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)

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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.

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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)

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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

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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.

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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.

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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.

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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.

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Access Level to perform changes within the Menu Timer: 3
Menu Text Selection Function
T1 to 1439 Duration of the phase Air in minutes
T2 to 1439 Duration of the phase Flushing in minutes
T3 to 1439 Duration of the phase Measuring in minutes
Flow ON, OFF For IMC-Biogas2 the setting has to be OFF.
Attention: Changing of these settings should in no way be
done by the user. Changed measuring functions may other-
wise lead to loss of safety functions.
Measured
gas
- right co-
lumn -
Concentration Concentrations of test gases for the measuring channels of
the Biogas-Measurement have to be indicated. Only the
TIMER controlled channels are processed. On the left side
the measured gas and on the right side the corresponding
concentration is indicated.
The menu point OPTIONS now comprises the possibilities of setting for flow rate monitoring (see
6.1).
Access Level to perform changes in the 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.
(Standard setting: 15 l/h)
FLOW-MAX 0 to 300 l/h Only activated on 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)
MAX-CHAN-
NEL
1…4 (IMC-4D)
and
1…6 (IMC-8D)
Number of measuring points (only for Option switching be-
tween measuring points, see 5.2.5)
▪ Channel Configuration
Besides the Mode settings ON and OFF the setting TIMER is accessible in Biogas Mode. All meas-
uring points with this setting are integrated in the discontinuous course of biogas measurement.
Attention: Please note that oxygen measurement – if available – always has to be on Channel 2
due to system internal reasons.
5.2.3 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) Control of magnetic valve (MV2) for closing the gas flow during batch
measurement
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)

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IMC-8D (IMC-4D) Application
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
5.2.4 Calibration and Adjustment
Calibration and adjustment of the biogas-types is only done via automatic control.
▪ Preparation
You have to enter the concentrations of the used calibration gases in the menu "System Param-
eter/Mode/Bio/Timer". On the right side of the display you could enter the concentrations for
CH4, O2, CO2and H2S. These values are necessary for automatic calibration. You will normally
find this information on the test gas bottle. In case the test gases are filled in different pressure
gas bottles, you have to follow the instructions following below for all used test gases. For cali-
bration of the O2-Measuring Channel you have to apply a test gas which does not contain any
oxygen.
▪ Course
You have to select the menu point "Calibration" 'in the menu "Setup". For that purpose you have
to activate minimum Access Level 2 before. The calibration menu appears and the internal mag-
netic valve switches to flushing air. In case the system should not be calibrated you could leave
the menu via "Esc". By means of "Start" the automatic calibration is started. The analogue out-
puts keep the measured values of the last measurement.
Calibration is done in five phases:
Phase Indication on Display
ET-8D-(ET-4D2-) Course
1 RINSING AIR
(RINS AIR)
The system is flushed with air for three minutes
2 READING ZERO
(READ ZERO)
The gas suction pump is switched off. The system waits one
minute until stabilisation of measured values. Then the
measured values are stored (zero point values for CH4, CO2,
H2S or 20.9 Vol.-% for O2).
3 RINSING GAS
(RINS GAS)
The gas suction pump is switched on again and the system
is flushed with connected test gas for four minutes.
Attention: Only during this phase the test gas bottle has
to be connected and the test gas has to be applied to the
IMC. The test gas has to be applied pressure less. It has
always to be ensured that an adequate test gas volume
stream is provided, that means on application of test gas
has to be set which corresponds to the one in measuring
operation4. This is to avoid that air is additionally sucked in
and dilution of the test gas resulting from this falsifies cali-
bration / adjustment.
4 READING SENSITIVITY
(READ SENS)
The measured gas pump is switched off and batch meas-
urement is done within two minutes.
4Depending on type the necessary test gas volume stream may be considerably above the indicated volume stream.

