact your nearest sales office or representative, or call TSI at 1-800-874-2811 (USA) or 651-490-2811.

Trademarks CERTITEST® is a registered trademark of TSI Incorporated.

vii

Safety

This section gives instructions to promote the safe and proper operation of the CERTITEST Model 8127/8130 Automated Filter Tester. The photometers used in the Filter Testers are Class I laser-based instruments. This means that during normal operation and normal maintenance performed by you, no human access to laser fields is possible. To maintain this safety rating, it is imperative that the photometers must not be altered, serviced or dismantled in any way. They contain no user-serviceable parts. Failure to observe this precaution may expose you to hazardous optical radiation in the form of intense, focused invisible light. Exposure to this light can cause blindness. Take these precautions when using a Model 8127 or 8130 Filter Tester:

❑ Do not remove any parts from the Filter Tester unless you are specifically told to do so in this manual.

❑ Do not remove the Filter Tester housing while power is applied to the instrument.

❑ For safety precautions related to use of the Model 8118A Salt Aerosol Generator, refer to the Model 8118A manual in Appendix H.

❑ Be aware that the Emergency Off/On button shuts off compressed air to the aerosol generator, the filter holder, and the make-up air flowmeter. However, when this button is pushed, the air inlet regulator, liquid trap, and inlet filter remain pressurized. To dissipate this pressure, remove the air line by disconnecting the QUICK-CONNECT fitting on the back of the instrument.

❑ The Emergency Off/On button and the Start/Stop button DO NOT cause electrical power to the Tester to be disconnected. To remove electrical power from the Tester, unplug the power cord located at the back of the instrument.

viii CERTITEST® Model 8127/8130 Automated Filter Tester

❑ Common safety practice dictates that a fire extinguisher should be located in close proximity to the Filter Tester. The fire extinguisher must be rated for use on electrical fires. If the Tester is exposed to a fire, once the fire is extinguished, power must be removed from the Tester by unplugging the power cord located at the back of the instrument. Do not return the Filter Tester to service or attempt to operate it in any way. The instrument must be returned to the factory for servicing and a complete safety check, before it may be used again.

❑ If the Filter Tester is exposed to fire, flood, mechanical damage, electrical damage or other similar situation, do not attempt to operate the Tester. The instrument must be returned to the factory for servicing and a complete safety check, before it may be used again.

❑ The Model 8127/30 Automated Filter Tester is designed for measuring the pressure drop and efficiency of filters and filter media. Standard, safe operating procedures are described in Chapter 5, “Operating the Tester.” You must read and thoroughly understand this section before attempting to operate the instrument. Any other use, other than the express intended use of this instrument, may subject you to conditions which are immediately dangerous and may void the instrument warranty.

❑ Never alter or attempt to defeat any of the operating and/or safety systems, including (but not limited to) the open/close buttons, the heater safety switch, electrical fuses and the Emergency Off/On button. Any physical modifications to the Tester (other than those authorized or performed by factory engineering personnel) may subject you to conditions which are immediately dangerous and may void the instrument warranty.

❑ The Model 8127/30 Filter Tester with it’s automated operating and safety systems, is designed to be operated by a single user. The dual close buttons (with tie-down protection) require the single operator to have both hands in a safe position while initiating a test. You must ensure that no persons or foreign objects are within the path of the pneumatically actuated filter chuck, before initiating a test.

❑ Once a test is initiated the pneumatic piston will force the filter holders to a closed position. Filter holder movement continues even if a foreign object is encountered. Pressure on the filter holders can only be released automatically (by the Tester) or by depressing the Open button or the Emergency Off/On button.

Note: The Models 8127 and 8130 must be operated by a single user.

Safety ix

❑ If two or more operators work in conjunction to perform a test, or if a test is initiated with another person or object in close proximity to the Tester, it may create conditions which are immediately dangerous.

❑ Common industrial safety practice dictates that you dress appropriately for operating moving machinery. Loose sleeves, neckties, jewelry or other objects, which may become caught in the machine, must be avoided.

D A N G E R

Electrical hazard that can cause severe injury or death.

The electronics housing contains a high-voltage source. Do not remove the cover

or insert any objects under it.

W A R N I N G

The use of controls, adjustments, or performance of procedures other than those

specified in this manual may result in exposure to hazardous laser radiation.

!

W A R N I N G

The manufacturer of the pressure regulator has the following warning concerning

the plastic water/oil trap at the base of the regulator. DO NOT REMOVE THE

METAL GUARD on the bowl. This warning is to minimize the danger of flying

fragments in the event of a plastic bowl failure.

!

C a u t i o n

When using oil aerosols, make sure the Filter Tester is properly exhausted.

(Refer to accompanying documents.)

xi

Contents

Manual History...........................................................................iii

Safety ........................................................................................ vii

About This Manual ................................................................... xix Purpose................................................................................ xix Submitting Comments ......................................................... xix

C h a p t e r s 1 Product Overview .......................................................... 1-1

Product Description ............................................................ 1-2 How the Models 8127 and 8130 Operate............................. 1-3

2 Unpacking the Tester .................................................... 2-1 Packing List ........................................................................ 2-1 Unpacking .......................................................................... 2-2

3 Tester Components ....................................................... 3-1 Oil Aerosol Generator .......................................................... 3-2 Salt Aerosol Generator (TSI Model 8118A) ........................... 3-4 Aerosol Neutralizer.............................................................. 3-5 Make-up Air Heater............................................................. 3-6 Mixing Manifold and Chamber ............................................ 3-7 Flowmeter ........................................................................... 3-8 Filter Holder........................................................................ 3-9 Pressure Transducers ....................................................... 3-11 Photometer Assembly........................................................ 3-12 Electronics Housing .......................................................... 3-14 CPU/Controller ................................................................. 3-15 Control Buttons ................................................................ 3-16 Touch-Panel Display ......................................................... 3-17 Printer............................................................................... 3-18 Emergency Off/On Button ................................................ 3-19 Vacuum Pump .................................................................. 3-20 Flow Control Valve and On/Off Switch.............................. 3-21

4 Setting Up the Tester .................................................... 4-1 Before You Begin................................................................. 4-1 Mounting the Touch-Panel Display ..................................... 4-2 Connecting Electrical Power ................................................ 4-3 Connecting Compressed Air ................................................ 4-3

xii CERTITEST® Model 8127/8130 Automated Filter Tester

How to Tell if Your Compressed Air is Clean Enough........ 4-4 Filling and Installing the Aerosol Generator......................... 4-6

The Oil Aerosol Generator ................................................ 4-6 The Salt Aerosol Generator (TSI Model 8118A).................. 4-8

Connecting the Aerosol Exhaust ....................................... 4-12 Connecting the Thermal Printer ........................................ 4-13 Connecting the Serial Interface ......................................... 4-16 Changing the Filter Holder ................................................ 4-17

5 Operating the Tester: The Basics ...................................5-1 Before You Begin................................................................. 5-1 Tester Controls ................................................................... 5-1

Using the Touch-Panel Display......................................... 5-1 Using OPEN, CLOSE, and Emergency Off/On Buttons ..... 5-2

Operating Procedure ........................................................... 5-4 Step 1. Check Aerosol Generator Solution Level ............... 5-5 Step 2. Turn Power On ..................................................... 5-5

Software Initialization.................................................... 5-6 Step 3. Turn the Heater On (Salt Generator only) ............. 5-7 Step 4. Set the Main Regulator Pressure........................... 5-7 Step 5. Set the Filter Holder Regulator Pressure ............... 5-8 Step 6. Set the Aerosol Generator Pressure ...................... 5-9 Step 7. Set the Make-Up Air Flowrate............................... 5-9 Step 8. Check That the Aerosol Neutralizer Is On ........... 5-10 Step 9. Warm-up Period ................................................. 5-11 Step 10. Turn the Thermal Printer and/or the

RS-232 Serial Port On (optional).................................. 5-11 Step 11. Perform TESTER SET UP.................................. 5-12 Step 12. Perform a Filter Test ......................................... 5-14

6 Software Reference Guide ..............................................6-1 Filter Test Software Description .......................................... 6-1

Touch-Panel Display ........................................................ 6-1 Software Screens.............................................................. 6-1 Software Version .............................................................. 6-2

Making Entries.................................................................... 6-2 Entering Numbers............................................................ 6-2 Turning On an Operation Flag.......................................... 6-3

Menus and Options Overview.............................................. 6-3 Main Menu.......................................................................... 6-6

[*]TESTER SET UP (Establish Operating Conditions) ........ 6-6 Calculating a Photometer Correlation Factor (CF) .......... 6-7 Using the TESTER SET UP Mode................................... 6-7

[*]FILTER TEST (Starting the Filter Test)........................... 6-8 Using the FILTER TEST Mode........................................ 6-8 Penetration Calculation ................................................. 6-9

FLOW/LOAD Menu .......................................................... 6-9 [*]FLOW ADJUSTMENT (Adjust the Filter Flow) ............. 6-9

Using the FLOW ADJUSTMENT Mode......................... 6-9

Contents xiii

[*] LOADING TEST (Perform a Load Test) ..................... 6-10 Using the LOADING Test Mode ................................. 6-10

Options Menu ................................................................... 6-11 [*]TEST PARAMETERS (Controlling Test Times and

Options) ...................................................................... 6-12 [*]SAMPLE TIME (Set Sampling Time) .......................... 6-12 [*]RISE TIME (Set Rise Time) ....................................... 6-13 [*]DISP. P/F (Set and Activate Pass/Fail Limits) .......... 6-13 [*]RESISTANCE, [*]FLOW, and [*]PENETRATION

(Set Pass-Fail Setpoints) ........................................... 6-13 [*]PRINTER (Activate the Printer) ................................. 6-14 [*]RS232 (Activate the Serial Port)................................ 6-15 [*]UNITS (Select Resistance Units) ............................... 6-16 [*]PURGE (Set Purge Time)........................................... 6-16

[*]PROTOCOL (Save Test Parameters) ............................. 6-17 [*]SELECT TEST PROTOCOL ....................................... 6-18 [*]CREATE TEST PROTOCOL....................................... 6-19

[*]VOLTAGES (Read Photometer and Pressure Transducer Voltages) ................................................... 6-20

[*]TIME/DATE (Set Time and Date)................................. 6-21 [*]SYSTEM...................................................................... 6-21

CALIBRATIONS (Calibrate Flowmeter and Pressure Transducers) ............................................................ 6-22

[*]FLOW CALIBRATION................................................ 6-22 [*]PRESSURE CALIBRATION ....................................... 6-23 [*]SPECIAL TIMING...................................................... 6-23 [*]WATCH POINTS ....................................................... 6-25

[*]AEROSOL (Turn Aerosol Generator On/Off, Turn Heater On/Off) ............................................................ 6-27

7 Checking System Performance ...................................... 7-1 Measuring Aerosol Mass Concentration Using Gravimetric Test..................................................................................... 7-1 Verifying Penetration Data .................................................. 7-4

Performing the Verification Test........................................ 7-6 Acceptance Zone .............................................................. 7-7

Checking for Flowmeter Contamination............................... 7-8 8 Application Notes.......................................................... 8-1

Changing the Aerosol Concentration ................................... 8-1 Setting Test Time ................................................................ 8-3

Rise Time and Sample Time ............................................. 8-4 Other Factors Affecting Test Time..................................... 8-4 Technique for Determining Rise and Sample Times .......... 8-5 Rise and Sample Time Example........................................ 8-6

Performing a Loading Test................................................... 8-8 Calculating the Load Level on Your Filter ......................... 8-9 Calculating the Test Duration .......................................... 8-9

xiv CERTITEST® Model 8127/8130 Automated Filter Tester

9 Maintaining the Filter Tester .........................................9-1 Removing the Back Panel .................................................... 9-1 Opening the Top of the Tester Cabinet ................................ 9-2 Closing the Top of the Tester Cabinet .................................. 9-2 Regular Maintenance .......................................................... 9-3

Salt Aerosol Generator Maintenance................................. 9-4 Filling the Oil Aerosol Generator....................................... 9-4 Filling the Salt Aerosol Generator ..................................... 9-5 Cleaning the Mixing Manifold ........................................... 9-6 Cleaning the Flowmeter.................................................... 9-7 Replacing the Flow Line Filter .......................................... 9-9 Replacing the Air Line Filter ........................................... 9-10 Maintaining the Spool Valve ........................................... 9-12 Replacing the Photometer Filters .................................... 9-13 Removing the Photometer............................................... 9-15

Removing the Photometer Module................................ 9-15 Replacing the Photometer Module................................ 9-18

Cleaning the Vacuum Pump Filters ................................ 9-20 Draining the Compressed Air Liquid Bowl ...................... 9-21 Setting Ion Balance ........................................................ 9-22 Cleaning or Replacing the Ionizing Needles..................... 9-23

Special Maintenance ......................................................... 9-24 Using a Different Oil....................................................... 9-24 Replacing Oil Aerosol Generator Felt .............................. 9-25 Cleaning the Oil Atomizer Jets ....................................... 9-26 Zeroing the Pressure Transducers .................................. 9-29 Replacing the EPROM Program Chip .............................. 9-31 Replacing Fuses ............................................................. 9-33 Replacing and Cleaning Tubing ...................................... 9-34 Replacing Old Oil ........................................................... 9-34

10 Troubleshooting and Obtaining Service ........................10-1 Error Messages ................................................................. 10-1

HIGH ZERO ON DOWNSTREAM PHOTOMETER ............ 10-1 HIGH ZERO ON UPSTREAM PHOTOMETER .................. 10-2 ZERO ERROR ON RESISTANCE TRANSDUCER ............. 10-2 ZERO ERROR ON FLOW TRANSDUCER......................... 10-2 LOW AEROSOL CONCENTRATION................................. 10-3 FLOW FOR PASS-FAIL OUT OF RANGE ......................... 10-3 INVALID ......................................................................... 10-3

Statistical Diagnostics ................................................. 10-4 Troubleshooting the Tester................................................ 10-7 Service ............................................................................ 10-11

Technical Contacts....................................................... 10-11 Returning for Service.................................................... 10-11

Contents xv

A p p e n d i x e s A Specifications ............................................................... A-1 B Theory of Operation...................................................... B-1

Aerosol Generation..............................................................B-2 Aerosol Mixing and Transport .............................................B-2 Particle Detectors (Photometers)..........................................B-3 Microprocessor Control .......................................................B-4 Operating the Models 8127 and 8130 Filter Testers ............B-5

C Verification of Aerosol Particle Size .............................. C-1 D Aerosol Generator Data and Operating Parameters ........D-1

Salt Aerosol Generator ........................................................D-1 Oil Aerosol Generator ..........................................................D-1

E Maintenance Kits.......................................................... E-1 Model 8127 Filter Tester Maintenance Kit (P/N 1035497) ... E-1 Model 8130 Filter Tester Maintenance Kit (P/N 1081840) ... E-3

F Filter Tester Schematics ............................................... F-1 G TSI’s Portable Printer....................................................G-1 H TSI Model 8118A Salt Aerosol Generator.......................H-1 I Dismantling and Disposal of Filter Tester...................... I-1

F i g u r e s 1-1 The CERTITEST Automated Filter Tester ............................. 1-1 1-2 Schematic Drawing of Models 8127 and 8130

Automated Filter Testers .................................................. 1-3 3-1 The Oil Aerosol Generator................................................. 3-2 3-2 The Salt Aerosol Generator (Model 8130 only)................... 3-4 3-3 The Aerosol Neutralizer..................................................... 3-5 3-4 The Make-up Air Heater (Model 8130 only) ....................... 3-6 3-5 The Mixing Manifold ......................................................... 3-7 3-6 The Flowmeter.................................................................. 3-8 3-7 The Filter Holder............................................................... 3-9 3-8 Pressure Transducers..................................................... 3-11 3-9 Photometer Assembly, From Back With Back Panel

Removed, Showing Photometer Filters ............................ 3-12 3-10 Electronics Housing........................................................ 3-14 3-11 The CPU/Controller PC Board (mounted inside the

NEMA enclosure)............................................................ 3-15 3-12 The Control Buttons ....................................................... 3-16 3-13 The Touch-Panel Display ................................................ 3-17 3-14 The Thermal Printer........................................................ 3-18

xvi CERTITEST® Model 8127/8130 Automated Filter Tester

3-15 The Emergency Off/On Button ....................................... 3-19 3-16 The Vacuum Pump......................................................... 3-20 3-17 The Flow Control Valve Handle and the On/Off Switch... 3-21 4-1 The Touch-Panel Display Mounted in Position .................. 4-2 4-2 The Compressed Air Regulator.......................................... 4-5 4-3 Oil Aerosol Generator Reservoir Cover (top view)............... 4-6 4-4 The Oil Aerosol Generator Installed .................................. 4-8 4-5 Salt Aerosol Generator Reservoir Cover (top view) ............. 4-9 4-6 The Oil Aerosol Generator Installed ................................ 4-10 4-7 Connectors and Indicators on the Salt Aerosol

Generator....................................................................... 4-11 4-8 a The Exhaust Line (A) and Mixing Manifold (B)................ 4-12 4-8b External Air Line Connectors: Exhaust and Air Inlet....... 4-13 4-9 Print Test Sample ........................................................... 4-15 4-10 Location of Mounting Screws for Upper Half of Filter

Holder ............................................................................ 4-17 4-11 Location of Mounting Screws for Lower Half of Filter

Holder (top view)............................................................. 4-18 5-1 OPEN and CLOSE Buttons ............................................... 5-3 5-2 Emergency Off/On Button................................................ 5-3 5-3 Oil Aerosol Generator Oil Level Indicator .......................... 5-5 5-4 The Power On/Off Switch ................................................. 5-6 5-5 Main Pressure Regulator, Gauge, and Adjustment Knob... 5-8 5-6 (A) Filter Holder Pressure Regulator and (B) Aerosol

Generator Pressure Regulator .......................................... 5-9 5-7 Make-up Air Flowmeter and Valve .................................. 5-10 5-8 Aerosol Neutralizer Power Supply ................................... 5-11 5-9 Flow Control Valve.......................................................... 5-13 6-1 Software Menu Structure.................................................. 6-4

7-1 Gravimetric Filter Holder (A) and Separation Tool (B)........ 7-3 7-2 Sample Reference Graphs................................................. 7-5 8-1 Graph of Penetration Versus Time Using Standard

Media Filter Holder .......................................................... 8-6

9-1 Model 8127/8130 With Top Cover in Open Position ......... 9-3 9-2 Oil Aerosol Generator Oil Level Indicator .......................... 9-5 9-3 The Mixing Manifold ......................................................... 9-7 9-4 The Flowmeter.................................................................. 9-8 9-5 The Flow Line Filter ........................................................ 9-10 9-6 The Air Line Filter........................................................... 9-11 9-7 The Spool Valve .............................................................. 9-12 9-8 The Photometer Filters.................................................... 9-14 9-9 Three Philips Screws in the Photometer Box ................... 9-16 9-10 Three Screws Holding Photometer Box in Place............... 9-16 9-11 Upstream Sample Line and Compressed Air Connection. 9-17 9-12 Photometer Box, Downstream Sample Line, and High

Vacuum Purge Line........................................................ 9-17

Contents xvii

9-13 Photometer Connector and Electrical Connection Valves ............................................................................ 9-18

9-14 The Vacuum Pump (showing filter end caps)................... 9-20 9-15 The Compressed Air Line Liquid Collection Bowl ............ 9-21 9-16 The Aerosol Neutralizer, Including the Power Supply (A)

and the Ionizing Air Nozzle (B) ........................................ 9-22 9-17 The Oil Aerosol Generator Exhaust Assembly and Felt

Filter .............................................................................. 9-26 9-18 The Oil Aerosol Generator with Cover Removed .............. 9-27 9-19 Atomizer Jet Assembly in Inverted Position (numbers

indicate order of disassembly) ........................................ 9-28 9-20 The Pressure Transducers .............................................. 9-31 9-21 CPU Board...................................................................... 9-32 B-1 Schematic Drawing of CertiTest Automated Filter

Testers .............................................................................B-1 B-2 Schematic of Photometer Used for Measuring

Downstream Particle Concentrations................................B-3 C-1 Filter Penetration Versus Particle Size ..............................C-2 C-2 Filter Penetration Versus Geometric Standard Deviation ..C-3

T a b l e s 2-1 Packing List for CERTITEST Model 8127/8130 Automated

Filter Tester................................................................... 2-1

5-1 Basic Operating Procedure ............................................... 5-4

6-1 Main Menu Options.......................................................... 6-4 6-2 Flow/Load Menu Options ................................................. 6-5 6-3 Options Menu Options...................................................... 6-5 6-4 System Menu Options ...................................................... 6-6 6-4 SELECT TEST PROTOCOL and CREATE TEST

PROTOCOL Parameters ............................................... 6-18

9-1 Maintenance Schedule...................................................... 9-4

10-1 Troubleshooting the Tester ............................................. 10-7

A-1 Specifications for the CERTITEST Models 8127 and 8130 Automated Filter Testers ............................................... A-1

D-1 Operating Parameters ......................................................D-2

E-1 Model 8127 Filter Tester Maintenance Kit ........................ E-1 E-2 Model 8130 Filter Tester Maintenance Kit ........................ E-3

xix

About This Manual

P u r p o s e This operation and maintenance manual describes how the TSI CERTITEST® Model 8127/8130 Automated Filter Tester is used and maintained.

S u b m i t t i n g C o m m e n t s TSI values your comments and suggestions on this manual. Please use the comment sheet on the last page of this manual to send us your opinion on the manual’s usability, to suggest specific improvements, or to report any technical errors. If the comment sheet has already been used, please mail your comments on another sheet of paper to:

TSI Incorporated 500 Cardigan Road Shoreview, MN 55126 Fax: (651) 490-3824 E-mail address: [email protected] Website: www.tsi.com

mailto:[email protected]

http://www.tsi.com/

1-1

C H A P T E R 1 Product Overv iew

This chapter provides an introduction to the CERTITEST Automated Filter Testers and a brief explanation of how they operate. For a more detailed theory of operation, refer to Appendix B.

Figure 1-1 The CERTITEST Automated Filter Tester

1-2 CERTITEST® Model 8127/8130 Automated Filter Tester

P r o d u c t D e s c r i p t i o n TSI's CERTITEST Models 8127 and 8130 Automated Filter Testers represent a new generation of testers designed for testing filters, respirator cartridges, and filter media. The Model 8127 uses an oil aerosol, while the Model 8130 can use either salt or oil. Both provide fast, reliable filter efficiency measurements for penetrations as low as .001% (99.999% efficiency). They are designed for rapid testing of filters, specifically for production and quality control. They can handle over six filters per minute, running complete tests with minimum operator intervention. The Models 8127 and 8130, built for shipment to the European community, meet all of the mandatory requirements for sale within the European community, as defined by European Union Directive 89/336/EEC and 89/392/EEC. Compliance with the directives was verified using the following standards: EN50081-1 (1993), EN50082-1 (1993), EN6101-1 (1993), EN292-2 (1991) and Annex A of EN292-2 (1991). An on-board microprocessor calculates information on filter penetration and resistance over a wide range of filter flows. The processor also performs self-checks during testing to ensure correct system operation. Filter test results are presented on a 240-character touch-panel display and data can be printed by a thermal printer or output to a computer. System status information and operator instructions are presented on the easy-to-read touch-panel display. This greatly reduces the amount of training needed to operate the CERTITEST Filter Testers. The filter test software lets you specify pass/fail criteria so that at the end of a test a PASS or FAIL message is presented in large characters on the display. Simple software menus allow you to easily change test parameters to accommodate special testing requirements.

Product Overview 1-3

H o w t h e M o d e l s 8 1 2 7 a n d 8 1 3 0 O p e r a t e The system operator places a filter or test sample of filter media on the lower half of the filter holder and starts a test by pressing the dual start buttons simultaneously. A pneumatic cylinder lowers the top half of the filter holder into place, and the test begins. Aerosol travels from the aerosol generator to the top filter holder and is pulled down through the filter by a vacuum on the downstream side. Two solid-state, laser-based, light scattering photometers measure the aerosol concentration upstream and downstream of the filter. Filter penetration is determined from the ratio of the two concentration measurements. Highly accurate, electronic pressure transducers determine filter resistance and flow. Pressure transducer and photometer readings are taken between every test to determine the zero offsets and background values.

Figure 1-2 Schematic Drawing of Models 8127 and 8130 Automated Filter Testers

The entire process is controlled by a dedicated microprocessor. Inputs to the microprocessor include photometer and pressure transducer voltages, touch-panel display inputs, and open/close button interrupts. An optional capability for tester control through a special external control port is available.


When the test is completed, the filter holder opens automatically. Test data is displayed and output to the printer, or routed to the serial port. If the operator selected a specific pass/fail level, the tester also displays a large PASS or FAIL message.

The Model 8127 incorporates a unique “cold” oil aerosol generator and the Model 8130 includes both oil and salt generators. This means a variety of oils can be used as well as salt. Refer to Appendix D for recommended oils and Appendix H for detailed information on the salt aerosol generator.

2-1

C H A P T E R 2 Unpacking the Tester

Use the information in this section when unpacking a CERTITEST Automated Filter Tester.

P a c k i n g L i s t Table 2-1 lists the instruments and accessories included with CERTITEST Automated Filter Testers.

Table 2-1 Packing List for CERTITEST Model 8127/8130 Automated Filter Tester

Qty. Item Part No.

1 Model 8127/8130 main cabinet ......................................... 800399/800404

1 Touch-panel display with mount ........................................ 1081581 1 Gravimetric filter holder ..................................................... 1080566 1 Oil aerosol generator .......................................................... 1080604 1 Salt aerosol generator (Model 8130 only) and accessories

(refer to Chapter 2 in Appendix H for complete list) ......... 1035752

1 Aerosol neutralizer (standard on Model 8130 and optional on Model 8127) including:...............................................

1081843

1 Ionizer nozzle—installed in tester .................................. 2401069 1 Power supply—installed in tester (120 VAC/60 Hz) ........

or (230 VAC/50 Hz) .......................................................

2613046 2613047

1 Spare needles (pair) ....................................................... 2402554 1 Ion balance meter.......................................................... 2301111 3 Manuals (located at back of this manual) 1 TSI Model 8928 portable printer and accessories

(refer to Chapter 2 in Appendix G for complete list) ......... N/A

1 Model 8127/8130 instruction manual................................ 1980207 1 box 102 mm gravimetric filters ................................................. 1602076 1 tube Silicone vacuum grease...................................................... 1502249 1 Oil aerosol generator air inlet cap....................................... 1601834 1 Calibration pressure drop plate .......................................... 2601279 10 ft ¾ inch I.D. vinyl exhaust tubing ........................................ 3001185 1 box Test filter media ................................................................. 813010 1 3⁄16 inch ball driver wrench (to install touch panel) 3305065

2 Oil aerosol generator atomizer draw tubes with filters 2 MSA cartridge filters (spares) ............................................. 1602011

(continued)


Table 2-1 Packing List for CERTITEST Model 8127/8130 Automated Filter Tester (continued)

Qty. Item Part No.

3 Oil aerosol generator felts (spares) ..................................... 1602075 1 Aerosol generator lid gasket (spare).................................... 1704026 7 HEPA capsule filters (spares) ............................................. 1602051 2 Filter holder gaskets (spares) ............................................. 1704036 2 Replacement capsule filter fittings (spares) ........................ 1601935 2 Lower filter adapter O-rings (spares) .................................. 2501151 2 Upper filter adapter O-rings (spares) .................................. 2501236 2 Lower filter holder O-rings (spares) .................................... 2501632 10 Filter holder air cylinder bumpers ..................................... 1704059 1 Compressed air fitting for air line input ............................ 1601471 Optional special filter holder(s)

U n p a c k i n g TSI's Model 8127/8130 Automated Filter Tester is shipped in two or more containers. The main Filter Tester cabinet is packed in a wooden crate. Several of the main Tester components and all accessories are shipped in one or more separate packing boxes. If you ordered a special filter holder, it will be shipped with the other accessories. To unpack the main cabinet, remove the front cover of the crate, grasp the side of the cabinet, and carefully roll it out of the crate. If necessary, you can open the front door of the cabinet and grasp it by the frame. Note: To avoid excessive jarring of the tester cabinet, make sure it

does not drop to the floor when the back wheels roll free of the crate.

The Tester is mounted on casters and is easy to move in any direction. Once the instrument is placed into the final position, it should be raised up onto the leveling feet located at the four corners. To raise the instrument (lower the feet), turn the levelers clockwise with a wrench until the instrument weight is supported on all four feet. It may be necessary to make several adjustments until the Tester is both level and stable.

Packing List 2-3

The Tester must be installed on a flat, level surface. To allow for easy cleanup of liquid aerosol spills, the floor surface should be hard and nonporous. The Model 8127/30 must be installed in a location which allows unobstructed access to the instrument front. A minimum front clearance of 2 M (6.5 ft) is required. Since routine maintenance requires access to the instrument back, a back clearance of 1 M (3.2 ft) is recommended. Note: Since the Tester is mounted on casters and is relatively easy

to move, it may be placed close to a side or back wall, while maintaining a minimum clearance of 15 cm (6 in.) at all times.

Open the accessories packing box(es) and carefully unpack the components and accessories included. Check the contents against the packing list in Table 2-1. If any parts are missing or obviously damaged in shipment, please notify TSI immediately at 1-800-874-2811 (USA) or (651) 490-2811. Set all the accessories aside for future use.

