ES 642 9800 Manual Rev K

ES-642 Dust Monitor
Operation Manual
Met One Instruments, Inc

Corporate Sales & Service: 1600 NW Washington Blvd. Grants Pass, OR 97526
Tel (541) 471-7111 Fax (541) 471-7116
www.metone.com service@metone.com
ES-642 Operation Manual - © Copyright 2013 Met One Instruments, Inc. All Rights Reserved worldwide. No part of this
publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language in any
form without the express written permission of Met One Instruments, Inc.
Page 2 ES-642-9800 Rev K
Table of Contents
1 INTRODUCTION 6
1.1 About This Manual........................................................................................................... 6
1.2 Technical Service and Warranty ...................................................................................... 6
1.3 About the ES-642 ............................................................................................................ 6
1.4 Laser Radiation Safety and Conformity ........................................................................... 6
1.5 ES-642 Specifications ..................................................................................................... 8
2 ES-642 SETUP and STARTUP 9

2.1 Standard and Optional Accessories ................................................................................ 9
2.2 Setting Up the ES-642 ..................................................................................................... 9
2.3 Mounting Options .......................................................................................................... 10
2.3.1 Basic Unit Mounting:...................................................................................................... 10
2.3.2 Wall or Pole Mounting: .................................................................................................. 10
2.4 Electrical Connections ................................................................................................... 12
2.4.1 Power Requirements ..................................................................................................... 13
2.4.2 RS-485 Connections ..................................................................................................... 13
2.4.3 RS-232 Connections ..................................................................................................... 13
2.4.4 Analog Sense ................................................................................................................ 13
2.4.5 Analog Voltage Output .................................................................................................. 13
2.4.6 4 to 20 mA Analog Output ............................................................................................. 14
2.4.7 Concentration Relay Contact ......................................................................................... 14
2.5 Power-Up and Starting Operation.................................................................................. 14
2.5.1 Default Setup ................................................................................................................. 15
3 SITE SELECTION 16
3.1 Site Selection Requirements ......................................................................................... 16
4 CONCENTRATION ALARM RELAY SET POINT 17

4.1 Setting the Concentration Alarm Relay Set Point .......................................................... 17
5 FIELD CALIBRATIONS 18
5.1 Ambient Temperature Calibration .................................................................................. 18
5.2 Ambient Pressure Calibration ........................................................................................ 19
5.3 Sample RH Calibration .................................................................................................. 19
5.4 Flow Sensor Calibration ................................................................................................ 20
5.5 K Factor ......................................................................................................................... 20
6 MAINTENANCE and TROUBLESHOOTING 21

6.1 ES-642 Alarm Displays and Alarm Codes ..................................................................... 21
6.2 Basic Problem and Cause/Solution Table ..................................................................... 22
6.3 Suggested Periodic Maintenance Intervals ................................................................... 24
6.4 PUMP and PURGE Filter Changes ............................................................................... 25
ES-642-9800 Rev K Page 3

6.5 TSP Inlet and Cyclone Cleaning .................................................................................... 25
6.6 Factory Service Interval ................................................................................................. 26
7 ACCESSORIES and PARTS 27

7.1 Consumables, Replacement Parts, and Accessories .................................................... 27
8 APPENDIX A - ES-642 MEASUREMENT METHOD 29

8.1 Forward Laser Light Scatter Nephelometer System ...................................................... 29
8.2 Automatic Zero Self-Tests for the Optical System ......................................................... 31
8.3 The Airflow Control System Diagram and Description ................................................... 31
9 APPENDIX B - COMMUNICATION 33
9.1 Comet Software ............................................................................................................. 33
9.2 Serial Communication ................................................................................................... 33
9.3 Computer Mode ............................................................................................................. 34
9.4 User Mode ..................................................................................................................... 34
9.5 Output Formats.............................................................................................................. 35
9.6 MetRecord Format......................................................................................................... 35
9.7 Legacy Format............................................................................................................... 35
9.8 Status Field.................................................................................................................... 36
9.9 Example output.............................................................................................................. 36
9.10 Basic Command Summary ............................................................................................ 37
9.11 Report Model and Firmware Version [RV] ..................................................................... 37
9.12 Set Unit ID [ID x] ............................................................................................................ 37
9.13 Set Sample Time [ST x] ................................................................................................. 38
9.14 Set Operation Control [S x] ............................................................................................ 38
9.15 Exit User Mode [Q,X] ..................................................................................................... 39
9.16 Enter Calibration Mode [CAL] ........................................................................................ 39
9.17 Exit Calibration Mode [CAX] .......................................................................................... 39
9.18 Default Sensor Calibrations [DFLT] ............................................................................... 39
9.19 Reference AT [RA] ........................................................................................................ 40
9.20 Reference Flow [RF]...................................................................................................... 40
9.21 Reference Pressure [RP] ............................................................................................... 40
9.22 Reference Humidity [RR] ............................................................................................... 41
9.23 RH Set Point [SPR] ....................................................................................................... 41
9.24 Output Interval [OI] ........................................................................................................ 41
9.25 Advanced Command Summary ..................................................................................... 42
9.26 Modbus Address [MA] ................................................................................................... 42
9.27 Measurement Request [ME] .......................................................................................... 42
9.28 Request Query [RQ] ...................................................................................................... 42
9.29 Set K-Factor Multiplier [SK] ........................................................................................... 43
9.30 Network Mode [NW] ...................................................................................................... 43
9.31 Operation Mode [OP]..................................................................................................... 43

9.32 Query Header [QH]........................................................................................................ 43
9.33 List Record Formats [RL] ............................................................................................... 44
9.34 Record Type [RT] .......................................................................................................... 44
9.35 Descriptor Table Retrieval [DS] ..................................................................................... 44
9.36 DS 0 – Query Abbreviated Descriptor Information......................................................... 44
9.37 DS c – Specific Channel Descriptor Information ............................................................ 45
9.38 Request Units [UN] ........................................................................................................ 45
10 APPENDIX C - NETWORK MODE 46

10.1 Identification Command Prefix ....................................................................................... 46
11 APPENDIX D - MODBUS 47
11.1 Modbus 3X Registers .................................................................................................... 47
11.2 4X Registers .................................................................................................................. 48
12 APPENDIX E – WIRING ANALOG OUTPUT. 49

12.1 Single supply (logger and sensor) ................................................................................. 49
12.2 Separate supplies, logger and sensor. .......................................................................... 50
12.3 Using the 4-20 ma output option.................................................................................... 51
Table of Figures
Figure 2-1 Sharp cut cyclone attached to intake.............................................................................. 9
Figure 2-2 Basic Mounting Installation ........................................................................................... 10
Figure 2-3 Typical Wall Mounting .................................................................................................. 10
Figure 2-4 Typical Pole Mounting .................................................................................................. 10
Figure 2-5 Connector Layout ......................................................................................................... 12
Figure 2-6 ES-642 Power Connector ............................................................................................. 13
Figure 6-1 Pump Filter and Purge Filter Replacement .................................................................. 25
Figure 8-1 MDF Forward Light Scatter Laser Optical Engine ........................................................ 29
Figure 8-2 MDF Clean Air and Particulate Scatter Conditions in the MD Engine .......................... 30
Figure 8-3 The Effects of RH on Sample Concentration ................................................................ 30
Figure 8-4 ES-642 Flow System Diagram - Simplified for Clarity .................................................. 32

1 INTRODUCTION
1.1 About This Manual
This document is organized with the most important information grouped together for easy
reference by the user. All ES-642 owners and operators should read and understand the sections
on installation, setup, and field calibrations. Other sections that provide in-depth information on
subjects such as theory, diagnostics, accessories, and alternate settings provide valuable
information which should be consulted as needed. An electronic version of this manual is also
available.
1.2 Technical Service and Warranty
This manual is structured by customer feedback to provide the required information for setup,
operation, testing, maintaining, and troubleshooting your ES-642. Should you still require support
after consulting your printed documentation, we encourage you to contact one of our expert
Technical Service representatives during normal business hours of 7:00 a.m. to 4:00 p.m. Pacific
Time, Monday through Friday. In addition, technical information and service bulletins are often
posted on our website. Please contact us and obtain a Return Authorization (RA) number before
sending any equipment back to the factory. This allows us to track and schedule service work and
to expedite customer service.
Phone: (541) 471-7111 Fax: (541) 471-7116
E-Mail: service@metone.com Web: www.metone.com
Address: Technical Services Department
Met One Instruments, Inc.
1600 NW Washington Blvd.
Grants Pass, OR 97526
1.3 About the ES-642

The Met One Instruments, Inc. model ES-642 is a type of nephelometer which automatically
measures real-time airborne PM10, PM2.5, PM1 or TSP particulate concentration levels using the
principle of forward laser light scatter.
Laser Light Scatter System
Sample air is drawn into the ES-642 and through the laser optical module, where the particulate in
the sample air stream scatters the laser light through reflective and refractive properties. This
scattered light is collected onto a photodiode detector at a near-forward angle, and the resulting
electronic signal is processed to determine a continuous, real-time measurement of airborne
particulate mass concentrations.
1.4 Laser Radiation Safety and Conformity

The ES-642, when properly installed and operated, is considered a Class I laser product.
Class I products are not considered to be hazardous.