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Phase Indication on Display
ET-8D-(ET-4D2-) Course
5 READY
(READY)
Calibration is completed and a plausibility check of the new
values for zero point and sensitivity takes place. Offset for
the zero point may not exceed ± 2 mA. The gain factor for
sensitivity has to be between 0.5 and 2 (see comments on
adjustment of the control units). Calibration values outside
these limits are rejected, in the calibration menu the mes-
sage "ERROR" is issued after completed calibration and the
previous settings are kept.
Attention: The message "ERROR" for channels with meas-
uring components which are not part of the test gas does
not indicate a malfunction of the measuring channel. These
measuring channels will be calibrated and adjusted later on
or have already been calibrated and adjusted on application
of other test gases.
When using several test gases please change now the bottle and start another calibration cycle
by pressing "Start".
Calibration is definitely completed with "Esc".
5.2.5 Switching between Measuring Points (Option)
This option allows use of one IMC for several measuring points. Measurement is done one after
another on specified scheme. To do this all magnetic valves which access the corresponding
measuring line for measurement inside the IMC are driven by the control unit. Via relay outputs
the control unit signalises the measuring point for which the measured values are actually indi-
cated.
Attention: The standard type is described below. As in many cases customer specific adaptations
take place you have to pay attention to system specific deviations in the documentation.
Switching between measuring points is configured in the menu SETUP>SYSTEMPARAMETER>OP-
TIONS. The drawing shows an example for a system with switching between 4 measuring points.
OPTIONS M1: ON 1 H
RS232 : 1 M2: ON 1 H
FLOW-MIN : 15 l/h M3: ON 1 H
FLOW-MAX : 300 l/h M4: ON 2 L
MAX-CH : 4
< ^ v > ESC SAVE
MAX-CHANNEL indicates the number of measuring points (here: 4).
Function of these measuring points is displayed on the right side: the first column shows the
ON/OFF-Status of the measuring point. This parameter can be set without entering a password.
By this the user has the possibility to deactivate measuring points easily in case it is needed
(maintenance on the fermenter for example). The second column indicates how often the meas-
uring point is processed (possible settings: 1, 2, 4, 8). The above mentioned example shows that
at measuring points M1, M2 and M3 it is measured in every cycle, at measuring point M4 only
every second cycle. It results M1-M2-M3-M4-M1-M2-M3-M1-M2-M3-M4…. The fourth column is
only important for type KAT (see 5.3).

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The following relays cannot be configured freely.
IMC-8D (IMC-4D) Application
Relays
K1,K2,K3,K4,K9,K11
(K1,K2,K3,K4)
Control of magnetic valves for switching between measuring points:
Relay 1 closed: Magnetic valve for measuring point 1 activated
Relay 2 closed: Magnetic valve for measuring point 2 activated
Relay 3 closed: Magnetic valve for measuring point 3 activated
Relay 4 closed: Magnetic valve for measuring point 4 activated
Relay 9 closed: Magnetic valve for measuring point 5 activated
(IMC-8)
Relay 11 closed: Magnetic valve for measuring point 6 activated
(IMC-8)
Relays
K12, K18, K19
(K6, K7, K8)
BCD-coded indication of measuring point, for which the measured
value is actually indicated as 4…20 mA-Signal:
K19 K18 K12
(K8 K7 K6)
Measuring point
0 0 0 no valid 4…20 mA-Signals
0 0 1 valid 4…20 mA-Signals Measuring point 1
0 1 0 valid 4…20 mA-Signals Measuring point 2
0 1 1 valid 4…20 mA-Signals Measuring point 3
1 0 0 valid 4…20 mA-Signals Measuring point 4
1 0 1 valid 4…20 mA-Signals Measuring point 5 (IMC-8)
1 1 0 valid 4…20 mA-Signals Measuring point 6 (IMC-8)

