PortaCount Operation and Service Manual
Contents
1. Maintenance Adding alcohol 49 Charging battery packs 51 Changing battery packs 52 Storage and shipment 53 Troubleshooting 55 Theory of Operation 59 Printer Control Codes 61 Printer s Serial Interface 63 PORTACOUNT s Serial Interface Connections 65 Changing the Output Level of the PORTACOUNT s Serial Interface 67 CONTENTS iii Illustrations I 1 PORTACOUNT and accessories 6 I 2 Front of PORTACOUNT 7 1 3 Back of PORTACOUNT 7 I 4 Twin tube assembly connections 8 I 5 Removing the battery cover 8 1 6 Plugging in the battery connector 9 I 7 Installing the battery pack 9 1 8 Alcohol indicator white dry 10 1 9 Alcohol indicator dark wet 10 I 10 Removing the alcohol fill cap 10 I 11 Filling the syringe 11 I 12 Inserting the syringe 11 I 13 Injecting the alcohol 11 1 14 Correct angle for filling 12 1 15 Wrong angle for filling 12 1 16 Connecting the printer interface cable to the PORTACOUNT 13 I 17 Connecting the printer interface cable to the printer 13 I 18 Connecting the AC adapter to the printer 14 IlI 1 Parts and functions of the PORTACOUNT 20 IlI 2 Parts and functions of the PORTACOUNT 21 IV 1 Zero checking the PORTACOUNT 24 IV 2 Removing the front cover 28 IV 3 Setting the DIP switches 28 VIII 1 Removing the print mechanism cover 40 VNII 2 Removing the cartridge ribbon 41 VNI 3 Installing the cartridge ribbon 41 VIII 4 Removing the slack from the ribbon 41 VII 5 Installing the cartridge ribbon with paper in the print2. Step 3 With a scissors cut the paper that is fed to the printer Make the cut as square as possible to ease reloading fig VITI 14 Figure VIII 14 Cutting the paper Step 4 Pull the remaining paper through the printer mechanism Be sure to pull out the paper from the front paper cutter side The paper roll removal process is now complete Installation Instructions IX AC Adapter Note The MODEL 8018 AC Adapter is an optional accessory and may not have been purchased with your PORTACOUNT The MODEL 8018 AC Adapter consists of two parts a power supply that converts 115 volts AC or 220 volts AC for 220 volt Ac Adapters to 5 volts Dc and an electronics module that contains circuitry for noise and spike suppression The noise and spike suppression are needed to protect the sensitive laser diode inside the PORTACOUNT fig IX 1 Figure IX 1 Model 8018 AC Adapter Step 1 Remove the battery cover and battery from your PORTACOUNT Store the battery cover in the PORTACOUNT carrying case so that it will be available in case you need to use batteries again in the future Step 2 Connect the battery con nector from inside the PORTACOUNT to the elec tronics module as shown in figure IX 2 Make sure the polarity is correct The connector should mate easily you should not need to force it into place Figure IX 2 Connecting the battery connector Step 3 Insert the electronics module into the battery compartmen
3. connector fits only one way fig 1 6 Figure I 6 Plugging in the battery connector Step 3 Insert the battery pack into the battery compartment in the orientation shown fig 1 7 Figure 1 7 Installing the battery pack Step4 Replace the battery cover and fasten the latch clip 10 CHAPTER I Adding alcohol Alcohol should be added when the PORTACOUNT is first received new from TSI and whenever the alcohol indicator turns white The instructions below describe how to add alcohol to the PORTACOUNT Do not add alcohol if the fill indicator is dark If the fill indicator is white fill the PORTACOUNT using the procedure below During operation when the fill indicator first begins to turn white the PORTACOUNT will operate approximately 45 minutes before the low particle count E E message appears WARNING A PORTACOUNTs should always be shipped dry as a precaution against inadvertent flooding To dry a PORTACOUNT you should run it in COUNT mode until the alcohol fill indicator is a solid white color This may take several hours UI Never add alcohol to the PORTACOUNT when the fill indicator is dark Do not continue to add alcohol once the fill indicator has turned from white to dark Caution Alcohol is extremely flammable Do not fill near open flame or source of ignition U Never fill the PORTACOUNT with alcohol other than 100 reagent grade iso propyl alcohol Figure I 8 Alcohol indicator white dry Figur
4. At the end of a fit test the overall fit factor is calculated and displayed based on the individual fit factors for each test cycle and calculated according to ANSI Z88 2 1980 Equation 2 gives the calculation 100 s n 2 Overall FF where s sum of the penetrations for each test cycle in percent n number of test cycles Written in expanded form equation 2 yields equation 3 100 Overall FF AP ETOP SER Ae OP 2 PAPIER where P penetration in percent for each test cycle Pass fail indication THE FIT TEST MODE 27 Multiplying both the numerator and denominator by n and dividing the numer ator and denominator by 100 yields equation 4 Overall FF ict Pel Soa ae ee Dr j where p penetration for each test cycle Since fit factor is the inverse of penetration equation 4 can be written as Overall FF Sa a m ur 5 1 1 1 1 1 tt FF FF FF PP Fn where FF fit factor for each test cycle n number of test cycles Equation 5 is used to calculate the overall fit factor in the PORTACOUNT Atthe end of each test cycle a pass fail indication is given for that cycle Either a green light comes on next to PASS on the front panel or a red light comes on next to FAIL PASS means that the measured fit factor is greater than or equal to the set pass fail level At the end of a fit test when the overall fit factor is displayed an overall pass fail indication is given PASS means tha
5. OUTPUT LEVEL OF THE PORTACOUNT S SERIAL INTERFACE 69 Step 3 Install a jumper wire between the two pads marked by an arrow directly to the right of the arrow referred to in step 2 fig E 4 Step 4 Install the front cover on the PORTACOUNT making sure the membrane switch is properly plugged into the printed circuit board
6. PORTACOUNT when the indicator is dark Shipping When shipping the instrument follow the long term storage proce dures 54 CHAPTER X XI Troubleshooting Table 8 lists a series of symptoms their possible causes and recommended solutions for the PORTACOUNT Table 9 does the same for the MODEL 8902 Printer If your symptom is not listed or if none of the solutions solves your problem please contact TSI TABLE 8 Troubleshooting the PORTACOUNT Symptom Does not switch on LO message appears Fit factor of 1 or very low Possible Causes Battery pack is discharged battery pack witha Battery connector is un plugged Battery pack is not installed Membrane switch is discon nected AC adapter not plugged in Battery pack is discharged Alcohol fill cap is loose or missing Respirator is not equipped with HEPA filters Twin tube assembly is disconnected Twin tube assembly is not connected to respirator sampling port Twin tube assembly leaks tube assembly Respirator has loose filters or a malfunctioning outlet valve Switching valve is not functioning Solution Replace the discharged charged pack Plug the battery connector into the battery pack Install the battery pack Open the front cover and plug the membrane switch into the PORTACOUNT electronics Connect AC adapter Replace the discharged battery pack with a charged pack Tightly close the alcohol fi
7. it in an inverted position alcohol may clog the nozzle or coat the optics To switch on the PORTACOUNT simultaneously press ENABLE and ON The LCD display counts down from 60 seconds while the instrument warms up After warm up the PORTACOUNT is in the Fit Test Mode If Lo appears on the dis play see Error Messages at the end of this chapter The PORTACOUNT has three operating modes In the Fit Test Mode the instru ment can perform quantitative respirator fit tests In the Sequential Mode it can be used to test filter penetration In the Count Mode it can be used as a stand alone particle counter To select a mode simultaneously press ENABLE and MODE until the indicator light next to the desired mode comes on To switch off the PORTACOUNT simultaneously press ENABLE and OFF This section briefly describes how to operate the PORTACOUNT in the Fit Test Mode See Chapter IV for detailed instructions To perform a quantitative respirator fit test follow these three steps Step 1 Attach the free end of the twin tube marked s to the sample port on the respirator Step 2 Simultaneously press ENABLE and TEST the E then flashes After com pleting the first test cycle the fit factor appears in scientific notation and a PASS or FAIL indication is given The PORTACOUNT continues testing and updating the displayed fit factor every 80 seconds Perform each exercise for 80 seconds synchronized with the PORTACOUNT Step 3 To en
