Salt Aerosol Automated Filter Tester 100S Operation and Maintenance Manual

Transcription

1 Automated Filter Tester Salt Aerosol Automated Filter Tester Operation and Maintenance Manual U.S. Patent 7,694,548 P/N , Revision F March 2013

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4 Content Chapters CHAPTER 1 Introduction and Precautions 2 Scope of Manual 2 Definitions 2 Definiciones 3 Définitions 3 Definitioner 4 定义 4 Intended Use 5 User Responsibility 5 Precautions 6 For Customers in Canada 9 For Customers in the USA 9 For All Customers 10 CHAPTER 2 Automated Filter Tester Overview 12 Instrument Description 13 How the Penetrometer Operates 15 Utility Requirements 15 CHAPTER 3 Unpacking the Penetrometer 18 Packing List 18 Unpacking 19 Installing the Local Exhaust option 20 CHAPTER 4 Know Your Equipment: The Components 22 Introduction 22 Salt Aerosol Generator 22 Generator Replenishment Pump 23 Generator Solution Level Sensor 23 Air Inlet Conditioning System 24 Aerosol Neutralizer 24 Dilution Air Heater 25 Flow Controller 26 Test Fixture (Chuck) 26 Pressure Transducers 27 Differential Pressure Transducer 28 Photometer 28 Touch Screen Display 29 Control Buttons 29 Vacuum Pump 30 Sample Clear Valve 30 Safety Pressure Relief Valve 31 ii

5 Filters 31 Mixing Manifold 32 Interface Ports 32 Electrical Architecture 33 CHAPTER 5 Setting Up The 34 Installation 34 Before you begin 34 Connecting Electrical Power 34 Connecting Compressed Air 34 Connecting Exhaust 35 Connecting Interface Ports 35 Installing the Generator 37 CHAPTER 6 Operating the : Basic Operation 38 Before You Begin 38 Automated Filter Tester Controls 38 Basic Operation 40 Test Modes 46 Filter Test 46 Gravimetric Test 46 Load Test 47 EN143 Test 48 CHAPTER 7 Software Reference 50 Software Description 50 Touch Screen Display 50 Software Version 50 Making Entries 51 Entering Numerical Values 51 Turning Options Flags On or Off 52 General Screen Structure 53 Test Fixture Latching Indicator 54 Menu Structure and Options 55 Menu Structure 55 Top Level Menu Options 56 Test Mode Menu: Detailed Screens Description 57 Menu Options 57 Filter Test 58 Load Test 60 Penetration Calibration (Pen Cal): Detailed Screen Description 65 Setup Menu: Detailed Screens Description 66 Setup Menu Options 66 Test Setup Options 66 Alarm Settings Options 68 Maintenance Menu: Detailed Screens Description 69 Diagnostic Options 70 Gravimetric Test 71 LSC Diagnostics 71 iii

6 LSC Calibration 72 Pressure Sensors & Flow Controller 74 Valves 77 User Status Lines 78 User serial I/O 78 Temperature Monitor Status 80 Machine Setup Parameters 82 Changing the Machine ID 82 Changing Date and Time 82 Changing the Pressure Units 83 System Variables 84 Security 85 Result Format 88 New Operator 89 Error Messages 90 Operator Generated Errors 90 Initialization Errors 90 LSC Error 91 Operational Alarms 92 Penetration Calibration Alarms 93 CHAPTER 8 Verifying the System Performance 94 Aerosol Mass Concentration 94 Verifying the Differential Pressure Sensor 94 Verifying Penetration Test Data 94 CHAPTER 9 Application Notes 96 Abbreviations List CFR Part 84 Standard 96 Load Test Calculations 98 CHAPTER 10 Maintaining the Penetrometer 100 Definitions and Features 100 Recommended Scheduled Maintenance 100 Daily 100 Weekly 100 Monthly 100 Biannually 100 Annually 100 Replacing the Main Power Fuses 101 Replacing the Memory Backup Battery 102 Draining and/or cleaning the Salt Aerosol Generator 102 Removing the generator from the machine 102 Opening the generator 103 Draining and cleaning the generator 103 Refilling and reassembling the generator 103 Filling the Replenishment Solution Reservoir 104 Cleaning the Test Fixture 104 Cleaning the Mixing Manifold 105 iv

7 Cleaning the Aerosol Lines 106 Generator Aerosol Line 106 Test Fixture Aerosol Line 106 Replacing the Flow Controller Coalescing Filter 106 Check and Clean the Ionizer Needles 107 Check Ion Balance using Charge Meter 107 Replacing the Flow Meter Carbon/HEPA Filter 107 Compressed Air Conditioning Elements 108 Cleaning the bowls 108 Replacing the elements 108 Preparing the for storage 109 Draining and cleaning the generator 109 Cleaning the pump, refill lines and liquid level sensor 109 Cleaning the test fixture 110 Cleaning the aerosol lines 110 Clean the mixing manifold 110 CHAPTER 11 Automatic Version 112 Introduction 112 Setting Up the Automatic 112 Interface Ports 112 Aerosol and Pressure Lines Connections 116 Timing Diagram 117 Overall Sequence 117 Timing Diagram Key 117 Warm-up Sequence 118 Setup Sequence 118 Operation Sequence 119 Pen Cal (Calibration) Sequence 120 CHAPTER 12 Hybrid Version 122 Introduction 122 Setting Up for Automatic Mode 122 Setting Up for Manual Mode 122 Interface Ports 122 Aerosol and Pressure Lines Connections 123 CHAPTER 13 Troubleshooting Guide 126 Tester Will Not Power Up 126 Tester On - No Response 126 Insufficient Sample Flow 126 Aerosol Generator Pressure Unstable 127 Low Aerosol Concentration 127 Unstable Photometer Readings 127 Flow or Resistance Incorrect 127 Parameter(s) and/or Calibration Data Corrupted 128 Aerosol Leaking 128 Slow Test Fixture Movement 128 Heater Not Functioning 128 v

8 Appendixes Ionizer Inoperable 129 Ionizer Not Functioning Properly 129 Liquid in Dilution Air Flow Meter 129 APPENDIX A Contacting ATI A-0 For Technical or Application Questions A-0 For Customer Service A-0 APPENDIX B Warranty B-0 APPENDIX C Declaration of Conformity C-0 APPENDIX D Specifications D-0 Physical Characteristics D-0 Operational Requirements D-0 Operating Conditions D-0 Aerosol Generation D-1 Aerosol Detection D-1 Flow Measurements D-1 Pressure Differential Measurements D-1 Efficiency Measurements D-1 Outputs D-2 APPENDIX E Theory of Operation E-0 Introduction E-0 Aerosol Generation E-1 Aerosol Detection - Photometry E-1 Electrical Architecture E-1 Operation of the Penetrometer E-2 APPENDIX F Preparing the Sodium Chloride Solution F-0 APPENDIX G Maintenance and Spare Items G-0 APPENDIX H Service Items H-0 APPENDIX I Accessories I-0 Base Storage Cabinet I-0 Local Exhaust Module I-0 Gravimetric Filter Test Adapter I-1 N95 Mask Adaptor I-1 APPENDIX J Ionizer Service J-0 Cleaning, Inspection or Replacing the Ionizing Needles J-0 APPENDIX K Ionizer Balance K-0 Verifying and Setting the Ionizer Output Balance K-0 APPENDIX L Manual Revision History L-0 APPENDIX M Español Precauciones M-0 APPENDIX N Français Précautions N-0 APPENDIX O 中文 预防 O-0 APPENDIX P Svenska Försiktighetsåtgärder P-0 vi

9 Figures Figure 5-1: PLC Control Port Pin Description 36 Figure 5-2: Connection Circuit Example 36 Figure 6-1: Basic Operation of the Automated Filter Tester 40 Figure 7-1: Numerical Keypad 52 Figure 7-2: Screen Structure 53 Figure 7-3: Overview of the Menu Structure 55 Figure 7-4: Top Level Menu Screenshot 56 Figure 7-5: Test Mode Menu Screenshot 57 Figure 7-6: Filter Test Screenshot 58 Figure 7-7: Gravimetric Test Parameters Screenshot 60 Figure 7-8: Load Test Options Screenshot 63 Figure 7-9: Load Test Screenshot 64 Figure 7-10: Penetration Calibration Screenshot 65 Figure 7-11: Test Setup Options Screenshot 66 Figure 7-12: Alarm Settings Options Screenshot 68 Figure 7-13: Maintenance Menu Screenshot 69 Figure 7-14: Diagnostic Menu Default Screen 71 Figure 7-15: LSC Diagnostic Screenshot 72 Figure 7-16: LSC Calibration Options Screenshot 73 Figure 7-17: Pressure Transducers Options Screenshot 74 Figure 7-18: Pressure Transducers Pop up Screen Screenshot 75 Figure 7-19: Flow Controller Pop up Screen Screenshot 76 Figure 7-20: Valves Diagnostic Options Screenshot 77 Figure 7-21: User Status Lines Screenshot 78 Figure 7-22: User Serial I/O Screenshot 80 Figure 7-23: Machine Setup Options Screenshot 82 Figure 7-24: Character Entry Screen 83 Figure 7-25: Date and Time Entry Keypad 83 Figure 7-26: Operators Maintenance Screenshot 85 Figure 7-27: Add New Operator Screenshot 86 Figure 7-28: Deleting an operator Screenshot 86 Figure 7-29: PIN Entry Screenshot 87 Figure 7-30: Operator Roles Screenshot 88 Figure 7-31: New Operator Login 89 Figure 10-1: Aerosol Generator Exploded View 104 Figure 11-1: PLC Control Port Pin Description 115 Figure 11-2: Connection Circuit Example Status Line 115 Figure 11-3: Connection Circuit Example Input Line 115 Figure 11-4: PLC Auto Port Pin Description 115 Figure 11-5: Aerosol and Pressure Ports Connections 117 Figure 11-6: Timing Diagram Overall Sequence 117 Figure 11-7: Timing Diagram Warm-up Sequence 118 vii

10 Figure 11-8: Timing Diagram Setup Sequence 118 Figure 11-9: Timing Diagram Operation Sequence 119 Figure 11-10: Timing Diagram Pen Cal Sequence 120 Figure 12-1: Aerosol and Pressure Ports Connections 124 Appendix Figure E-1: Schematic Diagram of the Automated Filter Tester... E-0 Tables Table 7-1: Top Level Menu Options Table 7-2: Test Mode Menu Options Table 7-3: Gravimetric Test Parameters Table 7-4: Post Gravimetric Test Parameters Table 7-5: Load Test Parameters Table 7-6: Setup Menu Options Table 7-7: Test Setup Options List Table 7-8: Alarm Settings Options List Table 7-9: Maintenance Menu Options Table 7-10: Diagnostic Menu Options Table 7-11: Access Privilege Table Table 7-12: List of Operator Error Messages Table 7-13: List of Initialization Error Messages Table 7-14: List of LSC Error Messages Table 7-15: List of Operational Error Messages Table 7-15: List of Penetration Calibration Error Messages Table 9-1: Abbreviations List Table 9-2: Filter Classes under 42 CFR part Table 10-1: Replacement Fuses for the Appendix Table G-1: Maintenance Kit Items... G-0 Appendix Table H-1: Service Kit Items... H-0 Appendix Table I-1: Accessories List... I-1 Appendix Table L-1: Manual Revision History... L-0 viii

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12 CHAPTER 1 Introduction and Precautions Scope of Manual These instructions cover the specifications, features, operation, maintenance, and troubleshooting for Salt Aerosol Automated Filter Tester. These instructions also contain important information required for operation of this piece of equipment. Before using this equipment, all personnel associated with the operation must read and understand this entire manual and become familiar with the terminology. Failure to follow the specified procedures and precautions could result in PERSONAL INJURY or DAMAGE to the unit. Definitions!! i The following defines the warnings, cautions and notes used throughout this manual. Warning Indicates a strong possibility of severe personal injury or death if instructions are not followed. Caution Indicates a possibility of equipment damage if instructions are not followed. Note Indicates that helpful information is provided. 2

13 Definiciones!! i Las siguientes anotaciones definen los peligros, cuidados y notas usadas a lo largo de este manual. Advertencia Indica una fuerte probabilidad de serias lesiones personales o muerte si no son seguidas las instrucciones. Cautela Indica una posibilidad de daños al equipo si no son seguidas las instrucciones. Nota Indica que se suministra información útil. Définitions!! i Les informations suivantes, définissent les symboles, précautions et notes présentes dans ce manuel. Avertissement Indique la possibilité de dommages corporels graves pouvant entraîner la mort, si les instructions ne sont pas suivies. Attention Indique la possibilité d endommager l équipement si les instructions ne sont pas suivies. Note Indique que des informations utiles sont fournies. 3

14 Definitioner!! i Efterföljande text beträffande varningar, varsamhet och noteringar är genomgånde för hela manualen. Varning Innebär att allvarlig personlig skada eller död kan inträffa om instruktionerna inte följs. Varsamhet Innebär att skador på utrustning kan inträffa om instruktionerna inte följs. Notera Innebär att användbar information ges. 定义 下面定义了在这本说明书中所有的警告, 小心, 注意.!! 警告 表示如果不按照指导操作. 引起个人人身伤害甚至死亡的可能性很高. 小心 表示如果不按照指导操作. 可能会损害仪器 i 表示提供了有用的信息. 注意 4

15 Intended Use This product is intended to be used for the efficiency testing of high efficiency filters. This is accomplished using an aerosolized pre-determined mixture of sodium chloride and de-ionized water. It may be used for Research & Development, Quality Assurance or Production level testing in controlled environments where deemed appropriate. This product is not intended for use in freezing, wet, intense sunlight or other extreme ambient conditions. Any other use of this product may impair the equipment s protective devices and is the user s sole responsibility and at the user s risk. User Responsibility The user must: 1. read and comprehend the information contained in this manual before using the product; 2. have an understanding of the electrical and mechanical system principles used in the operation of this penetrometer; 3. be trained in the proper use of electro-mechanical equipment; 4. properly use this product for the intended purpose and follow all regulations and procedures that apply to the location where this product is used; 5. maintain the product as specified in this manual; 6. maintain and keep in proper working condition any other equipment associated with the operation of this product; 7. insure there is adequate pressure and flow of compressed air supplied to the product; 8. insure there are adequate exhaust systems in place to remove excess aerosol from the operating environment; 9. verify and maintain the type and quality of sodium chloride reagent to be used with this product. 5

16 Precautions! i! Warning General Safety Rules Read and understand all instructions. Failure to follow all instructions listed below may result in electric shock, fire or serious personal injury. The warnings, cautions, and instructions discussed in this operation and maintenance manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are a factor which cannot be built into this equipment, but must be supplied by the operator. Warning Tip Hazard Failure to follow the prescribed procedures may result in a hazardous situation. The must only be placed and used on a firm, stable, and level surface. NEVER transport the unit while containing liquid or in operation. Take caution against liquid aerosol reagent spillage. In case of spillage clean up contamination immediately.! \! Warning Hot Surfaces The dilution heater surfaces within the unit may be HOT. Avoid contact with exposed flesh at all times while the unit is in operation or during cool-down periods. Caution Shipping Hazard Do not ship the Salt Aerosol Automated Filter Tester with liquid inside the generator cylinder or re-fill reservoir. Drain the of all liquid before shipping. 6

17 Caution - Maintenance To perform maintenance on the generator, the machine must be turned off.! When reinserting the fuseholder in the power inlet module verify that you have selected the appropriate voltage for your location. Incorrect fuse replacement may damage internal components of the automated filter tester. Only use clean, warm water when cleaning the generator. Alcohol, acetone or other solvents will damage the generator.!! K! k Warning Maintenance Before performing maintenance on the compressed air conditioning elements, the machine must be turned off and the compressed air feed to the machine must be disconnected. Warning Electrical Hazard Electrical hazard that can cause severe injury or death. The electrical housing contains multiple high voltage sources. Do not insert any objects under the cover Only remove the cover if you have been properly trained. Warning Lifting Hazard Two persons minimum are required to move or lift the Salt Based Automated Filter Tester. Failure to do so may result in serious injuries. 7

18 ! ^! O! Warning Safety Features The operator shall not try to override any of the safety features put in place by the manufacturer. Protection impairment and serious injury might result if used in a manner not specified by the manufacturer. Do not attempt to override the test fixture interlock switch. Do not attempt to defeat the anti tie-down feature. Warning Compressed Air Only trained personnel should operate pneumatically operated machinery and equipment. Compressed air can be dangerous. Assembly, handling or repair of pneumatic systems should be performed by trained and experienced operators. Do not remove, replace or tamper with the safety pressure relief valve. Warning Damaged Equipment Do not operate the equipment with a damaged cord or plug or after the equipment has malfunctioned, or been damaged in any way. Contact ATI Service Department for advice on examination, repair, electrical or mechanical adjustment. Failure to follow the prescribed procedures may result in a hazardous situation. 8

