XD-502 Operator’s Manual · 2019. 8. 9. · XD-502 Digital Isokinetic Console XD-502 Digital Isokinetic Console Apex Instruments, Inc. 4 Apex Instruments, Inc. 5 Warranty Policy

XD-502Operator’s Manual

204 Technology Park Lane,Fuquay-Varina, NC 27526 USA

Tel: (919) 557-7300Web: www.apexinst.com

XD-502 Digital Isokinetic Console XD-502 Digital Isokinetic Console

Apex Instruments, Inc.2


204 Technology Park LaneFuquay-Varina, NC 27526

www.apexinst.com(919) 557-7300(800) 882-3214

For Support or Service contact:

Technical Services [email protected]

(877) 726-3919

XD-502 Operator’s Manual - SF v2.1 Revision Date: 5.2.19

Apex Instruments Inc. makes no representations or warranties with respect to this manual and, to the maximum extent permitted by law, expressly limits its liability for breach of any warranty that may be implied to the replacement of this manual with another. Furthermore, Apex Instruments reserves the right to revise this publication at any time without incurring an obligation to notify any person of the revision.

The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. 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.

All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer shall perform repairs to components.

Failure to observe this information can result in injury or equipment damage.

Copyright © 2019 by Apex Instruments, Inc.

All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher.

Disclaimer




Warranty Policy

Product Limited Warranty Policy Apex Instruments, Inc. warrants products to be free from defects in materials and workmanship for a period of one year from date of delivery. During the warranty period, we will repair or replace, at our option, any component that fails due to a defect in materials or workmanship under normal use excluding installation. Items not manufactured by Apex Instruments are subject to original manufactures warranty. All returns must be shipped freight prepaid at the purchasers’ expense.

Repair Services Limited 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.

What is Not CoveredAccidents, misuse, abuse and modifications. All forms of corrosion or other environmental conditions including lightning, natural disasters, improper installation and installation of an incorrect part. Normal wear and tear, used or salvage parts installed and shipping damage.

ContaminationCustomer is responsible for decontamination of all equipment returned to Apex Instruments. Apex Instruments reserves the right to return or decontaminate any equipment deemed unsafe or contaminated at the customers expense. Additional Important Information This limited warranty does not cover labor cost or incidental, indirect, special or consequential damages such as, but not limited to, psychical injuries or property damage, loss of time, loss of use of the component, inconvenience, rental equip-ment charges, or accommodations resulting from a defect in or failure of the component. You must be the original pur-chaser of the component, warranty is not transferable.

This limited warranty represents the exclusive remedy for any component defect or failure and the total liability of Apex Instruments for any component it warrants.

Apex Instruments makes no other warranties, express or implied, including any warranties of merchantability, condition of any kind or fitness for a particular purpose.

Some states do not allow disclaimers of implied warranties. Therefore, all implied warranties that may apply to the compo-nent are limited to the duration of this written warranty. Some states also do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental, special or consequential damages, so the above information may not apply. This warranty provides specific rights, and there may be other rights which vary from state to state. Apex Instruments, Inc does not authorize any entity to vary the terms, conditions or exclusions of this warranty. If any provision of the warranty should become invalid or unenforceable because of any laws, the remaining terms and provisions of the warranty shall remain in full force and effect. To the extent allowed under local law, the remedies provided in this Limited Warranty Policy are the purchaser’s sole and exclusive remedies. Apex Instruments, Inc., 204 Technology Park Lane, Fuquay-Varina, NC 27526. Visit us on the web at www.apexinst.com.

Acceptance of Terms and Conditions Apex Instruments manufactures and sells its products under the foregoing terms and conditions and will not be bound to terms and conditions stated by any purchaser in any offer, acceptance or other contractual document. Placing an order or accepting delivery of products constitutes acceptance of terms and conditions.

Table of Contents

Disclaimer .........................................................................................................................3Warranty Policy ................................................................................................................41.0 Preface ........................................................................................................................8

1.1 Description of the User .................................................................................................... 8

1.2 Purpose of this manual .................................................................................................... 8

1.3 Explanation of Safety Warnings ...................................................................................... 9

1.4 Retaining Instructions ...................................................................................................... 9

1.5 Obtaining Documentation and Information .................................................................... 101.5.1 Internet ...........................................................................................................................101.5.4 Support and Service.......................................................................................................10

2.0 Description of the Product ...................................................................................... 112.1 Intended Use and Reasonably Foreseeable Misuse ......................................................11

2.3 System Overview .......................................................................................................... 12

2.4 Technical Specifications ................................................................................................ 14

2.5 Product Compliance ...................................................................................................... 15

2.6 Console Components .................................................................................................... 16

3.0 Safety Instructions ...................................................................................................183.1 How to Use the Product Safely ..................................................................................... 18

3.1.3 Safety Information related to the intended use ..............................................................18

4.0 Audit and Leak Checks with the XD-502 ................................................................194.1 Transducer Calibration Check ....................................................................................... 19

4.2 Calibration Checks: Pressure Transducers ................................................................... 20

4.3 Console Leak Check Procedure (Vacuum Side) ........................................................... 24

4.4 Pre-Calibration Leak Test for Consoles with a Diaphragm Pump ................................. 26

4.5 Thermocouple and Barometric Pressure Calibration Checks ....................................... 27

4.6 Setting the Fuji Temperature Controller ......................................................................... 28

5.0 Preparation ...............................................................................................................295.1 What to do when you receive your console ................................................................... 29

5.1.1 Unpack and inspect .......................................................................................................295.1.2 Leak Checks ..................................................................................................................295.1.3 Calibration Audits ...........................................................................................................29




5.1.4 Test Plan and Methods ...................................................................................................29

