TITLE: ECAM: A low-cost vaping device for collection of electronic cigarette condensate and in vitro studies
AUTHORS: Rosa Campbell, Kelly  Burrowes, Vinod  Suresh

[DESCRIPTION]
<div class = "text-blocks"><div class = "text-block"><span>The use of electronic cigarettes (ECs) has become widespread despite many unknowns around their long-term health impact. ECs work by vapourising a liquid, known as an e-liquid, typically consisting of propylene glycol, glycerol, flavourings and nicotine. The chemical constituents and resultant impact on cells and tissue are dependent on several factors, including the flavourings used, the vaping topography/use pattern, and the device used. ECAM (Electronic Cigarette Aerosol Machine) is an open source, portable device for creating EC aerosol – for condensate collection and </span><span style = "font-style:italic;">in vitro</span><span> studies - using a controlled methodology. ECAM was developed as a low cost, automated, and customisable alternative to commercial devices. ECAM consists of a micro diaphragm gas pump to draw air/EC aerosol through the system. The device is automated using an Arduino and solenoid pinch values are used to alternate between air and EC vapour. Condensate is collected in a vial within a cold-water bath. Each ECAM unit uses a temperature/humidity sensor to measure ambient air conditions and a differential pressure sensor to determine the pressure within the system. ECAM is programmed to adhere to International Standards Organisation 20768:2018. The design files, source code, and build instructions for this device can be found at </span><a href="https://osf.io/3ngu4" style = "text-decoration:underline;color:blue;cursor:pointer;"><span style = ":;">https://osf.io/3ngu4/</span></a><span>.</span></div></div>

[STEPS]
?. [Case Construction]
The Structure holds all electrical, mechanical and pneumatic components of ECAM. The parts required are:A1 Acrylic SheetsA2 M6 Threaded RodA3 4xM6 Hex NutsA4 4xM6 WashersA12 M8 x100 mm BoltsConsumablesX5 Electronic CigaretteRecommended ToolsZ1 M3 TapZ2 M3 Tap WrenchZ3 M8 TapZ4 M8 Tap WrenchZ5 HacksawZ14 SpannerConsumablesX5 Electronic CigaretteRecommended ToolsZ1 M3 TapZ2 M3 Tap WrenchZ3 M8 TapZ4 M8 Tap WrenchZ5 HacksawZ14 SpannerRecommended ToolsZ1 M3 TapZ2 M3 Tap WrenchZ3 M8 TapZ4 M8 Tap WrenchZ5 HacksawZ14 Spanner
?. [Case Construction]
Laser cutting
?. [Case Construction]
Download the laser cutting files from https://osf.io/chvne/The laser cut components have been laid out in two template drawings of maximum dimensions 400x600 mm, the size of the acrylic sheets (A1)ECAM_011, 012 v1.SLDDRW ECAM_013, 014, 015, 016 v1.SLDDRW.
?. [Case Construction]
Tap the holes indicated in the drawing files below, located in the 'Laser Cutting Files" folder https://osf.io/chvne/. Holes marked with M3 should be tapped using the M3 tap (Z1) and the M3 tap wrench (Z2). Holes marked with M8 should be tapped using M8 tap (Z3) and M8 tap wrench (Z4).TappedHolesECAM_011 v1 AcrylicBase6mmTappedHolesECAM_013 v1 AcrylicLeftWall6mmTappedHolesECAM_014 v1 AcrylicRightWall6mmHoles not marked are through holes and have been laser cut to specification.