This system contains a diode laser operating at < 5 mW power and 670 nm wavelength. This is
visible to the naked eye, and can cause damage to the eye if directly exposed. A protective optical
housing fully encapsulates the laser beam and optics system within the ES-642. Do not attempt to
disassemble the optical module. Failure to comply with this instruction could cause accidental
exposure to laser radiation. The manufacturer certifies that this product operates in compliance
with the following standards and regulations:
 FDA / CDRH This product is tested and complies with 21 CFR, Subchapter J, of the
Health and Safety Act of 1968.
 US 21 CFR 1040.10.
Always power down the system whenever service or repair work is to be performed inside the
instrument enclosure. Only trained technicians should attempt to repair the ES-642. Routine
maintenance does not require removing the instrument from its weatherproof enclosure.

1.5 ES-642 Specifications
PARAMETER SPECIFICATION
Measurement Principles: Particulate concentration by forward light scatter laser Nephelometer.
Available Cut Points: TSP Inlet Standard. PM10, PM2.5, and PM1 sharp-cut cyclone inlets available.
Measurement Range: 0 to 100 mg/m3 (0 to 100,000 µg/m3)
Measurement Sensitivity: .001 mg/m3.
Nephelometer Accuracy: ± 5% traceable standard with 0.6 µm PSL.
Particle Size Sensitivity: 0.1 to 100 micron. Optimal sensitivity 0.5 to 10 micron particles.
Long Term Stability: 5% with clean optics.
Laser Type: Diode Laser, 5 mW, 670 nm. Visible red.
2 X 16 backlit LCD. Provides information on operation including: Power, Flow
Display:
Operation, Status and Concentration.
Zero Calibration: Automatic Zero Calibration every hour or as programmed from 1 to 999 minutes.
Flow Rate: 2.0 liters/minute ± 0.1 lpm. Actual volumetric flow.
Pump Type: Brushless Diaphragm (20,000 hour).
Power: 11 – 40 VDC @ 1.5 A maximum.
Power Consumption: 350 mA (no heater) 1.1 A (with heater) @ 15 VDC.
Analog Output: 4-20 mA and 0 – 2, 0 – 5 or 0 - 10 VDC, selectable.
Digital I/O: RS-485 half duplex, RS-232.
Alarm Output: Normally open and normally closed relay 30 VDC @ 1A maximum.
Purge Filter 0.2 micron
Protection Filter: 5.0 micron.
Serial Communication: ASCII and MODBUS RTU.
Operating Temperature: 0 to +50°C . (Ambient Temperature Sensor Range -30 to +50°C).
Barometric Pressure: 600 to 1040 mbar absolute barometric pressure sensor range.
Ambient Humidity Range: 0 to 90% RH, non-condensing.
Humidity Control: Automatic 10 Watt inlet heater module controlled to sample RH, with set point.
CE, ISO-9001. Designed to agree with EPA Class I and Class III FRM/FEM
Approvals:
particulate samplers and monitors. Not an EPA-designated equivalent method.
Factory Service Interval: 24 Months typical, under continuous use in normal ambient air.
Mounting Options: Optional wall mount bracket. Optional mounting tripod.
Unit Weight: 2.7 kg (6 lbs)
25.4cm high, 17.8cm wide, 10.8cm deep. (10.0” x 7.0” x 4.25”). Without inlet
Unit Dimensions: assembly.
48.3cm high, 17.8cm wide, 10.8cm deep. (19.0” x 7.0” x 4.25”). With inlet assembly.
Specifications may be subject to change without notice.

2 ES-642 SETUP and STARTUP
The ES-642 is designed for rapid deployment and easy setup by a single person. This section
describes the basic assembly, setup, and start-up of the instrument.
2.1 Standard and Optional Accessories
When unpacking a new ES-642, verify that the contents are undamaged. If the shipping cartons
are damaged, notify the carrier immediately. Verify that the included accessories are correct and
complete. If anything is missing, contact the technical service department at service@metone.com
or (541) 471-7111. See the Accessories section at the back of this manual for more details. The
normal configuration of the ES-642 is supplied with the following standard accessories:
 Weatherproof TSP inlet with debris screen.
 Multi-Signal cable PN 80959 (10 ft)
 External Power cable PN 80943 (10 ft)
 Instruction manual. ES-642-9800
 Mounting ears
The following optional accessories may or may not also be included, depending on the order:
 Sharp Cut Cyclone for PM10, PM2.5 or PM1 cut-points
 82836 Mounting Bracket Kit
 81039 Solar Shield Kit
 9438-4 Weatherproof Power Supply (100-240 VAC input 12 VDC output)
2.2 Setting Up the ES-642
Set up the rest of the ES-642 hardware items and accessories as described below:
1. Install PM10, PM2.5, PM1 cyclones and TSP inlets: For TSP (Total Suspended Particulate)
monitoring, the included weatherproof TSP inlet is simply installed directly onto the top of
the ES-642 inlet tube to keep water, insects, and debris out of the instrument. For PM10,
PM2.5 or PM1 monitoring, the optional sharp-cut cyclone of the desired cut-point must be
installed onto the inlet tube, under the TSP inlet. Lubricate the o-rings if necessary. Never
operate the ES-642 outdoors without at least the TSP inlet in place, as the resulting
water/debris damage is not covered under warranty.
Figure 2-1 Sharp cut cyclone attached to intake

2.3 Mounting Options
2.3.1 Basic Unit Mounting:
The ES-642 can be mounted using the included mounting ears. The unit must be screwed or
bolted to the support structure with appropriate hardware. For normal wall or pole mounting the
optional mounting bracket is recommended.
Figure 2-2 Basic Mounting Installation
2.3.2 Wall or Pole Mounting:

The ES-642 can be wall mounted using the optional mounting bracket. This bracket can be used
for both wall and pole mounting of the ES-642. The mounting bracket must be screwed or bolted
to the support structure with appropriate hardware. When pole or tripod mounted, the V-Bolts can
be used to attach the mounting bracket. 1/4-20 hardware is used to mount the ES-642 to the
mounting bracket.
Figure 2-3 Typical Wall Mounting Figure 2-4 Typical Pole Mounting

Note: Take care to ensure that there is adequate clear space around the inlet to allow unrestricted
airflow into the instrument. Mount the instrument with no large obstructions nearby whenever
possible.
In some applications, an optional solar and weather shield may be required due to extreme
weather conditions. Request part number 81039. It attaches to the mounting bracket for the ES-
642.

2.4 Electrical Connections
The standard ES-642 has two weatherproof connectors on the bottom of the unit. These
connectors provide the connections for the power supply, analog outputs, alarm outputs, and
communications options. The ES-642 will turn on automatically whenever a power source is
connected to the power input, there is no power switch. The ES-642 is supplied with two 10 foot
long cables (80959, 80943). The user can cut these cables to any desired length. NOTE: Make
sure you have cut any exposed wires, which are not being used, so that they can’t short together.
Because of the heater power required and to prevent any ground loops, it is recommended that a
junction box be used to terminate the supplied cable. At this point larger AWG wires can be used
for longer connections, or the power source can be located in this junction box. This will help to
reduce any power lost in the heater power wires.
Pin 1
Figure 2-5 Connector Layout

Signal Pin Number Color (80959)
Power Input 11 – 40 VDC Pin 1 Red
Ground Pin 2 Black
RS-485 TX+ / RX+ (Pre 2022 RS-485 TX+) Pin 3 White
RS-485 TX- / RX- (Pre 2022 RS-485 TX-) Pin 4 Green
Ground (Pre 2022 RS-485 RX + ) Pin 5 Orange
Ground (Pre 2022 RS-485 RX - ) Pin 6 Blue
RS-232 TX Pin 7 White/Black
RS-232 RX Pin 8 Red/Black
Analog Sense Pin 9 Green/Black
Analog Voltage Signal Output Pin 10 Orange/Black
4 – 20 mA Signal Output Pin 11 Blue/Black
Relay Normally Closed Alarm Output Pin 12 Black/White
Relay Normally Open Alarm Output Pin 13 Red/White
Relay Common Alarm Output Pin 14 Green/White
Mid 2022 four wire RS-485 discontinued

Pin 1
Figure 2-6 ES-642 Power Connector
Signal Pin Number Color (80943)

