ExTox ET-8D-230 User manual

Instruction Manual
ExTox Integral Measuring Concepts
IMC-8 and IMC-4

Instruction Manual
ExTox IMC-8/-4
Page 2 of 22 BA_IMC-8_-4_e_2019-12-17.docx
Foreword
We thank you very much for your confidence in our products and us, the ExTox Gasmess-Sys-
teme GmbH.
The Integral Measuring Concepts of the IMC Series as well as all other ExTox-Products and ser-
vices stand for our high quality targets. Our business is the health protection of mankind, pro-
tection of the environment and installations. We are glad to take this responsibility. Our Quality
Management System therefore follows ISO 9001 and our Production Monitoring is to keep the
European Directives 2014/34/EU ("ATEX"). You profit of the high reliability due to modern sensor
techniques and consequent interpretation acc. to the requirements of the regulations and stand-
ards valid for industrial application.
The Integral Measuring Concepts serve for monitoring gas concentrations in sealed off processes
or not accessible areas. The IMC Series combines all necessary components in one compact wall
mounted housing – from sampling and preparation of measured gas, sensor technique and eval-
uation. The modular construction leads to a high adaptation to the different applications, such as
for example land fill gas measurement or bio gas facilities.
Reliable and permanent application as well as easy maintenance has been important develop-
ment targets.
The IMC Series can be equipped with all ExTox-Transmitters ExSens(-I) and Sens(-I).
Please do not hesitate to contact anytime in case of questions or if you require information:
ExTox Gasmess-Systeme GmbH
Max-Planck-Straße 15 a
59423 Unna
Germany
Telefon: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.ExTox.de
BA_IMC-8_-4_e_2019-12-17.docx, Rev.: 17.12.2019
(Subject to technical changes)

Instruction Manual
ExTox IMC-8/-4
BA_IMC-8_-4_e_2019-12-17.docx Page 3 of 22
Content
1Introduction 4
2Features of the Integral Measuring Concepts (IMC) 5
3Indications and Facilities 7
4Configuration 7
5Description 8
5.1Type IMC 8
5.1.1Functions 8
5.1.2Parameter Settings 8
5.1.3Pre-configured Relays and Digital Inputs 9
5.1.4Calibration and Adjustment 9
5.2Type Biogas 10
5.2.1Functions 10
5.2.2Parameter Settings 10
5.2.3Pre-configured Relays and Digital Inputs 11
5.2.4Calibration and Adjustment 12
5.2.5Switching between Measuring Points (Option) 13
5.3Type KAT 15
5.3.1Functions 15
5.3.2Calibration and Adjustment 16
5.4Type M 17
5.4.1Description 17
5.4.2Replacement of a Transmitter Module 17
6Operation of the IMC 18
6.1Flow rate monitoring 18
6.1.1Types with DDL-Module 3.0 (Art. 940285) and 2.0 (Art. 940178) 18
6.1.2Types with Flow-Meter (Art. 940025) 18
6.2Housing Fans 19
6.3Condensate Trap incl. Hose Pump 19
6.4Measured Gas Cooler incl. Automatic Removal of Condensate 19
6.5Flame Arrestor 19
6.6Enclosures Heating with Thermostat Control 19
6.7Data Logger, Data Interfaces, Customer Specific Modifcations 19
7Application Hints 20
8Installation 20
8.1Mechanical Installation 20
8.2Connection to the Process 21
8.3Electrical Installation 21
9Maintenance of Gas Detection Systems 22
10Spares, Expendables, Options 22
11Technical Data, EC-Declaration of Conformity 22

