Trolex XD One User manual

1
USER MANUAL

1
1.1
1.2
2
6General description.................................................................................
Main features......................................................................................................
Performance data..............................................................................................
Intended use.......................................................................................................
Limits of use........................................................................................................
Product safety.........................................................................................
Danger from process..............................................................................
Safety procedures..................................................................................
Laser safety precautions.................................................................................
System components...............................................................................
TX8005 Air XD Real-Time Dust Monitor.....................................................
Particulate flow path.........................................................................................
Peripherals and accessories..........................................................................
Certification.............................................................................................
Compliance.........................................................................................................
Technical information.............................................................................
Product specification........................................................................................
Product dimensions..........................................................................................
Hardware installation.............................................................................
Safety precautions............................................................................................
Mounting details................................................................................................
Main parts............................................................................................................
Electrical connections......................................................................................
I/O terminals........................................................................................................
Power connections............................................................................................
RS485 – output signals....................................................................................
RS485 – line connections...............................................................................
Commisioning.........................................................................................
First power on....................................................................................................
Breathe software...............................................................................................
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
6
7
17
17
18
20
21
21
22
23
24
26
27
29
29
1.3 7
1.4 7
8
9
10
10
12
13
14
15
18
8.6
8.7
8.8
9
9.1
9.2
30
30
30
CONTENTS Air XD_User manual_P5628.1600_Rev D

11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.13
11.14
11.15
11.16
11.17
11.9
11.10
11.11
11.12
11.18
11.19
31
31
32
34
35
35
35
10
10.1
10.2
10.3
Controls and indicators.............................................................................
Navigation...............................................................................................................
Main function keys................................................................................................
Shortcut navigation...............................................................................................
General operation.......................................................................................
User interface display...........................................................................................
PM value display map...........................................................................................
Top cap closed........................................................................................................
Settings structure...................................................................................................
Passcode protection.............................................................................................
Change passcode..................................................................................................
“Enable”/“Disable” passcode protection.........................................................
PM settings...............................................................................................................
Setting custom PM values....................................................................................
PM density................................................................................................................
Averaging settings.................................................................................................
Alarm settings..........................................................................................................
Channel select.........................................................................................................
Threshold channel..................................................................................................
Set alarm threshold................................................................................................
Alarm latching..........................................................................................................
“Enable”/“Disable”..................................................................................................
4 - 20 mA outputs...................................................................................................
Select PM channel..................................................................................................
Map 4 - 20 mA.........................................................................................................
Set maximum PM value.........................................................................................
“Enable”/“Disable”..................................................................................................
Status.........................................................................................................................
Communications.....................................................................................................
Ethernet communications.....................................................................................
36
37
38
39
39
39
40
41
41
41
42
43
43
43
44
44
45
11.20
11.21
11.22
45
45
46
11.23
11.24
11.25
46
46
46
Air XD_User manual_P5628.1600_Rev D

54
55
55
11.28
11.29
11.30
11.31
11.32
11.33
11.34
11.35
11.36
11.37
11.38
11.39
11.40
11.41
11.42
11.43
11.44
11.45
11.46
11.47
11.48
11.26
11.27
Network status.........................................................................................................
IP settings..................................................................................................................
Ethernet operating mode......................................................................................
Ethernet connection status...................................................................................
RS485 MODBUS communications.....................................................................
Set baud rate............................................................................................................
Set device address.................................................................................................
Set communications parity....................................................................................
Display........................................................................................................................
Adjusting display contrast.....................................................................................
Set display backlight..............................................................................................
Set display colour....................................................................................................
Set display sleep.....................................................................................................
Date and time...........................................................................................................
Set date......................................................................................................................
Set time......................................................................................................................
System........................................................................................................................
System information.................................................................................................
Restart controller......................................................................................................
Data download.........................................................................................................
Memory module.......................................................................................................
Firmware update......................................................................................................
Relay override...........................................................................................................
Watchdog...................................................................................................................
Instrument configuration............................................................................
Default settings.......................................................................................................
On-site configuration.............................................................................................
MODBUS addresses..............................................................................................
Reading floating point registers..........................................................................
Coil register...............................................................................................................
47
47
47
48
48
48
49
49
49
49
50
50
50
51
51
51
51
52
52
52
53
11.49
12
12.1
12.2
12.3
12.4
12.5
56
56
56
56
58
59
Air XD_User manual_P5628.1600_Rev D

