Trolex Air XS User manual

1
USER MANUAL

CONTENTS
1
1.1
1.2
2
4
General description.................................................................................
Main features......................................................................................................
Limits of use........................................................................................................
Product safety..........................................................................................
Danger from process..............................................................................
Safety procedures...................................................................................
Laser safety precautions..................................................................................
System components........................................................................................
TX8100 AIR XS Silica Monitor......................................................................
Particulate flow path.........................................................................................
Peripherals and accessories..........................................................................
Certification.............................................................................................
Compliance.........................................................................................................
Technical information.............................................................................
Product specification........................................................................................
Product dimensions..........................................................................................
Hardware installation.............................................................................
Safety precautions.............................................................................................
Mounting details.................................................................................................
Electrical connections.......................................................................................
I/O terminals........................................................................................................
Power connections............................................................................................
Commissioning.......................................................................................
First power on....................................................................................................
System shutdown..............................................................................................
BreatheXS software..........................................................................................
Controls and indicators...........................................................................
Navigation...........................................................................................................
3
4
4.1
5
5.1
5.2
5.3
6
6.1
7
7.1
7.2
8
8.1
8.2
8.3
8.4
8.5
9
9.1
9.2
9.3
5
5
6
7
8
8
10
11
12
13
14
14
15
15
17
18
18
19
20
21
21
22
22
22
23
AIR XS_User manual_P5633.1601_ Rev J
10 24
10.1 24

General operation...................................................................................
User interface display.......................................................................................
Particulate display information.......................................................................
Instrument configuration.......................................................................
Default settings..................................................................................................
On-site configuration........................................................................................
Custom alarms....................................................................................................
External audio-visual (AV) alarm set-up.......................................................
Updating firmware..................................................................................
Maintenance............................................................................................
Visual checks......................................................................................................
Cleaning labels...................................................................................................
Particulate entry/exit apertures......................................................................
Filter replacement..............................................................................................
Cleaning...............................................................................................................
Compliance audit check..................................................................................
Warranty...............................................................................................................
Troubleshooting......................................................................................
High temperature operating...........................................................................
Fault codes..........................................................................................................
Glossary and definitions.........................................................................
Disposal....................................................................................................
Get in touch.............................................................................................
Technical Support..............................................................................................
Feedback.............................................................................................................
Disclaimer.................................................................................................
Trademark................................................................................................
11
11.1
11.2
12
12.1
12.2
12.3
13
14
14.1
14.2
14.3
14.4
14.5
12.4
15
15.1
15.2
16
17
18
18.1
24
25
25
26
28
28
28
28
29
31
32
32
32
33
33
36
37
37
37
38
39
40
40
40
41
AIR XS_User manual_P5633.1601_ Rev J
14.6 33
14.7
18.2
41

AIR XS USER MANUAL4
1. GENERAL DESCRIPTION
The Trolex AIR XS Silica Monitor is designed to provide detailed, accurate and real-time
data on airborne RCS content based on the chosen installation environment. Using innovative
optical refraction technology (ORT), the AIR XS combines a consistent particle flow rate with
advanced sensing technology to provide information on airborne dust mixtures.
As the AIR XS processes and analyses particulate data, an adaptive algorithm is used to
calculate and identify the average level of RCS from the overall particle count. Measurement
information can be viewed via the instrument display or as historical readings using the
accompanying Trolex Breathe application software.
TX8100 AIR XS Silica
Monitor
AIR XS_User manual_P5633.1601_ Rev J