8. it is necessary to sample air from within the respirator This is accomplished by using a respirator with a sampling port Almost all respirator manufacturers can supply respirators with sampling ports for quanti tative fit testing purposes Caution To achieve proper results in fit testing the respirator being tested must be equipped with a HEPA filter s The test subject should not smoke for at least 30 minutes before the test When measuring respirator fit it is important that any particles measured inside the respirator actually leaked around the face seal into the respirator and did not originate from some other source Therefore the respirator being fit tested should be equipped with a HEPA filter s Ifa HEPA filter is not used particles that leak through the filter will be sampled inside the respirator giving a low measured fit factor It is also important that the test subject not smoke before the fit test Tests have shown that smokers exhale smoke for up to 30 minutes after smoking The smoke particles are then sampled inside the respirator resulting in lower measured fit factors If the PORTACOUNT is to be used for testing respirators in a positive pressure mode precautions must be taken to ensure the supplied air is particle free This can be accomplished by installing a HEPA filter in the air supply line 24 Zero checking the PORTACOUNT Test sequence CHAPTER IV The integral blower in a powered air purif
9. of filter penetration Particle concentration In the Count Mode the concentration of the aerosol drawn through the Sample port is displayed as a bEc in particles per cubic centimeter In the 1 second averaging mode the display is updated each second indicating the concentration measured during the previous second In the 15 second averaging mode the concentration is updated every 15 seconds indicating the average concentration measured during the previous 15 seconds Low battery indication LO appears on the display if the battery voltage drops below 3 5 volts It means the battery pack needs charging The PORTACOUNT will turn itself off one minute after the LO message appears Low particle count indication If the measured ambient particle concentration is less than 1000 particles per cubic centimeter in the Fit Test Mode or the Sequential Mode E E appears on the display Instrument problems can cause this message if they reduce the instru 625 particles cm on PORTACOUNTSs with Rev A and earlier firmware 1500 particles cm on PORTACOUNTS with Rev B C and D firmware Indicator lights The twin tube assembly Sampling and exhaust ports Battery compartment PARTS AND FUNCTIONS 21 ment s ability to count particles However the message usually means that the PORTACOUNT is either flooded or low on alcohol See Chapter I Setup and Chapter XI Troubleshooting Warm up time When the PORTACOUNT is switched on th
10. test cycle lasts 9 seconds longer than subsequent test cycles since an extra ambient air sample is taken Table 1 shows the test sequence for the PORTACOUNT in the Fit Test Mode THE FIT TEST MODE 25 TABLE 1 Test sequence in the Fit Test Mode Action Time Notes Purge 4 seconds Test started Ambient sample 5 seconds Purge 11 seconds Respirator sample 60 seconds Purge 4 seconds Ambient sample 5 seconds Display fit factor First cycle completed Purge 11 seconds Respirator sample 60 seconds Purge 4 seconds Ambient sample 5 seconds Display fit factor Second cycle completed Purge 11 seconds Respirator sample 60 seconds Purge 4 seconds Ambient sample 5 seconds Display fit factor nth cycle completed Display overall fit factor Test completed The test cycle repeats until you stop the test by pressing the ENABLE and TEST keypads The overall fit factor is then displayed Reading the The fit factor is displayed in scientific notation using a two digit mantissa and display one digit exponent The format is a bEc where a b is the mantissa and c is the exponent This corresponds to a b 10 To convert from scientific notation multiply the two digit mantissa by 10 raised to the c power thus 1 2E4 1 2 104 1 2 10 000 12 000 Table 2 shows the value of 10 for various values of c TABLE 2 Values of 10 Expo nent c 10 Multiplier 0 100 1 1 10 10 2 10 100 3 103 1 000 4 104 10 000 5 10 100 000
11. 26 Calculating the fit factor CHAPTER IV Fit factor is defined as the concentration outside the respirator divided by the concentration inside the respirator In the PORTACOUNT the ambient concentration is measured for 5 seconds and the respirator concentration for 60 seconds in each test cycle Because ambient concentration can vary over time the PORTACOUNT calculates the fit factor by taking the average of the ambient concentrations measured before and after the respirator sample and then dividing by the concentration measured in the res pirator This is why the first test cycle is longer than additional test cycles in the Fit Test Mode It is necessary to measure the required additional ambient concentration sample before the first fit factor can be calculated Both the ambient and respirator concentrations are determined by integration The integrated concentrations are determined by the total number of particles counted during the sample periods Fit factor is actually calculated by C C FF where FF fit factor Cg particle concentration in the ambient sample before the respirator sample C particle concentration in the ambient sample after the respirator sample Cr particle concentration in the respirator sample If no particles are counted in the respirator sample the PORTACOUNT automati cally adds one particle This prevents dividing the ambient concentration by zero and obtaining a fit factor of infinity
12. COUNT transmits at predictable intervals To see firsthand what the transmission intervals are connect the PORTACOUNT to a microcomputer and run the sample BASIC program listed above or connect the PORTACOUNT to a serial printer such as the MODEL 8902 Refer to Chapter IV of this manual for the test cycle timing in the Fit Test Mode The con centration data is output approximately 2 seconds after the end of each sample in the test cycle and the fit factor is output approximately 2 seconds after the ambient concentration 38 CHAPTER VII Using the printer VII Printer The optional MODEL 8902 Printer is compact portable and extremely versatile It can print out PORTACOUNT data wherever testing is being performed It can also be connected to a microcomputer through a serial interface port To activate the printer press and release the right side of the power switch It will return to the center ON position The power LED comes on and a READY mes sage is printed indicating that its internal microprocessor is operating properly When you switch off the printer be sure to wait at least 3 seconds before switching it on again The printer stores characters for printing until one of two events occur 1 Its character holding buffer becomes full 2 It receives a line feed hexadecimal 0A or a carriage return code hexadecimal OD When either occurs the printer prints out the contents of its character buffer If the buffer is emp
13. No Signal Direction Description 1 Chassis ground Cable shield 2 RD Received To printer Printer data input data line 5 CTS Clear to From printer Signal equivalent to Send Busy indicating that printer is ready for operation and can receive data 7 SG Signal Signal ground 13 I oO000000000000o0 000000000000 25 14 Figure C 1 Pin arrangement of the serial connector TABLE 12 Serial interface voltage levels Received data Mark OFF Logic 1 25V to 3V Space ON Logic 0 25V to 3V Clear to send Busy OFF Logic 1 14V to 8V Not Busy ON Logic 0 5V 63 64 APPENDIX C PRINTER S SERIAL INTERFACE TABLE 13 Serial data format Start bits 1 Data bits 8 Stop bits 2 or 1 TABLE 14 Signal connections for the printer s serial interface Model 8902 Printer PORTACOUNT Pin 2 enter pin Pin 7 shield Pin 5 not used Pin 1 not used The MODEL 8902 Printer operates at four different baud rates 300 600 1200 and 2400 To select a baud rate set the DIP switches under the paper roll Table 15 shows the DIP switch settings for various baud rates The MODEL 8920 Printer is shipped from the factory with the baud rate set to 1200 TABLE 15 Baud rate switch settings Baud Rate Switch 1 Switch 2 300 OFF OFF 600 ON OFF 1200 OFF ON 2400 ON ON Appendix D PORTACOUNT s Serial Interface Connections The interface cable that connects the PORTACOUNT to the micr
14. ORTACOUNT may be blocked Check for obstructions m The flow may be blocked by dirt or debris inside the PORTACOUNT This would require factory service m The switching valve that diverts the flow between the ambient and sample tubes may not be functioning This would require factory service LO message A LO message appears when the battery pack voltage drops to an inadequate level Replace the battery pack with a fully charged battery pack when this message appears The PORTACOUNT will automatically turn itself off one minute after the LO message appears See Chapter XI for detailed information on the causes and solutions of error mes sages To switch on the printer push down the right side of the power switch it will return to the center ON position To switch off the printer push down the left side of the power switch To advance the paper in the printer push down and hold the right side of the power switch 625 particles cm on PORTACOUNTSs with Rev A and earlier firmware 1500 particles cm on PORTACOUNTs with Rev B C and D firmware 1000 particles cm on PORTACOUNTSs with Rev E firmware 18 CHAPTER II Front panel membrane switch II Description of Parts and Functions The membrane switch part of the front panel includes the display window and six keypads 18 fig II 1 The keypads are explained below DISPLAY LIGHT 1 fig III 1 Switches on the display lighting when pressed while the PO