?. [Firmware]
Arduino Programming requires components:A.E1 Arduino UNOA.E2 USB A/B Cable
?. [Firmware]
If you don't already have the open-source Arduino IDE installed you can download it from the website https://www.arduino.cc/en/software
?. [Electronics]
Prepare the custom jumper cables and wire electrical componentsThe parts required are:A.S1 2 Solenoid Pinch ValvesA.S2 1 Tubular Push SolenoidA.S3 2 DIN connectors A.P2 Pump MicrocontrollerA.PW2 DC PlugA.PW3 DC SocketA.PW5 24V-12V DCDC ConverterA.E1 ArduinoA.E2 USB cableA.E3 Relay ModuleA.E4 4 DiodesA.E5 LCDA.E6 I2C expander for LCDA.E7 Flow meterA.E8 Temp/Humidity SensorA.E9 Pressure SensorA.E10 DACA.E11 Vero Strip boardA.E12 Pin Crimp contactA.E13 Socket Crimp contactA.E14 1 6-way housingA.E15 2 3-way housingsA.E16 3 4-way housingsA.E17 3 2-way housingsA.E18 Red WireA.E19 Green WireA.E20 Black WireA.E21 Blue WireA.E22 Yellow WireA.E23 White WireA.E24 Purple WireA.E25 Orange WireRecommended ToolsZ6 Wire StripperZ7 Crimping ToolZ8 ScrewdriverZ16 Soldering IronZ17 Solder WireRecommended ToolsZ6 Wire StripperZ7 Crimping ToolZ8 ScrewdriverZ16 Soldering IronZ17 Solder Wire
?. [Electronics]
Crimp a socket crimp contact (A.E13) to one end and a pin crimp contact (A.E12) onto the other end of the wires below:3 Blue: 1x 200, 1x 150, 1x 1001 Purple: 1x 1001 Orange: 1x 1001 Yellow: 1x 100Crimping instructions:Cut the stripped wire to approximately 5 mmPlace the wire in the crimp contact so the insulation will only be crimped by the insulationUse the 1.3 die on the crimp tool (Z7) to crimp the wireDo a light tug test to ensure the wire is fixedUse the 1.6 die on the crimp tool (Z7) to crimp the insulation.Crimping instructions:Cut the stripped wire to approximately 5 mmPlace the wire in the crimp contact so the insulation will only be crimped by the insulationUse the 1.3 die on the crimp tool (Z7) to crimp the wireDo a light tug test to ensure the wire is fixedUse the 1.6 die on the crimp tool (Z7) to crimp the insulation.
?. [Electronics]
Crimp a socket crimp contact (A.E13) only to one end of the wires below, as per crimping instructions in 8.3 above.5 Red: 2x 150, 3x 1001 Black: 1x 1005 Green: 2x 150, 3x 1001 Blue: 1x 1001 White: 1x 1501 Yellow: 1x 150
?. [Case Construction]
Prepare the threaded rod (A2)
?. [Firmware]
Open ECAMSystemControl014.ino in the Arduino IDEInstall the DAC, LCD and Temperature/Humidity Sensor libraries:Tools > Manage Libraries > Search: "MCP4725" > INSTALL Tools > Manage Libraries > Search: "liquid crystal I2C" > INSTALL Tools > Manage Libraries > Search: "DHT" > INSTALL DHT sensor library by AdafruitWhen the dialog opens asking if you would also like to install additional required libraries click Install AllTo check that the library has been successfully installed navigate to C:/Documents/Arduino/libraries
?. [Firmware]
Plug the Arduino (A.E1) into your computer using the USB cable (A.E2). Under the Tools tab check that the:S1Board selected is the Arduino UNO.S2 Port selected is the COM port associated with your Arduino. This will vary depending on your computer however it could look like Port: COM 3 (Arduino UNO)S3 Programmer selected is Arduino ISPClick the tick in the top left-hand corner of the Arduino IDE. This will verify that the code compiles and will complete if all required libraries are installed.Click the upload arrow S8 to deploy the firmware on the Arduino UNO. Wait a few seconds for the onboard LED to flash. Then you can unplug the Arduino UNO.
