OPERATORS MANUAL FOR DOP SOLUTIONS PHOTOMETER SP200DAS with Data Acquisition System

DOP Solutions Ltd Unit 10, Protea Way, Pixmore Avenue, Letchworth, Hertfordshire SG6 1JT Telephone :+44 (0)1462 676446 Facsimile : +44 (0)1462 486078
email : sales@dopsolutions.com web : www.dopsolutions.com

Dated: July 2009 DOP Solutions Ltd 2009

P/N : 910-0202-008 Operators Manual for SP200DAS.doc

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

TABLE OF CONTENTS

DISCLAIMER .................................................................................................................................. 3 WARNING ....................................................................................................................................... 3 ELECTRICAL WARNING ............................................................................................................... 3 STARTING UP ................................................................................................................................ 4 1. AEROSOL PHOTOMETER ................................................................................................. 4 1.1 BASIC FEATURES OF THE INSTRUMENT ................................................................................. 5 1.1.1 General ...................................................................................................................... 5 1.1.2 Test Guidelines .......................................................................................................... 6 1.1.3 Hour Meter ................................................................................................................. 6 1.2 MECHANICAL DESCRIPTION .................................................................................................. 6 2 OPERATION OF THE INSTRUMENT ................................................................................... 12 2.1 2.2 3 MODE OF OPERATION SP200DAS - METHOD 1 THE ABSOLUTE CALIBRATED METHOD ......... 12 MODE OF OPERATION SP200DAS - METHOD 2 THE PERCENTAGE PENETRATION METHOD . 13

USER MAINTENANCE PROCEDURES ............................................................................... 15 3.1 3.2 3.3 3.4 3.3 CLEANING IN-LINE PARTICULATE FILTERS ........................................................................... 15 REPLACEMENT OF ZERO AIR FILTER ................................................................................... 16 REPLACEMENT OF INLINE HEPA AIR FILTER ...................................................................... 17 REPLACEMENT OF POWER FUSES ...................................................................................... 17 GENERAL CLEANLINESS ..................................................................................................... 18

4 5

FAULT DIAGNOSIS .............................................................................................................. 19 SERVICE AND CALIBRATION............................................................................................. 20 5.1 5.2 5.3 CALIBRATION..................................................................................................................... 20 SERVICE ........................................................................................................................... 20 PACKING FOR FREIGHT....................................................................................................... 21

DECLARATION OF CE CONFORMITY................................................................................ 22

TABLE OF FIGURES
FIGURE 1 - AEROSOL PHOTOMETER BASIC BLOCK DIAGRAM............................................................... 8 FIGURE 2 - DIAGRAM OF THE OPTICAL CHAMBER ................................................................................ 9 FIGURE 3 - PANEL LAYOUT OF AN SP200DAS AEROSOL PHOTOMETER ............................................. 10 FIGURE 4 - SP200DAS AEROSOL PHOTOMETER WITH DNS ............................................................. 11

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 2

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

DISCLAIMER

This manual is intended to explain the use and operation of the aerosol photometer. It in no way attempts to instruct the reader in the full requirements for the testing of HEPA filters in their many varied applications. It is strongly recommended that users of the aerosol photometer consider participating in a training course on the testing of HEPA filters.

WARNING
You MUST NOT expose the Aerosol Photometer to high concentrations of aerosol. sampling concentrations in excess of 10g/l NEVER sample continuously. When

Sampling periods of less than 30 seconds MUST be used.

Excessive exposure to high concentrations of aerosol will damage the instrument.

NEVER turn the instrument off immediately after sampling.

Allow the instrument to purge for at least 10 minutes after having completed a test and then switch off.

Turn the span and zero dials slowly. Turning them quickly may cause the gears to slip. The dial will then not read zero when turned to zero.

Do not restrict the cooling air flow around the sides of the instrument. Papers etc. should NOT be stored down the sides of the instrument.