Instruction Manual
ExTox IMC-8/-4
Page 4 of 22 BA_IMC-8_-4_e_2019-12-17.docx
1 Introduction
This Instruction Manual generally describes operation, installation and maintenance of the fol-
lowing ExTox-Products:
Continuous Measurement Article1
IMC-8D (k)2420106
IMC-8DA (k) 420107
IMC-4D (k)/(m)/(g) 420108 (k), 420114 (m), 420119 (g)
IMC-4DA (k)/(m)/(g) 420109 (k), 420115 (m), 420120 (g)
Biogas-Application Article
IMC-8D-Biogas2 (m)/(g) 430106 (m), 430114 (g)
IMC-8DA-Biogas2 (m)/(g) 430107 (m), 430115 (g)
IMC-4D-Biogas2 (k)/(m)/(g) 430108 (k), 430120 (m), 430122 (g)
IMC-4DA-Biogas2 (k)/(m)/(g) 430109 (k), 430121 (m), 430123 (g)
With exchangeable transmitter module:
IMC-4M-Biogas2 (m) 430116
IMC-4MA-Biogas2 (m) 430117
Biogas-KAT-Application Article
IMC-8D-KAT (m)/(g) 430124 (m), 430112 (g)
IMC-8DA-KAT (m)/(g) 430125 (m), 430113 (g)
IMC-4D-KAT (m)/(g) 430110 (m), 430126 (g)
IMC-4DA-KAT (m)/(g) 430111 (m), 430127 (g)
With exchangeable transmitter module:
IMC-4M-KAT (m) 430118
IMC-4MA-KAT (m) 430119
All herein described installations or options may not consequently form part of your type of In-
tegral Measuring Concept IMC. Type specific data of your IMC should be taken from the customer
specific set of drawings, which includes "Gas flow", "Connection Scheme", "Terminal Assignment"
and "Mounting plate". The set of drawings forms part of the written documentation and is on
delivery attached.
Type specific data for each device should be taken from a corresponding separate and specific
Data Sheet. This Data Sheet forms consequently part of this Instruction Manual. References on
the Data Sheet within this text are marked with DB.
IMC types use control units of the Series ET-8D and ET-4D2. Configuration, operation and
maintenance are described in the enclosed Instruction Manual of the Series ET-8D and ET-4D2.
You will find details regarding every transmitter being installed in your IMC in the separate doc-
umentation which has also been prepared individually for your IMC.
Please read this Instruction Manual carefully before installation and initial operation. We kindly
ask you to pay attention to all details and cross-references.
We kindly ask you not to repair the IMC or to perform any changes which go beyond the measures
described herein. Otherwise you endanger your own safety and your warranty claims of mer-
1 All mentioned article numbers are valid for standard IMC. Due to reasons concerning production we do often use special
article numbers 700xxx. The corresponding standard article can be taken from the name of the article or the attached
test certificate.
2(k), (m), (g): to differ between types with small (k), medium (m) or bigger (g) housing (DB). The housing types vary
regarding number of transmitters to be integrated and selectable options, i.e. measured gas cooler.

Instruction Manual
ExTox IMC-8/-4
BA_IMC-8_-4_e_2019-12-17.docx Page 5 of 22
chantability. In such cases please contact ExTox or authorised ExTox Service Partner. Third par-
ties take the responsibility for correct performance of work when maintenance and repairs are
done by them.
On receipt of goods please take care that packing and consignment are not damaged and the
goods supplied correspond to the articles described in the delivery note. Please do also compare
with your order. In case of any damage please inform your forwarding agent and your supplier.
Please keep the damaged packing.
Please keep in mind that our IMCs are sensitive measuring devices and take special care when
unpacking and installing them.
2 Features of the Integral Measuring Concepts (IMC)
We are often faced with the task to monitor gas concentrations even in sealed off processes or
not accessible areas. Typical applications are for example monitoring of silos and tanks, meas-
urement on dumpsites or biogas plants. Due to the adverse operation conditions direct measure-
ment within these processes is often impossible. Instead of that sampling from process gas and
external measurement are necessary.
With the Integral Measuring Concepts of the Series IMC ExTox offers efficient solutions even for
these measuring tasks. This Series combines all necessary components from sampling of meas-
ured gas, preparation, sensor techniques and evaluation in one compact wall mounting housing.
The IMC includes the control unit ET-8D or ET-4D2 which takes over evaluation of measured
signals and triggering of switching commands. Software expansions in the control unit integrate
controlling and monitoring of the components for sampling and preparation of measured gas.
The measuring channels which are not used for analysis can easily be taken for external trans-
mitters, for continuous monitoring of ambient air for example.
The modular construction and the use of the approved ExTox-Transmitters and control units
assure a cost effective acquirement and maintenance. ExTox is glad to offer customer specific
types on demand.
The IMC Series can be equipped with all ExTox-Transmitters ExSens(-I) and Sens(-I) in principle.
In some cases the applicability in a sampling system may be limited due to physical and chemical
properties of the measuring gas. ExTox will provide advice in such cases.
The control units in combination with ExTox-Transmitters comply with EN 60079-29-1 and
EN 45544 for Gas Detection Systems. Furthermore they are in conformity with the European
Directives 2014/34/EU (ATEX), 2014/30/EU (EMC) and 2014/35/EU (LVD).
IMC for continuous measurement
 compact wall mounted housing in maintenance friendly construction
 up to 8 or 4 transmitters (Indications for the different types: DB)
 allocation of transmitter inputs to analysis including sampling and preparation of measured
gas as well as monitoring of ambient air freely selectable
 evaluation and indication of measured values and status messages as well as control of
sampling and preparation of measured gas by control units of the series ET-8D or ET-4D2
 gas suction pump (distance of suction ≥50 m length of hose)
 pressure at sampling point: -100 to +100 hPa (in comparison with environment)
 electronic flow rate monitoring
 condensate trap with automatic manual removal of condensate by means of a hose pump
 hosing: PE/PP
 magnetic valve to change from measured gas to test gas
 2 housing fans, rotary speed monitored
 4..20 mA-outputs (only Types IMC-xDA)