3-1

C H A P T E R 3 Tester Components

This chapter describes the key components of the CERTITEST Model 8127/8130 Automated Filter Tester. It is important that anyone responsible for operating and maintaining one of these testers be familiar with each of the components described here. The key components discussed are:

❑ Oil Aerosol Generator

❑ Salt Aerosol Generator (Model 8130 only)

❑ Aerosol Neutralizer (Model 8130 and optional on Model 8127)

❑ Heater (Model 8130 only)

❑ Mixing Manifold

❑ Flowmeter

❑ Filter Holder

❑ Pressure Transducers

❑ Photometer Assembly

❑ Electronics Housing

❑ CPU/Controller

❑ Control Buttons

❑ Touch-panel Display

❑ Printer

❑ Emergency Off/On Button

❑ Vacuum Pump

❑ Flow Control Valve and On/Off Switch Electrical schematics and assembly drawings of the testers and many of their components are located in Appendix F of this manual.


O i l A e r o s o l G e n e r a t o r The oil aerosol generator, shown in Figure 3-1, is a standard component in both the Model 8127 and the Model 8130 Automated Filter Testers. It produces the challenge aerosol particles used for filter testing with various oils. Consisting of a liquid reservoir and multiple atomizer assemblies, it uses compressed air for operation. Pressurized air forms a high velocity jet in each atomizer which, in turn, draws liquid oil from the reservoir, through a draw tube, and into the jet. The jet shears the oil into tiny droplets which make up the aerosol.

Collection Bottle

Figure 3-1 The Oil Aerosol Generator The number of atomizers used can be varied from one to four depending on the aerosol concentration required for a specific application. For example, when using Emery oil, two atomizers are used to produce a concentration of 100 mg/m3 or higher. To change the concentration, you may need to change the number of atomizers used. Refer to "Changing the Aerosol Concentration" in Chapter 8 and "Cleaning the Oil Atomizer Jets" in Chapter 9 for more information on this procedure.

Tester Components 3-3

Note: Emery 3004 oil is recommended for use with the Models 8127 and 8130 Automated Filter Testers. DOP (dioctyl pthalate) and paraffin oil can also be used. Refer to Appendix D for information on using these oils.

The aerosol generator pressure is adjusted using a pressure regulator inside the cabinet. Different aerosols will require different pressures. TSI recommends a pressure of 40 psi for Emery 3004 oil. For paraffin oil, a pressure of 35 psi is recommended. The different pressures account for differences in aerosol properties. For information on setting the pressure, refer to "Step 6. Set the Aerosol Generator Pressure" in Chapter 5. The oil aerosol generator has a special outlet assembly which conditions the aerosol by passing it through an in-line felt filter. The felt removes the largest particles and narrows the size distribution to one closely matching that of an ideal test aerosol, one with a mean centered in the “most penetrating size range” for a typical filter. Oil collected by the felt coalesces and is pushed out to form a liquid stream after the felt. The liquid is collected in a bottle, shown in Figure 3-1. The conditioned aerosol passes through the outlet to the mixing manifold above where the aerosol is mixed with “make-up” air. A check valve installed on the generator pressure line prevents aerosol from backing into the aerosol regulator and on/off solenoid valve when the tester is turned off or pressure is lost.


S a l t A e r o s o l G e n e r a t o r ( T S I M o d e l 8 1 1 8 A ) The Model 8118A Salt Aerosol Generator (Figure 3-2), is supplied only with the Model 8130. It produces a solid aerosol of NaCl used as a challenge aerosol. It consists of a liquid reservoir, multiple atomizer jets. Pressurized air (30 psi is recommended) forms a high velocity jet in each atomizer. This draws a salt solution from the reservoir, through a draw tube, and into the jet.

Figure 3-2 The Salt Aerosol Generator (Model 8130 only) The atomizers output a broad particle size distribution. The largest particles are removed by a mist impactor which creates a high velocity jet which impacts out large particles. The result is a narrower particle size distribution suitable for measurements at a filter’s “most penetrating particle size.” Detailed operation and maintenance of the Model 8118A Salt Aerosol Generator are described in a separate manual in Appendix H. For questions related to the salt generator, refer to Appendix H.


A e r o s o l N e u t r a l i z e r An aerosol neutralizer (Figure 3-3) is supplied as a standard accessory on the Model 8130 Automated Filter Tester and is optional on the Model 8127. The neutralizer reduces the electrical charge that builds up on the aerosol particles when the liquid is atomized. It must be turned on when using the salt aerosol generator and is optional with the oil aerosol generator.

A

B

Figure 3-3 The Aerosol Neutralizer, Including the Power Supply (A) and the Ionizing Air Nozzle (B) The neutralizer consists of a high voltage power supply and an in-line, ionizing air nozzle. The air nozzle houses two tungsten needles. Pulsed high voltage applied to the needles ionizes air passing through the nozzle. Ionized air mixes with aerosol in the mixing chamber, effectively neutralizing the aerosol particles. A pressure switch turns off AC line voltage to the neutralizer when there is no make-up air flow.


M a k e - u p A i r H e a t e r A heater used to warm the make-up air is standard on the Model 8130 Automated Filter Tester (Figure 3-4). It is not needed on the Model 8127 since the oil aerosol does not require heated make-up air which helps speed drying of the atomized salt particles when using the salt aerosol generator. The 70 Watt tube heater, shown in Figure 3-4, is mounted on the bottom panel near the back of the Filter Tester. For safety, a pressure switch turns off AC line voltage to the heater when there is no make-up air flow.

Figure 3-4 The Make-up Air Heater (Model 8130 only)


M i x i n g M a n i f o l d a n d C h a m b e r The mixing manifold, shown in Figure 3-5, has two inlets, one for aerosol from the generator and one for make-up air, and two outlets, one for the mixed aerosol and one for exhaust aerosol. Aerosol from the aerosol generator and make-up air from the make-up air flowmeter are mixed in the mixing chamber attached to the mixing manifold. The mixed aerosol then passes through the mixing manifold and on to the upper filter holder. In a typical test, excess aerosol beyond that needed for the filter test is generated. The unneeded aerosol is exhausted through the excess aerosol exhaust port. For information on adjusting the make-up air, refer to “Step 7. Set the Make-up Air Flowrate” in Chapter 5.

A

BC

Figure 3-5 The Mixing Manifold (A), Mixing Chamber (B), and Exhaust Line (C)


F l o w m e t e r The flowmeter (Figure 3-6) measures the air flow through the filter or filter media under test. It consists of a metal tube with an internal orifice. The flow passes upward through the flowmeter and the pressure difference across the orifice is measured with a pressure transducer. The pressure difference is converted to flowrate using a calibration data curve. The flowmeter calibration data is contained in an EEPROM on the CPU board. You can view the calibration data and, in special cases, change the data. For more information on this topic, refer to “CALIBRATIONS” under the “[*]SYSTEM” selection in Chapter 6.

Figure 3-6 The Flowmeter


F i l t e r H o l d e r The upper half of the filter holder is mounted on the steel support frame located on top of the tester cabinet, the lower half on the cabinet top itself. The standard holder shipped with the system (Figure 3-7) is designed to test flat sheet media. Even if you are not testing filter media, the media holder is used with supplied standard media to check out the Filter Tester. Refer to “Verifying Penetration Data” in Chapter 7 for more information.

EMERGENCY OFF

ON

OPEN

Figure 3-7 The Filter Holder If you ordered a custom filter holder, install it in place of the flat media holder once correct system operation is verified. For information on replacing the filter holder, refer to “Changing the Filter Holder” in Chapter 4. Retain the media filter holder for later use in checking tester operation. Note: The filter holder is easily changed for each type of filter that

you test. Because filters come in different shapes, contact TSI to obtain a filter holder for your specific application.


Generally, the filter holder consists of two halves, or cups, into which the filter is inserted. Aerosol flowing from the mixing manifold passes from the top half of the filter holder to the bottom half. A nonrotating air cylinder lowers the upper half of the filter holder and compresses the filter between the filter holder cups. A pressure regulator controls pressure to the air cylinder. You can apply a wide range of sealing forces using the regulator to adjust the pressure settings. For information on adjusting the pressure regulator, refer to “Step 5. Set the Filter Holder Regulator Pressure” in Chapter 5. Any filter holder designed for use with the Model 8127 or 8130 must provide a seal against outside air when empty. This is required so that a TESTER SET UP operation can be performed. For help in designing your own filter holder, contact TSI.


P r e s s u r e T r a n s d u c e r s CERTITEST

® Automated Filter Testers use two electronic pressure transducers to measure filter resistance and filter air flow. The transducers shown in Figure 3-8, are located behind the mixing chamber in the back center of the cabinet.

For CE compliance customers: The transducers are located inside the electronics housing, in the top, right corner. Access to the transducers is gained by removing the cabinet back panel and opening the electronics housing (NEMA enclosure). Refer to “Removing the Back Panel” in Chapter 9 for more information.

Figure 3-8 Pressure Transducers Both transducers have a nominal 1 to 6 volt linear output, with standard ranges of 0 to 6 inches of H2O (0 to 152.4 mm H2O) resistance and 0 to 1.3 psi for filter air flow. The filter air flow transducer is used in conjunction with the flowmeter described earlier in this chapter.


P h o t o m e t e r A s s e m b l y TSI's Automated Filter Testers rely on two diode laser-based, light scattering photometers to make filter penetration measurements. One photometer measures aerosol concentration upstream of the filter and one measures aerosol concentration downstream.

Figure 3-9 Photometer Assembly, From Back With Back Panel Removed, Showing Photometer Filters The photometers differ in physical size and measurement resolution. The upstream photometer offers relatively low resolution for measuring the high upstream aerosol concentration. The downstream photometer uses a high power laser diode to measure the very low downstream concentrations with the sensitivity needed to make penetration measurements to 0.001 percent.

W A R N I N G

The use of controls, adjustments, or performance of procedures other than those

specified in this manual may result in exposure to hazardous laser radiation.


Looking at the back of the Filter Tester, both photometers are located in an enclosure mounted on the right side of the cabinet. The enclosure also contains the photometer PC board, two venturi vacuum pumps to draw the sample flow, exhaust and sheath air filters, and inlet flow control solenoid valves. Figure 3-9 shows the photometer enclosure from the back of the Filter Tester with the back panel removed.

(continued on next page)


E l e c t r o n i c s H o u s i n g The electronics housing (Figure 3-10) consists of a NEMA enclosure mounted at the back of the Filter Tester cabinet. The housing provides protection for the CPU board, relay board, and power supplies, and improves electrical safety by enclosing high voltage AC connections.

D A N G E R

Electrical hazard that can cause severe injury or death.

The electronics housing contains a high-voltage source. Do not remove the cover

or insert any objects under it.

You can access the housing by removing the cabinet back panel. Refer to “Removing the Back Panel” in Chapter 9 for more information.

Figure 3-10 Electronics Housing


C P U / C o n t r o l l e r The Filter Tester is controlled by a dedicated microprocessor and 64k EPROM chip on the CPU (central processing unit) board (Figure 3-11) housed in the NEMA electrical enclosure described in the previous section “Electronics Housing.” Inputs to the microprocessor include photometer and pressure transducer voltages, interrupt-driven touch-panel display inputs, and open-close button interrupts. Note: TSI Automated Filter Testers offer the capability for tester

control through a special external input. This allows for filter testing using automated filter insertion and removal. Contact TSI for information on the external control kit, Model 800402.

EPROM Program Chip

EEPROM Data Chip

Figure 3-11 The CPU/Controller PC Board (mounted inside the NEMA enclosure)


C o n t r o l B u t t o n s The control buttons consist of two CLOSE buttons and an OPEN button located at the front of the Filter Tester cabinet (Figure 3-12). When both CLOSE buttons are pressed simultaneously, the filter holder closes and a filter test begins. The OPEN button opens the filter holder at any time during a test in progress. The CLOSE buttons only function in certain software modes. These include the TESTER SET UP, FILTER TEST, FLOW ADJUSTMENT, and VOLTAGES modes. More information on use of the control buttons is found in “Using OPEN, CLOSE, and Emergency Off/On Buttons” in Chapter 5. Note: The OPEN button does not have the same function as the red

Emergency Off/On button also described in this chapter.

CLOSECLOSE OPEN

FLOWCONTROL

Figure 3-12 The Control Buttons


T o u c h - P a n e l D i s p l a y The touch-panel display, shown in Figure 3-13, is mounted on the filter holder support frame. It serves as a terminal to input test parameters and output data results. The display uses vacuum fluorescent technology to display characters, and an infrared touch-input switch matrix to record user inputs and responses. The screen has six lines of 40 characters, enabling a menu-driven software capability, detailed data display, and system status message display. Selections are activated when you remove your finger from the panel. Additional information on the touch-panel display is found in “Using the Touch-Panel Display” in Chapter 5.

1 2 3 4 5 6 7 8 9 0 ENTER

ESC

Figure 3-13 The Touch-Panel Display


P r i n t e r A 20-character per line thermal printer (Figure 3-14) is included with CERTITEST Automated Filter Testers. This printer provides a hard copy of the data when the test finishes. Output to the printer is turned on and off via the software. Use of the printer lengthens the filter test time by the amount of time it takes to print the test results. For convenience, the printer can be placed on the top of the tester cabinet. For more information on the printer, refer to “Connecting the Thermal Printer” in Chapter 4, “Step 10. Turn the Thermal Printer and/or the RS-232 Serial Port On (optional)” in Chapter 5, or “[*] PRINTER” in Chapter 6. A manual for the printer itself is included in Appendix G.

Figure 3-14 The Thermal Printer


E m e r g e n c y O f f / O n B u t t o n The red Emergency button (Figure 3-15) quickly shuts off the compressed air supply valve and releases the internal air pressure in the system. Use this button to release the force holding the filter holder, stop the make-up air flow, or stop air flow to the aerosol generator. For more information on using the Emergency Off/On button, refer to “Using OPEN, CLOSE, and Emergency Off/On Buttons” in Chapter 5.

EMERGENCY OFF

ON

Figure 3-15 The Emergency Off/On Button


V a c u u m P u m p The Models 8127 and 8130 Automated Filter Testers use a carbon vane vacuum pump, shown in Figure 3-16, to create the vacuum necessary to obtain the correct filter flowrate. The vacuum pump is located at the bottom near the back of the Filter Tester cabinet.

Figure 3-16 The Vacuum Pump


F l o w C o n t r o l V a l v e a n d O n / O f f S w i t c h The flow control valve and On/Off switch are located on the front panel of the Filter Tester cabinet (Figure 3-17). The flow control valve adjusts the filter flow for testing. Refer to “Step 11. Perform TESTER SET-UP” in Chapter 5 for more information on using the flow control valve. The On/Off switch turns the Filter Tester on and off. When it is turned off, compressed air flow to components after the main valve is stopped automatically. The filter holder will stay closed or slowly settle closed if it was in the open position.

W A R N I N G

AC voltage and high air pressure can be present in some parts of the Filter

Tester when the power switch is turned off.

CLOSECLOSE OPEN

FLOWCONTROL

Figure 3-17 The Flow Control Valve Handle and the On/Off Switch

4-1

C H A P T E R 4 Set t ing Up the Tester

This chapter describes the following procedures required to get your CERTITEST Automated Filter Tester ready for operation:

❑ Mounting the touch-panel display

❑ Connecting electrical power

❑ Connecting compressed air

❑ Filling and installing the aerosol generators

❑ Connecting the aerosol exhaust

❑ Connecting the printer (optional)

❑ Connecting the serial interface (optional)

❑ Changing the filter holder (optional) Perform the procedures in the order presented.

B e f o r e Y o u B e g i n You need these items to set up the Automated Filter Tester:

3⁄16 inch ball driver wrench (supplied)

An electrical outlet (110 VAC or 230 VAC)

A source of compressed air (with line having a quick-connector fitting with a ¼ inch male pipe thread that connects to back of Filter Tester)

Emery 3004 oil or NaCl (Model 8130 only)

¾ inch I.D. vinyl exhaust tubing (10 feet supplied)


M o u n t i n g t h e T o u c h - P a n e l D i s p l a y The 240-character vacuum fluorescent touch-panel display is shipped detached from the Filter Tester to prevent damage. Use the following procedure to attach the touch-panel display to the filter holder support frame as shown in Figure 4-1: 1. Looking from the front of the tester, locate the mounting block

attached to the upper right of the filter holder support frame. 2. Locate the two screws that secure the touch-panel display to

the mounting block. They will be attached to the display. 3. Carefully lift the display, insert the two screws in the mounting

holes, and align them with the threaded holes in the block. 4. Using the 3⁄16 inch ball driver (supplied) securely tighten each

screw. 5. Locate the cable on the back of the display and plug the

connector into the DISPLAY port on the back of the cabinet.

Figure 4-1 The Touch-Panel Display Mounted in Position

Setting Up the Tester 4-3

C o n n e c t i n g E l e c t r i c a l P o w e r Voltage and current requirements for the Models 8127 and 8130 are:

100 to 120 VAC, 5 amps, or

230 to 240 VAC, 2.5 amps The Filter Tester is set at the factory to operate at the correct AC voltage for the destination country. This voltage is noted on a label attached to the back panel of the Filter Tester. The power cord contains a plug which is specifically adapted to the destination country. For example, Filter Testers sent to Germany, and to most Scandinavian countries, contain a plug which conforms to the CEE7/7 standard. You are responsible for plugging the power cord into a matching receptacle. To connect the Filter Tester to electrical power, do the following:

1. Check to make sure the Filter Tester is turned off. (Refer to “Flow Control Valve and On/Off Switch” in Chapter 3 to find the location of the Filter Tester On/Off switch.)

Note: Before connecting the power cord to the power outlet, make sure the cord has not been cut or otherwise damaged during shipment.

2. Plug the power cord into a matching power outlet. It is highly recommended that the Filter Tester power receptacle be installed on a dedicated circuit.

!

C a u t i o n

To prevent damage to the Filter Tester, make sure the voltage listed on the back

panel matches the power outlet where you plug it in.

C o n n e c t i n g C o m p r e s s e d A i r TSI Automated Filter Testers require clean, dry, compressed air that meets the following requirements:

Supply line pressure at 80 to 125 psi (552 to 862 kilopascals).

Compressed air at 7 CFM (198 liters/min) at standard conditions.


!

C a u t i o n

To prevent damage to the Filter Tester, do not exceed 125 psi (862 kilopascals)

inlet line pressure. This is the pressure limit on the inlet regulator and water trap.

To connect the compressed air, do the following:

1. Locate the compressed air inlet at the back of the Filter Tester (just above the power cord).

2. Connect your compressed air line to the air inlet using a quick-connector fitting with a ¼ inch male pipe thread that connects to the fitting on the back of the tester cabinet. One style of quick-connector fitting is supplied with the Filter Tester.

How to Tell if Your Compressed Air is Clean Enough Compressed air often contains water and oil. Your compressor must have a capability for trapping water and oil. Small or portable compressors normally do not provide sufficient water removal for use with your Automated Filter Tester. A coarse coalescing filter, located under the main system pressure regulator (Figure 4-2), removes the bulk of any liquid found in the compressed air supply line. Liquid removed is collected in the clear plastic reservoir around the coarse filter. When you first begin using the Filter Tester, check the reservoir frequently and release any liquid by pushing the drain plug at the bottom of the reservoir to the side. Never let the reservoir fill completely. If you have to release the liquid every few hours, or more often, consider using a compressor with better water removal capability, or consider purchasing a commercially-available, in-line compressed air dryer.


If a large quantity of water or oil is collected, it is likely that some will get past the regulator into the air inlet filter. To check this, disconnect the compressed air line to the tester and remove the air inlet filter following the procedure for changing the filter listed in Chapter 9. If the filter appears to be loaded with oil or water, you should replace it.

!

W A R N I N G

The manufacturer of the regulator has the following warning concerning the

plastic water/oil trap at the base of the regulator. DO NOT REMOVE THE

METAL GUARD on the bowl. This warning is to minimize the danger of flying

fragments in the event of a plastic bowl failure.

A

B

Figure 4-2 The Compressed Air Regulator (A) with Water Trap (B)


F i l l i n g a n d I n s t a l l i n g t h e A e r o s o l G e n e r a t o r

The aerosol generator supplies the challenge aerosol for filter testing. The Model 8127 tester includes an oil aerosol generator while the Model 8130 includes both oil and salt generators. They are shipped with the accessories, separate from the main Filter Tester cabinet. This section provides information on filling, installing, and preparing the generators for use.

The Oil Aerosol Generator Locate the oil aerosol generator. If you have both oil and salt generators, it is the one with the bottle attached to the side. Use the following procedure to fill and install it:

1. Examine the oil aerosol generator for loose fittings, making sure the six wing nuts that hold the cover are tight.

2. Remove the fill cover (refer to Figure 4-3).

H

L

Aerosol Outlet

Collection Bottle

Pressure Relief Valve

Compressed Air Inlet(low concentration)

Compressed Air Inlet(high concentration)

Liquid LevelIndicator

Fill Cover

Figure 4-3 Oil Aerosol Generator Reservoir Cover (top view) 3. Fill the oil reservoir with the oil until the top of the red marker

in the liquid level indicator on top of the reservoir cover (see Figure 4-3) is just below the top black ring. Do not overfill.


Notes: If you use an oil other than Emery 3004, or anytime you switch from one oil to another, you must clean the aerosol generator thoroughly and replace the impaction felt. Refer to “Using a Different Oil” in Chapter 9 for instructions on doing this.

Although DOP oil is still widely used for filter testing, TSI is concerned with the reported adverse health effects of DOP. Refer to Appendix D, “Aerosol Generator Data and Operating Parameters,” and “Changing the Aerosol Concentration” in Chapter 8 for information on using different oils with the oil aerosol generator.

4. Replace the fill cover and place the aerosol generator in the cut-out made for it on the bottom shelf of the tester cabinet (see Figure 4-4).

5. Connect the black compressed air supply line found inside the Filter Tester to the “H” (high concentration) fitting identified by an H inscribed on the generator cover (see Figure 4-3). Finger tighten, being careful not to cross-thread the nut.

Note: If your application requires an unusually low aerosol concentration, you may want to connect the compressed air line to the “L” (low concentration) fitting (see Figure 4-3). See “Changing the Aerosol Concentration” in Chapter 8 for more information.

6. Connect one end of the short length of ¾ inch vinyl tubing packed with the aerosol generator to the barbed fitting on the generator. Connect the other end to the fitting on the mixing manifold (see Figure 4-4). (If you cannot locate the short tubing, use the ten-foot length of ¾ inch vinyl tubing supplied with the tester. Connect one end to the barbed fitting on the oil generator, route it to the fitting on the mixing chamber, cut the tubing to fit making sure there are no kinks or sharp bends, and connect it to the mixing manifold.)


Figure 4-4 The Oil Aerosol Generator Installed

The Salt Aerosol Generator (TSI Model 8118A) Locate the salt aerosol generator. If you purchased a Model 8130 Automated Filter Tester, you will have both salt and oil generators. The salt generator is the one with the motor mounted on top. Note: There is an extensive manual for the Model 8118A Salt Aerosol

Generator included as Appendix H in this manual. Refer to the Salt Aerosol Generator manual for detailed information on its use, maintenance, and troubleshooting.

Use the following procedure to fill and install the salt Aerosol Generator:

1. Examine the salt aerosol generator for loose fittings, making sure the six wing nuts holding the cover are tight.

2. Remove the fill cover (refer to Figure 4-5).

3. Fill the reservoir with a two percent salt solution until the top of the red marker in the liquid level indicator on top of the reservoir cover (see Figure 4-5) is just below the top black ring. Do not overfill. See “Mixing Salt Solution” in Chapter 4 of the


Salt Aerosol Generator manual in Appendix H for instructions on preparing the salt solution.

AerosolOutlet

Fill Cover

CompressedAir Inlet

LiquidLevelIndicator

PressureReliefValve

ImpactorNut

DrainBottle

Figure 4-5 Salt Aerosol Generator Reservoir Cover (top view) 4. Replace the fill cover and place the salt generator in the cut-out

on the bottom shelf of the Filter Tester cabinet (see Figure 4-6).

5. Connect the black compressed air supply line found inside the Filter Tester to the ¼ inch threaded compressed air fitting on the generator cover. Finger tighten, being careful not to cross-thread the nut.


Figure 4-6 The Salt Aerosol Generator Installed 6. Connect one end of the short length of ¾ inch vinyl tubing

packaged with the aerosol generator to the barbed fitting on the generator cover. Connect the other end to the fitting on the front of the mixing manifold (see Figure 4-6). (If you can’t locate the short tubing, use the ten-foot length supplied with the tester. Connect one end to the barbed fitting on the aerosol generator, route the tubing to the fitting on the mixing manifold, cut the tubing to fit making sure there are no kinks or sharp bends, and connect the tubing to the mixing manifold.)


Aerosol OutletLiquid Level Indicator

CompressedAir Inlet

Figure 4-7 Connectors and Indicators on the Salt Aerosol Generator


C o n n e c t i n g t h e A e r o s o l E x h a u s t Your Filter Tester exhausts excess oil aerosol, or salt in the Model 8130, from a fitting at the back of the mixing manifold (Figures 4-8a and 4-8b). This exhaust air must be routed away from the operator of the Filter Tester and from occupied work areas, preferably outside. To do this:

1. Check to see that the ¾-inch vinyl tubing supplied with the tester is connected to the elbow fitting at the back of the mixing manifold.

2. Remove the ¾-inch port connector and nut from the accessory kit and install on the exhaust fitting at the back of the tester. Connect the long ¾-inch vinyl exhaust tubing supplied in the accessory kit to the port connector and run it to the desired exhaust location. If the tubing is not long enough, obtain additional fittings and tubing from a local supplier or from TSI.

A

B

Figure 4-8a The Exhaust Line (A) and Mixing Manifold (B)


Figure 4-8b External Air Line Connectors: Exhaust and Air Inlet

C o n n e c t i n g t h e T h e r m a l P r i n t e r Filter test results are presented on the touch-panel display after each test is complete. If you need a hard copy printout of test results, you can use the portable printer supplied with the Automated Filter Tester.

Notes: Use of the printer is optional. When the printer is selected for use, the time required for a filter test is lengthened to allow sufficient time to print the data.

There is a complete manual for the Thermal Printer included as Appendix G of this manual. Refer to the printer manual for detailed information on its use, maintenance, and troubleshooting.

To connect the printer, use the following procedures:

1. Locate the TSI Thermal Printer, printer interface cable (9-pin connectors), and AC adapter/charger. If the printer does not have paper, then also find a roll of thermal printer paper, supplied with the system.

2. Connect the AC adapter cable to the printer and plug the AC adapter into an external power outlet.


C a u t i o n

The AC adapter is supplied in 100 to 120 VAC and 230 to 240 VAC versions.

This voltage is noted on a label attached to the back panel of the Filter Tester.

To prevent damage to the AC adapter, make sure the voltage listed on the back

panel matches the power outlet where you plug it in.

3. If it isn't already installed, load paper following instructions in the instruction manual in Appendix G.

4. Connect the printer interface cable to the printer and to the PRINTER connector on the back of the Filter Tester cabinet.

5. Place the printer in a convenient place. A suggested location is on top of the Filter Tester cabinet at the back.

Once you have connected the printer, execute a print test to confirm that the printer is operating correctly and the DIP switches are set correctly:

1. Make sure paper is installed in the printer.

2. Starting with the POWER switch off, turn the POWER switch on while simultaneously pressing the PAPER FEED switch.

3. Release the PAPER FEED switch when printing begins.

Do not turn the power switch off during the print test. The printer prints several lines of test characters, followed by six lines that show the DIP switch settings (Figure 4-9), and then shut off automatically. Make sure the DIP switch settings match those shown in Figure 4-9. If they do not, refer to the printer manual in Appendix G for information on setting the DIP switches. Figure 4-9 shows DIP switch settings for the Model 8925. If you have a TSI Model 8928 (new in 2003), all DIP switches should be set to on except switch 4 which should be set to off. To use the printer, you must select it in the system software. Filter Testers are shipped with the printer option turned off. For information on enabling the printer via software refer to “[*]PRINTER” under “[*]TEST PARAMETERS” in Chapter 6.


Figure 4-9 Print Test Sample Printout


C o n n e c t i n g t h e S e r i a l I n t e r f a c e You can download data directly to a personal computer or data logger using the RS-232 serial interface port provided on all CERTITEST Automated Filter Testers. Simply connect a standard 25-pin serial cable to the connector on the back of the Filter Tester and the other end to a serial port in your PC or data logger. Note: Use of the serial interface is optional. When the serial interface

is selected for use, the time required for a filter test is lengthened to allow time to complete the serial data transfer.

TSI does not supply a serial cable or data acquisition software with the Models 8127 and 8130 testers. You can find a standard serial cable at most computer stores and, using information presented in Chapter 6, you can develop a simple BASIC program to access the filter test data through the serial port or use any number of commercially-available data acquisition programs. For additional information, refer to “[*]RS-232” under “[*]TEST PARAMETERS” in Chapter 6.