ELECTRICAL WARNING
There are dangerous voltages inside the instrument. NEVER access the internal components of the photometer while it is plugged into the mains supply.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 3

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

Starting Up
The SP200DAS is shipped with the following : Model Sample Probe (Option) USB Cable DAS CD : SP200DAS : SP20 or SP20A or SP12 or no probe. : 581-24-001 : Software & Manuals SP200DAS Operators Manual DAS Operators Manual : 852-196 Standard UK (5 amp) 852-784 Europe Type (Schuke) 852-333 RSA 3-pin (15 amp) 852-661 USA C13 socket 852-174 Australia/NZ : 999-001-B : 2mm (609-578) : 700-067 3.66 metres

Power Lead (one of)

Transport Case Allen Key Upstream sample tube

Please read the Operator Manuals before starting to use the photometer.

1.

Aerosol Photometer

The DOP SP200DAS Aerosol Photometer is used for the determination of the penetration leaks in HEPA Filters. The overall efficiency of the HEPA media can also be determined. The SP200DAS has a built in Data Acquisition System (DAS). This allows direct connection to a PC running under Windows XP or Windows Vista. Please refer to the separate manual for the operation of the DAS. The HEPA Filter test method used is commonly known as the DOP Test. The SP200DAS is used in conjunction with an aerosol generator. This would be either the DOP1100 Thermal Generator or a Laskin Nozzle Generator from the DOP range of Generators. Both types of generators produce aerosol particle size within the range of the MPPS (Most Penetrating Particle Size) of HEPA Filters. The test set-up will very likely include a Positive Injection Pump (PIP) which enhances aerosol mixing at the point of injection, particularly when used with the DOP range of sparge pipes. Additionally an Aerosol Mixer Splitter System (AMSS) the DOP1350 may be used to introduce small amounts of aerosol to a test filter where the generators would provide a too larger aerosol challenge under normal circumstances.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 4

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

1.1

Basic Features of the Instrument

Please refer to Figure 3 for a panel layout of the SP200DAS Aerosol Photometer.

1.1.1

General

The power on/off switch enables power to be supplied to the instrument when plugged into the correct mains supply. The power switch is located on the left front side of the instrument. The photometer is fitted with a universal power supply enabling it to be operated from 110 volt or 220/240-volt 50 or 60 Hz. Fuses are found in the IEC connector below the switch on the left front side of the instrument. The photometer is a mass measuring device that relies on the sample flow through the instrument remaining constant. A supply frequency change would require the instrument to be recalibrated. The sample switch allows for either sample up or down to be selected. When neither are selected the instrument is sampling "zero" or clean air. When upstream mixing of the aerosol is erratic and unstable far greater accuracy of reading the DNS (Digital Noise Suppresser) has been incorporated. The DNS dampens the response time so a more stable reading is obtainable (Figure 4). When the DNS is on a green LED light is displayed on the photometer. The probe socket provides a low power signal to the remote alarm indicator. The indicator that is a red LED fitted to the hand held sampling probe, illuminates when the pre-set value is exceeded. If the audible alarm switch or control is switched on, an alarm also sounds when the LED is illuminated. To set an alarm value hold the alarm spring switch down and rotate the adjusting knob so that the alarm value is displayed. Release the switch. The SP200DAS Aerosol Photometer has a USB socket which connects directly to a PC USB port. A separate manual covers the operation of the DAS. DO NOT PLUG IN THE USB CABLE BEFORE THE USB DRIVER SOFTWARE HAS BEEN LOADED ON TO THE PC FROM THE CD.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 5