15. PORTACOUNT Operation and Service Manual July 1989 P N 1980048 TSI Incorporated P O Box 64394 500 Cardigan Road St Paul MN 55164 9877 USA Phone 612 490 2888 Fax 612 490 2874 Part number Copyright Address Telex no Limitation of warranty and liability Service policy 1980048 TSI Incorporated July 1989 All rights reserved TSI Incorporated 500 Cardigan Road P O Box 64394 St Paul MN 55164 USA 6879024 TSI Incorporated warrants that this product under normal use and service shall be free from defects in workmanship and material for a period of twelve 12 months from the date of shipment to the customer This limited warranty is subject to the following exclusions Batteries hot wire or hot film sensors are warranted for a period of 90 days from the date of shipment to the customer With respect to any repair services rendered Seller warrants that the parts repaired or replaced will be free from defects in workmanship and material under normal use for a period of 90 days from the date of shipment to the customer Seller does not provide any warranty on finished goods manufactured by others Unless specifically authorized in a separate writing by Seller Seller makes no warranty with respect to and shall have no liability in connection with any goods which are incorporated into other products or equipment by the Buyer The foregoing is IN LIEU OF all other warranties and is subject to the conditio
16. RTACOUNT is operating ENABLE 2 fig III 1 Controls the operation of the instrument when pressed simultaneously with the OFF ON TEST and MODE keypads OFF 3 fig III 1 Switches off the instrument when pressed simultaneously with the ENABLE keypad ON 4 fig III 1 Switches on the instrument and begins the warmup cycle when pressed simultaneously with the ENABLE keypad MODE 5 fig III 1 Selects the Fit Test Sequential or Count Mode when pressed simultaneously with the ENABLE keypad TEST 6 fig II 1 Performs several different functions when pressed simultaneously with the ENABLE keypad In the Fit Test Mode it either starts or stops a test In the Sequential Mode it starts either of the two samples In the Count Mode it switches between the 1 and 15 second averaging modes 20 Display CHAPTER III Figure III Parts and functions of the PORTACOUNT The PORTACOUNT contains a liquid crystal display LCD on the front panel 7 fig III 1 Under daylight conditions the LCD is highly visible under nighttime conditions the display is backlighted The LCD displays six items of information Fit factor This is the result of a respirator fit test measurement The fit factor FF value is displayed as a bEc which corresponds to a b 10 thus 2 5E3 means 2 5 10 or 2500 Filtration factor This is the result of a Sequential Mode test it too is displayed as a bEc Filtration factor is the inverse
17. aked felt A thermoelectric device TED is mounted between the saturator and condenser The TED transfers heat from the condenser to the saturator cooling the condenser and heating the saturator to just above the ambient temperature After passing through the saturator the aerosol now saturated with alcohol vapor enters the condenser tube The alcohol vapor condenses on the particles causing them to grow into droplets The droplets then pass through the nozzle and into the sensing volume The focussing optics in the sensor consist of a laser diode a collimating lens and a cylindrical lens The optics focus the laser light into a sensing volume 1 2 mm wide by 13 um thick just above the nozzle 59 60 Laser Diode bg Pump Exhaust _ Mask Sampling Ambient Sampling Port APPENDIX A THEORY OF OPERATION Each particle passing through the sensing volume scatters light The light is collected by a pair of lenses in the receiving optics and focussed onto a photo diode The photodiode generates an electrical pulse from the scattered light from each droplet that passes through the sensing volume The particle concentration is determined by counting the number of pulses generated Cylindrical Lens Receiving Optics Coliimating Lens Light Stop L t Detector Nozzle Condenser Thermo Electric Device gt gt Port gt _ gt Saturator Alcohol Soaked Felt Switching Valve __ Figur
18. artment at 612 483 4711 Chapters Contents I II III IV Aboutthis manual 1 Introduction 3 Setup Unpacking 5 Parts identification 7 The twin tube assembly 8 Installing the battery pack 8 Adding alcohol 10 Connecting the printer 13 Operation Switching the PORTACOUNT on and off 15 The Fit Test Mode 15 The Sequential Mode 16 The Count Mode 16 Lighting the display 16 Error messages 17 Switching the printer on and off 17 Advancing printer paper 17 Description of Parts and Functions Front panel membrane switch 19 Display 20 Indicator lights 21 The twin tube assembly 21 Sampling and exhaust ports 21 Battery compartment 21 Alcohol fillcover 22 Serial interface connector 22 Beltclip 22 Alcohol fillindicator 22 The Fit Test Mode 23 Zero checking the PORTACOUNT 24 Test sequence 24 Reading the display 25 Calculating the fit factor 26 Pass fail indication 27 Setting pass fail levels 28 Appendices CONTENTS VI VII Vill IX Hon The Sequential Mode Test sequence 31 Reading the display 32 Calculating the filtration factor 32 The Count Mode Averaging modes 33 Reading the display 33 Calculating the concentration 33 Serial Interface Serial interface outputs 35 Interfacing to a microcomputer 37 Printer Using the printer 39 The self test mode 39 Changing the ribbon 40 Installing a paper roll 43 Removing a paper roll 46 AC Adapter Installation instructions 47
19. ation card Please complete it and mail it promptly This allows TSI to support your instrument and inform you of product updates Figure I 1 PORTACOUNT and accessories SETUP Parts Figures I 2 and I 3 identify the main parts of the PORTACOUNT Become familiar identification With them before proceeding with the setup Figure I 2 Front of PORTACOUNT 1 DISPLAY LIGHT 5 MODE keypad 10 Exhaust port keypad 6 TEST keypad 11 Twin tube assembly 2 ENABLE keypad 7 Display 12 Serial interface 3 OFF keypad 8 Ambient port connector 4 ON keypad 9 Sample port 13 Alcohol fill cap 14 Alcohol fill indicator Figure I 3 Back of PORTACOUNT 15 Battery compartment 17 Latch clip 16 Battery cover 18 Belt clip CHAPTER I The twin tube The PORTACOUNT is shipped with the twin tube assembly attached If the tubes are detached attach the tube labelled A to the Ambient port and attach the tube assembl 4 labelled s to the Sample port as shown in figure I 4 Remove the two plugs from the other end of the twin tube assembly Figure I 4 Twin tube assembly connections Installing the Two battery packs are supplied both are fully charged To install a battery pack battery p ack in the PORTACOUNT follow these four steps Step 1 Open the latch clip and remove the battery cover fig 1 5 Figure I 5 Removing the battery cover SETUP 9 Step2 Plugthe battery connector into the battery pack The
20. before the syringe is empty Observe the following precautions while filling fig X 6 Figure X 6 Injecting the alcohol m Never fill when the PORTACOUNT is on m Never tip the PORTACOUNT backwards further than horizontal while filling m Never inject air into the PORTACOUNT fill port m Never fill the PORTACOUNT if the alcohol indicator is dark Stop filling the moment the alcohol indicator changes from white to dark Figure X 8 Wrong angle for filling Figure X 7 Correct angle for filling Note The PORTACOUNT will consume alcohol at the approximate rate of one cc per hour To charge a PORTACOUNT battery pack follow these three steps Step 1 Remove the battery charger and a battery pack from the carrying case Step 2 Plug the battery connector from the battery charger into the battery pack The connector fits only one way Step 3 Plug the charger into an outlet Charge the battery pack for at least six hours to fully charge the battery Battery packs should not be stored in discharged condition This can affect their ability to take a charge 52 CHAPTER X Changing Under normal conditions a fully charged battery pack will last for about 5 hours battery packs of operation A LO message appears when the battery s voltage drops too low at that point change the battery pack Follow this five step procedure Step 1 Open the latch clip and re move the battery cover fig X 9 Figure X 9 Remov
21. bic centimeters per second The resulting equation for calculating particle concentration then becomes NP ST x 1 67 9 where NP number of particles counted during the sampling time ST sampling time either 1 or 15 seconds 34 CHAPTER VI This means that in the 1 second averaging mode a single particle would be measured as 0 6 particles per cubic centimeter in the 15 second averaging mode a single particle would be measured as 0 04 particles per cubic centimeter These concentrations represent the minimum resolution of the PORTACOUNT in the Count Mode WARNING The alcohol indicator must be dark for the reading in Count Mode to be accurate Serial interface outputs VII Serial Interface The PORTACOUNT includes a serial interface that can be set internally to transmit at either RS 232 C or TTL voltage levels When shipped from the factory it is set to transmit at RS 232 C voltage levels The PORTACOUNT can be interfaced directly to a printer microcomputer or digital datalogger via the serial interface Table 5 shows the communication parameters for the serial interface TABLE 5 Communication parameters of the serial interface Baud rate 1200 Start bits 1 Data bits 8 Stop bits 1 Parity none Handshaking none Encoding ASCII The output of the serial interface varies with each of the operating modes In general however it outputs a description a value and measurement units each time data is transmitted Des