C h a n g i n g t h e F i l t e r H o l d e r All CERTITEST Automated Filter Testers are shipped with the standard flat sheet media filter holder installed. If your test application requires a special filter holder, use the following procedure to change filter holders:

1. Turn the Filter Tester off and manually lower the top half of the filter holder.

2. Locate the two screws that secure the top half of the holder (see Figure 4-10), remove the screws using a 3⁄16 inch hex wrench, remove the top filter half, and store it in a safe place along with the screws.

Figure 4-10 Location of Mounting Screws for Upper Half of Filter Holder

3. Replace the upper half using the screws supplied with the new filter holder. Make sure the rubber O-ring is in place. If missing, you can use the one from the holder you removed or use one of the spare O-rings supplied with the tester.

4. Turn the Filter Tester on. The top half of the holder will rise.

5. Locate the two screws that secure the bottom half of the holder (see Figure 4-11), remove the screws using a 1⁄8 inch hex


wrench, remove the bottom filter half, and store it in a safe place along with the screws.

6. Install the lower half using the screws supplied with the new filter holder. Make sure the rubber O-ring is in place. If missing, you can use the one from the holder you removed or use one of the spare O-rings supplied with the tester.

You are now ready for testing with the new filter holder.

Figure 4-11 Location of Mounting Screws for Lower Half of Filter Holder (top view)

5-1

C H A P T E R 5 Operat ing the Tester : The Basics

This chapter describes the basic procedure used to perform a filter test with the CERTITEST Model 8127/8130 Automated Filter Tester.

B e f o r e Y o u B e g i n Before you begin, make sure you have read Chapter 4, “Setting Up the Tester” and have done the following:

Mounted the touch-panel display

Supplied electrical power

Supplied compressed air

Filled and installed an aerosol generator

Connected the aerosol exhaust line If you are unfamiliar with the components or terminology used in this chapter, refer to Chapter 3, “Tester Components” and Chapter 6, “Software Reference Guide.”

T e s t e r C o n t r o l s When operating the tester, use the touch-panel display to select software options and make entries. The OPEN and CLOSE buttons to start and end a filter test.

Using the Touch-Panel Display During operation, the touch-panel display presents the symbol [*] followed by a software option. For example:

[*]FILTER TEST


To select an option, touch the [*] symbol next to it on the touch-panel display. The option is initiated when you remove your finger.

Note: Using the touch-panel display takes some practice. In some

cases, the options are close together on the display and it is easy to select an adjacent option by mistake. If this happens, touch ESC to return to the previous screen.

Using OPEN, CLOSE, and Emergency Off/On Buttons The OPEN and CLOSE and Emergency Off/On buttons are located on the front of the Filter Tester. The OPEN button (Figure 5-1) opens the filter holder, ending any test that is in process. Note: The OPEN button does not disable the filter holder in an

emergency. The two CLOSE buttons (Figure 5-1) are used to close the filter holder when starting a filter test and for certain other functions. They are enabled during the FILTER TEST, FILTER ADJUSTMENT, TESTER SET UP, and VOLTAGES modes. To operate the CLOSE buttons, you must press both buttons simultaneously and hold them down for approximately one second. The Emergency Off/On button (Figure 5-2) shuts off compressed air to the Aerosol Generator, the filter holder, and the make-up air flowmeter. Compressed air will still be present in some parts of the tester upstream of the air inlet regulator and inlet air filter. Specifically, the air inlet regulator, liquid trap, and inlet filter remain pressurized. To dissipate this pressure, remove the air line by disconnecting the QUICK-CONNECT fitting on the back of the instrument.

W A R N I N G

The Emergency Off/On button does not disconnect electrical power to the Filter

Tester. To remove electrical power from the Tester, unplug the power cord

located at the back of the instrument. Use the Emergency Off/On button if something gets caught in the filter holder or if you hear a very loud hissing, signifying that a compressed air line is not properly connected.

Operating the Tester: The Basics 5-3

CLOSECLOSE OPEN

FLOWCONTROL

Figure 5-1 OPEN and CLOSE Buttons

EMERGENCY OFF

ON

Figure 5-2 Emergency Off/On Button


O p e r a t i n g P r o c e d u r e This section outlines the basic operating procedure for the Models 8127 and 8130 Automated Filter Testers. Refer to Chapter 6, “Software Reference Guide” for additional information on software menus and options. The various steps that make up the basic operating procedure are listed in order in Table 5-1 and are described individually in this chapter. You should perform the operating procedure, in the order the steps are listed, when you start using the tester at the beginning of each work day. At a minimum, check all parameters indicated, making adjustments as required. Table 5-1 Basic Operating Procedure

Step Function 1 Check aerosol generator solution level 2 Turn power on 3 Turn the heater on (salt generator only) 4 Set the main regulator pressure (70 psi) 5 Set the filter holder regulator pressure (20 to 50 psi) 6 Set the aerosol generator pressure (30 psi for salt, 35 psi for

Paraffin oil, or 40 psi for Emery oil) 7 Set the make-up air flowrate (70 L/min for salt, 50 L/min for oil) 8 Check that the motor controller is on (salt generator only) 9 Check that the aerosol neutralizer is on (if needed) 10 Allow a warm-up period 11 Turn the thermal printer and/or the RS-232 port on (optional) 12 Perform the TESTER SETUP procedure 13 Perform a filter test or loading test


Step 1. Check Aerosol Generator Solution Level Open the front door of the Filter Tester cabinet and check the position of the red marker in the liquid level indicator on the aerosol generator cover (refer to Figure 5-3). The top of the red marker must be between the black rings.

Figure 5-3 Oil Aerosol Generator Oil Level Indicator If the red marker is below, or close to, the bottom ring, remove the aerosol generator and replenish the oil or salt solution. Refer to “Filling the Oil Aerosol Generator” in Chapter 9 for instructions on replenishing the oil, or “Mixing Salt Solution” in Chapter 4 of the Salt Aerosol Generator manual in Appendix H for directions on mixing and replenishing the salt solution in the salt generator.

Step 2. Turn Power On Turn on the electrical power. The On/Off switch is located on the front of the Filter Tester (Figure 5-4). When the tester is turned on, the main solenoid valve opens and compressed air is supplied to the tester. This results in the filter holder opening (the top half rising).


CLOSECLOSE OPEN

FLOWCONTROL

Figure 5-4 The Power On/Off Switch Note: If the holder does not open, either the red Emergency button is

pushed in or compressed air pressure is low. Check the Emergency button. It should be pulled out. If it is pulled out, the pressure is low. Don't worry about low pressure at this step since the filter holder pressure is adjusted in a later step.

Software Initialization

When the tester is turned on, the following message is presented on the touch-panel display and the tester goes through an initialization cycle:

Initializing Version X.X

The initialization takes about 25 seconds. During this time, the system microprocessor downloads program screens to the touch-panel display memory. The display RAM is battery-backed so a complete initialization is not necessary every time the tester is turned on. Touch ESC on the display screen to skip the initialization process. The following tester identification screen appears briefly after the initialization is complete.

************************************ ** ** ** TSI INCORPORATED ** ** 8127/8130 FILTER TESTER ** ** ** ************************************


The tester identification is followed by the Main Menu screen.

[*]FILTER TEST [*]TESTER SET UP [*]FLOW/LOAD [*]OPTIONS

Step 3. Turn the Heater On (Salt Generator only) You must have the heater on when using the salt aerosol generator. The heater ON/OFF condition is controlled through the software. To turn the heater on, select OPTIONS from the Main Menu. Then select AEROSOL from the Options Menu and select the HEAT option. An asterisk will appear indicating the heater has been turned on. The heater defaults to the OFF condition when the Filter Tester is turned off so when you turn the Filter Tester on you must activate the heater. Even though the heater is turned on, there must be make-up air flow for it to operate.

Step 4. Set the Main Regulator Pressure Locate the main pressure regulator adjustment knob and gauge mounted just inside the front door of the Filter Tester cabinet (Figure 5-5). Adjust the pressure regulator to read 70 to 80 psi on the gauge. (Turning the adjustment knob clockwise causes the pressure to increase.) If the pressure won’t reach at least 70 psi, check to ensure a facility line pressure between 80 and 125 psi is supplied to the Filter Tester, as described in “Connecting Compressed Air” in Chapter 4.


Figure 5-5 Main Pressure Regulator, Gauge, and Adjustment Knob

Step 5. Set the Filter Holder Regulator Pressure Look through the front door of the Filter Tester cabinet and locate the filter holder pressure regulator, adjustment knob and gauge (A in Figure 5-6). Pull the regulator knob up to release the knob lock and adjust the filter holder pressure to read 20 psi on the gauge. If the top half of the filter holder was down, it should rise when this adjustment is made. Higher pressures can be used as needed to improve the seal between the filter and the filter holder.

!

W A R N I N G

Higher pressures cause the filter holder to close with greater force. Keep fingers

and hands away from the filter holder.

Note: If the filter holder does not rise, check to see if the Emergency

button is pushed in.


B

A

Figure 5-6 (A) Filter Holder Pressure Regulator and (B) Aerosol Generator Pressure Regulator

Step 6. Set the Aerosol Generator Pressure The aerosol generator turns on automatically when the Filter Tester is turned on. Look through the front door of the Filter Tester cabinet and locate the aerosol generator pressure regulator, adjustment knob, and gauge (B in Figure 5-6). Using the adjustment knob, adjust the generator pressure to read 30 psi on the gauge when using salt or 40 psi when using Emery 3004 oil. Set to 35 psi for paraffin oil. Refer to Appendix D for information regarding other oils.

Step 7. Set the Make-Up Air Flowrate Look through the front door of the Filter Tester and locate the make-up air flowmeter and adjustment knob on the left side of the cabinet (Figure 5-7). Use the flowmeter to adjust the make-up air flowrate to 50 liters per minute (nominal for oil, 70 liters per minute for salt). Read the flowrate in the middle of the flowmeter float ball.


Figure 5-7 Make-up Air Flowmeter and Valve

Step 8. Check That the Aerosol Neutralizer Is On The aerosol neutralizer must be operating when using the salt aerosol generator and is sometimes recommended for use with the oil generator. As with the heater, make-up air is required for the neutralizer to operate. A pressure switch in the make-up air line detects the presence of make-up air, allowing AC power to be supplied to the neutralizer. Open the front door of the Filter Tester cabinet and locate the neutralizer power supply mounted at the front center of the cabinet (Figure 5-8). Toggle the switch on the power supply to the ON position. The indicator lights on the power supply will begin to flash when the neutralizer is on. If the neutralizer fails to turn on, make sure the power cable is connected to the connector on top of the power supply and fully inserted. Also check to make sure there is make-up air flow. The pulse rate should be set at 10 Hz. If the switch on the neutralizer power supply is left on, the neutralizer will come on whenever the Filter Tester is turned on and there is sufficient make-up air flow.


Figure 5-8 Aerosol Neutralizer Power Supply

Step 9. Warm-up Period Once the Filter Tester is turned on and the regulator pressures and flowrates checked and adjusted, allow a period for the tester to warm up before going on to the TESTER SET UP function and actual filter testing. If testing with oil, allow 15 minutes for warm-up. If using salt, allow 30 minutes. This allows adequate time for tester components to reach operating temperature. If you are turning the tester on after recently turning it off, allow an appropriate warm-up time. If the tester was off for five minutes or less, no warm-up is required. If longer than five minutes, allow an equivalent warm-up time, up to the recommended warm-up period.

Step 10. Turn the Thermal Printer and/or the RS-232 Serial Port On (optional) Use the portable thermal printer supplied with the CERTITEST Filter Testers to obtain hard copies of your filter test data and the RS-232 serial port to send data to an external device. You should have connected the printer when setting up the tester in Chapter 4. Turn it on by toggling the power switch on the back left corner of the printer to the ON position. To use the serial port, connect a 9-pin serial cable as described in “Connecting the Serial Interface” in Chapter 4.


You can confirm that the printer is operating correctly and the internal DIP switches are set correctly by executing a print test. To perform a test, make sure paper is installed and, with the POWER switch off, turn the POWER switch on while simultaneously pressing the PAPER FEED switch. Release the PAPER FEED when printing begins. The printer will print several lines of test characters, followed by six lines that show the DIP switch settings, and then shut off automatically. Do not turn the power switch off while the print test is in progress. Refer to “[*]TEST PARAMETERS” in Chapter 6 for instructions on enabling the printer and the RS-232 port. For additional printer information, refer to “Connecting the Thermal Printer” in Chapter 4 or to the printer manual in Appendix G. For more on the serial port, see “[*] RS-232 (Activate the Serial Port)” in Chapter 6. To have the printer or serial port options default to an ON condition, they must be set under the PROTOCOL menu.

Notes: To ensure correct printer operation, always turn the Filter Tester on before you turn the printer on. If the printer feeds paper but doesn’t print data, reset the printer by turning it off and back on again.

If serial data is not sent to your remote device, see “[*] RS-232 (Activate the Serial Port)” in Chapter 6 for information on the communications protocol.

Step 11. Perform TESTER SET UP Note: If you haven’t read the “Making Entries” section in Chapter 6,

do so now. Following the warm-up period, run the [*]TESTER SET UP function from the Main Menu, displayed when you turned the Filter Tester on. The [*]TESTER SET UP function establishes initial operating conditions. During this time, the transducer and photometer zeros are checked, the aerosol concentration level is checked, and the photometer correlation factor (CF) is determined. The CF is used to correlate upstream photometer measurements with those made downstream. Notes: To use TESTER SET UP, your filter holder must provide an

airtight seal to the outside. The media filter holder supplied with your Filter Tester does provide an airtight seal. If designing your own filter holder, make sure it seals when empty. Contact TSI for assistance in designing your own filter holder.


The [*]TESTER SET UP function is required each time the Filter Tester is turned on. Once started, it runs automatically and takes about 35 seconds.

Use the following procedure for [*]TESTER SET UP: 1. Make sure the filter holder is empty and select the TESTER SET

UP option from the Main Menu screen.


2. A “WAIT” message is displayed for a few seconds. When it

disappears, close the filter holder by pressing both CLOSE buttons simultaneously for approximately one second. The filter flow is displayed on the screen:

FLOW ADJUSTMENT FOR SETUP [*]FLOW lpm [*]RESISTANCE mm [*]CONTINUE SET UP

3. Use the flow control valve (Figure 5-9) to set the flow for your

filter test or loading test. 4. Select [*]CONTINUE SET UP from the screen display. In less

than one minute, the test finishes, the filter holder opens, and a "SET UP COMPLETED" message appears.

When "SET UP COMPLETED" appears, the tester is ready to begin filter testing and the Main Menu screen appears.

CLOSECLOSE OPEN

FLOWCONTROL

Figure 5-9 Flow Control Valve


Step 12. Perform a Filter Test At this point, filter testing can be done. You can also perform a loading test, a gravimetric test, or a pressure plate test. Refer to Chapters 7 and 8 for more information on these procedures. Use the following procedure to perform a standard filter test:

Note: If you adjusted the flow under TESTER SETUP to the flow you will be using, skip to number 5. If not, start at number 1.

1. Select the [*]FLOW/LOAD option from the Main Menu.

[*]FILTER TEST [*]TESTER SET UP

[*]FLOW/LOAD [*]OPTIONS

Select the [*]FLOW ADJUSTMENT option from the FLOW/LOAD menu.

2. Place the filter in the lower half of the filter holder and close the filter holder by pressing the two CLOSE buttons simultaneously. A screen similar to the following is displayed:

RESULTS FLOW: 32.0 LITERS/MIN RESISTANCE: 12.3 mm H2O PENETRATION: 0.013 %

3. Adjust the flow using the flow control valve. If later you want to

test at a flow significantly (x2) different than that used during TESTER SET UP, redo the setup operation in Step 12.

Note: Once the flow is set, it is very stable. You will not need to

set the flow before each filter test. 4. When the flow is adjusted, press the OPEN button to open the

filter holder and press ESC to return to the Main Menu.


5. Select the [*]FILTER TEST option to perform a test. The

following is displayed:

PRESS CLOSE BUTTONS TO BEGIN FILTER TEST


6. Place a filter in the lower half of the filter holder and press both CLOSE buttons simultaneously. The following message is displayed:

** TEST IN PROGRESS **

7. When the test is complete, the filter holder opens and the

results are displayed on the touch-panel display.

RESULTS FLOW: 32.0 LITERS/MIN RESISTANCE: 12.3 mm H2O PENETRATION: 0.013 % READY

If the printer is connected and enabled (see Step 11, above) the results will also be printed. Note: When the thermal printer is activated, the time required for a

filter test is lengthened by the time it takes to complete the printout.

To perform another test, insert a filter in the filter holder, wait for "READY" to appear on the lower right of the screen and press both CLOSE buttons to close the filter holder. The test starts automatically.

6-1

C H A P T E R 6 Sof tware Reference Guide

This chapter describes the software supplied with the CERTITEST Automated Filter Testers. It includes the following sections:

A general description of the filter test software

Directions for making entries

An overview of the menus and options

A description of the Main Menu

A description of the Options Menu Refer to Chapter 5, “Operating the Tester: The Basics,” for a description of the basic procedure used to perform a filter test.

F i l t e r T e s t S o f t w a r e D e s c r i p t i o n The CERTITEST Automated Filter Testers use a software program contained in a 64k EPROM mounted on a custom CPU (central processing unit) board. The software controls all aspects of the filter test, including reading the photometers and pressure transducers, controlling the filter holder, turning on and directing the aerosol flow, and presenting test data to the display screen.

Touch-Panel Display The software uses the 240-character touch-panel display as a terminal for data input and output. For instructions on using the touch-panel display, refer to the “Making Entries” section in this chapter or “Tester Controls” in Chapter 5.

Software Screens The software incorporates over 30 separate screens. Ten are Menu screens, eleven are Entry screens, and the remainder are Display screens. Menu screens present options which call up another


screen. Entry screens are used by the operator to enter numerical data or to turn options such as printer or RS-232 output on and off. Display screens provide information only. No entries can be made. Displays include instructions, error messages, and test results.

Software Version During the initialization cycle when the Filter Tester is first turned on, the following message displays the software version number:

Initializing Version X.X

The standard version 1 software will have a one as the leading number followed by a decimal point and one or more numbers representing the revision level (e.g., 1.2 or 1.32). Special programs with unique or special functions will have version numbers with a leading number other than one (e.g., 2.1 or 3.2). If, in the future, you are supplied with software upgrades, an EPROM will be included to replace the one on your existing CPU board.

M a k i n g E n t r i e s This section gives information for making software entries using the entry screens. Entry screens let you enter numbers, set test times, set calibration data, and similar functions. You can also turn certain program operation flags, such as the one that sends data to the serial port, on or off. To select an entry, touch the [*] symbol that precedes the desired option. If you inadvertently touch an adjacent option, press ESC to return to the original screen and try again.

Entering Numbers To change a software parameter value, press the [*] symbol preceding the option on the touch-panel display. A blinking cursor appears in the far left position in the number field. Enter a number in that position and the cursor moves one position to the right while the decimal point remains fixed. Once you have entered the right-most digit, the software assumes it is the last digit, the number is automatically installed as the new value, and the cursor stops blinking.

Software Reference Guide 6-3

If you only want to change specific digits, position the cursor over those you want to change using the left and right arrow touch-keys on the display and enter the new numbers. When you finish, touch the ENTER touch-key to install the new value. If a save option ([*]SAVE) is displayed on the screen, you must press it before exiting the screen so that the new values will not be lost when the tester is turned off. If you don‘t, the new values you just entered will not be saved.

Turning On an Operation Flag Some options on an entry screen do not require a number but are followed by a “Y” (yes) or “N” (no) status flag. A yes means the operation will be performed and a no means the operation will not be performed. The current status is indicated by the presence or absence of an asterisk in the brackets. A [*] symbol indicates an active status, a [ ] indicates inactive. To change the active condition of an operation status flag, press the [*] symbol preceding the option to toggle it off and on.

M e n u s a n d O p t i o n s O v e r v i e w This section provides a brief overview of the menu structure for the Filter Tester software along with a short description of the various selections available from the different menus. Figure 6-1 shows the menu structure. Table 6-1 defines choices from the Main Menu, Table 6-2 defines choices from the Options Menu, and Table 6-3 defines choices from the System Menu.


Main Menu

Filter Test Flow/Load Tester Set Up Options

Voltages Test Parameters Time/Date Protocol System Aerosol

Calibrations Special Timing Watch Points

Select Create

(heater)

Flow PressureCalibration Calibration

Flow Adjustment Loading Test

Figure 6-1 Software Menu Structure

Table 6-1 Main Menu Options

Option Purpose Refer To

Filter Test Use to enter the filter test mode. This chapter—the Main Menu section and “Step 12. Perform a Filter Test” in Chapter 5.

Flow/Load Use to select flow adjustment or loading test.

This chapter—the Main Menu section and “Step 12. Perform a Filter Test” in Chapter 5..

Tester Set Up Checks transducer and photometer zeros, aerosol concentration level, and establishes the photometer correlation factor.

This chapter—the Main Menu section and “Step 11. Perform TESTER SET UP” in Chapter 5.

Options Use to control parameters that affect test timing, data outputs, calibrations, and error watch points.

Table 6-2 for a description of choices under the Options Menu.


Table 6-2 Flow/Load Menu Options


Flow Adjustment Use to set filter flow before a test. This chapter—the Main Menu section and “Step 12. Perform a Filter Test” in Chapter 5.

Loading Test Use to perform a loading test. This chapter—Flow/Load Menu section and “Performing a Load Test” in Chapter 8.

Table 6-3 Options Menu Options


Voltages Use to view the actual signal voltages produced by the photometers and pressure transducers.

This chapter—[*]VOLTAGES under the Options Menu section.

Test Parameters Use to control key functions related to a filter test. Current test parameters can be viewed and changed from this screen, but these changes are not stored when the tester is turned off.

This chapter—[*]TEST PARAMETERS under the Options Menu section.

Time/Date Use to set the time and date, which is output to a printer and through the RS-232 serial port.

This chapter—[*]TIME/ DATE under the Options Menu section.

Protocol Use to create and save up to ten unique sets of filter test parameters as a group.

This chapter—[*]PROTOCOL under the Options Menu section.

System Use to input calibration data for the flowmeter and the pressure transducer, error check points, and special timing values.

This chapter—[*]SYSTEM under the Options Menu section.

Aerosol (Heater On/Off)

Use to turn the aerosol generator off, without turning the tester off, to conserve solution. Also use this option to turn the heater on and off.

This chapter—[*]AEROSOL under the Options Menu section.


Table 6-4 System Menu Options


Calibrations Use to enter and save calibration values for the flowmeter and resistance transducers.

This chapter—”Calibrations” section under the Systems Menu under the Options menu.

Special Timing Use to control timing for the test setup and other system-related timing.

This chapter—”[*]SPECIAL TIMING” section under the Systems Menu under the Options menu.

Watch Points Used by the software, in conjunction with error messages, to assess the correct operation of the tester.

This chapter—"[*]WATCH POINTS" section under the Systems Menu under the Options menu.

M a i n M e n u The Automated Filter Tester has five operating modes where output data is displayed. These are TESTER SET UP,” FILTER TEST, FLOW ADJUSTMENT, LOADING TEST, and VOLTAGES. The first two are accessed through the Main Menu, shown below, which appears following completion of the initialization cycle begun when the Filter Tester is turned on. The third and fourth modes are accessed through the FLOW/LOAD options menu. The last of these operating modes, VOLTAGES, is accessed through the OPTIONS menu. Refer to the following “Options Menu” section for a description of selections available under the OPTIONS menu.


The TESTER SET UP mode must be performed before either the FLOW ADJUSTMENT or FILTER TEST modes can be initiated. This section describes these three selections from the Main Menu.

[*]TESTER SET UP (Establish Operating Conditions) The TESTER SET UP mode performs a test to establish initial system operating conditions. In normal operation, you should use this mode a minimum of once each day, usually when the Filter Tester is first turned on and warmed up at the beginning of the work day.


The TESTER SET UP mode obtains a good background reading for the two photometers and a precise concentration voltage reading with the two photometers sampling the same aerosol concentration. Concentration (voltage) measurements are taken with the filter holder closed, with a long rise-time interval, and with a long sample time to ensure a good statistical average. See the [*]SPECIAL TIMING section later in this chapter for additional information on test timing during TESTER SET UP. When TESTER SET UP is complete, the filter holder opens and the Main Menu returns. The tester uses the results of the measurements to compute a Correlation Factor (CF). The CF is used to relate the upstream and downstream readings during filter testing. Calculating a Photometer Correlation Factor (CF)

When making penetration measurements, the upstream photometer signal must be expressed in terms of the downstream photometer signal. This is achieved by multiplying the upstream photometer signal by the correlation factor. The actual correlation factor can be seen in the VOLTAGES display screen. Refer to the “[*]VOLTAGES” section later in this chapter. The correlation factor is determined with an empty filter holder and is calculated as shown below:

CFDownstream Photometer Voltage Downstream Background Voltage

Upstream Photometer Voltage Upstream Background Voltage=

−

−

Using the TESTER SET UP Mode

To use the TESTER SET UP mode, choose that option from the Main Menu. A WAIT message is displayed for a few seconds. When the WAIT message disappears, make sure there is no filter in the holder and close the filter holder by pressing both CLOSE buttons simultaneously for approximately one second. The software displays the flow information on the screen:

FLOW ADJUSTMENT FOR SETUP [*]FLOW lpm [*]RESISTANCE mm [*]CONTINUE SET UP

Use the flow control valve to set the flow at the value that you will be using for testing filters. Then select [*]CONTINUE SET UP from the screen display. The software records the flow setting and completes the various setup functions. In less than one minute, the


test finishes, the filter holder opens, a SET UP COMPLETED message appears for a short time, and then the Main Menu reappears. The tester is now ready for filter testing. You can now select the FLOW ADJUSTMENT and FILTER TEST options from the Main Menu. For additional information, refer to “Step 11. Perform TESTER SET UP” in Chapter 5.

[*]FILTER TEST (Starting the Filter Test) The FILTER TEST mode initiates the standard filter test process used to measure filter penetration and pressure drop (resistance) at a specific flowrate. Note: The TESTER SET UP mode must be completed before the

FILTER TEST mode can be used. Using the FILTER TEST Mode

Choose the FILTER TEST selection from the Main Menu. The software displays the following message:

PRESS CLOSE BUTTONS TO BEGIN FILTER TEST

Place a filter in the lower half of the filter holder and press both CLOSE buttons. The software begins the filter test and displays this message:

** TEST IN PROGRESS ** When the test is complete, the filter holder opens automatically and the software displays the results, similar to the following example, on the touch-panel display.

RESULTS FLOW: 32.0 LITERS/MIN RESISTANCE: 12.3 mm H2O PENETRATION: 0.013 %

The software waits a brief time for the system to stabilize, then displays a READY message, and the Filter Tester is ready for another test.


Penetration Calculation

The software determines the percent penetration of particles passing through the filter by measuring the relative aerosol concentration upstream and downstream of the filter:

Percent PenetrationDownstream Concentration

Upstream Concentration= ×100

For information related to the determination of concentration, refer to “Particle Detectors (Photometers)” in Appendix B.

FLOW/LOAD Menu The FLOW/LOAD menu offers two selections: FLOW ADJUSTMENT and LOADING TEST. These two selections are described in detail below. [*]FLOW ADJUSTMENT (Adjust the Filter Flow)

The FLOW ADJUSTMENT mode is used for a variety of purposes. First, it is used to adjust the flow through a filter before a filter test. Second, it is used to determine how quickly penetration results stabilize. Monitoring filter penetration output every second helps determine the delay time needed to achieve the required accuracy in a filter test. For more information on this, refer to “Setting Test Time” in Chapter 8. Third, the FLOW ADJUSTMENT mode is useful for gravimetric tests to determine the aerosol mass concentration output of the aerosol generator. For more information on this, refer to “Measuring Aerosol Mass Concentration” in Chapter 7. Fourth, the FLOW ADJUSTMENT mode is used when performing filter loading tests. See “Performing a Loading Test” in Chapter 8 for additional information. Using the FLOW ADJUSTMENT Mode

Choose FLOW ADJUSTMENT from the Main Menu. The following screen is displayed:

PRESS CLOSE BUTTONS TO BEGIN FLOW TEST READY


A “READY” message must appear on the lower right of the screen before the FLOW ADJUSTMENT mode can be performed. Note: The TESTER SET UP mode must be completed before the

FLOW ADJUSTMENT mode can be used. Install a filter and close the filter holder. The flow adjustment screen shown below gives filter flow, resistance, and a real-time percent penetration. Real-time penetrations are possible since two photometers take upstream and downstream aerosol concentration measurements at the same time.

FLOW ADJUSTMENT FLOW: LITERS/MIN RESISTANCE: mm H2O PENETRATION: %

If you need to adjust the filter flow, use the flow control valve on the front of the Filter Tester. When finished, press the OPEN button to open the filter holder. Then press ESC to return to the Main Menu. [*] LOADING TEST (Perform a Load Test)

The LOADING TEST mode performs a test of the filter to determine the effect particle accumulation has on filter resistance and penetration. Prior to the release of software version 1.24, the FLOW ADJUSTMENT mode was used as the loading test mode. Unlike the FLOW ADJUSTMENT mode, the LOADING TEST mode uses a fixed sample time parameter of 30 seconds, data is conditioned to reject bad data, and performs statistical diagnostics on the test data to improve its reliability. This is done by invalidating data which does not meet defined statistical criteria. For details on the statistical diagnostic routines used and invalid tests, refer to the discussion of the “INVALID” error message section in Chapter 10. Using the LOADING Test Mode

Choose LOADING TEST from the FLOW/LOAD options menu. The following screen is displayed: PRESS CLOSE BUTTONS

TO BEGIN FLOW TEST

READY


As in the FILTER TEST and FLOW ADJUSTMENT modes, a READY must appear in the lower right of the display in order for the test to begin.