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

1.1.2

Test Guidelines

Below are some requirements for testing. The aerosol generator being used for the tests is capable of providing a constant output of aerosol during the test period and is suitable for DOP testing. The aerosol generator can provide sufficient concentration for the system under test which should be between 10-100g/l The aerosol generator is employing a similar oil to that with which the photometer was calibrated. The photometer is in good working order and is within its calibration period. The system test specifications must be known. For filter leakage penetration testing (The DOP Test) a means must be provided for the measurement of the upstream concentration. DO NOT sample upstream of the filter while the aerosol is stabilising within the air stream. It can take up to 2 minutes for any adjustment of the aerosol generator to be measured depending on the point of aerosol introduction and system design. Be patient and wait for a steady reading. The sample probe length for the upstream and downstream sample should not exceed 3.66 metres. The upstream sample ports on the system under test should not have an internal diameter of less than 5.0 mm. Use just above minimum challenge aerosol required for the test. This minimises any filter loading. Only over challenging the filters will cause loading problems on the filter.

1.1.3

Hour Meter

The digital SP200DAS photometer is fitted with an hour meter. This is provided to enable the user to determine the frequency of USER MAINTENANCE and in certain circumstances the interval between calibrations. It is advised that a logbook is kept of when the USER MAINTENANCE is carried out.

1.2

Mechanical Description

Please refer to Figure 1 for a basic block diagram showing the major part of an aerosol photometer. The instrument may draw sample air in through one of two sample ports (Upstream or Downstream) which are switched by solenoid valves. The zero Air HEPA filter is operative when the sample ports are closed. The zero air filter is the reference filter against which the instrument is zeroed. Two coarse particle filters brick catchers prevent large particles from entering the sample system. The sample or zero air is drawn into the optical chamber sample vacuum pump. This pump will draw nominally 1 scfm through the optical chamber. The expelled sample from the pump passes through an inline exhaust HEPA filter. This exhaust is vented to the outside of the instrument. Through a port on the lid. This clean exhaust air may be used to flush out dead zones during testing. The optical chamber is an optically blackened forward scattering light chamber. The lamp provides the necessary light source for the optical chamber. The presence of particles (aerosol) in the chamber causes light to be scattered forward to the detector. The detector signal is amplified and then linearised to be displayed on the digital meter. In order to understand the operation of the photometer it is necessary to look at the optical chamber in a little more detail. Please refer to Figure 2. The light source 6 is focused using two lenses 1 and 2. The focus is at the apex of the sample 3. The sample is drawn in at 8 and out at 9. The sample travels through the point of focus. The design of this chamber is such that it is self cleaning without any dead space. FILE: 910-0202-008 Operators Manual for SP200DAS.doc Page 6

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

In the zero sample mode when clean air is being drawn through the sample chamber there is no forward scattered light. The detector then only sees the background light. The image of the lamp is prevented from reaching the detector by a disc 10 that is adhered to lens 2. This is the key feature in the operation of the optical chamber. A sample introduced into the chamber scatters light forward due to its intersection with light from the lamp. The forward-scattered light causes an apparent image. The image intensity is dependent upon the concentration of sample aerosol in the chamber at the time. The apparent image is then focused on to the detector 5 through lens 4. A calibration lamp 11 is provided for the calibration of the instrument. This is used to provide a stable set point against which the instrument can be calibrated to 10 g/l for both ONDINA-EL oil and EMERY 3004 PAO. The display meter 1 (figure 1) is fitted with an alarm function. An alarm set point is used to give an audible and visual indication of when the meter has exceeded the set point value. A switch or control to enable the audio alarm ONLY to be turned off is located above the hand held probe socket. The photometer may be provided with a number of probe options. All probes are optional and purchased separately. Probe options are : SP12 A Fish tail probe with alarm LED indicator built into the handle. SP20 A 316 stainless steel Fish tail probe with alarm LED indicator built into the handle with a digital display mirroring the display on the instrument. The fish tail may be removed from the handle. SP20A An 316 stainless steel handle with alarm LED indicator built into the handle and LCD digital display mirroring the display on the instrument . The articulated Fish tail probe is PVC with a PVC fish tail. This allows the fish tail to be located at any angle relative to the display and handle. The fish tail may be removed from the handle. The fish tail enables approximately 62mm of filter face to be scanned at a time.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 7