5.2 How to Transport and Store the Console ...................................................................... 295.2.1 Dimensions ....................................................................................................................295.2.2 Lifting and handling ........................................................................................................29

6.0 Using the Console ...................................................................................................306.1 User Interface Design .................................................................................................... 31

6.1.1 User Interface Buttons ...................................................................................................326.1.2 Button Functions Explained ...........................................................................................336.1.3 User Interface - Button Function Chart ..........................................................................346.1.4 User Interface - Screen Hierarchy..................................................................................356.1.5 User Display Screen Navigation ....................................................................................36

6.2 (UI) Sampling Test Operations with the User Interface ................................................. 38UI.1 Pre-Test Preparation........................................................................................................38UI.2 On Site Preparation .........................................................................................................41UI.3 Sample Test Operations ..................................................................................................45

6.3 Software Design ............................................................................................................ 486.3.1 Main Screen ...................................................................................................................496.3.2 Monitor Screen ...............................................................................................................566.3.3 Job Information Screen ..................................................................................................576.3.4 Storage Screen ..............................................................................................................586.3.5 Utility Screen ..................................................................................................................59

6.4 (SW) Sampling Test Operations with the Software ....................................................... 65SW.1 Pre-Test Preparation......................................................................................................65SW.2 On Site Preparation .......................................................................................................71SW.3 Sample Test Operations ................................................................................................79SW.4 Exporting Data ...............................................................................................................84

7.0 Maintenance .............................................................................................................857.1 User Inspection and Maintenance of Console ............................................................... 85

7.1.2 Pitot Tube Lines .............................................................................................................857.1.3 Orifice Meter Lines .........................................................................................................857.1.4 Timer ..............................................................................................................................857.1.5 Temperature Controller ..................................................................................................857.1.6 User Interface Display ....................................................................................................85

7.1.7 Dry Gas Meter ................................................................................................................867.1.8 Console In-Line Filter .....................................................................................................877.1.9 Thermocouple Plugs ......................................................................................................87

7.2 Manufacturer Support for your Product ......................................................................... 887.2.1 Technical Services .........................................................................................................887.2.2 Calibration Services .......................................................................................................88

7.3 Identifying and Solving Common Console Problems .................................................... 89

8.0 Appendix ...................................................................................................................908.1 Console Maintenance Front Panel Parts Chart ............................................................. 90

8.2 Console Maintenance Interior Parts Chart .................................................................... 91

8.3 Console Replacement Parts .......................................................................................... 92

8.4 Plumbing Diagram ......................................................................................................... 94

8.5 Electrical Diagram ......................................................................................................... 96

9.0 References and Related Documentation ...............................................................989.1 References .................................................................................................................... 98

9.2 Related Documentation ................................................................................................. 98




1.0 Preface

1.1 Description of the UserIsokinetic 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 the theory of isokinetic source sampling, including basic gas laws and chemistry.

! DANGER

In addition, all technicians should have adequate general safety training as well as site specific training to identify, abate, and prevent job related hazards including site specific training.

1.2 Purpose of this manual

The purpose of this manual is to provide a basic understanding of the Apex Instruments Isokinetic XD-502 Source Sampling Console. The XD-502 is applicable for use with a variety of US EPA Isokinetic Sampling Methods.

Additionally, this manual provides the users with a reasonable amount of reference information on system configuration, calibration procedures, maintenance and troubleshooting referencing the specific product and the US EPA Regulations.

For more information about isokinetic sampling, see our reference materials (Isokinetic Sampling Handbook or the 450 Sampling Student Manual).

Isokinetic Sampling

The first four source test reference methods are applied before conducting Method 5. If prior data is available or reasonably good assumptions can be made, not all of the methods need to be conducted. If you look at the isokinetic rate equation and the nozzle diameter equation, you can see that there are a number of parameters that must be followed before one can proceed with isokinetic sampling.

US EPA Method Descriptions:

Method 1 Determination of Sampling Location and Traverse PointsMethod 2 Determination of Stack Gas Velocity and Volumetric Flow-ratesMethod 3 Determination of Dry Molecular Weight and Percent Excess AirMethod 4 Determination of Moisture ContentMethod 5 Determination of Particulate Matter Emissions from Stationary Sources

Detailed information on method sampling may be found through the US EPA website - please visit http://www.epa.gov/emc-tests-methods/ for complete method descriptions.

1.3 Explanation of Safety Warnings

! DANGER

Danger indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury

! WARNING

Warning indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

! CAUTION

Caution indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates information considered important, but not hazard-related.

1.4 Retaining InstructionsRead and understand this manual and its safety instructions before using this product. Failure to do so can result in serious injury or improper execution of sampling procedures.

Follow all relevant instructions. This will avoid fire, explosions, electric shocks or other hazards that may result in damage to property and/or severe or fatal injuries.

The product shall only be used by persons who have fully read and understand the contents of this user manual.

Ensure that each person who uses the product has read these warnings and instructions and follows them.

Keep all safety information and instructions for future reference and pass them on to subsequent users of the product.

The manufacturer is not liable for cases of material damage or personal injury caused by incorrect handling or non-compliance with the safety instructions. In such cases, the warranty will be voided.




1.5 Obtaining Documentation and Information

1.5.1 Internet

Detailed product information, stack sampling guides and EPA regulation references are available on our website:

https://www.apexinst.com

1.5.4 Support and Service

Our knowledgeable service staff includes skilled industry professionals, stack testers and technicians ready to help you with your specific service needs.

From basic troubleshooting to full equipment overhauls and repairs, our technical service team is available to offer support to the user.

Toll Free (877) 726-3919 or (919) 346-5754

E-mail: [email protected].

