Apex Instruments XC-5000 User manual

APEX INSTRUMENTS, INC.
Source Sampling Console Manual
XC-5000
Operator’s Manual

XC-5000
204 Technology Park Lane
Fuquay-Varina, NC 27526
www.apexinst.com
[phone] [phone]
For Support or Service Contact:
Technical Services Group
[e-mail]
[phone]
XC-5000 Operators Manual
Revision Date: 2.7.18

XC-5000
Apex Instruments Limited Warranty Policy
General Limited Warranty Period and Applicability
The warranty period is 1 year from date of purchase or any longer warranty period that may be indicated on the
original sales order. During the warranty period, we will replace or repair, at our option, any new component failing
due to a defect in materials or workmanship under normal use and service after proper use.
Contact Apex Instruments to receive a return merchandise authorization. Properly label and package the component and
return to:
Apex Instruments,
Inc. Attention:
Warranty RMA #
204 Technology Park
Lane Fuquay-Varina,
NC 27526
You must be the original purchaser of the component. This warranty is NOT transferrable.
What is Not Covered
Failure due to:
Accident or collision; misuse, abuse or modification; all forms of corrosion or other environmental conditions
including lightning, natural disasters; improper installation; installation of an incorrect part; and damages caused
by other faulty parts.
Normal wear and tear.
Used or salvage parts.
Shipping damage.
Additional Important Information
THIS LIMITED WARRANTY DOES NOT COVER LABOR COSTS OR INCIDENTAL, INDIRECT, SPECIAL OR
CONSEQUENTIAL DAMAGES SUCH AS, BUT NOT LIMITED TO, PHYSICAL INJURIES OR PROPERTY
DAMAGE, LOSS OF TIME, LOSS OF USE OF THE COMPONENT, INCONVENIENCE, RENTAL EQUIPMENT
CHARGES, OR ACCOMMODATIONS RESULTING FROM A DEFECT IN OR FAILURE OF THE COMPONENT.
This limited warranty represents the exclusive remedy for any component defect or failure and the total liability of APEX
INSTRUMENTS, INC. (“APEX”) and its affiliates for any component it warrants.
APEX 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
component 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 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.