Power Input 11 – 40 VDC Pin 1 Red
Ground Pin 2 Black
2.4.1 Power Requirements
The ES-642 will require at least 11 VDC @ 1.5 Amp when the heater is operating. The positive
connection will be connected to pin 1 Red while the negative connection will be connected to pin 2
black.
2.4.2 RS-485 Connections
The RS-485 works in Half Duplex (2 wire command response serial communication). To connect
to a half Duplex system, connect the TX+ / RX+ output from the computer (sometimes referred to
as A+) to the white wire (TX+ / RX+) and connect TX- / RX from computer (Sometimes referred to
as B-) to the green wire (TX- / RX-) connections of the ES-642. The orange or blue wire can be
used as common ground. Legacy units made before mid 2022 had four wire RS-485 . Connect
orange and white wires together for A+. Connect on green and blue wires together for B-.
2.4.3 RS-232 Connections
The RS-232 can be connected to a computer using RS-232 TX (white/black) input to pin 2 of a
female DB-9 connector and RS-232 RX (red/black) output to pin 3 of the DB-9 connector. Please
note you will need to share the power ground (black) with pin 5 of the DB-9 connector.
2.4.4 Analog Sense
The heater and pumps can draw a large amount of current from the power supply. The ground
current will have an effect on the analog output voltage. When the heater turns on, it would make
the analog output appear to change due to the voltage drop in the cable. The analog sense wire
should be connected to the ground input of the external logger monitoring the analog voltage. The
power supply ground, should also be connected to the loggers input ground (see appendix F).
This will compensate the analog output for any change in current from pumps and heater.
2.4.5 Analog Voltage Output
The analog voltage output is the proportional voltage output for the concentration. The maximum
concentration for the analog output can be set using the AR serial command and the analog
voltage range can be set with the AV command (See Appendix C for more information on serial
commands). For example if the maximum concentration is set to 10,000 µg/m3 and the analog
output voltage range is set to 0 – 10 VDC, the output voltage would represent 0 to 10,000 µg/m3
or 1 µg/m3/mv. Note: See appendix F for suggested wiring.
2.4.6 4 to 20 mA Analog Output
The 4 to 20 mA analog output is the proportional current output for the measured concentration.
The maximum concentration span value for the analog output can be set using the AR serial
command (See Appendix C for more information on serial commands). For example if the
maximum concentration span is set to 10,000 µg/m3, the output current of 4 to 20 mA would
represent 0 to 10,000 µg/m3 or 1µg/m3/1.6 µA. Note: See appendix F for suggested wiring.
2.4.7 Concentration Relay Contact
The ES-642 has the ability to activate a relay if the concentration limit set by the SPA serial
command has been exceeded (See Appendix C for more information on serial commands).
This relay has a normally open contact which closes when the relay is activated and a normally
closed contact which opens when the relay is activated (Form C). The COM connection is going
to be one of the connections used while the user will decide if they want a Normally Open or
Normally Closed connection. See section 4 for more information on the alarm relay.
2.5 Power-Up and Starting Operation
As soon as power is applied to the ES-642, the unit will start and display the following screens
while the automatic zero process is running.
CONC: 0.000 mg CONC: 0.000 mg CONC: 0.000 mg

ZEROING TEMP 25.2 C RH 42 %
CONC: 0.000 mg
BP 978 mbar
When the zero process has completed the unit will show the following screens:
CONC: 0.010 mg CONC: 0. 010 mg CONC: 0. 010 mg

SAMPLING TEMP 25.2 C RH 42 %
CONC: 0. 010 mg CONC: 0. 010 mg

BP 978 mbar FLOW 2.0 lpm
The concentration is always displayed on the top line while the second line cycles through the
various measurements.
If an error occurs, the display will change to show the fault on the second line as shown below:
CONC: 0. 010 mg
Flow Error!

2.5.1 Default Setup
The ES-642 is factory configured to measure continuously and perform hourly self-tests. The
following table lists some of the factory default configurations which may need to be changed for
your application. See Section 9 for details about the settings.
Parameter Setting
Update Period 1 Second
Sampling Mode Continuous
Auto Zero Interval Hourly
Concentration Range Display 0 - 100 mg/m3
Concentration Range Analog Output 0 - 1 mg/m3
Analog Output Current Range 4 - 20 mA
Analog Output Voltage Range 0 – 10 VDC
K-Factor 1.0
RH Set Point 40%
Baud Rate 9600
Concentration Alarm Relay Output Off

3 SITE SELECTION
Use the following criteria when deciding on a sampling location for the ES-642. Always consider
the safety and security of the unit, as well as the suitability of the sampling environment.
3.1 Site Selection Requirements
Selection of a proper site for the ES-642 is critical for accurate measurements.
The following is a summary of general ambient particulate monitoring site requirements that will be
appropriate for use with the ES-642 in many cases. Some of these criteria may not be appropriate
in some applications, due to the versatile nature of the ES-642:
Inlet Height:
 The inlet should be located in the “breathing zone”, between 2 and 15 meters above ground
level. When installed on the standard tripod, the ES-642 inlet is positioned two meters
above the ground or other mounting surface, when used with a cyclone.
 If the ES-642 is to be collocated with other particulate instruments, such as FRM filter-type
samplers or BAM units, then the air inlet must be the same height as the inlet of the other
samplers, within one meter vertically. Within one foot is preferred.
 If the ES-642 inlet is the highest point on a building, then lightning rods must be installed to
prevent destruction of the unit during electrical storms.
Inlet Radius Clearance:
 If an ES-642 is to be collocated at a station along with BAM or FRM samplers, the inlets of
each sampler must be no less than one meter apart from each other, and no more than
four meters apart. Two meter inlet spacing is recommended where possible.
 If installed near a PM10 Hi-Volume sampler, then the distance between the inlet of the ES-
642 and the Hi-Vol must be no less than two meters.
 There should be at least a 270 degree arc of unrestricted airflow around the inlet. The
predominant direction of concentration movement should be included in the arc.
Artificial Particulate Sources:
To avoid possible errors in the concentration measurements, the inlet must be located as far as
possible from any artificial sources of particulate, such as blowers, vents, or air conditioners on a
rooftop. Especially if any of these types of devices blow air across the inlet of the ES-642. Even
sources of filtered air must not blow across the inlet.

4 CONCENTRATION ALARM RELAY SET POINT
The ES-642 has a relay output designed to indicate that the measurement has exceeded a set
point for an average period of 1 minute. The relay has a normally open contact and a normally
closed contact. The relay will energize when the concentration exceeds the concentration alarm
set point for more than 1 minute. The normally closed contact will open and the normally open
contact will close.
Note: The ES-642 relay is intended for DC operation only with a 30VDC @ 1A maximum load.
4.1 Setting the Concentration Alarm Relay Set Point

To change the concentration alarm set point using a serial communication program you would use
the SPA serial command to change the set point.
Example:
The maximum value of concentration desired is 1000 µg/m3. Type SPA 1000 <ENTER> The
concentration alarm relay set point is now 1000 µg/m3.

5 FIELD CALIBRATIONS
The ES-642 has a system of serial commands which allow the operator to audit or calibrate the
airflow control system parameters for optimal performance. These parameters are often audited
monthly and calibrated quarterly during continuous operation. The exact frequency may vary
depending on the harshness of the local conditions and the data validation requirements
established by the sampling program administrator and your resulting standard operating
procedures (SOP).
Note: The ES-642 temperature and pressure should always be checked before any flow
calibrations are performed, since the flow calculation is dependent on these parameters.
5.1 Ambient Temperature Calibration
The AT screen is used for field audits or calibrations of the ambient temperature measurement of
the ES-642.
CONC: 0. 010 mg
TEMP 25.2 C
Note: The ES-642 ambient temperature sensor is a thermistor bead on the bottom panel of the
ES-642. As such it is not particularly accurate compared to solar shielded or motor aspirated
temperature sensors. An accuracy of ±2 degrees C is adequate for flow control purposes.
To change the temperature calibration using a serial communication program you would collocate
a reference standard near the intake head and then use the RA serial command to change the
temperature calibration.
Example:
The collocated temperature sensor reads 26 degrees C and the temperature sensor on the ES-
642 reads 23 degrees C. Type RA 26 <ENTER> The temperature calibration has now been
corrected to read 26 degrees C on the display.

5.2 Ambient Pressure Calibration
The CALIBRATE BP screen is used for field audits or calibrations of the ambient barometric
pressure measurement of the ES-642.
CONC: 0. 010 mg
BP 978 mbar
The BP parameter is the current reading from the ES-642 pressure sensor. To change the BP
calibration using a serial communication program you would collocate a reference standard and
then use the RP serial command to change the BP calibration.
Example:
The collocated pressure sensor reads 974 mbar and the BP sensor on the ES-642 reads 978
mbar. Type RP 974 <ENTER> The BP calibration has now been corrected to read 974 mbar on
the display.
5.3 Sample RH Calibration
The CALIBRATE RH screen is used for field audits or calibrations of the sample relative humidity
measurement of the ES-642.
CONC: 0. 010 mg
RH 42 %
Note: The ES-642 sample RH sensor is located inside the pulsation dampening chamber. If the
ES-642 has been operating with the inlet heater running, the inside of the unit will likely be hotter
than ambient temperature, resulting in sample RH readings that will be lower than an ambient
standard. If the sample RH sensor is to be calibrated, make sure that the unit has equilibrated to
ambient conditions first, or a large artificial positive offset could be calibrated into the sensor
reading. This will result in the ES-642 over-reading the sample RH and turning the inlet heater on
when the actual RH is lower. Leave the factory default calibration in place unless necessary.
If the sensor fails, it will usually read an impossible value such as 125% or -25%.
The RH parameter is the current reading from the ES-642 humidity sensor. To change the RH
calibration using a serial communication program you would collocate a reference standard and
then use the RR serial command to change the RH calibration.
Example:
The collocated RH sensor reads 55% and the RH sensor on the ES-642 reads 50%. Type RR 55
<ENTER> The RH calibration has now been corrected to read 55% on the display.

