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Related Manuals for Apex Instruments XD-502
Summary of Contents for Apex Instruments XD-502
- Page 1 XD-502...
- Page 2 XD-502 Digital Console 204 Technology Park Lane Fuquay-Varina, NC 27526 www.apexinst.com (919) 557-7300 (800) 882-3214 For Support or Service contact: Technical Services Group support@apexinst.com (919) 346-5754 (877) 726-3919 XD-502 Operator’s Manual Revision Date: 2023.02.09 Apex Instruments, Inc.
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Page 3: Retaining Instructions
Neither Apex Instruments nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information that is contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us. -
Page 4: Warranty Policy
Apex Instruments, Inc. warrants repairs to be free from defects in materials for a period of one year and workmanship for a period of 90 days from date of delivery. During the warranty period, we will repair any item Apex Instruments repaired or replaced that fails due to a defect in materials or workmanship under normal use. -
Page 5: Table Of Contents
XD-502 Digital Console Table of Contents Disclaimer............................... Retaining Instructions........................Warranty Policy............................1.0 Preface.............................. 1.1 Product Introduction......................... 1.2 Purpose of this Manual......................1.2.1 Relevant US EPA method descriptions............... 1.3 Safety Instructions........................1.3.1 Safety information related to intended use..............1.3.2 Explanation of safety warnings................... - Page 6 XD-502 Digital Console 3.2 Pre-Field Test Operations......................3.2.1 Console configuration....................3.2.2 Moisture determination....................3.2.3 Preparation of impinger train..................3.2.4 Preparation of sampling train..................3.2.5 Console leak check procedure................... 3.2.6 Sample train leak check procedure................3.3 Field Test Operations....................... 3.3.1 Performing a Method 5 sampling test.................
- Page 7 XD-502 Digital Console 4.5 Annual Maintenance........................ 4.6 Manufacturer support for the product..................4.6.1 Technical services....................... 4.6.2 Calibration services..................... 4.6.3 Obtaining documentation and information..............5.0 Troubleshooting..........................5.1 LCD Screen..........................5.1.1 No power to LCD screen..................... 5.1.2 Screen contrast too dim or bright, cannot read characters on screen......
- Page 8 XD-502 Digital Console Figures Fig. 1 Example Sampling Syste m......................Fig. 2 Front Panel Overview........................Fig. 3 User Interface..........................Fig. 4 Menu Overview..........................Fig. 5 Front-Side Leak Check........................Fig. 6 System Leak Check........................Fig. 7 Temperature Controller Configuration................... Fig. 8 PC to Console Connection......................
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Page 9: Preface
1.2 Purpose of this manual The purpose of this manual is to provide a basic understanding of the Apex Instruments XD-502 source sampling console. The XD-502 is applicable for use with a variety of US EPA sampling methods and other isokinetic sampling procedures. -
Page 10: Safety Instructions
XD-502 Digital Console 1.3 Safety Instructions 1.3.1 Safety information related to the intended use Source sampling is intended to be performed by technicians who have been trained in source sampling methods. Personnel conducting source sampling are expected to understand basic gas laws and chemistry. -
Page 11: Weight
XD-502 Digital Console 1.3 Safety Instructions cont. 1.3.4 Weight CAUTION Although the unit is compact and lighter than previous versions, the unit itself can present risks due to its weight. When carrying the unit, make sure to use proper form to lift using your legs. Lift and carry the unit using the provided handles or by holding the entire unit close to the body. -
Page 12: What To Do When The Unit Arrives
XD-502 Digital Console 1.4 What To Do When the Unit Arrives 1.4.1 Unpack and inspect Unpack the unit from its shipping container. Inspect the exterior of the unit for visible damage or missing components. Remove the lid by using the four butterfly latches and visually inspect the front of the unit. -