XC-5000
Table of Contents
1 Introduction
1.1 Purpose of Manual. ........................................................................................................................... 1
1.2 Definition of Isokinetic........................................................................................................................ 1
1.3 Methods of Knowledge Required...................................................................................................... 1
1.4 User Friendly Interface and Data Management Control.................................................................... 1
1.5 Multiple Method Versatility...................................................................................................................... 1
2 System Description
2.1 Source Sampler Console................................................................................................................... 3
2.2 User Interface Software..................................................................................................................... 5
2.3 Software and Firmware Installation/Upgrade..................................................................................... 6
2.4 Electrical Subsystem.......................................................................................................................... 9
2.5 Thermocouple Subsystem................................................................................................................10
2.6 Vacuum Subsystem......................................................................................................................... 10
3 Operating Procedures for Conducting a Test
3.1 Establish Communications. .............................................................................................................13
3.2 Complete Job Information ............................................................................................................... 13
3.3 Attach Pre-Console Audit.................................................................................................................. 14
3.4 Complete Other Pre-Test Data – Method 3 and Method 4..............................................................15
3.5 Method 1 – Determining Sample Velocity Traverse Points.............................................................16
3.6 Method 2 – Stack Gas Velocity and Volumetric Flow Rate................................................................19
3.7 Preliminary Determinations Verification/Nozzle Size Selection....................................................... 20
3.8 K-Factor Calculation........................................................................................................................21
3.9 Sampling Run Procedure.................................................................................................................22
4 Recommended Reading List for Isokinetic Sampling
4.1 Recommended Reading List........................................................................................................... 26
5 System Calibration and Audits
5.1 Calibration Procedures....................................................................................................................27
5.2 Audit Procedures............................................................................................................................. 35
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Tables
Table 1-USEPA Test Methods Applicable to XC-5000 Source Monitoring Console..........................................1
Table 2 -XC-5000 Application–Associated US EPATest Methods................................................................... 2
Table 3 -System Featuresand Specifications ..................................................................................................... 5
Figures
Figure 1 - XC-5000 SourceSampling Train......................................................................................................... 3
Figure 2 - XC-5000 SourceSampling Console.................................................................................................... 3
Figure 3 - Main Screen - Console is NOT Connected ........................................................................................ 5
Figure 4 -Main Screen - Console ISConnected.................................................................................................. 6
Figure 5 - Config /UtilitiesWindow................................................................................................................................... 7
Figure 6 - Firmware File Selection Window.......................................................................................................... 8
Figure 7- Firmware Upload SuccessfulWindow.................................................................................................. 8
Figure 8 - Monitor Window................................................................................................................................... 9
Figure 9 - Config /UtilitiesWindow.................................................................................................................................10
Figure 10 -Monitor Window............................................................................................................................... 11
Figure 11 - Main Menu Before Establishing Communications Window.............................................................13
Figure 12 - Job InformationMenu Window........................................................................................................14
Figure 13 - Pre-Console AuditMenu Window.................................................................................................... 14
Figure 14 - Other Pre-Test DataMenu Window................................................................................................. 15
Figure 15- Method 1 Traverse Points Required Window..................................................................................16
Figure 16 - Top Section of Method 1 MenuSection Window.............................................................................16
Figure 17 -Method 1Menu Windows............................................................................................................... 17
Figure 18 - Bottom Section Method 1 Menu Window........................................................................................ 18
Figure 19 - Method 2Menu Window..................................................................................................................19
Figure 20 - Stack StaticPressure Windows.......................................................................................................20
Figure 21 - Nozzle Size Calculator Window.......................................................................................................20
Figure 22 - K-Factor Calculator Menu Window..................................................................................................22
Figure 23 - Leak Test Menu Window ................................................................................................................. 23
Figure 24 – Monitoring Menu/Display Window .................................................................................................. 24
Figure 25 – Leak Test Menu Window................................................................................................................25
Figure 26 – Export Data to File Window............................................................................................................ 25