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

FIGURE 1 - AEROSOL PHOTOMETER BASIC BLOCK DIAGRAM

Upstream Downstream Sample Sample

Solenoid Valve

Solenoid Valve

Inline "Brick" Catchers

Mini USB Socket to PC

0.0005
HEPA Filtered Exhaust Sample Vacuum Pump Main Electronics Data Acquisition Board

Exhaust HEPA Filter

Lamp Housing

Lens Assembly

Measuring Chamber

Cal LED

Detector Assembly HEPA Zero Air Filter

Optical Chamber
FILE: 910-0202-008 Operators Manual for SP200DAS.doc Page 8

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

FIGURE 2 - DIAGRAM OF THE OPTICAL CHAMBER

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 9

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

FIGURE 3 - PANEL LAYOUT OF AN SP200DAS AEROSOL PHOTOMETER

FIGURE 3 - PANEL LAYOUT OF AN SP200DAS AEROSOL PHOTOMETER

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 10

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

FIGURE 4 - SP200DAS AEROSOL PHOTOMETER WITH DNS

SP200DAS Aerosol Photometer with DNS

Test Conditions : A 610 mm x 610 mm filter was challenged with a high output Mini Aerogene with a mixing distance of 1 metre. The upstream sample port was 100 mm from the filter face on the downstream side of the blower. The SP200 sampled from the port and the aerosol concentration was adjusted to about 100 g/l. The SUPPRESSION OFF section of the graph shows the poor mixing taking place. The value was impossible to interpret until the DNS was applied. The improvement was 5 fold.

120

100

Micrograms per litre aerosol

80

Rise time zero to 100% 12 sec

SUPPRESSION ON
60

SUPPRESSION OFF Average Minimum Maximum Peak to Peak difference Time 96% 84% 110% 26% 51 sec

40

Average Minimum Maximum Peak to Peak difference Time

98% 95% 100% 5% 51 sec

20

The Digital Noise Suppresser - DNS

0 0 20000 40000 60000 80000 100000 120000 140000 160000

Time in milli seconds

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 11

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

2
2.1

Operation of the Instrument

Mode of Operation SP200DAS - Method 1 The Absolute Calibrated Method

This procedure allows the set-up of the Photometer so that any air sample reading obtained is a direct representation of mass aerosol concentration in g/l. 1. Prior to switching the instrument on it is good practice to set a standard for switch positions as detailed. a) b) c) d) Sample switch Audible alarm switch Range switch Zero potentiometer - ZERO (i.e. central position) - OFF - HIGH - fully turned to the right. (Ensure that the lock is unlocked position to the left) - fully turned to the left. (Ensure that the lock is unlocked position to the left) - OFF

e) Span potentiometer f) DNS Switch

NOTE: When adjusting the Zero and Span potentiometer ensure the locking levers are unlocked. The lock is in the unlocked position when the levers are to the left. If forced when in the locked position, damage may occur. Do not turn the dials rapidly. 2. Switch the instrument on and allow a 15-minute warm up time. 3. Hold the spring loaded CAL REF switch in the appropriate direction dependent on the aerosol being used (SHELL ONDINA EL or EMERY 3004 / DURASYN164 - PAO). This simulates an artificial aerosol concentration inside the optical chamber equal to 10 g/l. 4. Rotate the span vernier dial slowly to the right until the digital meter indicates 10.00. Release the calibration switch. 5. Switch the range to LOW. 6. Observe the reading. This is the stray light value for the optical chamber. As the chamber ages this value will increase. A value of 0.0100 indicates the instrument should be returned for service as the optical chamber is contaminated. 7. Rotate the zero dial slowly to the left until the meter indicates 0.0000. This sets zero. The indicated digital display value should be steady on this range and not fluctuate more than 3 minor divisions. 8. Set the range switch to HIGH and return to Step 3 to check the settings and repeat the sequence if they are incorrect. 9. The ABSOLUTE calibration of the instrument is now complete. The instrument may now be used to measure directly in mass concentration i.e. in micrograms per litre (g/l) on both HIGH LOW ranges.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 12