2.1 Intended Use and Reasonably Foreseeable Misuse

2.1.1 Isokinetic Sampling

The Sampling Console is the operator’s control station. The XD-502 can be used via the user interface or the software to execute sampling operations for EPA regulation or EPA equivalent regulation compliance.

2.1.2 Versatile Use

You can easily adapt the basic Method 5 sampling train to test for many other gaseous and particulate emissions from stationary sources. Adapting basic test methods allows you to expand testing to include parameters of interest such as metals, polychlorinated biphenyls (PCBs), dioxins/furans, polycyclic aromatic hydrocarbons (PAHs), particle size distributions and an ever-increasing group of other pollutants.

2.0 Description of the Product




2.3 System OverviewNOTE: This manual covers the sampling console part of the train. The rest of the console is sold separately.

The first step to effective sampling is to familiarize yourself with the standard equipment. To illustrate the necessary components of source sampling, we’ve included an overview of the six main components of the Apex Instruments Source Sampling Train.

The main components of an Isokinetic Sampling system are: probe assembly, filter oven, impinger case, umbilical, sampling pump, and the console.

2.3.1 Probe Assembly

Includes a probe sheath, probe liner, tube heater, Type-S pitot tubes, nozzle, stack and probe Type K thermocouples. The probe nozzle draws in sample from the source effluent and the probe sheath protects the heated probe liner.

2.3.2 Heated Filter Oven (Hot Box)

The insulated, heated filter oven contains the filter assembly to collect particulate from the gas sample while preventing condensation of moisture within the sample.

2.3.3 Impinger Case (Cold Box)

The impinger serves the purpose of preventing the moisture from entering the console. The case includes a durable, foam-insulated, drainable reservoir with a pre-punched foam insert for positioning and holding the impinger bottles in place. The ice lowers the sample gas temperature which causes condensation inside the impingers. Moisture and other condensables are trapped for gravimetric or chemical analysis. The sample gas exits the last impinger and passes through a check valve designed to eliminate back pressure.

2.3.4 Umbilical Cable

Connects the impinger case and heated filter oven assembly to the source sampling console and includes the sample line, two pitot lines, 5 type K thermocouples, a power output line, and a spare orsat line.

2.3.5 Sampling Console

The sampling console houses the dry gas meter, internal sampling pump, temperature controllers, differential pressure measurement devices, flow adjustment valves and a user interface display.

Some sampling trains use an external pump assembly to pull the sample. An external pump is not necessary when a console, like the XD-502, uses an internal sampling pump to pull the sample.

Sample gas enters the console through the umbilical, passes through a filter to remove any foreign matter, then through the pump and dry gas meter, and exits the system through a calibrated orifice tube. The calibrated orifice tube is connected to the differential pressure measurement device to allow the user a

***The other components of the Sampling System are sold separately.***

reference of sample gas flow. The ∆P reading is then compared to the ∆H and flow is adjusted to maintain an isokinetic sampling rate.

The console is housed in a strong and durable polyethylene case with a carrying strap on top.

Probe Assembly

Heated Filter Oven

Impinger Case

Umbilical Cable

Sampling Console




2.4 Technical SpecificationsDry Gas Meter: Model SK25EX, with 100 CPR Quadrature Encoder, 0.7L/rev., 41 LPM max.

Sample Pump: Internal Double Head Diaphragm Pump, 24VDC, 18 LPM @ 15” Hg and 70 LPM free flow.

Display: 4x20 Character Back-lit Transflective Liquid Crystal Display with digital operation of Timer, ∆P, ∆H, DGM Volume, Vacuum, Barometric Pressure, and up to 8 Temperature Channels.

Display Control: Six-button Long-Life Membrane Keypad for display operation and standard operations.

Flow Indicator: Precision Machined Stainless Steel Orifice with Pressure Transducer, Range 0 - 5” H2O (1245 Pa) resolution of 0.01” (1 Pa).

Temperature Measurement: 8 channel individually isolated Type-K thermocouple channels, °C/°F selectable, -200°C to 1372°C range. (-328°F to 2502°F).

Digital Pressure Transducers: Ultra high resolution temperature-compensated, miniaturized,ΔP +/-1.0” H2O (+/- 248.8 Pa) Range Bi-Directional with 0.001” (1 Pa) Resolution, ΔP +/-10.0” H2O (+/- 2488 Pa) Range Bi-Directional with 0.001” (1 Pa) Resolution, ΔH +/-5.0” H2O (+/-1245 Pa) Range Bi-Directional with 0.01” (1 Pa) Resolution.

Vacuum Measurement: PCB-mounted Sensor.

Umbilical Connection: Sample Inlet: 1/2” Stainless Steel Instrumental Quick-Connect (alternate sizes available). Pitot Connections: 1/4” Stainless Steel Instrumental Quick-Connects. Power Output Connector: Twist to lock, 120V/220V for Aux, Probe, Filter Power. TC Connections: AUX, STACK, PROBE, OVEN, FILTER, EXIT.

Power: Input Power: 120V/15A 60Hz, IEC C-14 Inlet. Pump Power: 150W, 24V/6.3A. Display Power Supply: 15W, 12VDC. Optional Input Power: 240V/10A 50Hz, IEC C-14 Inlet.

Dimensions: H17” x W17” x D12” (43 cm x 43 cm x 30.5 cm).

Weight: 37 lbs (9.98kg).

2.5 Product ComplianceThis product complies with all relevant US EPA Sampling Regulations and was designed based on the schematics and sampling practices established by the EPA in the Code of Federal Regulations.