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5.3 Type KAT
5.3.1 Functions
Type KAT completes Type Biogas by the possibility to monitor with activated carbon filter (AKF).
This type is always coupled with switching between measuring points (see 5.2.5). The measuring
points can be configured that way that the gas composition is determined alternately before and
after the AKF. Depending on the configuration the H2S-Transmitter with corresponding measuring
range is activated automatically.
The following relays cannot be configured freely.
IMC-8D (IMC-4D) Application
Relay K21 (K9) Switching of magnetic valves for high (before AKF) and low H2S-
Measuring Range (after AKF)
closed = low measuring range (100 ppm)
open = high measuring range (1000 ppm)
The measuring range of the H2S-measuring points is configured in the menu SYSTEMPARAME-
TER>OPTIONS. The drawing shows an example for a system with switching between 4 measuring
points.
OPTIONS M1: ON 1 H
RS232 : 1 M2: ON 1 H
FLOW-MIN : 15 l/h M3: ON 1 H
FLOW-MAX : 300 l/h M4: ON 2 L
MAX-CH : 4
< ^ v > ESC SAVE
MAX-CHANNEL indicates the number of measuring points (here: 4).
Function of these measuring points is displayed on the right side: the first column shows the
ON/OFF-Status of the measuring point. This parameter can be set without entering a password.
By this the user has the possibility to deactivate measuring points easily in case it is needed
(maintenance on the fermenter for example). The second column indicates how often the meas-
uring point is processed (possible settings: 1, 2, 4, 8). The above mentioned example shows that
at measuring points M1, M2 and M3 it is measured in every cycle, at measuring point M4 only
every second cycle. It results M1-M2-M3-M4-M1-M2-M3-M1-M2-M3-M4….
In the fourth column the measuring range of the H2S-Channel can be configured:
H (High) = Measurement before AKF (Raw gas, Measuring range 1000 ppm)
L (Low) = Measurement after AKF (Measuring range ≤200 ppm)
ATTENTION:on wrong definition of measuring range (H/L) the H2S-Sensor can be damaged due
to overload.

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5.3.2 Calibration and Adjustment
Calibration shows the following specific features: In case there is no H2S-Transmitter for meas-
urement after AKF configured calibration is done as usual. Configuration of a H2S-Transmitter
with low measuring range is recognized by the software and calibration menu is automatically
extended:
CALIBRATION FLOW= 31 l/h
F1:CAL. H2S 0-3000 ppm
F2:CAL. H2S 0- 100 ppm
H2S-HI H2S-LO ESC
In case calibration is started with F1 (H2S-HI) the IMC expects a H2S-test gas concentration for
high measuring range, the gas flow is switched correspondingly. When starting with F2 (H2S-
LOW) a test gas concentration for calibration of the low H2S-measuring range is expected. To
calibrate both transmitters you have to perform the calibration process for both measuring
ranges.

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5.4 Type M
5.4.1 Description
In Type M all transmitters are combined in one exchangeable TransmitterModule. This module
can in case of maintenance easily be taken out of the IMC and replaced by a new pre-adjusted
module. All functions correspond to the IMC-Types BIOGAS and KAT.
There are three types of transmitter modules available:
IMC-Transmitter Module Article (new/replace-
ment) In combination with:
KAT-CH4, O2, H2S100, H2S3000
Standard-Measuring ranges:
0-100 % (v/v) Methane
0-25 % (v/v) Oxygen
0-100 ppm Hydrogen Sulphide
0-3000 ppm Hydrogen Sulphide
290006/
295006 IMC-4M(A)-KAT
CH4, O2,H2S3000
Standard-Measuring ranges:
0-100 % (v/v) Methane
0-25 % (v/v) Oxygen
0-3000 ppm Hydrogen Sulphide
290007/
295007 IMC-4M(A)-Biogas2
CH4, O2, H2S100
Standard-Measuring ranges:
0-100 % (v/v) Methane
0-25 % (v/v) Oxygen
0-100 ppm Hydrogen Sulphide
290008/
295008 IMC-4M(A)-Biogas2
5.4.2 Replacement of a Transmitter Module
On delivery of the IMC a new transmitter module is installed (Art. 290xxx). In case you need a
new one you will get a Replacement Transmitter Module (Art. 295xxx), on which all wear parts
have been replaced. The module has been checked completely and adjusted. It has the same
warranty as for a new module. In case you return the defective module you will get a credit note
for the defective one.
Replacement is done in few steps:
1. Release access level 3 on the control unit (see Instruction Manual).
2. Press the keys "F1+F5+F6". On the display "CHANGE MODULE" is indicated.
3. Select "Change". The latest actual measuring value is frozen and is constantly sent to the
connected periphery for the duration of the module exchange.
4. Replace Module:
a. Untighten glands at measured gas inlet and outlet and remove hoses.
b. Remove cable(s) from transmitter module.
c. Losen the four fixing screws and remove transmitter module.
d. Install new module in reverse order.
5. Selet "Ready". Measurement is started again.
6. Select "End". The IMC returns to the standard indication.
The transmitter module is pre-adjusted. After exchange it is necessary to let it run for ca. 1 to 3
hours till the final measuring accuracy is reached. During this time you should not perform any
adjustment. Afterwards the IMC with exchangeable transmitter modules can be calibrated and
adjusted as Types Biogas2 and/or KAT (see 5.2.4 or 5.3.2).