Instruction Manual
ExTox IMC-8/-4
Page 6 of 22 BA_IMC-8_-4_e_2019-12-17.docx
Extension for Type "Biogas2"
 software extension Biogas: discontinuous measurement in batch mode with configurable in-
tervals for measuring / flushing / air; indication of the latest measured value during flushing
and air phases; control of overload protection for H2S-Measurement
 magnetic valves to change from measured gas to flushing air and to control the batch meas-
urement
 pressure compensation
 Flame arrestor (Measured gas inlet)
Extension for Type "KAT"
 Extension for type "Biogas"
 Biogas-Application with integrated monitoring of activated carbon filters by means of switch-
ing between measuring ranges for H2S-Measurement. Assignment of the H2S-Measuring
range configurable to the corresponding measuring point
 Switching between the measuring ranges minimum 2-times (before / after activated carbon
filter
Extension for Type "M(odule)"
 Extension for Type "Biogas" or "KAT"
 Exchangeable Transmitter Module
 all transmitter for CH4, H2S and O2 integrated
 Easily exchangeable (complete module)
 preadjusted ("Plug and Play")
Options
 Monitoring of Ambient Air:
A continuous monitoring of ambient air, such as for example for Methane (CH4) and Hydrogen
Sulphide (H2S), can also be realised via external ExTox-Transmitters.
 Switching between Measuring Points:
Determination of gas composition at different measuring points temporally one after another.
Supplementation of switching between measuring points forms a cost saving alternative to
using several IMC. One single IMC performs the analysis one after another for the different
measuring points. Switching can be done cyclically or externally controlled. The IMC-4D can
cover up to four, the IMC-8D even up to six measuring points (special types: twelve).
 Flame Arrestor IIG IIB3 (Standard) or IIG IIC:
When sampling in hazardous areas the gas flow inside the IMC is decoupled of the monitored
process as far as the danger of explosion is concerned. The flame arrestor is connected pre-
vious to the measured gas inlet. When returning the measured gas into the process (Hint:
Not recommended by ExTox) another flame arrestor at the measured gas outlet is necessary.
 (Compact-) Measured gas cooler incl. Automatic Removal of Condensate:
 Gas dehumidification by means of a Peltier cooler with monitoring of Tmax or ∆T. Heating
for Enclosure with thermostat control +5 to +30 °C:
Necessary for very low temperatures at the place of application. Formation of condensate
inside the housing is avoided when installing the IMC outside.
 Preparation for Installation outside:
Rain protection covers for housing fans, internal control unit and heating for enclosure. A
rain protection roof can be offered as option. Hint: Installation inside of premises is recom-
mended. In spite of the choosen measures the measurement performance and life time will
be degraded always, when an IMC is installed outside. For installation outside a protection

