Apex Instruments XD-502G2 Operator's Manual

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XD-502G2

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Page 1 XD-502G2...
Page 2 XD-502G2 Digital Console 204 Technology Park Lane Fuquay-Varina, NC 27526 www.apexinst.com (919) 557-7300 For Support or Service contact: Technical Services Group support@apexinst.com (919) 346-5754 XD-502 Operator’s Manual Revision Date: 2024.06.20 Apex Instruments, Inc.
Page 3: Disclaimer
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-502G2 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-502G2 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-502G2 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-502G2 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......................
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-502G2 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-502G2 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-502G2 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-502G2 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: 39 lbs (17.7 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
XD-502G2 Digital Console 2.0 Description of the Product 2.1 Intended Use and Reasonably Foreseeable Misuse 2.1.1 Source sampling The sampling console is the operator’s control station. The XD-502 sampling console includes a precision dry gas meter ﬁtted with a high-resolution rotary encoder, a leak-free pump, a digital vacuum gauge, ﬂow control valves and a venturi-style oriﬁce tube for monitoring the gas ﬂow rate.
Page 15: System Overview
ﬁve main components of the Apex Instruments Source Sampling Train. The main components of a Source Sampling system are: probe assembly, heated ﬁlter, glassware case, umbilical cable and the console with an internal or external sampling pump.
Page 16: Technical Specifications
Sample inlet - 1/2”, pitot connections - 1/4”, Type K thermocouple plugs - AUX, STACK, PROBE, OVEN, FILTER, EXIT Processor Apex Instruments PEAK32 Microcontroller Module Firmware Scaling factor gamma correction, input and target ΔH via K-Factor, pressure sensor damping, temperature sensor oﬀset, user-selectable unit types (Metric, Metric Pa, Imperial)
Page 17: Faceplate Components
XD-502G2 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 53 and 54 of this manual.
Page 18: Console Operation
XD-502G2 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-502G2 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 Menu button (Up Arrow) for 3 seconds.
Page 20 XD-502G2 Digital Console 3.1 User Control Overview cont. 3.1.3 Menu overview cont. Traverse Pt. SAVE: Sets a timer for the console to save a data point to memory in sync with traverse points in the sample run. This time should be set up to match the sample traverse point time at each point.
Page 21: Pre-Field Test Operations
XD-502G2 Digital Console 3.2 Pre-Field Test Operations 3.2.1 Console conﬁguration Ensure that the following console settings are conﬁgured before performing a ﬁeld test: unit types, ΔH, K-Factor and ΔP damping, time and data saving settings. To access each of these settings on the console, enter the Menu by pressing and holding the Up arrow...
Page 22: Console Leak Check Procedure
XD-502G2 Digital Console 3.2 Pre-Field Test Operations cont. 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 23: Sample Train Leak Check Procedure
XD-502G2 Digital Console 3.2 Pre-Field Test Operations cont. 3.2.6 Sample train leak check procedure Navigate to the Leak Test function by pressing and holding the Insert Note button for 3 seconds and selecting Leak Test. The leak test may be performed from the main screen.
Page 24: Field Test Operations
XD-502G2 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 25 XD-502G2 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.
Page 26: Post-Test Field Operations
XD-502G2 Digital Console - Press the Select key to begin data export. - While the console is writing to the ﬂash drive the LED will ﬂash green and return to solid green. MENU:USB Drv Export then SELECT Select Press Select to begin USB Drive Export...
Page 27: Setting The Temperature Controller
XD-502G2 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 28: Operation Using Software
XD-502, which should be labeled as XD-502G2 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 29: Main Screen Overview
XD-502G2 Digital Console 3.6 Operation using software cont. NOTICE The software requires 0 (zero) to be added in front of each 2 digit number or two 0’s (zeroes) in the case of a single digit. Add the 0 (zero) to the IP Address as shown in the examples below.
Page 30: Navigation/Connection Section Overview
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.5 Navigation/Connection section overview DISABLED 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.
Page 31: Traverse Point, Data Saving And Volume Section Overview
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.6 Traverse Point, Data Saving and Volume section overview The Traverse Point and Periodic Save section of the Main screen allows the user to control the timer on the console. Traverse Point...
Page 32: Pressure Section Overview
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.8 Pressure section overview The Pressure section of the Main screen displays the set K-Factor, live P and H values, calculated Δ Δ target H, live vacuum value, maximum recorded vacuum value and the barometric pressure reading.
Page 33: Sample Timer And Data Point Section Overview
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.9 Sample Timer and Data Point section overview The bottom panel of the Main screen displays the run timer, Start/Stop timer button, pump control setting, current run and data point numbers and note saving functionality.
Page 34: Job Information Screen Overview
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.10 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. General Sampling Test Information ﬁelds - Client Name...
Page 35: Storage Screen Overview
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.11 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 - A Red “<Current>” indicates which run is currently being used (a diﬀerent run may be...