?. [Assembly]
Fix all components into the acrylic case. Locations are indicated on the image belowYou will need:ECAM_011 BaseECAM_012 TopECAM_013 Left WallECAM_014 Right WallECAM_015 Front Wall ECAM_016 Back WallECAM_113 Pump FixingECAM_122 Relay FixingECAM_212 EC Base FixingECAM_213 EC Top FixingECAM_322 Condensing FixingA5 4 M4x12 screwsA6 21 M3x8 screwsA7 4 M3x12 screwsA8 2 M3x16 screwsA9 4 M4 nutsA10 4 M3 nutsA11 7 PCB edge supportsA.P1 PumpA.P2 Pump MicrocontrollerA.C2 21G NeedleA.S1 Solenoid Pinch ValvesA.S2 Tubular Push SolenoidA.S3 DIN ConnectorA.PW2 DC PlugA.PW3 DC SocketA.PW5 DCDC Converter A.E1 ArduinoA.E3 Relay ModuleA.E5 LCDA.E7 Flow MeterA.E8 Temperature/humidity SensorA.E9 Pressure SensorConsumablesX4 GlueRecommended ToolsZ9 M3 hex keyZ10 M4 hex keyConsumablesX4 GlueRecommended ToolsZ9 M3 hex keyZ10 M4 hex keyRecommended ToolsZ9 M3 hex keyZ10 M4 hex key
?. [Electronics]
Cut wire to length (dimensions in mm)14 Red wires (A.E18): 4x 150, 7x 100, 3x 5011 Black wires (A.E20): 4x 150, 4x 100, 3x 506 Green wires (A.E19): 2x 150, 4x 1004 Blue wires (A.E21): 1x 200, 1x 150, 2x 1004 Yellow wire (A.E22): 3x 100, 1x 1502 White wire (A.E23): 1x 150, 1x 1003 Purple wire (A.E24): 1x 150, 2x 1003 Orange wire (A.E25): 1x 150, 2x 100
?. [Electronics]
Strip 10 mm of insulation from both ends of each section of wire.
?. [Electronics]
Wire the DIN plug (A.S3) for the pinch solenoid valves (A.S1).
?. [Electronics]
Remove the screw terminal from the DIN plug housing by pushing the screw through the screw hole in the back, against the housing inside, the screw terminal should pop out the front.
?. [Electronics]
Push the crimp contacts into the connector housings.LCD 4-way housing (A.E15)1: Green 250 with socket crimp only2: Red 250 with socket crimp only3: Yellow 250 with socket crimp only4: White 250 with socket crimp onlyFlow Meter 6-way housing (A.E13)1: Red 200 with socket crimp only4: Green 200 with socket crimp only6: Blue 200 with socket crimp and pin crimp into 1x 1-way housing1x 4-way housing (A.E15) for Pressure Sensor: 2: Red 150 with socket crimp only3: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlyArduino I2C 2-way housing (A.E16)1: Yellow 100 with pin crimp only2: White 100 with pin crimp onlyArduino 5V and GND (A.E16)1: Red 100 with pin crimp only2: Green100 with pin crimp onlyRelay Module 2-way housing (A.E16)1: Red 100 with socket crimp only2: Black 100 with socket crimp onlySolenoid Signals Arduino 3-way housing (A.E14)1: Purple 100 with pin crimp and socket crimp into 1 of Relay 3-way housing2: Orange 100 with pin  and socket crimp into 1 of Relay 3-way housing3: Yellow 100 with pin crimp and socket crimp into 1 of Relay 3-way housingTemp/Humidity Sensor 4-way housing (A.E15): 1: Red 150 with socket crimp only2: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlyFlow Meter 6-way housing (A.E13)1: Red 200 with socket crimp only4: Green 200 with socket crimp only6: Blue 200 with socket crimp and pin crimp into 1x 1-way housing1x 4-way housing (A.E15) for Pressure Sensor: 2: Red 150 with socket crimp only3: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlyArduino I2C 2-way housing (A.E16)1: Yellow 100 with pin crimp only2: White 100 with pin crimp onlyArduino 5V and GND (A.E16)1: Red 100 with pin crimp only2: Green100 with pin crimp onlyRelay Module 2-way housing (A.E16)1: Red 100 with socket crimp only2: Black 100 with socket crimp onlySolenoid Signals Arduino 3-way housing (A.E14)1: Purple 100 with pin crimp and socket crimp into 1 of Relay 3-way housing2: Orange 100 with pin  and socket crimp into 1 of Relay 3-way housing3: Yellow 100 with pin crimp and socket crimp into 1 of Relay 3-way housingTemp/Humidity Sensor 4-way housing (A.E15): 1: Red 150 with socket crimp only2: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp only1x 4-way housing (A.E15) for Pressure Sensor: 2: Red 150 with socket crimp only3: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlyArduino I2C 2-way housing (A.E16)1: Yellow 100 