5.4 Flow Sensor Calibration
The CALIBRATE FLOW screen is used for field audits or calibrations of the sample flow
measurement of the ES-642. Remove the TSP inlet and any cyclones from the ES-642 inlet tube,
and then connect the top of the inlet tube to the outlet of your traceable flow meter using a length
of appropriate flexible tubing. The ES-642 temperature and pressure status must be checked
before performing any flow calibrations in order to prevent errors. The ES-642 flow rate should be
maintained to within ±0.1 LPM (1.9 to 2.1 LPM) for proper cut-point performance of inlet cyclones.
CONC: 0. 010 mg
FLOW 2.0 lpm
The FLOW parameter is the current reading from the ES-642 flow sensor, in actual volumetric
liters per minute. You must send the serial command CAL <ENTER> to put the ES-642 into the
flow calibration mode and will automatically regulate to the set point (2.0 LPM). This may take a
moment.
To change the FLOW calibration using a serial communication program you would use the value
from the flow reference standard and then use the RF serial command to change the flow
calibration.
Example:
The flow reference sensor reads 2.2 LPM and the flow sensor on the ES-642 reads 2.0 LPM.
Type RF 2.2 <ENTER>. The flow calibration has now been corrected and will adjust itself back to
2.0 LPM on the display.
Remember to exit the flow calibration mode by typing CAX <ENTER>
5.5 K Factor
The ES-642 is calibrated on latex 0.6 micron micro-spheres. These provide an extremely
consistent calibration, but do not generally match the characteristics of all ambient particulate.
A K-Factor (multiplier) must be established for good accuracy and correlation to collocated
instruments. The base K-Factor multiplier is set to 1.0 at the factory.
The K-Factor is only valid at the same site and for the same particulate type. If the local particulate
source changes, the K-Factor may no longer be valid.
The SK command is used to set the K Factor.

6 MAINTENANCE and TROUBLESHOOTING
This section provides information about routine maintenance of the ES-642, and for performing
more detailed diagnostic tests if a problem is encountered. The ES-642 can generate an error
message on the display if a problem is detected. Many times there is a simple solution. Persistent
errors often signify a failure which will require investigation.
Only skilled and trained electro-mechanical technicians should attempt any disassembly or repairs
inside the ES-642. Routine maintenance procedures do not involve removing the ES-642
assembly from the enclosure.
6.1 ES-642 Alarm Displays and Alarm Codes
The ES-642 contains a comprehensive system of error and alarm codes which are used to alert
the operator of any problems with the unit. These error codes may be generated during normal
operation or during a self-test routine. The errors appear on the ES-642 display and in the status
output if serial communications are used.
The following table describes each of the error and alarm types which can be generated by the
ES-642, along with the conditions which cause the alarms. Many of these alarms indicate critical
parameters which must be working correctly for machine operation.
Alarm/Error Alarm Description
Message
This alarm indicates that the flow system is more than 5% out of
FLOW FAILED
regulation.
This alarm indicates a problem during the Auto Zero phase and the sensor
ZERO FAULT
was not stable or the zero value was too high.
This alarm indicates a failure in the laser. This error requires the sensor to
SENSOR ERROR
be returned for repair.
COUNTER FAULT This alarm indicates the detector is not functioning correctly.
The following are some examples of how the alarm and error records appear when shown on the
main ES-642 display.
CONC: 0. 010 mg CONC: 0. 010 mg CONC: 0. 010 mg

Flow Error! Zero Fault! Sensor Error!
CONC: 0. 010 mg
Counter Fault!
Note: The alarm indication will continue to show until the start of the next sample.

The normal ES-642 digital data array also contains an “alarm” code column to indicate if there
were any alarm or error flags during that particular sample period. See sections 9.2 and 9.3 for
details and examples.
The following table defines the possible error codes that can appear in the “alarm” column of the
ES-642 data output:
Code Error/Alarm Type
0 No alarm
1 Auto Zero Low
2 Auto Zero High
3 Auto Zero Stability
10 Laser Current Failure
20 Detector Failure
40 Flow Failure
Note: If multiple errors or alarms occur in the same data period, then the alarm code stored in the
data array will be the sum of the two individual code numbers. This is a rare occurrence.
6.2 Basic Problem and Cause/Solution Table
The following table contains information on some of the more common ES-642 problems which
may be encountered, and some steps to identify and remedy the problems. Met One welcomes
customer suggestions for new items to include in this section of future manual revisions. If the
solution cannot be found in the following table, then contact one of our expert service technicians
for help in resolving your problem.
Problem: The ES-642 won’t start a measurement cycle.
Cause/Solution:  The ES-642 may not start a measurement cycle if it detects a
hardware failure, such as a pressure sensor failure or a pump failure.
 The unit will usually display an error message on the display if it
cannot start a cycle.
Problem: Flow failures or low flow.

Cause/Solution:  Check the PUMP and PURGE filters. These must be replaced
periodically.
 Check for insect debris or other obstructions in the small exhaust port
on the bottom of the unit.
 Verify the AT and BP sensor function. Failed sensors can affect the
flow.
 In some cases re-setting the sensor calibrations to Factory Default
and re-calibrating can solve flow calibration difficulties. In
Hyperterminal issue the DFLT <enter> command (see 9.2 for more
details).
 The sample pump itself will eventually wear out and need to be
replaced. It should last at least a year under normal conditions. Check
the other possibilities first.

Problem: Optical system alarms and failures
Cause/Solution:  The ES-642 must be periodically returned to the factory for optical
system cleaning. The period will depend on your particulate levels.
 Check the PURGE filter and replace it as needed.
 The laser diode has a finite lifetime which will be reduced at high
temperatures. It may eventually fail and need to be replaced at the
factory.
 Never disassemble the MDF laser optical subassembly!
Problem: The ES-642 data is not consistent with other sensors.

Cause/Solution:  An external K-Factor (multiplier) must be established for good
accuracy and correlation to collocated instruments. The base K-
Factor is assumed to be 1.
 The K-Factor will sometimes be very significant, such as a multiplier of
3 or 5.
 The ES-642 is calibrated on latex 0.6 micron micro-spheres. These
provide an extremely consistent calibration, but do not generally
match the characteristics of all ambient particulate.
 The K-Factor is only valid at the same site and for the same
particulate type. If the local particulate source changes, the K-Factor
may no longer be valid.
 Make sure the correct cyclone is used on the ES-642. The PM10,
PM2.5 or PM1 cyclones look very similar. The cyclone cut point must
match the cut point used on any collocated instruments.
 Clean the TSP inlet and any cyclones at least monthly.
 Check the sample RH data and RH sensor calibration. High sample
RH will cause ES-642 over-reading. The sensor itself can occasionally
fail.
 Check the ES-642 for flow calibration problems.

6.3 Suggested Periodic Maintenance Intervals
The following table shows the Met One recommended periods for routine maintenance items.
Some of these items will need to be performed more or less often depending on the exact
characteristics of your location. The program administrator should review these items and
establish SOPs appropriate for your application.
Maintenance Item Suggested
Period
Flow, temperature, and pressure audits or calibration Monthly
Clean sharp-cut cyclone, particle trap, and TSP inlet Monthly
Check filter RH sensors 6 Months
Replace PUMP filter and PURGE filter 12 Months
Factory service, recalibration, and optical system cleaning 24 Months

6.4 PUMP and PURGE Filter Changes
The ES-642 PUMP FILTER and PURGE FILTER are the two filter cartridges located in the front
panel of the instrument. They can be removed by unscrewing the black aluminum filter holders
with a coin using the slot in the face of the holder. The expected lifetime of the two filters is greater
than one year, but in heavy particulate areas they may need to be replaced more often.
The 5 micron PUMP filter keeps any large particles from entering the flow sensor or sample pump.
The 0.2 micron PURGE filter cleans the recirculated purge air which is used to keep the optics
clean during normal operation and the zero self-test.
Pump Filter
Purge Filter
Figure 6-1 Pump Filter and Purge Filter Replacement
6.5 TSP Inlet and Cyclone Cleaning

A TSP inlet must be installed on the inlet of the ES-642. In addition to the TSP inlet, sharp-cut
cyclones may be used to remove particles greater than the rated cut-point. These inlets need to
be periodically cleaned. The time interval between cleanings varies depending on the local
particulate levels. Met One recommends cleaning the cyclone particle trap at least once a month.
The TSP inlet and cyclone body should be disassembled and cleaned every three months during
continuous use.
Clean the cyclone particle trap by unscrewing the knurled cap from the cyclone body, then wipe it
out with a cloth or blow it clean with compressed air. Check the o-rings and lubricate if necessary.
Full cleaning of the cyclone requires unscrewing the three socket-head hex screws to access the
conical chamber inside. All of the inside surfaces must be cleaned. Isopropyl alcohol and cotton-
tipped applicators work well.
The TSP inlet can be disassembled for cleaning by removing the three screws in the cap. Soap
and water often work best for cleaning the TSP inlet and debris screen. Do not over-tighten the
screws during reassembly or the plastic threads will strip out.