22. cator is dark Stop filling the moment the alcohol indicator changes from white to dark 12 CHAPTER I Figure I 14 Correct angle for filling Figure I 15 Wrong angle for filling Note The PORTACOUNT will consume alcohol at the approximate rate of one cc per hour SETUP 13 Connecting the To connect the printer to the PORTACOUNT follow these five steps printer Step 1 Unscrew the cap from the PORTACOUNT serial interface connector Step 2 Screw the small end of the printer interface cable to the serial interface connector fig I 16 Figure I 16 Connecting the printer interface cable to the PORTACOUNT Step 3 Plug the other end of the printer interface cable into the connector on the back of the printer fig I 17 Figure I 17 Connecting the printer interface cable to the printer 14 CHAPTER I Step4 Plug the cable from the printer s AC adapter into the cable from the printer Ignore any polarity designation Polarity is not important fig I 18 ecting printer Step 5 Plug the printer s AC adapter into a nearby wall outlet The printer is now ready for operation AC adapter to the Switching the PORTACOUNT on and off The Fit Test Mode II Operation This chapter provides brief instructions on how to operate the PORTACOUNT Subsequent sections provide more detail Caution Operate the instrument on the stand provided or hold it in an upright position If you run
23. criptions of the output follow for each operating mode and for the error messages The fit factors and concentrations are output in scientific notation with a three digit mantissa and a one digit exponent The format is a bdEc where a bd is the mantissa and c is the exponent This corresponds to a bd 10 To convert from scientific notation multiply the three digit mantissa by 10 raised to the c power thus 1 23E4 1 23 104 1 23 10 000 12 300 Table 2 shows the value of 10 for various values of c Each message output through the serial interface is followed by a carriage return and a line feed The Fit Test Mode The serial interface outputs a new test message and the pass fail level at the beginning of each test The fit factor and pass fail indi cation are output at the end of each test cycle Each of the measured ambient and respirator concentrations are output too The overall fit factor and pass fail indication are output at the end of a test Table 6 shows the serial interface output for a fit test with two test cycles 36 CHAPTER VII TABLE 6 Serial interface output in the Fit Test Mode NEW TEST PASS 1 00 E2 Test started Ambient 1 10 E4 cc Mask 5 43 El cc Ambient 1 12 E4 cc First cycle completed FF 2 04 E2 PASS First fit factor Mask 4 79 El cc Ambient 1 09 E4 cc Second cycle completed FF 2 31 E2 PASS Second fit factor Overall FF 2 16 E2 PASS Overall fit factor The Sequential Mode In t
24. d a test simultaneously press ENABLE and TEST again The overall fit factor is displayed and an overall PASS or FAIL indication is given 16 The Sequential Mode The Count Mode Lighting the display CHAPTER II Ifyou leave the PORTACOUNT running for 10 minutes without starting a test the instrument automatically switches off to conserve battery life This section briefly describes how to operate the PORTACOUNT in the Sequential Mode See Chapter V for detailed instructions To perform a test in the Sequential Mode follow these three steps Stepl A 1 appears on the display when the PORTACOUNT is in the Sequential Mode Sample the upstream high concentration and simultaneously press ENABLE and TEST The 1 then disappears An E then appears and flashes until the end of the upstream test period 30 seconds Step 2 When the flashing stops and a 2 is displayed proceed to the down stream low concentration sampling location Step 3 After waiting at least 30 seconds for the instrument to purge itself si multaneously press ENABLE and TEST The Eagain flashes At the end of the downstream test period 30 seconds the filtration factor is displayed Inthe Sequential Mode sampling is done through the Sample port the Ambient port is not used This section briefly describes how to operate the PORTACOUNT in the Count Mode See Chapter VI for detailed instructions In the Count Mode the PORTACOUNT automatically displa
25. e 36 Serial interface output in the Sequential Mode 36 Troubleshooting the PORTACOUNT 55 Troubleshooting the MODEL 8902 Printer 57 Control codes for the MODEL 8902 Printer 61 Signal connections for the MODEL 8902 Serial Interface 63 Serial interface voltage levels 63 Serial data format 64 Signal connections for the printer s serial interface 64 Baud rate switch settings 64 About this manual The PORTACOUNT Operation and Service Manual tells you how to operate and maintain the PORTACOUNT Read it thoroughly before using the instrument Once you are familiar with its contents use the Operator Guide for day to day operations m Chapter I and Chapter II explain how to set up the PORTACOUNT and briefly how to operate it m Chapter III describes the parts and functions of the PORTACOUNT in detail m In depth explanations of each of the three operating modes are given in Chapters IV V and VI m Chapters VII VIII and IX cover the serial interface optional printer and optional AC adapter m Chapters X and XI cover maintenance and troubleshooting m Appendix A describes the theory of operation Appendix B lists the various printer control codes Appendix C explains the printer s serial interface Appendix D explains the signal connections for the PORTACOUNT s serial interface Appendix E shows how to change the output level of the serial interface References to front panel keypads on the MODEL 8010 PORTACOUNT along wi
26. e A 1 Schematic of PORTACOUNT Appendix B Printer Control Codes According to the American Standard Code of Information Interchange ASCH there are 32 control codes in addition to the codes for the printed characters Although control codes are sent as data the receiving device interprets them as abbreviated instructions communication status messages etc The MODEL 8902 Printer recognizes 13 of the control codes as listed in Table 10 and ignores the rest TABLE 10 Control codes for the Model 8902 Printer Code Function Abbreviation Hex Decimal Back Space BS 08 08 Line Feed LF 0A 10 Carriage Return CR 0D 13 Double Height SO OE 14 Double Width SI OF 15 Dot Graphics DC2 12 18 User Programmable Character DC3 13 19 Inhibit Line Space DC1 11 17 Stop Reverse Field CAN 18 24 Reverse Field EM 19 25 24 column Mode GS 1D 29 32 column Mode RS 1E 30 40 column Mode US 1F 31 62 APPENDIX B PRINTER CONTROL CODES Appendix C Printer s Serial Interface The MODEL 8902 Printer contains an RS 232 C serial interface Table 11 lists the sig nal connections for the printer Figure 34 shows the pin arrangement of the serial connector Unlisted pins are not used Table 12 defines the voltage levels used on the signals Table 13 de fines the serial data format and Table 14 gives the signal connections for the printer s serial interface TABLE 11 Signal connections for the Model 8902 Serial Interface Pin
27. e I 9 Alcohol indicator dark wet Step 1 Turn the PORTACOUNT Teana off and remove the alcohol fill cap fig 1 10 Figure 1 10 Removing the alcohol fill cap SETUP Step 2 Step 3 Step 4 Step 5 11 Open a disposable TSI alcohol bottle by twisting the top off Place the short plastic tube stub onto the end of a syringe and then connect the other end of the tube stub to the neck of the alcohol bottle fig I 11 Figure I 11 Filling the syringe Draw about 5 cc of alcohol into the syringe Remove the tube stub from the syringe If the alcohol bottle is not empty you may recap it and store it for later use Insert the end of the syringe into the alcohol fill port on the PORTACOUNT Make sure the syringe is inserted at the correct angle The syringe will remain in place without support if the angle is correct fig I 12 ve Figure I 12 Inserting the syringe While observing the alcohol fill indicator gently and slowly inject alcohol into the PORTACOUNT Stop filling the moment the indicator turns dark This may happen before the syringe is empty Observe the following precautions while filling fig I 13 Figure I 13 Injecting the alcohol m Never fill when the PORTACOUNT is on m Never tip the PORTACOUNT backwards further than horizontal while filling see figs I 14 and I 15 m Never inject air into the PORTACOUNT fill port m Never fill the PORTACOUNT if the alcohol indi
28. e trace on the printed circuit board This procedure is for Rev A and newer printed circuit boards For the earlier version of the printed circuit board the procedure varies slightly The arrows are not marked on the printed circuit board and in step 2 instead of cutting the trace the jumper wire across the location is removed 67 APPENDIX E CHANGING THE OUTPUT LEVEL OF THE PORTACOUNT S SERIAL INTERFACE Step 3 Solder a jumper wire between the two pads marked by an arrow directly to the left of the trace that was cut through in step 2 fig E 2 Figure E 2 Location of the jumper wire Step 4 Install the front cover on the PORTACOUNT making sure the membrane switch is properly plugged into the printed circuit board To switch back from TTL to RS 232 C voltage levels follow these four steps WARNING This is acomplex procedure Do not attempt it unless you have a thorough knowledge of electronics assembly tech niques TSI is not responsible for damage that may be done to the PORTACOUNT while attempting this procedure Step 1 With the battery pack disconnected remove the front cover from the instrument Step 2 Remove the jumper wire be tween the two pads marked by an arrow fig E 3 Figure E 3 Removing the jumper wire This procedure is for Rev A and newer printed circuit boards On the earlier version the arrows are not marked on the printed circuit board APPENDIX E CHANGING THE