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

2.2

Mode of Operation SP200DAS - Method 2 The Percentage Penetration Method

This method is used to obtain a leakage percentage penetration figure for the filter under test. Setting the instrument as described below allows testing to confirm the quality of the filter and to prove no leaks are present. 1. It is imperative to measure the absolute upstream aerosol concentration in g/l. 2. 3. The instrument should be calibrated by following the procedure defined in steps of Method 1. Having calibrated the instrument as a mass measuring device, you are ready to sample the homogeneously mixed upstream aerosol concentration. Connect one end of the sampling tube to Sample Port UP and ensure the other accesses the duct or plenum upstream of the filter under test. The sample should be taken from the centre of the filter system 5 to 10 cm from the filter face. Use DOP Solutions upstream sample ports to achieve this if no sample port is available.

4.

5. Switch to HIGH range. 6. Sample from the upstream sample port by selection of UP on the Stream Selection Switch. (DO NOT SAMPLE UPSTREAM CHALLENGE FOR MORE THAN 30 SECONDS.) 7. The reading should be stable to demonstrate good mixing of aerosol within the system airflow. If there is instability, as a rule of thumb in excess of +5%, (+15% in ISO EN 14644-3) insufficient mixing is taking place and the test becomes unreliable. If unstable mixing is occurring and it is not possible to increase the mixing length between the injection and upstream sample points, the DNS (Digital Noise Suppressor) should be used. Use of the DNS does not resolve the mixing requirements. When the instrument is sampling the upstream aerosol, switch on the DNS. Green LED will come on. Do not sample for more than 30 seconds. Improved mixing should be achieved using the DOP sparge pipe systems when required. (Consult DOP Solutions for guaranteed solutions to your mixing problems) When a satisfactory aerosol concentration is achieved record this value as your upstream aerosol challenge. Stop sampling and allow the instrument to purge (clear) the high concentration. (DO NOT SAMPLE UPSTREAM CHALLENGE FOR MORE THAN 30 SECONDS.) After 60 seconds sample the upstream challenge again. It should be similar to that found in the above. Now adjust the SPAN dial to produce a reading on the digital display of 100. Remember to sample for short periods only.

8.

9.

10. Switch off the Sample Port - Stop sampling and allow the instrument to purge (clear) the high concentration. This has now turned the mass weight of aerosol in g/l into the 100% reference. Any sample measurement will now be expressed as a % of the upstream test aerosol. Turn off the DNS switch, if used. 11. Switch to LOW range. Ensure the stream selection sample switch is in the ZERO position and the DNS switch is OFF. 12. Rotate the zero dial to the left until the meter indicates 0.0000. 13. Set the alarm to the desired value. To do this hold down the ALARM SET POINT switch while at the same time adjusting the vernier ALARM set-point control. 14. Turn the audio alarm switch to ON. 15. The instrument is now ready to scan the downstream side of the filter.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 13

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009 16. Ensure the sample probe is in the clean area and ready for testing. Switch on sample port DOWN. Hold the sampling probe over a clean area of the HEPA filter and OPEN the DOWN STREAM sample port. Move the probe around a small area and observe the reading. This is the average media penetration. Check other areas to confirm. Scan the filter frame and then the media according to the method being applied. 17. Testing protocols are described in a number of international standards. Commonly the filter media should not be scanned at a rate of more than 5 cm/sec at a distance of 0.05cm to 3.0 cm from the filter face. The frame and gasket would normally be scanned first followed by the filter media. Scan rates for the gasket and frame are the same as for the media. 18. The penetration value for good HEPA filters grades will typically be 0.0001%to 0.0005% penetration. The maximum penetration obtained during a scan of the filter media area would be considered the maximum penetration for the filter. The maximum penetration permissible for any international standard is 0.01%. The permissible maximum value should be declared in the test protocol and would typically be either 0.001%, 0.003% 0.005% or 0.01%. 19. At the end of the test check the upstream challenge again. It should be over 85% and less than 115%. 20. On completion of the test allow the instrument to purge for a minimum of 5 minutes to allow all aerosols to be driven from the instrument.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 14