Make sure you have your supplied thermal printer connected to the printer port and/or data logger (computer) connected to the serial port. Make sure the PRINTER and/or RS-232 options are selected “Y” in the TEST PARAMETERS screen. The loading test is usually a long duration test. Penetration data is output approximately every minute to the printer and serial port, but is not displayed. You must use your printer or serial data logger to access the data! Place your test filter in the filter holder and press the CLOSE buttons. The LOADING TEST screen is displayed as in the example below: RESULTS FLOW: 32.0 LITERS/MIN RESISTANCE: 12.3 mm H20 **LOADING TEST IN PROGRESS** For more information on using the LOADING TEST option, refer to “Performing a Loading Test” in Chapter 8 and the “INVALID” error message information in Chapter 10.

O p t i o n s M e n u The OPTIONS selection is the last one available on the Main Menu. Menu selections on the OPTIONS screen, shown below, offer flexibility for controlling parameters affecting test timing, data outputs, calibrations, error watch points, and other factors.

[*]VOLTAGES [*]PROTOCOL [*]TEST PARAMETERS [*]SYSTEM [*]TIME/DATE [*]AEROSOL

Each of the OPTIONS menu selections is described in detail below.


[*]TEST PARAMETERS (Controlling Test Times and Options) TSI Automated Filter Testers allow you to adjust a number of parameters that affect the format, test length, and output format of the standard filter test. These parameters can be changed using two different methods. The first is through the TEST PARAMETERS selection on the OPTIONS menu and the second is through the PROTOCOL selection. Changes made through the TEST PARAMETERS option take effect immediately but are temporary, staying active only until the Filter Tester is turned off. When it is turned back on, these settings revert to the values set in the last-used protocol. The PROTOCOL option, described later, lets you designate specific sets of conditions as defined protocols that can be recalled when the tester is turned off and back on. When you choose TEST PARAMETERS from the OPTIONS menu, the following screen appears. Each of the options is described below.

[*]RESISTANCE: [*]PRINTER: [*]FLOW: [*]RS232: [*]PENETRATION: [*]DISP. P/F: [*]SAMPLE TIME: [*]UNITS: [*]RISE TIME: [*]PURGE:

[*]SAMPLE TIME (Set Sampling Time)

SAMPLE TIME is the time spent sampling aerosol to determine the filter penetration. Photometer data is obtained and averaged for .2 second out of each one second test cycle. The other .8 second of each test cycle is used by the microprocessor to check other inputs, calculate averages, check for errors, and so forth. The sample time specified represents the number of one second test cycles for which results are averaged to determine filter flow, resistance, and penetration. A one second sample time is often adequate but longer times improve accuracy and repeatability. Refer to “Setting Test Time” in Chapter 8 for hints on selecting this time for specific test conditions. To change sample time, choose the SAMPLE TIME option. A blinking cursor highlights the leftmost digit of the previous entry. Enter a new number between 1 and 59 seconds. When finished, press ENTER to retain the new number.


[*]RISE TIME (Set Rise Time)

Rise time represents the number of seconds the tester waits (after you start the test) before it enters the sampling mode. This delay time is necessary because it takes time for the aerosol to flow from the mixing chamber, through the filter, to the photometers, and for the concentrations going through the photometers to stabilize. When testing filter media, check to make sure the rise time is set to at least four seconds. Refer to “Setting Test Time” in Chapter 8 for hints on how this should be set for specific test conditions. When you choose the RISE TIME option, the number of seconds previously entered will be highlighted. To change it, simply enter a new number between 1 and 59 seconds. When finished, press ENTER to retain the new number. [*]DISP. P/F (Set and Activate Pass/Fail Limits)

The Automated Filter Tester will automatically determine if a filter passes or fails a test based on preset criteria. It will then present a large PASS message on the left side of the touch-panel display or a FAIL message on the right side. Selecting DISP. P/F causes it to toggle from “Y” (yes) to “N” (no) to select or deselect the display pass/fail function. Selecting this option causes the tester to compare filter resistance, flow, and penetration results with limits you preset to determine if the result is a pass or fail. For this function to operate, RESISTANCE, PENETRATION and FLOW limits, discussed in the following section, must be set. A sample PASS screen is shown below:

#### ## #### #### # # # # # # TEST PROTOCOL: #### #### #### #### FLOW: # # # # # RESISTANCE: # # # #### #### % PENETR:

[*]RESISTANCE, [*]FLOW, and [*]PENETRATION (Set Pass-Fail Setpoints)

Resistance, flow, and penetration, determined from a filter test, are compared to preset values when the DISP. P/F function is selected (see above). The test fails if the Resistance or Penetration values are greater than the setpoint values displayed on the TEST PARAMETERS screen.


To change a setpoint value, choose the selected parameter. A blinking cursor highlights the most significant digit. Enter a new number, or press the arrow key, and the cursor moves to the right and highlights a new digit. When you've changed the digits you want to change, hit the ENTER key, and the new values will be saved. When entering setpoint values, be aware of the current UNITS setting for resistance. If you change UNITS, the setpoint value does not automatically change to reflect the new UNITS designation. The FLOW setpoint is the flowrate that must be used for the test. If the actual flowrate is different (more than ±5%) than the flow setpoint, an error message appears:

** FLOW FOR PASS-FAIL OUT OF RANGE ** To omit any of the three criteria from the pass/fail evaluation, set the limit value to zero for RESISTANCE or FLOW and to 100% for PENETRATION. When the software sees one of these values, it ignores the associated parameter when determining a pass or fail condition. [*]PRINTER (Activate the Printer)

Choosing the PRINTER option on the TEST PARAMETERS screen causes it to toggle from “Y” (yes) to “N” (no) to select or deselect the printout option. If you have the thermal printer connected, selecting this option causes the tester to print the results of each filter test. A printout also occurs automatically once each minute in the FLOW ADJUSTMENT mode if “Y” is selected. The following is a representative test printout:

F 32.0 R 15.2 P 0.007

where: F = flowrate in liters per minute R = filter resistance in mm H2O P = percent penetration A pass (P) or fail (F) indication is also provided at the end of the test line if the DISP. P/F function is selected. Note: Turn off the PRINTER option if no printout is needed. Selecting

the PRINTER option lengthens the filter test.


[*]RS232 (Activate the Serial Port)

Choosing the RS-232 option causes it to toggle from “Y” (yes) to “N” (no) to select or deselect the serial output option. If a device is connected to the serial output port on the back of the Filter Tester, selecting this option causes the tester to output the results of each filter test. A line of serial data is also sent automatically after the TESTER SET UP function is complete, once each minute when in the FLOW ADJUSTMENT function, and each second while in the VOLTAGE mode. Examples of the serial output data strings are provided below.

After TESTER SET UP:

C 17.84 Z .0003572 z .0020041

C = the correlation factor established during TESTER SET UP Z = downstream photometer background signal value in volts z = upstream photometer background signal value in volts

During FLOW ADJUSTMENT and LOADING TEST: F 32.0 R 22.0 P .250 U 135.712 mv 10 17 95 13 10 53

F = filter flowrate R = filter resistance P = particle penetration as a percent U = upstream signal voltage in millivolts (versions above 1.21) mv = milllivolts Date code (final six numbers) = October 17, 1995, 1:10 p.m. and

53 seconds. During FILTER TEST mode:

F 32.0 R 15.2 P 0.007

F = filter flowrate R = filter resistance P = particle penetration as a percent

During VOLTAGES mode:

U .0020068 D .0003383 R 1.008 F .998

U = upstream photometer signal voltage in volts D = downstream photometer signal voltage in volts R = resistance transducer output in volts F = flow transducer in volts


The examples above are for a filter holder open situation. The photometer values are background values without aerosol. The transducer readings are for zero flow and filter resistance (nominal values of 1.000). The serial communications protocol is as follows:

Baud rate = 9600 Data bits = 7 Stop bit = 1 Parity = Odd

As an example, the simple BASIC program below can be used to access data through the serial port: 50 CLS 60 KEY OFF 80 OUT 1021,96 100 OPEN "COM1:9600,O,7,1,RS,DS" AS #1 120 INPUT #1, A$ 130 PRINT A$ 140 GOTO 120 You can also use a data acquisition program such as Windows® Terminal. You can then download the data to a spreadsheet program for evaluation. Note: We recommend you leave the RS-232 function deselected

when it isn’t needed. When it is selected, with or without the port connected, it lengthens a test slightly. This is because the outputs are sent out at the end of the test before the filter holder opens.

[*]UNITS (Select Resistance Units)

Touch the UNITS touchpad to toggle between “M” for mmH2O and “P” for Pascals. [*]PURGE (Set Purge Time)

Purge time is used to remove excess aerosol from the filter holder before the holder opens following a filter test. The longer the delay, the less aerosol escapes to the work environment. The length of the purge time needed depends on the shape and size of the filter holder, the type of aerosol used, and the tester operating environment.


Emery 3004 oil or salt are not dangerous, so reasonable air circulation in a spacious work environment should be sufficient to remove the nuisance aerosol without the need for a purge time. If the space is confined, efforts should be made to prevent buildup of aerosol by using a purge time of at least 2 seconds. When fast test times are critical, vacuum fans or blowers near the filter holder can draw escaping aerosol away and eliminate the need for a purge time. To change the purge time, select the PURGE option. A blinking cursor highlights the previous entry. Enter a new number from 0 to 9. When finished, press ENTER to retain the new number. The purge time is added to the total test time. Whenever the OPEN button is pressed, the purge time delay will occur before the filter holder opens. Press ESC to exit the TEST PARAMETER screen. Press ESC a second time to return to the Main Menu.

[*]PROTOCOL (Save Test Parameters) The PROTOCOL option under the OPTIONS menu is the second way to set a number of parameters that affect the format, test length, and output format of the standard filter test. It gives you the ability to create, save, and later recall unique groups of test parameters, called protocols. Data in a protocol is saved in memory until changes are made, even when the Filter Tester is turned off. A Filter Tester is shipped with protocol “0” as the “default” protocol so that when the tester is first turned on protocol 0 is active. If you do not set additional protocols, preferring to make any parameter changes via the test parameter screen, protocol 0 will remain the default protocol. Once you install additional protocols, the last one installed or in use before the Filter Tester is turned off becomes the default protocol when it is turned on again. These protocol files can be used to store sets of conditions that are used to test specific filter types. You may have one filter type, for example, where you want to set pass/fail criteria for penetration and pressure drop, have a six second rise time, a three second sample time, and print the results. For a second type of filter, you may not have a pass/fail criteria but instead want to send the results to the serial port for later statistical analysis by computer. The two protocols can be saved and installed when needed. You can save up to ten unique parameter groups, protocols zero through nine. The parameter values are saved on the CPU board in an EEPROM (electrically erasable programmable read only memory) chip.


When you choose the PROTOCOL option from the OPTIONS menu, this screen appears:

[*]SELECT TEST PROTOCOL

[*]CREATE TEST PROTOCOL

[*]SELECT TEST PROTOCOL

Choosing the SELECT TEST PROTOCOL selection from the PROTOCOL screen lets you review and install protocols that have been created and saved previously. When this selection is made, the following screen appears:

PROTOCOL: RISE TIME: RESISTANCE: PRINTER: FLOW: RS232: PENETRATION: DISP. P/F SAMPLE TIME: UNITS: [*]NEXT PURGE: [*]INSTALL

To review protocols, select [*]NEXT. Select [*]INSTALL to choose the test parameter group you want to use. Those values will be installed as the new test parameters. If you then turn the tester off, they are also the values that will be saved and loaded when the tester is turned back on. Table 6-4 provides a brief description of the parameters found on the SELECT TEST PROTOCOL and CREATE TEST PROTOCOL screens. These are the same parameters found on the TEST PARAMETERS screen but in a different order. For more detailed information on a specific parameter, refer to the [*]TEST PARAMETERS section in this chapter. Table 6-4 SELECT TEST PROTOCOL and CREATE TEST PROTOCOL Parameters

Option Description Range

PROTOCOL The protocol number. 0 to 9

RESISTANCE Applies only if the DISP. P/F option is “Y.” If the filter resistance is higher than shown, a FAIL message is displayed after the test is completed.

0 to 150 mm H2O, 0 to 1470 Pascals

FLOW The operating flow for the protocol. Applies only if the DISP. P/F option is “Y.” If the flow during the test is 5 percent different than the flow shown, a message appears.

15 to 100 L/min


Option Description Range

PENETRATION Applies only if the DISP. P/F option is “Y.” If the filter penetration is higher than shown here, a FAIL message is displayed after the test is completed.

.001% to 100%

SAMPLE TIME The time spent reading the photometers.

1 to 99 seconds

RISE TIME Time for the aerosol to stabilize in the filter holder.

1 to 99 seconds

PRINTER If “Y,” data is output through the printer port.

Y or N

RS232 If “Y,” data is output through the serial port

Y or N

DISP. P/F If “Y,” the program checks to see if the filter test data meets preset criteria for pass or fail.

Y or N

UNITS Choose resistance units: “M” for mmH2O, “P” for Pascals.

M or P

PURGE Delay to remove residual aerosol from the filter holder before filter holder opens.

0 to 9 seconds

[*]CREATE TEST PROTOCOL

The CREATE TEST PROTOCOL selection lets you create new protocols or change existing ones. When you choose this selection, the following screen appears:

PROTOCOL: PRINTER: RESISTANCE: RS232: FLOW: DISP. P/F PENETRATION: UNITS: SAMPLE TIME: PURGE: RISE TIME: SAVE:

To establish or change a protocol, use the following procedure:

1. Select [*]PROTOCOL.

2. Enter a protocol number from zero to nine.

3. Select a parameter you wish to change. (Remember, if it is a number entry, the decimal point is fixed. Position the cursor with the arrow touch pads.)

4. Change any additional parameters.

5. Check your entries for correctness.

6. Press the [*]SAVE selection to save the protocol values to the EEPROM. (If you don't save the values, they will be lost when you turn the Filter Tester off.)


7. Touch ESC to return to the OPTIONS menu.

Note: To use a newly-created protocol for testing filters, you must return to the OPTIONS menu, choose the PROTOCOL selection, choose SELECT TEST PROTOCOL, enter the new protocol number on the SELECT TEST PROTOCOL screen, and select INSTALL.

[*]VOLTAGES (Read Photometer and Pressure Transducer Voltages) The VOLTAGES option on the OPTIONS menu is used to display photometer and pressure transducer voltages, a feature that helps when checking and adjusting system parameters. The VOLTAGES screen is a display screen only. Parameters displayed cannot be changed via this screen. The photometer signal voltage, for example, can be used to evaluate aerosol concentration and provide a means to adjust make-up air. This is discussed under “Changing the Aerosol Concentration” in Chapter 8. The pressure transducer voltage display lets you adjust for zero drifts should they occur. The following screen appears when the VOLTAGES option is chosen:

VOLTAGES ----------------------------------- UPSTREAM PHOTO.: VOLTS DOWNSTREAM PHOTO.: VOLTS RESISTANCE: VOLTS FLOW: VOLTS CF:

The photometer readings are valuable for monitoring the stability and health of the photometers. With the filter holder open, these voltages correspond to the “zero” voltages, the background signals when no aerosol is present. When the filter holder is closed, they show the voltages that result when challenge aerosol is sampled. The pressure transducer voltages (RESISTANCE and FLOW), with the filter holder open, let you see the zero reading. The standard pressure transducers have a one-volt zero offset. The last result displayed on the screen shows the correlation factor (CF). If you enter the VOLTAGES mode before performing a TESTER SET UP, it will display a CF of one. Following TESTER SET UP, this value corresponds to the CF value computed from set-up results. While this mode is used primarily for troubleshooting the tester, it


will provide a serial output every second which could be used in special applications.

To exit the VOLTAGES selection, the filter holder must be open. If the holder is closed, press the OPEN button to open it. Then press ESC to return to the OPTIONS menu.

[*]TIME/DATE (Set Time and Date) The TIME/DATE option under the OPTIONS menu lets you set the current time and date. Time and date is output to the printer and to the RS-232 serial port. A battery-backed, 24-hour clock on the CPU board maintains the time and date even when the Filter Tester is turned off. Use the following procedure to set the date and time:

1. Choose the TIME/DATE option from the OPTIONS menu. The following entry screen appears:

[*]DAY [*]MONTH [*]HOUR [*]YEAR [*]MINUTE [*]SAVE CHANGES

2. Select the parameter to be changed.

3. Enter the new value using the numeric keypad. For numbers with only one digit, enter a zero for the first digit.

4. Repeat until you've changed all incorrect parameters.

5. When finished, select SAVE CHANGES.

[*]SYSTEM Information accessed through the SYSTEM option on the OPTIONS menu includes calibration data for the flowmeter and pressure transducers, error check points, and special timing values for the system. Note: The parameters shown under the SYSTEM menu are set at the

factory and normally do not have to be changed. When you choose the SYSTEM option, the following screen appears:

[*]CALIBRATIONS [*]SPECIAL TIMING [*]WATCH POINTS


CALIBRATIONS (Calibrate Flowmeter and Pressure Transducers)

The CALIBRATIONS option under the SYSTEM menu is used to examine or change the calibrations for the flowmeter and pressure transducers. When you choose the CALIBRATIONS selection, the following screen appears:

[*]FLOW CALIBRATION [*]PRESSURE CALIBRATION

[*]FLOW CALIBRATION

Filter flow is measured using an orifice flowmeter. A twenty-point calibration in which the pressure drop across the orifice is determined at known flows is performed at TSI. In the tester, flow is calculated from the voltage output of an electronic pressure transducer. A linear interpolation is used to calculate the flow between data points. The twenty calibration data points used for determining flow are saved to an EEPROM on the CPU board. The data points are entered at the factory following the point-by-point flowmeter calibration. Choose the FLOW CALIBRATION option from the CALIBRATIONS screen and the following entry screen appears:

[*]FLOW LITERS/MIN [*]VOLTAGE: VOLTS [*]SAVE POINT DATA POINT [*]NEXT [*]PREVIOUS

Step through the points by pressing the NEXT or PREVIOUS selections to advance to the next data point or return to the previous one. You can enter new values for FLOW or VOLTAGE by selecting the appropriate parameter, entering a new value, and pressing SAVE POINT. Note: The flow calibration is preset at the factory and you should

never need to change it under normal operation. If a data point is inadvertently changed, refer to your flowmeter calibration sheet supplied with your Filter Tester documentation and re-enter the correct value.

Press ESC to return to the CALIBRATIONS menu.


[*]PRESSURE CALIBRATION

Filter resistance is determined using a linear output, electronic pressure transducer. Zero voltage, span voltage, and the pressure range for the transducer are entered and saved on an EEPROM during testing at TSI. A simple linear interpolation is performed to convert transducer voltage to filter resistance. The PRESSURE CALIBRATION entry screen displays the calibration screen for the electronic transducer. Select the PRESSURE CALIBRATION option from the CALIBRATIONS screen and the following entry screen appears:

[*]PRESSURE SPAN: 152.4 mm H2O [*]VOLTAGE SPAN: 5 VOLTS [*]VOLTAGE @ P=0: 1 VOLTS [*]SAVE

The PRESSURE CALIBRATION screen shows data for a pressure transducer with a linear output that relates pressure to voltage. The standard pressure transducer output voltage is from 1 to 6 volts for a pressure range from 0 to 152.4 mm of H2O. The pressure calibration can be changed by selecting the appropriate parameter and entering a new value and then saved using the SAVE selection. Note: The pressure calibration is preset at the factory and you

should not need to change it under normal operation. If a calibration value is inadvertently changed, reset them to the values listed above. If you have a nonstandard pressure transducer, your values will differ.

Press ESC to return to the CALIBRATIONS menu. Press ESC a second time to return to the SYSTEM menu. [*]SPECIAL TIMING

The SPECIAL TIMING option under the SYSTEM menu lets you preview and enter values for certain operating parameters that control the Filter Tester during the TESTER SET UP function and during the normal filter testing process. When you choose the SPECIAL TIMING selection, the following screen appears:

SPECIAL TIMING SET UP [*]ZERO INTERVAL: [*]CLOSE DELAY: [*]RISE INTERVAL: [*]TEST ZERO [*]DATA SAMPLING: INTERVAL: [*]SAVE


The values shown in the column under SET UP are the test parameters used for the TESTER SET UP function. The ZERO INTERVAL is the time spent taking the background voltage readings on the upstream and downstream photometers at the beginning of the TESTER SET UP cycle. During this time, the filter holder is open and the aerosol turned off. Set at four seconds at the factory, this time should not have to be changed under normal operation. The RISE INTERVAL is the time during TESTER SET UP when the aerosol generator is turned on and aerosol begins flowing to the filter holder. It allows sufficient time for the aerosol concentration to stabilize prior to making upstream and downstream concentration measurements. A RISE INTERVAL of 15 seconds is set at the factory. This is an optimum time based on tests using various filter holders with different geometries and volumes. If your filter holder has an unusually large volume, you should increase this number. The DATA SAMPLING time is the interval in TESTER SET UP during which the upstream and downstream concentrations are sampled. Set at four seconds at the factory, it should not have to be changed under normal operation. During filter testing, CLOSE DELAY is the delay time incorporated to ensure the filter holder is closed before aerosol flow begins. Since it lengthens total filter test time, CLOSE DELAY time should be kept short. Set at 0.6 second at the factory, it should not have to be changed under normal operation. Once a filter test is completed, and the filter holder opens, the photometers are purged with clean air to prepare for the next filter test. Aerosol concentration measurements are immediately begun to check for a photometer zero reading. When successive measurements match, a photometer zero reading is assumed and the READY signal generated, indicating the tester is ready for the next test. The TEST ZERO INTERVAL setting is the time between concentration measurements. Set at 0.2 second at the factory, the TEST ZERO INTERVAL time should not have to be changed during normal operation. Refer to the following WATCH POINTS section for additional information. Parameters listed under the SPECIAL TIMING menu can be changed by selecting the appropriate parameter, entering a new value, and then saved using the SAVE selection. Note: Parameters under the SPECIAL TIMING menu are preset at the

factory and you should never need to change them under normal operation. If a parameter is inadvertently changed, refer to this section and re-enter the value set at the factory.


Press ESC to return to the SYSTEM menu. Press ESC a second time to return to the OPTIONS menu. [*]WATCH POINTS

WATCH POINTS are used by the software to assess the overall working condition of the Automated Filter Tester. If the tester has a problem which could affect the filter test measurement, it is detected and an error message is displayed. See Chapter 10 "Troubleshooting the Tester" for a description of software error messages. When you choose the WATCH POINTS selection, the following screen appears:

[*]P1 (mv) : [*]MATCH %: [*]P2 (mv) : [*]EX1 : [*]FLOW Z : [*]EX2 : [*]PRESS Z : [*]LOW CON.: [*]SAVE

The values listed under P1 and P2 are the maximum acceptable background (zero) voltage readings for the upstream (P1) and downstream (P2) photometers, displayed in millivolts. Periodically, during operation, the tester checks to make sure the photometer zero readings do not exceed the P1 and P2 values. If one or both do, an error message is displayed. A high photometer zero value may result from something as simple as an improperly connected tube or low system air pressure. Though much less likely, it could also mean contaminated optics or an electronic failure. Refer to Chapter 9, "Maintaining the Filter Tester" and Chapter 10, "Troubleshooting the Tester" for more information.

The values listed under FLOW Z(ero) and PRESS Z(ero) represent the maximum acceptable range for zero voltage readings for the flow and pressure transducers. For example, the acceptance range expressed as a percent for the flow zero is given as ±FLOW Z/1.000 × 100. The ideal flow transducer zero voltage is 1.000. If FLOW Z is 1.100, the acceptable range is 10 percent. Before each test, the voltage output values for the transducers are compared with the FLOW Z and PRESS Z values. If the absolute value of a pressure transducer is outside the range, an error message is displayed. The transducer probably needs to be zeroed again. This procedure is described under "Zeroing the Pressure Transducers" in Chapter 9.


The LOW CON. value is a voltage level used to determine if there is sufficient aerosol concentration for testing. During a test, the upstream photometer voltage is compared with the LOW CON. value. If the photometer voltage is lower, an error message is displayed. A low concentration error usually means the aerosol generator fluid level is low or the aerosol generator has been turned off. Refer to Chapter 9, "Maintaining the Filter Tester" for more information. The MATCH % parameter defines the point where the downstream photometer has purged sufficiently. The MATCH% is the percent difference between successive downstream photometer voltage readings necessary before a “READY” is issued. See the TEST ZERO INTERVAL information in the previous "SPECIAL TIMING" section for more information. Also refer to “Setting Test Time” in Chapter 8 for more information on optimizing test timing. EX1 and EX2 are reserved for special applications and future requirements. In current Automated Filter Testers, they are unused. Parameters listed under the WATCH POINTS menu can be changed by selecting the appropriate parameter, entering a new value, and then saved using the SAVE selection. Note: Parameters under the WATCH POINTS menu are preset at the

factory and you should not need to change them under normal operation.

Press ESC to return to the SYSTEM menu. Press ESC a second time to return to the OPTIONS menu.


[*]AEROSOL (Turn Aerosol Generator On/Off, Turn Heater On/Off) When the Filter Tester is turned on, the aerosol generator automatically turns on. The AEROSOL option under the OPTIONS menu gives you the ability to turn the aerosol generator off without turning the Filter Tester off. Thus, you can keep the tester "warmed up" without consuming the solution in the aerosol generator. You also use the AEROSOL option to restart the aerosol generator once it has been turned off. When you choose the AEROSOL selection, the following screen appears:

AEROSOL [*]ON [ ]OFF [*]HEAT

Press either ON or OFF to turn the aerosol generator on or off. If using salt, turn the aerosol generator impeller motor off also. When you turn the generators back on, allow 10 minutes for the oil generator to stabilize. Refer to the Salt Aerosol Generator manual in Appendix H for salt generator warm-up requirements. The HEAT selection under the AEROSOL menu turns a special heater on or off. This heater is supplied only with the Model 8130 Filter Tester and used for salt testing only. It is not included in the Model 8127 Automated Filter Tester. It must be turned on, indicated by an asterisk in the brackets, when using the salt aerosol generator. Press ESC to return to the OPTIONS menu. Press ESC a second time to return to the Main Menu.

7-1

C H A P T E R 7 Checking System Per formance

The CERTITEST® Automated Filter Testers have built-in, self-

diagnostics. The software monitors voltages from the photometers and pressure transducers and provides a descriptive message on the display if it detects a problem. A low aerosol concentration message, for example, usually indicates a low solution level, low atomizer pressure, or the generator being turned off. It can also indicate loose tubing or an electronic problem. Together with monitoring of the pressure transducer voltages, the software self-checks significantly reduce the likelihood of getting bad data. Note: Refer to “Troubleshooting the Tester” in Chapter 10 for more

information on self-diagnostics and specific system problems. You can perform additional system checks to verify system performance, meet test requirements, and boost confidence in the Filter Tester measurement results. The tests described in this chapter help you determine aerosol output concentration and verify percent penetration measurements using standard test media.

M e a s u r i n g A e r o s o l M a s s C o n c e n t r a t i o n U s i n g G r a v i m e t r i c T e s t

One check of system performance is to determine the mass concentration output of the aerosol generator. Normally, the oil aerosol generator produces about 100 milligrams per cubic meter (100 mg/m3) and the salt generator about 15 milligrams per cubic meter (15 mg/m3). If it is important that you know your aerosol concentration precisely, perform the following gravimetric measurement. If you need to change or adjust the aerosol concentration, refer to “Changing the Aerosol Concentration” in Chapter 8.


Before you begin, you should locate the following items:

The 102 mm-diameter gravimetric filter holder (TSI P/N 1080566) supplied with TSI Filter Testers.

The box of 102 mm-diameter filter media sheets supplied with your tester (one required for each test). Additional media sheets (TSI P/N 1602076) can be ordered from TSI.

A stop watch or other timing device capable of measurement resolution in seconds.

A scale with a minimum resolution of 0.001 gram and a capacity of at least 5 grams.

A calculator (optional). To make a gravimetric test, use the following procedure:

1. Use the standard media filter holder supplied with the Filter Tester when performing a gravimetric test. If it is not already installed, turn the Filter Tester off and install the media filter holder. Refer to “Changing the Filter Holder” in Chapter 4 for information on doing this.

2. Start the tester as described in Chapter 5, “Operating the Tester: The Basics.” Set the aerosol generator pressure and make-up air to the values listed on the “Aerosol Generator Operating Parameters” sheet located at the front of this manual.

3. Select the FLOW ADJUSTMENT option from the Main Menu.

4. Close the filter holder using the CLOSE buttons. Adjust the filter air flow to 50 liters per minute using the flow control valve on the front panel.

5. Open the filter holder using the OPEN button.

6. Open the gravimetric filter holder (Figure 7-1) by placing the separation tool supplied with it (or a coin or screwdriver) in the radial slot and twisting gently.