19 For Customers in Canada Note Regulatory Information i Cet appareil numérique de la Classe A est conforme à la This Class A digital apparatus complies with Canadian ICES norme NMB-003 du Canada.. For Customers in the USA Declaration of Conformity Trade Name : ATI Model Number : Responsible Party: Hamilton Associates Inc. Address: Cronridge Drive Owings Mills, MD USA Telephone No: This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. i Note Regulatory Information This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna Increase the separation between the equipment and 9

20 receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radio/tv technician for help For All Customers Disposal of Old Electrical & Electronic Equipment This product shall not be treated as household waste. Instead it shall be handed over to the applicable collection point for recycling of electrical and electronic equipment. By ensuring this product is disposed of correctly, you will help prevent potential negative consequences for the environment and human health, which could otherwise be caused by inappropriate waste handling of this product. The recycling of materials will help to conserve natural resources. For more detailed information about recycling of this product, please contact your local Civic Office, your household waste disposal service or the Company where you purchased this equipment. 10

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22 CHAPTER 2 Automated Filter Tester Overview 12

23 Instrument Description The Salt Aerosol Automated Filter Tester is designed to test high-efficiency filter based products using a sodium chloride salt aerosol. The aerosol particle size and distribution are designed to meet all requirements as defined in the relevant sections of NIOSH 42 CFR, Part 84 and is also suitable for testing to JMOL and in-house QC to EN143/related standards. The Automated Filter Tester is also know as a Penetrometer. The following is the definition of a Penetrometer: penetrometer noun (plural penetrometers) 1 1. A mechanical device that measures the ease of penetration of an object into a semisolid. The Salt Aerosol Automated Filter Tester meets the above definition perfectly. A mechanical device that measures the ease with which an object (sodium chloride aerosol particles) penetrate into, or through, a semisolid (filter media). While the outcome is seemingly rather simple, the steps needed to complete this measurement can become quite complex. Sodium chloride aerosol must be continuously generated at a known, reproducible concentration and particle size, while at the same time being dried, neutralized and maintained in a ready state for availability at a moments notice when a test is initiated. The Forward Light Scattering Chamber (LSC) accurately provides a near real-time response to the sodium chloride aerosol across six decades of gain all the while minimizing the introduction of electronic noise. Care must also be taken to prevent deposits of 1 Source: Wiktionary.org 13

24 salt from forming on the detector surfaces decreasing stability and accuracy. Human and automation interfaces must provide error free, intuitive operation of the instrument and ready access to results, while remaining versatile enough to accommodate special testing needs that are becoming commonplace in today s filter industry. When all of these elements come together as they have in the, the testing process ceases to be a training intensive exercise and can become a set and forget secondary routine performed as part of the daily work requirements in filter production. The is powered up, has its daily operational setup procedures performed, setting concentration, detection levels and test flow, and is ready for testing. The is available in multiple configurations to meet end-user testing requirements; Manual, Automatic, and Hybrid. The Manual configuration is ideal for lab-oriented and/or production Lot testing. The product to be tested is placed in the Test Fixture by an operator and a test is started by placing one finger in each of the optical actuators provided. Aerosol sample stabilization and testing times may be controlled by the operating system or by operator selection. At the completion of the test cycle the results are displayed in clear text on the main display until the start of the next text cycle. At the end of the next test cycle the past test results move to a lower display showing the three most recent results in addition to the current test. Test results can also be transmitted to a computer via the Communication port. The Automatic configuration is suited for 100% production QC testing. The unit is designed to integrate and act as a slave device with a customer designed automated PLC driven production line. The automated line places the product to be tested in a customer designed test fixture, signals the unit to perform a test, and captures the results. 14

25 The Hybrid instrument affords the system integration of the Automatic version while allowing for Manual operation, if necessary. How the Penetrometer Operates The test aerosol is generated by an innovative patented method utilizing a nebulizer nozzle suspended in an aqueous solution. The nebulizer air jet generates an aerosol mist that is passed through an impactor and controlled drying chamber to achieve the desired aerosol characteristics. During testing, aerosol is drawn from the aerosol generator mixing manifold, through the object under test and a Light Scattering Chamber (LSC). The LSC is used to measure the level of sodium chloride aerosol content which has succeeded in passing through the sample under test. This level of penetration is expressed as a percentage of the total available system aerosol or % Penetration. Utility Requirements Compressed Air A clean, dry, compressed airflow rate of bars (10 cfm at 80 psig) is required to successfully operate the. The minimum recommended internal diameter (ID) for the compressed air supply line is 9.5 mm (0.375 inches). Power Stable electrical power at 115 VAC, 5 Amps, 50/60 Hz is required. A line power conditioner and surge protector is recommended. 230 VAC, 2 ½ Amps, 50/60 Hz is optional. i Note A dedicated power line is recommended for stable machine operation. Ventilation Aerosol exhaust with a controlled negative draw capacity of greater than 200 lpm or optional Local Exhaust Module (ATI P/N ); 15

26 Ambient Air Conditions Temperature controlled environment: 20 to 30 Celsius (68 to 85 Fahrenheit) recommended. Humidity controlled environment: 45 75% relative humidity recommended. 16

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28 CHAPTER 3 Unpacking the Penetrometer Packing List The ships complete, ready to install and operate. Any additional accessories purchased on the same order will be listed as separate line items on the shipment packing list. Please confirm receipt of all line items prior to commissioning of the instrument. Shipping with the standard will be the following. Individual items may be packaged separately or installed: Operation and Maintenance Manual Calibration Reports Aerosol Generator Liquid Re-fill Reservoir (2) Power Cord (NEMA V or CEE 7/4 Schuko 250V configuration) Filter Test Fixture-146 mm Diameter (5.5 Diameter) Tapered Flat Sheet Media Insert Flat Sheet Media Support Canopy Exhaust Connection Greenline Penetration Verification Media Gravimetric Test Media Adapters Reagent Grade NaCl, 500 grams NaCl Material and Safety Data Sheet 1000mL Graduated Cylinder Brush Ball end hex drivers (4mm, 2.5mm and 9/64 ) 3mm Allen wrench The Automatic ships with the same items as the standard with the exception of a Filter Test Fixture, Tapered Flat sheet Media Insert and Media Support. It also ships with: 18

29 (2) Aerosol Lines, 152cm (5ft) long (2) Pressure Lines, 152cm (5ft) long PLC Port Connection Cable, 365cm (12ft) long Auto Port Connection Cable, 365cm(12ft) long The Hybrid ships with the same items as the standard with the addition of the following: (2) Aerosol Lines, 152cm (5ft) long (2) Pressure Lines, 152cm (5ft) long (2) Pressure Lines Jumper Tubes (2) Aerosol Lines Jumper Tubes PLC Port Connection Cable, 365cm (12ft) long Auto Port Connection Cable, 365cm(12ft) long Unpacking Wherever possible, packing materials should be retained for storage or future shipment and transportation needs. A locking mechanism has been installed on the test fixture of your instrument to prevent damages during shipment. It has to be removed before the machine is first powered up. i Note Failure to remove the locking mechanism could result in a potentially dangerous situation. Using a number 2 Phillips screwdriver, remove the screws retaining the green strap located on the top and the side of the pneumatic slide. This strap prevents damages to the test fixture during shipment. Using the 2.5mm hex driver remove the screws holding the left access panel (when looking at the machine from the front). Remove the panel and place it aside. If you have ordered the Local Exhaust option, skip this step and proceed to the next step. Otherwise, remove the top panel and place it aside. Install the canopy exhaust connection on the exhaust stack and 19

30 secure it in place by tightening the set screws using the 3mm Allen wrench. Replace the top panel and secure it with its retaining screws. Proceed to the next step. Insert the grey tube through the grommet in the top panel and pull it through allowing some slack in the line. Reinstall the side panel and secure it using the screws. Install the stylus. We recommend placing it on the front of the instrument, about 7 below the touch screen bezel and 1 from the outside edge. Fill and install the generator according to the procedure page 103 titled Refilling and reassembling the generator. Fill and install the replenishment reservoir as described in the procedure titled Filling the Replenishment Solution Reservoir page 104 of this manual. You are now ready to use your. Installing the Local Exhaust option To install the Local Exhaust, remove the right side access panel using the 2.5mm hex driver. Remove the three hole-plugs on the top panel and place the Local Exhaust on top of the instrument. Two locating pins on the exhaust will match the holes in the top panel. Secure the exhaust using the provided thumb screw. Insert the screw from inside the instrument through the top panel hole and tighten it. Connect the local exhaust to the instrument using the cable provided. It should be connected to the accessories power port on the back side of the instrument (see Interface Ports page 32). Open the Local Exhaust cover by loosening the two thumb screws and make sure that the pre filter is correctly inserted as it may have shifted during 20

31 shipment. Replace the cover and secure it by tightening the two thumb screws. Your Local exhaust is now ready. 21

32 CHAPTER 4 Know Your Equipment: The Components Introduction The was designed with discrete compartments intended to isolate components having similar maintenance requirements or characteristics. For example, all the filters requiring periodic replacement are located within the left portion of the enclosure as viewed from the front of the instrument, and printed circuit boards are located within the right side, etc. Salt Aerosol Generator The uses a unique patented pneumatic nebulization, impaction & conditioned dilution air to generate a salt aerosol having characteristics as defined in NIOSH 42 CFR Part

33 Generator Replenishment Pump The is equipped with an innovative patented integrated Generator Replenishment Pump & reservoir. During operation, as solution is consumed, the Generator Replenishment Pump automatically maintains the necessary liquid level in the main aerosol generator tank using the Generator Solution Level Sensor. Generator Solution Level Sensor The Salt Aerosol Automated Filter Tester is equipped with an integrated liquid level sensor to insure consistent aerosol generation characteristics. 23

34 Air Inlet Conditioning System Compressed air utilized within the is conditioned by a series of regulators, dryers and heating elements. This provides for a consistent, high quality, source of aerosol as well as reduced maintenance requirements for air operated components. Aerosol Neutralizer An aerosol neutralizer is supplied as standard equipment on the. The neutralizer reduces the electrical charge that builds up on the aerosol particles when the salt solution is atomized. This neutralization technique enables the aerosol to reach the Boltzmann equilibrium. 24

35 The neutralizer consists of a high voltage power supply and an inline, ionizing air nozzle containing two tungsten needles. Pulsed high voltage applied to the needles ionizes air passing through the nozzle which mixes with aerosol, effectively neutralizing the aerosol particles. A pressure switch removes AC line voltage to the neutralizer when there is insufficient dilution air flow. Dilution Air Heater Dilution air is required to adjust and maintain the desired aerosol concentration levels. An integrated heater is used to standardize the dilution air temperature and provide a controlled drying environment for formation of the aerosol particles. 25

36 Flow Controller A state-of-the-art mass flow controller is used to set and maintain a constant test flow rate regardless of varying test conditions. Test flow rates may be selected for display in either volumetric or mass lpm of flow. This allows for greater results repeatability, as well as a significantly lower instrument monitoring burden to maintain flow during extended or load testing. Test Fixture (Chuck) The Test Fixture, often referred to as a Chuck is designed to be as versatile as possible while still allowing necessary operational routines. The Test 26

37 Fixture is back mounted on a pneumatically driven, linear actuator with a standard stroke length of 146 mm (5.75 inches). This allows incorporation of a variety of test adapters up to a diameter of 30.5 cm (12 inches) provided that a seal is maintained on the 13.9 cm (5.5 inch) OD upper and lower fixtures. Pressure Transducers The incorporates a series of internal pressure transducers to monitor operating pressure levels. This allows systems messages and warnings to be presented when pressures fall outside of predetermined values necessary for consistent, accurate operation of the unit. 27

38 Differential Pressure Transducer Photometer An integrated circuit based differential pressure sensor provides a real-time measurement of the pressure differential generated across the component under test. The incorporates a near forward, light scattering photometer capable of measuring to 200 micrograms per liter with an accuracy of ± 1% of reading. Measurement is accomplished by passing the entire sample through the optical detection window of the sampling chamber and measuring the resulting scattered light intensity. The scattered light intensity is directly proportional to the mass of the suspended particulate within the sample. 28

39 Touch Screen Display A 14.5 cm (5.7 in) Color LCD touch screen display is the primary interface with the operating system. Clear, intuitive instructions and response options are displayed in manner familiar to any user of a commonplace computer graphical user interface. Control Buttons Control buttons external to the touch screen interface are limited to the power buttons (ON & OFF) located at the bottom right side of the Touch Screen bezel and the Optical touch actuators for operation of the Filter Test Fixture. 29

40 Vacuum Pump A pneumatically driven, venturi vacuum pump, is capable of continuously supplying 0 to 100 lpm of sample flow. A minimalist design philosophy provides virtually maintenance free operation over the instrument life. Sample Clear Valve A high-cv, pilot assisted, ball valve configuration is incorporated to minimize system loss and subsequent collection of solid particulate within the valve body. This provides a longer MTBF over spool or plunger based valve designs. 30

41 Safety Pressure Relief Valve Filters The safety pressure relief valve is located inside the, at the point of entry of the compressed air line into the machine. The set pressure is 8.6 bar (125 PSI) with a discharge capacity of 3256 lpm (115 SCFM). This safety relief valve provides the with protection over pressurization. All routinely changed filters are located in an area of the enclosure readily accessible to maintenance personnel. This enables routine maintenance to be a straight-forward procedure, performed without interference from or potential damage to other internal components. 31

42 Mixing Manifold The mixing manifold mixes aerosol from the generator with dilution air and also balances the sodium chloride charge to reach the Boltzmann equilibrium. Interface Ports An industry standard USB style serial interface is provided for communication to and from the. The unit also includes a male 7-pin circular connector with bayonet lock for system status indicators and a 4-pin circular connector with bayonet lock that functions as a dedicated 24 VDC power port for ATI designed accessories. A RJ-45 Ethernet port provides data connectivity between the and some ATI designed accessories. 32

43 Electrical Architecture The electrical system within the was designed to be intrinsically safe & maintenance friendly. Electrically actuated valves and all other control voltages within the instrument are 24 VDC based. The presence of higher AC voltages (115VAC or 230VAC) within the instrument enclosure is limited to a separately enclosed, tool accessible, area. All interconnections between printed circuit boards are created using industry standard RJ- 45 style terminations. 33

44 CHAPTER 5 Setting Up The Installation The should be installed in a controlled environment. The design of the is suitable for installation in a production area or laboratory environments. Uncontrolled environmental conditions will provide greater need for increased maintenance and may negatively affect performance. Before you begin Inspect the Aerosol Generator and ensure that it is free of contaminants. i Note Positioning When installing the Salt Aerosol Automated Filter Tester, do not block access to the compressed air inlet or the power inlet. Access to these connection points is required to allow easy disconnection. Connecting Electrical Power Ideally, a dedicated circuit should be provided for operation of the. If a dedicated circuit is not available, line conditioners may be necessary to minimize susceptibility to line noise and subsequent interruption of the microprocessor systems. Connecting Compressed Air A source of clean, instrument quality air should be used for operating the. The use of higherquality compressed air conditioners prior to introduction to the will provide increased component operating life. The compressed air supply 34

45 line needs to be of sufficient diameter to allow enough flow to pass while maintaining necessary operating pressures. A minimum inside diameter of 9.5 mm (0.375 inch) is recommended.! Warning Compressed Air Do not use operate the machine with a pressure feed higher than 8.6 bar (125 PSI) If you can hear the safety pressure relief valve, reduce the pressure of the feed line. Connecting Exhaust If a Local Exhaust Module was purchased, install according to the manufacturer s instructions. Connection to a pre-existing exhaust system requires the use of the supplied Canopy Exhaust Connection to isolate the from extremes in exhaust flow. The pre-existing exhaust system should have a minimum flow capacity of 200 liters per minute and be compatible with exposure to salt aerosol. Connecting Interface Ports All units come equipped with standard Interface Ports. USB Port Provides serial data acquisition capability. Port connection requirements are 9600, N, 8, 1 (9600 baud, Non-parity, 8 bits & 1 stop bit). Drivers can be downloaded from The device name is FT232R. For the driver installation, follow the instructions for your operating system at htm. PLC Control Port 7-pin circular connector with bayonet lock provides the ability to install remote status indicators (see Figure 5-1: PLC Control Port Pin Description for the pin description). The outputs are an open collector type capable of sinking 50 ma for a non-inductive load (see Figure 5-2: Connection Circuit Example for a 35