13
14
14.1
14.2
14.3
14.4
14.5
15
15.1
15.2
16
61
62
64
64
64
65
65
67
67
67
67
67
68
68
69
71
12.6
12.7
13.1
13.2
13.3
13.4
14.6
14.7
Holding register.......................................................................................................
Instrument self-test.................................................................................................
Updating firmware.......................................................................................
Units with controller v 1.2.3 or earlier and/or memory module v1.4 or
earlier..........................................................................................................................
Preparation................................................................................................................
Steps to update controller.....................................................................................
Steps to update memory module.......................................................................
Maintenance.................................................................................................
Visual checks............................................................................................................
Cleaning labels.........................................................................................................
Air entry/exit apertures...........................................................................................
Filter replacement....................................................................................................
Preventative maintenance.....................................................................................
Sensor cleaning........................................................................................................
Compliance audit check.........................................................................................
Compliance audit check – results........................................................................
Troubleshooting............................................................................................
High temperature start-up.....................................................................................
Low temperature start-up......................................................................................
Fault codes................................................................................................................
Glossary and definitions..............................................................................
Disposal.........................................................................................................
Get in touch...................................................................................................
Technical support.....................................................................................................
Feedback....................................................................................................................
Disclaimer.......................................................................................................
Trademark......................................................................................................
14.8
73
7373
73
73
75
76
77
77
77
78
78
15.3
17
18
18.1
18.2
Air XD_User manual_P5628.1600_Rev D

AIR XD USER MANUAL
1. GENERAL DESCRIPTION
The Trolex Air XD particulate monitor is designed to provide detailed, accurate, real-time data
on airborne particulates so that users can take appropriate actions to stay safe and ensure
personnel are fully protected from particulate-related health hazards. The Air XD allows users
to simultaneously monitor multiple Particulate Matter (PM) sizes (PM1.0, PM2.5, PM4.25, PM10,
as well as custom) and can report on Total Suspended Particulates (TSP). Precise data is
collected for measurable particulates, enabling detailed size profiling and analysis using the
application software.
The Air XD uses an innovative optical particle counter (OPC) that combines adaptive particle
flowrate with advanced sensing technology to ensure a high level of measurement accuracy.
The size of each particle is instantaneously measured and classified at up to 10,000 samples a
second to allow detailed real-time reporting in high dust environments.
As the Air XD records data on all particulates between 0.35 μm and 40 μm, users can
easily access and view detailed information about a wide range of PM sizes. Measurement
information can be viewed via the instrument display or as a live or historical readings using
the application software.
1.1 Main features
• Real-time, continuous measurement of atmospheric dust concentration
• High-reliability, low-maintenance for high dust environments
• High capacity OPC
• Industry standard sizing PM1.0, PM2.5, PM.4.25 and PM10
TX8005 Air XD Real-Time Dust Monitor
6
Air XD_User manual_P5628.1600_Rev D

7
Using current advancements in light-scattering techniques combined with patented data
processing algorithms, the Air XD is able to achieve levels of accuracy (± 5%) normally
only found in high-end laboratory instruments.
1.2 Performance data
• Low-end resolution measuring down to 0.35 µm with 99.9% capture
• Ability to display TSP measurement reading
• Quantification of particle size categories to customer requirements (custom sizing)
• Operational stability in varying environment and atmospheric conditions
• On-device display readout
• Choice of display modes: ‘Live’ readout or configurable ‘Averages’
• Two configurable relay output contacts for remote alarms and control functions
• Two 4 - 20 mA analogue output signals of measured averages
• Remote RS485 MODBUS RTU Serial I/O interface
• Ethernet MODBUS TCP/IP output
• High visibility warning indicators
• ‘Plug and play’ installation
The Air XD is a particulate monitor designed for use in range of applications and environments.
The instrument is suitable for monitoring in either indoor or outdoor ambient air conditions and can
cope with both high and low particulate concentration levels (up to 1,500 mg/m³). The instrument is
designed to be low maintenance and does not use pumps or filters. The sensing element has an
adaptive flowrate to increase accuracy in environments with varying airflow.
1.3 Intended use
To ensure the optimum performance and safe operation, the Air XD must be operated as per the
limits detailed in the technical data section of this user manual. Operation outside these limits may
result in damage to the equipment or failure to achieve the performance specification.
Continual operation of the Air XD 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 in a failure to follow the procedures and safety instructions
provided in this user manual.
1.4 Limits of use
Air XD_User manual_P5628.1600_Rev D