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1 Introduction
1.1 The purpose of this manual is to provide a basic understanding of the Apex Instruments Model XC-5000
Source Sampler Console. Sections of the manual include System Description, Calibration Procedures,
Sampling Procedures as well as Maintenance and Troubleshooting Guides. The manual is based on the
procedures established by the United States Environmental Protection Agency (USEPA) in accordance with
Reference Methods 1 through 5- Determination of Particulate Emissions from Stationary Sources.
1.2 The Apex Instruments XC-5000 Automatic Isokinetic Source Sampling System enables the operator toextract
a sample from a stack isokinetically. The word “isokinetic” is comprised of two Greek root words “Iso” meaning
“the same as” and “Kinet” meaning “relating to motion of material bodies.” Isokinetic Sampling is therefore the
extraction of a gas sample from a gas stream at the same velocity as the gas travels in the stack. Isokinetic
sampling is necessary because of the inertial effect of particulate matter in a gas stream. The isokinetic sampling
ratio, or percent isokinetic, is the ratio of the sample velocity at the inlet of the sampling nozzle to the stack gas
velocity.
1.3 Isokinetic testing requires a thorough understanding of the first five test methods presented in Title 40 Part 60
Appendix A of the Code of Federal Regulations (40CRF60 App A). Method 5 provides the general sampling train
operation protocol, but Methods 1 through 4 prescribe techniques underpinning the sampling activities associated
with Method 5. Together, these methods outline the basic protocols for determining particulate concentrations
and mass emission rates.
Table 1- USEPA Test Methods Applicable to XC-5000 Source Monitoring Console
Method Description
Method 1 Determination of Sampling Location and Traverse Points
Method 2 Determination of Stack Gas Velocity and Volumetric Flow rates
Method 3 Determination of Dry Molecular Weight
Method 4 Determination of Moisture Content in Stack Gases
Method 5 Determination of Particulate Matter Emissions from Stationary Sources
1.4 Unlike manually operated source sampling systems, the XC-5000 eliminates the time consuming effort required
to perform the isokinetic sampling calculations and recording measurement data. The system’s software provides a
form –driven user interface and data management control for:
• Entering,calculating andstoringdatarequiredtodefine stack traverse points adhering to USEPA Method
1protocols.
• Configuring and performing USEPA Method 2 Stack Gas Velocity and Volumetric FlowRate
determinations, and performs required calculations and stores collected Method 2 data.
•
Determining Stack Gas Dry Molecular Weight and Concentrations of Oxygen (O2), Nitrogen (N2), Carbon
Dioxide (CO2) and Carbon Monoxide(CO).
• Determining Moisture Content in StackGases
• Performing allcalculations necessaryto determine the isokinetic sampling parameters,e.g.,nozzle size,
sample flowrate, test point locations, etc.
1.5 The basic XC-5000 sampling train is easily adapted to test for many other gaseous and particulateparameters
of interest from stationary sources. Parameters of interest may include metals, polychlorinated biphenyls (PCBs),
dioxins/furans, polycyclic aromatic hydrocarbons (PAHs), particle size distributions and an ever-increasing group
of pollutants by adaptations of basic test methods. While the different methods are designated by other US EPA
or agency method numbers, they are variations of Method 5 procedures such as using: different impinger
solutions, organic resin traps, different filter media, sampling temperatures or a range of other alternative
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The Model XC-5000 Series Sampling System can be configured to perform the following isokinetic
test methods and pollutants:
Table 2 - XC- 5000 Application – Associated USEPA Test Methods
Method No. Pollutants
5A
PM from Asphalt Roofing
5B
Non-sulfuric Acid PM
5D
PM from Positive Pressure Fabric Filters (Bag House Filters)
5E
PM from Fiberglass Plants
5F
Non-sulfate PM from Fluid Catalytic Cracking Units
5G
PM from Wood Stoves - Dilution Tunnel
5H
PM from Wood Stoves – Stack
8
Sulfuric Acid Mist, Sulfur Dioxide
12
Inorganic Lead (Pb)
13A & 13B
Total Fluorides
14
Determination of Fluoride Emissions from Potroom Roof Monitors for Primary Aluminum Plants
17
Particulate Matter
23
Polychlorinated Dibenzo-p-Dioxins and Dibenzofurans (Dioxins and Furans)
26A
Hydrogen Halides and Halogens
29
Multiple Metals
101A
Mercury (Hg) from Sewage Sludge Incinerators
104
Beryllium (Be)
108
Inorganic Arsenic (As)- Particulate and Gaseous Arsenic Emissions
111 Polonium- 210
201A PM2.5 /PM10 Particulate Matter (Constant Sampling Rate)
202
Condensable Particulate Matter
206
Ammonia (Tentative)
207
Iso cyanates (Tentative)
306 Hexavalent Chromium from Electroplating and Anodizing Operations
315
PM and Methylene Chloride Extractable Matter (MCEM) from Primary Aluminum Production
316
Formaldehyde from Mineral Wool and Wool Fiberglass Industries (Proposed)
Waste Combustion Source Methods in EPA – SW- 846
0010
Semi volatile Organic Compounds Formaldehyde
0011 Other Aldehydes and Ketones
0023A
Polychlorinated Dibenzo-
p
-Dioxins and Dibenzofurans
0050
Hydrogen Chlorine and Chlorine
0060 Multiple Metals
0061 Hexavalent Chromium

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2 System Description
The Apex Instruments isokinetic source sampling system consists of five (5) main components, shown in Figure 1-1:
1. Source Sampler Console which includes dual digital pressure sensors, automated flowcontrolvalves with
orifice flow meter, dry gas meter, and electrical controls. The Console is housed in a weather resistant
ultra high molecular weight polyethylene (UHMW) custom designed case complete with carrystrap.
2. ExternalSample Pump,Vaneincludes: hoses with quick-connect fittings and lubricator.
3. Probe Assembly, including a SS probe sheath, probe liner, tube heater, Type-S Pitot tubes, stack and heater
Type K thermocouples and an Orsat line.
4. Modular SampleCase,including hot box for filter assembly,cold box for impinger glassware,andelectrical
connections.
5. Umbilical Cable, including electrical and pneumatic lines to connect the Modular Sample Case tothe
sample pump and Source Sampler Console.
2.1 Source Sampler Console
Figure 1 - XC-5000 Sampling Train
The Source Sampler Console is the operator’s control station that monitors gas velocity and temperatures at the
sampling location and controls system sampling rate and system temperatures. Figure 1-2 illustrates the Apex
Instruments Model XC 5000-Source Sampler Console’s front panel.
Figure 2 - XC-5000 Source Sampling Console
Field assembly and setup is simplified. The connections for sample line, Pitot tube lines, vacuum pump (non-
reversible), and electrical (4- pin circular connector and Thermocouple jacks) are all located on the front panel for
easy access. The XC Case has a removable front and back covers for easy access.