7. Inspect for and remove any oil or dust particles that may be on the gravimetric filter holder assembly.

8. One 102 mm-diameter filter media sheet is required for each test. Use a flat blade tweezers to pick up a filter media sheet and inspect it for loose particles or damage. It is a good idea to lightly tap the sheet a couple of times to remove any loose particles or flakes of filter media.

9. Weigh the filter media sheet to the nearest 0.001 gram and record this weight as W1.

Checking System Performance 7-3

A

AB

102-mm DiameterFilter Sheet

Figure 7-1 Gravimetric Filter Holder (A) and Separation Tool (B). 10. Place the filter media in the half of the gravimetric filter holder

having the plastic grid. Assemble the holder by pressing the two halves together.

11. Place the assembled gravimetric filter holder in the media filter holder with the plastic grid down.

12. Select the FLOW ADJUSTMENT option from the OPTIONS menu. Close the filter holder using the CLOSE buttons and record the starting time or start your stopwatch.

13. Perform a final flow adjustment if needed (50 liters per minute).

14. Allow the test to run from ten to fifteen minutes for oil or 40 to 60 minutes for salt. When the selected time has elapsed, stop the test by pressing the OPEN button. Record the stopping time.

15. Remove the gravimetric filter holder from the media filter holder, separate the two halves, and carefully remove the filter. Weigh the filter and record its weight to the closest 0.001 gram. Record the weight as W2.


You should now have the following data:

Initial filter weight: W1 (milligrams)

Final filter weight: W2 (milligrams)

Flowrate: F (50 liters per minute)

Elapsed time: T (minutes)

Calculated weight of aerosol: W=W2-W1 To calculate aerosol mass concentration, use the following formula:

Aerosol Mass Concentration =W

(F /1000)(T )mg / m3

Conversions:

1 m3/min =1000 liters/min 1 gram=1000 milligrams

If you need to change or adjust the aerosol concentration, refer to “Changing the Aerosol Concentration” in Chapter 8.

V e r i f y i n g P e n e t r a t i o n D a t a This section discusses a technique for verifying the Models 8127 and 8130 test data. Sometimes referred to as the “media test,” the technique uses standard, or “calibrated,” filter media to determine tester integrity. To verify integrity, the aerosol penetration through standard media sheets is measured and compared against expected values for the filter material. This test will verify that the flowrate and particle size meet normal operating criteria and that the tester is, overall, operating as expected. Graphs of penetration versus resistance (pressure drop) for different numbers of media sheets are included in the front of this manual (see Figure 7-2). When you perform verification tests using the standard media sheets, your test data should fall within an acceptance zone having boundaries defined by the dashed lines on the graphs. To obtain differing levels of aerosol penetration, the media sheets are stacked together. Each reference graph will list the number of standard media sheets used to obtain the penetration range of interest. A box of fifty filter media sheets is supplied with every TSI Filter Tester and the media test has been used to verify tester performance at TSI prior to shipment. Refer to Appendix C for further information regarding the theory behind the technique.


Before you begin verification testing, locate the following items:

A box of standard glass fiber media sheets (HE-1071 grade, H&V brand) supplied with your Filter Tester. Additional media sheets (P/N 813010) can be ordered from TSI.

The standard media filter holder supplied with the Filter Tester. The standard holder has a 100 cm2 sample area with a cross-section diameter of 4.44 inches (11.28 cm).

Reference graphs relating penetration to pressure drop. Graphs for the oil and salt aerosol generators are included in the front of this manual. Sample reference graphs are shown below in Figure 7-2.

Figure 7-2 Sample Reference Graphs


Performing the Verification Test To perform a verification test, use the following procedure:

1. Use the standard media filter holder supplied with the Filter Tester when verifying particle size. If it is not already installed, turn the tester off and install the media filter holder. Refer to “Changing the Filter Holder” in Chapter 4 for information on doing this.

2. Turn the Filter Tester on and allow it to warm up for at least 15 minutes with the oil aerosol generator on or 30 minutes when using the salt generator. If you have just replaced the generator felt, allow 30 minutes or more for warm-up.

3. Perform a new TESTER SETUP procedure at 32 liters per minute. Refer to Chapter 5, “Operating the Tester: The Basics,” if needed.

4. Select the TEST PARAMETERS screen under the OPTIONS menu and check the RISE TIME and SAMPLE TIME settings. RISE TIME should be set to 4 seconds or higher and SAMPLE TIME to 3 seconds or higher. If they aren’t, select the RISE TIME and/or SAMPLE TIME options and make the necessary changes.

5. Select a reference graph of penetration versus pressure drop (from the front of this manual) and note the number of media sheets called out at the top of the graph. (We recommend you select the one with the largest number of sheets first to save on filter media.) Stack the appropriate number of media sheets and perform a filter test at the flowrate of 32 liters per minute. Refer to “Step 12. Perform a Filter Test” in Chapter 5, if necessary.

6. Record the penetration and resistance (pressure drop) presented on the RESULTS screen.

7. Repeat steps 5 and 6 until five standard tests are completed.

8. Calculate the averages of the five penetration and resistance (pressure drop) readings.

9. Plot the data points for the averaged penetration and resistance (pressure drop) readings on the corresponding reference graph.

10. Select the other reference graph and repeat steps five through nine using the number of filter media sheets specified.


Note: Filter loading (accumulation of particles on the filter) will cause a noticeable change in penetration. When testing with salt, we recommend you add a new bottom media sheet and discard the top one after each test. To conserve filter media, perform the tests requiring the most media sheets first.

Acceptance Zone If the data points plotted in Step 9 above fall within the acceptance zones (the areas defined by the dotted lines on the reference graphs) proper tester performance is verified. If a data point falls outside an acceptance zone, make sure the average is not being skewed by a single data point. If it is, eliminate that data point. It is possible that a bad data point can be caused by the filter media. If you are using the Model 8118A Salt Aerosol Generator, refer to Chapter 7, “Troubleshooting the Generator” in the salt aerosol generator manual in Appendix H. Table 7-1 lists possible causes if problems are encountered during the media test. For the oil aerosol generator, if the resistance (pressure drop) measurement lies to the left or right of where the dashed lines end, it probably indicates an incorrect filter flow or pressure measurement. Double check to ensure the flowrate is 32 liters per minute. Also, try increasing the filter holder pressure. Then retest. If you retest, make sure you are using the correct number of new sheets and that you are using the correct reference sheet. If the filter resistance is within the correct range but the percent penetration is out of range, the problem is in the aerosol generator. Check the generator pressure first. It should be 30 psi when DOP is used and 40 psi with Emery 3004 oil. If the results are close, try performing a new TESTER SETUP procedure. Discard your old media sheets and select new ones. Also, if your oil is old, replace it. Old oil can affect the size of the aerosol produced. Low penetration measurements can be caused by something reducing the internal flow through the generator. If the percent penetration is below the bottom dashed line on the graph, it could mean a plugged jet orifice or other flow restriction. If the penetration is high it could be due to higher internal flow through the generator caused by a missing or leaking jet. If you just finished cleaning the aerosol generator, this could be the problem. Refer to Chapter 10, “Troubleshooting the Tester” for more detailed information on tracking the cause of a data point being outside the acceptance zone.


C h e c k i n g f o r F l o w m e t e r C o n t a m i n a t i o n Use the metal pressure plate supplied to check the pressure drop through the flowmeter. A label on this plate tells what pressure drop the AFT should read at 32 liters per minute. If the actual pressure drop varies greatly from the label value, the flowmeter should be cleaned, see “Cleaning the Flowmeter” in Chapter 9. To check the flowmeter contamination level do the following:

1. Place pressure drop plate in the media filter holder.

2. Select FLOW ADJUSTMENT under the Main Menu.

3. Close the filter holder.

4. Adjust the flowrate to 32 liters per minute.

5. Check pressure drop indicated on LED display. If the pressure drop varies from the label value by more than 5%, the flowmeter should be cleaned. If cleaning does not solve the problem, refer to Table 10-1 for additional suggestions.

8-1

C H A P T E R 8 Appl icat ion Notes

This chapter gives practical information on setting up your system for your application. It includes discussions on changing the aerosol concentration, setting test timing, and performing filter loading tests.

C h a n g i n g t h e A e r o s o l C o n c e n t r a t i o n The aerosol output concentration depends on the aerosol used, the make-up air flowrate, the number of atomizer jets used, and the aerosol generator pressure. You can set the oil aerosol generator, for example, to produce an output concentration from less than 100 mg/m3 to greater than 200 mg/m3 by varying the make-up air flowrate and the number of jets used.

!

I m p o r t a n t

A change in aerosol generator pressure will change the aerosol particle size

distribution. The size distribution change will influence the percent penetration

measurement. Thus, do not change aerosol generator pressure in order to

change aerosol output concentration. The Aerosol Generator Operating Parameters Sheet included in the front of this binder lists the aerosol output concentration (mass concentration) produced by your Filter Tester during check-out prior to shipment. It also lists the aerosol generator pressure (atomizer pressure) and make-up air flowrate (dilution air) used to obtain that concentration. If your testing requires a different output concentration, you need to adjust the make-up air or change the number of atomizer jets in use. Note: We recommend you do not remove jets from the salt aerosol

generator. To evaluate how changing make-up air affects aerosol concentration, turn the Filter Tester on and let it warm up for at least 15 minutes for oil and 30 minutes for salt. Then select the VOLTAGES option from the OPTIONS menu and, with no filter


installed, close the filter holder. Use the make-up air flowmeter and adjustment valve, shown in Figure 5-8, to increase and decrease the make-up air flow. From the VOLTAGES screen, you can see how the photometer voltages change. As the make-up air increases, the photometer voltage decreases, and vice versa. The photometer voltage change is proportional to the change in aerosol concentration. Note: We do not recommend you adjust the make-up air flow below

50 liters per minute. If you are using an aerosol neutralizer, this nominal flowrate is required for the neutralizer and heater to operate.

Refer to the Aerosol Generator Operating Parameters Sheet. It lists the photometer voltage for your Filter Tester during checkout. You can determine your current aerosol concentration using the following formula:

Current Concentration =Current Photometer Voltage

Checkout Photometer VoltageCheckout Concentration×

Checkout numbers in formula refer to the values on your checkout sheet supplied with the tester or a recently measured value relating photometer voltage and mass concentration obtained using the gravimetric test described in Chapter 7. The information on oil on the Aerosol Generator Operating Parameters Sheet is for Emery 3004 oil, typically used to check out the tester. If using other oils such as DOP, or for special applications, adjusting the make-up air flow may not provide a sufficient range for you to obtain the desired aerosol concentration. If so, you can change the number of atomizer jets used in the oil aerosol generator by adding or deleting atomizer draw tubes. A Filter Tester is normally shipped with two atomizer draw tubes installed in the oil aerosol generator which yield an aerosol concentration for Emery 3004 oil of somewhat greater than 100 mg/m3. The number of jets used can be increased to four or decreased to one. Ordinarily, four jets would be required for DOP. Note: When increasing or decreasing the number of jets, never

remove the entire jet assembly. Instead, simply add or remove the liquid draw tube and filter. The flow from each jet is important even if the jet itself is not dispersing oil.

Application Notes 8-3

The oil aerosol concentration will increase or decrease approximately proportionally with the number of jets used. If four jets yield 160 mg/m3, for example, three would yield about 120 mg/m3 under the same operating conditions. Refer to “Cleaning the Oil Atomizer Jets” in Chapter 9 for information on disassembling the oil aerosol generator and installing atomizer draw tubes. If you require only one draw tube for a special low oil aerosol concentration application, you have two options. You can continue to use the high concentration (H) side of the oil aerosol generator, using only one of the draw tubes, or you can use the low concentration (L) side which has only a single draw tube. If you choose the low concentration option, you can leave the high concentration side in the normal configuration. For information on connecting the aerosol generator, refer to “Filling and Installing the Oil Aerosol Generator” in Chapter 4. Note: Whenever you change aerosol concentration using the

methods discussed here, we recommend you go back and verify the concentration using the techniques discussed in Chapter 7.

S e t t i n g T e s t T i m e The software allows you to change the timing of the filter test sequence. Usually, there is an optimum time for a test, that is, the shortest time which still gives accurate, repeatable data. Test time will vary depending upon the type of filter being tested and the filter holder. For a large or complex filter, a filter tested at a low flow, or an oddly shaped filter holder, a longer test time is required to stabilize the test aerosol or purge the holder. Test time is influenced by the rise time, sample time and purge time values as well as whether a printout is required or whether data is output through the serial port. A description of these test time values was presented in Chapter 6, “Software Reference Guide,” in the “TEST PARAMETERS (Controlling Test Times and Options)” section. The information provided below helps you determine the test times that best meet your requirements. To determine the optimum test time, you first need to identify your measurement requirements. If, for instance, accuracy is your most important requirement, you will want to lengthen the test time to ensure the aerosol is stable before sampling and that sampling variation is minimized. If, on the other hand, speed is most important, say for a production application, you will want to reduce


test time to a minimum while still achieving adequate accuracy and repeatability.

Rise Time and Sample Time The most important test time values are the rise time and sample time since they directly affect the penetration measurement made by the Filter Tester. Rise time is the time required for the aerosol to stabilize once the filter holder is closed. The type, shape and size of the filter holder and the filter flowrate will influence the rise time. Typically, large filter holders or those with a complex design require longer rise times than smaller, simpler holders. For the standard media filter holder supplied with your Filter Tester, we normally recommend a rise time of 4 seconds. Sample time is the time spent making the filter test measurement. Data is taken from the upstream and downstream photometers during each second of sample time. Because there is time-related variability in the upstream and downstream concentrations, using a sample time longer than the minimum one second will reduce test-to-test variability. A sample time of 3 seconds, the value set when you receive your Filter Tester, works well for the standard media filter holder supplied.

Other Factors Affecting Test Time Although rise time and sample time are the most important test time parameters, purge time, printing time, and the time required to output data via the RS-232 serial port also directly affect test time. Purge time is optional and can be added to the end of the filter test. It allows up to nine seconds to purge aerosol from the filter holder before it is opened. The filter test sequence pauses while data is sent to the printer or the serial interface. Setting the PRINTER option to “Y” in the PARAMETERS menu lengthens a filter test, whether or not the printer is actually used. Setting the RS-232 option to “Y” also lengthens the test. If your goal is to minimize test time, make sure these options are set to “N” if they are not needed.


Technique for Determining Rise and Sample Times The rise and sample time values set when you receive your Filter Tester (4 seconds and 3 seconds, respectively) are for the standard media filter holder shipped with the tester. These values may not be optimum if you have made your own custom filter holder or plan to install a different style holder purchased from TSI. For such cases, you will want to establish new rise and sample time values. To determine RISE time, you need to perform tests to determine the time needed for the aerosol to stabilize by measuring the length of time it takes for penetration to reach 100 percent (±2 percent). The test is performed without a filter in the filter holder. A penetration value near 100 percent indicates that stability has been achieved. In general, to perform a test, open the filter holder, select the FLOW ADJUSTMENT mode from the FLOW/LOAD menu, close the empty filter holder, and watch the penetration rise toward 100 percent. The rise-rate of the penetration indicates how quickly the photometers are responding, and how quickly the challenge aerosol concentration is stabilizing upstream and downstream of the filter holder. Figure 8-1, shows a representative graph of penetration versus time obtained using the standard media filter holder. Graph time zero indicates the start of the filter test, when the filter holder was closed. The graph shows that after five seconds the penetration measurement has risen to 97 percent, and 100 percent penetration is reached after nine seconds. You can use this graph to select the rise time to use for your testing. When you follow the same procedure with a filter installed, you will obtain a similar graph.


Once you have determined the rise time to use, you need to determine sample time. You should select a low value to start with. One second is the shortest SAMPLE time possible. If subsequent testing indicates the test-to-test variability is too high, experiment by lengthening the sample time until the variability is minimized.

Figure 8-1 Graph of Penetration Versus Time Using Standard Media Filter Holder

Rise and Sample Time Example An example will serve to show how this procedure works. In this example, we will consider optimizing the test speed for flat sheet media. We want to test as many sheets as possible per minute, at a filter flow of 32 liters per minute, using the standard media filter holder. In addition, we are interested in identifying filters with penetrations over .03%. To determine how quickly the tester stabilizes using the media filter holder, select the FLOW ADJUSTMENT option from the FLOW/LOAD menu and set the filter flow to 32 liters per minute. Open the filter holder. Using the FLOW ADJUSTMENT option again, close the empty filter holder and watch the penetration rise toward 100 percent. For this example, using the standard media filter holder, the graph in Figure 8-1 represents the rise in penetration. (If you are using a different filter holder or a different filter flowrate, you must record the second-by-second penetration readings to obtain a similar graph.)


The graph shows that after five seconds penetration has risen to 97 percent. Because we want a fast test, we will accept the measurement bias, which is 3 percent less than 100 percent, and use 4 seconds as our rise time. The fifth second will be the sample second. One second, the shortest sampling time possible, is chosen to keep the test short. If testing shows the test-to-test variability to be excessive, we have the option of extending the sample time. Be advised that if variability is in the filters themselves, measurement variability will not be reduced by extending the sampling time. Finally, to enter the test time parameters we have established, use the following procedure:

1. Enter the TEST PARAMETERS option from the OPTIONS menu.

Note: For more information on entering test parameters, refer to “[*]TEST PARAMETERS (Controlling Test Times and Options)” in Chapter 6. If you want these parameter values to be recalled each time the tester is turned off and on again, enter the values through the CREATE TEST PROTOCOL option, save them under the desired protocol number, then INSTALL the protocol from the SELECT TEST PROTOCOL option. INSTALL will save the values to the EEPROM as the default protocol and also load them as the current test parameters.

2. Select RISE TIME and enter four seconds.

3. Select SAMPLE TIME and enter one second.

4. If you do not need a printout, enter “N” for the PRINTER option. This will reduce the total test time by approximately one second.

5. If you want a pass-fail level for penetration only, set RESISTANCE to 0.0 and FLOW to 32 liters per minute. Set the PENETRATION to 0.03 percent or, since you know you are reading low by three percent, set the pass-fail setpoint three percent lower, or 0.029 percent (97 percent × 0.03 percent).

6. Enter “Y” for the display pass-fail option (DISP. P/F).

7. Make sure the PURGE is 0.0 or blank.

8. Set the RS-232 option to “Y” if you want to output the data to a computer or data logger.

The tests that follow will use these test parameters to perform a test, taking approximately six seconds (if the printer and RS-232 are set to “N”), with a PASS or FAIL indication at the completion of the test.


P e r f o r m i n g a L o a d i n g T e s t A loading test is performed to determine the effect particle accumulation has on filter resistance and penetration. With the Models 8127 and 8130 Automated Filter Testers, you can perform a loading test using the FLOW ADJUSTMENT option found in the Flow/Load menu. When testing with the FLOW ADJUSTMENT option, filter resistance and filter penetration data are provided continuously to the operator. Data are output through the printer and serial output ports approximately once each minute. The test continues until you press the OPEN button on the front of the Filter Tester. The following is an example of the printer output during the loading test:

FLOW......LPM 32.0 RESIT..MMH20 12.3 PENETRATION % 0.013 12/13/94 11:39

The output to the serial port is a single line of data containing filter flow, resistance, and penetration information. The upstream photometer voltage and the date and time are also output. Proportional to the aerosol concentration, upstream photometer voltage can be used to track small changes in the aerosol challenge concentration. The following shows an example of the serial output: F 32.0 R 22.0 P .250 U 135.712 mv 10 17 95 13 10 53

where: F = filter flowrate in liters/minute R = filter resistance in mm H2O P = particle penetration as a percent U = upstream signal voltage in millivolts (versions above 1.21) mv = millivolts Date Code (final six numbers) = October 17, 1995, 1:10 p.m.

and 53 seconds To perform a loading test, use the following procedure:

1. If you have not already done so, prepare your Filter Tester for operation using the procedure listed in Chapter 5. You will need to record the data obtained during the loading test. If a printout is desired, you can prepare your printer using the instructions for setting up the printer provided in Chapter 4. If you want to


record data, connect your computer or data logger to the serial port at the back of the Filter Tester as described in Chapter 4.

2. Select OPTIONS from the Main Menu and then select the TEST PARAMETERS option.

3. Select the PRINTER and/or RS-232 options to output data.

4. Press ESC to return to the Main Menu and select the FLOW/LOAD option, then LOADING TEST.

5. Install your filter in the filter holder and close the filter holder using the CLOSE buttons. When you close the filter holder, the loading test begins automatically. Make final adjustments to your flow as the test begins.

6. When sufficient time for the loading test has elapsed, press the OPEN button to end the test. You can calculate the appropriate test duration using the formula shown below.

Calculating the Load Level on Your Filter To determine the amount (weight) of material collected on your filter during a loading test, use the following formula:

W = (C Qf t)/1000 where: W = weight of particle accumulation in mg C = aerosol concentration in mg/m3 (see “Measuring Aerosol

Mass Concentration” in Chapter 7) Qf = filter flowrate in L/min t = elapsed time in minutes

Calculating the Test Duration If you know the weight of the aerosol you want to collect, to determine how long a test is required, simply rearrange the equation shown above:

t = W (1000)/(C Qf)

9-1

C H A P T E R 9 Mainta in ing the F i l ter Tester

This chapter provides information about maintaining the CERTITEST Automated Filter Testers. The maintenance procedures are divided into two categories, regular and special maintenance. Regular maintenance includes the procedures listed in Table 9-1 that are performed periodically. Special maintenance includes procedures performed to correct potential or actual problems that occur during normal operation. You should recognize that when you use salt for testing filters, maintenance will be more frequent than when you use oil. Most of the described maintenance procedures can be performed from the front of the Filter Tester through the main access door. Some, however, require removing the back panel or raising the top of the Filter Tester. If you need to do either of these, use the following procedures.

R e m o v i n g t h e B a c k P a n e l Use the following steps to remove the back panel.

1. Turn the Filter Tester off.

2. Remove the four retaining screws on the back panel, making sure you remove the back panel screws and not those holding the upper connector panel.

3. Slowly remove the panel from the Filter Tester cabinet.

4. Note that a power cord is connected to a fan mounted on the panel. Carefully slide the panel around to the side of the Filter Tester and lean it against the cabinet. The fan cord should be long enough to allow this. Make sure the fan power cord does not become disconnected.


O p e n i n g t h e T o p o f t h e T e s t e r C a b i n e t Use the following steps to open the top of the tester cabinet.


2. Remove the four mounting screws from the top cover.

3. Place your hand under the upper filter holder cylinder cover (just below the red Emergency button) and push up and back to raise the top (refer to Figure 9-1).

4. Locate the support rod mounted on the left side of the cabinet frame just under the top cover, remove the support rod, and use it to support one front corner of the top cover. (The upper end of the rod fits into a hole in the front corner of the top cover, and the lower end in the corner of the frame.)

C l o s i n g t h e T o p o f t h e T e s t e r C a b i n e t Use the following steps to close the top of the tester cabinet.

1. Place your hand under the filter holder cylinder cover and push up far enough to remove the support rod.

2. Remove the support rod and return it to the holder on the left side of the cabinet frame.

3. Slowly lower the top, making sure attached tubing does not become kinked.

Note: If the top cover comes to rest on the top of the control button panel, lift the back of the cover using the filter holder support frame and slide it into position.

4. Replace the four mounting screws.

Maintaining the Filter Tester 9-3

Figure 9-1 Model 8127/8130 With Top Cover in Open Position

R e g u l a r M a i n t e n a n c e A list of common periodic maintenance procedures required for the CERTITEST Automated Filter Testers is shown in Table 9-1 along with recommended performance intervals. These procedures are described in detail in this section. For your convenience, an Operation Time meter on the top back panel of the Filter Tester cabinet provides an up-to-the-hour record of tester operation. Note: Different maintenance schedules are called for depending on

whether salt or oil is used as the challenge aerosol.


Table 9-1 Maintenance Schedule

Elapsed Time (Hours)

Maintenance Item Using Oil Using Salt

Fill aerosol generator 20 see salt generator manual

Clean mixing manifold ⎯ 40

Clean the flowmeter 400 80

Replace flow line filter* as necessary as necessary

Replace air line filter 800 800

Clean spool valve 1000 300

Replace photometer filters** 1500 1000

Clean vacuum pump filters 3000 3000

Drain air line bowl as necessary as necessary

Check ion balance 6 months 6 months

*The flow line filter should be changed whenever you change between salt and oil.

**If you are doing mostly loading tests, see “Replacing the Photometer Filters” in this chapter for a recommended schedule.

Salt Aerosol Generator Maintenance The salt aerosol generator has routine and special maintenance requirements not covered in this manual. Refer to Chapter 6, “Maintaining the Generator” in the Model 8118A Salt Aerosol Generator Manual in Appendix H for detailed procedures.

Filling the Oil Aerosol Generator Use the following procedure to remove the oil aerosol generator and add oil (refer to Figure 9-2):

1. With the Filter Tester turned off, disconnect the compressed air line.

2. Disconnect the aerosol outlet line from the generator, being careful that oil does not drip from the tubing onto other tester components.

3. Remove the oil aerosol generator from the cabinet and place it on a flat surface.


Figure 9-2 Oil Aerosol Generator Oil Level Indicator 4. Remove the fill cover and fill the oil reservoir with oil until the

top of the red marker in the liquid level indicator is just below the top black ring.

5. Unscrew the atomizer collection bottle and empty the collected oil.

Note: Oil from the atomizer collection bottle can be re-used three or four times without affecting the performance of the oil aerosol generator. Do not continue use beyond this, however, since the oil can age, causing system performance to degrade. Dispose of old oil in an environmentally sound manner.

6. Reinstall the atomizer collection bottle and the generator fill cover, place the oil aerosol generator back in the cutout in the Filter Tester cabinet, and reconnect the compressed air line and aerosol outlet line.

Filling the Salt Aerosol Generator Setting up the salt generator, mixing the salt solution, operating the generator, and adding water are discussed in Chapters 4 and 5 of the Salt Aerosol Generator Manual in Appendix H. Refer to that manual for detailed instructions on filling the salt generator.


Cleaning the Mixing Manifold We recommend that you clean the mixing manifold (Figure 9-3) every 40 hours of operation when you are using the salt aerosol generator. When using oil, mixing manifold cleaning is required far less frequently. To clean the manifold, use the following procedure:

1. Remove the white plastic mixing chamber bottle by unscrewing it from the manifold.

2. Grasp the exposed black plastic mixing tube, rock and twist the tube gently, and pull it down to remove it from the manifold.

3. Rinse the tube in water to remove the accumulated salt and set it aside to dry.

4. Remove the clear plastic aerosol generator tubing from the fitting on the front of the manifold. Use a bottle brush, or equivalent (not supplied), and water to clean the interior of the fitting to its full depth. Look through the fittings to make sure no salt remains. Salt can become caked where the mixing tube pushes into the manifold. Use your fingernail or stiff implement to dislodge caked salt.

5. Holding the manifold firmly with your free hand to reduce stress on the mounting hardware, replace the plastic mixing tube by pressing it back into the manifold.

6. Replace the plastic mixing bottle and reconnect the aerosol tubing by pushing it over the manifold fitting.


Figure 9-3 The Mixing Manifold

Cleaning the Flowmeter We recommend that you clean the flowmeter at least every 80 hours of operation for salt and every 400 hours of operation for oil. To clean the flowmeter, use the following procedure:


2. Open the front door of the Filter Tester cabinet and locate the flowmeter on the right side of the cabinet (refer to Figure 9-4).

3. Note the position of the pressure tap ports toward the top of the flowmeter and the orientation of the pressure lines, with the blue line connected to the top port.

4. Remove the pressure lines from the flowmeter ports.


Blue Tube

Pressure TapPorts

Figure 9-4 The Flowmeter 5. Loosen the thumbscrews on the block at the bottom of the

flowmeter and, with a slight rocking motion, pull down and remove the block from the flowmeter tube.

6. With a slight rocking motion, pull the flowmeter down and out of the top block.

7. Remove the slow straightener from the bottom end of the flow tube. Clean it separately and set it aside in a safe place.

8. Clean the flowmeter by rinsing it with hot soapy water. Then rinse it with clean water to remove the soap.

!

C a u t i o n

Do not use a brush or other implement to clean the inside of the flowmeter. You

could dislodge the orifice plate and void the calibration. If the flow orifice plate is

dislodged accidentally, use a wooden dowel about the size of the inside of the

flow tube and press down on the flow plate until it seats. Press from the end of

the tube nearest the hose barbs.

9. Allow the flowmeter tube to dry thoroughly.

10. Reinstall the flow straightener.


11. Place a small amount of vacuum grease (supplied with tester) on the rubber O-rings at the ends of the flowmeter tube.

12. Replace the flowmeter tube in the mounting blocks, inserting it into the upper one first and then sliding the bottom block on the tube.

Note: Ensure that the flowmeter tube is oriented so the pressure tap ports are closer to the top mounting block than the bottom one.

13. Replace the thumbscrews in the bottom block and tighten.

14. Reattach the pressure lines.

Note: Ensure that the blue pressure line is on top.

Replacing the Flow Line Filter The flow line filter traps aerosol downstream of the filter holder to prevent contamination of the flow adjustment valve and vacuum pump. When this filter becomes loaded, it can limit the filter test flowrate. If you are testing near the upper flow limit of the tester (100 liters/minute with oil, for example), and it becomes loaded, you may not be able to achieve the required flow. If you are unable to achieve the necessary flow, the flow line filter needs to be replaced.