5
1.1 Main features
The AIR XS has been designed for use in environments where hazardous RCS is present. Resulting
RCS detection can be influenced by total particle orientation, shape, size, and overall dust loading.
The AIR XS sensor may see some cross-responsivity from poly-crystalline particles present in the
local environment.
To ensure the optimum performance and safe operation, the AIR XS must be operated according to
the limits detailed in the technical data section of this user manual. Operation outside of these limits
may result in damage to the equipment or failure to achieve the performance specification.
Continual operation of the AIR XS at extremes of the specified temperature limits may reduce the
operating lifetime of the product.
Trolex will not be liable for any injury or damage caused by incorrect installation, setup,
operation, or maintenance resulting from a failure to follow the procedures and safety
instructions provided in this user manual.
• Real-time, continuous measurement of atmospheric RCS concentration
• Real-time, continuous measurement of dust particle count
• High-reliability and low-maintenance
• On-device display readout
• High visibility alarm warning indicators
• ‘Plug and play’ installation
1.2 Limits of use
AIR XS_User manual_P5633.1601_ Rev J

6 AIR XS USER MANUAL
2. PRODUCT SAFETY
The following symbols are used in this manual or on the instrument to indicate procedures
that if not followed correctly, may result in personal injury or damage to equipment.
In addition, the following symbols are used on the instrument
Alerts the user to a potentially hazardous procedure or practice
which if not followed correctly can result in serious personal injury or
injury of others.
WARNING!
Alerts the user to a procedure or practice which, if not followed
correctly can result in damage to the system or ancillary equipment.
The use of controls, adjustments, or procedures other than those
specified in this user manual may result in exposure to hazardous
optical radiation.
WARNING! – LASER RADIATION
CAUTION!
WARNING! – ELECTRIC SHOCK RISK
AIR XS_User manual_P5633.1601_ Rev J

7
It is possible that the AIR XS could be installed in environments that contain process particulates
which can be hazardous to health.
Unless process conditions are known to be entirely safe, suitable precautions such as the use of
breathing apparatus or environmental purging / detoxifying should be employed before entry is
made into the installation or maintenance environment.
Note: This product variant is not designed for use within Explosion Group or Zoned hazardous areas.
In order to maintain a high level of hazard control and accommodate any detection variability, it is
good practice to set any on device warning thresholds to ~50% of the applicable WEL Limit.
3. DANGER FROM PROCESS AIR XS_User manual_P5633.1601_ Rev J

AIR XS USER MANUAL8
Always observe the safety precautions detailed in this user manual. Personnel installing, operating,
or maintaining the equipment are responsible for their personal safety and correct handling of the
equipment in accordance with all safety instructions detailed.
Follow all warnings and instructions marked on the instrument. Warning labels are situated on the
instrument, indicating a hazard at or near the location of the warning label.
Retain these instructions in a safe and known place for future use.
The AIR XS has been designed to be as simple to install and commission as possible.
Nevertheless, installation in working environments can be challenging and correct set up is critical
to the function of the instrument. It is important that you carefully read the entire User Manual
before using and installing the AIR XS for the first time and keep it in a safe place for future
reference.
Peripheral components such as the power supply and communications module/peripheral or
interface must be installed according to the manufacturer’s instructions and the installation
location’s prevailing statutory regulations.
The installation of the instrument must only be carried out by competent personnel. Each
installation needs to be considered with reference to the local safety regulations and authorities.
Observe the national safety regulations issued, for example, by the employers’ liability insurance
association, social security institutions, occupational safety and health or other safety authorities.
4. SAFETY PROCEDURES
The AIR XS is rated via the Class 1 ‘Laser Safety Guideline’ under all conditions of normal use.
Class 1 laser products may contain laser systems of a higher class but there are adequate
engineering control measures to ensure that access to the beam is not permitted during normal
use.
4.1 Laser safety precautions
WARNING – Class 3B laser radiation: do not open the laser
housing when the laser is powered on as it may result in eye
damage from directly viewing the laser beam.
AIR XS_User manual_P5633.1601_ Rev J

9
Sensor housing
WARNING – There are no user-serviceable parts
inside the AIR XS unit. Servicing should only be carried out by
Trolex or an approved service technician.
AIR XS_User manual_P5633.1601_ Rev J