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Table 3-System Features and Specifications
Feature / Component
Description
User Interface Software Windows 7 & Higher;
Communications Integrated data acquisition board with Ethernet LAN connectivity;
Gas Meter
Precision DGM, 0.7 liters per revolution, digital gas volume with Internal
Quadrature Encoder with 6 digit LCD display, 1cc resolution.
Thermocouple Display Seven (7) temperatures displayed simultaneously on the PC User Interface,
°F or °C, Probe, Stack, Oven, Filter, Exit, AUX and DGM.
Temperature Control
Integrated temperature control via the Control and Data Acquisition Board,
probe and oven with solid state relays.
Δ P +/- 2.5” (+/- 63 mm) 0.010” resolution ( +/- 63mm 0.01 mm resolution)
Δ H +/- 5” (+/- 127 mm) 0.01” resolution ( +/- 63mm 0.1 mm resolution)
Barometric Pressure
Sensor
17.7 in Hg – 32.5 in Hg 0.01 in Hg resolution.
450 mm Hg –825 mm Hg 0.01 mm Hg resolution.
Umbilical Connectors Electrical: 4 conductor circular connector grounded shell.
Sample line: Stainless Steel 1/2” Quick Connector.
Pitot Line: Stainless Steel 1/4” Quick Connectors (optional 3/8”).
External pump: Stainless Steel 3/8” Quick Connect.
Thermocouples: Type- K standard size.
Vacuum Gauge Displays system vacuum 0-100 kPa (0-30 in. Hg).
Timer Integrated Elapsed Timer monitors sampling time.
Dimensions Console: 23” x 21” x 12” (58 mm x 523 mm x 30.5 mm).
Weight Console: 39 lb (17.7 kg).
Power Console: 120V / 60 Hz 220V / 50 Hz (optional), 15 A max (includes pump,
probe and umbilical heaters).
Pump: 120V / 60 Hz 220V / 50 Hz (optional).

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2.2 User Interface Software
The configuration and operation of the XC- 5000 is completely controlled through the system’s User Interface
software and the operating system running on the XC-5000 embedded computer resident on the Console’s mother
board.
The software is constructed to provide a convenient, reliable and consistent methodology for all operations and
basically leads the user through the process of performing a test. User interactions with the system are managed
using menu buttons, user inputs fields, tabs, check boxes, etc., in specific form driven windows organized by task.
All system operations including sensor calibrations and audits, test operations, viewing current system information
and viewing any status alerts are initiated through the Main Screen, shown below in Figure 2, by clicking on the
appropriate tab or button.
Figure 3 - Main Screen - Console is NOT Connected
Note that the Main Menu interface windows generally have three major structural components:
1. Menubar tabs providing access to the “Main” menu window, the “Monitor” display and system status
“Alerts”page.
2. Job Progress menu buttons. By completing information and procedures contained in each JobProgress
menu item, in a stepwise fashion, the entire testing process is efficiently and consistently performed. As
each menu item is completed, a checkbox is automatically displayed immediately to the left of the menu
item. The next menu item becomes available when its predecessor is completed.
3. System control functions: Connect, Load Project, Save Project,NewProject,Config/Utilities, and End.
IMPORTANT: Access to many functions and operations is only possible when the software has established
connection with the Console.
An active connection between the Console and the User Interface software is indicated when the current date and
time are displayed on the Main window in the lower left corner and by the removal of the Connect button. To
establish the connection, connect an Ethernet cable between your computer and the Ethernet connector on
the front panel of the XC-5000 Console, then click the . Button. Figure 2 is a screen shot of the
software when it is not connected. Figure 3 shows the display when the system is connected.
IMPORTANT: A data entry field with a yellow background indicates that field must be completed in order to
continue.