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6 Operation of the IMC
The operation of the control unit is described in the Instruction Manual of the Series ET-8D and
ET-4D2.
Furthermore the following remarks are valid for the additional functions and options.
Remark: Please note that some options or their combination is not available for all IMC-Types.
ExTox is at your disposal for planning your IMC-System.
Furthermore customer specific designed IMC-Types can dispose of deviating functions, which are
described separately in the corresponding documentation of your device.
6.1 Flow rate monitoring
The IMC are in general equipped with the System DDL-Module 3.0 (Art. 940285). Special types
can also be equipped with other types of flow rate monitoring. The installed type is specified in
the corresponding documentation of your device.
6.1.1 Types with DDL-Module 3.0 (Art. 940285) and 2.0 (Art. 940178)
Flow rate monitoring bases on measurement of pressure difference. The measurement of pres-
sure difference is built in the assembly group DDL-Module together with the monitoring of hous-
ing fans. The normal flow through is ca. 30 l/h. In case the gas flow is constraint the lower alarm
level is over-run. Leakages or loosening of a hose connection leads to the entering of leak air.
The upper alarm is triggered due to the higher volume stream.
The DDL-Module transfers the measured value serially to the control unit. It is detailed indicated
on the display ("FLOW"). In case the alarm levels are reached the indication on the display
switches between measured value and the message "ERROR" every second. In case the serial
data link between control unit and DDL-Module is interrupted for more than 15 s, the message
"COMERROR" is issued. A fault of control unit is indicated at the control unit.
Remark: in the Biogas-Types the gas suction pump is switched off during some operation phases,
so that no gas flow takes place. During these planned phases the DDL-Module does not show
any flow through, but a system fault is correctly not triggered.
The setting of the alarm levels is done at the control unit in the extended submenu OPTIONS of
the menu System Parameter.
6.1.2 Types with Flow-Meter (Art. 940025)
The flow rate monitoring is built in a common housing together with a dust filter. At the front
side there is a text display and three keys (M, +, -). In the text display the measured gas volume
stream is indicated in litre per hour (l/h) during normal measuring mode. The flow rate monitor-
ing is equipped with an upper (MAX) and lower (MIN) alarm level; the nominal range which
should be kept is in between. 5
In case the gas flow is constraint the lower alarm level is over-run. Leakages or loosening of a
hose connection leads to the entering of leak air. The upper alarm is triggered due to the higher
volume stream.
Alarm Levels
For setting the alarm levels press key M until the required alarm level is indicated. By means of
the keys + and – the alarm level can newly be set. The displayed value is immediately effective.
Adjustment
When setting the zero point there should definitely be no measured gas. Then you have to press
first key + and then additionally key M to store the zero value.
Then the volume stream is set to the nominal value 30 l/h. For storing you first have to press
Key – and then additionally Key M.
5On this type the indication of volume stream on the display of the control unit is not applied.