8 AIR XD 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.
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 XD_User manual_P5628.1600_Rev D

9
It is possible that the Air XD 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/detoxification should be employed before entry is
made into the installation or maintenance environment.
Note: This product variant is not designed for use with flammable or explosive dust in combustible
concentrations. In the event of potential combustible concentrations becoming present in a non-
hazardous location, this variant of the Air XD must be powered down.
It is the responsibility of the installer to risk asses the suitability of the instrument for installation and
use in the intended application.
3. DANGER FROM PROCESS Air XD_User manual_P5628.1600_Rev D

10 AIR XD USER MANUAL
“Always observe the safety precautions detailed in this user manual. Personnel installing and
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 instrument, indicating a
hazard at or near the location of the warning label.
Installation in working environments can be challenging and correct setup 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 XD for the first time.
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.
Refer to the ‘Certification and Conformity’ section of this user manual and to the relevant
certificates for any installation parameters and special conditions of safe use.
Observe the national safety regulations issued, for example, by the employers’ liability insurance
association, social security institutions, occupational safety and health authorities or other safety
organisations.
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.
The Air XD complies with:
• IEC 60825-1 2014
• 21 CFR-1040.10 and 1040.11
Air XD_User manual_P5628.1600_Rev D

11
Sensor housing
WARNING – There are no user-serviceable parts inside the
Air XD sensor housing. Servicing should only be carried out by
Trolex or an approved service technician.
Air XD_User manual_P5628.1600_Rev D

12 AIR XD USER MANUAL
The Air XD 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 power supplies and data outputs.
The Air XD instrument and supporting Trolex Breathe software is specifically designed to work
in conjunction with each other using proprietary protocols and design features. The system also
supports 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 XD_User manual_P5628.1600_Rev D

13
5.1 TX8005 Air XD Real-Time Dust Monitor
The Air XD Real-Time Dust Monitor uses an OPC 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 coated steel enclosure.
Information and settings can be accessed using the keypad and display located on the front of the
instrument.
The Air XD can be configured to report on PM size concentrations or TSP based on user
requirement, with the option of two configurable setpoint relay outputs. Detailed information can be
transmitted via an RS485 or ethernet connection to a computer running the Trolex Breathe software
or downloaded directly from the internal memory module using a USB storage device.
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 XD can be wall or stand mounted via mounting brackets.
Particle inlet
Door lock Navigation buttons
LCD
Status
Mounting brackets M20 cable
entry glands
USB interface
Air XD_User manual_P5628.1600_Rev D

14 AIR XD USER MANUAL
The Air XD 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 increased 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 XD conforms to IPX6.
The Air XD can detect whether the flow path is ‘open’ or ‘closed’ and will record top cap positions
to aid with instrument maintenance schedules.
5.2 Particle flow path
Note: Rotate the top cap to move between ‘open’ and ‘closed’ positions.
‘Open’ flow path. ‘Closed’ flow path.
Air XD_User manual_P5628.1600_Rev D

15
‘Open’ flow path. ‘Closed’ flow path.
The Air XD can be ordered and configured to allow connection to a standard 100 to 240 V ac
power supply or a 9 to 36 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
Windows PC or server
A Windows PC or server is required to run the Trolex Breathe software (required to collect and
process data from the Air XD instrument).
It is recommended that client computers meet or exceed the following system requirements,
before installing the Trolex Breathe software. This applies to both dedicated hardware and virtual
machines. Other configurations may work but cannot be guaranteed.
CPU Intel® Core™ i5-6300U CPU @ 2.4 GHz
RAM 8 GB (minimum)
Disc space* 20 GB (recommended)
Communications DB9 serial port, USB serial port, and ethernet port
Operating system Windows 10
*This is dependent on the data capture.
Air XD_User manual_P5628.1600_Rev D