6.6 Factory Service Interval
The ES-642 needs to be periodically returned to the factory for service and recalibration. The
recommended period is typically two years during continuous use. However, some users establish
their own interval depending on the harshness of the sampling conditions, particulate levels, and
data scrutiny. High concentration operation will often require more frequent factory service.
Factory service primarily consists of optical system cleaning, laser/detector checks, and
recalibration. As-found calibration checks can also be requested. Contact the Met One technical
service department to schedule ES-642 service. A Return Authorization (RA) number must be
obtained before the unit is returned.

7 ACCESSORIES and PARTS
7.1 Consumables, Replacement Parts, and Accessories
The following parts are available from Met One for maintenance, replacement, service, and
upgrades. If unsure about a part you need, please contact the technical service department. Some
of these parts may require technical skills or special instructions before use or installation.
Description Part Number Graphic
Flow System Components
Sample Pump Module Assembly 80949
Flow Sensor, ES-642 (older ES-642’s) 9049-3
Flow Sensor, Differential Pressure 82258
Ambient Temperature Thermistor and Harness 81410
RH Sensor 9278-1
Purge Filter Holder, Black Aluminum 8912

Pump Filter Holder, Black Aluminum 8913
Purge Air Filter, 0.2 micron 580302
Pump Filter, 5.0 micron 580345
O-Ring, For Purge and Pump Filter Holders 720063
PM2.5 Sharp Cut Cyclone, 2 LPM SCC 112
PM10 Sharp Cut Cyclone, 2 LPM SCC 110
PM1 Sharp Cut Cyclone, 2 LPM SCC 111
TSP Sampling Inlet 9441
Harsh environment, with insect screen and rain cap

ES-642 I/O Board 80950-2
LCD Display, ES-642, 2x16 Character 80830-1
MDF Engine Assembly, Frequency to Voltage 80868-3
External Cable, ES-642 80959
External Power Cable, ES-642 80943
Power Supply, 100-240 VAC input 12 VDC output, 9438-4

Weatherproof
ES-642 Factory Service and Recalibration Call Met One

Kit, Mounting Bracket 82836
Kit, Solar Shield 81039
CometTM Software CD 80248

8 APPENDIX A - ES-642 MEASUREMENT METHOD
The Met One Instruments, Inc model ES-642 is a type of nephelometer which automatically
measures and reports real-time airborne PM10, PM2.5, PM1 or TSP particulate concentration levels
using the principle of forward laser light scatter. This section describes the measurement systems.
8.1 Forward Laser Light Scatter Nephelometer System

Sample air is drawn into the ES-642 by an internal diaphragm pump. The flow rate is controlled
based on actual conditions for accurate cut-points through sharp-cut cyclones.
This sample air is drawn through the MD laser optical module or “laser engine”, where an internal
visible laser diode beam is collimated and directed through the sample air stream. The particulate
in the sample air stream scatters the laser light through reflective and refractive properties. This
scattered light is collected onto a silicon photodiode detector at a near-forward angle, and the
resulting electronic signal is processed to determine a continuous, real-time measurement of
airborne particulate mass.
The forward light scatter method allows for a more accurate total mass estimate compared to
right-angle light scatter, which is better suited for counting and sizing individual particles. Met One
also manufactures a complete line of right angle particle counters.
Purge Air
Particulate
Scatter Collection Laser Trap
Lenses
Laser Diode Laser Beam Photo Diode
Figure 8-1 MDF Forward Light Scatter Laser Optical Engine

Forty detector measurements are made and averaged into an updated concentration value each
second. The 1-second values are also displayed on the LCD and available on the analog output.
Figure 8-2 MDF Clean Air and Particulate Scatter Conditions in the MD Engine
Sample RH Control for Light Scatter Mass

The relative humidity (RH) of the sample air has an influence upon the measurement of particulate
mass by nephelometers. At RH values greater than about 50% this effect begins to increase due
to particle aggregation and particle size increases as water is absorbed. The ES-642 mitigates this
through a heated inlet tube that uses an internal sample RH sensor. The RH of the incoming air is
measured and the inlet heater is turned on whenever the user-set set-point is exceeded (typically
50% RH). See section 5.3.
A study in Atmospheric Environment showed that RH can drastically affect the concentration
measurement as shown in the graph in Figure 8-3 from volume 34, pp 4829-4838, 2000. The
following article references also contain related information:
Volume 35, Issue 30, Oct 2001:
-Aerosol Light Scattering Measurements as a Function of Relative Humidity. (Malm, Day).
-Diurnal and Seasonal Patterns in Light Scattering, Extinction, and Relative Humidity. (Malm, Gebhart, Copeland).
Volume 35, Issue 16, June 2001:
-Estimates of Aerosol Species Scattering Characteristics as a Function of Relative Humidity. (Malm, Day).
Figure 8-3 The Effects of RH on Sample Concentration

8.2 Automatic Zero Self-Tests for the Optical System
To assure stable concentration data, the ES-642 performs optical system zero self-tests at a rate
that is controlled by the sample period. See section 9.7.
A separate zero air pump activates and circulates clean air through the optical system. The ES-
642 filters the air through a 0.2-micron pore size, 99.99% efficient filter element before it enters
the sensor. This is the PURGE FILTER located in the front panel of the instrument. The ES-642
zeros itself based on this clean air condition.
8.3 The Airflow Control System Diagram and Description
The flow control system is an integral component of the ES-642. A complete description is
included to assist the user in understanding the ES-642 flow system:
1. Ambient air is drawn in through the TSP inlet and the PM10, PM2.5 or PM1 cyclone (if used) at
2.0 lpm. This flow rate is used because the cut-point of the cyclones is dependent on the
velocity of the particles and is only accurate at the rated flow rate.
2. The sample air goes through the vertical inlet tube, which is heated, if necessary, to keep the
sample air humidity below 50% RH to prevent measurement errors caused by moisture.
3. The sample air stream immediately enters the laser optical module where it passes through
the laser beam and the particulate is measured.
4. The pump filter removes particles larger than 5 microns to protect the flow sensor and pump.
The air stream then passes through the flow meter which measures the mass flow rate of the
sample air as an analog electronic signal which is sent to the CPU where the ambient
temperature and pressure are used to calculate the actual flow.
5. Down-stream of the flow meter, a pulsation chamber is used to reduce the pressure pulsations
caused by the diaphragm pump, which would otherwise appear as noise in the flow sensor
signal. There is nothing inside the pulsation chamber.
6. The air is drawn into the vacuum side of the main sample pump. This is a brushless diaphragm
pump which is pulse-width modulated (PWM) by the CPU to control the flow rate.
7. Most of the sample air exhausts through the pump to the exhaust hole on the bottom of the
ES-642. A small amount (about 10%) of the pump exhaust is recirculated through a simple
purge adjust valve (a screw installed in one of the ports). This purge adjust is factory-set to
control the ratio of the purge air, and should not be tampered with.
8. The purge air passes through the purge filter which removes any remaining particles larger
than 0.2 microns in size. The purge air enters the laser optical module in a ring around the
detector lenses, and through a port in front of the laser focus lens. The clean air circulating
past the lenses greatly reduces the amount of dirty sample air which would otherwise contact
and contaminate the optics.
9. During the zero portion of the automatic periodic self-test cycle, the main sample pump is
turned off and the purge pump is turned on. The air is filtered by the purge filter and circulated
through the laser module at a higher flow rate. The air in the laser module is 100% filtered
during this process, and no scattered light should enter the detector. The ES-642 takes a zero

reading and establishes a new signal baseline. A check valve prevents air from back-flowing
through the purge pump during normal sampling.
Inlet
Purge
MD
Laser
Pump
Filter
Purge
Filter
Flow
Sample
RH
Purge
Pulsatio
n
Check
Sampl
e
Purge
Exhaust
Figure 8-4 ES-642 Flow System Diagram - Simplified for Clarity

9 APPENDIX B - COMMUNICATION
9.1 Comet Software
The ES-642 is supplied with a CD containing a free copy of the Comet™ program, which is a
simple Windows-based communications terminal program developed by Met One Instruments.
Comet allows the user to connect to the ES-642 and read/set various parameters (K factor,
Concentration Alarm, Analog Output Range and DAC Output Range), and log real time data.
The Comet CD also contains a very comprehensive pdf user’s manual for the program. Install the
program onto the computer that you will be using and review the manual for more details. The
“ES-642” help section under “Plugins” provides specific information for the ES-642.
9.2 Serial Communication
Command Description
?,H Displays the help menu.
AR Enters the Analog Output Range in µg/m3.
Enters the DAC Voltage. 0=2V, 1=5.0V, 2= 10V. Range
AV
selection must be 2 for the 4 – 20 mA output to be correct.
CAL Enters Calibration Mode. Regulates flow to 2.0 lpm
CAX Exits Calibration Mode.
Clears sensor calibrations to defaults (Flow, Ambient Temp,
DFLT
BP, RH and Case Temp)
MA MODBUS Address. 1 - 247
ME Request Measurement.
NW Network Mode. 0=Off, 1=On
OP Report Operation Status.
RA Reference Ambient Temperature for Calibration.
RF Reference Flow for Calibration.
RP Reference BP for Calibration.
RR Reference RH for Calibration.
RV Returns the current software revision.
SID Sets / Reads the Unit ID.
SK Sets / Reads the Unit K Factor.
ST Sets / Reads the Sample Time in seconds.
S Manually Start/Stop a measurement. 1=Start, 0=Stop
SPA Sets / Reads Concentration Alarm Setpoint
SPR Sets / Reads the RH Set Point for the Inlet Heater Control.