29. e warm up time 60 seconds counts down on the display Pass fail lights In the Fit Test Mode the two lights indicate PASS or FAIL at the end of each test cycle as well as after ENABLE and TEST are pressed to end a test 19 fig III 1 The pass fail level is determined by DIP switches inside the instrument Mode lights These lights indicate the PORTACOUNT s current operating mode 20 fig II 1 The sampled aerosols are drawn into the PORTACOUNT through the twin tube assembly 11 fig III 1 The tubes are connected to the instrument at the sampling ports they are labelled accordingly s is the Sample port and Ais the Ambient port There are three barbed ports on the left side of the PORTACOUNT cabinet In the Fit Test Mode the aerosols are sequentially sampled from the Ambient and Sam ple ports 8 and 9 fig III 1 In the Sequential Mode and Count Mode the samples are always drawn from the Sample port The pump exhaust exits through the Exhaust port 10 fig III 1 The battery pack is installed at the back of the PORTACOUNT in the battery compartment 14 fig III 2 A connector in the battery compartment plugs into the battery Battery cover A removable plastic cover fits over the battery compartment 15 fig II 2 Latch clip A latch clip holds the battery cover in place 16 fig III 2 15 Figure III 2 Parts and functions of the PORTACOUNT 22 Alcohol fill cap Serial interface connector Be
30. er 42 VIII 6 Inserting paper into the printer 43 VIII 7 Feeding paper through the printer 43 VNI 8 Pulling paper through the printer 44 VIII 9 Sliding paper through the printer cover 44 VNI 10 Installing the printer cover 45 VNI 11 Locking down the printer cover 45 VII 12 Installing the paper spindle 45 VIII 13 Advancing the paper 46 VIII 14 Cutting the paper 46 IX 1 Model 8018 AC Adapter 47 IX 2 Connecting the battery connector 47 IX 3 Connecting the power supply 49 X 1 Alcohol indicator white dry 49 X 2 Alcohol indicator dark wet 49 X 3 Removing the alcohol fillcap 50 X 4 Filling the syringe 50 Illustrations continued Tables CONTENTS X 5 Inserting the syringe 50 X 6 Injecting the alcohol 51 X 7 Correct angle for filling 51 X 8 Wrong angle for filling 51 X 9 Removing the battery cover 52 X 10 Plugging in the battery connector 52 X 11 Installing the battery pack 53 A 1 Schematic of PORTACOUNT 60 C 1 Pin arrangement of the serial connector 63 D 1 25 pin serial interface signal connections 65 D 2 9 pin serial interface signal connections 66 E 1 Cutting through the trace on the printed circuit board 67 E 2 Location of the jumper wire 68 E 3 Removing the jumper wire 68 E 4 Location of the jumper wire 69 Test sequence in the Fit Test Mode 25 Values of 10 25 Pass fail level settings 29 Test sequence in the Sequential Mode 31 Communication parameters of the serial interface 35 Serial interface output in the Fit Test Mod
31. es to detect them In 1943 the Nolan Pollack photoelectric CNC was described In the 1950s and 1960s commercial automatic CNCs were avail able However none were of the continuous flow type and the PORTACOUNT is the first highly portable continuous flow CNC The PORTACOUNT grows submicrometer particles to supermicrometer alcohol droplets and then measures the concentration of the alcohol droplets This makes the PORTACOUNT sensitive to particles having diameters as small as 0 02 micrometer but insensitive to variations in particle size shape composition and refractive index Thus quantitative fit testing can be performed with vir tually any aerosol including ambient air The flow path through the PORTACOUNT is shown in figure 33 Aerosol is drawn through the instrument by a diaphragm vacuum pump operating at a flowrate of 0 7 liter per minute The flow enters the instrument through either the ambient port or the sample port The switching valve determines which port is used The outlet of the switching valve leads to the saturator end cap where the flow splits A flowrate of 0 1 liters per minute enters the saturator and passes through the condenser nozzle and sensing volume The remaining 0 6 liter per minute passes through the excess air line and is remixed with the sampled flow down stream of the sensing volume The PORTACOUNT sensor consists of a saturator condenser and optical elements The saturator is lined with an alcohol so
32. eter It can accurately measure concentrations as high as 500 000 particles per cubic centimeter In the Count Mode there is a 1 second and a 15 second averaging mode In the 1 second mode the PORTACOUNT calculates and displays the particle concentration every second In the 15 second mode the PORTACOUNT calculates and displays the concentration every 15 seconds To switch between modes simultaneously press the ENABLE and TEST keypads while in the Count Mode The particle concentration is displayed in scientific notation using a two digit mantissa and one digit exponent The format is a bEc where a b is the mantissa and c is the exponent This corresponds to a b 10 To convert from scientific notation multiply the two digit mantissa by 10 raised to the c power thus 1 2E4 1 2 104 1 2 10 000 12 000 Table 2 shows the value of 10 for various values of c The particle concentration is displayed in units of particles per cubic centimeter Because the PORTACOUNT is a single particle counting instrument the concen tration measurement is a direct measurement and does not require calibration The particle concentration is calculated by dividing the number of particles counted by the volume of air The volume of air is the flowrate multiplied by the sampling time Depending on which averaging time is used the sampling time is either 1 or 15 seconds The flowrate through the PORTACOUNT sensor is 0 1 liter per minute or 1 67 cu
33. fore depressing the power switch to ON again or simply allow printing to continue until it stops automatically When printing becomes faint replace the cartridge ribbon Spare cartridge ribbons are available as part of the MODEL 8904 Printer Supplies Kit Ifthe printer is used infrequently the print impression sometimes weakens because the ribbon dries out If the print is difficult to read and you suspect a dry ribbon is the cause press the POWER switch to the PAPER FEED position to advance the ribbon to a better inked portion To replace the cartridge ribbon follow these six steps Step 1 With the printer switched off push down on the left side of print mechanism cover and remove the cover fig VIII 1 Figure VIII 1 Removing the print mechanism cover PRINTER Step 2 Step 3 Push down on the right side of the cartridge ribbon marked PUSH and remove the cartridge fig VIII 2 Install the new cartridge rib bon Be sure the cartridge is inserted firmly to prevent weak or irregular printing For best printing results be careful to properly seat and align the cartridge fig VIII 3 Step 4 Turn the cartridge knob marked by an arrow clockwise to remove any slack from the ribbon fig VIII 4 Figure VIII 2 Removing the cartridge ribbon Figure VIII 3 Installing the cartridge ribbon Figure VIII 4 Removing slack from the ribbon 41 42 CHAPTER VIII Step 5 Replace the p
34. he Sequential Mode the serial interface outputs the measured upstream and downstream concentrations and then the calculated fil tration factor Table 7 shows a sample serial interface output in the Sequential Mode TABLE7 Serial interface output in the Sequential Mode Upstream 1 26 EA cc Downstream 4 73 El cc FF 2 66 E2 The Count Mode In the Count Mode the serial interface outputs the measured concentrations in particles per cubic centimeter In the 1 second averaging mode the concentration is output as follows Conc 1 28 E4 cc In the 15 second averaging mode the concentration is output as follows Avg Conc 1 28 E4 cc Inthe 1 second averaging mode the MODEL 8902 Printer cannot print fast enough to keep up with the serial interface Only every other value will be printed Error messages The serial interface also outputs the two error messages When the E E message appears the serial interface outputs a low particle count message along with the measured ambient concentration The serial interface output reads as follows Ambient Low Particle Count 1 67 EO cc When the Lo message appears the serial interface outputs a low battery power message The serial interface output reads as follows Low Battery Interfacing to a microcomputer SERIAL INTERFACE 37 A TSI MODEL 8905 9 or 8905 25 Interface Cable is used to connect the PORTACOUNT to an IBM or IBM compatible microcomputer that has an RS 232 C in
35. he filtration factor which is defined as the particle concentration upstream of the filter divided by the particle concentration downstream of the filter is equivalent to the inverse of filter penetration In the PORTACOUNT each of the concentrations is sampled for 30 seconds Both the upstream and downstream concentrations are determined by integration The concentrations are determined by the total number of particles counted dur ing the sample periods Since the flowrate is the same for both samples it can cels out in the calculation The filtration factor is then calculated by equation 6 NP FF NP 2 6 where FF filtration factor NP number of particles counted in the upstream sample NP number of particles counted in the downstream sample If no particles are counted in the downstream sample the PORTACOUNT auto matically adds one particle to prevent dividing the upstream concentration by zero and obtaining a filtration factor of infinity To calculate penetration from the filtration factor use the following equation peta FF 7 where p penetration Percent penetration is then calculated by P p x100 19 FF 8 where P percent penetration Averaging modes Reading the display Calculating the concentration VI The Count Mode In the Count Mode the PORTACOUNT directly measures and displays the concentration of the aerosol being drawn through the Sample port in units of particles per cubic centim