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Full details on using the software to configure the system to perform a test and then instruct the Console to
perform the test is provided in the following chapters.
Figure 4- Main Screen- Console IS Connected
2.3 Software and Firmware Installation/Upgrade
XC-5000 software is composed of two parts the PC application and the firmware that controls the XC-5000. The
version number is also made up of two parts. An example wouldbe 70605-1246. The numbers to the left (70605)
of the –is the PC application and the numbers to the right (1246) are for the console firmware. It important to note
the Software and Firmware are released as a set and must be installed as such. Mixing versions of software and
firmware will cause unreliable results. The installed software and firmware version can be seen on the right side
of the screen when connected.
Software installation simply requires downloading the curr ent software package and unpacking the XC-5000 zip file to
the computer that will be used when operating the XC-5000 as follows: (Installation instructions are also included
in the zip file.)
Software and firmware updates are performed the same as installation with the addition of deleting the desktop
shortcut for the previous version. All Projects should be recreated after an upgrade. The old projects will not
correctly with new software and firmware.
1. Using a Web Browser download the current version of the XC-5000 software from
http://www.apexinst.com/resources/software
2. Using Windows Explorer, locatethedownloadedfilenamedXC5000_Vxxx.zip. Double click on the file and
extract it.
3. In the extracted folder locate the folder Apex_5. Right click on it and select “Copy”
4. Navigate to the C:\drive and right click. Then select “Paste”This will create afolderonyourhard drive.
named: C: \ Apex_5 . If performing an upgrade the Apex_5 folder will already be present. When the
paste is performed a warning about the files and folder already exist and will be overwritten. Accept
the error to continue.

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5. Navigate to the Apex_5 folder. In this folder locate the file Apex_AutoKinetic_xxxxx. Right click on
the file and select “Send to Desktop” This will create a shortcut to the application on the Desktop,
shown below, on your desktop. If performing an update delete the old version shortcut from the
desktop.
By default, all data and audit files created by the XC -5000 software during a test will be stored in the
C:\ Apex_5 folder.
6. Make sure the PC and laptop are powered on and connect the PC to XC-5000 with Ethernet cable.
7. Double click the desktop icon to launch the application.
8. On the main screen select the Config/Utilities button
9. On the Config/Utilities Screen select the Firmware Upload button then select Yes to continue.
Figure 5- Config/Utilities Window

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Figure 4 Config / Utilities Screen
10. Navigate to the C:\Apex_5 folder if not there by default. Select the Main firmware 5_Mainxxx.hex
where xxx is the version number. Select Open
Figure 6 Firmware File Selection C:\ Apex_5 Folder
Figure 7 Firmware Upload Successful Window
11. The PC will automatically connect to the XC-5000.

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2.4 Electrical SubSystem
The Source Sampler Console is factory- configured for 120VAC/60Hz electrical power. Configuration for
240VAC/50Hz operation is an available option. The Electrical Schematics for the Source Sampler Console are
presented in Appendix B.
Circuits are protected by front panel mounted circuit breaker switches labeled Main (15 Amp for 110VAC or 10
Amp for 220VAC) and PUMP/OVEN/HEATERS. Circuit breakers detect and interrupt overload and short circuit
conditions, providing an important safety factor. If the circuit breaker opens, or “trips,” indicating interruption of
the circuit, investigate and repair the electrical fault. Then reset the breaker by toggling the power/circuit breaker
switch off then on
The electrical subsystem provides switched power to several circuits, including: MAIN POWER, PUMP POWER,
PROBE heater and OVEN heater.
• The MAINPOWER switch controls allpower toallcircuits. Also, whenthisswitchison,thecabinetcooling
fan shouldoperate.
• The PUMP/OVEN/HEATERS POWER isactivated via the PUMP POWER switch ontheConsole’s
front panel and then controlled by the XC-5000 software. Setpoints are established during the test
setup.
Figure 8-"Monitor" Window