46 sample connection circuit). The mating connector is manufactured by Hirose Electric Co Ltd (Part Number RM12BPE-7PH(71) ). External Start Used to start an instantaneous test Ready Indicates that the unit is ready to start a new test Pass Indicates a passed test Fail Indicates a failed test Fault Indicates a non calibrated state for the system when coupled with the Cal Mode status indicator or a fault. Cal Mode Indicates when a calibration routine is taking place. Figure 5-1: PLC Control Port Pin Description Pin Description: 1 External Start 2 - Ground 3 - Ready 4 Fault 5 - Fail 6 - Pass 7 Cal Mode Figure 5-2: Connection Circuit Example Status Line 3-7 R = 470Ω +24V GND Power Supply 2 Accessories Power Port 4-pin circular connector with bayonet lock provides a dedicated 24VDC power supply for ATI designed accessories such as the Local Exhaust Module. 36

47 i Note Port Usage equipment might result from such action Do not use the accessories power port with equipment other than those designed and supplied by ATI. Damage to the Accessories Data Port RJ-45 Connection provides a communication interface for ATI designed accessories. Installing the Generator The Aerosol Generator is designed to hold 1 liter of pre-mixed 4% sodium chloride solution. Place the Aerosol Generator to the left of the Test Fixture in the space provided. Attach the tube fittings to their colorcoded matching ports. Firmly push the reinforced aerosol sample line onto the large outlet port located in the Aerosol Generator lid to the left of the submerged liquid nozzle retention fitting. Refer to Refilling and reassembling the generator page 103 for a detailed procedure. 37

48 CHAPTER 6 Operating the : Basic Operation Before You Begin 1) Inspect the power inlet module fuse block and verify that the correct input voltage is selected. Attached the supplied power cord and connect to an appropriately rated electrical outlet. 10 Amps or 5 Amps. 2) Connect the compressed air source to the swivel fitting located at the rear of the instrument using an appropriate adapter coupling. 3) Check aerosol generator solution level. Remove the top of the Aerosol Generator if necessary and fill with 1 liter of pre-mixed 4% sodium chloride solution. Replace the generator top and attach the lines to their respective fittings. 4) Remove the cap from the Replenishment Reservoir and fill with pre-mixed 0.9% sodium chloride solution. Replace the cap, fully insert the feed line into the cap mounted quick-connect fitting and place the Replenishment Reservoir in its recess with the cap/fitting towards the top. 5) Enable operational power by switching the power entry module to the ON position. Automated Filter Tester Controls The ON and OFF controls for the are located at the lower-right side of the Touch Screen bezel. The green, right-most, button acts as the ON control, while the adjacent, red, button turns the unit OFF. In this configuration the does not incorporate an Emergency Stop control. Design considerations were implemented to eliminate the potential for personnel or product damage that would necessitate the incorporation of this feature. 38

49 Pressure regulators and other adjustments for the successful operation of the are either Factory set or may be adjusted during maintenance. Test fixture operation, closing and opening, is controlled by two (2) electro-optical actuators located on the front outside corners of the unit. Placing a finger in each actuator simultaneously at the display prompt will close the test fixture. A test may be interrupted by insertion of a finger into either actuator. Note Two Hands Anti Tie-Down The two actuators are identified by the following symbol located on the front of the machine below the actuators. The symbol depicts a hand with the index extended inserted into the actuator. i The actuators are physically located so that the operator must use both hands to operate both buttons. The operator must operate both buttons by placing a finger in each actuator simultaneously (within 500 milliseconds) to start the chuck cycle, and hold them both until the chuck has reach the "safe point" (closure within 1/8 ) --i.e. where the operator cannot physically get his hand(s) into the chuck. He then may release the buttons and the cycle will complete. All other controls used in the daily operation of the are based on the graphical touch screen interface. 39

50 Basic Operation Figure 6-1: Basic Operation of the Automated Filter Tester Step 1 Power On Step 2 Initializing Sensors Step 3 Check Liquid Level Prompt Step 4 Warm-up Period Wait for Warm-up to complete Bypass Step 5 Selecting Operator Step 6 Gravimetric Test Start Perform a Gravimetric Test Cancel Step 7 LSC Calibration Cancel Begin Perform LSC Calibration Step 8 Penetration Calibration Begin Perform Penetration Calibration Step 9 Ready Step 10 Performing a Test It is recommended that all routines presented to the operator be completed in the order they appear to 40

51 ensure reliable unit operation. Completion of these routines will provide a daily confirmation of the operational state of the Salt Aerosol Automated Filter Tester. The Start Up steps are common to all testing performed on the Salt Aerosol Automated Filter Tester. Steps four (4) through eight (8) are intended to be completed in sequence to reach a stable operational test state. Step 1. Power On Press the GREEN button located at the lower right of the touch screen bezel. Step 2. Initializing Sensors When the unit is powered on, it undergoes an initialization cycle during which it polls the system for available sensors and verifies communication with those sensors. This process takes only a few seconds to complete. If a sensor fails to initialize, the operator is presented with the option to retry or enter the maintenance menu. To retry, press the Retry button. If the retry is not successful at initializing all the sensors, it is recommended to enter the maintenance menu by pressing the Maintenance button. i Note The maintenance menu is password protected to prevent access to untrained operators. See New Operator page 89 for more details on access restriction within the software. Step 3. Check Liquid Level Prompt Press Continue button to proceed after verification that the liquid level in the main aerosol generator and replenishment reservoirs are adequate. 41

52 i Note Other information available on the screen is the unit serial number, software revision, machine identification number and the total operating hours. Step 4. Warm-up Period This period is provided to allow stabilization of the aerosol generator and system temperatures. A Bypass button is available to skip this portion of the start-up sequence if desired, though this is not recommended. A progress bar is displayed to indicate remaining warm-up interval. During this warm up interval the following states will occur. a. System compressed air solenoid will open. b. Dilution air heater will begin heating up. c. Aerosol generator will begin production of aerosol. Step 5. Selecting Operator After the initial warm-up period the unit will automatically proceed to the Security screen. The user is prompted to select an operator from the menu. Once an operator is selected, the user will be prompted for the password. To know more about password protection, refer to Security page 85 and New Operator page 89. Step 6. Gravimetric Test After the initial warm-up period the unit will automatically proceed to the Gravimetric Test menu screen. a. Set Test Flow (lpm): Select the desired test flow by pressing the Change button. This will allow user selection of the test flow to be used during the gravimetric test. Acceptable flow values are limited to between 0 and 100 lpm. In most applications the test flow selected for the 42

53 gravimetric test will be the same as the operating test flow. b. Set Test Duration (sec): Select the desired duration of the gravimetric test by pressing the Change button. Enter the total time allocated for the gravimetric test routine. The recommended default is the Industry Standard of 600 seconds. The acceptable input range is 1 to 1000 seconds. c. Enter the initial filter mass (g): Input the starting weight of the filter sample in use while performing the gravimetric test routine by pressing the Change button. The acceptable input range is to 100 grams. d. Press Start Accepts the value(s) entered above and enters the Gravimetric Test routine. Performing a Gravimetric Test e. Place the weighed gravimetric test sample into an appropriate holder and place the holder on the lower test fixture. f. Close the Test Fixture by placing a finger into each of the electro-optical actuators when the message Close chuck to proceed is displayed. The screen will indicate a Busy state. A progress bar indicating the percentage of test time remaining will also be shown along with the average test flow during testing. g. Final Filter Mass (g): At the end of the gravimetric test interval enter the filter sample weight in the Final Filter Mass field by pressing the Change button. This value is used for determining the amount of material deposited during the gravimetric test routine. The acceptable input range is to 100 grams. h. The new aerosol concentration in µg/l will be displayed. i. Press the Accept button This action stores the concentration value to memory and proceeds to the LSC Calibration routine. Step 7. LSC Calibration This routine is used to set the LSC sensitivity to achieve a 100% response from the available aerosol concentration. 43

54 a. Accept or Change Test Flow (lpm): The test flow setting currently being maintained by the mass flow controller is displayed. Selecting the Change button will allow user selection of the test flow to be used during the gravimetric test. Acceptable flow values are limited to between 0 and 100 lpm. In most application the test flow selected for the gravimetric test will be the same as the operating test flow. b. Press Begin. c. Close the Test Fixture by placing a finger into each of the electro-optical actuator when Close chuck to proceed is displayed. d. After completion of the sensitivity setting routine two fields will change. An additional field will be displayed indicating previous LSC sensitivity carried over from the Current LSC sensitivity field on the previous screen and the Current LSC sensitivity will update to reflect the new value just obtained through testing. e. Press Accept at the conclusion to store the new LSC Sensitivity value to memory and proceeds to Penetration Calibration routine. Step 8. Penetration Calibration This routine adjusts the upper limit of the LSC response, 100%, to the available aerosol concentration as well as the zero base-line achieved while sampling particle free air. a. Accept or change test flow: The test flow setting currently being maintained by the mass flow controller is displayed. Selecting the Change button will allow user selection of the test flow to be used during the gravimetric test. Acceptable flow values are limited to between 0 and 100 lpm. The test flow selected for the penetration calibration must be the same as the operating test flow. b. Press Begin. c. Close the Test Fixture by placing a finger into each of the electro-optical actuators when Close chuck to proceed is displayed. 44

55 d. Press Continue at the conclusion to proceed to the Ready menu. Step 9. Ready The Ready menu screen is the main display from which all of the functions may be accessed. The default Test Mode upon initial entry into this menu is Filter Test. If this is acceptable, placing a sample within and closing the test fixture by placing a finger into each of the electro-optical actuators will start a test cycle and enter the Filter Testing menu display. Other Test Modes are available such as Load Test (see Test Modes page 46 for a description of each Test Mode). To choose an alternate Test Mode, refer to. Test Mode Menu: Detailed Screens Description page 57. Step 10. Performing a Test The Filter Test routine provides a single point or user defined test interval. This type of test will continue until the defined test interval has expired, an alarm parameter value has been exceeded or a user interrupt command is received. % Penetration, Resistance and Test flow are displayed throughout the test interval. If multiple tests are performed, the preceding three (3) tests are displayed at the bottom left of the display for reference. a. Place the sample to be tested in the test fixture. b. Close the Test Fixture by placing a finger into each of the electro-optical actuators. c. Testing will continue until the test interval selected has expired, an alarm parameter value has been exceeded or a user interrupt command is received. d. Complete. 45

56 Test Modes Filter Test The Filter Test routine provides a single point or user defined test interval. This type of test will continue until the defined test interval has expired, an alarm parameter value has been exceeded or a user interrupt command is received. % Penetration, Resistance and Test flow are displayed throughout the test interval. If multiple tests are performed, the preceding three (3) tests are displayed at the bottom left of the display for reference. a. Place the sample to be tested in the test fixture. b. Close the Test Fixture by placing a finger into each of the electro-optical actuators. c. Testing will continue until the test interval selected has expired, an alarm parameter value has been exceeded or a user interrupt command is received. d. Complete. Gravimetric Test The Gravimetric Test routine provides the ability to verify and update the aerosol concentration output of the generator. i Note It is recommended to perform this operation when the machine is first turned on at the beginning of the work day but also prior to a load test to ensure the most accurate test results. At the end of the test, the user has the opportunity to accept the new results or reject them and keep the previous value. We recommend that the new value be accepted as it is the most representative concentration put out by the generator. a. Select GRAVIMETRIC TEST from the Test Mode menu. b. Accept or change test flow - The test flow setting currently being maintained by the mass flow controller is displayed. Selecting the Change 46

57 button will allow user selection of the test flow to be used during the gravimetric test. Set the test flow that will be used to perform the test. We recommend a test flow of 85 lpm. c. Accept or change test duration - The default test duration setting is displayed. Selecting the Change button will allow user selection of the test duration to be used during the gravimetric test. i Note We recommend the Industry Standard of 600 seconds for accurate gravimetric results. d. Weigh the media used to perform the gravimetric test and place the media in the test fixture. e. Enter the initial mass of the test media by pressing the Change button. f. Press the Start button. g. Close the Test Fixture by placing a finger into each of the electro-optical actuators. h. Testing will continue until the test interval selected has expired. i. When the test has completed, remove the filter media from the test fixture and weigh it. j. Enter the final mass of the filter media in the software by pressing the Change button and the concentration value will be calculated. k. Accept the new value. Load Test Load Testing provides an evaluation of the filter to determine the effect particle accumulation has on flow resistance and particulate penetration during a predefined aerosol exposure-based test interval. Testing will continue until the pre-defined weight of aerosol particulate exposure has been achieved. Media performance characteristics for all measured data are graphically displayed continuously throughout the test interval. a. Select LOAD TEST from the Test Mode menu. b. Perform a Gravimetric Test (see Gravimetric Test page 46 for the detailed procedure). 47

58 c. Accept or change test flow - The test flow setting currently being maintained by the mass flow controller is displayed. Selecting the Change button will allow user selection of the test flow to be used during the load test. Acceptable flow values are limited to between 0 and 100 lpm. In most application the test flow selected for the gravimetric test will be the same as the operating test flow. d. Input the Target Load Mass in milligrams (mg). e. Choose whether or not you want to terminate the test after the peak penetration has been reached. If you choose this option, the test will be interrupted after the peak penetration has been reached and the filter will not be loaded with your target load mass. f. Place the sample to be tested in the test fixture. g. Select Begin. h. Close the Test Fixture by placing a finger into each of the electro-optical actuators. i. After the test duration has elapsed the test is complete. EN143 Test The EN143 Testing enables the user to automatically perform a test following the EN143 standard. It will load the filter with aerosol for a period of 3 minutes and then average the penetration measurements over a period of 30 seconds. a. Select EN143 TEST from the Test Mode menu. b. Place the sample to be tested in the test fixture. c. Select Begin. d. Close the Test Fixture by placing a finger into each of the electro-optical actuators. e. After the test duration has elapsed the test is complete. 48

59 49

60 CHAPTER 7 Software Reference This section describes the software supplied with the Salt Aerosol Automated Filter Tester. It includes the following sections: A general description of the Software and User Interface Hardware Instructions for making selections or typing Entries An overview of the menus and options Detailed reviews of all the functions and screens A list of error messages Refer to CHAPTER 6 Operating the : Basic Operation for a description of the basic procedure to be followed to perform a filter test. Software Description The Salt Aerosol Automated Filter Tester uses a software program contained in a Flash memory mounted on a custom PCBA (Printed Circuit Board Assembly) board. The software controls all aspects of the filter test, including reading the forward light scattering photometer, pressure transducers, controlling the test fixture, turning on and directing the aerosol flow, and outputting test data on the touch screen display. Touch Screen Display The uses a 14.5 cm (5.7 in) touch screen display as the main user interface for input and output of data. Touch screen usage is intuitive by nature and requires minimal, if any, operator training. Simply use a stylus or finger to touch the button representing the desired action. Software Version The software version as well as other useful information is displayed during the machine 50

61 initialization. The message block located in the bottom left corner of the touch screen is similar to the following: Serial No: # Software Version: #. ## Machine ID: # Hours: # i Note The Serial Number is a Factory set value. The standard version software will have a numeric character as the leading number followed by a decimal point and one or more numbers, representing the revision level (e.g., 1.2 or 1.21). The value for Machine ID is user settable and accessed through the Machine Set Up Menu ( Changing the Machine ID page 82). Hours indicates how much run time the machine has. Making Entries Entering Numerical Values The operator need to press the Change button associated with the numerical value he wants to change. Pressing that button will prompt the user to enter a value via a numerical keypad. The entry can be made by pressing the desired numbers as one would do on a calculator. 51

62 Figure 7-1: Numerical Keypad /- The function keys are: Backspace: to delete the last typed digit Enter: To validate your entry. Reset: To revert to the default value. Cancel: To cancel entry and return to the previous menu Turning Options Flags On or Off There are two types of flags in the software. The first type is used to toggle an action (ON or OFF) or change the status of an option (enable/disable) while the second type is used to set the status of a flag from a list of possible choices. The first type is a square box (also called check box) and is used to toggle an action ON or OFF. Changing the state is accomplished by pressing on the square. Depending on the context, the check box status might not be saved in memory and exiting the screen will reset it to its normal operating state. A filled square is 52

63 indicates a selection (or ON state) while the empty square shows the option deselected (or OFF state). The second type of flag is a circle (also called radio button) and is used to enable or disable a flag and the resulting choice is stored in memory. When this option is present, only one of the radio buttons within the group can be selected. It is used when multiple choices are available but only one choice can be made. General Screen Structure The screen is generally divided in two sections: The top section of the screen provides the user with an indication of its location within the menu structure along with the function currently being performed or the machine status depending on the function. The bottom section contains the actual function being performed. Figure 7-2: Screen Structure TOP SECTION BOTTOM SECTION 53