Instruction Manual
ExTox IMC-8/-4
BA_IMC-8_-4_e_2019-12-17.docx Page 7 of 22
against strong influences from the environment, e. g. driving rain or direct solar radiation,
shall be provided always.
 ProfiBus-, ProfiNet-, ModBus- and Ethernet-Connection:
Measured values and messages can be transfered to a superior PLT-System via Interface.
Further interfaces on demand.
 Data Logger:
Measured values and messages are stored on a SD memory card. All data can be read out
and processed on every standard PC later on.
 Customer specific modifications – Ask us!
Different biogas concepts also require different monitoring concepts. The modular design of
our IMC-Systems allows us to respond to your special wishes and requirements.
3 Indications and Facilities
The control unit covering the indication of measured values, alarms and messages as well as
keys is installed in the door of the wall mounted housing.
For description of the indications and facilities please see the Instruction Manual of the control
unit.
In the survey on measured values of ET-4D2 and ET-8D the volume stream of measured gas
(Measured value, see 6.1.1, or Status, see 6.1.2) and state of housing fans are indicated instead
of date and time on IMC. The active measuring point is also indicated on IMC with switching
between measuring points.
4 Configuration
For description of configuration possibilities please see the Instruction Manual of the control unit.
The menu system parameter serves for factory sided activation of operating modes “IMC” or for
the biogas and KAT types “BIO” instead of “ET-8” or “ET-4”.
Attention: Changing of these settings should in no way be done by the user. Changed measuring
functions may otherwise lead to loss of safety functions.
Software extensions and pre-settings of inputs and outputs depend on the different operation
modes.

Instruction Manual
ExTox IMC-8/-4
Page 8 of 22 BA_IMC-8_-4_e_2019-12-17.docx
5 Description
The following indications are valid for the standard types mentioned in Clause 1.For special types,
generally with Article Number 7xxxxx, further amendments can be necessary. Please take ac-
count of the hints in your customer specific documentation.
Documentation supplied with each IMC contains individually generated indications of the gas
flow, connection scheme, terminal assignment and construction of mounting plate. These are
also attached to the system and are located inside the housing.
5.1 Type IMC
5.1.1 Functions
▪ Course of Measurement
Measurement is done continuously even on the transmitters built in the IMC. The included chan-
nels are activated in the menu Channel Configuration by setting the Mode ON.
▪ Monitoring of Ambient Air
Channels not to be used for the IMC measurement can be used for continuous monitoring of
ambient air. Behavior of these channels corresponds to the normal measuring operation of the
gas detection control unit. The channels included in monitoring of ambient air are activated in
the menu Channel Configuration by setting the Mode ON.
▪ Status Monitoring
The following status monitoring functions are integrated in this type:
 Rotary speed monitoring of both housing fans
 Flow rate monitoring: message for under-scale / over-scale of the nominal range
 Monitoring Tmax or ∆T of the measured gas cooler (on request)
In the first two cases a message leads to system fault of the control unit.
As long as the measured gas cooler does not reach its operating temperature, for example during
the warm-up phase after initial operation, the gas suction pump remains switched off.
▪ Functional Extensions
For maintenance purposes the gas inlet of the IMC can be switched to the inlet test gas / flushing
air by means of the magnetic valve. For that purpose you have to select the menu Maintenance.
By means of the keys SHIFT + F4 it can be switched between both gas inlets.
5.1.2 Parameter Settings
▪ System Parameter
In the menu System Parameter the operation mode „IMC“ instead of "ET-8" and "ET-4" is factory-
sided activated.
Attention: Changing of these settings should in no way be done by the user. Changed measuring
functions may otherwise lead to loss of safety functions.
The menu point OPTIONS comprises now also the possibilities of setting for flow rate monitoring
(see 6.1.2) and change-over of measuring points.