AIR XS USER MANUAL10
The AIR XS is typically installed as a stand-alone instrument for general purpose applications. The
instrument is supplied with peripherals fitted to allow for the ‘plug and play’ installation to universal
mains/dc power supplies and data outputs.
The instrument and Trolex BreatheXS software are specifically designed to work in conjunction with
each other using proprietary protocols and design features. The system has, however, been designed
to support third-party power supplies and communication protocols where required.
Note: M20 gland entries are provided for custom installation requirements. Gland entries may be
blanked, and installations may vary from diagram shown.
5. SYSTEM COMPONENTS
Example installation configuration
Windows PC/Mac
or server
USB interface port
ac or dc power supply
AIR XS_User manual_P5633.1601_ Rev J

11
5.1 TX8100 AIR XS Silica Monitor
The AIR XS Silica Monitor uses a custom particle sensor that is located inside a robust stainless-
steel housing. This provides isolation and ingress protection between the particle flow path and
the main control circuits. Control circuits are housed in a lockable, IP66 rated steel enclosure.
Information and settings can be accessed using the keypad and display located on the front of the
instrument.
The figure below shows the location of the navigation buttons, display screen and status LEDs.
Power and network connections enter the main housing via cable entry glands located on the
bottom of the instrument. The AIR XS can be wall or stand mounted via the integrated external
mounting brackets.
Particle inlet
Door lock
Navigation buttons
LCD
Status
Mounting brackets M20 cable
entry glands
USB interface
AIR XS_User manual_P5633.1601_ Rev J

AIR XS USER MANUAL12
The AIR XS has been designed with the ability to restrict ingress through the particulate flow path
during routine maintenance and cleaning periods. A rotational top cap is used to open or close the
particle flow path to provide ingress protection during cleaning.
It is recommended that the top cap is set to the closed position during instrument maintenance
and cleaning to ensure the dust sensor is not exposed to unnecessary ingress. When the top cap is
rotated into the closed position, the AIR XS conforms to IPX6.
Note: Rotate the top cap to move between ‘open’ and ‘closed’ positions.
5.2 Particle flow path
AIR XS_User manual_P5633.1601_ Rev J

13
The AIR XS can be connected to a standard 100 V to 240 V ac power supply or a 9 to 18 V dc
power supply. Before connecting a power supply to the instrument, ensure that the supply source is
compatible with the instrument and information outlined on the appropriate rating plate.
See below for rating plate details.
Power supply
5.3 Peripherals and accessories
AIR XS_User manual_P5633.1601_ Rev J

AIR XS USER MANUAL14
6. CERTIFICATION
The AIR XS complies with the following European Union
Directives:
Electromagnetic Compatibility (EMC) Directive 2014/30/
EU
- EN 61326-1:2013
Low Voltage Directive (LVD) 2014/35/EU
- EN 61010-1:2010+A1:2019
6.1 Compliance
The AIR XS complies with the following RoHS Directives:
- RoHS Directive 2002/95/EC
- RoHS 2 Directive 2011/65/EU
AIR XS_User manual_P5633.1601_ Rev J

15
UK 50 100
Thorlabs Aus AES
7. TECHNICAL INFORMATION
7.1 Product specification
Sensing technology Optical refraction technology (ORT)
Light-scatter photometer (OPC)
Particulate measurement Target RCS identification range 1 to 10 µm
Max. typical dust loading* 150 mg/m³
Continuous range 25 mg/m³
Displayed data RCS mg/m³
Total particles/litre
Resolution 1,000ʰ of a mg
Averaging period 15 minutes, 1, 4, 8 and 12 hours (rolling average)
Sampling interval 1 to 60 seconds
Particle count > 600 particles/second
Total airflow rate ~1.5 L/m (nominal)
Typical RCS accuracy ± 25%
*The instrument can define particulate measurement peak trends up to the quantity specified.
Note: Sustained exposure to dust quantities above 25 mg/m will be logged; however, it may aect
the operating life of the AIR XS sensor.
As applications of use are outside our control, the information provided is given without legal
responsibility. Customers should test under their own conditions to ensure that the unit is suitable for
their own requirements.
Particulate sensing parameters
AIR XS_User manual_P5633.1601_ Rev J