16 AIR XD USER MANUAL
Trolex Breathe software
Data transmitted to a PC or server is collected, stored, and processed using the supporting Trolex
Breathe software. The instrument communicates with the Breathe software using MODBUS RTU
(RS485).
Information collected by the Air XD device can also be locally downloaded, via USB, and imported
into the software for data analysis and interrogation.
Breathe application software can be used to monitor in real time or review historical data. It allows
user to monitor instrument information, graph live data sets and monitor alarms.
Note: Operating instructions for the application software are provided in a separate user manual.
Air XD_User manual_P5628.1600_Rev D

17
Electromagnetic Compatibility (EMC) Directive
2014/30/EU
Low Voltage Directive (LVD) 2014/35/EU
• EN 61326-1:2013
• EN 61000-6:2:2019
• EN 61000-6-3:2007+A1:2011
Low Voltage Directive (LVD) 2014/35/EU
• EN 61010-1:2010
6.1 Compliance
The Air XD complies with the following European Union directives:
Restriction of Hazardous Substances (RoHS)
Directive 2011/65/EU
6. CERTIFICATION AND CONFORMITY Air XD_User manual_P5628.1600_Rev D

18 AIR XD USER MANUAL
7. TECHNICAL INFORMATION
7.1 Product specification
PM size range PM1.0, PM2.5, PM4.25, PM10 TSP
TSP range Up to 40 µm displayed in mg/m³ or µg/m³
Extended range TSP indicative up to 150 µg displayed in mg/m³ or µg/m³
PM measurement range 0.35 to 40 µm over 24 bins
PM measurement capability* Up to 1,500 mg/m³
PM continuous operating
range**
Up to 25 mg/m³
PM density 0.8 g/ml - 8.0 g/ml (default: 1.65 g/ml)
PM measurement units mg/m³ or µg/m³
Averaging period 1 second to 24 hours
Averaging channels ~1.5 L/m (nominal)
Sampling interval ± 25%
Particle count Up to 10,000 (particle/second)
Flow rate Dynamic (1.2 L.min nominal)
Total flow rate 5.5 L/min (typical)
Accuracy ± 5%
*The instrument can define particulate measurement peak trends up to the quantity specified.
**During sustained high dust loading periods, the instrument will report on PM data up to the quantity
specified.
Note: Sustained exposure to PM quantities above 25 mg/m³ will be logged; however, this may aect
the operating life of the OPC.
.
Particulate sensing parameters
Air XD_User manual_P5628.1600_Rev D

19
Technical specification
Air XD_User manual_P5628.1600_Rev D
Ambient temperature limits -10 to 45 °C
Humidy 0 to 95% RH (non-condensing)
Protection classification Main enclosure, dust and waterproof: IP66
Particulate flow path (cap open): IP22
Particulate flow path (cap closed): IPX6
Housing material Polymer coated stainless steel
Net weight 8.2 kg
Cable entries 5 x M20 with removable blanks
1 x M20 breather gland (where specified)
1 x M20 USB connector (where specified)
Power 100 V to 240 V ac 50/60 Hz
9 to 36 V dc
Supply current 100 mA nominal ac variant
660 mA nominal dc variant
Power consumption 6 W
Inrush current 350 mA peak
Relay outputs Two configurable (alarm outputs)
Dry contact
Maximum rating 36 V ac/dc 300 mA (internal overcurrent and
overvoltage protection fitted
4 - 20 mA outputs Two configurable (real time or average readings)
R1 and R2 with adjustable setpoints
Maximum attached load: 280 Ω
Communications RS485 data output with MODBUS RTU protocol
Ethernet (MODBUS TCP/IP optional)
Data download External USB interface
Instrument data storage 8 GB > 10 years (log rate dependent)
Stored device data can be cleared as required
User interface 128 x 64 dot matrix display with RGB backlight
Visual alarms Display RGB backlight
Indicators 1 x green high brightness LED – sensor heartbeat
1 x blue high brightness LED – communications

AIR XD USER MANUAL20
7.2 Product dimensions
Note: Recommended 100 mm inlet clearance.
.
156 mm
305 mm
305 mm
Air XD_User manual_P5628.1600_Rev D