The unit provides a serial command set for accessing settings. Commands are one or more
characters in length and require a carriage return. Commands which need additional information
prompt for the appropriate information.
Commands can be entered in either Upper or Lower Case.
Optionally, a command integrity checksum can be added. If used, a “*” delimiter character will be
added to the end of the command string followed by the decimal checksum of all characters in the
command line up to but not including the “*” character. If the command integrity checksum is
supplied, the response string will also include an integrity checksum. The command will be
ignored if an incorrect checksum is given. For ease in human operation, the special checksum
string “*//” (without quotation marks) will resolve as a correct checksum without the need to
calculate it.
In general, issuing a command by itself will respond with the current value of the setting. Issuing a
command with a value will change the setting to the new value. For example, to read the current
analog output range, type AR <ENTER> and the current full scale setting for the analog output
range will be returned.
To set the analog output range, type AR 1000 <ENTER> and the output range would then be set
to a full scale reading of 1000 µg/m3.
All serial commands work in this fashion.
9.3 Computer Mode
The unit is designed to primarily be connected to a computer or data logger. This is the default
mode called Computer Mode.
In Computer Mode, the unit will ignore all incoming serial characters until an <Esc> (ASCII 27)
character is received. A command can then be entered. No characters will echo out the serial port
while entering commands in Computer Model. All commands are executed using the <ENTER>
key.
Each time the <Esc> key is pressed, the unit will reset to Computer Mode and start the command
over.
When in Computer Mode, commands should use the command integrity checksum. The <Esc>
character is Not included in the checksum.
9.4 User Mode
User Mode is intended for direct user interaction. In User Mode, all incoming characters are
echoed back to the user.
The user can wake the unit into User Mode by sending three <CR> (Enter Key) characters within
3 seconds. The prompt character ‘*’ will be displayed when the unit is in Terminal Mode.
Once in User Mode, the unit will continue to respond to serial commands until User Mode is
exited. This can be done by issuing the Q or X command or pressing the <Esc> key. The unit will
also revert back to Computer Mode if no serial traffic is seen for two minutes.
All commands are accessible in either User or Computer Mode and behave the same except for
the echo behavior of incoming characters.
9.5 Output Formats
The unit supports two output formats for the data. The record formats are MetRecord and Legacy.
The MetRecord format provides some additional output fields that the original Legacy format did
not. The default is MetRecord. The Legacy format is provided for backward compatibility with older
units as necessary.
The RL command will list the available Record Formats. The RT command can be used to view
and set the Record Format Type.
9.6 MetRecord Format
The output of the Measurement command is both Comma delimited and fixed length to facilitate
data parsing as well as importing into spreadsheets / databases. All fields are padded with leading
and trailing zeros as necessary. Fields which can go negative will be preceded with either a + or –
character.
Once the flow has settled, the measurements will be output once per second until the
measurement cycle is completed.
The format is as follows.
mmm.mmm,f.f,+ttt.t,rrr,bbbb.b,ss,*ccccc
Where mmm.mmm is the measurement in milligrams per cubic meter. The Field f.f is the Flow
rate. The field ttt.t is the Temperature in degrees C.
The field rrr is the Relative Humidity. Note: this is not an Ambient RH measurement but is taken
inside the instrument after the Inlet Heater. This is the measurement that controls the Inlet Heater.
The bbbb.b field is the barometric pressure in mbar (millibar) units.
The ss field is the Status field. See below.
The ccccc field is a 5 character checksum field with leading zeros as necessary. This is the 16 bit
sum of all the characters from the start of the output string up to but not including the ‘*’ delimiter
character. This value is in Decimal.
9.7 Legacy Format
The Legacy Format is preceded by the characters ME and indicates a Measurement follows.
Once the flow has settled, the measurements will be output once per second until the
measurement cycle is completed.
The output of the Measurement command is both Comma delimited and fixed length to facilitate
data parsing as well as importing into spreadsheets / databases. The format is as follows.
ME, iiiiiiii, mmm.mmm, ss,*cccc<CR><LF>
Where iiiiiiii is an 8 character Unit Identifier. This can be from 1 to 8 characters alpha numeric and
will be padded by ASCII Space characters at the end of the string.
The field mmm.mmm is the measurement in milligrams per cubic meter. The field will be padded
with leading and trailing zeros as necessary.

The field ss is the Status field. This is a numeric field where 00 indicates no errors and a non-zero
value will indicate various error conditions. (See Below).
The cccc field is the checksum and is a three character checksum which is the Decimal sum of all
characters from the start of the string up to but not including the “*” delimiter character.
9.8 Status Field
The Status Field is a two character Hexadecimal representation of the status and error flags.
Bits 0-3 of the Status Field are reserved for the Sensor Calibration Status Code. These codes are
mutually exclusive and are stored as a status code number.
Value Status Description
0 OK Zero Calibration good. No errors
1 Low Zero Reading Too Low
2 High Zero Reading Too High
3 Stability Stability error. Too Many Retries
Bits 4-15 are reserved for single bit error flags which allow for multiple error conditions to be
represented concurrently.
Bit Decimal Hex Description
Value Value
0-3 Calibration Status. See codes above
4 16 0x10 IOP Alarm (Laser).
5 32 0x20 Counter Error (Sensor)
6 64 0x40 Flow Regulation
9.9 Example output
Following is an example of the serial output in MetRecord format.
000.002,2.0,+27.3,044,0974.0,00,*01543
The CSV header for this format is as follows:
Conc(mg/m3),Flow(lpm),Temp(C),RH(%),BP(mbar),Status
Legacy Format is as follows
ME, 01 , 000.002, 00,*1139
Command, Station ID, Concentration, Status, Check Sum followed by <CR><LF>

9.10 Basic Command Summary
The following is a summary of the basic commands.
Command Description
?,H Displays the help menu to assist users.
CAL Enters Calibration Mode.
CAX Exits Calibration Mode.
DFLT Sets Sensor Calibration offsets to zero (factory calibration)
ID Sets / Reads the Unit ID.
OI Output Interval.
Q Exit User Mode.
RA Reference Ambient Temperature for Calibration.
RF Reference Flow for Calibration.
RP Reference BP for Calibration.
RR Reference RH for Calibration.
RV Returns the current software revision.
ST Sets / Reads the Sample Time in seconds.
S Manually Start/Stop a measurement.
SPR Sets / Reads the RH Set Point for the Inlet Heater Control.
9.11 Report Model and Firmware Version [RV]
Command Response Description
RV<CR> This command reports the
model, part number and
firmware version.
RV<CR> ES-642, 80708, R1.1.0 <CR><LF>
9.12 Set Unit ID [ID x]
The SID command is the same and is also supported for backward compatibility.
ID x<CR> This command will Set or Get the Unit ID
string. This can be anywhere from 1 to 8
characters
ID 001<CR> ID 001<CR><LF> Set Station ID.
Issuing the command without a
parameter will respond with the current
setting value.
ID<CR> ID 01<CR><LF> Station ID “01”.

9.13 Set Sample Time [ST x]
ST x<CR> This command will Set or Get the
Sample Time in Seconds. This sets the
actual measurement time excluding the
Zero Calibration, Flow settling and Purge
times.
When the sample is finished, the unit will

restart with a new Auto Zero. The default
time is 3600 seconds (1 Hour)
A Sample Time of 0 will run indefinitely

and can only be stopped by issuing a
manual Stop Command from the serial
port. The unit will not perform a new Zero
cycle unless manually re-started.
Issuing the command without a
parameter will respond with the current
setting value.
ST<CR> ST 3600<CR><LF> Sample Time is set to 3600 Seconds (1
Hour).
9.14 Set Operation Control [S x]
S x<CR> This command will start or stop a sample event.
Issuing a start command while the unit is
sampling will restart the sample event.
S 1<CR> Start the sample event.
S 0<CR> Stop the sample event.
Issuing a Stop command will have different results depending on the Operation Mode the unit is in
when the command was issued.
If the Operation Mode is the Zero Calibration cycle, the unit will stop immediately.
If the Operation Mode is Sampling, the unit will proceed directly to the Purge Cycle then stop.
If the Operation Mode is Purging, the unit will continue with the Purge cycle to its completion
before stopping.