2.6 Console Components

1. Hard Plastic, Lightweight Case

9. Fine Valve andCoarse Valve

2. Transflective Backlit User Display

3. Membrane Switch Buttons

4. Company Contact Information

5. Console Calibration Information

6. Temperature Controllers

7. Probe and Oven Switches

8. Main, Pump and AUX Switches

10. Thermocouple Jacks

12. Power Supply Receptacle

13. Power

14. Main Circuit Breaker Switch

15. PC Input Connection

11. Sample and Pitot Line Quick Connects

Console Components List

1. Hard plastic, lightweight case

2. Transflective, back-lit User Display - Displays measurements and sampling data during operation

3. Membrane Switch Buttons - Used to interact with the user display to control sampling operations

4. Company Contact Information

5. Console Calibration Information - The annual calibration results data is displayed via decal in a prominent location on the face

plate.

6. Temperature Controllers - 6 easy-access thermocouple jacks for connecting the aux/stack/probe/oven/filter/exit

7. Probe and Oven Switches

8. Main, Pump, and AUX Switches

9. Fine and Coarse Valves - Flow may be adjusted with a ball valve for coarse adjustment and a needle valve for fine

adjustment.

10. Thermocouple Jacks

11. Sample and Pitot Line Quick Connects - Pitot connections for ∆P+ and ∆P- pressures and a sample inlet quick connect.

12. Power Supply Receptacle

13. Power Output - Supplies power for probe heater, filter oven, and aux

14. Main Circuit Breaker Push/Pull Switch - The electronics are protected by a resettable panel mounted circuit breaker.

15. USB Data Port - Establishes a connection to a device that can use the software to operate the console and export

data




3.1 How to Use the Product Safely

3.1.3 Safety Information related to the intended use

Isokinetic 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 the theory of isokinetic source sampling, including basic gas laws and chemistry.

! DANGER

In addition, all technicians should have adequate general safety training to identify, abate, and prevent job related hazards including site specific training.

Please visit the following link for more information on Stack Sampling Safety Procedures and Protocols: http://www.sesnews.org/

3.0 Safety Instructions 4.0 Audit and Leak Checks with the XD-502

4.1 Transducer Calibration CheckThe Transducers on the XD-502 Electronics Package are high resolution, digital ultra low pressure sensors. The operational range of the transducers are 1”, 5” and 10” H2O with an accuracy of 0.25% FSS BFSL (full scale span, best fit straight line). All error compensation is performed internally by an advanced ASIC (application specific integrated circuit) Therefore, no external calculation/calibration is required. When a calibration check is required by EPA method regulations it is recommended that a NIST-traceable, handheld manometer be utilized to verify the transducers are within regulation.

Check the calibration of the transducer at a minimum of three points approximately representing the range of ∆P values in the stack. The ∆P values, as read by the transducer and NIST device, must agree to within 5 percent for each point for the transducer to be considered within proper calibration. The following pages provide the procedures for conducting Transducer Calibration Checks.

ATTACH LINE FROMMANOMETER TO LUER “T”

TO SYRINGE OROTHERPRESSURE

GENERATINGDEVICE

1” HO

10” HO

5” HO

XD-502 MAIN BOARDPCB-502MAIN-COMP

Co

m 1

2 3

4

5

6 7

8

SW

ITC

HE

S

8V

-29V -

+

1

5

10

1234

rP+

rP-

Pitot 1 +

Pitot 1 -

ATTACH LINE FROMMANOMETER TO LUER “T”

TO SYRINGE OROTHERPRESSURE

GENERATINGDEVICE

1” HO

10” HO

5” HO

XD-502 MAIN BOARDPCB-502MAIN-COMP

Co

m 1

2 3

4

5

6 7

8

SW

ITC

HE

S

8V

-29V -

+

1

5

10

1234

rP+

rP-

Pitot 1 +

Pitot 1 -

Air Flow in Diagramin T Valve




4.2 Calibration Checks: Pressure Transducers

NOTICE

DO NOT EXCEED THE TRANSDUCER PRESSURE RATING OF 100 INCHES OF H2O. DOING SO MAY RESULT IN OPERATIONAL SENSOR FAILURE

! CAUTION

REMOVE THE CONSOLE FROM THE CASE. NOT DOING SO COULD POSE AN ELECTRICAL HAZARD

See US EPA Method 5 Section 8.4.1 concerning Leak Check Procedures.

A 20ml syringe, a tee valve and a manometer may be used.

1. Close the coarse valve to seal off the sample line from the rest of the system. (Figure 4-1)

2. The dry gas meter (DGM) outlet orifice must be sealed off using the 18mm stopper provided in the audit kit. (Figure 4-2)

3 Locate the positive and negative ∆H lines on the DGM Orifice. Trace the lines back. (Figure 4-3)

4. Disconnect (using a 1/2 twist) the ∆H line luer connections and attach the luer Lock “T”’s as shown to both lines. (Figure 4-4)

5. Reposition the positive ∆H valve to the ALL OPEN position as shown. This position vents the positive side of the ∆H transducer through all three directions. (Figure 4-5)

6. Reposition the negative ∆H line in the VENT position as shown. This position vents the Negative side of the ∆H transducer to atmosphere. (Figure 4-6)

to PCB

to PCB

to PCB

to PCB

to Orifice

to Orifice

to Orifice

to Orifice

Positive ∆H

Negative ∆H

- +

- +

to PCB

to PCB

to PCB

to PCB

to Orifice

to Orifice

to Orifice

to Orifice

Positive ∆H

Negative ∆H

- +

- +

to PCB

to PCB

to PCB

to PCB

to Orifice

to Orifice

to Orifice

to Orifice

Positive ∆H

Negative ∆H

- +

- +

to PCB

to PCB

to PCB

to PCB

to Orifice

to Orifice

to Orifice

to Orifice

Positive ∆H

Negative ∆H

- +

- +

to PCB

to PCB

to PCB

to PCB

to Orifice

to Orifice

to Orifice

to Orifice

Positive ∆H

Negative ∆H

- +

- +

Figure 4-1

Figure 4-2

Figure 4-3

Figure 4-4

Figure 4-5

Figure 4-6

1

2

3

4

5

6

7. The ∆H readout should be 0.00. Both sides of the transducers are vented to air. (See Figure 4-7)

8. Connect a vacuum tee to the +∆H tee and position the lever as shown. (See Figure 4-8)

9. Pull the plunger on the syringe to the end of its travel within the cylinder or turn the adjustment counterclockwise on the pressure generator to the halfway point. (See Figure 4-9)