!

I m p o r t a n t

For maximum service life from your filter, use a different filter when testing with

salt and oil. If the same flow line filter is used for both salt and oil, filter

resistance increases rapidly, limiting filter flow. Filters can be labeled for “salt”

and “oil,” stored, and reused with the appropriate aerosol. The replacement procedure described here is for Filter Testers delivered after Spring, 1994. If you have a tester that was delivered earlier, refer to your old instruction manual for the filter replacement procedure. The flow line filter is located behind the flow control panel, above the front access door. The location of the filter is shown in Figure 9-5. To change this filter, use the following procedure:


2. Open the front access door, reach up behind the flow control panel, and find the cylindrical flow line filter.


CLOSE CLOSEOPEN

FLOWCONTROL

Figure 9-5 The Flow Line Filter 3. Grasp the right side of the filter and pull it down into view.

Grasp the flexible tubing on the right side of the filter and pull the tubing off the barbed fitting on the filter using a back and forth twisting motion to ease removal.

4. The other end of the flow filter is attached to the flow control valve with a short length of tubing. To remove the filter, grasp it and pull to the right, using a back and forth twisting motion to ease removal.

5. Spare capsule filters (TSI P/N 1602051) are supplied with the Filter Tester. Additional filters are available from TSI. They are normally shipped from the manufacturer with fittings included but not installed. Insert the fittings into a new filter and tighten with a wrench. If fittings were not supplied, remove the fittings from the old filter and attach them to the new one.

6. Install the new flow line filter by reversing the removal steps for the old filter.

Note: The arrow on the side of the filter that indicates flow direction should point toward the flow control valve (point left) when the filter is installed correctly.

Replacing the Air Line Filter The air line filter is a high efficiency cartridge filter mounted inside a stainless steel holder connected to the output of the compressed air regulator (Figure 9-6). As this cartridge filter becomes loaded, it begins to restrict compressed air flow to the system. We recommend you replace this filter at least every 800 hours of operation. To replace this filter, use the following procedure:


1. Turn the Filter Tester off and disconnect the compressed air supply line.

!

W A R N I N G

The compressed air line must be disconnected or turned off external to the

tester. With compressed air connected, this filter remains at high pressure even

when the tester is turned off. 2. Loosen the fitting and remove the black hose connected to the

output side (right side) of the cartridge filter holder.

3. Separate the halves of the filter holder. Use two wrenches, one placed on the input side (left side) fitting and the other on the output side fitting, and turn the wrench on the output side counter-clockwise.

Figure 9-6 The Air Line Filter

4. Unscrew the old cartridge filter from the filter holder housing and remove it from the holder.

5. Screw in a new filter. Two spare MSA cartridge filters (TSI P/N 1602011) are supplied with the Filter Tester. Additional filters can be obtained from TSI.


6. Make sure the rubber seal is in place and reassemble the cartridge filter holder.

7. Replace the black hose.

8. Reconnect the compressed air supply.

Note: The INLET side, marked on the filter holder, must be connected to the regulator.

Maintaining the Spool Valve The spool valve (Figure 9-7) controls aerosol flow to and from the filter holder. The spool is rotated by an air cylinder from the close to the open position during each filter test. We recommend you clean the spool valve at least every 300 hours of operation for salt and every 1000 hours for oil using the following procedure:

1. Turn the Filter Tester off and open the cabinet front panel. The spool valve is located in the upper right corner of the cabinet.

2. Rotate the spool retainer from the front of the spool to free it for removal.

3. Grasp the knurled end of the spool and, twisting, pull out.

4. Wipe out the spool valve cavity using a lint-free swab or cloth.

5. Wipe off all exposed surfaces of the spool valve using a lint-free swab or cloth.

Figure 9-7 The Spool Valve


6. Inspect the O-rings for breaks, pits, or gouges and replace any damaged O-rings. They are included in the maintenance kit that can be purchased from TSI.

7. Apply a generous amount of silicone vacuum grease (supplied) to the surface of each O-ring.

8. Insert the spool valve into the valve cavity. Push and twist the spool until the alignment pins find the matching holes. Push the spool valve in, and reposition the spool retainer.

Replacing the Photometer Filters Each photometer has two associated filters, one for sheath air and one to remove all aerosol exiting the photometer. We recommend you replace these filters at least every 1500 hours of operation for oil or every 1000 hours for salt and you should replace all four at the same time. You will need to replace your photometer filters more often if you are doing mostly loading tests and you frequently switch between salt and oil. If you follow this type of test regimen, you should change the two filters positioned horizontally at the bottom of Figure 9-8 every 300 hours. Change the vertical filters every 600 hours. To change these filters, use the following procedure:


2. Remove the back panel using the procedure described earlier in this chapter.

3. Find the four photometer filters, shown in Figure 9-8.

!

I m p o r t a n t

When replacing the filters, replace one before going on to the next. In this way,

you will minimize the likelihood of reconnecting the tubes incorrectly.


Figure 9-8 The Photometer Filters 4. Select the lowest filter first. Pull it away from the clamps

holding it to the side panel and bring it toward you. The tubing should be long enough for you to move it outside the cabinet.

Note: Carefully note the filter flow direction, printed on the filter, and the relationship of the filter to the connecting tubing. If necessary, label the tubes with tape to ensure you can correctly reconnect them.

5. Remove the tubing from the fittings using a slight rocking motion.

6. Remove the fittings from the ends of the old filter. Clean the threads, place plumbers' Teflon® tape or thread compound on the threads, and then insert the fittings into a new filter. Spare capsule filters are supplied with the Filter Tester. Additional filters are available from TSI.

Note: The filters are normally shipped from the manufacturer with fittings included. You can discard the fittings since they are not used for this application.

®Teflon is a registered trademark and a brand name owned by DuPont.


7. Reconnect the tubing by pushing it over the barb on the fitting and replace the filter by pressing it into the mounting clamps. Check to ensure the tubing is not kinked. If it is, rotate the filter and/or turn one or both of the fittings to alleviate the problem.

8. Repeat steps 4 through 7 for the remaining three filters.

Removing the Photometer The following pages are the instructions for the earliest units shipped. In step 7 of the next section “Removing The Photometer Module” it refers to the screws inside the photometer box. In the newer design testers the screws go into the photometer box from the outside of the box. Threaded inserts were added to the box so that there is no nut to hold or fall off when the screw is removed. For this style of photometer you need to remove the side panel of the tester to access these screws. The screws holding the photometer are the three that go through the center rail and into the photometer box. This means that the screws shown in Figure 9-9 are actually on the opposite side of the box. Removing the Photometer Module

You should work in close contact with TSI Service Personnel.

1. Turn the filter tester off and disconnect power and compressed air.

2. Open the top of the filter tester as described in “Opening the Top of the Tester Cabinet” earlier in this chapter.

3. Refer to Figure 9-11. Disconnect the compressed air connections depicted. These connections are found at the front of the filter tester. Turn the hex nuts counterclockwise.

4. From the top, disconnect the upstream sample line at the quick-connection. Refer to Figure 9-11 to identify the upstream sample line.

5. Refer to Figure 9-13. Disconnect the photometer connector from the photometer board. Also disconnect the valves #1 electrical power connection by separating the connector shown in Figure 9-13.

6. Refer to Figure 9-12. Disconnect the downstream sample line at the quick-connect. Disconnect the high vacuum purge line at the quick-connect. At this point there should be no electrical or tubing connections to the photometer box.

7. Remove the three Philips screws in the photometer box as shown in Figure 9-9. Be careful when reaching in with your screwdriver so you don’t damage the photometers.


Figure 9-9 Three Philips Screws in the Photometer Box

Figure 9-10 Three Screws Holding Photometer Box in Place


Figure 9-11 Upstream Sample Line and Compressed Air Connection

Figure 9-12 Photometer Box, Downstream Sample Line, and High Vacuum Purge Line


Figure 9-13 Photometer Connector and Electrical Connection Valves

8. Remove the back panel from your filter tester cabinet. This is described earlier in this chapter in the section “Replacing the Photometer Filters.”

9. Remove the three screws holding the photometer box in place as shown in Figure 9-10. Remove the top two screws first. When removing the last screw you must hold the photometer box (top-inside) to prevent the box from falling. This process is best done with two people.

10. Carefully (slowly) pull the photometer out the back of the cabinet. Make sure the tubes or wires inside the cabinet don’t get pinched.

Replacing the Photometer Module

1. Find the new replacement photometer module.

2. Identify the following tubes and electrical connection on your replacement photometer module: • Upstream photometer sample line • Downstream photometer sample line • High vacuum purge line • 1⁄16” diameter compressed air valve supply lines. Two with

brass nuts. • Valves #1 electrical power wires with connector.


3. Separate the tubes and wires if taped together.

4. With the tubes tucked into the photometer box, grasp the box at the top and bottom and insert slowly into the back of the cabinet. If you wish, let the box rest on the bracket above the motor, while installing.

5. Lift the box up and align the notches on the back of the box with the screw clips. Install all three screws as depicted in Figure 9-10. Make sure the box is pushed fully right.

6. Carefully install the three screws as shown in Figure 9-9.

Note: The screws shown in Figure 9-9 are actually on the opposite side of the box.

7. Connect the 1⁄16” tube and hex nut compressed air connections as depicted Figure 9-11. Tighten with fingers.

8. Connect the photometer electrical connector to the mating connector in the photometer box. Note the orientation of the connector in Figure 9-13.

9. Connect the valves #1 electrical connection as shown in Figure 9-13.

10. Connect the upstream line from the photometer box to the upstream line depicted in Figure 9-11. Use the quick-connect.

11. Connect the downstream sample line from the photometer box to the downstream line depicted in Figure 9-12.

12. Connect the vacuum purge line to the tee fitting on the line from the vacuum pump. Refer to Figure 9-12.

13. Close the top of the filter tester as described earlier in this chapter in “Closing the Top of the Tester Cabinet.” As you close the top make sure the downstream sample line, draw line, etc., do not get pinched or kinked. Push lines free as you close the top.

14. Replace the top cover screws.

15. After restarting the filter tester use the [*] VOLTAGES option to check the photometer zeros. After verifying that they are okay, close the filter holder. Verify that the signals for both the upstream and downstream photometers reach the appropriate value as well.

16. Check and, if necessary, reset the watch point settings as described on the bright pink label on the Model 8100 Exchange Photometer.


Cleaning the Vacuum Pump Filters The vacuum pump incorporates two felt filters. One is located in the inlet and the other in the outlet of the vacuum pump. The pump will not draw in aerosol because of the in-line filter upstream of the pump. However, the carbon vanes in the pump itself will wear, producing carbon dust. Dirty filters restrict air flow and could lead to a pump overload. We recommend you clean these filters at least once every 3000 hours of operation. The vacuum pump filters are located in the pump face toward the back of the Filter Tester cabinet. To clean these filters, use the following procedure:

1. Shut the Filter Tester off.

2. Remove the cabinet back panel using the procedure described earlier in this chapter.

3. From the back of the cabinet, locate the vacuum pump and the filter end caps (see Figure 9-14).

4. Remove the felt filters by unscrewing the filter end caps.

5. Wash the filters with soap and water and let them dry. Drying can be accelerated by blowing the filters with compressed air.

Figure 9-14 The Vacuum Pump (showing filter end caps)

6. Replace the filters by screwing the filter end caps in until they are finger tight. Do not use a wrench to tighten.


Draining the Compressed Air Liquid Bowl The shielded plastic bowl below the compressed air regulator collects water and oil droplets removed from the compressed air. Monitor the liquid level in the bowl carefully to determine if and how quickly it fills. Do not allow it to fill up or the air flow will be restricted. Your air compressor may remove water and oil well enough so you'll need to drain the bowl only occasionally or not at all. On the other hand, you may need to drain the bowl every few hours. Note: If you need to drain the bowl frequently, you should provide

additional liquid removal for your compressed air supply. Compressed air dryers are available commercially. Note also that wet or oily air may cause your air line filter to load, requiring premature replacement.

To check for liquid collection, open the front panel of the Filter Tester cabinet and locate the bowl in the lower left part of the cabinet (see Figure 9-15). Looking from the right side, through the holes in the shield, you can determine if liquid has collected.

Figure 9-15 The Compressed Air Line Liquid Collection Bowl


To drain the bowl, locate the rubber stopper at the bottom of the bowl. Place a container under the stopper to collect the liquid and push the stopper to the side. Compressed air will force the liquid from the bowl.

Setting Ion Balance To ensure optimum neutralization of the generated aerosol, the ion balance should be checked semi-annually. The ionizing needles should be replaced annually, or sooner if needed. See the next section for details on replacing needles. Extra pairs of needles are supplied with the Filter Tester and can be easily replaced when needed. The procedure for checking and setting the ion balance is as follows:

1. Turn the Filter Tester power off.

2. The ionizer head is connected to the left side of the mixing manifold by a quick-connect (Figure 9-16). Release the head from the quick-connect by depressing the thumb-catch.

A

B

Figure 9-16 The Aerosol Neutralizer, Including the Power Supply (A) and the Ionizing Air Nozzle (B) 3. Unscrew the air nozzle cap to expose the ionizing needles.


4. Inspect for damaged or deteriorated needles. Clean or replace the needles of the ionizing air nozzle if necessary (see “Cleaning or Replacing the Ionizing Needles” in the next section. Screw the cap back on the ionizing air nozzle.

5. Turn the Filter Tester power on and turn the aerosol generator and the heater off using the AEROSOL menu.

6. Set the make-up air flow to 70 liters per minute.

7. Turn the neutralizer power on.

8. Use the ion balance meter supplied with the Filter Tester to verify a balanced ion output as described below.

9. Set the balance meter switch to BATT to verify proper battery power.

10. Set the switch to X1 scale.

11. Connect the ground cable from the front of the balance meter to the Filter Tester cabinet.

12. Identify the sensing slit on the top of the balance meter and position the ionizing air nozzle two inches from this slit.

13. Using a small screwdriver, adjust the positive or negative potential controller, if needed, until the balance meter reads zero. Do not adjust the pulse rate on the controller. If possible, try to achieve neutral by reducing the drive to the high side.

14. Connect the make-up air line to the mixing manifold.

15. Turn on the aerosol generator and the heater (if using salt). The tester is now ready for normal operation.

Cleaning or Replacing the Ionizing Needles The ionizing needles are made of pure tungsten, which is presently the best known electrode material. The needles should be checked and cleaned semi-annually. They should be replaced annually or once the point reaches a length of 1⁄16 inch from the socket base. Always replace both needles at the same time. The procedure for cleaning or replacing the ionizing needles is as follows:

1. Turn the Filter Tester power off.

2. The ionizer head is connected to the left side of the mixing manifold by a quick connect (Figure 9-16). Release the head from the quick-connect by depressing the thumb-catch.

3. Unscrew the air nozzle cap to expose the ionizing needles.

4. Inspect the needles for excessive wear or particle accumulation and to ensure they are firmly seated.


5. If they only need cleaning, clean the needles using a soft, short-hair brush and denatured alcohol. Then go to step 9.

6. If the needles need replacing, pull each needle straight out from its base using a small pair of needle-nose pliers. Do not squeeze the needle too hard with the pliers to prevent damaging the needles.

7. Hold the new needle at its base using a pair of small needle-nose pliers and carefully insert it into one of the socket bases.

8. Carefully push the needle down into the base until firmly seated.

9. Repeat steps 6 and 7 for the other needle.

10. Screw the cap back on the ionizing air nozzle. Reconnect the dilution air line to the mixing manifold.

The ionizing air nozzle is now ready for operation.

S p e c i a l M a i n t e n a n c e This section describes special maintenance procedures that are not required on a regular basis. Typically, they are used when a system performance problem has been identified and the troubleshooting procedures listed in Chapter 10 direct you to one of these procedures.

Using a Different Oil The oil aerosol generator is currently checked out using Emery 3004 oil. If you use a different type of oil, clean the aerosol generator thoroughly before adding the new oil. Use the following procedure to clean it:

1. Turn the Filter Tester off, disconnect the compressed air line and aerosol outlet tube, and remove the aerosol generator from the Filter Tester.

2. Remove the six wing nuts and separate the cover from the reservoir.

3. Pour the old oil into a suitable container for disposal or later use.

4. Clean the reservoir using hot water and detergent. Set aside to dry.


5. Remove the atomizer liquid draw lines and filters (see Figure 9-18). Use compressed air to blow out the old oil.

6. Refer to the section, “Cleaning the Oil Atomizer Jets,” found later in this chapter. Remove, clean, and replace the jets as described.

7. Replace the generator felt with a new uncontaminated felt. Refer to the section, “Replacing Oil Aerosol Generator Felt,” in this chapter. While the felt is removed from the outlet assembly, clean the outlet assembly with detergent and hot water. Set aside to dry before reassembling with new felt.

8. Reassemble the generator components, fill, and install the generator in the Filter Tester cabinet.

Replacing Oil Aerosol Generator Felt The oil aerosol generator outlet assembly contains a special in-line felt filter that serves to remove large oil particles. The large particles coalesce and form pools at the bottom of the felt. The oil is then pushed out and deposited in a collection bottle.

Under normal operation, the felt does not need to be changed. However, any solid contaminants in the oil can load the felt over time, adversely affecting its performance. Also, it is suspected that long-term use of DOP (greater than one year) will cause the felt to deteriorate. Use the following procedure to remove the oil aerosol generator and change the felt:

1. Turn the Filter Tester off, disconnect the compressed air line and aerosol outlet line, remove the oil aerosol generator from the cabinet, and place it on a flat surface.

2. Remove the four socket head screws from the back of the exhaust assembly mounted on top of the aerosol generator (see Figure 9-17).

3. Separate the halves of the assembly and remove the old felt filter.

4. Install a new felt filter. Spare felts (TSI P/N 1602075) were shipped with the Filter Tester. Additional felt filters are available from TSI.

5. Reverse this procedure to reassemble the aerosol generator, install it in the Filter Tester cabinet, and reconnect the generator.


Note: Operate the oil aerosol generator for 25 minutes after the felt is replaced to ensure the felt becomes totally saturated with oil. No filter penetration testing should be performed until after this break-in period is completed. Changing the felt may change the mass output concentration.

Felt Filter

Figure 9-17 The Oil Aerosol Generator Exhaust Assembly and Felt Filter

Cleaning the Oil Atomizer Jets The most common reason for a low concentration output from the oil aerosol generator is the presence of foreign material blocking one or more atomizer jets. Although screen filters are used on the atomizer draw lines to help eliminate the chance of jet blockage, even a small fleck of foreign material can have a significant effect on output. The atomizer jets should be cleaned when the aerosol generator output is low or erratic or when the generator will be stored for an extended period. Note: For information on cleaning the atomizer jets in the salt

aerosol generator, refer to the manual in Appendix H. To clean the atomizers, use the following procedure:

1. Turn the Filter Tester off, disconnect the compressed air line and aerosol outlet line, remove the oil aerosol generator from the cabinet, and place it on a flat surface.


2. Remove the six thumbscrews securing the top, separate the top of the generator from the reservoir, and lay the top of the generator on its side (see Figure 9-18).

Note: If the generator cover is stuck, use a screwdriver to gently pry between the cover and the reservoir.

3. Use mild soap and warm water or isopropyl alcohol to clean the aerosol generator. Clean the reservoir and exposed parts of the cover, including the atomizer jet block which is attached to the cover.

Note: Use a plastic bottle brush or similar device when cleaning the generator. Do not use cloth, paper towels or other materials that leave lint or fibers behind that can clog the atomizer jets.

Figure 9-18 The Oil Aerosol Generator with Cover Removed 4. Disassemble each atomizer jet assembly, following the order

indicated in Figure 9-19. The retainer that holds the jet parts together can be difficult to remove. If necessary, use a pliers to pull on the tab with a gentle rocking motion. Each jet assembly incorporates a small O-ring. Set them aside in a safe place.


O-ring

6

5

4

3

2

1

Jet Orifice

Draw Line Support

Liquid Draw Line

Retainer

ScreenFilter

Figure 9-19 Atomizer Jet Assembly in Inverted Position (numbers indicate order of disassembly) Note: Five atomizer jets are mounted in the oil atomizer jet block,

four on one end and a fifth one by itself (see Figure 9-18). The four are used for the high concentration operating mode, by far the most common way of operating the Filter Tester. The fifth is used in the low concentration mode. You need only clean the jets for the operating mode in use.

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I m p o r t a n t

Note the number of draw tubes installed on the jets and their locations. When

operating in the high concentration mode, only two or three jets out of the four

total may be fitted with draw tubes. Whether or not all four have draw tubes to

disperse oil, they are all important for controlling the total output flow from the

aerosol generator. All four jet assemblies must be re-installed before the oil

aerosol generator is used.

5. Use mild soap and clean warm water or isopropyl alcohol to rinse off the jet assembly parts. Examine the orifices for plugging. Rinse a second time if necessary. Use clean compressed air to dry them or air dry.


Note: The orifices are easily damaged. Do not insert anything in the orifices in an attempt to clean them.

6. Reassemble and install all atomizer jets, making sure you replace the O-rings. When you replace the retainer, make sure it is completely pushed in.

7. Attach the draw tubes that you noted earlier. Be sure to replace the small filters on the ends of the draw tubes. They help keep the nozzles from becoming plugged with foreign matter.

8. Air dry the generator top with compressed air or let sit to dry. Do not use lint-producing paper towels for drying.

9. Inspect the inside of the reservoir and the cover for foreign matter and remove any found.

10. Set the cover down on the reservoir over the screw studs. Make sure the gasket which seals the lid is correctly positioned.

11. Install and tighten the six thumbscrews finger tight.

Zeroing the Pressure Transducers When there is no differential pressure across the pressure ports of the pressure transducers, the corresponding voltage reading is referred to as the zero reading. The ideal zero reading for the pressure transducers in the Models 8127 and 8130 Automated Filter Testers is 1.000 volt. Actual zero readings will differ from the ideal, however. If the zero drift exceeds 100 millivolts, a transducer error is indicated. The difference between the ideal zero reading and the actual zero reading is corrected for in the software by subtracting the difference, or offset voltage, from 1.000 before measuring the differential pressure voltage. This is done for both the flow and resistance transducers. The zero offset voltage is determined prior to each filter test. When the zero offset is measured, solenoid valves are used to isolate the pressure lines to make sure any offset voltage is due to the electronics only. To zero the pressure transducers, use the following procedure:

1. The transducers are most easily accessed through the cabinet top. Raise and support the top as described earlier in this chapter.

For CE compliance customers: The transducers are accessed by removing the back panel and opening the cover on the electronics housing. The transducers are located in the top, right corner inside the housing.


2. Make sure the Filter Tester is turned on. If it is off, turn it on and allow it to warm up for 15 minutes.

3. The transducers are labeled “Resistance” and “Flow.” Remove the plastic plugs covering the adjustment potentiometers on the front of the transducers. A penlight flashlight may aid in this process.

4. Make sure the filter holder is open. If closed, push the OPEN button on the front panel to open it.

5. Select OPTIONS from the Main Menu and then VOLTAGES from the OPTIONS menu. The following screen appears.

VOLTAGES ----------------------------------- UPSTREAM PHOTO.: VOLTS DOWNSTREAM PHOTO.: VOLTS RESISTANCE: VOLTS FLOW: VOLTS CF:

6. Using a small, straight-blade screwdriver, adjust both transducer potentiometers until the transducer voltages shown after RESISTANCE and FLOW both read 1.000 volts. Make very small adjustments until the proper reading is obtained.

For CE compliance customers: Since the touchscreen is not directly readable from this position, it may be helpful to have a companion call out the voltages while the adjustments are being made.

7. Replace the plastic hole plugs.

8. Lower the top of the Filter Tester.

For CE compliance customers: Secure the cover on the electronics housing and replace the back panel.


Figure 9-20 The Pressure Transducers

Replacing the EPROM Program Chip

W A R N I N G

Before touching any electronic components you must be properly grounded to

prevent static discharge from damaging any static-sensitive ICs. Use a static-

dissipating wrist strap to ensure your body is discharged. The strap must be

connected to a suitable earth ground. You should also connect a grounding

strap from the Filter Tester to the same earth ground. When you start your Filter Tester, the software version number is displayed, as shown in the example below. After you install a new EPROM program chip, a new version number will appear, identifying the new software version. Initializing Version 1.2

To install the new EPROM chip, follow the steps outlined below:

1. Unplug the Filter Tester electrical power cord.

2. Remove the cabinet back panel using the procedure described in the “Removing the Back Panel” section earlier in this chapter.


3. Find the two screws on the electrical enclosure. Loosen both screws until the enclosure door can be opened.

4. Find the CPU board (refer to Figure 9-21) and locate the program chip.

EPROM Program Chip

EEPROM Data Chip

Figure 9-21 CPU Board 5. Using a small, flat blade screwdriver, carefully insert the blade

under the program chip and twist gently to separate the pins of the chip from the socket. Move the screwdriver further under the chip and twist until all the pins are freed. When the chip is sufficiently loose, grasp it with your fingers and pull it out. Do not touch the pins.

6. Find the new program chip. With the notch on the chip pointing toward the top of the cabinet, tilt the chip slightly so one row of pins fits into the chip socket. Make sure all pins have a socket. Press gently. Position the other side of the chip so the pins fit into sockets. Press gently.

Note: Typically, the pins in new chips are separated. This can make insertion into the chip socket difficult. To correct this, find a flat surface, angle the chip, and press gently first on one set of pins and then on the other. Examine the chip from an end view. The pins should be roughly perpendicular to the chip body.

7. Before pressing the chip completely into the socket, put one hand behind the CPU board, roughly at the chip location. While pushing in on the chip, hold the board to prevent undue


flexing. Push the chip in slowly until there is no clearance between the chip body and the socket.

8. Examine the inserted chip. Are all the pins in sockets? Are any pins bent? Is the notch on the chip pointing up? If the answer to any of these questions is no, remove the program chip as described in the earlier steps and start over. You can straighten a bent pin using a pliers but be careful not to break the pin. If damage should occur, contact TSI Incorporated.

9. Close the electrical box door and tighten the retaining screws. Before replacing the back panel you may wish to test to make sure the program chip has been installed properly. To do this simply turn the tester on. The program should start and display the new version number. If it doesn’t, the chip has not been installed properly. Refer to step 9 above.

10. Replace the back panel. Replace and tighten the four panel screws.

Replacing Fuses The system fuses are mounted on the bottom of the NEMA electronics enclosure in the back of the Filter Tester cabinet. Systems designed to operate on 115 VAC electrical power use a single .25 inch diameter by 1.25 inch long, 10 amp, slow blow fuse (TSI P/N 1605049). Systems that operate on 230 VAC use two .25 inch diameter by 1.25 inch long, 5 amp, slow blow fuses (TSI P/N 1605041). These are standard fuses that can be obtained at most electronics and hardware stores. To replace a fuse, use the following procedure:


2. Remove the back panel of the Filter Tester cabinet as described in the “Removing the Back Panel” section earlier in this chapter.

3. Locate the fuse holder(s) on the outside bottom panel of the NEMA electronics enclosure.

4. Remove the fuse by turning the fuse holder cap counterclockwise, replace the fuse with the size and type fuse listed above, and reinstall the fuse holder and fuse.

5. Replace the back panel and turn the Filter Tester on.

Note: The 5-volt and 12-volt power supplies, contained within the electronics housing, have self-contained overcurrent protection. The 230-volt versions of the Models 8127 and 8130 also contain external fuses. These fuses are not user-replaceable. If you suspect there is a problem with


the power supply fuses, please contact the factory for service information.

Replacing and Cleaning Tubing Tubing used in the Model 8127/8130 seldom needs to be cleaned or replaced. If cleaning is required, clean only tubing that is dirty, contaminated, or you suspect is blocked. Clean tubing with soapy water, rinse with clean water, and then dry with compressed air. Often, it's easier to remove tubing from the top of the Filter Tester. See “Opening the Top of the Tester Cabinet” earlier in this chapter for instructions on raising and supporting the top of the cabinet. Clean or replace one tube at a time. Cut new tubes to length using the old tube as a guide. If you purchased a Filter Tester maintenance kit from TSI, it includes spares for all the tubing used in the tester. Appendix E provides additional information on the maintenance kit designed for use with the Models 8127 and 8130 Automated Filter Testers.

Replacing Old Oil The oil used in the oil aerosol generator may age over time, meaning that it absorbs water or changes chemically (oxidizes), especially if it is in continual contact with room air. Aging oil can cause a drop in aerosol concentration. The effect can be fairly dramatic when using DOP. Do not reuse the oil in the atomizer collection bottle more than three or four times. Keep your oil supply tightly sealed from room air and moisture. If you suspect the oil has become contaminated, discard it and install new oil using the procedure in “Filling the Oil Aerosol Generator” found earlier in this chapter.

10-1

C H A P T E R 1 0 Troubleshoot ing and Obta in ing Serv ice

This chapter lists software error messages and provides troubleshooting procedures for the CERTITEST Model 8127/8130 Automated Filter Tester. It also provides instructions for obtaining service on a tester or its component parts. This chapter does not include troubleshooting tips for the Model 8118A Salt Aerosol Generator. For a detailed guide to troubleshooting the salt generator, refer to the Model 8118A manual in Appendix H.