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

3
3.1

User Maintenance Procedures

Cleaning In-Line Particulate Filters

As a good rule of thumb, if the instrument is used on a daily basis then this procedure should be carried out weekly. If you are not familiar with the history of the instrument then it is advised that the procedures be carried out the first time the instrument is prepared for use. NOTE: The In-Line Particulate Filters (ILPF) are NOT to be used with any filter paper present. They are designed to collect GROSS contamination (large fluff balls and large particulates), which may over time cause a performance degradation of the instrument. They therefore require regular cleaning. EACH PARTICULATE FILTER SHOULD BE REMOVED SINGLE ONE AT A TIME. a) b) Disconnect the instrument from the mains supply. Open the lid of the instrument by removing the screws found on either side of the front of the lid. Locate the ILPF. They are the 25mm white narrow white nylon cylinders in each sample line, secured to the lid with Velcro tape. Open the securing Velcro tape. Remove the ILPF, one at a time, as detailed below: Mark the end of the ILPF and the tubing if you are in any doubt about its orientation. Care should be taken, as it is possible to reverse these filters. The top of the filter is connected to the elbow fitting with a nylon pipe or silicone tube. If there is a length of nylon pipe between the inlet fitting and the ILPF then remove the nylon pipe from the fitting on the ILPF by pushing back the blue outer ring of the fitting and at the same time pulling on the nylon pipe and filter. The pipe will now pull out of the fitting. Long nose pliers may be required to push back the blue fitting on the ILPF. If the tube connecting the top of the filter to the inlet elbow fitting is silicone remove the silicone tube from the top of the filter. Do not remove the silicone tube from the other side of the filter ILPF. Remove the silicone tube from the solenoid valve, keeping the tube attached to the bottom end of the ILPF. This way it is more difficult to make an error in the replacement of the filter holder. e) The main filter body unscrews and breaks into two parts. Take care not to lose the "O" ring. Dust off the filter gauze using a stiff brush. An old toothbrush is ideal for this. Examine the filter for traces of oil. If oil is present on the filter face, then rinse off with a solvent. Methanol. IPA or Ethanol is suitable for this. Clean the "O" ring and examine for damage - replace if necessary. DO NOT use a to clean the "O" ring. Warm soapy water is best. h) i) The filter should be dry and clean before re-assembly. Apply a very small amount of silicone grease to the O ring. solvent

c)

d)

f) g)

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 15

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009 j) Hold the portion of the filter with the gauze such that the gauze is horizontal. Place the "O" ring on top of the filter and locate it centrally. Gently attach the other half of the filter maintaining the gauze and "0" ring in a horizontal position. Replace the filter into the instrument so that it is orientated the same way as it was before removal. This should be such that the gauze portion of the filter is on the solenoid side of the tubing. Remove the other in-line filter and carry out the steps e to k.

k)

l)

m) Hold the two filters against the front panel and secure the Velcro tape to keep the filters in place.