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• Check the temperature display to verify if the heaters are working. Allow time for the temperatures
to stabilize and verify operation of the circuits. The Config / Utilities interface window showing the
Heater Controls is represented in Figure 9 - Config / Utilities Window, below.
Figure 9 - Config / Utilities Window
2.5 Thermocouple SubSystem
The thermocouple subsystem displays, measures and/or provides feedback for the temperature controls critical to
isokinetic sampling operation. The thermocouple system consists of Type-K thermocouples, extension wires,
male/female connectors, receptacles, and on-screen temperature display.
There are automatic temperature controllers for probe and filter oven heat which receive temperature feedback
signals from the electrical subsystem to control and maintain temperatures within range of the set point. The
thermocouple electrical diagram is presented in the Electrical Schematic.
All thermocouple readings are displayed on the “Monitor” screen, shown in Figure 4.
2.6 Vacuum SubSystem
The vacuum subsystem consists of an external vacuum pump assembly, quick-connects, internal fittings, two (2)
control valves (Coarse and Fine), an orifice meter and digital pressure sensors.

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The external vacuum pump assembly provides the vacuum for extracting the gas sample from the stack and then
through the various components of the isokinetic source sampling system.
The sample flow rate is controlled by the Coarse Control Valve and the Fine Increase Valve through software
controls in the XC- 5000 User Interface “Monitor” window, shown in Figure 6, above.
This Coarse Control valve blocks the flow from the SAMPLE inlet quick- connect to the Vacuum Pump inlet.
The Fine Increase Valve allows flow to recirculate from the pump outlet back to the pump inlet. This dual valve
configuration enables very precise control of the sample flow rate.
A calibrated Orifice Tube located on the outlet of the Dry Gas Meter, indicates the sample flow rate. The orifice
pressure drop is displayed in the XC-5000 User Interface “Monitor” window. The stack gas velocity pressure drop is
also measured using its own dedicated digital pressure sensor. The instrument sample flow control can be
managed either automatically by the system software or manually by the operator. When running in manual mode,
the operator can observe the orifice reading (∆H) on the User Interface “Monitor” window, shown above in Figure 6.
and quickly adjust the sample flow rate using the Manual Adjust button on the “Monitor” window so the sample is
extracted under isokinetic conditions.
When running in automatic mode, the system will automatically calculate the dynamic K factor and adjust the
pump valves as required to maintain isokinetic sampling conditions.
Figure 10 - "Monitor" Screen

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3 Operating Procedures Conducting a Test
The XC-5000 Source Sampling System has been designed and developed to perform a test following USEPA
stationary source testing methodology. The XC -5000 software design considers each individual sample run
comprising one or more traverse points and traverse lines as a single “Test”.
The hardware and software work together to guide the user through the entire test process including Methods 1
through 4, necessary for gathering the preliminary values for Method 5 sampling, all associated system leak
checks, sensor calibration/audits and then performing the Method 5 test.
It is vitally important that the system operator follow the Console’s menu structure in order to carry out a valid
test in conformance with USEPA method requirements. By accurately completing required user input data and
conducting the test according to method protocols, the XC-5000 ensures the completion of a valid test run.
During the conduct of the test, the software performs all required calculations and automatically monitors the
status of all system sensors and operating parameters and also provides operator prompts, for example, when to
change the test point location.
Each test results in a test run specific data file (.CSV format) containing all required preliminary values including
user desired test and site identification details, quality control checks, sensor parameter data.
As mentioned previously, the User Interface software menus have been constructed to follow the logic and steps
used in the USEPA’s source testing methods. Any and all necessary calculations in the methods are normally
performed automatically by the XC-5000 User Interface software and operating system firmware.
These features will be evident as the test is configured and carried out.
This chapter has been divided into several sections detailing each part of the test process:
3-1. Establish Communications
3-2. Complete Job Info
3-3. Attach Pre -Test Console Audit
3-4. Complete Other Pre -Test Data
3-5. Complete Method 1
3-6. Complete Method 2
3-7. Calculate Nozzle Size
3-8. K Factor Determination and Configuration
3-9. Perform Pr e- Test Lea k Check
3-10. Conduct Sample Traverse
3-11. Perform Post -Test Leak Checks
Where appropriate, the operational details, requirements and calculations underpinning Methods 1 –5 have been
retained in the following sections to provide background on what is being performed by the instrument when a
test is being conducted.