Page 36: Setup Screen Overview
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.12 Setup Screen overview The Setup screen is where the user can view and update the settings for the console and software. Fig. 18 Setup Screen Overview The Setup Screen is divided into the following subsections: 1.
Page 37 XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.12 Setup Screen overview cont. Calibrations Window - Click on the Calibrations Button to open the Calibrations Window. Password Protections - Passwords protect diﬀerent areas of the Calibrations Window against unintentional changes.
Page 38: Fig. 19 Wireless Settings And Formats Panel Overview
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.12 Setup Screen overview cont. 6. Console Connection Conﬁgurations - Allows the operator to connect to the console wirelessly in two diﬀerent manners as well as disabling the wireless connection by selecting the radio button and entering a an SSID and a password.
Page 39 XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.12 Setup screen overview cont. 6. Set Date/Time section - Allows the user to set the console’s date and time parameters to match that of the PC operating the software. This is a quick way to update the console’s date and time, which can be especially important when changing time zones.
Page 40: Outline Of Sampling Test Operations Using Software
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.13 Outline of Sampling Test Operations Using the Software 1. Plug in and power on the console. The console will respond with two quick chirps. 2. Double-click on the software icon to initiate the program.
Page 41 XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.13 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).
Page 42: Accessing Console Via Web Browser
XD-502G2 Digital Console 3.6 Operation using software cont. 3.6.14 Accessing console via web browser Once the console has been set up and used wirelessly for the ﬁrst time, the user is able to access the console via web browser on a mobile device or PC. This feature allows the operator or any other interested party to access the console to view live data being streamed by the sensors and even start or stop the run timer, which can also start or stop the pump if conﬁgured appropriately.
Page 43: Maintenance
( 5 Point High Flow Calibration. 10 to 30 LPM) 4.1.2 Initial end user calibration checks Apex Instruments suggests that the end user perform calibration checks on the dry gas meter, thermocouples, and vacuum and pressure sensors before performing a ﬁeld test (post-test calibrations can also fulﬁll this suggestion).
Page 44: Post-Test Calibrations
4.2 Post-Test Calibrations 4.2.1 Dry gas meter Apex Instruments and the EPA recommend that the user perform post-test calibration checks 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 45: Post-Test Maintenance
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. All sensors and the dry gas meter can also be calibrated at this time.
Page 46: 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 47: Troubleshooting
XD-502G2 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 48: Pressures
XD-502G2 Digital Console 5.2 Pressures 5.2.1 Vacuum transducer non-zero 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 CAUTION Resolution - Check the tubing connections between the inlet to the console and the vacuum...
Page 49: Temperatures
XD-502G2 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 50: Additional Common Console Problems
XD-502G2 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 51: Diagrams And Schematics
XD-502G2 Digital Console 6.0 Diagrams and Schematics 6.1 Electrical Diagram (XD-502, 120V Shown) 16Ga 16Ga 16Ga OEM CORD RA-911 °F °F INPUT OUTPUT - AC Probe Oven DC + ACN (BL) Vo- BK ACL (BN) Vo+ RD POWER SUPPLY + AC...
Page 52: Plumbing Diagram
XD-502G2 Digital Console 6.2 Plumbing Diagram (XD-502, 120V Shown) Fig. 22 Plumbing Diagram Apex Instruments, Inc.
Page 53: Parts List - Front Panel
XD-502G2 Digital Console 6.3 Parts List - Front Panel (XD-502, 120V Shown) 1. XC-CS51 (120V) 20. M-PXR3-F (x2) Case with lid Temperature controllers 19. M-CBR10A-M 2. M-LCD-NHD0420-A Temperature controller LCD display assembly power switches 18. M-RA911 (x3) 3. EL-SMA-ANT-S Power switches Antenna, 2.4 GHz...
Page 54: Parts List - Interior
XD-502G2 Digital Console 6.4 Parts List - Interior (XD-502 120V Shown) 1. M-PXR3-F (x2) Temperature controllers 2. SSR-AD25-RS (x2) Relays 13. PCB-502MAIN-ASY2 XD-502 main board 3. TU-6/4 12. M-OT10 Vacuum sample tubing Venturi-style oriﬁce 11.TSIL-4/2 Pressure sensor tubing 4. TC-PJK (x6, obscured) Thermocouple jacks 10.
Page 55: 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 58: Equations And Nomenclature
XD-502G2 Digital Console 7.3 Equations and Nomenclature 7.3.1 Equations Apex Instruments, Inc.
Page 59: Nomenclature
XD-502G2 Digital Console 7.3 Equations and Nomenclature cont. 7.3.2 Nomenclature actual cubic feet static pressure in ﬂue in inches water, acfm actual cubic feet per minute average eﬀective area of ﬂue in square feet ΔP stack velocity diﬀerential pressure, as...
Page 60: Firmware Upload Procedure
XD-502G2 Digital Console 7.4 Firmware Upload Procedure 1. Select and open the mikroBootloader USB HID application ﬁle. 2. Turn oﬀ Console. Remove the USB connection at PC port (if used). 3. Locate a USB A / USB C cable- Plug the USB A into the computer.