3.2

Replacement of Zero Air Filter

NOTE: It is not normally necessary to change the zero air filter between service intervals. The Zero Air filter is the instrument reference filter and is a high grade 0.2 m/0.45m HEPA filter. When the instrument is used 8 hours or more per day on a daily basis the filter may require changing every 3 or 4 months. The frequency of change is entirely dependant upon the cleanliness of the environment in which the instrument is operating. Replacement part number: 650-507 If a replacement filter is required, to be fitted, then the following procedure should be used to change it. a) b) Disconnect the instrument from the mains supply. Open the lid of the instrument by removing the screws found either front side corners of the lid. Locate and remove the complete zero air filter holder by disconnecting the silicone tubing first. The filter is located at the front right hand corner of the photometer. Remove the pipe fitting (and grey adaptor which it is screwed into) from the filter by pulling the fitting from the body of the filter. Rotate the whole fitting around the filter and pull. The grey plastic adaptor entering the filter is a push fit and sealed with an O ring integral to the filter. DO NOT attempt to unscrew the elbow fitting from the grey plastics adaptor. This is sealed with a special sealing compound. e) h) Apply a very small amount of silicone grease to the O ring of the new filter. Push the grey adaptor and elbow fitting back into the new filter ensuring that you rotate one against the other while pushing the two together. Place the filter assembly back into the photometer and re-connect the zero air tube ensuring it is secure and will not be pinched when the photometer lid is closed. Close the photometer lid and secure it with the screws. Test UP and DOWN ports to ensure there is suction on them, thus ensuring no tubes are pinched.

c)

d)

i)

j) k)

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 16

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

3.3

Replacement of Inline HEPA Air Filter

NOTE: It is not normally necessary to change the zero air filter between service intervals. The Zero Air filter is the instrument reference filter and is a high grade 0.2 m/0.45m HEPA filter. When the instrument is used 8 hours or more per day on a daily basis the filter may require changing every 3 or 4 months. The frequency of change is entirely dependant upon the cleanliness of the environment in which the instrument is operating. Replacement part numbers 650-509 Filter only 650-509-ASSY2 Filter and fittings If a replacement filter is required, to be fitted, then the following procedure should be used to change it. 1. Disconnect the instrument from the mains supply. 2. Open the lid of the instrument by removing the screws found either front side corners of the lid. 3. Locate the complete inline. The filter is located either immediately over the pump or centrally at the rear of the instrument behind the power supply. Make a careful note of which hose goes to which end of the filter. The filter is marked with an arrow showing the air flow direction. 4. Remove the complete inline filter by disconnecting the silicone tubing. The filter is located either immediately over the pump or centrally at the rear of the instrument behind the power supply. 5. Remove the pipe fittings from the filter by unscrewing them. 6. Screw the fittings back into the new filter, ensuring the correct direction of air flow. The air is flowing into the pump. 7. Place the filter assembly back into the photometer and secure with cable ties. Check all tubing is secure and will not be pinched when the photometer lid is closed. 8. Close the photometer lid and secure it with the screws. 9. Power up the instrument. 10. Test UP and DOWN ports to ensure there is suction on them, thus ensuring no tubes are pinched.

3.4

Replacement of Power Fuses

The SP200DNS is fitted with 2 anti-surge fuses DOP part number 450-01-ASG-03150A. Both the Live and Neutral line are fused. To replace a fuse : Switch the mains switch off. Disconnect the mains IEC plug from the instrument socket. Using a terminal flat head screw driver pull the fuse drawer out as shown. Lift out the fuses and replace them as required. Push the fuse drawer closed. Plug the IEC plug back into the instrument socket.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 17

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

Figure 5 - SP200DAS Fuse replacement

3.3

General Cleanliness

Always maintain the instrument in a clean condition. DO NOT clean the instrument case with any solvents. Use warm soapy water and a damp cloth to wipe it down. REMEMBER a well cared for instrument always operates better. This completes the user maintenance applicable to the photometer. NOTE: The optical lamp should never be replaced without re-calibration. Fitting of a new optical lamp will change the calibration of the instrument completely. Adhere to the calibration schedules issued by your Service Centre to ensure maximum operating reliability and life cycle out of your instrument. Testing filters with an instrument that is out of calibration or not functioning correctly could be life threatening. Not for the tester but for the operator believing the filters checked are operating correctly for their protection.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 18

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

Fault Diagnosis

When the photometer is used according to the instructions herein it is unlikely any problems will be encountered. Following is a brief list of the "problems" most likely to occur.