10. Attach the syringe or pressure generator to the vacuum tee as shown. (See Figure 4-10)

11. Verify positive ∆H reading is 0.00. (See Figure 4-11)

12. Use a digital manometer for the final steps in this procedure. (See Figure 4-12)

Figure 4-7

Figure 4-8

Figure 4-9

Figure 4-10

Figure 4-11

Figure 4-12

to PCBto Orifice

∆H+

∆H+

T� � � � : 0:00:00PITOT: 0.0ORIFICE: .00TEMPERATURE 25C

to PCBto Orifice ∆H+




to PCBto Orifice

∆H+

∆H+






to PCBto Orifice

∆H+

∆H+






to PCBto Orifice

∆H+

∆H+






11

12

7

8

9

10

♦

♦




13. Connect the digital manometer tubing to the ∆H+ tee and to the P1 port on the manometer as shown. (See Figure 4-13)

14. SLOWLY push the plunger on the syringe to approximately 5ml. The digital manometer reading should match the console ∆H reading. Repeat procedure at 10ml and 15ml. The readings between the ∆H display and the digital manometer should match indicating there are no leaks and the transducers have passed audit. (See Figures 4-14a, 4-14b and 4-14c)

Figure X413

Figure 4-14a

Figure 4-14cFigure 4-14b

to Orifice to PCB

to Orifice to PCB

to Orifice to PCBto Orifice to PCB

∆H+

∆H+

∆H+∆H+

.05” H2O

.05” H2O .05” H2O

13

14a

14c14b

15. Repeat steps 1-14 as needed for the 1” ∆P transducer and the 10” ∆P transducer.

Each transducer must be checked at 0 (zero), 30% of full range, 60% of full range and 90% of full range for both positive and negative ranges.

16. Reconnect plumbing in reverse order.

17. See CFR sections 10.8.1 and 10.8.2 for performing a post-test single-point calibration check.

∆P 1”H2O Transducer

Full Range Values: Reading must be within 3% or +/- .03” H2O 90% = -.90” H2O60% = -.60” H2O30% = -.30” H2O0 (Zero)30% = .30” H2O60% = .60” H2O90% = .90” H2O

∆P 10”H2O Transducer

Full Range Values: Reading must be within 3% or +/- .30” H2O 90% = -9.00” H2O60% = -6.00” H2O30% = -3.00” H2O0 (Zero) = +/- .30” H2O30% = 3.00” H2O60% = 6.00” H2O90% = 9.00” H2O

Method 2, 2F, 2G Post-test Single-Point Transducer Calibration Checks

16.2.2.1.1 “Before calibrating the meter box, leak check the system as follows: Fully open the coarse adjust valve, and completely close the by-pass valve. Plug the inlet. Then turn on the pump, and determine whether there is any leakage. The leakage rate shall be zero (i.e., no detectable movement of the DGM dial shall be seen for 1 minute).”

16.2.2.1.2 “Checkalsoforleakagesinthatportionofthesamplingtrainbetweenthepumpandtheorificemeter.See section 8.4.1 for the procedure; make any corrections, if necessary. If leakage is detected, check for cracked gaskets, loosefittings,wornO-rings,etc.,andmakethenecessaryrepairs.”




4.3 Console Leak Check Procedure (Vacuum Side)

NOTICE

DO NOT EXCEED THE TRANSDUCER PRESSURE RATING OF 100 INCHES OF H2O. DOING SO MAY RESULT IN OPERATIONAL SENSOR FAILURE

1. Go to Leak Test screen and position the valves

- Press Insert Note button on the console and use the up and down arrows to select the Leak Test. - Close the coarse valve by turning the handle right to

horizontal position. - Increase the fine tune knob fully by turning all the way to

the right (clockwise).

2. Block airflow of sample inlet

- Insert a capped quick-connect into the sample quick-connect 1/2” inlet.

3. Initiate flow

- Turn on the pump, then open the coarse valve (twist to vertical position).

4. Adjust vacuum (if necessary)

- If your vacuum is below 15” Hg (380mm) slowly increase the fine tune knob until the vacuum reading is at least 15”Hg (380mm).

1

2

3

4

5♦

♦

♦

♦

♦

♦

♦

5. Run the test

- Start the timer and monitor the DGM flow for 1 minute. If the flow through the DGM exceeds 0.02 CFM (0.00057m3/min or 4% of average sample rate) the leaks must be found and corrected.

6. Run second test

- Turn off the pump. Monitor the vacuum for one minute. If the vacuum decreases any amount, then you have a leak somewhere between the plugged QC and the vacuum sensor.

7. Stop the test

- Remove the plug from the sample inlet.




4.4 Pre-Calibration Leak Test for Consoles with a Diaphragm Pump

Apex Instruments recommends the following procedure to be followed for conducting a “back-side” leak check:

10.3.1.1 (Method 5) “Before calibrating the metering system, it is suggested that a leak check be conducted. For metering systems having diaphragm pumps, the normal leak-check procedure will not detect leakages within the pump.

For these cases the following leak-check procedure is suggested:

Makea10-minutecalibrationrunat0.00057m³/min(0.020cfm).Attheendoftherun,takethedifferenceofthemeasuredwettestmeterandDGMvolumes.Dividethedifferenceby10(numberofminutesinthecalibration run) to get the leak rate. The leak rate should not exceed 0.00057 m³/min (0.020 cfm).”