64 Test Fixture Latching Indicator When a function calls for the test fixture to be closed, the software will display a graphical representation of the test fixture position. This graphical representation informs the operator when the Test Fixture is closed and it is safe to remove its fingers from the actuators. Close Chuck Chuck Closing Chuck Closed Waiting for actuation Test Fixture Moving Test Fixture Closed Releasing the fingers from the anti tie-down actuators before the Chuck Close graphic is displayed will result in the operation being aborted. 54

65 Menu Structure and Options Menu Structure The following figure gives an overview of the menu structure. Menu depth has been limited to facilitate the navigation between the different options. Grayed out options are password protected to prevent changes from untrained operators. To know more about password protection, refer to Security page 85 and New Operator page 89. Figure 7-3: Overview of the Menu Structure Filter Test Test Mode Load Test EN143 Test Pencal Main Menu Setup Test Setup Alarm Settings Maintenance Diagnostic Machine Setup Standby Shutdown 55

66 Top Level Menu Options Figure 7-4: Top Level Menu Screenshot Main Menu Operator: SERVICE Wed 08:30:00 Sep 16, 2009 Test Mode Mode: Filter Test Close chuck to begin test Pen Cal Test Setup Maintenance Standby New Operator Shutdown Table 7-1: Top Level Menu Options Option Purpose Test Mode Displays selection menu for the available operating test modes, Filter and Load, of the. Highlight the desired test mode and press Select or press Cancel to close the selection menu and return to the Ready menu. Pencal Opens the Penetration Calibration menu to establish the LSC aerosol response. Setup Enters a Tabbed menu allowing operator access to Test Setup values and Alarm Settings. Maintenance Provides diagnostic and machine adjustment, service & calibration capabilities. Standby Places the unit in a wait state with the aerosol generator turned off. Exiting Standby mode after extended periods initiates a Warm-up interval and prompting for a gravimetric test prior to a return to operational state. Shutdown Powers the unit off. 56

67 Test Mode Menu: Detailed Screens Description Menu Options To access the Test Mode Menu, press the Test Mode button. Figure 7-5: Test Mode Menu Screenshot Main Screen Operator: SERVICE 2009/12/01 08:30:00 Test Mode Pen Cal Test Setup Filter Test Load Test EN143 Test Mode: Filter Test Close chuck to begin test Maintenance SELECT CANCEL Standby New Operator Shutdown Table 7-2: Test Mode Menu Options Option Purpose Filter Test Instantaneous or user defined test interval. This type of test will continue until the defined test interval has expired, an alarm parameter value has been exceeded or a user interrupt command is received. % Penetration, Resistance and Test flow are displayed immediately. The preceding three (3) tests are displayed at the bottom left of the display for reference purposes. Load Test A Load Test provides an evaluation of the filter to determine the effect particle accumulation has on flow resistance and particulate penetration during a pre-defined aerosol exposure-based test interval. Testing will continue until the pre-defined weight of aerosol particulate exposure has been achieved. Media performance characteristics for all measured data are graphically displayed continuously throughout the test interval. 57

68 Option EN143 Test Purpose Automatically performs the EN143 post load test testing. This test will load the filter with aerosol for 3 minutes and then average the penetration readings over a period of 30 seconds. Filter Test The Filter Test routine provides a single point or user defined test interval. This type of test will continue until the defined test interval has expired, an alarm parameter value has been exceeded or a user interrupt command is received. % Penetration, Resistance and Test flow are displayed throughout the test interval. If multiple tests are performed, the preceding three (3) tests are displayed at the bottom left of the display for reference (see Figure 7-6: Filter Test Screenshot). Figure 7-6: Filter Test Screenshot Filter Test Busy 2009/12/01 08:30:00 Filter Testing Penetration (%) Resistance (mmh20) Test Flow (lpm) 85.0 Insert Filter and Close Chuck Prior Test Results Count Time Pen Res Flow 1 08:29: :29: :29: Exit Testing a. Place the sample to be tested in the test fixture. b. Close the Test Fixture by placing a finger into each of the electro-optical actuators. c. Testing will continue until the test interval selected has expired, an alarm parameter value has been 58

69 exceeded or a user interrupt command is received. d. Complete. If one of the measured parameters exceeds its corresponding alarm threshold and the alarm is enabled (see Alarm Settings Options page 68), the parameter background will become red to provide a visual indicator for the alarm. 59

70 Load Test The Load Test routine provides the user with a defined test interval based on the desired mass of aerosol to be deposited on the filter face. This type of test will continue until the defined test interval has expired or a user interrupt command is received (see Figure 7-8: Load Test Options Screenshot and Table 7-5: Load Test Parameters). Prior to the start of a test, the operator will be presented with the opportunity to run a gravimetric test in order to have the latest concentration measurement. We recommend not skipping this option. Gravimetric Test The Gravimetric Test routine provides a user defined test interval. This type of test will continue until the defined test interval has expired or a user interrupt command is received. It is primarily used to verify the concentration of the aerosol produced by the generator (see Figure 7-7: Gravimetric Test Parameters Screenshot). Figure 7-7: Gravimetric Test Parameters Screenshot Load Test Gravimetric Test 2009/12/01 08:30:00 Aerosol Concentration (µg/l) 40.0 Test Flow (lpm) Test Duration (sec) Initial Filter Mass (g) Change Change Enable Start Cancel The different parameters for pre and post gravimetric test are explained in Table 7-3: Gravimetric Test 60

71 Parameters and Table 7-4: Post Gravimetric Test Parameters. Table 7-3: Gravimetric Test Parameters Option Aerosol Concentration (ug/l) Test Flow (lpm) Test Duration (sec) Initial Filter Mass (g) Start Cancel Purpose This is the concentration value established after completion of the previous gravimetric test cycle and stored in unit operating memory. This value can only be changed by successful completion of the gravimetric test routine. Flow setting currently being maintained by the mass flow controller. Selecting the Change button will allow user selection of the test flow to be used during the gravimetric test. Acceptable flow values are limited to between 0 and 100 lpm. In most applications the test flow selected for the gravimetric test will be the same as the operating test flow. Total time allocated for completion of the gravimetric test routine. Sufficient time must be allowed to ensure that the quantity of any deposited material is large enough to accurately determine the aerosol concentration. As a general rule of thumb the minimum amount of deposit material necessary is grams. The recommended default is 600 seconds. The acceptable input range is 1 to 1000 seconds. Selecting the Change button will allow the user to change the gravimetric test duration. User input field for the starting weight of the filter sample used while performing the gravimetric test routine. This value is used as the base line for determining the amount of material deposited during the gravimetric test routine. The acceptable input range is to 100 grams. Accepts the values entered for the above parameters and enters Gravimetric Test routine. Skips the gravimetric test routine and uses the Aerosol Concentration value stored in memory. 61

72 Post Gravimetric Test Parameters Table 7-4: Post Gravimetric Test Parameters Option Aerosol Concentration (µg/l) Test Aerosol Flow (l) Test Duration (sec) Initial Filter Mass (g) Final Filter Mass (g) New Concentration µg/l Accept Cancel Purpose This is the concentration value established after completion of the previous gravimetric test cycle and stored in unit operating memory. This value can only be changed by successful completion of the gravimetric test routine. This value is the cumulative volume of test flow that has passed through the filter sample during the gravimetric test routine. Total elapsed time of the gravimetric test routine. Displays the filter sample weight input from the gravimetric test set up screen. User input field for the ending weight of the filter sample used while performing the gravimetric test routine. This value is used for determining the amount of material deposited during the gravimetric test routine. The acceptable input range is to 100 grams. Aerosol concentration value auto-calculated using the set up, gathered gravimetric test data and user entered final filter mass information. Stores the concentration value to memory and proceeds to the LSC Calibration Test routine. Leaves the gravimetric test routine without storing values to memory & proceeds to LSC Calibration Test using previously stored concentration memory values. 62

73 Following the gravimetric test, the software will proceed to the load test routine. Figure 7-8: Load Test Options Screenshot Load Test Test Setup 2009/12/01 08:30:00 Aerosol Concentration (µg/l) 41.6 Test Flow (lpm) Target Load Mass (mg) Change Terminate test after peak penetration Test Duration (min:sec) 80:02 Begin Cancel Table 7-5: Load Test Parameters Option Aerosol Concentration (ug/l) Test Flow (lpm) Target Load Mass (mg) Terminate test Test Duration (min: sec) Purpose This is the concentration value established after completion of the previous gravimetric test cycle and stored in unit operating memory. This value can only be changed by successful completion of the gravimetric test routine. Flow setting currently being maintained by the mass flow controller. The test flow used by the instrument for the Load Test can be set in the Test Setup Options page 66 Total amount of aerosol exposure that is required for completion of the Load Test interval. This option when selected will terminate the test 5 minutes after the peak penetration has been reached. Total calculated elapsed time necessary to achieve the desired aerosol exposure based on the Target Load Mass, Test Flow and Aerosol concentration values. 63

74 Pressing the Begin button will prompt the user to close the chuck in order to start the test cycle. After the test is started, % Penetration, Resistance and Accumulated Mass are displayed throughout the test interval on a graph for an overall view of the filter performance (Figure 7-9: Load Test Screenshot). Individual data points are output on the USB port for data collection at 5 seconds intervals. Upon completion of the load test, the maximum penetration value and corresponding resistance are displayed and output: Load Test (T,M,P,R,F), 5, 0.27, , 7.3, 85.2 Load Test (T,M,P,R,F), 10, 0.54, , 7.4, 85.0 Load Test (T,M,P,R,F), 15, 0.81, , 7.4, 85.1 Load Test (T,M,P,R,F), 20, 1.08, , 7.3, 84.9 Load Test (T,M,P,R,F), 25, 1.35, , 7.2, 84.9 Load Test (T,M,P,R,F), 30, 1.63, , 7.4, 85.2 [ ] Load Test (T,M,P,R,F),3670,198.81, , 30.4, 85.2 Load Test (T,M,P,R,F),3675,199.08, , 30.1, 85.1 Load Test (T,M,P,R,F),3680,199.35, , 30.2, 84.9 Load Test (T,M,P,R,F),3685,199.62, , 30.4, 85.0 Load Test (T,M,P,R,F),3690,199.89, , 30.6, 84.9 Load Test Max Penetration = with resistance = 9.8 Figure 7-9: Load Test Screenshot Load Test Busy 2009/12/01 08:30:00 Accumulated Mass (mg) Penetration(%) Resistance (mmh20) Cancel 64

75 Penetration Calibration (Pen Cal): Detailed Screen Description The only option available during Pen Cal is the ability to change the test flow. Selecting the Change Flow button will allow user selection of the test flow to be used during all future operation until changed. Acceptable flow values are limited between 0 and 100 lpm. The test flow chosen should be the same as the test flow to be used in operational testing. Selecting the Begin button Prompts with Close chuck to proceed and enters the Penetration Calibration routine. Close the Test Fixture by placing a finger into each of the electro-optical actuators. Prompts will be displayed updating the progression throughout the routine. A Calibration Complete statement will be displayed at the successful completion of the routine as well as a Continue button. Select Continue to proceed to the Ready menu. Pressing the Cancel button will exit the Penetration Calibration menu and return the operator to the Ready menu Figure 7-10: Penetration Calibration Screenshot Penetration Calibration 2009/12/01 08:30:00 Test Flow (lpm) 85.0 Change Begin Cancel 65

76 Setup Menu: Detailed Screens Description Table 7-6: Setup Menu Options Option Test Setup Alarms Settings Setup Menu Options To access the Setup Menu Options, press the Setup button on the main menu screen. The operator is presented with a screen featuring two tabs: Test Setup and Alarm Settings Purpose This option allows the operator to enter the test parameters to be used for the Filter Test option. It allows setting the test flow, the timing of the different parts of the test (load, sample and extended load) and the number of test cycles before a calibration is forced by the machine. A number of alarm flags can be set by the operator to monitor test results while in the Filter Test option. Alarms include upper and lower limits. The parameters that can be monitored are penetration, resistance, concentration and a flow tolerance. Test Setup Options Figure 7-11: Test Setup Options Screenshot Test Settings 2009/12/01 08:30:00 Test Setup Alarm Settings Exit Test Flow 42.5 lpm Change Load Time 8.0 sec Change Extended Load Time 12.0 sec Change Sample Time 2.0 sec Change Open Time 1.0 sec Change Cycles till Calibration 1000 Change 66

77 Table 7-7: Test Setup Options List Parameter Function Limits Test Flow Set the flow for the Filter Test 0.0 to lpm Load Time Time period that allows 1.0 to 60.0 stabilization of challenge seconds in aerosol and LSC 1/10 th response prior to test increments evaluation for pass/fail Can be state. disabled Extended Load Time Sample Time Same functionality as Load, but this value is used immediately following a failing test or Penetration Calibration providing extra time for recovery from high levels of aerosol in the sampling stream. This value must be greater than the value used for Load. Period during which the sample under test is evaluated for % penetration, differential resistance and sample flow. An active alarm exceeding any of the measured parameters immediately halts the test and results in a Fail response. Open Time Minimum time period during which the test fixture must remain open before another test can be started. Cycles till Calibration Number of test cycles between two forced Penetration Calibration. Load Time to 100 seconds in 1/10 th increments 1.0 to seconds in 1/10 th increments Can be disabled 0.0 to 60.0 seconds in 1/10 th increments 1 to 9999 Can be disabled 67

78 Alarm Settings Options Figure 7-12: Alarm Settings Options Screenshot Test Settings 2009/12/01 08:30:00 Test Setup Alarm Settings Exit Limit Setting Enb Page 2 Penetration High Limit Change Penetration Low Limit Change Resistance High Limit 25.0 Change Resistance Low Limit 15.0 Change Flow Tolerance 2.0 Change Table 7-8: Alarm Settings Options List Option Function Limits Penetration High Sets the upper limit for the to Limit maximum allowable percent penetration value. Penetration Low Sets the lower limit for the to Limit minimum allowable percent penetration value. Resistance High Sets the upper limit for the 0.0 to Limit maximum allowable mmh2o resistance value. Resistance Low Sets the lower limit for the 0.0 to Limit minimum allowable mmh2o resistance value. Flow Tolerance Sets the band of 1.0 to 10.0 lpm acceptable flow tolerance. Concentration Sets the upper limit for the 0.0 to 60.0 µg per High Limit maximum allowable liter aerosol concentration value. 68

79 Option Function Limits Concentration Sets the lower limit for the Low Limit minimum allowable aerosol concentration value. Intermediate Readings Allows for test results to be sent to the USB port every second during an instantaneous test. 0.0 to 60.0 µg per liter Enabled / Disabled Maintenance Menu: Detailed Screens Description The maintenance menu is password protected. Refer to New Operator page 89 for more information on password management. To enter the Maintenance menu, press the Maintenance button on the main menu screen. Figure 7-13: Maintenance Menu Screenshot Maintenance 2009/12/01 08:30:00 Diagnostics Machine Setup Exit Sensor Current Reading More This section is defined in the following pages. See Table 7-10: Diagnostic Menu Options for the sensors and their recommended set points. More More More More 69

80 Table 7-9: Maintenance Menu Options Option Purpose Reference Diagnostic The diagnostic menu is a Diagnostic powerful tool intended for easy troubleshooting and calibration of the machine. It gives the operator access to the low level functions of the machine, the ability to see Options page 70, Table 7-10: Diagnostic Menu transducers voltages, system Options pressures and control of each individual valve. It also gives access to the scattering chamber diagnostic tools. Machine Setup If selected, this option allows an authorized user to change the machine ID, set the time and date, modify the differential pressure unit of measurement, enable or disable the console mode, transmit the system variables to the USB port and enable or disable the security feature. Machine Setup Parameters page 82 Diagnostic Options There are seven (7) screens under the Diagnostic tab accessible by pressing or. Continuously pressing on the same arrow will allow you to access all the screens. At any time the operator can go back to the previous screen by pressing on the arrow opposite the direction he was flipping the screens. For the purpose of this reference guide, we will use the right pointing arrow to move from screen to screen. Table 7-10: Diagnostic Menu Options on page 81 provides a summary of all the options described in the following pages. The default screen in the diagnostic menu is shown below. It allows the operator to diagnose and adjust the settings related to the scattering chamber. 70

81 Figure 7-14: Diagnostic Menu Default Screen Maintenance 2009/12/01 08:30:00 Diagnostics Machine Setup Exit Sensor Current Reading Gravimetric Test (µg/l) LSC Diagnostics LSC Calibration More More More Gravimetric Test Pressing on the More button for the Gravimetric Test option will open a window allowing the operator to perform a new gravimetric test. (See Gravimetric Test page 46 for details on how to perform a gravimetric test). LSC Diagnostics Pressing on the More button for the LSC Diagnostics option will open a pop up window (Figure 7-15: LSC Diagnostic Screenshot). This window gives the operator temporary control over the LSC gain and allow him to toggle the Sample/Clear valve on or off. To enter the function, the operator must close the chuck when prompted. To change the gain of the LSC, turn the rotary wheel by pressing on the touch screen. Going in a clockwise movement will increase the gain while going counterclockwise will decrease it. To toggle the Sample/Clear valve, press on the Sample button. To close the test fixture, insert a finger in each of the electro-optical actuators. 71