E r r o r M e s s a g e s This section lists software error messages, discusses the meaning of each message, and identifies some possible causes. The troubleshooting section below lists additional causes.

“HIGH ZERO ON DOWNSTREAM PHOTOMETER” Between tests, clean air is passed through the photometer and the voltage level is read. This voltage is referred to as the zero voltage. If the zero voltage is greater than the value set in the WATCH POINTS software option, the error message above is displayed. The photometer zero WATCH POINT (P2) is set at the factory above the initial photometer zero value. The HIGH ZERO error message warns you if the photometer is contaminated or if it is not purging properly. It may mean the photometer assembly needs to be returned to the factory to be cleaned and refurbished. A shift upward in the zero voltage over time may be normal.


This message may appear if a test is improperly started a couple of times and the photometer simply needs more time to purge. In this case, press ESC and reselect the menu you were using. Then wait a few moments and try again. Using the VOLTAGES display option, if you notice that the zero voltage reading exceeds the WATCH POINT setting, contact TSI for instructions on how to proceed. For this examination, make sure the filter holder is open. Refer to Table 10-1 below for additional causes for this message to appear.

“HIGH ZERO ON UPSTREAM PHOTOMETER” This message serves the same purpose as the previous error message, that is, to warn of a contaminated or improperly purged photometer, but for the upstream photometer. The message may also appear if a test is started and ended improperly. In this case, the problem is temporary and is resolved with the next test. Examine the photometer voltage using the VOLTAGES display option. If the upstream photometer voltage remains high, with the filter holder open, contact TSI. Refer to Table 10-1 below for additional causes for this message to appear.

“ZERO ERROR ON RESISTANCE TRANSDUCER” The resistance transducer voltage has drifted out of range. This will require that you re-zero the resistance pressure transducer. This process is described in the “Special Maintenance” section of Chapter 9. Normally a 10 percent difference from the nominal transducer voltage at 1.000 causes this error to occur. The 10 percent difference is expressed as a value of 1.100 volts in the WATCH POINTS display screen. If the transducer needs to be re-zeroed frequently, it may be necessary to replace the transducer.

“ZERO ERROR ON FLOW TRANSDUCER” The flow transducer voltage has drifted out of range. This will require that you re-zero the flow pressure transducer. This process is described in the “Special Maintenance” section of Chapter 9. Normally a 10 percent difference from the nominal transducer voltage of 1.000 causes this error to occur. The 10 percent difference is expressed as a value of 1.100 volts in the WATCH POINTS display screen.

Troubleshooting and Obtaining Service 10-3

If the transducer needs to be re-zeroed frequently, it may be necessary to replace the transducer.

“LOW AEROSOL CONCENTRATION” Indicates that the aerosol generator is low on fluid or turned off. Refill or turn on your aerosol generator. Refer to Table 10-1 for additional causes for this message to occur or see the troubleshooting guide in the Salt Aerosol Generator manual in Appendix H.

“FLOW FOR PASS-FAIL OUT OF RANGE” Indicates that the actual filter flow, when using the pass-fail test option, is different by at least 5 percent than the value specified in the TEST PARAMETERS display screen. You can change your actual flow, or the FLOW parameter in TEST PARAMETERS. If you set the FLOW parameter to zero (0), no error message will be displayed.

“INVALID” This message is output to the printer and serial port during LOADING TEST, and optionally after a FILTER TEST. INVALID tests result if the variability in the sampled data is too high. High variability can result when accumulated salt particles break off the sample lines and filter holder and contaminate the downstream sample flow. The large break-off particles cause voltage spikes during the penetration measurement. A voltage spike, averaged into a low downstream signal can significantly increase the measured penetration. INVALID tests occur most often when a salt aerosol is used. An INVALID test can also indicate a problem with the filter tester. Frequent or continuous INVALID tests may indicate the need to clean the sample tubing, tees and filter holder tubing. INVALID tests will result if the sample tubing is kinked. Kinking often occurs after servicing the tester, especially if the top of the tester has been opened and closed. Frequent INVALID test messages may also indicate that the photometer filters are loaded and require changing. If your salt aerosol concentration is low, you will experience a greater number of INVALID test error messages. Use the VOLTAGES mode to check your upstream photometer signal (see [*] VOLTAGES, in Chapter 6). Your upstream photometer signal should not be more than 20 percent below the value on the data


sheet. If it is, refer to the troubleshooting table in Chapter 10, “LOW AEROSOL CONCENTRATION.” If salt is used, also make sure you have an adequate solution concentration and make sure your make-up airflow is not higher than the recommended 70 liters/minute.

A special statistical diagnostic routine is used to determine if a test is invalid. Information on the diagnostics routine is presented below.

UNASSIGNED MESSAGE # or USER MEMORY FULL Memory overflow is indicated by an UNASSIGNED MESSAGE # or USER MEMORY FULL error. Following this procedure will clear the memory. To clear the memory, the software package Pepclr.exe must be downloaded from TSI’s website (http://software.tsi.com) and installed onto a personal computer.

1. Turn off the power on the 8127/8130.

2. Remove the 11 screws that hold the display in its mount. Do not remove the mounting arm that connects to the main center column. Loosen the nut on the strain relief so that the cable to the display is free. Carefully lay the display on the top of the instrument. Remove the 25-pin connector from the back of the display. Do not remove the 6-pin power connector. Connect a standard RS-232 cable to a null modem and to the 25-pin connector on the back of the display. Connect the other end of the cable to a COM port on your PC. Tip up the display and prop it in this position to prevent it from running face down.

3. Turn on the power for the 8127/8130.

4. After initialization completes (about 1 minute), run the program “pepclr.exe”. The program will end when it is finished clearing the memory. Disconnect the RS-232 cable and reassemble the display.

5. It may be necessary to cycle the power for the 8127/8130 once more to restore proper operation.

Statistical Diagnostics

The Model 8127/30 version 1.24 contains special routines which are used in the loading test mode (when the LOADING TEST option is selected), to help prevent bad data from voiding the loading test. If the filter test sample time is set for 20 seconds or more, the statistical routines are applied to individual filter tests (when the

http://software.tsi.com/


FILTER TEST option is selected). The LOADING TEST uses a fixed sample time of 30 seconds.

The statistical diagnostic routines determine if the measured penetration data is within the stated accuracy of the filter tester. The filter test accuracy used for the statistical routines is defined for the salt aerosol since the salt aerosol produces a lower signal than oil and represents a worst case.

Accuracy = ± 0.10 × penetration + LOWER LIMIT LOWER LIMIT = 0.00004

Penetrationdownstream background

upstream background=

−−

% Penetration = penetration × 100

Software version 1.24 computes the standard error of the mean for the downstream concentration and uses that value to determine the uncertainty in the penetration measurement. The penetration uncertainty must be less than the specified accuracy of the tester, for penetrations above the LOWER LIMIT, or the test is invalidated. In the loading test mode an invalid test produces an “INVALID % PEN” message on the printout. The serial data from the loading mode includes the calculated penetration data, but the data string is followed by an “INVALID” message. In addition to determining the uncertainty in the penetration measurement, the software checks to see if the downstream concentration value is greater than the uncertainty in the downstream measurement. If it is not, the penetration data is displayed with a question mark “?” indicating that this is the measured penetration but the signal level is indistinguishable from the noise level. This permits penetration values below the LOWER LIMIT to be indicated even if the variability exceeds the invalidation criteria.

The flowchart on the next page outlines the testing logic used to determine the validity of the penetration data.


Loading Test inProgress

orFilter Test Complete

Sample Time > 19 Seconds

Calculate Penetration

Downstream Conc.Upstream Conc.

Penetration =

Computer the Uncertainty in theDownstream Measurement (U)

Compute the Penetration UncertaintyUsing the Calculated Uncertainty in

the Downstream Measurement

Accuracy = ±0.10 × Penetration + LOWER LIMITLOWER LIMIT = 0.00004

Penetu = UUpstream

Is Penetu >Accuracy of the

Tester?

Is thePenetration >

the LOWER LIMIT

Is the MeanDownstream

Concentration <the Uncertainity

U?

Complete Test

Data Displayed andPrinted

Test Invalid

No Data Printed

Complete Test

"?" Displayedwith Printout

No

No

No

Yes

Yes

Yes

U = 2 × VarianceNo Data Points


T r o u b l e s h o o t i n g t h e T e s t e r This section gives possible problems that may be encountered with the CERTITEST

® Model 8127/8130 Automated Filter Tester and possible solutions. If you encounter a problem that you are unable to resolve after reading this section, contact TSI at the number listed in the “Service” section of this chapter. Note: For a troubleshooting guide for the Model 8118A Salt Aerosol

Generator, refer to the salt generator manual in Appendix H.

Table 10-1 Troubleshooting the Tester

Problem Possible Cause(s) Corrective Action Manual Reference

Tester will not power up.

Power cable not plugged in.

Plug power cable into an appropriate power outlet.

See “Connecting Electrical Power” in Chapter 4.

Fuse blown. Check system fuse(s). See “Replacing Fuses” in Chapter 9.

Tester on but no response.

Emergency button pressed in.

Pull emergency button out. See “Using OPEN, CLOSE, and Emergency Off/On Buttons” in Chapter 5.

Tester hung up. Press OPEN button, then ESC on the touch-panel display.

Tester hung up. Reboot the system (turn it off and on again).

Cannot get full filter flow.

Flow line filter plugged.

Replace flow line filter. See “Replacing the Flow Line Filter” in Chapter 9.

Dirty vacuum pump motor filters.

Clean vacuum pump motor filters.

See “Cleaning the Vacuum Pump Filters” in Chapter 9.

Flowmeter tubing kinked, blocked, or disconnected (including pressure lines).

Check flowmeter tubing and connections for kinks or blockage.

See “Cleaning the Flowmeter” in Chapter 9.

Flowmeter incorrectly installed.

Check orientation of the flowmeter.


Aerosol generator pressure unstable.

Main air supply pressure low.

Set supply pressure to at least 70 psi. If it does not remain at this pressure, you may have an air supply problem.

See “Step 4. Set the Main Regulator Pressure” in Chapter 5.

Generator pressure low.

Adjust generator pressure in FLOW ADJUSTMENT mode with filter holder closed.

See “Step 6. Set the Aerosol Generator Pressure” in Chapter 5.

Leaks in supply pressure lines, especially the generator supply line.

Check air lines and fittings for leaks and repair or replace faulty lines if any are found.

(continued)


Table 10-1 Troubleshooting the Tester (continued)


Low aerosol concentration.

Aerosol generator not turned on.

Turn aerosol generator on. Also turn on motor controller and motor (salt generator only).

See “[*]AEROSOL (Turn Aerosol Generator On/Off)” in Chapter 6.

Low aerosol generator liquid level.

Refill aerosol generator. See “Filling and Installing the Aerosol Generator” in Chapter 4.

Inadequate aerosol generator pressure.

Adjust aerosol generator pressure.

See “Step 6. Set the Aerosol Generator Pressure” in Chapter 5.

Aerosol generator atomizer jets plugged.

Clean atomizer jets. See “Cleaning the Oil Atomizer Jets” in Chapter 9.

Low upstream photometer sample rate.

Check upstream photometer sample tube for kinks. Also check for plugged photometer filters.

See “Replacing the Photometer Filters” in Chapter 9.

High photometer zero.

Inadequate system air pressure.

Check to see that system air pressure is 70 psi or greater.

See “Step 4. Set the Main Regulator Pressure” in Chapter 5.

Previous test aborted because CLOSE buttons not held in long enough.

Restart test sequence. See “Using OPEN, CLOSE, and Emergency Off/On Buttons” in Chapter 5.

Downstream photometer zero does not settle to a value lower than the WATCH POINT.

Check the photometer zero readings in the VOLTAGES option. If the photometer zero is above the WATCH POINT, contact TSI.

See “[*]VOLTAGES (Read Photometer and Pressure Transducer Voltages)” in Chapter 6.

%MATCH set too high, giving READY before photometer is purged.

Check %MATCH setting under WATCH POINTS.

See “[*]WATCH POINTS” in Chapter 6 and “Setting Test Time” in Chapter 8.

Erratic photometer readings.

Plugged atomizer jets on the aerosol generator.

Clean the atomizer jets. See “Cleaning the Oil Atomizer Jets” in Chapter 9.

Kinked sample lines. Check sample lines for kinking (may occur after cabinet top has been raised and lowered).

Plugged photometer filters.

Replace photometer filters. See “Replacing the Photometer Filters” in Chapter 9.

(continued)




Flow or resistance not correct.

Flowmeter dirty. Clean flowmeter. See “Cleaning the Flowmeter” in Chapter 9.

Pressure tube(s) disconnected.

Check and reconnect tubes on filter holders.

Flowmeter calibration data points accidentally changed.

Check and reset calibration data points.

See “CALIBRATIONS (Calibrate Flowmeter and Pressure Transducers)” in Chapter 6.

Flowmeter connection tube(s) disconnected.

Check and reconnect tubes on the flowmeter.


Flowmeter orifice not seated correctly.

Check flowmeter orifice. See “Cleaning the Flowmeter” in Chapter 9.

Pressure transducer zero error.

Transducer zeros are high.

Check transducer zeros in VOLTAGES option. If high, zero the transducers.

See “[*]VOLTAGES (Read Photometer and Pressure Transducer Voltages)” in Chapter 6 and “Zeroing the Pressure Transducers” in Chapter 9.

Parameter and/or calibration data scrambled.

Electrical noise. Turn tester off for 5 seconds, then turn back on.

Incorrect values set. Change the corrupted values by entering new values from the screen.

Refer to specific sections in Chapter 6.

Electronics problem. Call TSI.

Aerosol leaking. Normal release of aerosol following a test.

Add or lengthen purge time. See “[*]PURGE (Set Purge Time)” in Chapter 6 and “Setting Test Time” in Chapter 8.

Tester not properly exhausted.

Check the aerosol exhaust line for kinks or plugging. There should be little or no resistance on the exhaust line.

See “Connecting the Aerosol Exhaust” in Chapter 4.

Liquid seen in make-up air flowmeter.

Ruptured air line filter allowing oily compressor air to enter system.

Replace the air line filter. Call TSI.

See “Replacing the Air Line Filter” in Chapter 9.

(continued)




Slow filter holder. Filter holder pressure set incorrectly.

Increase the filter holder pressure.

See "Step 5. Set the Filter Holder Regulator Pressure" in Chapter 5.

Relief valve not properly adjusted.

Turn the relief valve screw on the filter holder control solenoid counterclockwise. Call TSI.

Heater is not on (salt only).

Heater not turned on.

Turn heater on. See “[*]AEROSOL” in Chapter 6 for information on the HEAT option.

Inadequate make-up air flow.

Increase make-up air flow to at least 40 L/min.

See “Step 7. Set the Make-up Air Flowrate” in Chapter 5.

Defective heater. Call TSI.

Neutralizer will not turn on.

Neutralizer not turned on.

Check the On/Off switch on the neutralizer.

See “Step 8. Check that the Aerosol Neutralizer Is On” in Chapter 5.

Inadequate make-up air flow.

Increase make-up air flow to at least 40 L/min.

See “Step 7. Set the Make-up Air Flowrate” in Chapter 5.

Defective neutralizer. Call TSI.

Neutralizer not working properly.

Out of balance. Adjust balance. See “Setting Ion Balance” in Chapter 9.

Worn needles. Replace needles. See “Cleaning or Replacing the Ionizing Needles” in Chapter 9.

Printer not working properly.

Printer batteries not charged.

Plug printer AC adapter into appropriate power outlet and connect to printer. Set printer switch to CHARGE/AC.

See “Connecting the Thermal Printer” in Chapter 4 or the Thermal Printer manual in Appendix G.

Printer data cable not connected.

Connect cable. See “Connecting the Thermal Printer” in Chapter 4 or the Thermal Printer manual in Appendix G.

Printer out of sync. Reset printer by turning off and then on.

See “Step 10. Turn the Thermal Printer and/or the RS-232 Serial Port On (Optional)” in Chapter 5.

Incorrect DIP switch settings.

Check DIP switch settings and reset if necessary.

See the Thermal Printer Instruction Manual in Appendix G.


S e r v i c e This section gives directions for contacting TSI Incorporated personnel for technical information and directions for returning the Model 8127/8130 Automated Filter Tester or their components for service or repair.

Technical Contacts If you have any difficulty installing the tester, or you have

technical or application questions about the Automated Filter Tester, contact a service engineer at TSI Incorporated, telephone 1-800-874-2811 (USA) or 651-490-2811.

If the Automated Filter Tester fails, or you are returning it or any of its components for service or repair, contact TSI Customer Service, telephone 1-800-874-2811 (USA) or 651-490-2811. E-mail support is available at [email protected] or our website at service.tsi.com.

Returning for Service TSI discourages returning the tester or any of its components to TSI for service under normal circumstances since problems can normally be resolved at the customer site. If you find it necessary to return the tester or any of its component parts for service, you must first contact TSI Customer Service at 1-800-874-2811 (USA) or 651-490-2811 for specific return instructions. Customer Service will require the following information when you call:

The instrument model number

The instrument serial number

A purchase order number (unless under warranty)

A billing address

A shipping address

Name and phone number of the contact person Customer service will also provide packing instructions for shipment back to TSI.



A-1

A P P E N D I X A Speci f icat ions

The following specifications list the most important data for the primary system components.

Table A-1 Specifications for the CERTITEST Models 8127 and 8130 Automated Filter Testers

Oil Aerosol Generator Salt Aerosol Generator

Challenge aerosol generation

Aerosols ............................................ Emery 3004, DOP, Sodium Chloride DEHS, paraffin

Mass mean diameter ......................... 0.33 µm* 0.26 µm*

Count median diameter ..................... 0.20 µm* 0.07 µm*

Geometric standard deviation ............ <1.6* <1.83*

Concentration.................................... 50 to 200 mg/m3 15 to 20 mg/m3 (70 L/min dilution)

Challenge aerosol detection

Technique ......................................... Dual, solid-state photometers

Dynamic range .................................. 1.0 μg/m3 to > 200mg/m3

Flow measurement

Technique ......................................... Orifice with electronic pressure transducer

Range................................................ 15 to 100 L/min

Accuracy ........................................... 2% of full scale

Pressure measurement

Technique ......................................... Electronic pressure transducer

Range................................................ 0 to 15 cm H2O

Accuracy ........................................... 2% of full scale

Efficiency measurement

Flowrate through media..................... 15 to 100 L/min

Operating range Penetrations to 0.001%, efficiencies up to 99.999%

Automation and data management . Dedicated, internal microprocessor

Outputs ............................................ 240-character display, thermal printer, and RS-232 serial communications port

*Aerosol particle size and geometric standard deviation determined using TSI Model 3934 Scanning Mobility Particle Sizer.

(continued)

A-2 CERTITEST® Model 8127/8130 Automated Filter Tester

Table A-1 Specifications for the CERTITEST Models 8127 and 8130 Automated Filter Testers (continued)

Operating requirements

Power................................................ 100 to 120 VAC, 60 Hz, 5 A or 230 to 240 VAC, 50 Hz, 2.5 A

Compressed air ................................. 80 psig, 7 scfm (550 kPa, 198 std L/min)

Aerosol exhaust venting ................... 7 scfm (198 std L/min)

Environmental conditions ................ The Tester must be operated in a temperature-controlled, filtered air environment. 10° to 50°C (50° to 95°F) temperature. Non-condensing humidity. Overvoltage category II Pollution degree II

Dimensions (LWH) .......................... 69 cm × 71 cm × 147 cm (27 in. × 28 in. × 58 in.)

Weight ............................................ 95 kg (210 lb)

Noise Level

Operator exposure, under normal conditions ........................................

<75dB

Specifications are subject to change without notice.

B-1

A P P E N D I X B Theory of Operat ion

This Appendix provides a more detailed discussion of the theory of operation underlying the CERTITEST

® Models 8127 and 8130 Automated Filter Testers than is found earlier in Chapter 1 of this manual.

Figure B-1 Schematic Drawing of CERTITEST Automated Filter Testers

B-2 CERTITEST® Model 8127/8130 Automated Filter Tester

The CERTITEST Automated Filter Testers use two laser-based light scattering photometers to measure the concentration of fine aerosol particles upstream and downstream of the filter or filter media under test (Figure B-1). Particles are produced by an oil or salt aerosol generator incorporated in the Filter Tester. Laser light, focused on the particle stream, is scattered by the aerosol particles. The scattered light is collected by a photodetector, producing a signal level proportional to particle concentration. Filter penetration (efficiency) is determined from the ratio of particle concentrations measured before and after the filter.

A e r o s o l G e n e r a t i o n The Models 8127 and 8130 Filter Testers incorporate unique oil and salt aerosol generators developed by TSI specifically for filter testing applications. The TSI generators use atomizer jets to disperse a liquid oil or salt solution into small droplets. These droplets form an aerosol which is then passed through a special felt coalescing filter for oil or an impactor for salt. The process produces an aerosol with a size distribution which closely matches that of an ideal test aerosol—that is, one which has a mean centered in the “most penetrating size” range (MPPS) of a typical filter, the size where testing is usually performed. In the Model 8127, the aerosol has a mass mean particle size of approximately 0.3 micrometers. The oil generator produces a narrow size distribution without using heat to condition the aerosol. No heat means a variety of oils can be used. This helps alleviate concerns over potential health risks associated with use of dioctyl phthalate (DOP). Recommended alternatives are Emery 3004 oil and paraffin oil.

A e r o s o l M i x i n g a n d T r a n s p o r t A main component in the Models 8127 and 8130 Automated Filter Testers is the aerosol transport system. Aerosol particles produced by the aerosol generators are drawn into and through a mixing manifold, through the upstream filter holder and photometer, through the filter under test, and through the downstream filter holder and photometer using a vacuum pump. In the mixing manifold, aerosol is mixed with clean make-up air supplied at a constant rate. The upstream aerosol concentration is thereby maintained constant and independent of the filter flowrate.

Theory of Operation B-3

The Filter Testers are configured so that aerosol flows from top to bottom through the filter.

P a r t i c l e D e t e c t o r s ( P h o t o m e t e r s ) The Automated Filter Testers employ light scattering photometer technology for aerosol detection. Photometers, unlike single particle counting instruments, rely on light scattering from multiple particles to obtain a relative concentration measurement. If the aerosol composition is controlled, as in a TSI Filter Tester, photometer signal output is linear with particle concentration. The Models 8127 and 8130 use two stable, solid-state, laser-based photometers calibrated against one another. One is dedicated to measuring the particle concentration upstream of the filter being tested, the other to measuring the downstream concentration. A representative particle sample is drawn from the particle stream, combined with a filtered sheath air stream, and directed through the photometer (Figure B-2). The sheath air serves to define the particle stream, improving photometer performance, and keep the internal optics clean.

Figure B-2 Schematic of Photometer Used for Measuring Downstream Particle Concentrations

B-4 CERTITEST® Model 8127/8130 Automated Filter Tester

The upstream photometer is a simple device offering relatively low resolution, since it only needs to measure the high upstream particle concentration. The downstream photometer, on the other hand, uses a high power laser diode and offers much higher resolution in order to measure the very low downstream concentrations necessary when making penetration measurements down to 0.001 percent. Concentration is determined from the photometer output signal voltage. The signal voltage is proportional to the mass of aerosol sampled by the photometer. When calculations are performed by the tester firmware, the background voltage is subtracted from the total signal voltage. The background voltage is the voltage produced by the photometer when no aerosol is present.

M i c r o p r o c e s s o r C o n t r o l The CERTITEST Filter Testers are controlled by a dedicated microprocessor and user-friendly software resident in a 64k EPROM. The microprocessor provides automatic control of all tester operations, based on parameters specified by the operator and inputs from the photometers, pressure transducer, touch-display panel, and filter holder close buttons. The microprocessor calculates information on filter penetration and resistance over a wide range of filter flow conditions. It also performs operational self-checks during testing to ensure test accuracy. System status information and operator instructions are presented on an easy-to-read touch-panel display. The microprocessor and built-in software greatly simplify system operation, reducing the training required to run the system effectively. Simple software menus allow the operator to change test parameters to accommodate special testing or research requirements. An RS-232 serial interface provides a means for outputting test data to an external computer or data logging device. A special, built-in interface also provides the capability for external tester control. This feature facilitates filter testing using automated (robotic) filter insertion and removal.

Theory of Operation B-5

O p e r a t i n g t h e M o d e l s 8 1 2 7 a n d 8 1 3 0 F i l t e r T e s t e r s

Whenever you turn the tester on from a cold condition—at the beginning of the day, for example—allow it to warm up for 15 to 30 minutes, depending on the aerosol generator in use, to ensure all components have reached operating temperature and operation has stabilized. If the tester is turned off and back on during the day, allow an appropriate warm-up time. If it is off for less than five minutes, no warm-up is required before restarting filter testing. If it is off for longer than five minutes, allow an equivalent warm-up time, up to a maximum of 30 minutes. Once the warm-up cycle is complete, initiate the TESTER SET UP function. TESTER SET UP takes about 35 seconds, during which time the microprocessor checks the transducer zero, the photometer zero, and the aerosol concentration level, and establishes the photometer correlation factor. The correlation factor is used to relate upstream photometer measurements with those made using the downstream photometer. To perform a filter test, place a filter in the lower filter holder attached to a frame mounted on the top surface of the Filter Tester cabinet. Initiate the test by simultaneously pressing the two CLOSE buttons on the front of the cabinet. A pneumatic cylinder quickly lowers the upper filter holder into position and the test is begun automatically. For safety, the CLOSE buttons must be held in for approximately one second to allow time for the upper filter holder to close properly. The entire test proceeds under microprocessor control with no need for operator involvement. During the test, aerosol is drawn by the vacuum pump from the aerosol generator to the mixing manifold, then to the top filter holder, and finally through the filter. The aerosol is sampled upstream and downstream of the filter using the two photometers, one dedicated to upstream measurement and one to downstream. When the test is completed, the filter holder opens automatically and the test data is displayed on the touch-panel display and output to the printer or the RS-232 serial port. If a pass level has been selected, the tester will display a PASS or FAIL message in large characters in addition to the test data. Replace the tested filter with a new one and the tester is ready to begin another test cycle.

C-1

A P P E N D I X C Ver i f ica t ion of Aerosol Par t ic le S ize

The CERTITEST® Automated Filter Testers incorporate a means for

validating key system parameters. The validation procedure is designed to test many aspects of the Filter Tester, one of which is verifying the particle size, by performing filter penetration measurements on filters with a known aerosol penetration level and comparing the results. This technique is useful for testing the following:

Challenge aerosol size distribution

Filter test flow measurement

Filter pressure drop measurement

Proper photometer operation

General system operation The validation technique uses filter media sheets with a known penetration range. The filter media are the glass fiber type, in 6-inch disks. Supplied by TSI, the disks are accompanied by data sheets that list the expected penetration range for the specific media. This appendix discusses the theory underlying the use of penetration data to verify system performance. For more about conducting a verification test, refer to “Verifying Penetration Data” in Chapter 7. The aerosol penetration through a filter is a function of three test parameters: aerosol size, aerosol size distribution, and filter flowrate. Figure C-1 illustrates the relationship of particle size, filter flowrate, and penetration for a typical filter. Aerosol penetration reaches a maximum at the most penetrating particle size (approximately 0.1 μm diameter for the filter represented in Figure C-1) and then decreases for larger particles. Figure C-1 also shows the penetration increasing with increasing filter flowrates. The effect that aerosol size distribution has on aerosol penetration is shown in Figure C-2. It shows aerosol penetration decreasing with increasing width in the size distribution. The width of the size

C-2 CERTITEST® Model 8127/8130 Automated Filter Tester

distribution is generally measured and referred to as the geometric standard deviation (GSD). A polydisperse aerosol is one with a GSD greater than 1.2.

Figure C-1 Filter Penetration Versus Particle Size Figures C-1 and C-2 show the importance of a stable challenge aerosol for repeatable filter penetration measurements. If any of the three parameters (aerosol size, aerosol width, or flowrate) were to change, then the penetration measurement could be in error. By measuring the aerosol penetration through filter media with known penetration characteristics, a method for verifying a consistent challenge aerosol is available.

Verification of Aerosol Particle Size C-3

Figure C-2 Filter Penetration Versus Geometric Standard Deviation In addition to verifying a consistent challenge aerosol, the filter media penetration method also ensures the entire tester is operating properly. This technique indirectly tests the photometer output and also verifies that the pressure drop measured across the filter is within specification. Since the photometer is the device used to measure penetration, a malfunctioning photometer would be instantly recognized. Likewise, if the photometer is not purging correctly between tests, the results would indicate a problem. Filter pressure drop is also tested. If the pressure drop was measured incorrectly, the verification test would clearly indicate this parameter is out of specification. In conclusion, the filter media test method of system performance verification is a precise and easy-to-implement means of ensuring proper Filter Tester operation. The technique verifies not only the correct challenge aerosol but also tests the entire system as a whole.

D-1

A P P E N D I X D Aerosol Generator Data and Operat ing Parameters

S a l t A e r o s o l G e n e r a t o r A detailed description and specifications for the Model 8118A Salt Aerosol Generator used in the CERTITEST

® Model 8130 Automate Filter Tester are found in the manual in Appendix H.