The calibrated critical orifice to be used for this procedure is #09.

NOTICE

Italicized text is directly quoted from EPA method regulation documentation (See References and Related Documentation)

0000 168

DGM Out

Vac.

(Max.) BarometricPressure

Internal

0.0

0.0

0.0

0.0

LPM(CFM)

Liters(CF)

0.0

0.0

Display/Transducer Module

P-

P-

P+

P+

P-

H+P+

H-

1 10 5

Side View

To Vacuum Sensor on

PCB

Derived from Sensor onPCB Board

#09Orifice

Delta H

0.0

XD-502 Console

Delta P

0.0

Console Display

InsertNote

Select Stop/Start TimerPress to Open LeakTest Screen

Press to Open InsertNotes Screen

Return to Main Screen

Displays briefly

From Any Main Menu Screen

Leak Test and Notes Menu

4.5 Thermocouple and Barometric Pressure Calibration Checks

The six thermocouple jacks on the XD-502 console face plate require periodic calibration and audit per the EPA Methods.

Temperatures audited should encompass the range of conditions expected during testing.

Thermocouple 2: Stack

10.3.1 (Method 2*)“In-stackThermocouplesshallbecalibratedaftereachfielduseatatemperaturewithin10 percent of the average absolute stack temperature.”

10.3.2. (Method 2*) “The sensor being calibrated and the reference sensor shall agree to within 1.5%.,

Thermocouple E: Filter

6.1.1.7 (Method 5) A temperature sensor capable of measuring temperature towithin ±3 °C (5.4 °F) shall be installed so that the sensing tip of the temperature sensor is indirectcontactwiththesamplegasexitingthefilter.

Thermocouples 1, 3, 4, 6:Aux, Probe, Oven, Exit

10.5 (Method 5) “Temperature Sensors. Use the procedure in Section 10.3 of Method 2 to calibrate in-stack temperature sensors. Dial thermometers, such as are used for the DGM and condenser outlet, shall be calibrated against mercury-in-glass thermometers. An alternative mercury-free NIST traceable thermometer maybeusedifthethermometeris,ataminimum,equivalentintermsofperformanceorsuitablyeffectiveforthespecifictemperaturemeasurementapplication.Asanalternative,thefollowingsingle-pointcalibrationprocedure may be used. After each test run series, check the accuracy (and, hence, the calibration) of each thermocouplesystematambienttemperature,oranyothertemperature,withintherangespecifiedbythemanufacturer, using a reference thermometer (either ASTM reference thermometer or a thermometer that has been calibrated against an ASTM reference thermometer). The temperatures of the thermocouple and reference thermometers shall agree to within ±1 °F.”

10.6 (Method 5) “Barometer. Calibrate against a mercury barometer or NIST-traceable barometer prior to the fieldtest.Alternatively,barometricpressuremaybeobtainedfromaweatherreportthathasbeenadjustedforthe test point (on the stack) elevation.”

NOTICE

Italicized text is directly quoted from EPA method regulation documentation (See References and Related Documentation)

EXIT FILTER OVEN PROBE STACK AUX

1 2 3 4 5 6

Tg = ______ ºF + 459.67º = ______ ºC + 273.15º

Tg = ______ ºF + 459.67º = ______ ºC + 273.15º




To change the Set Value (SV) press once. Current Value is displayed and SV is lit.

Press the to increase or decrease the displayed SV (set value).

After the new setting is entered press to lock in the value and return to C1 (control 1) display.

Repeat procedure to check value if necessary.

SV

SV

C1

C1

C2

C2

AL1

AL1

AL2

AL2

SEL

SEL

SEL

SEL

SEL

SEL

°C

°C

72

ProGSVC1C2AL1AL2

SEL

°C

P

SVC1C2AL1AL2

SEL

°C

Pn-2

SVC1C2AL1AL2

SEL

°C

5

SEL

SVC1C2AL1AL2

SEL

°C

4SVC1C2AL1AL2

SEL

°C

3

SVC1C2AL1AL2

SEL

°C

38SVC1C2AL1AL2

SEL

°C

32

SEL

SV

SV

C1

C1

C2

C2

AL1

AL1

AL2

AL2

SEL

SEL

SEL

SEL

SEL

SEL

°C

°C

72

ProGSVC1C2AL1AL2

SEL

°C

P

SVC1C2AL1AL2

SEL

°C

Pn-2

SVC1C2AL1AL2

SEL

°C

5

SEL

SVC1C2AL1AL2

SEL

°C

4SVC1C2AL1AL2

SEL

°C

3

SVC1C2AL1AL2

SEL

°C

38SVC1C2AL1AL2

SEL

°C

32

SEL

SV

SV

C1

C1

C2

C2

AL1

AL1

AL2

AL2

SEL

SEL

SEL

SEL

SEL

SEL

°C

°C

72

ProGSVC1C2AL1AL2

SEL

°C

P

SVC1C2AL1AL2

SEL

°C

Pn-2

SVC1C2AL1AL2

SEL

°C

5

SEL

SVC1C2AL1AL2

SEL

°C

4SVC1C2AL1AL2

SEL

°C

3

SVC1C2AL1AL2

SEL

°C

38SVC1C2AL1AL2

SEL

°C

32

SEL

SV

SV

C1

C1

C2

C2

AL1

AL1

AL2

AL2

SEL

SEL

SEL

SEL

SEL

SEL

°C

°C

72

ProGSVC1C2AL1AL2

SEL

°C

P

SVC1C2AL1AL2

SEL

°C

Pn-2

SVC1C2AL1AL2

SEL

°C

5

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SVC1C2AL1AL2

SEL

°C

4SVC1C2AL1AL2

SEL

°C

3

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SEL

°C

38SVC1C2AL1AL2

SEL

°C

32

SEL

4.6 Setting the Fuji Temperature Controller

Set Value Setting 5.1 What to do when you receive your console

5.1.1 Unpack and inspect

Unpack your console from its shipping container. Inspect the console. Check your the Packing List to ensure everything has arrived.