82 To return to the main diagnostic menu, press the EXIT button. Figure 7-15: LSC Diagnostic Screenshot LSC DIAGNOSTICS LSC Voltage: LSC DAC Value: V 59 Sample EXIT LSC Calibration Pressing on the More button for the LSC Calibration option will open a new screen (Figure 7-16: LSC Calibration Options Screenshot) allowing the operator to perform a new LSC Calibration test. The LSC calibration screen displays the last aerosol concentration accepted during the gravimetric test just completed or most recent tests if the Cancel option was selected from the Gravimetric Test menu. The flow setting currently being maintained by the mass flow controller is also displayed. Selecting the Change button will allow user selection of the test flow to be used during the gravimetric test. Acceptable flow values are limited to between 0 and 100 lpm. In most application the test flow selected for the gravimetric test will be the same as the operating test flow. The current digital gain value stored in memory for the photomultiplier tube high voltage control (LSC sensitivity) is also displayed. This value is controlled and adjusted through successful completion of the gravimetric test routine. 72

83 Pressing the Begin button will prompt the operator with Close chuck to proceed and enters the next LSC Calibration Test menu. Close the Test Fixture by placing a finger into each of the electro-optical actuators. Pressing the Cancel button will exit the LSC Calibration Test. Figure 7-16: LSC Calibration Options Screenshot Maintenance LSC Calibration 2009/12/01 08:30:00 Aerosol Concentration (ug/l) 40.0 Test Flow (lpm) Current LSC Sensitivity Change Begin Cancel 73

84 Pressure Sensors & Flow Controller The next three pages display the value of the different pressure sensors and the flow controller. Figure 7-17: Pressure Transducers Options Screenshot Maintenance 2009/12/01 08:30:00 Diagnostics Machine Setup Exit Sensor Current Reading Air Dryer Pressure Main Air Pressure Vacuum Pump Pressure Ionizer Pressure Chuck Differential 65.3 PSI 74.5 PSI 60.1 PSI 1.0 PSI 1.5 mmh2o More More More More More Pressing the More button associated to any of the pressure sensor will initiate a new screen (Figure 7-18: Pressure Transducers Pop up Screen Screenshot) containing additional information. The operator will have access to the real time voltage from that particular sensor, the calculated pressure as well as the date of last calibration for that sensor. Note that for the Dilution Air option, a Calculated Flow field is present in the additional information pop up screen. This field gives the operator an approximation of the dilution air flow rate based on the differential pressure across the dilution air flow meter. The Mass Flow Controller last calibration date as well as its serial number are displayed for convenience. Pressing the More button for the Flow Sensor will initiate a screen containing more information about the Mass Flow Controller (Figure 7-19: Flow Controller Pop up Screen Screenshot). The operator can see the current flow, pressure and temperature 74

85 but also change the maximum flow of the flow meter and the measurement mode. i Note The maximum flow corresponds to the maximum range of the flow controller. The standard flow controller provided with the has a maximum flow of 120 lpm. If you have ordered a custom flow controller range, refer to the controller calibration certificate for the maximum flow. If you are unsure, contact ATI for more information. The maximum flow is by default 120 lpm but can be changed to accommodate custom ranges by pressing the Change button. The numerical value keypad will appear to allow you to type your entry. The allowable boundaries are 10 to 500 lpm. The measurement mode can be set to be in SCFM (Mass Flow) or ACFM (Volumetric Flow) depending on the customer requirements by selecting the appropriate option. Figure 7-18: Pressure Transducers Pop up Screen Screenshot Dilution Air ADC Voltage: Calculated Pressure: Last Calibration: V 0.4 PSI 0000/00/00 EXIT 75

86 Figure 7-19: Flow Controller Pop up Screen Screenshot FLOW CONTROLLER DIAGNOSTIC Flow: 42.5 Gas Absolute Pressure: 12.8 Gas Temperature: 24.6 Calibration Date: 2010/01/01 Maximum Flow 120 Measurement Mode: SLPM lpm inhg C Change ALPM EXIT 76

87 Valves The next screen displayed in the diagnostic menu is the valves options screen. This screen allows the operator to actuate each valve independently. Figure 7-20: Valves Diagnostic Options Screenshot Maintenance 2009/12/01 08:30:00 Diagnostics Machine Setup Exit Main Air Valve Valves Cylinder Up/Down Gen Nozzle Air Sample/Clear Valve Dilution Air Cylinder Clamp Purge Valve Vacuum Pump Legend: Valve On Valve Off To turn a valve on, tap on the empty square; filling in the square. To turn a valve off, tap on the filled square; emptying it. Note that the Cylinder Clamp toggle switch is unavailable until the Cylinder Up/Down valve has been actuated. This is to minimize the risk of injury to the operator.! ^ Warning Safety Features In Maintenance Mode, the two hands anti tie-down safety feature is disabled to allow for troubleshooting of the different functions. We recommend that the operator be very careful when toggling the test fixture valves in this mode to prevent serious injuries. Secure your workplace before operating in this mode to prevent unaware coworkers from getting injured. 77

88 User Status Lines This option gives the opportunity to test the status line reported by the machine. It is useful when integrating the in a production environment where the instrument is coupled to a Programmable Logic Controller (PLC) or other custom interface. Clicking on any status (Figure 7-21: User Status Lines Screenshot) will activate the corresponding output on the PLC Control Port (see Interface Ports page 32 for location). Activating the PLC command line will toggle the PENCAL SEEN or XSTART SEEN button from a blue background to a green background. Figure 7-21: User Status Lines Screenshot Maintenance 2009/12/01 08:30:00 Diagnostics Machine Setup Exit User Status Lines CalMode Fail Ready Pass Fault XSTART SEEN XSTART CLEAR XSTART SEEN XSTART CLEAR AUTO MODE User serial I/O This option allows testing of the user serial I/O port (USB port) also referred to as User Interface Port (see Interface Ports page 32 for location). The last message received on the port is displayed in the Last Input field. The user has multiple options to test the port. To select an option, click on the radio button associated with the option. 78

89 Simple Selecting this option and clicking on the Send Once button will send the following string to the User Interface Port: ATI Online Test Message This option is mainly used to test the connection to the User Interface Port. Sample Selecting this option and clicking on the Send Once button will send a set of fake data to the User Interface Port: 100,0.0003,32.1,50.1,P; This option is useful when testing an automated string parsing device. Sequence Selecting this option and clicking on the Send Once button will send a one sequentially numbered test string to the User Interface Port: ATI Online -- Test Message -- Number 1 Selecting this option and clicking on the Start button will send sequentially numbered test strings to the User Interface Port. Test strings will be sent until the Stop button is pressed: ATI Online -- Test Message -- Number 2 ATI Online -- Test Message -- Number 3 ATI Online -- Test Message -- Number 4 ATI Online -- Test Message -- Number 5 ATI Online -- Test Message -- Number 6 ATI Online -- Test Message -- Number 7 Echo The Echo option is used to test the proper operation of the miscellaneous I/O board assembly. One terminal should be connected to the debug port of the board while another terminal is connected to the User Interface Port. The Echo option will output text typed into the debug port terminal to the User Interface Port. 79

90 Typing the following in the debug terminal: W TEST will output the following string to the User Interface Port: TEST This option is used to troubleshoot connection issues with an automated data acquisition system. Figure 7-22: User Serial I/O Screenshot Maintenance 2009/12/01 08:30:00 Diagnostics Machine Setup Exit User Serial I/O Test Last Input: USB Output Mode Simple Sample Sequence Echo Send Once Start Stop Temperature Monitor Status This option gives the user diagnostic information on the temperature control system. The information displayed includes the current dilution air temperature and alarm set-point. It also displays the status of the thermocouple. Note that if the temperature exceeds the temperature limit, the instrument will automatically power off to prevent any damages to the heating system. 80

91 Table 7-10: Diagnostic Menu Options Option Function Recommended Value Gravimetric Test Performs a new N/A Gravimetric Test. LSC Diagnostics Permits access to a LSC diagnostic screen. N/A LSC Calibration Performs a new LSC N/A Air Dryer Pressure Calibration test routine. Measured pressure for the air conditioning system. Main Air Pressure Air pressure supplied to the machine. Vacuum Pump Air pressure supplied to Pressure the vacuum pump. Chuck Differential pressure Differential across the test fixture. Generator Nozzle Air pressure supplied to generator nozzle. Generator Air pressure supplied to Dilution Supply the generator air flow Cylinder Clamp Pressure Cylinder Up/Down meter. Air pressure supplied to cylinder clamp valve. Air pressure supplied to actuate the cylinder up/down movement. Stack Dilution Air Air pressure supplied to dilution air nozzle. Stack Dilution Flow meter setting for the Air stack dilution air Flow Sensor Provides information about the mass flow controller. Valves Gives temporary control over the status of each valve to the operator. User Status Lines Allows Testing of the PLC Control Port. User Serial I/O Allows testing of the Communication Port. Heater Displays heater current Temperature temperature and set-point 70 PSIG 80 PSIG 60 PSIG 0 to 150 mmh2o 51 PSIG 20 PSIG 55 PSIG 25 PSIG 14 PSIG 55 lpm N/A N/A N/A N/A N/A 81

92 Machine Setup Parameters Figure 7-23: Machine Setup Options Screenshot Maintenance 2009/12/01 08:30:00 Diagnostics Machine Setup Exit Machine ID Time & Date Pressure Units System Variables Security ATI0001 mmh2o Enabled Change Change Change Transmit Operators Result Format $S,$P,$R,$F,$?; Change Changing the Machine ID The operator needs to press on the Change button associated with the Machine ID field when changing it is desired. Pressing that button will pop up a character entry screen (Figure 7-24) where the entry can be made by typing the characters using the displayed keyboard. The number of characters is limited to 10. Changing Date and Time The operator needs to press on the Change button associated with the Date and Time field when changing it is desired. Pressing that button will pop up an entry screen (Figure 7-25) where the entry can be made by adjusting each field with the + or buttons. When the proper time and date has been set the operator must press SET to validate the setting. Pressing CANCEL will return to the previous menu without saving the changes. 82

93 Figure 7-24: Character Entry Screen Maintenance Machine ID 2009/12/01 08:30:00 ATI0001 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z -. SPACE Shift BkSpc CLEAR Cancel Enter Figure 7-25: Date and Time Entry Keypad MM DD YY Hr Min Sec SET CANCEL Changing the Pressure Units To change the units of measurement associated with the Resistance (differential pressure across the unit under test) the operator needs to press the Change button. A prompt screen will appear giving the operator the option to choose the following units: mmh2o inh2o Pa kpa 83

94 System Variables This function will output most system variables and their status to the User Interface Port. It is particularly useful when troubleshooting the machine or contacting ATI for support. Below is a sample of the output: =================================== Variables List Mar 01, :56:43 ATI Operating Hours: 1 Software Revision =================================== Console PCM DP Sensor DPB.1.1 Flow Contol Ifc FCI.1.1 LSC Interface LSC.1.03 Misc I/O MIO.1.01 Pressure Sensor 1 APB.1.1 Pressure Sensor 2 APB.1.1 Temp Monitor TMB Valve Control VCB.1.1 Pressure Settings =================================== Air Dryer Pressure: 65.2 PSI Main Air Pressure: 75.1 PSI Vacuum Pump Pressure: 61.1 PSI Stack Dilution: 20.7 PSI Generator Nozzle: 51.2 PSI Dilution Air: 1.0 PSI Dilution Flow: 62 lpm Chuck Differential: 0 mmh2o Cylinder Clamp: 49.4 PSI Cylinder Up/Down: 34.2 PSI Generator Dilution: 18.3 PSI Flow Settings =================================== Maximum Flow: 120 Measurement Mode: SLPM Alarms Settings =================================== Penetration High Limit: Disabled Penetration Low Limit: Disabled Resistance High Limit: 25.0 Disabled Resistance Low Limit: 15.0 Disabled Flow Tolerance: 2.0 Disabled Test Setup =================================== Test Flow: 85.0 Load Time: 8.0 Extended Load Time: 12.0 Sample Time: 2.0 Open Time: 1.0 Cycles till Calibration: 1000 Generator and LSC =================================== Gravimetric Test: 59.6 LSC Offset: 0 LSC Sensitivity: 79 LSC Zero(volts): =================================== 84

95 Security Pressing on the Operators button will enter the software security maintenance screens. The main security screen (Figure 7-26: Operators Maintenance Screenshot) offers multiple options such as adding a new operator, deleting an existing operator or changing pin or permissions for an existing operator. Figure 7-26: Operators Maintenance Screenshot Maintenance Operator Management 2009/09/28 08:30:00 OPER SUPER ADD NEW DELETE SET PIN ROLES EXIT Pressing the ADD NEW button will open a character entry screen (Figure 7-27: Add New Operator Screenshot) where the entry can be made by typing the characters using the displayed keyboard. The number of characters is limited to 7. Selecting an operator and pressing the DELETE button will prompt the user confirm the deletion. Pressing Yes will delete the selected operator while pressing No will cancel the action (Figure 7-28: Deleting an operator Screenshot). 85

96 Figure 7-27: Add New Operator Screenshot Maintenance Add User 2009/12/01 08:30:00 JOHN A B C D E F G H I J K L M N O P Q R S T U V W X Y Z -. SPACE Shift BkSpc CLEAR Cancel Enter Figure 7-28: Deleting an operator Screenshot Maintenance Operator Management 2009/09/28 08:30:00 PERSON1 PERSON2 PERSON3 Yes OK to delete PERSON1 No ADD NEW DELETE SET PIN ROLES EXIT To change or set the PIN for an operator, press the SET PIN button. A numerical keypad entry screen will be displayed where a new PIN can be entered (Figure 7-29: PIN Entry Screenshot). 86

97 Figure 7-29: PIN Entry Screenshot Enter Pin 2009/09/28 08:30: The last option allows the selection of the access level. There are three levels built into the software security giving access to different functions (see Table 7-11: Access Privilege for details). To change the access privileges (roles) of a given operator, select the operator in the list and press the ROLES button. The roles selection screen will be displayed (Figure 7-30: Operator Roles Screenshot). To add or remove a role, select/unselect the role by pressing on it. When done press the Save button or Cancel button to exit without saving the changes. Table 7-11: Access Privilege Table Role Operator Supervisor Service Test Mode X X X Pen Cal X X X Setup X X Maintenance X New operator X X X Standby X X X Shutdown X X X 87

98 Figure 7-30: Operator Roles Screenshot Maintenance Operator Management 2009/09/28 08:30:00 Roles for PERSON1 Operator Supervisor Service Save Cancel Result Format The operator needs to press on the Change button associated with the Result Format field when changing it is desired. Pressing that button will pop up a character entry screen (Figure 7-24) where the entry can be made by typing the characters using the displayed keyboard. The fields available for the output strings are described in Table 7-12: Fields Available for the Output String page 88. Table 7-12: Fields Available for the Output String Field Description $I Unit ID $S Sample # $P Penetration Value $R Resistance Value $F Flow Value $? Pass / Fail $D Test Date $T Test Time 88

99 New Operator i When an operation requiring added privileges must be performed, an operator with the necessary privileges must log into the software by pressing the New Operator button. He can then select himself and type in his PIN. Note When the operator with higher privileges has completed his work, it is recommended that he logs out of the software by pressing the New Operator button on the main screen and selecting the OPER user or any operator with only base access. This will prevent other operators from accessing parts of the software they are unauthorized to access. Figure 7-31: New Operator Login Select Operator OPER SUPER SERVICE SELECT Note Default Passwords The default passwords are: i Oper: 0 Super: Service:

100 Error Messages The has multiple error or abnormal operation checks built into the software. There are four errors types: Operator generated Initialization Errors LSC Error Operational Alarms Penetration Calibration Alarms Table 7-13: List of Operator Error Messages Operator Generated Errors When an error occurs, the operator is prompted for a course of action. Operator generated alarms require the operator acknowledgement to proceed. This is done by pressing the OK button. Message Reason Remedy Operator Abort The test was interrupted by inserting a finger in one of the actuator. Press OK and retry the intended action or proceed with a Chuck Abort Error One or both fingers were removed from the actuators before the test fixture was properly closed. different action Press OK and retry the intended action. Wait for the test fixture graphic to display the red line before removing your fingers from the actuator. Initialization Errors The Configuration Memory is used to store machine identification, machine operating parameters and other dynamic information required for machine operation. If either of the following errors are displayed on machine startup, the memory has been corrupted. In this situation, the configuration values will be set to factory defaults which should allow the machine to operate. However, the machine configuration should be reviewed before use. 90