with pin crimp only2: White 100 with pin crimp onlyArduino 5V and GND (A.E16)1: Red 100 with pin crimp only2: Green100 with pin crimp onlyRelay Module 2-way housing (A.E16)1: Red 100 with socket crimp only2: Black 100 with socket crimp onlySolenoid Signals Arduino 3-way housing (A.E14)1: Purple 100 with pin crimp and socket crimp into 1 of Relay 3-way housing2: Orange 100 with pin  and socket crimp into 1 of Relay 3-way housing3: Yellow 100 with pin crimp and socket crimp into 1 of Relay 3-way housingTemp/Humidity Sensor 4-way housing (A.E15): 1: Red 150 with socket crimp only2: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlyArduino I2C 2-way housing (A.E16)1: Yellow 100 with pin crimp only2: White 100 with pin crimp onlyArduino 5V and GND (A.E16)1: Red 100 with pin crimp only2: Green100 with pin crimp onlyRelay Module 2-way housing (A.E16)1: Red 100 with socket crimp only2: Black 100 with socket crimp onlySolenoid Signals Arduino 3-way housing (A.E14)1: Purple 100 with pin crimp and socket crimp into 1 of Relay 3-way housing2: Orange 100 with pin  and socket crimp into 1 of Relay 3-way housing3: Yellow 100 with pin crimp and socket crimp into 1 of Relay 3-way housingTemp/Humidity Sensor 4-way housing (A.E15): 1: Red 150 with socket crimp only2: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlyArduino 5V and GND (A.E16)1: Red 100 with pin crimp only2: Green100 with pin crimp onlyRelay Module 2-way housing (A.E16)1: Red 100 with socket crimp only2: Black 100 with socket crimp onlySolenoid Signals Arduino 3-way housing (A.E14)1: Purple 100 with pin crimp and socket crimp into 1 of Relay 3-way housing2: Orange 100 with pin  and socket crimp into 1 of Relay 3-way housing3: Yellow 100 with pin crimp and socket crimp into 1 of Relay 3-way housingTemp/Humidity Sensor 4-way housing (A.E15): 1: Red 150 with socket crimp only2: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlyRelay Module 2-way housing (A.E16)1: Red 100 with socket crimp only2: Black 100 with socket crimp onlySolenoid Signals Arduino 3-way housing (A.E14)1: Purple 100 with pin crimp and socket crimp into 1 of Relay 3-way housing2: Orange 100 with pin  and socket crimp into 1 of Relay 3-way housing3: Yellow 100 with pin crimp and socket crimp into 1 of Relay 3-way housingTemp/Humidity Sensor 4-way housing (A.E15): 1: Red 150 with socket crimp only2: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlySolenoid Signals Arduino 3-way housing (A.E14)1: Purple 100 with pin crimp and socket crimp into 1 of Relay 3-way housing2: Orange 100 with pin  and socket crimp into 1 of Relay 3-way housing3: Yellow 100 with pin crimp and socket crimp into 1 of Relay 3-way housingTemp/Humidity Sensor 4-way housing (A.E15): 1: Red 150 with socket crimp only2: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp onlyTemp/Humidity Sensor 4-way housing (A.E15): 1: Red 150 with socket crimp only2: Blue 150 with socket crimp and pin crimp into 1x 1-way housing4: Green 150 with socket crimp only
?. [Case Construction]
Download the 3D Printing STL files from https://osf.io/sc7eb/ and using an FDM 3D printer, print with settings:Infill: 20% Wall line count: 3Layer Height: 0.1 mmWhen the print is finished, remove supports and sand down the rough edges.
?. [Case Construction]
Slot the left (ECAM_013), right (ECAM_014), and front (ECAM_015) walls into the base (ECAM_011). Then slot the top (ECAM_012) onto these walls.
?. [Electronics]
Crimp a pin crimp contact (A.E12) only to one end of the wires below:1 Red: 1x 1001 White: 1x 1001 White: 1x 1001 Yellow: 1x 100
?. [Electronics]
Screw the positive wire (Purple or Orange 150 with both ends only stripped) into terminal 1 and the negative wire (Black 150 with both ends only stripped) into pin 2.
?. [Electronics]
Thread the wires through the DIN housing and push the terminal block into the housing ensuring the flat socket is in line with the wire opening.
?. [Electronics]
Thread the gasket, washer and housing cap screw over the wires and screw tight.