Page 13: How To Transport And Store The Unit
XD-502 Digital Console 1.5 How To Transport and Store the Unit 1.5.1 Dimensions Case: Mini 8U Height: 17” (43 cm) Width: 17” (43 cm) Depth: 12” (30.5 cm) Weight: 37.5 lbs (17 kg) 1.5.2 Lifting and handling CAUTION Avoid dropping the unit and other forms of collision during transport. When lifting, make sure to use the handles on the sides to lift. -
Page 14: Description Of The Product
The XD-502 console can be easily adapted to various gaseous sampling train systems. Using different configurations of sampling trains, the XD-502 console can be used to test for PM2.5 and PM10 fractions, metals, polychlorinated biphenyls (PCBs), dioxins/furans, polycyclic aromatic hydrocarbons (PAHs) and many more pollutants with adaptations of the standard particulate, isokinetic test method. -
Page 15: System Overview
Some sampling trains use an external pump assembly to pull the sample; an external pump is not necessary when a console, such as the XD-502, uses an internal sampling pump to extract the sample gas. -
Page 16: Technical Specifications
Electrical multi-conductor circular connector, instrumental grade stainless steel quick connects Sample inlet - 1/2”, pitot connections - 1/4”, Type K thermocouple plugs - AUX, STACK, PROBE, OVEN, EXIT Processor Apex Instruments PIC32 Microcontroller Module Firmware Scaling factor gamma correction input, pressure sensor damping, temperature sensor offset, user-... -
Page 17: Faceplate Components
XD-502 Digital Console 2.5 Faceplate Components Reference the image below for an introduction to the essential components of the X D-50 2 Source Sampling console. For specific part numbers and a detailed look at the internal components, go to Sections 6.3 and 6.4 on pages 55 and 56 of this manual. -
Page 18: Operation
XD-502 Digital Console 3.0 Console Operation 3.1 User Control Overview 3.1.1 Home screen overview The home screen on the XD-502 console allows the operator to view and manage run data. Timer: Run time displayed in MM:SS.ms format and can be started, stopped and reset using the membrane switch pad buttons. -
Page 19: Menu Overview
XD-502 Digital Console 3.1 User Control Overview cont. 3.1.3 Menu overview The menu on the XD-502 console allows the operator to set data averaging values, change units and provide TC offsets. The menu can be accessed by pressing and holding the Previous Screen (Menu) button for 3 seconds. -
Page 20: Pre-Field Test Operations
XD-502 Digital Console 3.2 Pre-Field Test Operations 3.2.1 Console configuration Ensure that the following console settings are configured in the lab before performing a field test: unit types, ΔH and ΔP damping and time and data saving settings. To access each of these settings on the console, enter the Menu by pressing and holding the Up arrow button for 3 seconds (timer must be at or reset to 0:00 to access full menu). -
Page 21: Console Leak Check Procedure
XD-502 Digital Console 3.2.5 Console leak check procedure (front side): NOTICE DO NOT EXCEED THE TRANSDUCER PRESSURE RATING OF 100 INCHES OF H O. DOING SO MAY RESULT IN OPERATIONAL SENSOR FAILURE. Navigate to the Leak Test function by pressing the Insert Note button and selecting Leak Test or perform the leak test from the main screen. -
Page 22: Sample Train Leak Check Procedure
XD-502 Digital Console 3.2.6 Sample train leak check procedure Navigate to the Leak Test function by pressing the Insert Note button and selecting Leak Test or perform the leak test from the main screen. A leak check before the sampling run is recommended, but not required. -
Page 23: Field Test Operations
XD-502 Digital Console 3.3 Field Test Operations 3.3.1 Performing a Method 5 sampling test This operation guide is written based on US EPA Method 5 sampling. Ensure that you follow the appropriate procedures outlined in the applicable isokinetic method to be performed. EPA Methods 1, 2, and 4 should already be performed and an approximation of Method 3 should be made or measured. - Page 24 XD-502 Digital Console 3.3 Field Test Operations cont. 3.3.1 Performing a Method 5 sampling test cont. 9. At the conclusion of each run, close the coarse valve and record the final readings (clock time and final DGM volume). Now the pump can be turned off and the probe can be removed from the stack.