101 Table 7-14: List of Initialization Error Messages Message Reason Remedy Configuration The configuration memory has been It is possible that the Memory has been set to defaults due to a failure of the memory can be lost. RTC failure. Reset to defaults memory device. recovered by powercycling the machine. If the error persists Configuration Memory has been corrupted. Reset to defaults Unable to initialize I2C - line(s) held low. Code n. Shutdown/Restart recommended The configuration memory has been set to defaults due to a mismatch in the memory check value. The intra-system communications bus is not working correctly. contact ATI Service. Review machine configuration before use. Record the reason code, n, then power off the machine, wait five seconds, then restart the machine. Table 7-15: List of LSC Error Messages LSC Error The following error is detected during the LSC calibration and/or diagnostic functions of the machine. These are LSC calibration, LSC diagnostic check, and LSC offset adjustment. Frequency: This condition is checked when entering any of three functions: Penetration Calibration, LSC Calibration and LSC Diagnostic Check. Sound: Beep for ten minutes then goes silent. It can be silenced by pressing the Silence button on the message dialog box. Reset: The Reset button on the message dialog box causes an immediate retest. Message Reason Remedy LSC LED Failure The power source for the LED in the Verify that the LED LSC is not functioning. This may be cable is properly due to a damaged LED or the LED cable being disconnected. connected. Verify the operation of the LED by looking into the LED peep hole on the LSC. 91

102 Table 7-16: List of Operational Error Messages Operational Alarms The following alarms are checked continuously while the machine is powered on. Primary Air inlet Pressure Dilution Air Temperature Flow Ambient Temperature Message Reason Remedy Primary Inlet Air This alarm signals that the inlet air Verify that the Failed pressure is less than 70 PSI compressed air line is properly secured and/or the compressor working Dilution/Nozzle Air Overtemp Flow Too Low Ambient Temp Too Low Ambient Temp Too High This alarm signals that the nozzle air temperature is greater than the allowable upper limit (60 C by default) This alarm signals that the flow reading has been less than 50% of the requested flow. This alarm signals that the ambient air temperature (as reported by the flow controller) is less than 10 C. This alarm signals that the ambient air temperature (as reported by the flow controller) is greater than 35 C. properly Turn off the machine and call ATI service immediately. Verify the aerosol lines for obstruction and clean them if necessary. Check the flow meter coalescing filter for cleanliness. Place the instrument in a controlled environment consistent with its operational requirements. Place the instrument in a controlled environment consistent with its operational requirements. Frequency: Condition checked every 5 seconds for the inlet air pressure, every 30 seconds for the other alarms. An alarm is signaled if the condition is present for two successive checks. 92

103 Sound: Beep for ten minutes then goes silent. It can be silenced by pressing the Silence button on the message dialog box. Reset: The Reset button on the message dialog box causes an immediate retest. Table 7-17: List of Penetration Calibration Error Messages Penetration Calibration Alarms The following alarms are checked during the penetration calibration process. Message Reason Remedy Concentration Too Low Concentration Too High Insufficient 100% value for LSC This alarm signals that the aerosol concentration during the PenCal 100% calibration is less than the limits set during the last gravimetric test. This alarm must be enabled on the setup screen. This alarm signals that the aerosol concentration during the PenCal 100% calibration is greater than the limits set during the last gravimetric test. This alarm must be enabled on the setup screen. This alarm signals that during the PenCal the machine encountered no LSC output or LSC output less than 60% of target. Check the generator liquid level. Check the dilution air flow rate. Clean the aerosol lines and mixing chamber. Check the generator liquid level. Check the dilution air flow rate. Check the generator liquid level. Check the dilution air flow rate. Check the LSC connections. Frequency: The condition is checked during the penetration calibration. Sound: Beep for ten minutes then goes silent. It can be silenced by pressing the Silence button on the message dialog box. Reset: The Reset button on the message dialog box terminates the penetration calibration. 93

104 CHAPTER 8 Verifying the System Performance Aerosol Mass Concentration The aerosol mass concentration of the Salt Aerosol Automated Filter Tester is determined by performing a gravimetric test similar to NIOSH NMAM Method Immediately upon start-up the will prompt for a gravimetric test. Gravimetric test capability also exists within the Maintenance menu and may be accessed at any time during operation. Verifying the Differential Pressure Sensor The pressure differential sensors used in the are verified and/or calibrated using a NIST traceable external pressure calibrator and source. Verifying Penetration Test Data The Salt Aerosol Automated Filter Tester incorporates a means for validating key system parameters. The validation procedure is designed to test many aspects of the Penetrometer, one of which is verifying the particle size, by performing filter penetration measurements using filters with a known aerosol penetration level and analyzing the results. This technique is useful for qualifying 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 ATI, the disks are accompanied by data sheets that list the expected penetration range for the specific media. 94

105 This section discusses the theory underlying the use of penetration data to verify system performance. The aerosol penetration through a filter is a function of four test parameters: aerosol size, aerosol size distribution, filter flow rate and the filter or media being tested. Aerosol penetration reaches a maximum at the most penetrating particle size and then decreases for larger and smaller particles. Penetration also typically increases with increasing filter flow rates. The effect aerosol size distribution has on aerosol penetration decreases with increasing width in the size distribution. The width of the size distribution is generally measured and referred to as the geometric standard deviation (GSD). A poly-disperse aerosol is one with a GSD greater than 1.6. In addition to verifying a consistent challenge aerosol, the filter media penetration method also ensures the Penetrometer is operating properly. This technique indirectly tests the photometer output and also verifies the pressure drop measured across the filter is within specifications. Since the photometer is the device used to measure particulate penetration, a malfunctioning photometer would be instantly identified. 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 is 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-toimplement means of ensuring proper Filter Tester operation post installation. The technique verifies not only the correct challenge aerosol but also tests the entire system as a whole. 95

106 CHAPTER 9 Application Notes Abbreviations List Table 9-1: Abbreviations List Abbreviation Meaning g Grams l Liter µ micro (1x10-6 ) m milli (1 x 10-3 ) µg/l micrograms per liter mg/m 3 milligrams per cubic meter lpm liters per minute nmam NIOSH Manual of Analytical Methods STP standard temperature and pressure MTBF mean time between failures LSC light scattering chamber 42 CFR Part 84 Standard Introduction The new standard was published in the Federal Register on June 8, 1995, in Part II of that issue. This rule addresses the National Institute for Occupational Safety and Health (NIOSH) certification requirements for respiratory protective devices. The new standard 42 CFR part 84 replaces MSHA regulations at 30 CFR part 11, while also upgrading testing requirements for particulate filters, building on more than two decades of advances in respiratory protection technology. NIOSH now has exclusive authority for testing and certification of respirators with the exception of certain mine emergency devices, which continue to be jointly certified by NIOSH and MSHA. 96

107 NIOSH now certifies three classes of filters, N- (for Not resistant to oil), R- (for Resistant to oil), and P-(for oil Proof) series, with three levels of filter efficiency, 95%, 99%, and 99.97%, in each class. The resulting nine classes of filters are summarized in Table 9-2: Filter Classes under 42 CFR part 84. Tested to a specified maximum loading level (200 mg), the N- and R-series are certified with the recognition that in some settings time-use limitations apply. In addition to possible time-use restrictions, the N-series filters should be restricted to use in those workplaces free of oil or other severely degrading aerosols. The R-series filters do not have similar aerosol-use restrictions. The P-series filters are tested with DOP, or equivalent, until no further decrease in filter efficiency is observed. The P-series filters have neither aerosol-use nor time-use limitations. As for any filter, service time will be limited by considerations of hygiene and increased breathing resistance due to filter loading. Table 9-2: Filter Classes under 42 CFR part 84 Series N R P Challenge NaCl DOP DOP Minimum efficiency Non oil aerosols* Includes oil aerosols*,** Includes oil aerosols*** 95% N95 R95 P95 99% N99 R99 P % N100 R100 P100 * May have time use restriction. ** May have a time restriction when oil aerosols are present **** Used according to manufacturers time restrictions when oil aerosols are present Test Requirements The new certification tests use the most penetrating aerosol size, 0.3 µm aerodynamic mass median diameter, of either a mildly degrading particulate, sodium chloride (NaCl), or a highly degrading oil, dioctylphthalate (DOP). The efficiency of the filter 97

108 shall be monitored and recorded throughout the test period. The N-series respirators will be tested to a maximum loading level of 200 mg NaCl per respirator. The minimum efficiency for the filters tested must be equal to or greater than the filter efficiency criterion listed above for the filter class for which approval is sought. For example, after being loaded with 200 mg of NaCl, an N95 particulate filter must demonstrate filter efficiencies greater than or equal to 95%. Prior to filter efficiency testing of N series filters, the filters shall be taken out of their packaging and placed in an environment of 85 ± 5 % relative humidity at 38 ± 2.5 C for 25 ± 1 hours. These preconditioning requirements apply only to N-series filters. This requirement is to address the effect of humidity on the filter s efficiency because the sodium chloride aerosol is less severe than DOP in reducing filter efficiency. The R-series respirators will be tested to a maximum loading of 200 mg DOP, or equivalent, per respirator. The minimum efficiency for the filters tested must be equal to or greater than the filter efficiency criterion listed above for the filter class for which approval is sought. For P-series filters, if the filter efficiency is decreasing when the 200 mg of DOP, or equivalent, challenge point is reached, the test shall be continued until there is no further decrease in efficiency. The minimum efficiency for the filters tested must be equal to or greater than the filter efficiency criterion listed above for the filter class for which approval is sought. Load Test Calculations This section will explain how the calculates the duration of a load test. All calculations are based on parameters directly measured by the machine and one input from the operator: the target sodium chloride mass to be deposited on the filter under test. 98

109 To calculate the test duration, the software uses the following equation: M 1000 t = C F Where: t = test duration in seconds M = mass of sodium chloride to be deposited in mg C = aerosol concentration in µg/l F = test flow rate in liters per minute The aerosol concentration value used in the calculation is obtained during the gravimetric test. The test flow rate is set by the operator and is maintained constant by the innovative flow controller. The mass of sodium chloride to be deposited on the filter is entered by the operator. 99

110 CHAPTER 10 Maintaining the Penetrometer Definitions and Features Day Week Month Biannual Annual 8 hours of operation 40 hours of operation 174 hours of operation 1040 hours of operation 2080 hours of operation Recommended Scheduled Maintenance 2 Daily Drain and/or Clean the Salt Aerosol Generator Fill the Replenishment Solution reservoir Clean the Filter Test Fixture Weekly Clean the Mixing Manifold Clean the Aerosol Line between the generator and Mixing Manifold Monthly Clean the Aerosol Lines Replace the Flow Meter Coalescing Filter, if necessary Inspect O-rings and Gasket in the Test Fixture Biannually Check Ion Balance using Charge Meter Check and Clean the Ionizer Needles Replace the Flow Meter Carbon/HEPA Filter Annually Replace the Compressed Air Conditioning Filters 2 Replacement parts are available from ATI. For part numbers, refer to Appendix Table G-1: Maintenance Items 100

111 Replace the Ionizer Needles, if necessary Perform Service Maintenance Refer to Service Manual Replacing the Main Power Fuses Disconnect the power cord from the machine and from electrical source. Note the generator voltage rating through the fuse holder window before starting (shown below). It will either specify 115 VAC or 230 VAC. If the generator voltage rating is 115 VAC use the 115V orientation. If the generator voltage rating is 230 VAC use the 230V orientation. Using a small flat blade screwdriver, open the fuse cover and remove the fuse holder from the power inlet module. Remove old fuses and install two new fuses with ATI part number according to Table 10-1: Replacement Fuses for the. Table 10-1: Replacement Fuses for the For 115 V ATI Part Number (5 X 20 mm, 8A, 250V, FAST BLO) For 230 V ATI Part Number (5 X 20 mm, 4A, 250 V, FAST BLO) Replace the fuse holder by gently inserting it back into the power inlet module until the tabs snap back into their original location. Close the fuse cover. Verify the correct voltage is displayed in the fuse cover window before reconnecting the power cord. Reconnect the power cord! Caution When reinserting the fuse holder in the power inlet module verify that you have selected the appropriate voltage for your location. Incorrect fuse replacement may damage internal components of the automated filter tester. 101

112 Replacing the Memory Backup Battery Power off the machine. Open the service access panel located on the right side of the machine. Locate the main control board. Using a flat blade screwdriver remove the battery from its holder. Dispose of the used battery in an appropriate manner. Insert the new battery in the battery holder, placing the positive side facing up. Close the service access panel. i Note Battery Information The battery is a 3V coin cell lithium ion battery type CR2450. Draining and/or cleaning the Salt Aerosol Generator Caution! To perform maintenance on the generator, the machine must be powered off.! Caution Only use clean and warm water when cleaning the generator. Alcohol, acetone or other chemicals may damage the generator. Removing the generator from the machine Disconnect the liquid level and refill fitting located on the side at the bottom of the generator Disconnect the liquid level fitting as well as the nozzle blue tubing) and dilution air (red tubing) fittings located at the top of the generator Disconnect the aerosol tubing from the top of the generator Unhook the Velcro strap retaining the generator and remove the generator from the machine. 102

113 Opening the generator Unscrew the two thumb screws located on the top of the generator Remove the lid from the generator Draining and cleaning the generator Wipe the nozzle and dilution air tubes using a clean lint free cloth. If salt aggregates are present on the tube, rinse with warm water until it is removed and dry with a clean lint free cloth. Empty the generator in an appropriate container Pour clean warm water in the generator to dissolve any salt aggregate that might be present. Empty the generator in an appropriate container and repeat the step using clean warm water. The generator should now be clean. Refilling and reassembling the generator To refill the generator pour one liter of 4% sodium chloride solution into the generator using the provided graduated cylinder. i Note Storage Preparing the for storage. If the generator is to be stored refer to the section Replace the generator lid and secure with the thumb screws. Refer to Figure 10-1: Aerosol Generator Exploded View page 104 for orientation Place the generator in its tray on the machine and secure with the Velcro strap. Reconnect the fittings and tubing by following step 1 in reverse order. 103

114 Figure 10-1: Aerosol Generator Exploded View Filling the Replenishment Solution Reservoir If the is powered on, place the machine in Stand-By (refer to Top Level Menu Options page 56). Disconnect the fitting from the replenishment reservoir. Remove the reservoir from the machine. Unscrew the cap and refill with a 0.9% by weight sodium chloride solution. i Note - Salinity negative affect on performance. A replenishment solution at salinity other than 0.9% by weight will affect the aerosol size and distribution and have a Replace the cap on the reservoir and return it to its proper location on the machine Reconnect the fitting. Cleaning the Test Fixture Place the machine in standby Remove the screen from the bottom half of the test fixture. 104

115 Remove the tapered insert and gasket from the bottom half of the test fixture. i Note Custom Test Fixture If your test fixture has been custom designed, refer to the cleaning procedure provided with your custom text fixture. Remove any sizeable debris from the bottom half of the test fixture using your fingers. Using a compressed air gun or a spray can of compressed air, blow away any remaining debris from the fixture. Using a wet lint free cloth, wipe the inside of the upper and lower test fixture until all debris and aggregated salt is removed. Blow dry using a compressed air gun or a spray can of compressed air. Clean and replace the gasket in the test fixture. Clean and replace the tapered insert in the test fixture. Replace the screen on the tapered insert. Cleaning the Mixing Manifold Place the machine in standby or turn it off Remove the Local Exhaust if using one. Remove the top panel using the 2.5mm hex driver. Open the maintenance access panel located on the left side of the machine. Remove the canopy connection if using one. Disconnect the aerosol tube from the mixing manifold. Remove the mixing manifold. Unscrew the drip jar from the mixing manifold. Rinse the drip jar and mixing manifold with warm water until all aggregated salt is removed. Blow dry using a compressed air gun or a spray can of compressed air. Set aside. Using the brush and a damp cloth clean the upper part of the manifold in the machine. Pay attention to the dilution air nozzle and make sure all the holes are clear of salt. 105