9.15 Exit User Mode [Q,X]
Q<CR> This command will start or stop a sample event.
Issuing a start command while the unit is
sampling will restart the sample event.
Q<CR> Exit User Mode User Mode Exited. Returned to Computer Mode
X<CR> Exit User Mode
The Q command and X command both exit User Mode and return the unit to Computer Mode.
9.16 Enter Calibration Mode [CAL]
CAL<CR> This command will enter Calibration Mode.
Under normal circumstances, there should be no need to adjust the factory calibration of the
internal sensors.
The CAL command is provided to audit the performance of the internal sensors and adjust them
as necessary.
Entry to Calibration Mode is signaled by an OM, Test message. The pump will start and the flow
controller will control the flow rate to 2.0 lpm. Once in Calibration Mode, the unit will output internal
sensor values once per second. An example output follows.
F: 2.003 AT: 22.5 BP: 979.1 RH: 39 CT: 26.2
The sensors monitored are:
Flow in lpm.
Ambient Temperature (AT) in Deg C.
Barometric Pressure (BP) in mbar.
RH in percent.
Case Temperature (CT) in Deg C.
The AT and BP values are used to calculate Volumetric Flow and should be adjusted before the
Flow if necessary.
9.17 Exit Calibration Mode [CAX]
CAX<CR> This command will exit Calibration Mode.
9.18 Default Sensor Calibrations [DFLT]
DFLT<CR> Default Cal Clears sensor calibrations to defaults (Flow,
Ambient Temp, BP, RH and Case Temp)

9.19 Reference AT [RA]
RA x<CR> This command will enter the Reference
AT value for Calibration.
X = Reference Temperature in Deg C.
RA 24.0<CR> AT Cal 24.0 Set the Reference temperature to 24C.
This command is used to calibrate the Ambient Temperature reading and is entered in Calibration
Mode. The unit will calculate the correct offset to apply based on the current AT reading when the
RA command was entered.
9.20 Reference Flow [RF]
RF x<CR> This command will enter the Reference
Flow value for Calibration.
X = Flow Rate in lpm.
RF 2.07<CR> Flow Cal 2.070 Set the Reference Flow to 2.07lpm.
Not in Cal Mode! This warning will appear if not in Cal
Mode when the command was entered.
This command is used to calibrate the Flow sensor and is entered in Calibration Mode. The unit
will calculate the correct offset to apply based on the current Flow reading when the RF command
was entered.
If the unit is not in Calibration Mode when this command is entered, a warning will be issued and
the calibration will not take place.
Allow sufficient time for the flow to settle and stabilize before entering a flow value.
9.21 Reference Pressure [RP]
RP x<CR> This command will enter the Reference
BP value for Calibration.
X = BP in mbar.
RP 981.1<CR> BP Cal 981.1 Set the Reference Flow to 981.1mbar.
This command is used to calibrate the BP sensor and is entered in Calibration Mode. The unit will
calculate the correct offset to apply based on the current BP reading when the RP command was
entered.

9.22 Reference Humidity [RR]
RR x<CR> This command will enter the Reference
RH value for Calibration.
X = RH in percent.
RR 35<CR> RH Cal 35 Set the Reference RH to 35.
This command is used to calibrate the RH sensor and is entered in Calibration Mode. The unit will
calculate the correct offset to apply based on the current RH reading when the RR command was
entered.
9.23 RH Set Point [SPR]
SPR x<CR> This command will enter the RH Set
Point for the Inlet Heater Control.
X = RH in percent.
SPR<CR> SPR 0.0 RH Set Point at 0, (disabled).
SPR 50<CR> SPR 50.0 Set the Reference RH Set Point to 50%.
The Inlet Heater control is a simple On/Off style controller. If the RH goes over the Set Point, the
heater turns on and when it drops below, the heater turns off. This command allows the setting to
be changed.
A Set Point of 0 or 100% can be used to disable the Inlet Heater Control altogether.
9.24 Output Interval [OI]
OI x<CR> This command will set the Output
Interval for measurements when the
instrument is running.
X = Is the interval in Seconds.
OI<CR> OI 0 Output Interval 0, (disabled).
OI 1<CR> OI 1 Set the Output Interval to 1 second
The unit normally outputs its measurement once per second when it is in operation. This output
can be disabled by setting the Output Interval to 0. This allows for a computer or data logger to
Poll for the data instead.
While it is possible to set the Output Interval for longer than 1 second, it should be noted that no
averaging will take place. The output will be the instantaneous 1 second reading at the interval
period.

9.25 Advanced Command Summary
The following is a summary of the advanced commands. These consist of the more rarely used
settings or commands that are primarily intended for direct computer or data logger interaction
rather than user interaction.
Command Description
DS Field Descriptors
DSCRC Field Descriptor CRC Signature
MA Modbus Address.
ME Request Measurement (Legacy Format).
NW Network Mode.
OP Display Operation.
QH Query Header
RL List Record Formats.
RT Set Record Format Type.
RQ Request Measurement (MetRecord Format).
SK Set K-Factor multiplier
UN Set / Read Units
9.26 Modbus Address [MA]
MA a<CR> This command will set the Modbus
Address.
a = Is the Modbus Address from 1 to
247
MA<CR> MA 1 Modbus Address is set to 1
MA 3<CR> MA 3 Set the Modbus Address to 3
9.27 Measurement Request [ME]
ME<CR> Request the Measurement in Legacy
output format.
This command will respond with the current measurement result in Legacy output format
regardless of the current Record Type setting. This command is generally used by a computer or
data logger system to Poll for data and is usually used with the Output Interval set to 0.
9.28 Request Query [RQ]
RQ<CR> Request the Measurement in
MetRecord output format.
This command will respond with the current measurement result in MetRecord output format
regardless of the current Record Type setting. This command is generally used by a computer or
data logger system to Poll for data and is usually used with the Output Interval set to 0.

9.29 Set K-Factor Multiplier [SK]
SK k<CR> This command will set the K-Factor
multiplier.
k = Is the K-Factor multiplier
SK<CR> SK 1.000 See the current setting
SK 2.6<CR> SK 2.600 Set the K-Factor multiplier to 2.6
9.30 Network Mode [NW]
NW x<CR> This command is used to Enter or Exit
Network Mode.
x = 1 to Enter Network Mode
x = 0 to Exit Network Mode
<Esc>A 01 NW 0*// NW 0 Take the unit with the ID of “01” out of
Network Mode
This command is used to Enter or Exit Network Mode. The unit will also automatically enter
Network Mode if it detects network messages addressed to this unit or any other unit on the
network.
Note, to exit Network Mode, you will need to use the proper network address as shown in the
example above. It the unit is the only device on the network, the Global address of 0 can be used.
9.31 Operation Mode [OP]
OP<CR> This command is used to display the
current Operation Mode.
0 = Stopped, 1 = Zeroing, 3 = Sampling,
4 = Purging
OP OP, 3, SAMPLING The unit is currently Sampling.
This command is primarily intended to be used by another computer controlling the unit
9.32 Query Header [QH]
QH<CR> Display the CSV
column header
for the
MetRecord
format output
QH Conc(mg/m3),Flow(lpm),AT(C),RH(%),BP(mbar),Status
This command is intended to be used by a computer accessing the instrument to retrieve the CSV
record header for the MetRecord format data.