AIR XS USER MANUAL16
Technical specification
Operating temperature -10 to 45 °C
Humidity 0 to 95% RH (non-condensing)
Housing material PC/ABS – stainless steel
Ingress protection Main enclosure: IP66
Particle flow path, cap open: IP22
Particulate flow path (cap closed): IPX6
Weight 8.2 kg
Cable entries 3 x M20 with removable blanks
1 x M20 breather gland
1 x M20 USB connector
Nominal power supply 100 to 240 V ac 50/60 Hz
9 to 18 V dc
Power consumption 15 W
Communications RS485 data output with MODBUS RTU protocol
Ethernet (MODBUS TCP/IP) - not implemented yet
External power output 2 x 15 V dc 1 A outputs (for powering external devices)
Connectivity Trolex BreatheXS software
Data download External USB interface
Instrument data storage 6 GB
User interface 128 x 64 dot matrix display with RGB backlight
Navigation keypad (membrane)
Visual alarms Custom alarm setpoints
Latching/non-latching
Indicators 1 x green high brightness LED – sensor heartbeat
1 x blue high brightness LED – communications
Self-test routine Sensor hardware, circuitry and communications on power on
Manual self-test during use
Certification CE compliant
AIR XS_User manual_P5633.1601_ Rev J

17
7.2 Product dimensions
Note: Rotate the top cap to move between open and closed positions.
305mm
Panel key
387 mm
305 mm 156 mm
AIR XS_User manual_P5633.1601_ Rev J

AIR XS USER MANUAL18
8. HARDWARE INSTALLATION
Refer to section 4 of this user manual before undertaking the installation of the AIR XS device. The
installation location of the AIR XS device is the prerogative of the installer and care should be taken
to ensure an appropriate position has been selected. Consider the location of a suitable power
supply and external fuses, access to a communications network and the protection of cabling from
damage.
1. Secure the AIR XS to a suitable mounting surface using the integrated
mounting brackets.
2. Ensure that the AIR XS is mounted in an upright position.
3. Unlock and open the enclosure door to access the internals of the
enclosure.
4. Ensure power is isolated before making electrical connections to the
instrument.
5. Power supply voltage and frequency must match the instrument (refer to
rating plate).
6. Ensure external switches or fuses are installed where applicable.
7. Run the required cables through the cable glands provided in the bottom of
the enclosure.
8. Wire the cables into the relevant terminals as indicated on the internal plate (refer to
section 8.3).
9. Tighten the cable gland against the cable to ensure an IP seal.
10. Close and lock the door after use to maintain IP rating of the enclosure.
11. Ensure that the particulate entry and exit ports are not restricted or covered.
Note: The instrument is susceptible to ingress when the door is open so care must be taken to
ensure the location is clean during installation.
8.1 Safety precautions
AIR XS_User manual_P5633.1601_ Rev J

19
8.2 Mounting details
Note: Ensure the AIR XS is mounted vertically during installation.
The figure and tables below detail the connections available internally in the AIR XS. The
connections can be accessed by opening the front housing of the instrument using the supplied key.
4 x M10
362 mm
255 mm
AIR XS_User manual_P5633.1601_ Rev J

AIR XS USER MANUAL20
ac power dc power
LN
Power
1 2 3
V+
Power
45 6
0 V
ac power in dc power in Outputs
1
2
36
5
4 7
8
9
10
Live Supply voltage
Neutral 0 V
Earth Earth
RS485/USB switch
RS485 B
RS485 A
RS485 0 V
11
12
13
14
15
16
Supply voltage
0 V
Supply voltage
0 V
USB
Ethernet
Table 1: Power, RS485, external power, USB and ethernet terminal connections.
8.3 Electrical connections
AIR XS_User manual_P5633.1601_ Rev J