116 Cleaning the Aerosol Lines Blow dry using a compressed air gun or a spray can of compressed air. Screw the drip jar back on the mixing manifold. Inspect the o-ring on the upper part of the mixing manifold for integrity and reinsert the mixing manifold. Vacuum salt aggregates that might have fallen inside the machine. Reinstall the canopy connection if using one and replace the panels. Reinstall the Local Exhaust if using one. Generator Aerosol Line Place the machine in standby Disconnect the aerosol line from the top of the generator and the mixing manifold. Remove the line from the machine and rinse thoroughly with warm water until all salt aggregate has been removed. Blow dry using a compressed air gun or a spray can of compressed air. Reinstall the line in the machine. Test Fixture Aerosol Line Disconnect the line from the upper half of the test fixture. Blow inside the line using a compressed air gun or a spray can of compressed air. If you observe clogging in the line, the line should be cleaned as describe in the Service Manual. Reinstall the line by reattaching the fitting to the upper half of the test fixture. Replacing the Flow Controller Coalescing Filter i Note To order a replacement filter element refer to Appendix Table G-1: Maintenance Items. Turn the machine off. 106

117 Open the maintenance access panel located on the left side of the machine. Unscrew the filter housing by turning it counter clockwise. Remove and appropriately discard the used filter. Using a compressed air gun or a spray can of compressed air, blow away any remaining debris from the filter housing. Inspect the o-ring on the filter housing and replace if necessary. Insert the new filter in the filter housing and reinstall in the machine by turning it clockwise. Check and Clean the Ionizer Needles i Note Refer to Cleaning, Inspection or Replacing the Ionizing Needles, Page J-0 Check Ion Balance using Charge Meter i Note Refer to Verifying and Setting the Ionizer Output Balance, page K-0 Replacing the Flow Meter Carbon/HEPA Filter i Note To order a replacement filter refer to Appendix Table G-1: Maintenance Items. Turn the machine off. Open the maintenance access panel located on the left side of the machine (as if operating the instrument). Disconnect the clear tubing from the upper and lower fittings of filter. Remove and appropriately discard the used filter. Orient the new filter with the flow arrow pointing down. 107

118 Install the new filter by reinserting the filter s fittings into the clear tubing. Compressed Air Conditioning Elements Warning High Pressure Air! To perform maintenance on the compressed air conditioning elements, the machine must be turned off and the compressed air feed to the machine must be disconnected. i Note Repeat this procedure for the three pre filters. To order replacement elements refer to Appendix Table G-1: Maintenance Items. Cleaning the bowls Turn the machine off. Open the maintenance access panel located on the left side of the machine. Disconnect the compressed air feed from the machine. Push up the black lock button on the bowl, and turn the bowl 45 (Turn to the position where the marks on the body and bowl meet.). Release the lock button. Pull down (vertically) the bowl slowly until it comes off. Using a compressed air gun or a spray can of compressed air blow away any debris or liquids from the bowl. To replace the bowl, align the marks on the body with the ones on the bowl. Push up the bowl and turn it 45 until you hear the click; locking it in place. The bowl is now secured. Replacing the elements Turn the machine off. Open the maintenance access panel located on the left side of the machine. Disconnect the compressed air feed from the machine. Push up the black lock button on the bowl, and turn the bowl 45 (Turn to the position where the marks on the body and bowl meet.). 108

119 Release the lock button. Pull down (vertically) the bowl slowly until it comes off. Using a compressed air gun or a spray can of compressed air blow away any debris or liquids from the bowl. Turn the used element counterclockwise until it is disconnected from the body. Install the new element into the body by turning it clockwise. To replace the bowl, align the marks on the body with the ones on the bowl. Push up the bowl and turn it 45 until you hear the click. The bowl is now secured. Preparing the for storage Follow the following procedure if the instrument is to be stored for an extended period of time. Draining and cleaning the generator Use the procedure described page 102 Draining and/or cleaning the Salt Aerosol Generator but do not refill the generator with new solution. Cleaning the pump, refill lines and liquid level sensor Open and empty the replenishment solution reservoir in an appropriate container Pour clean warm water in the reservoir to dissolve any salt aggregate that might be present. Refill the reservoir with warm water and replace in the instrument. Power the machine on and bring the machine to the warm up state. Wait until the pump stops and the liquid has reached its operational level before powering the machine off. i Note During this procedure and this procedure only, you can ignore the check liquid level prompt and bypass it. Power the machine off. Use the provided tube adapter (labeled Adapter #1 ) and connect it to the low side of the liquid level 109

120 sensor. Insert the tube in an appropriate container such as the measuring flask. Use the provided tube adapter (labeled Adapter #2 ) and connect it between the red line and the high side of the liquid level sensor. Power the machine on and bring the machine to the warm up state. Once all liquid has been removed from the liquid level sensor, power the machine off. Repeat the cleaning procedure for the generator but do not refill the generator with new solution. Replace the generator on the machine. Empty the replenishment solution reservoir and clean it but do not refill the reservoir with new solution. Replace the reservoir in the machine. Remove the tube adapters and reconnect the lines to their proper locations. Cleaning the test fixture Use the procedure described page 104 Cleaning the Test Fixture. Cleaning the aerosol lines Use the procedure described page 106 Cleaning the Aerosol Lines. Clean the mixing manifold Use the procedure described page105 Cleaning the Mixing Manifold. 110

121 111

122 CHAPTER 11 Automatic Version Introduction The Automatic configuration is suited for 100% production QC testing. The unit is designed to integrate and act as a slave device with a customer designed automated PLC driven production line. The automated line places the product to be tested in a customer designed test fixture, signals the unit to perform a test, and captures the results. Setting Up the Automatic For general setup instructions such as connecting electrical power, compressed air line, exhaust system and accessories, refer to Setting Up The page 34. Interface Ports All Automatic units come equipped with standard Interface Ports. 112

123 USB Port Provides serial data acquisition capability. Port connection requirements are 9600, N, 8, 1 (9600 baud, Non-parity, 8 bits & 1 stop bit). Drivers can be downloaded from The device name is FT232R. For the driver installation, follow the instructions for your operating system at htm. PLC Control Port 7-pin circular connector with bayonet lock provides the ability to install remote status indicators or input lines from the PLC (see Figure 11-1: PLC Control Port Pin Description ). The outputs are an open collector type capable of sinking 50 ma for a non-inductive load (see Figure 11-2: Connection Circuit Example Status Line and Figure 11-3: Connection Circuit Example Input Line for a sample connection circuit). The mating connector is manufactured by Hirose Electric Co Ltd (Part Number RM12BPE- 7PH(71) ). External Start Used to start an instantaneous test or a routine during start up. Ready Indicates that the unit is ready to start a new test Pass Indicates a passed test Fail Indicates a failed test Fault Indicates a non calibrated state for the system when coupled with the Cal Mode status indicator or a fault. 113

124 Cal Mode Indicates when a calibration routine is taking place. i Note External Start have a minimum duration of 300ms. The electrical pulse applied to the External Start input must Auto Port 4-pin circular connector with bayonet lock provides the ability to set the unit as an automated unit and to start a Penetration Calibration from a PLC. (see Figure 11-4: PLC Auto Port Pin Description for the pin description and Figure 11-3: Connection Circuit Example Input Line for a sample connection circuit). The outputs are an open collector type capable of sinking 50 ma for a non-inductive load (see Figure 11-2: Connection Circuit Example for a sample connection circuit). The mating connector is manufactured by Hirose Electric Co Ltd (Part Number RM12BPE-4S(71) ). Auto Select Enables the automatic mode for the unit. Pen Cal Used by the PLC to request a Pen Cal routine. i Note Auto Select To enable the automatic mode, 24VDC must be connected between the input Auto Select and ground at all time. That voltage must be applied prior to powering on the unit. i Note Pen Cal a minimum duration of 300ms. The electrical pulse applied to the Pen Cal input must have 114

125 Figure 11-1: PLC Control Port Pin Description Pin Description: External Start 2 - Ground 3 - Ready 4 Fault 5 - Fail 6 - Pass 7 Cal Mode Figure 11-2: Connection Circuit Example Status Line Status Line 3-7 R = 470Ω +24V GND 2 Power Supply Figure 11-3: Connection Circuit Example Input Line Input Line 1 Momentary Switch +24V GND 2 Power Supply Figure 11-4: PLC Auto Port Pin Description Pin Description: External Ground 2 Pen Cal 3 External Ground 4 Auto Select 115

126 Accessories Power Port 4-pin circular connector with bayonet lock provides a dedicated 24VDC power supply for ATI designed accessories such as the Local Exhaust Module. i Note Port Usage equipment might result from such action. Do not use the accessories power port with equipment other than those designed and supplied by ATI. Damage to the Accessories Data Port RJ-45 Connection provides a communication interface for ATI designed accessories. Aerosol and Pressure Lines Connections The Automatic has two pressure ports and two aerosol ports located at the back of the unit. Follow the diagram from Figure 11-5: Aerosol and Pressure Ports Connections when connecting the ports: PH1 Connects to the upstream side of the filter under test. PL1 Connects to the downstream side of the filter under test. SUPPLY 1 Connects to the upstream side of the filter under test. RETURN 1 Connects to the upstream side of the filter under test. 116

127 Figure 11-5: Aerosol and Pressure Ports Connections PH1 SUPPLY 1 Upstream Test Fixture Flow Orientation RETURN 1 PL1 Downstream Test Fixture Timing Diagram Figure 11-6: Timing Diagram Overall Sequence Overall Sequence The following chart details the overall timing diagram when using the Automatic unit. Each step is detailed in the following paragraphs. WARM-UP SETUP OPERATION CALIBRATION OPERATION Time Timing Diagram Key The following key applies to the timing diagrams from this section: Status Line Touch screen Entry Machine Operation Prior or Next Sequence Screen Prompt / Message Input from PLC PLC Action 117

128 Warm-up Sequence Figure 11-7: Timing Diagram Warm-up Sequence FAULT CAL MODE WARM-UP SECURITY SIGN ON SETUP Time ON SYSTEM INITIALIZATION PASSWORD INPUT CHECK LIQUID LEVEL CONTINUE BYPASS SELECT USER During the warm up sequence, no action is required from the PLC. All interaction between the operator and the unit takes place from the touch screen. Setup Sequence Figure 11-8: Timing Diagram Setup Sequence FAULT CAL MODE READY CLOSE CHUCK EXTERNAL START OPEN CHUCK CLOSE CHUCK EXTERNAL START OPEN CHUCK CLOSE CHUCK EXTERNAL START OPEN CHUCK GRAVIMETRIC LSC SENSITIVITY PEN CAL OPERATION Time CANCEL BEGIN DATA INPUT DATA INPUT DATA INPUT DATA INPUT START CANCEL ACCEPT OR CANCEL ACCEPT OR CANCEL The setup sequence requires a Human Machine Interface (HMI) to give the operator temporary control of the PLC for the operation of the test fixture and the external start signal. 118

129 i Note Test Fixture result from such action. The test fixture must not contain any filter or assembly during the LSC Sensitivity operation. Improper setup would Operation Sequence Figure 11-9: Timing Diagram Operation Sequence READY PASS OR FAIL READY PASS OR FAIL EXTERNAL START EXTERNAL START MAIN MENU LOAD TEST OPEN TIME IDLE LOAD TEST OPEN TIME Time PLACE PART CLOSE CHUCK CHUCK CLOSED OPEN CHUCK REMOVE PART PLACE NEW PART CLOSE CHUCK CHUCK CLOSED OPEN CHUCK REMOVE PART During operation, the PLC or Automated Production Line is responsible for: Loading and unloading filters into and out of the test fixture, Ensuring that the test fixture is properly closed, Sending an External Start signal to the, After test completion, opening the test fixture and removing the filter. Upon completion of the test, the machine will enable the Pass or Fail status line depending on the test outcome for the duration of the Open Time setting (see Setup Menu Options page 66). Once the Ready status line is enabled, the machine is ready for the next test. 119

130 Pen Cal (Calibration) Sequence Figure 11-10: Timing Diagram Pen Cal Sequence PASS OR FAIL READY CAL MODE READY EXTERNAL START OPEN TIME IDLE Time OPEN CHUCK REMOVE PART CLOSE CHUCK CHUCK CLOSED PEN CAL PEN CAL MAIN MENU The Pen Cal sequence is called by sending a momentary voltage pulse to the Pen Cal input line of the Auto Port. Its purpose is to reset the 100% and 0% references at a user determined interval rather than a number of cycles. During the Pen Cal sequence, the PLC is responsible for ensuring that the test fixture is properly closed prior to sending an External Start signal to the Automated Filter Tester. Once the has acknowledged the Pen Cal signal, the Ready status will be disabled and the Cal Mode status will be enabled. i Note Test Fixture would result from such action. The test fixture must remain empty and not contain any filter or assembly during the Pen Cal operation. Improper setup 120

131 121

132 CHAPTER 12 Hybrid Version Introduction Switching the Hybrid from the automatic mode to manual mode or vice versa has been made simple and convenient for the operator. The conversion is achieved by looping back the aerosol and pressure lines using provided jumper hoses and disconnecting an interface port (or disabling the Auto Select input line). If using the hybrid in manual mode, refer to CHAPTER 6 page 38 for operation otherwise refer to CHAPTER 11 page 112 for automatic operation. When the Hybrid is used in the automatic mode, the test fixture and optical touch button will be disabled during operation. i Note Test Fixture The test fixture will open when the unit is powered on and remain in the open position until the unit is powered off. Setting Up for Automatic Mode To setup the machine for automatic operation, refer to Setting Up the Automatic page 112. Setting Up for Manual Mode Interface Ports Disconnect the PLC Interface Port and Auto Port when using the Hybrid in manual mode. 122

133 i Note Auto Select To enable the Manual mode, ensure that no voltage is applied between the input Auto Select and ground at all times. This input must be disconnected prior to turning the unit on. Aerosol and Pressure Lines Connections The Hybrid has four pressure ports and four aerosol ports located at the back of the unit. Use the connecting hoses provided with the Hybrid to connect the ports according to the diagram from Figure 12-1: Aerosol and Pressure Ports Connections. Use the following jumper hoses to connect the ports: Jumper hose labeled SUPPLY to connect ports SUPPLY 1 and SUPPLY 2. Jumper hose labeled RETURN to connect ports RETURN 1 and RETURN 2. Jumper hose transparent green to connect ports PH1 and PH2. Jumper hose transparent red to connect ports PL1 and PL2. 123

134 Figure 12-1: Aerosol and Pressure Ports Connections SUPPLY 1 PH1 PH2 SUPPLY 2 RETURN 1 PL1 RETURN 2 PL2 124

135 125

136 CHAPTER 13 Troubleshooting Guide i Note If any remedy listed is not effective, contact ATI for repair service. Tester Will Not Power Up Probable Cause Power cable not plugged in Fuse blown Tester On - No Response Tester hung up Probable Cause Insufficient Sample Flow Probable Cause Flow line filter plugged Dirty vacuum pump filters Flowmeter tubing kinked, blocked, or disconnected (including pressure lines) Flowmeter incorrectly installed Remedy Plug power cable into an appropriate power outlet Check system fuse(s) Remedy Reboot the system (turn it off and on again) Remedy Replace flow line filter Clean vacuum pump filters Check flow meter tubing and connections for kinks or blockages Check orientation of the flow meter 126

137 Aerosol Generator Pressure Unstable Probable Cause Main air supply pressure low Generator pressure low Leaks in supply pressure lines, especially the generator supply line Remedy Set supply pressure to at least 70 psi. If it does not remain at this pressure, you may have an air supply problem Adjust generator pressure in maintenance Check air lines and fittings for leaks and repair or replace faulty lines if any are found Low Aerosol Concentration Probable Cause Low aerosol generator liquid level Clogged aerosol line Inadequate aerosol generator pressure Aerosol generator atomizer jets plugged Dilution nozzle in the generator clogged Incorrect Solution or Replenishment solution Remedy Refill aerosol generator Remove and clean any salt deposits in the aerosol lines Adjust aerosol generator pressure Clean atomizer jets Clean dilution nozzle Empty both the generator and the refill reservoir, clean them and refill with newly made solutions Unstable Photometer Readings Probable Cause Plugged atomizer jets on the aerosol generator Kinked sample lines Dirty test fixture Dirty sample lines Plugged photometer filters Flow or Resistance Incorrect Probable Cause Blockage in the sample line Pressure tube(s) disconnected Differential Pressure sensors calibration data points accidentally changed Flow meter connection tube(s) disconnected Remedy Clean the atomizer jets Check sample lines for kinks. Check the test fixture for salt deposits Check sample line for salts deposits. Replace photometer filters Remedy Check the sample line tubing or external valves for any blockages. Check and reconnect tubes on filter holders Check and reset calibration data points Check and reconnect tubes on the flow meter 127