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Page 25: Post-Test Field Operations
XD-502 Digital Console 3.4 Post-Field Test Operations 3.4.1 Post-test calibration check After each field test series, conduct a calibration check using the procedures outlined in EPA Method 5, Section 10.3.2 (or Section 16.3), noting that three calibration runs at a single, intermediate orifice setting (based on the previous field test) with the vacuum set at the maximum value reached during... -
Page 26: Setting The Temperature Controller
XD-502 Digital Console 3.5 Setting the Temperature Controller 3.5.1 Set value setting 1. The current temperature of the equipment is °C shown on the Fuji controller. To change the set value (SV) press once. 2. Current value is displayed and SV is lit. Press to increase or decrease the displayed value (set value). -
Page 27: Operation Using Software
XD-502, which should be labeled as XD-502 Software and Firmware Package. This will take you to a cloud storage location that will always contain the latest software and firmware for the console. Download the zip file and extract it somewhere accessible on the PC. -
Page 28: Main Screen Overview
XD-502 Digital Console 3.6.4 Main screen overview Fig. 9 Main Screen Overview The Main screen of the software is where the user can monitor all of the necessary information for a sampling operation. The Main screen is divided into the following subsections: 1. -
Page 29: Navigation/Connection Section Overview
XD-502 Digital Console 3.6.5 Navigation/Connection section overview Fig. 10 Software Navigation The Navigation section of the Main screen allows the user to control the connection of the console and switch between the software screens/tabs. The Navigation section features the following buttons/tabs: 1. -
Page 30: Traverse Point Section Overview
XD-502 Digital Console 3.6.6 Traverse Point section overview The Traverse Point section of the Main screen allows the user to control the timer on the console. The Traverse Point section features the following buttons/tabs: 1. Start/Stop Timer button - Starts and stops the timer (a data point can optionally be saved using this button) 2. -
Page 31: Volume/Temperature Section Overviews
XD-502 Digital Console 3.6.8 Volume/Temperature section overviews Volume section The Volume section of the Main screen allows the user to view volume and flow data and set the zero point for the pressure transducers. The Volume section features the following information and control: 1. -
Page 32: Pressure/Console Time Section Overviews
XD-502 Digital Console 3.6.9 Pressure/Console Time section overviews Pressure section The Pressure section of the Main screen allows the user to view pressures measured by the various pressure transducers and barometric and vacuum sensors. The user can also start a leak test from this section. -
Page 33: Data Point And Note Saving Menu Section Overview
XD-502 Digital Console 3.6.10 Data Point and Note Saving menu section overview The Data Point and Note Saving menu is the section of the software where the user can save data points manually and insert notes for reference. This section of the software is available at the bottom of the window from any of the software screens. -
Page 34: Job Information Screen Overview
XD-502 Digital Console 3.6.11 Job Information screen overview The Job Information screen allows the user to input general test information that will be added to the data export spreadsheet. 1. General Sampling Test Information fields - Client Name - Plant Name... -
Page 35: Fig. 18 Storage Screen Overview
XD-502 Digital Console 3.6.13 Storage screen overview The Storage screen displays a list of runs, and their associated data, as well as buttons to export run data. 1. Run Name list - The green arrows indicate which run is currently being used (a different run may be highlighted... -
Page 36: Monitor Screen Overview