5.1.2 Leak Checks

Perform your console leak checks as explained in section 4.

5.1.3 Calibration Audits

Perform your console calibration audits as explained in section 4.

5.1.4 Test Plan and Methods

Begin your sampling operation procedures as directed by the method regulations.

5.2 How to Transport and Store the Console

5.2.1 Dimensions

Height: 17” (43 cm)Width: 17” (43 cm)Depth: 12” (30.5 cm)Weight: 40lbs (16.8 kg)

5.2.2 Lifting and handling

! CAUTION

Avoid dropping the console and any other forms of collision during transport.

When lifting, make sure to use the handles on the sides to lift.

Do not try to lift the console by anything other than the handles or the carrying strap.

5.0 Preparation

User Interface - DesignXD-502 Digital Isokinetic Console


XD-502 Digital Isokinetic Console


6.0 Using the Console

Methods of Operation

The XD-502 Sampling Console can be operated using two different methods: User Interface Control and Software Control.

User Interface Console Control

Operation of the sampling console can be performed using the panel-mounted User Interface. The multifunction membrane switches allow the user to perform all necessary sampling operations and monitor all critical information by interacting with the display.

Software Console Control

Operation of the sampling console can be also performed using the Console Software. After the software is installed on a Windows Operating System device and the device is connected to the console, the user is able to perform all the necessary sampling operations and monitor all critical information using the software.

Certain settings and features that provide extra versatility are only accessible through Software Control. See Section 6.3 for more information.

LEAK TEST AND NOTES MENU

1 to 254 Averaging Size

Select Press to Save

0 to 50% Change

Press to Save


Press to Save

0.0 to 25.0% Change

Press to Save

InsertNote

Return to Damping Menu Screen

Press to Open SelectedMenu Item Screen

Select


Select


Select


MAIN SCREENOPENING SCREEN TEMPERATURE SCREEN TEST INFORMATION SCREEN


Press to Open Selected Menu Item Screen

Select Menu Item

Select Menu Item

Select Menu Item

9999 Maximum Value

Select Press to Reset Counter

Return to Test Options Screen

1 to 15

Select Press to Overwrite

Return to Additonal Menu Screen

Press to Reset TransducersSelect


Set mm:ss

Select

Select

Press to Save


Stop/Start Timer




Select

Select

Press to Save

0 to 50% Change

Press to Save


Press to Save

0.0 to 25.0% Change

Press to Save

Return to Damping Menu Screenu

Select


Select


Select



Set mm:ss (5 Second Minimum)





Metrics, Imperials, Metrics (Pa)

Timer is ZEROTEST OPTIONS SCREEN ADDITIONAL MENU SCREEN

TIMER IS ACTIVE

NO = Back to NEW Run Screen

YES= Back to Standby Menu


Select Select Select

Return to MarkerScreen

Displays briefly

Select Press to Save Marker

Displays briefly then Returns to Previous Main Menu Screen

Hold for 3 Seconds to access OPERATION OPTIONS MENU

Select Menu Item

----------------

----------------

----------------

----------------

--------------------------------

--------------------------------

MAIN DISPLAY SCREENS FROM ANY MAIN MENU SCREEN

DISPLAYS BRIEFLY

DAMPING MENU SCREEN

1234

1234

Timer is ZERO Timer is ZERO

5678

9

1

10

2

DAMPING MENU SCREEN

**

**

**

**

**

**

**

**

**

**

**

**

**

ACTUAL SLOTLOCATION TBD

Select

MenuDGM

ZeroTimer

PreviousScreen

InsertNote

¹ Does not include Error Screens 10.01.2018




0 to 50% Change

Press to Save


Press to Save

0.0 to 25.0% Change

Press to Save

InsertNote



Select


Select


Select





Select Menu Item

Select Menu Item

Select Menu Item

9999 Maximum Value



1 to 15





Set mm:ss

Select

Select

Press to Save


Stop/Start Timer




Select

Select

Press to Save

0 to 50% Change

Press to Save


Press to Save

0.0 to 25.0% Change

Press to Save


Select


Select


Select










TIMER IS ACTIVE






Displays briefly




Select Menu Item

----------------

----------------

----------------

----------------

--------------------------------

--------------------------------


DISPLAYS BRIEFLY

DAMPING MENU SCREEN

1234

1234


5678

9

1

10

2

DAMPING MENU SCREEN

**

**

**

**

**

**

**

**

**

**

**

**

**


Select

MenuDGM

ZeroTimer

PreviousScreen

InsertNote


6.1 User Interface DesignThe multifunction membrane switches allow the user to perform all necessary sampling operations and monitor all critical information by interacting with the display.