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3.1 Establish Communications
a) Turn on the XC-5000 Main Power Switch and allow console to fully initialize. The display will show the
currently installed firmware. Verify it corresponds with the PC software version.
b) Connect an Ethernet cable between your computer and the XC- 5000 Console. Once the
softwareisrunningand the cable is connected, establish communications between the XC-5000
by clicking the button on the Main Menu (see below).
Figure 11 - Main Menu Before Establishing Communications
c) When communications have been established, the button will not be displayed
and the console firmware displayed with the software version. Also, the Main Menu will show
the currentdateand timein thelower left-handportion of the menu.
3.2 Complete Job Info
a) To start anew test file,clickthe button. Touse anexisting test profile, click the
button.
b) Next, click the button to open the Job InfoMenu.
This menu, shown in Figure 23, below, contains data entry fields for Plant Name, Sampling Location,
Project / Job # and Notes. These fields can accept any alphanumeric characters. Any data entered is
stored in the test data file to provide for information in a test report.
c) Select the appropriate radio button to choose the reporting units in either English Units or in
Metric Units. This choice determines the configuration of units used in all calculations, sensor
information displays and measurement data.
d) Verify the values for Standard Pressure and Standard Temperature. The default values
supplied by the program are those specified in the USEPA Source Emissions Reference
Methods. The user may modify the values by entering new values in the respective fields.

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the
e) Zero pressure sensors if required by pressing button. Make sure the pump is not
running and no pressure is being applied to the pitot.
f) When all data has been entered, click the button to accept data entered into this
menu form and return to the Main Menu.
Figure 12- Job Information Menu Screen
3.3 Attach Pre-Console Audit
The Pre-Console Audit Menu allows the operator to attach the data compiled during a previously conduct system
audit. Performing a Console Audit will be covered in another section
a) Click the button depicted in the Pre -Console Audit menu, Figure 24, below, to
attach an Audit data file to the current test file. The Audit file will be attached to the test record
when the button on this screen is clicked and the program will return the user to the Main
Menu.
b) Click if an audit file is not desired. The program will return the user to the
Main Menu. The exported data will show AUDIT FILE NOTFOUND
Figure 13 - Pre- Console Audit Menu Screen
Note: The Pre-Console Audit is generally performed in the laboratory or instrument shop prior to
transporting the system to the test site. Instructions for conducting the audit are provided in Chapter 5 -
System Calibration and Audits.

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3.4 Complete Other Pre-Test Data- Method 3 and Method 4
This Other Pre-Test Data menu is used to enter data for stack gas composition in order to calculate the stack gas
dry molecular weight and for the water content of the stack gas. This menu also includes fields for entering the
desired set points for the Probe and Oven/Filter Heaters.
The program offers two options for entering Method 3 data. The program can either automatically calculate the
Dry Molecular weight using the data in the input fields that is supplied from data determined previously using
Method 3. Or, if known, directly enter the Dry Molecular Weight value in its field. If the user enters data for each
gas parameter, the program calculates the Dry Molecular Weight when the cursor is placed in the Dry Molecular
Weight field. If the user directly enters the Dry Molecular Weight into its field, the program will use that value for
subsequent calculations.
To complete the Other Pre-Test Data:
a) From the Main Menu, click button. The menu is shown in Figure25,
below.
Figure 14 – Other Pre-Test Data Menu Screen
b) Enter the Stack Gas Compositions calculate the Dry Molecular Weight or enter the Dry Molecular Weight
directly using EPA Method 3
c) Enterthedecimal fraction of water determinedusingMethod 4.
d) Enter the desired heater temperature set points for the Probe and Oven / Filter
e) When all data has been entered press the button.
NOTE: The Heater Control option is used in special cases where the oven temperature is used instead of the
filter temperature control. Normally this is off (unchecked)