9.33 List Record Formats [RL]
RL<CR> List Available Record Type formats
RL RL 1-MetRecord 2-Legacy
9.34 Record Type [RT]
RT f<CR> Sets or views the current Record Type.
Refer to the RL command for available
formats.
RT RT 1-MetRecord Unit is currently set to the MetRecord
output format.
RT 2 RT 2-Legacy Set the unit to Legacy output format.
Starting with Revision 1.1.0 of the firmware, the default behavior of the instrument is to follow the
MetRecord protocol. In order to maintain backward compatibility with installations which were
programmed for the earlier systems, this command allows the user to set the unit to output data in
the old format.
9.35 Descriptor Table Retrieval [DS]
The Descriptor Table Retrieval commands are used by a computer or data logger to discover the
number of data fields and their parameters to automatically setup the data logging process.
9.36 DS 0 – Query Abbreviated Descriptor Information
Command Description
DS 0 This command returns the general header information
Response Description
DS n,id,r The response indicates the general header information
n – Number of field descriptor lines available.
id – Location ID
r – Reserved for future use. 0 is the default.
Example
DS 0<cr>
DS 5,01,0

9.37 DS c – Specific Channel Descriptor Information
Command Description
DS c This command returns the specific channel descriptor information
c – Channel number.
Response
DS c,FieldName,MeasureType,units,prec,math,max,min
Parameter Description
c Field Number – 1 based.
FieldName Field Name string in printable ASCII.
MeasureType Measurement Type string in printable ASCII.
Units Engineering Units in printable ASCII.
prec Display decimal precision.
math Math type field. Vector (V), Scalar (S), Total (T), Minimum (MIN),
Maximum (MAX), Standard Deviation (STD).
max Maximum measurement value.
min Minimum measurement value.
Example
DS 1<cr>
DS 1,Conc,CONC,mg/m3,3,S,100.000,0.000
9.38 Request Units [UN]
Command Description
UN c Request the list of available channel / field units.
c – Desired channel/field 1 based
Response Description
UN c 1-a,... Returns the available units for the channel/field specified.
c – Specified field number
1-a – Unit enumerator and name.
... – More enumerators and names as the field requires
Example
UN 1<cr>
UN 1 1-mg/m3

10 APPENDIX C - NETWORK MODE
The following extension is used for networking the unit in a multi-drop RS-485 network.
The unit is not in Network Mode on power up. Any Network command will automatically place the
unit in Network Mode until the unit is powered off or taken out of Network Mode with the NW
command.
Once in Network Mode, all command input echo is turned off and all automatic serial output is
suppressed. The only output from the unit is in response to a network poll command with the
correct identifier for this instrument.
10.1 Identification Command Prefix
When in Network Mode, the unit will only respond when correctly addressed. The network address
is the Unit ID setting. This is set with the SID command. NOTE: This ID string is a 9 character
Alpha String. The Identifier string must match exactly including upper/lower case and leading
zeros in the case of numeric identifiers. The Default ID is “01” (no quotes)
The Identification Prefix takes the following form:
<Esc>A<sp>id<sp>cmd …*cs<cr>
Receipt of an Identification command will cause the unit to recognize that it is in a network and
disable command echo and real time output.
Command Component Description
<Esc> ASCII escape character (0x1B hex, 27 decimal)
A ASCII character ‘A’ (0x41 hex, 65 decimal)
<sp> ASCII space character (0x20 hex, 32 decimal)
id 1 to 9 alphanumeric ASCII characters 0 – 9 (0x30 – 0x39
hex, 48 – 57 decimal) and A-F upper and lower case.
An address of 0 will function as a “Global Address”
<sp> ASCII space character (0x20 hex, 32 decimal)
cmd Normal serial command with 0 or more additional
parameters.
* ASCII ‘*’ character (0x2A hex, 42 decimal). Checksum
Delimiter
cs Checksum described above.
<cr> ASCII carriage return character (0x0D hex, 13 decimal)
After the Identification Prefix, any standard terminal command can be used with the exception of
the Calibration Commands which require the unit to not be in Network Mode.
The two ASCII Space characters above are mandatory.
The Command Integrity Checksum is also mandatory or the network command will be ignored as
will any other command not addressed to this specific unit. The checksum will be a 16 bit sum of
all the characters After the <Esc> Character, up to but Not Including the “*” delimiter character.
The number will be printed in Decimal format.

11 APPENDIX D - MODBUS
11.1 Modbus 3X Registers
MODBUS Name Addr Type Points Description
Known value for easier Byte Order
MB_123456 = 0 float 2
configuration
MB_Op_State = 2 Int 1 Purge, Sample, Zero etc
When used with modes above which
MB_Time_Remain = 3 Int 1
have set times in each state
31 Char + Zero Terminator word aligned
MB_Revision = 4 char 16
to 32 bytes
MB_Conc = 100 float 2 Concentration in uG/M3

MB_AT = 102 float 2 Temperature in C
MB_RH = 104 float 2 Relative humidity %
MB_BP = 106 float 2 Barometric pressure mbar
MB_IOP = 110 float 2 Laser current mA
MB_Flow = 112 float 2 Flow rate lpm
MB_Alarm_Flags = 200 word 1 16 Bit Alarm Flags

Alarm Code of first alarm in the queue, 0
MB_Alarm_Code = 201 word 1
if none left to read in
Long Parameter for reason (Alarm
MB_Alarm_P1 = 202 dword 2
Dependent)
Float Parameter for reason ( Alarm
MB_Alarm_P2 = 204 float 2
Dependent )

11.2 4X Registers
MODBUS Name Addr Type Points Description
MB_Byte_Order = 0 Int 1 1 thru 4
MB_OP_Mode = 1 Int 1
MB_Out_Mode = 2 int 1 Settings Based
1=Run, 2=Stop, 3=Zero, 4=Span,
MB_Cmd = 3 Int 1 5=Sample, 6=Purge, 7=Cal Low,
8=Cal High, 9=Cal Exit
MB_ModBus_Addr = 4 Int 1 1 to 247
Baud Rate Enumerator value
MB_Baud = 5 int 1
(reserved, not implemented)
8 Char + Zero Terminator (word
MB_Unit_ID = 10 char[10] 5
aligned to 10 bytes)
16 Char + Zero Terminator (word
MB_Name = 15 char[18] 9
aligned to 18 bytes)
DAC Full Scale Voltage 0=2V, 1=5V,
MB_DAC_V = 24 Int 1
2= 10V
MB_DAC_Range = 25 Float 2 DAC Range in µg.
Any value written here pops the next

MB_Nxt_Alarm = 50 Int 1 alarm message off the queue and puts
it in the Alarm 3X read area
Triggers an Offset calculation and

MB_AT_Reference = 100 float 2
settings change
MB_RH_Reference = 102 float 2
MB_BP_Reference = 104 float 2
MB_T_Internal_Ref = 106 float 2
Sets Low X1,Y1 and triggers an M & B
MB_Flow_Low_Ref = 108 float 2
calculation
MB_Sample_Time = 202 dword 2 Sampling Time in Seconds

MB_RH_Setpoint = 209 float 2
MB_Relay_SP = 214 float 2 Concentration Alarm Relay Set Point
MB_K_Factor = 218 float 2 K-Factor Mulitpier

12 APPENDIX E – WIRING ANALOG OUTPUT.
Long cable length can cause a voltage drop in the ground from the power source to the ES-642
electronics. This can cause 100’s of millivolts of error in the analog output, as seen at the end of
the cable. To correct for this DC offset, the ES-642 comes with an analog sense wire which
measures the difference in ground potential from the logger to the ES-642. You should always use
this remote analog sense wire, so the error can be removed. This wire should be connected at the
ground side of the loggers input. The power ground of the ES-642 should also be connected to the
power ground side of the logger as well. (see the following wiring examples):
12.1 Single supply (logger and sensor)

12.2 Separate supplies, logger and sensor.

12.3 Using the 4-20 ma output option.

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ES-642 Dust Monitor

Met One Instruments, Inc

2 ES-642 SETUP and STARTUP 9

4 CONCENTRATION ALARM RELAY SET POINT 17

6 MAINTENANCE and TROUBLESHOOTING 21

ES-642-9800 Rev K Page 3

7 ACCESSORIES and PARTS 27

8 APPENDIX A - ES-642 MEASUREMENT METHOD 29

Page 4 ES-642-9800 Rev K

10 APPENDIX C - NETWORK MODE 46

12 APPENDIX E – WIRING ANALOG OUTPUT. 49

ES-642-9800 Rev K Page 5

1.3 About the ES-642

1.4 Laser Radiation Safety and Conformity

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ES-642-9800 Rev K Page 7

Specifications may be subject to change without notice.

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Figure 2-1 Sharp cut cyclone attached to intake

ES-642-9800 Rev K Page 9

Figure 2-2 Basic Mounting Installation

2.3.2 Wall or Pole Mounting:

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ES-642-9800 Rev K Page 11

Figure 2-5 Connector Layout

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Figure 2-6 ES-642 Power Connector

Signal Pin Number Color (80943)

CONC: 0.000 mg CONC: 0.000 mg CONC: 0.000 mg

CONC: 0.010 mg CONC: 0. 010 mg CONC: 0. 010 mg

CONC: 0. 010 mg CONC: 0. 010 mg

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4.1 Setting the Concentration Alarm Relay Set Point

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CONC: 0. 010 mg CONC: 0. 010 mg CONC: 0. 010 mg

ES-642-9800 Rev K Page 21

Problem: Flow failures or low flow.

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Problem: The ES-642 data is not consistent with other sensors.

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Figure 6-1 Pump Filter and Purge Filter Replacement

6.5 TSP Inlet and Cyclone Cleaning

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Flow Sensor, ES-642 (older ES-642’s) 9049-3

Flow Sensor, Differential Pressure 82258

Ambient Temperature Thermistor and Harness 81410

Purge Filter Holder, Black Aluminum 8912

ES-642-9800 Rev K Page 27

LCD Display, ES-642, 2x16 Character 80830-1

MDF Engine Assembly, Frequency to Voltage 80868-3

External Cable, ES-642 80959

External Power Cable, ES-642 80943