?. [Electronics]
Plug and screw DIN connector into the Solenoid Pinch Valves
?. [Pneumatic Circuit]
Cut tubing to length using the tube cutter (Z19):3.2 mm silicone tube (A.T2)2x 85 mm (Pump to Buffer, Buffer to Flow Meter)1x 120 (Flow Meter to Luer)1x 35 (Luer to Y Connector)1x 50 (Flow Meter to T Connector)2x 100 mm (T Connector to Buffer, Buffer to Pressure Sensor)6.2 mm silicone tube (A.T3)80 mm (Y connector through Air Solenoid Pinch Valve)160 mm (Y connector to reducer)7.9 mm silicone tube (A.T1)120 mm (Reducer to EC mouthpiece)6.2 mm silicone tube (A.T3)80 mm (Y connector through Air Solenoid Pinch Valve)160 mm (Y connector to reducer)7.9 mm silicone tube (A.T1)120 mm (Reducer to EC mouthpiece)7.9 mm silicone tube (A.T1)
?. [Electronics]
Solder components together using the soldering iron (Z16) and solder wire (Z17) following the instructions below. You may wish to refer to the electrical circuit diagram below.
?. [Electronics]
Solder the LCD, pump, pressure sensor and temperature/humidity sensor wires to the Vero board connecting the 5V (Red), Ground (Green), SDA (Yellow) and SCL (White) wires to each strip.
?. [Electronics]
Solder a 6 Position Terminal Block Header to the DAC (A.E10). Cut a piece of Vero strip board (A.E11) at least 6 columns and 16 rows. Solder the pins of the DAC (A.E10) to the Vero board (A.E11) making sure each pin is connected to a separate copper strip.
?. [Electronics]
Wire the Solenoid electrical control components. Refer to the image below when following instructions in sub-steps below.
?. [Electronics]
Cut a section of Vero board at least 4 strips wide and 10 holes long. Solder a Red 150, and Black 150 wire to separate strips.Solder the Red 100 from the 2-way socket housing to the same strip as the Red 100 and the Black 150 from the 2-way socket housing to the same strip as the Black 150.Solder the Red 100 to the red strip and the Black 100 to the Black strip (pictured) we are using a DC power plug (A.PW2) with soldered wires however ECAM uses a DC power plug with screw terminals (A.PW2), screw the Red and Black 100 wires into the positive and negative terminals of the DC power plug (A.PW2) respectively.Solder another Red 100 to the red strip and the Black 100 to the Black strip.
?. [Electronics]
Solder the Solenoid Vero boardCut a piece of Vero strip board (A.E11) to at least 20 rows, 5 holes long.Solder three diodes (A.E4) in the middle of the Vero board making sure the positive and negative legs are soldered to separate copper strips. Solder the positive wire (Purple 150) of the EC solenoid pinch valve (A.S1) to the same strip as the first diodes cathode (-) leg (the one closest to the grey stripe).Solder the Purple 100 wire to the other side of the first diodes cathode leg on the same strip.Solder the negative wire (Black) of the EC solenoid pinch valve (A.S1) to the same strip as the first diodes anode (+) leg.Solder the Black 100 wire to the other side of the first diodes anode leg on the same strip.Solder the positive wire (Orange) of the Air solenoid pinch valve (A.S1) to the same strip as the second diodes cathode (-) leg (the one closest to the grey stripe).Solder the Orange 100 wire to the other side of the second diodes cathode leg on the same strip.Solder the negative wire (Black) of the Air solenoid pinch valve (A.S1) to the same strip as the second diodes anode (+) leg.Solder the Black 100 wire to the other side of the second diodes anode leg on the same strip.Solder one wire (Either can be positive) of the tubular push solenoid (A.S2) to one to the same strip as the third diodes cathode (-) leg.Solder the Yellow 100 wire to the other side of the third diodes cathode leg on the same strip.Solder the other wire of the tubular push solenoid (A.S2) to one to the same strip as the third diodes anode (+) leg.Solder the Black 100 wire to the other side of the third diodes anode leg on the same strip.
?. [Electronics]
Solder the 24V Vero BoardCut a piece of Vero strip board (A.E11) to at least 4 rows, 12 holes long.Solder a Red 150, and Black 150 wire to separate strips.Solder the free end of the Black 100 from each of the diodes anode legs to the same strip as the Black 150 wire.Solder three Red 50 wires to the same strip as the Red 150 wire.Solder another Red 150 and Black 150 wire to the Red and Black strips respectively
?. [Electronics]
Wire the relay module (A.E3)Screw the free end of each Red 50 wire into the normally open terminal of relays 1, 2, and 3.Screw the free end of the Purple 100 into the common terminal of relay 1.Screw the free end of the Orange 100 into the common terminal of relay 2.Screw the free end of the Yellow 100 into the common terminal of relay 3.