0 to 50% Change

Press to Save


Press to Save

0.0 to 25.0% Change

Press to Save

InsertNote



Select


Select


Select





Select Menu Item

Select Menu Item

Select Menu Item

9999 Maximum Value



1 to 15





Set mm:ss

Select

Select

Press to Save


Stop/Start Timer




Select

Select

Press to Save

0 to 50% Change

Press to Save


Press to Save

0.0 to 25.0% Change

Press to Save


Select


Select


Select










TIMER IS ACTIVE






Displays briefly




Select Menu Item

----------------

----------------

----------------

----------------

--------------------------------

--------------------------------


DISPLAYS BRIEFLY

DAMPING MENU SCREEN

1234

1234


5678

9

1

10

2

DAMPING MENU SCREEN

**

**

**

**

**

**

**

**

**

**

**

**

**


Select

MenuDGM

ZeroTimer

PreviousScreen

InsertNote





0 to 50% Change

Press to Save


Press to Save

0.0 to 25.0% Change

Press to Save

InsertNote



Select


Select


Select





Select Menu Item

Select Menu Item

Select Menu Item

9999 Maximum Value



1 to 15





Set mm:ss

Select

Select

Press to Save


Stop/Start Timer




Select

Select

Press to Save

0 to 50% Change

Press to Save


Press to Save

0.0 to 25.0% Change

Press to Save


Select


Select


Select










TIMER IS ACTIVE






Displays briefly




Select Menu Item

----------------

----------------

----------------

----------------

--------------------------------

--------------------------------


DISPLAYS BRIEFLY

DAMPING MENU SCREEN

1234

1234


5678

9

1

10

2

DAMPING MENU SCREEN

**

**

**

**

**

**

**

**

**

**

**

**

**


Select

MenuDGM

ZeroTimer

PreviousScreen

InsertNote


XD-502 Digital Isokinetic Console User Interface - Design User Interface - DesignXD-502 Digital Isokinetic Console



6.1.1 User Interface Buttons

The User Interface of the Console is where the user can monitor information and execute functions necessary for a sampling operation.

The User Interface Controls:

1. Arrow Up and Main Menu Button

2. Arrow Down and Zero DGM Button

3. Select and Zero Timer Button

4. Timer and Previous Screen Button

5. Insert Note Button

6. Save Data Button

7. Contrast Tuner

The functionality of the user interface buttons varies based on how long they are pressed and the situation in which they are used. See Table 6-1 on the next page for more details.

Specifically, the factors that change the function of the buttons are:

- The duration of the button press: INSTANT or 3 SECOND HOLD - The status of the Main Test Timer: NON-ZERO or ZERO - The type of screen that is displayed: Main Navigation, Menu Screens, Leak Test Screen, or Setting

1

2 3 4 5

6

7

6.1.2 Button Functions Explained

1. Arrow Up/Main Menu Button - Primary Function (Simple Press): Moves the indicator/value/main navigation screen up one unit - Secondary Function (Only in Main Navigation - Hold for 3 Seconds): Navigates to Standby Menu if

Timer is ZERO or Running Test Menu Screen if Timer is NON-ZERO.

2. Arrow Down Button - Primary Function (Simple Press): Moves the indicator/value/main navigation screen down one unit - Secondary Function (Only in Main Navigation - When Timer NOT ACTIVE Hold for 3 Seconds): Resets

the volume of the Dry Gas Meter reading - Leak Test Function: Zeroes the leak test DGM volume during a Leak Test

3. Select and Zero Timer Screen Button - Primary Function (Only in Menu Screens): Enters the selected Menu Screen option - Secondary Function (Only in Main Navigation - Hold for 3 Seconds): Zeroes the Main Test Timer - Leak Test Function: Zeroes the timer during a Leak Test

4. Timer and Previous Screen Button - Primary Function (Only if a TIMER is on screen - Simple Press): Starts and Stops a timer - Secondary Function (Only in Menu Screens): Navigates the user display back to the previous Main

Navigation screen the user was on

5. Insert Note Button - Primary Function (Only in Main Navigation): Navigates to the Insert Note Menu

6. Save Data Button - Primary Function (Only in Main Navigation): Creates a Save Data Point for Exporting - Leak Test Function: Saves and exits Leak Test Mode

7. Contrast tuner - Allows the user to use a screwdriver to adjust the degree of contrast of the characters on the screen of

the display




6.1.3 User Interface - Button Function Chart

Main Navigation (press once)

Previous Screen Next Screen N/A Starts/Stops the Timer

Goes to Note and Leak Test Menu

Creates a Save Data Point

Main Navigation (3 Second hold)

Go to Available

Menu

Zero DGM (If timer is INACTIVE) Zeroes the Timer Starts/Stops the Timer

Goes to Note and Leak Test Menu

Creates a Save Data Point

Menu Screens (press once)

Move Selection Cursor Up

One

Move Selection Cursor Down One

Enters Selected Menu Option or

Perform Selected Menu Option

Goes Back to Previous Main Navigation

ScreenN/A N/A

Leak Test Screen N/A

Press and Hold 3 Seconds to Reset the

Leak Test Dry Gas Meter Volume

Press and Hold 3 Seconds to zero the

Leak Test timer

Start and Stop the Leak Test timer N/A

Saves and Exits the Leak Test

Setting Screens (press once)

Increases Value of

Setting by One

Decreases the Value of Setting by One Saves Data

Goes Back to Previous Menu Screen N/A N/A

Table 6-1: In-depth table of the functions of each button on the User Interface

6.1.4 User Interface - Screen Hierarchy

Main Navigation

Menu Screens

Settings Screens

Running Test Menu

Pitot ∆P Damping

∆P Damping Band

Orifice ∆H Damping

∆H Damping Band

Main Screen Temperature Screen

Opening Screen

Test Information Screen

Standby Menu

Pitot ∆P Damping

Traverse Pt. SAVE

∆P Damping Band

NEW Run

Orifice ∆H Damping

∆H Damping Band

Reset Marker #

ZERO Sensors

Notes and Leak Check

Leak Test

Insert Note Option

Unit Type




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Retu

rn to

Documents

XD-502 Operator’s Manual · 2019. 8. 9. · XD-502 Digital Isokinetic Console XD-502 Digital Isokinetic Console Apex Instruments, Inc. 4 Apex Instruments, Inc. 5 Warranty Policy