XD-502 Digital Console 3.6.12 Monitor screen overview The Monitor screen displays a graphical form of the sampling train with real-time values and data (temperatures, flows, volumes and time). 1. AutoStop status 5. ΔP reading 2. Timer data (see the Main screen overview 6. -
Page 37: Utility Screen Overview
XD-502 Digital Console 3.6.14 Utility screen overview The Utility screen is where the user can view and update the settings for the console and software. The Utility Screen is divided into the following subsections: 1. Wireless Settings section 2. Timers section 3. -
Page 38: Fig. 21 Wireless Settings Panel Overview
Wireless Settings section - The Wireless Settings section of the Utility screen allows the user to modify and update settings related to the console connectivity. 1. XD-502 as Access Point - Allows the console to function as a router and connect to software wirelessly... -
Page 39: Fig. 22 Timers Settings Panel Overview
XD-502 Digital Console 3.6.14 Utility screen overview cont. Timers section - The Timers section of the Utility screen allows the user to modify and update settings related to time-based data point saving. 1. Traverse Auto Save settings - Minutes and Seconds fields: Allows the user to specify the amount of time of traverse points in minutes. -
Page 40: Fig. 23 Set Date/Time Panel Overview
XD-502 Digital Console 3.6.14 Utility screen overview cont. Set Date/Time section - The Timers section of the Utility screen allows the user to modify and update settings related to time-based data point saving. 1. PC - Displays the current date and time of the user’s PC 2. -
Page 41: Fig. 24 Formats Panel Overview
XD-502 Digital Console 3.6.14 Utility screen overview cont. Formats section - The Formats section allows the user to modify and update settings related to measurement units. 1. Metrics checkbox - Clicking this checkbox will change all units to metric in both the software and on the console. If this box is unchecked, all units will be imperial. -
Page 42: Fig. 25 Dgm Panel Overview
XD-502 Digital Console 3.6.14 Utility screen overview cont. DGM section - The DGM section allows the user to zero the dry gas meter reading and also access the Calibration menu. 1. Zero DGM (New Run) button - Allows the user to zero the DGM volume - The checkbox must be checked first to perform this action... -
Page 43: Outline Of Sampling Test Operations Using Software
XD-502 Digital Console 3.6.15 Outline of Sampling Test Operations Using the Software 1. Plug in and power on the console. 2. Attach USB cable to PC and to console. The console screen will flicker on and off indicating it has recognized the USB cable connection. - Page 44 XD-502 Digital Console 3.6.15 Outline of Sampling Test Operations Using the Software cont. 13. During the sample run, the probe is moved from point to point without turning off the pump or closing the flow valve (except when changing ports).
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Page 45: Maintenance
DGMC-5A-HF 4.1.2 Initial end user calibration checks Apex Instruments suggests that the end user perform calibration checks on the dry gas meter, thermo- couples, vacuum gauge and pressure sensors before performing a field test (post-test calibrations fulfill this suggestion). Perform an audit using a critical orifice set (rated for the intended sampling flow rates) plugged in to the sample inlet on the console. -
Page 46: Initial End User Audits
4.2 Post-Test Calibrations 4.2.1 Dry gas meter Apex Instruments and the EPA recommends that the user perform post-test audits following a field test series using the procedures outlined in EPA Method 5, Section 10.3.2 Calibration After Use. This procedure closely mirrors the pre-test calibration, except only three runs need to be made that are at or near the sample rate metered and at or higher than the vacuum observed during the test. -
Page 47: Post-Test Maintenance
Post-test calibrations and audits satisfy this suggestion. 4.5 Annual Maintenance Apex Instruments highly recommends that the console be returned to Apex Instruments on an annual basis. The Technical Services Group will perform an evaluation of all components of the system including functionality and build-integrity checks. -