?. [Electronics]
Connect the circuitScrew the free Red and Black 150 wires from the 24V Vero board into the positive and negative terminals of the DC power socket (A.P3).Screw the other free Red and Black 150 wires from the 24V Vero board into the positive (+Vin) and negative (-Vin) input terminals of the DCDC Converter (A.PW5).Screw the free Red and Black 150 wires from the 12V Vero board to the positive (+Vout) and negative (-Vout) output terminals of the DCDC Converter (A.PW5). Plug the 2-way socket from the 12V Vero board into the Relay Module (A.E3) power ensuring the Red wires socket plugs into the VCC pin and the black wire to the GND pin.Screw the Red and Black 100 wires from the 12V Vero Board into the positive and negative input voltage terminals on the Pump Microcontroller (A.P2) respectively.Plug the DC power plug (A.PW2) into the Arduino UNOs (A.E1) DC power socket. Push the 4-way LCD socket into the LCD 12C port expender (A.E6) making sure the green wire lines up with the GND pin. Push the 4-way Pressure socket housing into the Pressure sensor (A.E9) making sure the Red wire connects to pin 2.Connect the blue pin from the pressure sensor (A.E9) to PIN A1 on the Arduino UNO (A.E1).Push the 4-way Temperature/Humidity socket housing into the Temperature/Humidity sensor (A.E8) making sure the Red wire connects to Pin 1.Connect the blue pin from the temperature/humidity sensor (A.E8) to PIN 2 on the Arduino UNO (A.E1).Place the flow meter (A.E7) into the flow meter holder (ECAM_152) making sure P1 is facing the front and P2 facing the back as the sensor will only read flow in this direction. Push the 6-way socket housing into the Flow Meter (A.E7) making sure that the red wire lines up with Vin.Connect the blue pin from the flow meter (A.E7) to PIN A0 on the Arduino UNO (A.E1).Push the 3-way pin housing into the Arduino UNO (A.E1) making sure that the purple wire lines up with PIN 7, Orange with PIN 6, and Yellow with PIN 5.Push the 3-way socket housing on the other end into IN1, 2, and 3 on the Relay module (A.E3) ensuring the purple wire lines up with IN 1, Orange with IN 2 and yellow with IN 3.
?. [Case Construction]
Using a size 2.5 Hex Key (Z9) use two M3 x8 screws (A6) and two M3 nuts (A10) to screw the 3D printed flow sensor fixing (ECAM_152) into the top (ECAM_012).
?. [Pneumatic Circuit]
Fit hose connectors to glass buffer lids.Mark two holes on two blue screw caps (A.T4) 13 mm apart.Drill (Z11) a guide hole with a 3 mm drill bit (Z12) on each of the markings.Drill (Z11) over the 3 mm holes with an 8 mm drill bit (Z13).Tap the holes using the M8 Tap (Z3) and tap wrench (Z4).Wrap thread seal tape (X3) around the threads of the 4 mm Male Threaded hose fittings (A.T7).Screw the four hose fittings (A.T7) into the tapped holes in the lids and tighten with the spanner (Z14).
?. [Assembly]
Remove adhesive backing and stick the PCB Edge Supports (A11) in place following the layout diagram below. Then place the Vero boards in these mounts.
?. [Case Construction]
Cut the 1m threaded rod (A2) to 4 pieces, each 170 mm long using a hack saw (Z5).
?. [Case Construction]
Place each rod through the clearance holes in the corners of the top (ECAM_012) and base (ECAM_011).
?. [Case Construction]
For each of the four rods, place 4 spring washers (A4) over the four threaded rods against the base from the underside and fasten with an M6 hex nut (A3) and tighten using the adjustable spanner (Z14). Leave the top of the threaded rods resting in the holes in the top (ECAM_012).
?. [Assembly]
Feed the type B end through the square hole in the back (ECAM_016) from the outside in. Then plug the Type B end of the USB cable (A.E2) into the Arduino (A.E1) leaving a short section of cable and the Type A end outside.