Instruction Manual
ExTox IMC-8/-4
BA_IMC-8_-4_e_2019-12-17.docx Page 9 of 22
Access level to perform changes within this menu: 3
Menu Text Selection Function
FLOW-MIN 0 to 300 l/h Only activated in Systems with DDL-Module (see 6.1.1)
Lower limit of flow rate monitoring in l/h. Under-scale leads
to system fault
Unterer Grenzwert für die Durchflussüberwachung in l/h. Bei
Unterschreiten wird eine Gerätestörung ausgelöst.
(Standard setting: 15 l/h)
FLOW-MAX 0 to 300 l/h Only activated in Systems with DDL-Module (see 6.1.1)
Upper limit for flow rate monitoring in l/h. Over-scale leads
to system fault.
(Standard setting: 60 l/h)
▪ Channel Configuration
The IMC channels are activated in the same manner as channels for external transmitters in the
menu Channel Configuration by setting the Mode ON.
5.1.3 Pre-configured Relays and Digital Inputs
The following relays cannot be configured freely.
IMC-8D (IMC-4D) Application
Relay K21 (K9) Internally allocated
Relay K22 (K10) Internally allocated
Relay K23 (K11) Control of measured gas pump
Relay K24 (K12) Control of magnetic valve (MV1) for switching between measured gas
and test gas
Digital input E2 Status signal flow rate (only allocated in systems with Flow-Meter, see
6.1.2)
Digital input E3 Status signal housing fans (only allocated in systems with Flow-Meter,
see 6.1.2)
Digital input E4 External activation of maintenance mode is not provided
5.1.4 Calibration and Adjustment
Calibration and adjustment is done by application of test gases at the inlet of test gas. From the
inlet of measured gas the gas inlet can be changed-over to the inlet test gas/flushing air via
magnetic valve. For that purpose you have to select the menu maintenance. You can switch
between both gas inlets by pressing the keys SHIFT + F4.
Application of test gas should be done pressure less. It has always to be ensured that an adequate
test gas volume stream is provided, that means an application of test gas has to be set which
corresponds to the one in measuring operation3. This is to avoid that air is additionally sucked in
and dilution of the test gas resulting from this falsifies calibration / adjustment.
When adjusting please follow the hints in the Instruction Manuals of transmitter and control unit.
3Depending on type the necessary test gas volume stream may be considerably above the indicated volume stream.

Instruction Manual
ExTox IMC-8/-4
Page 10 of 22 BA_IMC-8_-4_e_2019-12-17.docx
5.2 Type Biogas
5.2.1 Functions
▪ Course of Biogas-Measurement
During operation mode "BIO" discontinuous measurement takes place. All channels for biogas
measurement are selected in the menu Channel Configuration by setting the mode TIMER. Three
phases are run through cyclically:
1. Air: the gas flow is flushed with air that means the magnetic valve has switched to the inlet
test gas / flushing air.
2. Flushing: the system switches to the measured gas inlet. The gas concentration is not meas-
ured during this time. This phase is needed to transport the sampled gas from the process to
the IMC using the gas flow. The gas suction pump is switched off two minutes before end and
the gas flow is closed. Measurement in batch mode is prepared.
3. Measuring: the system measures the actual values when changing over to phase measure-
ment. During this phase the gas suction pump remains switched off.
You can manually interfere in this process. Measurement can be started by pressing simultane-
ously the keys F8+F3 (IMC-8D) or F6+F3 (IMC-4D). The IMC-Biogas first changes to the phase
flushing and starts the measurement later on.
For measuring points in TIMER Mode all measured values, alarms and outputs remain frozen on
the latest value of the previous measuring phase during the phases “air” and “flushing”. Latching
alarms can only be reset during measuring phase. Attention: This means that reset will be pos-
sible in the next phase. If necessary measurement can be started manually (see above) to reduce
the waiting time on longer cycle times.
The times for the individual phases can be adjusted in the menu Timer which can be reached via
the menu System Parameter and selection of the menu setting Mode BIO.
▪ Monitoring of ambient air
Channels which are not needed for the IMC measurement can easily be used for a continuous
monitoring of ambient air. Performance of these channels corresponds to the normal measuring
operation of the control unit. Channels for monitoring of ambient air are also activated in the
menu Channel Configuration by setting the Mode ON.
▪ Status Monitoring
The following status monitoring functions are integrated in this type:
 Rotary speed monitoring of both housing fans
 Flow rate monitoring: message for over- and under-scale of nominal range
 Monitoring Tmax or ∆T of the measured gas cooler (on request)
In the first two cases a message leads to system fault of the control unit.
As long as the measured gas cooler does not reach its operating temperature, for example during
the warm-up phase after initial operation, the gas suction pump remains switched off.
5.2.2 Parameter Settings
▪ System Parameter
In the menu System Parameter the operation mode „BIO“ instead of „ET-8“ and „ET-4“ is factory-
sided activated.
Attention: Changing of these settings should in no way be done by the user. Changed measuring
functions may otherwise lead to loss of safety functions.
In the submenu BIO the following changes can be performed.