138 Parameter(s) and/or Calibration Data Corrupted Probable Cause Electrical noise Incorrect values set Calibration data not retained after power cycle Electronics problem Remedy Turn tester off for 5 seconds, then turn back on Change the corrupted values by entering new values from the screen Change coin cell battery on the main control board. Call ATI i Note Battery Information Filter Tester is a 3V lithium ion battery type CR2450. The battery type used in the Salt Aerosol Automated Aerosol Leaking Probable Cause Normal release of aerosol following a test Tester not properly exhausted Slow Test Fixture Movement Probable Cause Filter holder pressure set incorrectly Speed Control Valve not properly adjusted Heater Not Functioning Probable Cause Heater not turned on Inadequate make-up air flow Defective heater Remedy Add or lengthen purge time Check the aerosol exhaust line for kinks or plugging. There should be little or no resistance on the exhaust line Remedy Increase the filter holder pressure Turn the speed control valve adjustment screw on the actuator until the desired speed is attained. Call ATI Remedy Verify temperature controller setting at 45 Increase make-up air flow to at least 40 lpm Call ATI 128

139 Ionizer Inoperable Probable Cause Ionizer not turned on Insufficient air flow Defective ionizer Remedy Check the On/Off switch on the ionizer Airflow Controller. Increase make-up air flow to at least 40 scfh Call ATI Ionizer Not Functioning Properly Out of balance Worn needles Probable Cause Liquid in Dilution Air Flow Meter Probable Cause Failed air line filter allowing unfiltered compressor air to enter system Adjust balance Replace needles Remedy Remedy Replace the air line filters Call ATI 129

140 APPENDIX A Contacting ATI For Technical or Application Questions If you experience any difficulty setting up the Salt Aerosol Automated Filter Tester or have application questions, contact ATI at (410) or via at info@atitest.com. For Customer Service If the Salt Aerosol Automated Filter Tester is not operating properly, or if you are returning the instrument for service, contact ATI Customer Service (410) or by Info@ATITest.com. Customer Service will need this information when you call: The penetrometer serial number located on the back of the machine A purchase order number (unless under warranty) A billing address A purchasing point of contact A technical point of contact A shipping address The preferred return shipping carrier Use the original packing material to return the generator to ATI. If you no longer have the original packing material, you can order it from ATI or use sufficient packing material so the generator is not damaged during shipping. A-0

141 A-1

142 APPENDIX B Warranty Part Number / Revision F / March 2013 Address Air Techniques International / Cronridge Drive / Owings Mills, MD / USA Phone No. (410) Fax No. (410) Address Limitation of Warranty and Liability info@atitest.com Air Techniques International, hereinafter referred to as ATI, warrants the equipment purchased hereunder to be free from defect in materials and workmanship under normal use and service, when used for the purpose for which it is designed, for a period of (1) one year from the date of shipment. ATI further warrants that the equipment will perform in accordance with the technical specifications accompanying the formal equipment offer. ATI will repair or replace any such defective items that may fail within the stated warranty period, PROVIDED: a. That any claim of defect under this warranty is made within thirty (30) days after discovery thereof and that inspection by ATI, if required, indicates the validity of such claim to ATI s satisfaction. b. That the defect is not the result of damage incurred in shipment to or from our factory. c. That the equipment has not been altered in any way whether as to design or use, whether by replacement parts not supplied or approved by ATI, or otherwise. d. That any equipment or accessories furnished but not manufactured by ATI, or not of ATI design, shall be subject only to such adjustments as ATI may obtain from the supplier thereof. ATI s obligation under this warranty is limited to the repair or replacement of defective parts with the exception noted above. If the equipment includes a scattering chamber, ATI s warranty does not extend to contamination of the scattering chamber by foreign material. At ATI s option, any defective equipment that fails within the B-0

143 warranty period shall be returned to ATI s factory for inspection, properly packed with shipping charges prepaid. No equipment shall be returned to ATI without prior issuance of a return authorization by ATI. Service Policy No warranties, express or implied, other than those specifically set forth herein shall be applicable to any equipment manufactured or furnished by ATI and the foregoing warranty shall constitute the Buyer s sole right and remedy. In no event does ATI assume any liability for consequential damages, or for loss, damage or expense directly or indirectly arising from the use of ATI products, or any inability to use them either separately or in combination with other equipment or materials or from any other cause. Our service policy is designed to give prompt attention to any problems. If you encounter a defective product or discover a malfunction, please call ATI Customer Service to obtain a return authorization at (410) B-1

144 APPENDIX C Declaration of Conformity We: AIR TECHNIQUES INTERNATIONAL Cronridge Drive Owings Mills, Maryland USA Tel: (410) Fax: (410) Website: Declare under our sole responsibility that the product, Salt Aerosol Automated Filter Tester Manufactured beginning October, 2009 is in conformity with the following directives: Application of Council Directive(s) Electromagnetic Compatibility Directive (2004/108/EC) Low Voltage Directive (2006/95/EC) Standard(s) to which Conformity is Declared EN :2006 EN :2006 EN :2006 EN :2001 Design documentation is maintained at: Air Techniques International Cronridge Drive Owings Mills, Maryland USA Eric Hanson Date of Issue: 10/15/2009 President Place of Issue: Owings Mills, Air Techniques International Maryland USA C-0

145 C-1

146 APPENDIX D Specifications Physical Characteristics Dimension (L x W x H) Weight 71.1 cm (28 in) x 68.6 cm (27 in) x 88.9 cm (35 in) 74.8 kg (165 Lbs) Operational Requirements Power Electrical Fuses Primary Aerosol Reagent Replenishment Reagent Generator Liquid Capacity Replenishment Reservoir Capacity Compressed Air Operating Conditions 115 VAC, 60 Hz, 5.5 Amps 230 VAC, 50 Hz, 2.5 Amps For 110V, Two Required, 5 x 20 mm, 8A, 250V, FAST BLO For 220V, Two Required, 5 x 20 mm, 4A, 250V, FAST BLO 4% NaCl (Sodium Chloride) solution by weight 0.9% NaCl (Sodium Chloride) solution by weight 1 Liter (1000 ml) 4 liters (4000 ml) 5.52 Bar ± 0.35 Bar (80 psi ± 5.0 psi) Ambient Temperature 10 to 35º C (non-condensing or icing) Ambient Pressure 760 ± 30 mm Hg Ambient Humidity 5% to 95% Storage requirements -20 to 60º C Less than 95% Relative Humidity noncondensing D-0

147 Aerosol Generation Generation Pneumatic Nebulization Aerosol Sodium Chloride Mass Mean Diameter.29 µm Count Median Diameter.08 µm Geometric Std Deviation <1.80 Concentration 35 to 45 mg/m 3 Aerosol Detection Technique Near Forward Light Scattering Photometer Dynamic Range to 200 mg/m3 Accuracy ± 1% Sample Flow Rate Full flow through detection 10 to 120 liters per minute - volumetric or mass Flow Measurements Technique Range Accuracy STP Conditions Laminar Flow Element w/ digital pressure transducer 10 to 120 lpm ± 0.4% of reading/+ 0.2% of Full Scale 21.1 C, 760 mm Hg Pressure Differential Measurements Technique Electronic pressure transducer Range mm H 2 O ( in of H 2 O) Accuracy ± 2.5% of Full scale reading Efficiency Measurements Flow Rate through media 10 to 100 L/min Efficiency % D-1

148 Outputs Display Communication Color Touch Screen, Quarter VGA USB Port D-2

149 D-3

150 APPENDIX E Theory of Operation Introduction The Salt Aerosol Automated Filter Tester is designed to meet the sodium chloride testing requirement of NIOSH 42 CFR Part 84. This testing specification requires a NaCl aerosol with a count median diameter (CMD) of ± µm with a particle distribution having a standard geometric deviation of less than The aerosol produced is also subjected to an ionized air stream to shift the electrically charged generated aerosol to a neutral state (Boltzmann Equilibrium) characteristic of naturally occurring aerosols. Appendix Figure E-1: Schematic Diagram of the Automated Filter Tester Flow Control Valves Pneumatic Cylinder Air Conditioning System Heater Ionizer Test Filter Test Fixture Differential Pressure Transducer Solution Level Monitoring / Replenishment system Mixing Manifold Reference Filter Photometer Selector Valve Replenishment Reservoir Aerosol Generator Exhaust Indicates Aerosol-laden Air Filters Mass Flow Controller Vacuum Pump E-0

151 Aerosol Generation Aerosol generation in the is achieved using an ingenious, patented submerged nozzle nebulizer and regeneration technique. An air jet exiting the nozzle at high speed below the surface of the aerosol liquid generates bubbles that remain suspended within the liquid. When these bubbles reach the surface of the liquid they burst and generate airborne particles containing water and sodium chloride. As the airborne particles rise within the generator cylinder, the water is evaporated from the particle, forming the dry, sodium chloride aerosol necessary to perform efficiency testing. Aerosol generation occurs at a level exceeding the maximum test flow capabilities of the. The purpose of this excess aerosol is to maintain constant levels of aerosol regardless of the sample rate. Excess aerosol is exhausted from the and captured either by a user supplied exhaust or an ATI Self-Contained Exhaust Module, if installed. Aerosol Detection - Photometry The forward light scattering photometer is designed based on MIE scattering theory for analyzing particles dispersed in a fluid. This design includes a cylindrical housing enclosing a pair of axially spaced, sphericalsurfaced, bi-convex lenses which provide axial focusing of the lamp image in an intermediate light scattering chamber through which the aerosol sample being analyzed is passed. Electrical Architecture The electrical system within the was designed from the start to be intrinsically safe & maintenance friendly. All interconnections between printed circuit boards are created using industry standard RJ-45 style terminations. Electrically actuated valves and all other control voltages within the instrument are 24 VDC based. E-1

152 The presence of higher AC voltages (120VAC or 240VAC) within the instrument enclosure is limited to a separately enclosed area accessed only by using tools. Operation of the Penetrometer Whenever the Salt Aerosol Automated Filter Tester is first started at the beginning of the day or after the generator solution has been replaced, allow it to warm up for 15 to 30 minutes to ensure the heater and generator have reached their proper operating temperature. You should also allow for an appropriate warm-up time if the tester is turned off during the course of the day or placed in standby mode. If it is off for a brief period of time (less than five minutes), no warm-up is required before resuming filter testing. After the tester is first powered on and once the warm-up period is complete, you will be prompted to perform three set up functions. The first function will be to perform a gravimetric test for the tester to know the exact aerosol concentration being generated. The second function will be to perform an LSC calibration, during which time the system adjust the photometer gain to a proper level based on the aerosol concentration. The last set up function is to perform a penetration calibration or Pen Cal. During the Pen Cal function, the system will checks the photometer zero level and correlate the 100% level with the aerosol being produced. It will also establish the tare for the test fixture. It is important to understand that the pressure drop across the test fixture will change with the flow rate and therefore, the Pen Cal function should be performed every time the flow is changed. To perform an instantaneous test on a filter, place the filter in the lower part of the test fixture 3,4. Initiate the test by simultaneously inserting a finger in each of the actuators. A test fixture diagram will inform the user 3 Some filters might require a custom adapter to be properly tested. If you require a special adapter, contact ATI. 4 To test flat sheet media, make sure the flat sheet media adapter and supporting screens are inserted properly in the lower part of the test fixture. E-2

153 when it is safe to remove the fingers from the actuators. The test begins automatically once the test fixture is closed and the fingers are removed from the actuators. The test sequence is automated and controlled by the system main computer. During the test, aerosol is drawn from the mixing chamber and passed through the filter and the photometer by the vacuum pump. The photometer is a full flow detection device, meaning that there are no bypass and all the aerosol being drawn through the filter is seen by the detector. At the end of the test the test fixture opens automatically and the test results are displayed on the screen 5 as well as the User Interface Port. The system will check each of the values against the alarm settings and highlight the value in red if it fails and green if it passes. The data string on the User Interface Port will have a pass or fail indicator. The tester is ready to perform another test. Simply replace the filter and close the actuators. 5 The previous three test results will also be displayed at the bottom of the screen. E-3

154 APPENDIX F Preparing the Sodium Chloride Solution The is designed to operate utilizing a 4% mixture of sodium chloride by weight in the main aerosol generator reservoir. A separate replenishment reservoir contains a 0.9% solution. Main Aerosol Generator Solution: To achieve a 4% solution by weight, 40 grams of reagent grade NaCl must be mixed with 1000 ml of distilled water. Measure 40 ± grams of NaCl on a calibrated balance. Place the NaCl into 1000 ml of distilled water and mix until completely dissolved. Replenishment Reservoir Solution: To achieve a 0.9% solution by weight, 9 grams of reagent grade NaCl must be mixed with 1000 ml of distilled water. Measure 9 ± grams of NaCl on a calibrated balance. Place the NaCl into 1000 ml of distilled water and mix until completely dissolved. Unused solution for either the Main Aerosol Generator or the Replenishment Reservoir may be stored in a tightly sealed container for a maximum of one (1) week. Expired solution should be disposed of in an appropriate manner. F-0

155 F-1

156 APPENDIX G Maintenance and Spare Items Appendix Table G-1: Maintenance Items Part Number Description Required Quantity Graduated Cylinder, 1 ea 1000ml Spare Refill Bottle 1 ea Spare Refill Bottle Cap 1 ea Green Line Media, Ø6.0, 1 ea Qty Gravimetric Media, 1 ea Ø127mm, Qty Sodium Chloride, 500g 1 ea Stylus with cushion tip and 1 ea tether Chuck Gasket, 4.5 OD X 1 ea 1.0 ID Chuck O-ring 1 ea Gravimetric Filter Holder 1 ea Cleaning Brush 1 ea Ball-Point Hex Driver, 2mm 1 ea Hex Local Exhaust Pre Filter 1 ea Local Exhaust HEPA Filter 1 ea USB Cable, 6ft 1 ea Non Terminated PLC Cable 1 ea G-0

157 G-1

158 APPENDIX H Service Items Appendix Table H-1: Service Items Part Number Description Required Quantity Filter, 0.01µm element 1 ea Filter, 0.3 µm element 1 ea Filter, dew point indicator 1 ea Filter, ZFC element, 10 µm 2 ea Filter, 5 µm element 2 ea Reference Filter 1 ea Coalescing Filter 1 ea HEPA Carbon Filter 1 ea Conductive Tubing, ½ ID 5 ft Black Tygon Tubing, ½ ID 4 ft Refill Pump Fuse 1 ea Power Entry Module Fuses 1 ea O-ring Kit 1 ea Service Kit 1 ea Ball-Point Hex Driver, 4mm 1 ea Hex Ball-Point Hex Driver, 1 ea 2.5mm Hex Ball-Point Hex Driver, 9/64 1 ea Hex Ionizer Spare Needles 2 ea RAL 7035 touch up paint 1 ea RAL 7030 touch up paint 1 ea O-ring Kit includes: Chuck Qty Fluorosilicone Exhaust Stack Qty Viton -035 Scattering Chamber Qty Buna -031 Scattering Chamber Qty Buna -032 Generator Lid Qty EPDM Aerosol Tubing Qty Silicone -019 Scattering Chamber Qty Closed Cell Foam Colder Quick-connect Qty Buna H-0

159 Service Kit includes: Filter, 0.01µm element Qty Filter, 0.3 µm element Qty Filter, ZFC element, 10 µm Qty Filter, 5 µm element Qty Reference Filter Qty Coalescing Filter Qty HEPA Carbon Filter Qty Conductive Tubing, ½ ID Qty 5ft Black Tygon Tubing, ½ ID Qty 4ft O-ring Kit Qty H-1

160 APPENDIX I Accessories Base Storage Cabinet Local Exhaust Module The Base Storage Cabinet is a multipurpose accessory that not only supports and positions the instrument at an ideal operating height, but also provides ample storage for all your testing accessories & consumable items. Large industrial casters with a locking mechanism allow for easy transport and immobilization of the instrument. The Local Exhaust module is designed for applications where the operating environment doesn t afford an industrial ventilation system or where it may be undesirable to plumb the instrument to a fume hood or other facility exhausting system. Using a readily available HEPA filter and remotely powered fan, the exhaust aerosol is captured directly at the instrument outlet. A resistance gauge indicates when the filter should be changed for ideal performance. I-0

161 Gravimetric Filter Test Adapter N95 Mask Adaptor To make routine gravimetric testing easy, ATI offers a robust, easy to use Gravimetric Filter Test Adapter which integrates seamlessly with the standard test fixture (chuck). It is constructed of a durable black acetal housing & stainless steel honeycomb support structure and was designed to last the life of the instrument. The N95 Mask Adaptor is an innovative, simple, and reusable test fixture for testing N95 and other filter face pieces without the use of messy bees wax or adhesives that require curing times. Constructed out of durable acrylic, a closed cell neoprene foam gasket material and a stainless steel support structure, the N95 Mask Adaptor sets up in seconds and will provide years of service without all of the mess. N95 Mask Adaptors are design for a customer specific mask. Inquire with ATI Sales for informations. Appendix Table I-1: Accessories List Description Part Number Base Storage Cabinet Local Exhaust Module Gravimetric Filter Test Adapter I-1