?. [Assembly]
Spread glue (X4) around the circular hole in the back (ECAM_016) and around the circular section of the DC power socket with screw terminals then push the socket through the back from the inside. Allow to dry for 24 hours before applying force to the joint.
?. [Pneumatic Circuit]
Set up tubes and connectorsYou will need:A3 M6 hex NutA4 M6 WasherA.T1 7.9 mm ID TubeA.T2 6.4 mm ID TubeA.T3 3.2 mm ID TubeA.T4 Glass jarA.T5 Y connectorA.T6 T connectorA.T7 Threaded hose connectorA.T8 ReducerA.C2 21 Gauge needlesA.C3 Luer to barb fittingConsumables:X1 Sample vialX3 Thread TapeX6 Isopropyl AlcoholRecommended Tools:Z3 M8 TapZ4 M8 Tap WrenchZ11 DrillZ12 3mm Drill bitZ13 8mm Drill bitZ14 SpannerZ15 19mm hole sawZ19 Tube cutterConsumables:X1 Sample vialX3 Thread TapeX6 Isopropyl AlcoholRecommended Tools:Z3 M8 TapZ4 M8 Tap WrenchZ11 DrillZ12 3mm Drill bitZ13 8mm Drill bitZ14 SpannerZ15 19mm hole sawZ19 Tube cutterRecommended Tools:Z3 M8 TapZ4 M8 Tap WrenchZ11 DrillZ12 3mm Drill bitZ13 8mm Drill bitZ14 SpannerZ15 19mm hole sawZ19 Tube cutter
?. [Pneumatic Circuit]
Lift up the top (ECAM_012) and slot the back tabs (ECAM_016) into the base slots (ECAM_011) and wall slots (ECAM_013, ECAM_014) into the back tabs. Then let the top down until the back tabs slot into the top slots. This might require some jiggling.
?. [Pneumatic Circuit]
Place a spring washer (A4) over each of the four threaded rods coming out the top then fasten with an M6 hex nut (A3) using the adjustable spanner (Z14)
?. [Pneumatic Circuit]
Put one lid with two hose fittings onto a glass jar and place this in the back right corner of the base. Connect one end of an 85 mm long 3.2 mm ID tube to the hose connector on the inlet of the pump, through the back tube hole and onto one hose connector on the glass jar lid. Connect the other 85 mm long 3.2 mm ID tube to the other hose connector on that glass jars lid and through the front tube hole onto the outlet barb of the flow meter.
?. [Pneumatic Circuit]
Drill a 19 mm hole in the centre of the third blue screw cap (A.T4) using the drill (Z11) and hole saw bit (Z15).
?. [Pneumatic Circuit]
Connect the following:120 mm long, 3.2 mm ID tube from the Flow Meter inlet barb (A.E8) to Luer barb (A.C3)35 mm long, 3.2 mm ID tube from the Luer barb (A.C3) to the Y Connectors primary barb (A.T5)One 21 gauge needle (A.C2) to each Luer lock (A.C3)Insert both needles into the silicone self-sealing cap of the sample vial (X1)Place the sample vial into the 19mm hole in the blue cap of one glass jar 80 mm long, 6.4 mm ID silicone tube from the Y connectors right branch (A.T5) through the Air Solenoid Pinch Valve (A.S1)160 mm long, 6.4 mm ID tube from the Y connectors left branch (A.T5) through the EC Solenoid Pinch Valve (A.S1) to the 6mm end of the reducer (A.T8)120 mm long 7.9 mm ID tube from the 8 mm end of the reducer (A.T8) to the EC mouthpiece (X5)
?. [Case Construction]
Place the EC (X5) into the base fixing (ECAM_212) then the top fixing (ECAM_213) over the cartridge of the EC. Place the bolts (A12) through the clearance holes in the sides of the top and base fixing and screw into the tapped M8 holes in the base (ECAM_011)
?. [Pressure Compensation Testing - Optional]
If ECAM has been constructed following these Build Instructions exactly - the machine will meet ISO 20768: 2018 requirements for the ability to compensate for a pressure drop of 3000 ± 50 Pa without a reduction of more than 3 ml from the puff volume. If changes to any components (such as the pump) have been made, the following calibration step is recommended.