36. ing the battery cover Step 2 Remove the battery pack from the battery compartment and unplug the battery connector Step 3 Plug the battery connector into the new battery pack The connector fits only one way fig X 10 Figure X 10 Plugging in the battery connector Storage and shipment MAINTENANCE 53 Step 4 Insert the battery pack into the battery compartment in the orientation shown fig X 11 Figure X 11 Installing the battery pack Step 5 Replace the battery cover and fasten the latch clip The battery pack replacement process is now complete Short term storage For periods of less than 14 days no special preparations are necessary other than making sure the PORTACOUNT is stored in an upright posi tion This is a precaution to avoid the possibility of having alcohol pool inside the optics section of the PORTACOUNT resulting in a flooded instrument Note that the cut out inside the PORTACOUNT carrying case is designed to hold the PORTACOUNT in an upright position while the case is being carried or stored vertically Long term storage or shipment For periods longer than 14 days or when preparing the PORTACOUNT for shipment it is essential that any alcohol inside the instrument be allowed to evaporate Shipping a wet PORTACOUNT will result in a flooded instrument To dry the PORTACOUNT run it in Count Mode until the alcohol indicator is a solid white color This may take several hours Do not ship the
37. ional fit test software and microcomputer 30 CHAPTER IV Test sequence V The Sequential Mode In the Sequential Mode the PORTACOUNT is used to manually take two samples in sequence This mode is useful for testing filter banks or similar items where it is not possible to simultaneously connect the twin tube assembly to the upstream and downstream sides of the item being tested The Sequential Mode lets you sample the concentration upstream of a filter and then move to the downstream side and sample the concentration The PORTACOUNT then calculates and displays the filtration factor In the Sequential Mode the PORTACOUNT sequentially measures and stores two concentrations typically upstream and downstream of a filter and then calcu lates and displays the filtration factor The Sample port is used for both samples The PORTACOUNT samples for 30 seconds during each of the two concentration measurements and stores the total number of particles counted in each sample When the instrument is switched to the Sequential Mode a 1 appears on the display It means that the instrument is ready to take the first or upstream sample Press the ENABLE and TEST keypads to start the first test cycle When this cycle is completed a 2 appears on the display It means that the instrument is ready to take the second or downstream sample Press ENABLE and TEST to start the second test cycle At the conclusion of the second test cycle the filtrati
38. ll cap Install HEPA filter for fit for fit testing Connect the twin tube assembly to the PORTACOUNT Connect the twin tube assembly to the respirator sampling port Repair or replace the twin Repair the respirator Have valve replaced 55 CHAPTER XI TABLE 8 Troubleshooting the PORTACOUNT continued Symptom Possible Causes Solution E E message appears Fails zero check Ambient particle concentration is low PORTACOUNT is flooded with alcohol Alcohol level is low Switching valve is not functioning Plugs are still in the end of the twin tube assembly Wrong tube is connected to respirator Twin tube assembly is kinked pinched or blocked Hoses are reversed on twin tube assembly Downstream sample is taken during first sampling period in the Sequential Mode Alcohol fill cap is loose or missing Rubber O ring is missing from the alcohol fill cap Twin tube assembly leaks Switching valve is not functioning Filter leaks Ends of twin tube assembly are poorly sealed Twin tube assembly is In the Count Mode check whether the concentration is less than 1000 particles per cubic centimeter If so move the instrument to an area having higher concentration Run overnight in Count Mode to dry the optics Add alcohol to the PORTACOUNT Have switching valve replaced Remove the plugs from the end of the twin tube assembly Connect the proper t
39. lt clip Alcohol fill indicator CHAPTER III The alcohol fill cap at the bottom of the PORTACOUNT 13 fig III 1 unscrews to reveal the alcohol fill port The connector on the side of the PORTACOUNT outputs serial data to a datalog ger computer or printer 12 fig III 1 The belt clip on the back of the PORTACOUNT 17 fig III 2 can also be used to hold the PORTACOUNT on its stand The alcohol fill indicator 21 fig III 1 turns white when the PORTACOUNT is low on alcohol It is dark colored when the alcohol level is adequate IV The Fit Test Mode Chapter IV The Fit Test Mode along with the following two chapters are critical to the operation of the PORTACOUNT They explain the instrument s three modes of operation Read them carefully The PORTACOUNT quantitatively measures respirator fit by comparing the con centration of particles outside the respirator to the concentration of particles inside the respirator The two concentrations are measured and the fit factor is calculated and displayed automatically WARNING The PORTACOUNT is designed to operate using the particles and concentrations that occur in ambient air Using the PORTACOUNT with generated aerosols DOP corn oil smoke etc will dirty the optics requiring factory service The PORTACOUNT should be used with a diluter when sampling with generated aerosols TSI recommends using the PORTACOUNT only with ambient air To measure the fit factor
40. ns and LIMITATIONS stated herein NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE THE EXCLUSIVE REMEDY OF THE USER OR PURCHASER AND THE LIMIT OF THE LIABILITY OF SELLER OR ANY OTHER SELLER FOR ANY AND ALL LOSSES INJURIES OR DAMAGE IN CONNECTION WITH THIS PRODUCT INCLUDING CLAIMS BASED ON CONTRACT NEGLIGENCE STRICT LIABILITY OTHER TORT OR OTHERWISE SHALL BE THE RETURN OF THE PRODUCT TO THE FACTORY OR DESIGNATED LOCATION AND THE REFUND OF THE PURCHASE PRICE OR AT THE OPTION OF SELLER THE REPAIR OR REPLACEMENT OF THE PRODUCT IN NO EVENT SHALL SELLER BE LIABLE FOR ANY SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES NO ACTION REGARDLESS OF FORM MAY BE BROUGHT AGAINST THE SELLER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED The purchaser and all users are deemed to have accepted the terms of this LIMI TATION OF WARRANTY AND LIABILITY which contains the complete and exclusive warranty of the Seller This LIMITATION OF WARRANTY AND LIABILITY may not be amended or modified nor may any of its terms be waived except by a writing signed by an authorized representative of Seller Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our customers our service policy is designed to give prompt attention to any problems If any malfunction is discovered please contact your nearest sales office or representative or call TSI s Customer Service dep
41. o or near zero PORTACOUNT is flooded with alcohol PORTACOUNT is flooded with alcohol Alcohol level is low Twin tube assembly is blocked Run overnight in Count Mode to dry the optics Run overnight in Count Mode to dry the optics Add alcohol Remove the blockage TABLE 9 Troubleshooting the MODEL 8902 Printer Symptom Does not switch on Does not print Prints incorrectly Possible Causes AC adapter is not plugged into outlet Outlet is switched off or does not have power AC adapter is not connected to the printer Printer cable is not connected to the printer and the PORTACOUNT Baud rate is incorrectly set on the printer Printer is not switched on Baud rate is incorrectly set on the printer Solution Plug the AC adapter into an outlet Plug the AC adapter into a powered outlet Connect the AC adapter to the printer Connect the printer cable to the printer and PORTA COUNT Set the baud rate on the printer to 1200 Switch on the printer Set the baud rate on the printer to 1200 58 CHAPTER XI Appendix A Theory of Operation The PORTACOUNT is based on a miniature continuous flow condensation nucleus counter CNC A CNC takes particles that are too small to be easily detected grows them to a larger easily detectable size and then counts them The idea of CNCs is not new As early as 1888 Aitken described a dust counter that grew particl