Page 48: Manufacturer Support For The Product
4.6.2 Calibration services Apex Instruments offers dedicated, climate-controlled precision calibration services for a variety of measuring instruments to help keep all equipment up to date and within US EPA calibration requirements. Calibration services are available for consoles, reference meters, critical orifice, orifice sets, pitot tubes (geometric and wind tunnel) and thermocouple simulators. -
Page 49: Troubleshooting
XD-502 Digital Console 5.0 Troubleshooting 5.1 LCD Screen 5.1.1 No power to LCD screen CAUTION 1. Connector in the bottom-right corner of the board is not secure Resolution - Ensure that all wires are firmly clamped inside of the connector and that the connector is plugged into the board 2. -
Page 50: Pressures
XD-502 Digital Console 5.2 Pressures 5.2.1 Vacuum transducer non-zero CAUTION 1. Vacuum transducer reads a non-zero value with no flow going through the system Resolution - Recalibrate the vacuum sensor using a NIST-traceable reference vacuum gauge Resolution - Check the tubing connections between the inlet to the console and the vacuum... -
Page 51: Temperatures
XD-502 Digital Console 5.3 Temperatures 5.3.1 TC displayed values are changing too quickly to read 1. TC values are too sporadic Resolution - Adjust TC damping settings in the console menu. If the value is jumping large amounts, increase the damping band. If the value is jumping small amounts, increase the damping block size. -
Page 52: Additional Common Console Problems
XD-502 Digital Console 5.4 Additional Common Console Problems CAUTION Issue Resolution - Filters are dirty and need to be replaced Maximum vacuum or flow rate - Obstruction in sample flow path decreases - Blockage or kinks in plumbing - Leak in console plumbing or sample train... -
Page 53: Diagrams And Schematics
XD-502 Digital Console 6.0 Diagrams and Schematics 6.1 Electrical Diagram (XD-502, 120V Shown) RA-911 16Ga 16Ga OEM CORD °F °F M-PS-XLG-150-24-A - AC DC + Probe POWER SUPPLY Oven + AC DC - M-PXR3-F M-PXR3-F 10 11 12 13 14 15 16 17 18... -
Page 54: Plumbing Diagram
XD-502 Digital Console 6.2 Plumbing Diagram (XD-502, 120V Shown) Side View Top View Display/Transducer Module Display/Transducer Module Com 1 2 3 4 5 6 7 8 SWITCHES 3” 3” 3” 3” 3” 3” 8V-29V TSIL-2/1 38036 1.5” 3/32HBT-P (x2) 1.5”... -
Page 55: Parts List - Front Panel
XD-502 Digital Console 6.3 Parts List - Front Panel (XD-502, 120V Shown) 1. XC-CS51 (120V) Case with lid 15. M-PXR3-F (x2) Temperature controllers 2. M-LCD-NHD0420-A LCD display assembly 14. M-CBR10A-M Power switches 13. M-RA911 (x3) Power switches 12. B1VH-4S 3. MS-6X1 Coarse flow valve... -
Page 56: Parts List - Interior
XD-502 Digital Console 6.4 Parts List - Interior (XC-53B-MV 240V Shown) 1. M-PXR3-F (x2) 14.TSIL-4/2 15. TSIL-2/1 Temperature controllers Medium pressure tubing Small pressure tubing 13. PCB-502MAIN-ASY1 2. SSR-AD25-RS (x2) XD-502 main board (includes transducers) Relays 3. TU-6/4 12. PCB-SENS-B1B5B10... -
Page 57: References And Related Documentation
Method 3 Method 4 Method 5 Method 17 Method 23 Method 26A Method 29 Method 201A Method 202 Code of Federal Regulations (CFR) 40 Part 60 7.2 Related Documentation 7.2.1 Apex Instruments documentation Apex Instruments Isokinetic Sampling Handbook Apex Instruments, Inc. -
Page 60: Equations And Nomenclature
XD-502 Digital Console 7.3 Equations and Nomenclature 7.3.1 Equations Apex Instruments, Inc. -
Page 61: Nomenclature
XD-502 Digital Console 7.3.2 Nomenclature actual cubic feet standard absolute pressure (29.92 in Hg) acfm actual cubic feet per minute absolute pressure in flue in inches effective area of flue in square feet (millimeters) mercury actual cubic meters static pressure in flue in inches water,... - Page 62 XD-502 Digital Console [THIS PAGE IS INTENTIONALLY LEFT BLANK] Apex Instruments, Inc.
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