?. [Pressure Compensation Testing - Optional]
Disconnect the 120 mm long, 3.2 mm ID tube from the flow meter  (A.E8)Connect this free end to one straight barb of the T connector (A.T6)Connect the 50 mm long, 3.2 mm ID tube from the flow meter (A.E8) to the other straight barb of the T-connector (A.T6) Connect one 100 mm long 3.2 mm ID tube from the branched barb of the T-connector (A.T6) to the inlet barb on the lid of the other glass jar Connect the other 100 mm long, 3.2 mm ID tube from the outlet barb on the glass jar to the top barb of the pressure sensor (A.E9)
?. [Pressure Compensation Testing - Optional]
Cut the 16-gauge needles (A.C1) to 10 mm long using the Dremmel tool (Z18) with the 191 High Speed Cutter attachment. Then remove the 21-gauge needles from the silicone vial cap and the luer lock fittings. Replace with the short 16-gauge needles.
?. [Pressure Compensation Testing - Optional]
Section 6.3 Pressure Compensation Calibration outlines the protocol for determining if the ECAM is capable of sufficient compensation.Plug the USB Cable Type A end into a computer.Open the Arduino IDEOpen the serial monitor by clicking the magnifying glass icon in the top right corner (S9).Plug the power cable (A.PW4) into the power supply (A.PW1) and a mains wall socket making sure the power is switched off at the wall socket.Then switch the power on to let one test run.
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Place the three phase wires from the pump (A.P1) through the wire hole (to the left of the screw holes) and screw the pump into place on the top using four M3 x8 mm screws (A6)Use the screw driver (Z8) to screw the 3 phase wires from the pump (A.P1) to the screw terminal on the pump micro controller (A.P2). X: RedY: WhiteZ: BlackUse the M3 hex key (Z9) to screw the pump fixing (ECAM_113) into place on the base (ECAM_011).Then sit the pump micro (A.P2) into its fixing.
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Using the M4 hex key (Z10) screw the following into place:Air and EC Solenoid Pinch Valves (A.S1) with two M4 screws (A5) and two M4 nuts (A9) per valve.Using the M3 hex key (Z9), screw: the following into place:Arduino Fixing (ECAM_132) with four M3 x8 screws (A6)Relay Module Fixing (ECAM_122) with four M3 x8 screws (A6)DCDC Converter (A.PW5) with four M3 x8 screws (A6)Temperature/Humidity Sensor (A.E8) with two M3 x8 screws (A6)Pressure Sensor (A.E9) with two M3 x16 screws (A8)LCD (A.E5) with four M3x12 screws (A7) and four M3 nuts (A10)Using the M3 hex key (Z9), screw: the following into place:Arduino Fixing (ECAM_132) with four M3 x8 screws (A6)Relay Module Fixing (ECAM_122) with four M3 x8 screws (A6)DCDC Converter (A.PW5) with four M3 x8 screws (A6)Temperature/Humidity Sensor (A.E8) with two M3 x8 screws (A6)Pressure Sensor (A.E9) with two M3 x16 screws (A8)LCD (A.E5) with four M3x12 screws (A7) and four M3 nuts (A10)Then place the Arduino and relay module in their respective fixings.
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Screw on hose fitting (A.T7) into the pump inlet (the top hole).
?. [Pressure Compensation Testing - Optional]
Copy the serial data into an excel spreadsheet and make three plots; Pressure versus time in the compensating phaseFlow versus time in the compensating phase Flow versus time in the test phaseThe pressure at the start (with the machine calibrated for test conditions 21-gauge needles) should be 3000 ± 50 Pa at 0 s. This will increase as the pump speed increases to maintain the flow.The puff should remain within the rectangular profile guidelines outlined in Section 5.2.2 of ISO 20768:2018.The area under the graph can be calculated using the formula: Volume =\sum_{n=0}^{n=15}(f_{n+1}-f_n))( t_{n+1}-t_n)/2  + f_n( t_{n+1}-t_n)The volume should be greater than 52 ml.
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We recommend cleaning these components that are in contact with the aerosol and could contaminate samples before using the machine:All sections of tube, all sizes (A.T1, A.T2, A.T3)Glass jars (A.T4)Nylon hose connectors (A.T5, A.T6, A.T7, A.T8)Needles (A.C2)Luer fittings (A.C3)This can be done by rinsing in warm, soapy water, allowing to dry then sterilise with Isopropyl alcohol (X6).