42. ocomputer must be properly wired to allow proper communications The following two figures show the proper configurations for IBM PC and IBM compatible micro computers Figure D 1 shows the serial interface signal connections for 25 pin RS 232 C connectors and figure D 2 shows the signal connections for 9 pin connectors Figure D 1 25 pin RS 232 C serial interface signal connections 65 66 APPENDIX D PORTACOUNT S SERIAL INTERFACE CONNECTIONS Figure D 2 9 pin serial interface signal connections Appendix E Changing the Output Level of the PORTACOUNT s Serial Interface The PORTACOUNT s serial interface can be set internally to transmit at either RS 232 C or TTL voltage levels When shipped the interface is set to operate at RS 232 C voltage levels This is correct for the majority of applications It is possi ble however to set the serial interface to operate at TTL voltage levels To do so follow these four steps WARNING This is a complex procedure Do not attempt it unless you have a thorough knowledge of electronics assembly tech niques TSI is not responsible for damage that may be done to the PORTACOUNT while attempting this procedure Step 1 With the battery pack disconnected remove the front cover from the instrument Step 2 Using a sharp knife care fully cut through the trace on the printed circuit board that is marked by an arrow fig E 1 y Figure E 1 Cutting through th
43. on factor is calculated and displayed Table 4 lists the test cycle in the Sequential Mode No purge time is programmed into the test cycle in the Sequential Mode To ensure accurate measurements it is important that you allow the PORTACOUNT to draw a sample from the desired sampling location for at least 30 seconds before starting a measurement cycle This ensures that the PORTACOUNT and twin tube assembly are properly purged TABLE 4 Test sequence in the Sequential Mode Action Time Notes Display 1 Ready for first sample Upstream sample 30 seconds Display 2 Ready for second sample Downstream sample 30 seconds Display filtration factor Test completed 32 Reading the display Calculating the filtration factor CHAPTER V To conserve battery life the PORTACOUNT automatically switches off if it is left running for 10 minutes in the Sequential Mode without starting a test This is also done if more than 10 minutes elapse between the time of the first upstream sample and the start of the second downstream sample The filtration factor is displayed in scientific notation using a two digit mantissa and one digit exponent The format is a bEc where a b is the mantissa and c is the exponent This corresponds to a b 10 To convert from scientific notation multiply the two digit mantissa by 10 raised to the c power thus 1 2E4 1 2 104 1 2 10 000 12 000 Table 2 shows the value of 10 for various values of c T
44. rint mechanism cover Step 6 Replace the printer paper The cartridge ribbon may also be replaced with paper in the printer By holding the cartridge ribbon as shown in figure VIII 5 you can slide the cartridge over the paper and into the printer compartment Be sure the paper slides between the ribbon cartridge and the ink ribbon Figure VIII 5 Installing the cartridge ribbon with paper in the printer If you get ribbon ink on the printer s plastic case wipe it off immediately Once dried it is difficult to remove Installing a paper roll PRINTER 43 Spare paper rolls are available as part of the MODEL 8904 Printer Supplies Kit To install a new roll of paper follow these eleven steps Step 1 Unroll several inches of the new paper roll Step 2 If jagged cut a straight edge on the paper roll to ease its entry into the printer Step 3 Be sure the printer is switched off Slide the paper through the slot connecting the paper compartment and the printer compartment You can slide it in about 1 4 inch before it stops fig VIII 6 Figure VIII 6 Inserting paper into the printer Step 4 Press and release the right side of the power switch and wait a few seconds Step 5 While holding the paper in place press the power switch to the PAPER FEED position A rubber roller then pulls the paper into the printer compartment Hold the switch in the PAPER FEED position until about 1 inch of paper emerges f
45. rom the top of the printer mechanism Then release the power switch fig VIII 7 Figure VIII 7 Feeding paper through the printer 44 CHAPTER VIII Step 6 Now pull the paper through the printer until several inches are exposed fig VII 8 Step 7 Slide the paper through the slot in the printer cover fig VIII 9 Figure VIII 9 Sliding paper through the printer cover PRINTER 45 Step 8 Push the back of the printer cover down and into place fig VIN 10 Step 9 Press down the front of the printer cover to lock itin place fig VIII 11 Figure VIII 11 Locking down the printer cover Step 10 Put the paper spindle into the paper roll and press the roll with the spindle into the clips near the back of the printer fig VII 12 Figure VIII 12 Installing the paper spindle 46 Removing a paper roll CHAPTER VIII Step 11 Rotate the roll to take up any slack Make sure it turns freely If not the paper will jam and perhaps damage the printing mechanism The paper roll installation process is now complete To remove a roll of paper follow these four steps WARNING Do not pull the paper out of the back of the printer The printing mechanism will be damaged Step 1 Use the paper feed switch to advance the paper about one inch beyond the paper cutter fig VII 13 Figure VIII 13 Advancing the paper Step 2 Lift the paper roll away from the printer housing
46. t and latch the cover in place 47 CHAPTER IX Step 4 Plug the small connector from the power supply into the socket located on the outside ofthecover The label on the connector marked UP refers to the top of the PORTACOUNT The socket has been located so that the stand may still be used to hold the PORTA COUNT fig IX 3 Figure IX 3 Connecting the power supply Step 5 Plug the power supply into an AC outlet Make sure you use a 115 volt AC outlet for 115 volt power supplies and a 220 volt AC for 220 volt power supplies Your PORTACOUNT is now ready for use without batteries X Maintenance Adding alcohol Alcohol should be added when the PORTACOUNT is first received new from TSI and whenever the alcohol indicator turns white The instructions below describe how to add alcohol to the PORTACOUNT Do not add alcohol if the fill indicator is dark If the fill indicator is white fill the PORTACOUNT using the procedure below During operation when the fill indicator first begins to turn white the PORTACOUNT will operate approximately 45 minutes before the low particle count E E message appears WARNING 1 PORTACOUNTSs should always be shipped dry as a precaution against inadvertent flooding To dry a PORTACOUNT you should run it in COUNT mode until the alcohol fill indicator is a solid white color This may take several hours 1 Never add alcohol to the PORTACOUNT when the fill indicator is dark Do not contin
47. t the overall fit factor is greater than or equal to the set pass fail level 28 Setting pass fail levels CHAPTER IV The PORTACOUNT is shipped from the factory with the pass fail level set at 100 although it can be set to many different levels To set a different level follow these four steps Step 1 Make sure the instrument is switched off Using a slotted screwdriver remove the four screws on the front cover Step 2 Carefully lift the front cover to expose the printed circuit board and DIP switches fig IV 2 Step 3 Set the DIP switches to the desired pass fail level Table 3 gives the settings for the different levels fig IV 3 S Step 4 Replace the front cover and four screws making sure the membrane switch remains connected THE FIT TEST MODE TABLE3 Pass fail level settings Fit Factor SW1 SW2 SW3 SWA 0 off off off off Factory Setting 100 off off off on 250 off off on off 500 off off on on 1000 off on off off 1250 off on off on 1667 off on on off 2000 off on on on 4000 on off off off 5000 on off off on 6667 on off on off 10 000 on off on on Reserved on on off off Reserved on on off on Reserved on on on off Reserved on on on on Setting the pass fail level to zero effectively disables the pass fail indi cation The pass indicator will always light This setting can be used when the desired pass fail level is not available or when the PORTACOUNT is used with the opt
48. terface port Note that the microcomputer can read the PORTACOUNT serial interface only if its RS 232 C port is properly initialized Two methods are available both require a MODEL 8905 9 or 8905 25 Interface Cable or their equivalents One method is accomplished from within a BASIC language computer program using the OPEN command Before PORTACOUNT communications begin execute the following BASIC statement OPEN COM1 1200 N 8 1 AS 1 The other method for initializing the RS 232 C port uses the DOS MODE com mand Before PORTACOUNT communications begin execute the following DOS command MODE COM1 1200 N 8 1 The following sample BASIC program reads the PORTACOUNT output and dis plays it on the screen 10 PROGRAM TO READ AND DISPLAY PORTACOUNT OUTPUT 20 30 CLS CLEAR SCREEN 40 OUT 1021 96 CLEAR STATUS PORT 50 OPEN COM1 1200 N 8 1 AS 1 OPEN COMMUNICATIONS 60 INPUT 1 A INPUT DATA IN STRING FORMAT 70 PRINT AS PRINT RESULTS 80 GOTO 60 LOOP BACK FOR MORE DATA If you plan to write your own programs to communicate with the PORTA COUNT keep in mind that no handshaking takes place between the mi crocomputer and the PORTACOUNT This means that the PORTACOUNT transmits data whenever it is ready regardless of the microcomputer s readiness to receive data To make certain no data is lost be sure that the program is receiving when the PORTACOUNT is transmitting This is fairly easy to do since the PORTA