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Dust Filter
The dust filter is integrated in the housing of flow rate monitoring. The condition of the filter can
easily be checked in the inspection glass. This test should be done regularly in intervals which
depend on the dust load of the measured gas. For exchange of the used filter inlet the inspection
glass can be removed. When closing you have to ensure correct installation of the sealing and
the inspection glass. Please also check tightness.
6.2 Housing Fans
The housing fans are equipped with a dust protection mat which should be cleaned regularly
from dust. Therefore remove plug cover and clean mat.
The redundant ventilation of housing including monitoring of fans avoids safely the formation of
potentially explosive mixtures in case of leakages in the IMC. The state of the fans is detailed
indicated on the display of the control unit ("FAN"). In case even one of the fan fails the status
indication changes from "OK" to "FAULT" and a fault of control unit is indicated at the control
unit.
6.3 Condensate Trap incl. Hose Pump
The condensate removal is automatically done via the hose pump (standard for Biogas and KAT-
Types). Nevertheless we recommend checking the condensate trap and hose line regularly on
possible blockages. Condensate traps and hose lines should be cleaned on demand. It has to be
ensured that the measured gas flow is not interfered. For this purpose it might be necessary to
disconnect hose lines. After connecting everything again please check tightness of sample line.
Please make sure that the condensate can drain off failure free and depending on composition of
condensate even safe from the connection at the bottom of the housing.
6.4 Measured Gas Cooler incl. Automatic Removal of Condensate
Gas dehumidification is done by means of a Peltier cooler. The temperature of measured gas is
factory sided adjusted to +5 °C and monitored. During the warm-up phase a fault message is
issued until the cooler reaches operation temperature.
The measured gas cooler meets the high requirements of the industrial process analysis. The
responsiveness of the temperature monitoring is a sign for the fact that the measured gas com-
poses of very high temperatures or of a very high condensate load. It is the same with clearly
higher measured gas volume streams.
The cooler is nearly maintenance free.
The condensate removal is automatically done via the hose pump. We recommend checking the
hose line regularly on possible blockages. Condensate traps and hose lines should be cleaned on
demand. It has to be ensured that the measured gas flow is not interfered. For this purpose it
might be necessary to disconnect hose lines. After connecting everything again please check
tightness of sample line.
Please make sure that the condensate can drain off failure free and safe from the connection at
the bottom of the housing.
6.5 Flame Arrestor
It has to be ensured that the flame arrestors are not clogged with dust or condensate. In other
aspects they are maintenance free.
Please note that the measured gas for standard construction of the flame arrestor should only
contain flammable gases of ignition protection up to IIB3, such as for example methane. Please
ask ExTox who assists you anytime for special gas mixtures.
As an option we could offer a flame arrestor for ignition protection IIC, such as for mixtures with
significant contents of hydrogen.
6.6 Enclosures Heating with Thermostat Control
The nominal temperature can be adjusted in a range of +5°C to +30 °C by means of a
regulator. The temperature should be that high that no formation of condensate inside the
housing will occur.
6.7 Data Logger, Data Interfaces, Customer Specific Modifcations
You will find detailed information to these topics in the separate documentation.

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7 Application Hints
Here the application remarks in the Instruction Manual of the Control Units Series ET-8D and ET-
4D2 are valid.
8 Installation
The following figure shows the modular construction of the IMC with single transmitters.
Measured Gas Pumpe
Flame Arrestor,
automatic
condensate trap
Gas connection,
Condensate outlet
Space for
Gas Transmitter
Flow rate
Monitoring
Connection PCB for
transmitter and digital
inputs and relays out-
puts
Cable Glands
8.1 Mechanical Installation
The wall mounted housing should be installed at an easily accessible place to enable the
reading out of messages at every time and to ensure an easy maintenance.
Please pay attention to the indicated operation temperature for the IMC and build in transmitters
(DB). The IMC should be installed protected against weather conditions and bigger climatic
fluctuations.
In general we do not recommend an installation outside, as in principle measuring accuracy and
lifetime are influenced in a negative way. In case it is however necessary, please contact ExTox
to design a suitable type. For this the following measures are necessary: control unit to be in-
stalled inside, enclosure heating and rain protection cover for housing fans. In addition to this a
protection against driving rain and direct sun, for example in form of a housing, have to be
installed.
The dimensions for assembly and further installation dimensions can be taken from the Technical
Data Sheet (DB). The wall mounted housing can be opened by means of a usual two cam lock
key.
The IMC itself may not be installed in hazardous areas. The air change via ventilation of the
housing is that designed that in case of a leakage in the internal hosing the measured gas is
always that much diluted that a hazardous gas mixture cannot occur inside the housing. Due to
the rotary speed monitoring of the two fans the function of the so called "inner explosion protec-
tion" is ensured.