FAULT
1. The LOW range is unstable. 1a

ADVICE
The photometer has been exposed to high levels of aerosol, which have condensed into the optical chamber. Return to DOP Solutions for rectification. The zero air filter or in-line filters are leaking or the tube connection to the zero air filter has not been replaced. Check and correct as appropriate. One of the sample ports is open. The span on the photometer is too high. Check the span dial reading. If it is more than 1.0 (one full turn) above that quoted in the calibration report, page 4, then the upstream concentration is too low i.e. less than 10g/l. The in-line filters are blocked - see User Maintenance. See 2a above.

1b

1c 1d

2. No or low reading on upstream or downstream sample. 3. Low reading on upstream sample despite what appears to be a good challenge.

2a

3a

3b

3c

3d

Longer sample lines than those supplied are being used with the instrument. The instrument is calibrated with 3-metre sample tubing. This must NOT be lengthened or shortened. The upstream challenge is not reaching the sample port. Heat exchanger radiators or unknown filters may be in the path between the point of aerosol inject and the point of measurement of the upstream challenge. The sample port is too small. The sample port diameter should not be less than 6mm internal diameter.

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 19

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

5
5.1

Service and Calibration

Calibration

It is recommended that the instrument be calibrated at six monthly intervals or after 400 hours use. This will ensure optimum performance at all times provided the User Maintenance procedures are followed regularly. Under certain operating conditions it may be possible for DOP Solutions Limited to extend the calibration interval to 12 months. Please enquire with DOP Solutions to determine if your usage of the instrument meets these conditions.

5.2

Service

For service or calibration of your aerosol photometer please contact: DOP Solutions Limited Unit 10 Protea Way Pixmore Avenue Letchworth SG6 1JT Hertfordshire. U.K. Telephone: +44 (0) 1462 676446 Facsimile: +44 (0) 1462 486078 Email: sales@dopsolutions.com Website: www.dopsolutions.com

PRIOR TO RETURNING THE INSTRUMENT IT IS MOST IMPORTANT THAT YOU OBTAIN A RETURNS NUMBER FROM THE SERVICE CENTRE

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 20

Operation Manual for DOP Photometer SP200DAS DOP Solutions Ltd 2009

5.3

Packing For Freight

DOP Solutions can provide sturdy transportation cases for shipping of the instrument. It is advised that the instrument is shipped in a proper shipping box whenever possible. The SP200DAS is a sensitive measuring instrument and MUST always be well packed for shipment. NEVER SHIP IT WITHOUT ADEQUATE PROTECTION. Adequate protection for freight shipment is considered to be (when not shipped in a transport case provided by DOP Solutions Ltd.): a) The instrument bubble wrapped with a minimum of five times. b) This bubble wrapped packaged placed into a tight fitting box. This package placed in another larger box by approximately 120mm all around the first box and this second box is filled tightly with polystyrene chips, shredded paper or packing foam.

******************************************

FILE: 910-0202-008 Operators Manual for SP200DAS.doc

Page 21

Declaration of CE Conformity

DOP Solutions Ltd

Unit 10 Protea Way Letchworth Garden City Hertfordshire SG6 1JT United Kingdom

Declaration of CE Conformity
We : DOP Solutions Ltd under our sole responsibility declare that the product as listed below Model name: SP200DAS Digital Aerosol Photometer

conforms with the protection requirements of the European Directive 73/23/EEC, as

implemented by the Electrical Equipment (Safety) Regulations 1994, by application of the following standards: EN 61010-1:1993, EN 61010-1:2001

conforms with the protection requirements of European Directive 89/336/EEC, as implemented by the Electromagnetic Compatibility Regulations 1992, by application of the following standards: EN 61326:1998, EN 61326:2006

Year of affixation of the CE marking: 2009

Design Documentation is maintained at : DOP Solutions Ltd, Unit 10 Protea Way, Letchworth Garden City, Hertfordshire, SG6 1JT United Kingdom.

Signed :

Title

: Technical Director

Place : Letchworth Garden City : 3rd February 2009

Date