O i l A e r o s o l G e n e r a t o r The oil aerosol generator used in the Models 8127 and 8130 Automated Filter Testers is designed to produce a stable oil aerosol for filter testing applications. It produces filter penetration data equivalent to that obtained using the “hot DOP” (Q-127) aerosol generation method.* It is also easy to operate since the oil is unheated. For this reason, the generator produces an output that is inherently stable in aerosol concentration and particle size. The oil generator has been tested for use with three oils: Emery 3004 synthetic hydrocarbon, DOP (dioctyl phthalate), and paraffin or mineral oil. DOP is commonly used for filter testing in the United States and paraffin oil in Europe. Emery 3004, produced by the Henkel Corporation, has been recommended by the U.S. Army as a replacement for DOP in respirator cartridge testing. We also recommend this oil, or paraffin oil, for use with the Models 8127 and 8130 Filter Testers.

!

C a u t i o n

When using oil aerosols, make sure the Filter Tester is properly exhausted.

Refer to “Connecting the Aerosol Exhaust” in Chapter 4.

*Refer to TSI Application Bulletin ITI-012.

D-2 CERTITEST® Model 8127/8130 Automated Filter Tester

Table D-1 Operating Parameters

Using Emery Using DOP or 3004 Oil Paraffin Oil

Supply pressure................................ 40 psi 35 psi

Make-up air flow ............................... 40-60 L/min (nom) 40-60 L/min (nom)

Jets used .......................................... 2 or 3 of 4 4 of 4

Liquid capacity.................................. 1 liter 1 liter

Liquid consumption .......................... 50 ml/hr 50 ml/hr

Aerosol concentration........................ 100 mg/m3 (nom) 100 mg/m3 (nom)

Min. wait with new felt ...................... 20 min 20 min

Aerosol Characteristics

Count median diameter..................... 0.2 (μm)

Mass mean diameter ......................... 0.3 (μm)

Geometric standard deviation............ <1.6

Stability

Over 10-minute interval .................... < ±2%

Over 8-hour interval.......................... < ±10%

Variation in particle size with generator supply pressure (for DOP):

Pressure (psi) Number mean (µm)

25 .207 30 .199 33 .194 35 .193 40 .188

E-1

A P P E N D I X E Maintenance Ki ts

TSI offers maintenance kits for the Models 8127 and 8130 Automated Filter Testers. These kits contain additional parts and supplies beyond the limited spare parts supplied with the Filter Tester. We recommend you purchase a Maintenance Kit to help ensure your Filter Tester always remains functional. This appendix lists the parts included in the two Maintenance Kits.

M o d e l 8 1 2 7 F i l t e r T e s t e r M a i n t e n a n c e K i t ( P / N 1 0 3 5 4 9 7 )

Table E-1 lists the parts of the Model 8127 Filter Tester Maintenance Kit.

Table E-1 Model 8127 Filter Tester Maintenance Kit

Qty. Description Use Part No.

1 Vacuum grease On O-rings 1502249

20 Fitting, nylon, back ferrule, ¼” OD Various places 1601550

20 Fitting, nylon, front ferrule, ¼” OD Various places 1601551

20 Fitting, nylon, back ferrule, 3⁄8" OD Various places 1601552

20 Fitting, nylon, front ferrule, 3⁄8" OD Various places 1601553

20 Fitting, nylon, front ferrule, ½” OD Various places 1601707

20 Fitting, nylon, back ferrule, ½” OD Various places 1601708

2 Fitting, nylon plug, ¼” tubing Oil generator 1601834

2 MSA cartridge filter Air supply 1602011

6 HEPA capsule filter Photometer/ flowline

1602051

5 Oil aerosol generator felts Oil generator 1602075

1 box 102 mm gravimetric filters (100/box) Gravimetric tests 1602076

5 Oil generator draw tubes filters Oil generator 1602086

2 box Test filter media (50/box) Media tests 813010

2 Purge mode filter Purge line 1602094

1 Aerosol generator gasket Generators 1704026

4 Filter holder gaskets Filter holders 1704036

2 Generator bottle, 32 oz. Generators 2002022

(continued)

E-2 CERTITEST® Model 8127/8130 Automated Filter Tester

Table E-1 Model 8127 Filter Tester Maintenance Kit (continued)


5 Aerosol jet assembly Generators 2401041

1 O-ring, Buna 1-044 Dur 70 Filter media holder 2501044

5 O-ring, Viton 1-008 Generator jets 2501514

1 O-ring, Viton 1-016 Dur 70 Flowmeter 2501627

6 O-ring, Buna 1-216 Dur 50 Spool valve 2501632


4 O-ring, Viton 1-112 Dur 70 Spool valve 2501645

20 rolls Paper for thermal paper Printer 2608011

10 ft Tygon tubing, 1"OD 3⁄4"ID Mixing manifold 3001185

10 ft Tygon tubing, ¼” OD 1⁄8” ID Various places 3001220

1 ft Nylon 101 tubing, .148” "OD .118 ID Generators 3001247

20 ft Tygon tubing, 5⁄16” OD 3⁄16” ID Various places 3001248

6 ft Tygon tubing, 7⁄16” OD ¼” ID Various places 3001252

20 ft Flex Nyl-Seal tubing, ¼” OD Various places 3001254

1 ft Silichem tubing, ¼” OD 1⁄8” ID Oil generator 3001257

5 ft Polyethylene tubing, 1⁄8” OD 1⁄16” "ID Various places 3001787

1 Tape, Teflon, ½” wide Fitting replacement 3006003

1 Relief valve, 6 psi Generators 3201066

2 3-way solenoid valve Various places 3201097

10 ft Nylon Flex Tubing, 3⁄8” OD Various places 3829089

40 ft Vinyl tubing ¾” OD ½” ID Various places 3929420

10 ft Polyethylene tubing, ½” 0D Vacuum pump 3929439

Maintenance Kits E-3

M o d e l 8 1 3 0 F i l t e r T e s t e r M a i n t e n a n c e K i t ( P / N 1 0 8 1 8 4 0 )

Table E-2 lists the parts of the Model 8130 Filter Tester Maintenance Kit.

Table E-2 Model 8130 Filter Tester Maintenance Kit


1 Vacuum grease On O-rings 1502249

20 Fitting, nylon, back ferrule, ¼” OD Various places 1601550

20 Fitting, nylon, front ferrule, ¼” OD Various places 1601551

20 Fitting, nylon, back ferrule, 3⁄8" OD Various places 1601552

20 Fitting, nylon, front ferrule, 3⁄8" OD Various places 1601553

20 Fitting, nylon, front ferrule, ½” OD Various places 1601707

20 Fitting, nylon, back ferrule, ½” OD Various places 1601708

2 Fitting, nylon plug, ¼” tubing Oil generator 1601834

2 MSA cartridge filter Air supply 1602011

6 HEPA capsule filter Photometer/ flowline

1602051

5 Oil aerosol generator felts Oil generator 1602075

1 box 102 mm gravimetric filters (100/box) Gravimetric tests 1602076

5 Oil generator draw tubes filters Oil generator 1602086

2 box Test filter media (50/box) Media tests 813010

2 Purge mode filter Purge line 1602094

1 Aerosol generator gasket Generators 1704026

4 Filter holder gaskets Filter holders 1704036

2 Generator bottle, 32 oz. Generators 2002022

10 Aerosol jet assembly Generators 2401041

1 set Ionizer needles Ionizer head 2402554

1 O-ring, Buna 1-044 Dur 70 Filter media holder 2501044

10 O-ring, Viton 1-008 Generator jets 2501514


6 O-ring, Buna 1-216 Dur 50 Spool valve 2501632


4 O-ring, Viton 1-112 Dur 70 Spool valve 2501645

20 rolls Paper for thermal paper Printer 2608011

10 ft Tygon tubing, 1"OD 3⁄4"ID Mixing manifold 3001185

10 ft Tygon tubing, ¼” OD 1⁄8” ID Various places 3001220

1 ft Nylon tubing 101, .148” "OD .118 ID Generators 3001247

20 ft Tygon tubing, 5⁄16” OD 3⁄16” ID Various places 3001248

6 ft Tygon tubing, 7⁄16” OD ¼” ID Various places 3001252

(continued)

E-4 CERTITEST® Model 8127/8130 Automated Filter Tester

Table E-2 Model 8130 Filter Tester Maintenance Kit (continued)


20 ft Flex Nyl-Seal tubing, ¼” OD Various places 3001254

1 ft Silichem tubing, ¼” OD 1⁄8” ID Oil generator 3001257

5 ft Polyethylene tubing, 1⁄8” OD 1⁄16” "ID Various places 3001787

1 Tape, Teflon, ½” wide Fitting replacement 3006003

1 Relief valve, 6 psi Generators 3201066

2 3-way solenoid valve Various places 3201097

10 ft Nylon Flex Tubing, 3⁄8” OD Various places 3829089

40 ft Vinyl tubing ¾” OD ½” ID Various places 3929420

10 ft Polyethylene tubing, ½” 0D Vacuum pump 3929439

F-1

A P P E N D I X F F i l te r Tester Schemat ics

This appendix contains the following drawings and schematics:

Model 8130 Front View

Model 8130 Back View

Model 8130 Top View

1080566, Assembly Drawing, Gravimetric Filter Holder, Rev. B, Sheet 1 of 1

1080568, Aerosol Delivery/Orifice Assembly, Rev. D, Sheet 1 of 1

1081419, Assembly Drawing, Transducer Bracket (top) 8127/30, Rev. C, Sheet 1 of 1

2306671, Part Drawing, Lower Filter Holder Base, Rev. C, Sheet 1 of 1

2306672, Part Drawing, Upper Filter Media Holder, Rev. A, Sheet 1 of 1

2306673, Part Drawing, Lower Filter Media Holder, Rev. A, Sheet 1 of 1

9060681, Model 8127/30 Flow Schematic, Sheet 1 of 1

9081831, Assy. Dwg., Filter Holder Control Panel, Rev. A, Sheet 1 of 1

9081832, Assembly Drawing, Connector Panel, Rev. B, Sheet 1 of 1

9081834, Assembly Drawing, Switch/Flow Control Panel, Rev. C, Sheet 1 of 1

9081835, Assembly Drawing, Aero Regulator, Rev. A, Sheet 1 of 1

9081836, Assembly Drawing, Filter Holder, Rev. A, Sheet 1 of 1

9081837, Assembly Drawing, Photometer Pullout, Rev. D, Sheet 1 of 3

9081837, Rev. D, Sheet 2 of 3

9081837, Rev. D, Sheet 3 of 3

9081838, Assy. Dwg., Switch, Valve/Flowmeter 8130, Rev. B, Sheet 1 of 2

9081838, Rev. B, Sheet 2 of 2

F-2 CERTITEST® Model 8127/8130 Automated Filter Tester

9081839, Assy. Dwg., Air Supply/Manifold, Rev. B, Sheet 1 of 1

9081841, Assembly Drawing, Oil Aerosol Generator, Rev. C, Sheet 1 of 1

9081843, Assembly Drawing, Display, Rev. C, Sheet 1 of 1

9082255, Assembly Drawing, Heater Model 8130, Rev. A, Sheet 1 of 2

9082255, Rev. A, Sheet 2 of 2

9060649,* Wiring Diagram, Model 8127/8130 FTS, 120 VAC Unit, Rev. D, Sheet 1 of 1

9060651,* Wiring Diagram, Model 8127/8130 FTS, 220 VAC Unit, Rev. E, Sheet 1 of 1

9060652,* Wiring Diagram, Model 8127/8130 FTS, 100 VAC Unit, Rev. C, Sheet 1 of 1

9060653,* Wiring Diagram, Model 8127/8130 FTS, 230/240 VAC Unit, Rev. C, Sheet 1 of 1

9081181, Assy. Drawing, Model 8127/8130 FTS, CPU PC Board, Rev. F, Sheet 1 of 1

*Wiring diagram to match your system is included.

F-3

M o d e l 8 1 3 0 F r o n t V i e w


M o d e l 8 1 3 0 B a c k V i e w

Filter Tester Schematics F-5

M o d e l 8 1 3 0 T o p V i e w

G-1

A P P E N D I X G TSI ’s Por tab le Pr in ter

This appendix contains TSI’s Portable Printer instruction manual.

H-1

A P P E N D I X H TSI Model 8118A Sal t Aerosol Generator

This appendix contains TSI’s Model 8118A Salt Aerosol Generator instruction manual.

I-1

A P P E N D I X I D ismant l ing and Disposal o f F i l ter Tester

When properly maintained, the Model 8127/30 Automated Filter Tester will provide years of reliable service. When the Tester becomes obsolete or unused, the instrument may be dismantled and the components may be either recycled or placed in disposal. The primary metallic components (cabinet, sheet metal boxes, brackets) are either painted, mild steel or aluminum alloy. These items may easily be recycled. The Tester also contains components made of stainless steel, Delrin, rubber, vinyl, polyethylene, copper, brass and PVC (to name a few). Common environmental practice will dictate whether to recycle or properly dispose of these components. Some components of the aerosol generation, flow generation and transport systems may have been exposed to aerosol chemicals which may or may not be considered hazardous. These chemicals may include NaCl, emery oil, DOP or others, depending upon the individual user. Components exposed to hazardous chemicals should be handled with caution and should be disposed in an environmentally safe manner. Please contact TSI engineers for questions about instrument dismantling or disposal.

Index-1

Index

6 64k EPROM, 6-1

A acceptance zone, 7-7 accessories, 2-1 adjusting, leveling, 2-2 aerosol

filling, 4-1 generation, B-2

aerosol concentration calculating, 8-2 changing, 8-1

aerosol exhaust connecting, 4-1, 4-12

aerosol generator. (see also oil aerosol generator and salt aerosol generator) filling, 4-6 installation, 4-6 installing, 4-1 oil, D-1 operating parameters, 8-1 pressure, 5-9 salt, D-1

manual, 18-1 turned off, 7-1

aerosol mass concentration calculating, 7-4 measuring, 7-1

aerosol neutralizer, 3-1, 3-5, 5-10, 9-22 ionizing air nozzle, 3-5 power supply, 3-5, 5-11

AEROSOL option, 6-5, 6-27 aerosol particle size, verification, C-1 air inlet, 4-13 air line filter, 9-11

replacing, 9-10 application notes, 8-1 atomizer

number used, 3-2 pressure low, 7-1

atomizer jet assembly, 9-28

B back panel, removal, 9-1 brass, 19-1

C CALIBRATIONS option, 6-6, 6-22

capsule filter, 9-10 caution

cleaning, 9-8 inlet line pressure, 4-4 proper exhaustion, D-1 voltage, 4-3, 4-14

CERTITEST Automated Filter Tester, 1-1 basics, 5-1 checking performance, 7-1 components, 3-1 dismantling and disposal, 19-1 maintenance, 9-1, 9-3 maintenance kit, E-1 on/off switch, 3-21 operation, B-5 packing list, 2-1 schematic, 1-3, B-1 schematics, 16-1 servicing, 10-11 setting up, 4-1 specifications, A-1 troubleshooting, 10-7 unpacking, 2-1, 2-2

CLOSE button, 3-16, 5-2, 5-3, 7-3 coalescing filter, 4-4 comments

making, xviii sheet. (last page of manual)

compliance standards, 1-2, 4-3 components, 3-1 compressed air

connecting, 4-1, 4-3 inlet, 4-4 requirements, 4-3 source, 4-1

compressed air liquid bowl, 9-21 draining, 9-21

compressed air regulator, 4-5 CONTINUE SET UP screen display, 6-7 control buttons, 3-1, 3-16

CLOSE, 3-16 emergency off/on, 3-19 location, 3-16 OPEN, 3-16

copper, 19-1 CPU board, 3-8, 3-15, 6-1 CPU/controller, 3-1, 3-15

pc board, 3-15 CREATE TEST PROTOCOL option, 6-18, 6-19

Index-2 CERTITEST® Model 8127/8130 Automated Filter Tester

D Danger

electrical hazard, 3-14 dedicated microprocessor, 1-3 Delrin, 19-1 DIP switch, 5-12

settings, 4-14 dismantling

filter tester, 19-1 DISP. P/F option, 6-13, 6-19 DISPLAY port, 4-2 disposal

filter tester, 19-1 DOP oil, 3-3, 19-1

concerns, 4-7 operation parameters, D-2 psi, 7-7

E EEPROM, 3-8 electrical outlet

required voltage, 4-1 electrical power, 5-5

connecting, 4-1, 4-3 electronics housing, 3-1, 3-11, 3-14 emergency off/on button, 3-1, 3-19, 5-2, 5-3 Emery oil, 3-2, 4-1, 9-24, 19-1

operating parameters, D-2 psi, 7-7 recommendation, 3-3

EPROM 64k chip, 3-15, 6-1

replacing, 9-31 error messages, 10-1

FLOW FOR PASS-FAIL OUT OF RANGE, 10-3 HIGH ZERO ON DOWNSTREAM

PHOTOMETER, 10-1 HIGH ZERO ON UPSTREAM PHOTOMETER, 10-2 INVALID, 6-10, 10-3 LOW AEROSOL CONCENTRATION, 10-3 Unassigned Message #, 10-4 User Memory Full, 10-4 ZERO ERROR ON FLOW TRANSDUCER, 10-2 ZERO ERROR ON RESISTANCE

TRANSDUCER, 10-2 European compliance standards, 1-2 exhaust

air, 4-12 filter, location, 3-13 line, 4-12 tubing, 4-1

external air line connector, 4-13

F FAIL message, 1-4 felt filter, in-line, 3-3

filter media sheet, 7-2 penetration, C-3 resistance, measuring, 3-11

filter air flow, measuring, 3-11 filter holder, 3-1, 3-9

changing, 4-1 connecting, 4-17 mounting screws, 4-17, 4-18 seal, 3-10

FILTER TEST option, 5-14, 6-4, 6-6, 6-8 filter test software. (see software) FLOW ADJUSTMENT option, 5-14, 6-5, 6-6, 6-9,

7-3, 8-6, 8-8 FLOW CALIBRATION option, 6-22 flow control valve, 3-21, 5-13

on/off switch, 3-1 FLOW FOR PASS-FAIL OUT OF RANGE error

message, 10-3 flow line filter, 9-10

replacing, 9-9 FLOW option, 6-13, 6-18 FLOW/LOAD option, 5-14, 6-4, 6-6

FLOW ADJUSTMENT option, 6-5 LOADING TEST option, 6-5 menu

FLOW ADJUSTMENT option, 6-9, 8-6 LOADING TEST option, 6-9

flowmeter, 3-1, 3-8, 9-8 cleaning, 9-7 contamination, checking, 7-8

fuse, replacing, 9-33

G geometric standard deviation, C-3 gravimetric

filter holder, 7-2, 7-3 test, 7-1, 7-2

H hazardous chemicals, disposal, 19-1 heater, 3-1 HIGH ZERO ON DOWNSTREAM PHOTOMETER

error message, 10-1 HIGH ZERO ON UPSTREAM PHOTOMETER error

message, 10-2

I–J–K impaction felt, 4-7 important

filter, 9-9 jets, 9-28 replacing filters, 9-13 size distribution, 8-1

in-line felt filter, 3-3 INVALID error message, 6-10, 10-3 ion balance, setting, 9-22 ionizing air nozzle, 3-5

Index Index-3

ionizing needles cleaning and replacing, 9-23

L leveling, adjusting, 2-2 light scattering photometer, 3-12 load level

calculating, 8-9 LOADING TEST option, 6-5, 6-6, 6-9, 6-10, 8-8

FLOW ADJUSTMENT option, 8-8 printer output, 8-8

LOW AEROSOL CONCENTRATION error message, 10-3

low atomizer pressure, 7-1 low solution level, 7-1

M main cabinet

unpacking, 2-2 Main Menu, 6-6

FILTER TEST option, 6-6 FLOW ADJUSTMENT option, 6-6 LOADING TEST option, 6-6 options, 6-4 screen, 5-7, 5-13 TESTER SET UP option, 6-6 VOLTAGES option, 6-6

Main Menu screen FLOW/LOAD option

FLOW ADJUSTMENT, 5-14 main pressure regulator, 5-7 maintenance, 9-1

air line filter, 9-10 compressed air liquid bowl, 9-21 EPROM program chip, 9-31 flow line filter, 9-9 flowmeter, 9-7 fuse, 9-33 ionizing needles, 9-23 kit, E-1 list

contents, E-1 mixing manifold, 9-6 oil atomizer jets, 9-26 photometer filters, 9-13 photometer module, 9-15, 9-18 removing photometer, 9-15 replacing oil, 9-34 routine, 9-3 salt aerosol generator, 9-4 schedule, 9-4 special, 9-24 spool valve, 9-12 tubing, 9-34 vacuum pump, 9-20

make-up air flowrate, 5-9 make-up air heater, 3-6

description, 3-6

manual purpose, xviii

media filter holder, 7-3 sheet, ordering information, 7-2

menus FLOW/LOAD, 6-9 overview, 6-3

messages SET UP COMPLETED, 6-8

microprocessor, 1-3, 3-15 control, B-4

mixing manifold, 3-1, 4-12, 9-7 cleaning, 9-6 exhaust line, 3-7 mixing chamber, 3-7

Model 8118A Salt Aerosol Generator. (see salt aerosol generator)

Model 8127. (see CERTITEST Automated Filter Tester)

Model 8130. (see CERTITEST Automated Filter Tester)

modes, 6-6 mounting block, location, 4-2

N NaCl, 4-1, 19-1 NEMA electronics, 9-33 NEMA enclosure, 3-11, 3-14, 3-15

O oil aerosol generator, 1-4, 3-1, 3-2, 4-6, D-1, (see

also aerosol generator) aerosol neutralizer, 3-5 cover removed, 9-27 felt, 9-25 felt, replacing, 9-25 filling, 9-4 installation, 4-8 media test, 7-7 oil level indicator, 5-5 reservoir cover, 4-6

oil atomizer jets, cleaning, 9-26 oil level indicator, 5-5 oil, replacing, 9-34 on/off switch, 3-21, 5-5 OPEN button, 3-16, 5-2, 5-3 operating

parameters, D-2 procedures, 5-4

operation, 1-3, 5-1, B-5 operation flag, 6-3 options, 6-4, 6-9

AEROSOL, 6-27 CALIBRATION, 6-22 CREATE TEST PROTOCOL, 6-19 DISP. P/F, 6-13, 6-19 FILTER TEST, 5-14, 6-4, 6-8


options (continued) FLOW, 6-13, 6-18 FLOW ADJUSTMENT, 6-9, 7-3, 8-6, 8-8 FLOW CALIBRATION, 6-22 FLOW/LOAD, 6-4

FLOW ADJUSTMENT, 5-14, 6-5 LOADING TEST, 6-5

LOADING TEST, 6-10 Main Menu, 6-4 overview, 6-3 PENETRATION, 6-13, 6-19 PRESSURE CALIBRATION, 6-23 PRINTER, 6-14, 6-19 PROTOCOL, 6-17, 6-18 PURGE, 6-16, 6-19 RESISTANCE, 6-13, 6-18 RISE TIME, 6-13, 6-19 RS232, 6-15, 6-19 SAMPLE TIME, 6-12, 6-19 SAVE, 6-3 SELECT TEST PROTOCOL, 6-18 SPECIAL TIMING, 6-23 SYSTEM, 6-21 System Menu, 6-6 TEST PARAMETERS, 6-12 TESTER SET UP, 5-12, 6-4, 6-6, 6-7 TIME/DATE, 6-21 UNITS, 6-16, 6-19 VOLTAGES, 6-20 WATCH POINTS, 6-25

Options menu, 6-6, 6-11 TEST PARAMETERS, 6-12

DISP P/F, 6-13 FLOW, 6-13 PENETRATION, 6-13 PRINTER, 6-14 PURGE, 6-16 RESISTANCE, 6-13 RISE TIME, 6-13 RS232, 6-15 SAMPLE TIME, 6-12 UNITS, 6-16

Options Menu options, 6-5 Aerosol, 6-5 Protocol, 6-5 System, 6-5 Test Parameters, 6-5 Time/Date, 6-5 Voltages, 6-5

O-ring, 4-17 outlet assembly, 3-3 overview, 1-1

menus and options, 6-3

P packing list, 2-1 PAPER FEED switch, 4-14, 5-12

paraffin oil, 3-3 operating parameters, D-2

parameter value changing, 6-2

particle detector, B-3 PASS message, 1-4 penetration calculation, 6-9 penetration data

verifying, 7-4 PENETRATION option, 6-13, 6-19 photometer, 1-3, B-3

assembly, 3-1, 3-12 location, 3-13

compressed air connection, 9-17 connector, 9-18 correlation factor (CF), 6-7 downstream sample line, 9-17 electrical connection valves, 9-18 filter, 9-14

replacing, 9-13 high vacuum purge line, 9-17 PC board, location, 3-13 philips screws, 9-16 removing, 9-15 removing module, 9-15 replacing photometer module, 9-18 schematic, B-3 three screws holding box in place, 9-16 upstream sample line, 9-17

port DISPLAY, 4-2

POWER switch, 5-6, 5-12

printer, 4-14 power supply, 3-5, 5-10, 9-22 poyethylene, 19-1 pressure

recommendation, 3-3 PRESSURE CALIBRATION option, 6-23 pressure regulator

location, 3-3 pressure transducers, 3-1, 3-11, 9-29, 9-31

location, 3-11 printer, 3-1, 3-18, 5-11, 17-1

connecting, 4-1, 4-13 PAPER FEED switch, 4-14, 5-12 POWER switch, 4-14, 5-12

PRINTER option, 6-14, 6-19 printout, 4-15 product description, 1-2 PROTOCOL option, 6-5, 6-17, 6-18 PURGE option, 6-16, 6-19 PVC, 19-1

Q QUICK-CONNECT fitting, 5-2

Index Index-5

R reference graph

sample, 7-5 references

writer, xviii RESISTANCE option, 6-13, 6-18 RESULTS screen, 7-6 rise time, 8-4

example, 8-6 RISE TIME option, 6-13, 6-19 routine maintenance

clearance, 2-3 RS232 option, 6-15, 6-19 RS-232 serial port, 4-16, 5-11

S salt aerosol generator, 1-4, 3-1, 3-4, 4-6, D-1, (see

also aerosol generator) aerosol neutralizer, 3-5 connectors, 4-11 filling, 9-5 heater on, 5-7 indicators, 4-11 installation, 4-10 maintenance, 9-4 manual, 18-1 media test, 7-7 reservoir cover, 4-9

sample time, 8-4 example, 8-6

SAMPLE TIME option, 6-12, 6-19 SAVE option, 6-3 schematic

CERTITEST Automated Filter Tester, B-1 filter tester, 16-1

screen Main Menu, 5-7, 5-13 RESULTS, 7-6 TEST PARAMETERS, 7-6 Tester Identification, 5-6

SELECT TEST PROTOCOL option, 6-18 separation tool, 7-3 serial interface

connecting, 4-1, 4-16 servicing, 10-1

returning, 10-11 technical contacts, 10-11 tester, 10-11

SET UP COMPLETED message, 6-8 sheath air filter

location, 3-13 software

64k EPROM, 6-1 changing parameter, 6-2 description, 6-1 error messages. (see also error messages initiatlization, 5-6 making entries, 6-2

software (continued) menu structure, 6-4 menus, 6-3 overview, 6-3 reference guide, 6-1 screens, 6-1, 6-2 setting test time, 8-3 touch-panel display, 6-1 version, 6-2

solution level low, 7-1 SPECIAL TIMING option, 6-6, 6-23 specifications, A-1 spool valve, 9-12

maintenance, 9-12 statistical diagnostics, 10-4 SYSTEM MENU options, 6-6

Calibrations, 6-6 Special Timing, 6-6 Watch Points, 6-6

SYSTEM option, 6-5, 6-21

T technical contacts, 10-11 test duration

calculating, 8-9 TEST PARAMETERS option, 6-5, 6-12 TEST PARAMETERS screen, 7-6 tester cabinet

closing top, 9-2 opening top, 9-2

tester components, 3-1 Tester Identification screen, 5-6 TESTER SET UP option, 6-4, 6-6, 6-7

function, 5-12 theroy of operation, B-1 TIME/DATE option, 6-5, 6-21 touch-panel display, 3-1, 3-17, 6-1

mounting, 4-1, 4-2 using, 5-1

troubleshooting, 10-1 tester, 10-7

tube heater 70 watt, 3-6

tubing, maintenance, 9-34 tungsten needles, 3-5

U UNASSIGNED MESSAGE # error message, 10-4 UNITS option, 6-16, 6-19 unpacking, 2-1, 2-2

accessories, 2-3 components, 2-3 main cabinet, 2-2

USER MEMORY FULL error message, 10-4

V vacuum fluorescent technology, 3-17 vacuum grease, 9-9


vacuum pump, 3-1, 3-20, 9-20 cleaning, 9-20 felt filter, 9-20 location, 3-13

verification test, performing, 7-6 voltage, requirements, 4-3 VOLTAGES option, 6-5, 6-6, 6-20

W–X–Y warm-up period, 5-11 warning, 3-12

compressed air, 9-11 electrical power, 5-2 filter holder, 5-8 static discharge, 9-31 voltage and air pressure, 3-21 water/oil trap, 4-5

WATCH POINTS option, 6-6, 6-25

Z ZERO ERROR ON FLOW TRANSDUCER error

message, 10-2 ZERO ERROR ON RESISTANCE TRANSDUCER

error message, 10-2

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