49. th the instrument s data readout are represented in this manual by the sans serif typeface called Helvetica Light Example 1 To switch off the PORTACOUNT simultaneously press ENABLE and OFF from Switching the PORTACOUNT on and off in Ch II Example 2 The format is a bEc where a b is the mantissa and c is the exponent from Reading the display in Ch VI To call attention to an important note or comment a black four pointed star is used ABOUT THIS MANUAL Introduction The PORTACOUNT is a highly versatile portable particle counting instrument It can accurately measure respirator fit factors filter penetrations and particle con centrations Respirator fit factors and filter penetrations are measured using ambient air particles as the challenge aerosol Based on the technology of continuous flow condensation nucleus counters the PORTACOUNT counts individual airborne particles from sources such as smoke dust and engine exhaust It does so by growing particles that are too small to be otherwise detected to an easily detectable size In the Count Mode the PORTA COUNT measures the concentration of these airborne particles In the Fit Test Mode the instrument measures the concentration of these particles inside and outside a respirator and calculates the fit factor In the Sequential Mode the instrument measures the concentration on either side of a filter and calculates the filter penetration Various accessories can be
50. ty when the carriage return is received the paper simply advances one line leaving a blank line in the printout The PORTACOUNT serial output automatically provides the required line feeds and carriage returns to operate the printer properly The printer has a graphics mode and a reverse field mode Note that printing with patterns having high dot density wears out the print head faster It is recommended that you use patterns in which dot density is equal to that of or dinary alphanumerics Caution During operation do not subject the printer to temperatures below 23 F 5 C or above 104 F 40 C or to sudden changes in temperature Never place the printer where it is exposed to direct sunlight I Never apply power while you are plugging or un plugging an input connector I Do not print without paper and or ribbon you may damage the print head 39 40 The self test mode Changing the ribbon CHAPTER VIII The three steps of the printer s self test mode are performed as follows WARNING Perform the self test only after inserting paper into the printer Step 1 Depress the right side of the power switch until it reaches the paper feed position Step 2 Hold the switch in the paper feed position until the LED comes on and the printer starts to operate Release the switch Step 3 There are two ways to stop the printer Either turn the power switch to the OFF position during printing and wait 3 seconds be
51. ube to the respirator labelled S Straighten out the twin tube assembly or remove the obstruction Connect the hoses properly to the PORTACOUNT Measure the upstream concentration during the first sampling period in Sequential Mode Tightly close the alcohol fill cap Replace the rubber O ring on the alcohol fill cap Repair or replace the twin tube assembly Have switching valve replaced Repeat the test with a different filter Cut off the bad ends on the twin tube assembly Connect the twin tube disconnected assembly to the PORTACOUNT 625 on PORTACOUNTs with Rev A or earlier firmware 1500 on PORTACOUNTs with Rev B C or D firmware TROUBLESHOOTING 57 TABLE 8 Troubleshooting the PORTACOUNT continued Symptom Possible Causes Solution Suspicious readings optics PORTACOUNT is flooded with alcohol PORTACOUNT leaks Alcohol level is low Alcohol fill cap is loose or open Respirator is not equipped with HEPA filters Twin tube assembly is kinked Run overnight to dry the Zero check the PORTACOUNT and fix any leaks Add alcohol to the PORTA COUNT Tightly close the alcohol fill cap Install HEPA filters for fit tests Straighten out the twin tube pinched or blocked assembly or remove the obstruction Respirator is faulty Fix or replace the respirator Alcohol visible in twin tube assembly or coming out of exhaust port Particle count is zer
52. ue to add alcohol once the fill indicator has turned from white to dark Caution Alcohol is extremely flammable Do not fill near open flame or source of ignition I Never fill the PORTACOUNT with alcohol other than 100 reagent grade iso propyl alcohol Figure X 1 Alcohol indicator white dry 7 Figure X 2 Alcohol indicator dark wet 49 50 CHAPTER X Step 1 Step 2 Step 3 Step 4 naummeran mue Era Een 7 count MORE Turn the PORTACOUNT off and remove the alcohol fill cap fig X 3 mopar wur Figure X 3 Removing the alcohol fill cap Open a disposable TSI alcohol bottle by twisting the top off Place the short plastic tube stub onto the end of a syringe and then connect the other end of the tube stub to the neck of the alcohol bottle fig X 4 Draw about 5 cc of alcohol into the syringe Remove the tube stub from the syringe If the alcohol bottle is not empty you may recap it and store it for later use Insert the end of the syringe into the alcohol fill port on the PORTACOUNT Make sure the syringe is inserted at the correct angle The syringe will remain in place without support if the angle is correct fig X 5 Figure X 5 Inserting the syringe Charging battery packs MAINTENANCE 51 Step5 While observing the alcohol fill indicator gently and slowly inject alcohol into the PORTACOUNT Stop filling the moment the indicator turns dark This may happen
53. used with the PORTACOUNT to enhance its operation they include a portable printer digital datalogger and fit testing software INTRODUCTION I Setup The PORTACOUNT is easy to set up First use the component lists to be sure no items are missing next identify the various parts in the labelled photographs Then follow the setup instructions to prepare the instrument and its accessories for operation Unpacking The following items are included with the PORTACOUNT if any are missing or damaged notify TSI immediately Oty Item Part No 1 PORTACOUNT with 8010 115V or twin tube assembly 8010 1 220V 1 Carrying case 1319024 2 Battery pack 8903 1 Stand 1206214 1 Charger 2613026 115V or 2613028 220V 48 Alcohol bottles with material safety data sheet and 8 syringes 800362 1 HEPA filter 1602066 1 Operator Guide 1980013 1 Operation and Service Manual 1980012 2 Hose adapters with tubes to Ya W to Vs If a MODEL 8902 Printer was also purchased the following parts are included Qty Part No 1 Printer 8902 115V or 8902 1 230V 1 Printer cable 8906 1 AC adapter 2613029 115V or 2613030 230V CHAPTER I If a MODEL 8018 Adapter was also purchased the following parts are included 800387 2613042 115V or 2613043 230V Electronics Module Power Supply Figure I 1 is a photograph showing the PORTACOUNT and its accessories Included at the front of this manual is a registr
54. ying respirator PAPR could generate some particles which would need to be eliminated as well The PORTACOUNT should be zero checked each day it is used to ensure that there are no leaks in the instrument or in the sampling system If fit tests are performed with leaks the fit factors will be measured low Zero checking the PORTACOUNT is easy Follow the three step procedure listed below Step1 Attach the supplied HEPA filter to the Sample hose labelled s on the twin tube assembly The arrow on the filter indicates the direction of flow fig IV 1 Figure IV 1 Zero checking the PORTACOUNT Step 2 Set the instrument to the Count Mode Step 3 Watch the display The concentration should go to zero within 30 seconds If not there is a leak that must be found and eliminated before performing fit tests In the Fit Test Mode the PORTACOUNT automatically samples both the ambient air and the particles inside the respirator An internal switching valve auto matically switches between the two sampling ports In each 80 second test cycle both an ambient sample and a respirator sample are taken Also time is allowed for purging the sensor between each of the samples The twin tube assembly is designed to purge properly in the time allowed in the test sequence Lengthening the tubes may cause problems with purging the sensor and the tubes between samples The test starts when you press the ENABLE and TEST keypads The first
55. ys the concentration measured through the Sample port in particles per cubic centimeter When ini tially sampling in the Count Mode the display is updated every second To switch to the 15 second averaging mode simultaneously press ENABLE and TEST The display then shows the average concentration every 15 seconds To return to the 1 second averaging mode simultaneously press ENABLE and TEST again The PORTACOUNT switches between the 1 second and the 15 second averaging modes each time you press ENABLE and TEST simultaneously To light the display press and hold the DISPLAY LIGHT keypad Error messages Switching the printer on and off Advancing printer paper OPERATION 17 The PORTACOUNT s display can indicate two error messages E E and LO E E message The E E Message will be displayed if the ambient particle concentration is not sufficient for respirator fit testing There are several possible reasons that can cause this message to appear m There may not be sufficient particles in the air for fit testing This can be caused by such things as special HEPA filtered ventilation systems or on rare occasions unusual weather such as several days of heavy rain m The PORTACOUNT may be low on alcohol See the Maintenance section of this manual m The PORTACOUNT may be flooded with too much alcohol See the Adding Alcohol section in this manual and the Troubleshooting section in this manual m The twin tube on the P
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