ExTox IMC-8 User manual

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

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Instruction Manual
ExTox IMC-8/-4
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Foreword
We thank you very much for your confidence in our products and us, the ExTox Gasmess-
Systeme 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 94/9/EC ("ATEX"). You profit of the high reliability due to modern sensor
techniques and consequent interpretation acc. to the requirements of the regulations and stan-
dards valid for industrial application.
The Integral Measuring Concepts serve for monitoring gas concentrations in sealed off proc-
esses or not accessible areas. The IMC Series combines all necessary components in one com-
pact wall mounted housing – from sampling and preparation of measured gas, sensor tech-
nique and evaluation. The modular construction leads to a high adaptation to the different ap-
plications, 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
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.ExTox.de
BA_IMC-8_-4_e_2011-09-20.doc, Rev.: 22.02.2012
(Subject to Technical Changes)

Instruction Manual
ExTox IMC-8/-4
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Content
1Introduction 5
2Features of the Integral Measuring Concepts Series IMC 6
3Indications and Facilities 9
4Configuration 9
5Description 10
5.1 Type IMC 10
5.1.1 Functions 10
5.1.2 Parameter Settings 11
5.1.3 Pre-configured Relays and Digital Inputs 11
5.1.4 Calibration and Adjustment 11
5.2 Type Biogas 12
5.2.1 Functions 12
5.2.2 Parameter Settings 12
5.2.3 Pre-configured Relays and Digital Inputs 13
5.2.4 Calibration and Adjustment 14
5.2.5 Switching between Measuring Points (Option) 15
5.3 Type KAT 17
5.3.1 Functions 17
5.3.2 Calibration and Adjustment 18
6Operation of the Integral Measuring Concept 19
6.1 Flow Rate Monitoring 19
6.1.1 Types with DDL-Module 3.0 (Art. 940285) and 2.0 (Art. 940178) 19
6.1.2 Types with Flow-Meter (Art. 940025) 19
6.2 Housing Fans 20
6.3 Condensate Trap incl. Hose Pump 20
6.4 Condensate Trap 20
6.5 Measured Gas Cooler incl. automatic Removal of Condensate 20
6.6 Hydrophobic Dehumidification of Measured Gas 21
6.7 Flame Arrestor 21
6.8 Enclosure Heating with Thermostat Control 21
6.9 Switching between Measuring points, Data Logger, ProfiBus®, Customer Specific
Modifications 21
7Application 22
8Installation 22
8.1 Mechanical Installation 22
8.2 Connection to the Process 23
8.3 Electrical Installation 23
9Maintenance of Gas Detection Systems 24
10 Spares, Expendables, Options 24
11 Technical Data, EC-Declaration of Conformity 24

Instruction Manual
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1Introduction
This Instruction Manual generally describes operation, installation and maintenance of the fol-
lowing ExTox-Products:
Continuous
Measurement Article Biogas- Application Article Biogas-KAT Application Article
IMC-8D2 420106 IMC-8D-Biogas2 430106 IMC-8D-KAT 430112
IMC-8DA2 420107 IMC-8DA-Biogas2 430107 IMC-8DA-KAT 430113
IMC-4D2 420108 IMC-4D-Biogas2 430108 IMC-4D-KAT 430110
IMC-4DA2 420109 IMC-4DA-Biogas2 430109 IMC-4DA-KAT 430111
All herein described installations or options may not consequently form part of your type of
Integral Measuring Concept IMC.
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 a separate
documentation 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 meas-
ures described herein. Otherwise you endanger your own safety and your warranty claims of
merchantability. In such cases please contact ExTox or authorised ExTox Service Partner. Third
parties 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 com-
pare 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.

Instruction Manual
ExTox IMC-8/-4
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2Features of the Integral Measuring Concepts Series 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 meas-
urement within theses 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
measured gas, conditioning, 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 inte-
grate controlling and monitoring of the components for sampling and conditioning of measured
gas. The measuring channels which are not used for analysis can easily be taken for external
transmitters, 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).
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 94/9/EC (ATEX), 2004/108/EEC (EMC) and 2006/95/EEC (LVD).
Switching of
Measuring Point
(Option)
Sampling
and
Conditioning
Ambient air monitoring integrated
Sensors

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IMC for continuous Measurement
compact wall mounted housing in maintenance friendly construction
up to 8 or 4 transmitters
allocation of transmitter inputs to analysis including sampling and conditioning 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 conditioning of measured gas by control units of the series ET-8D or ET-4D2
gas suction pump (distance of suction up to 50 m length of hose)
pressure at sampling point: -100 to +100 hPa (relative to ambient air)
electronic flow rate monitoring
condensate trap with manual removal of condensate
hosing: PE/PP
magnetic valve to change from measured gas to test gas
2 fans, rotary speed monitored
4..20 mA-outputs (only Types IMC-xDA)
Extensions for type "Biogas"
software extension Biogas: discontinuous measurement in batch mode with configurable
intervals for measuring / flushing / air; indication of the latest measured value during flush-
ing 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
measurement
pressure compensation
condensate trap with automatic removal of condensate via hose pump
Flame arrestor (inlet of measured gas)
Extensions for type "KAT"
Extensions for type "Biogas"
Biogas-Application with integrated monitoring of activated carbon filters by means of
switching between measuring ranges for H2S-Measurement. Assignment of the H2S-
Measuring range configurable to the corresponding measuring point.
Switching between measuring points minimum 2-times (before / after activated carbon fil-
ter)

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Options
▪Monitoring of ambient air:
A continuous monitoring of ambient air, such as for example for Methane (CH4) and Hydro-
gen Sulphide (H2S), can also be realised via external ExTox-Transmitters.
▪Switching between measuring points (types Biogas2 and KAT):
Determination of gas composition at different measuring points temporally one after an-
other. Supplementation of switching between measuring points forms a cost saving alterna-
tive 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 moni-
tored process as far as the danger of explosion is concerned. The flame arrestor is con-
nected previous to the measured gas inlet. When returning the measured gas into the proc-
ess another flame arrestor at the measured gas outlet is necessary.
▪Measured gas cooler including automatic removal of condensate:
Gas dehumidification by means of a Peltier cooler, temperature of measured gas at outlet:
+5 °C. Recommended for very high humidity content in measured gas.
▪Hydrophobic Dehumidification of measured gas:
Dehumidification of gas is done via a chemical exchange process. Recommended for very
high humidity content in measured gas.
▪Heating for enclosure 100 W 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 and/or internal control unit
▪ProfiBus®-, ModBus®- und Ethernet-Connection:
Measured values and messages can be transferred to a superior PLT-System via Interface.
▪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 applications also require different monitoring concepts. The modular design of our
IMC-Systems allows us to respond to your special wishes and requirements.

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3Indications 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 the IMC the flow rate of measured gas and state of fans
are indicated instead of date and time (at ET-4D2 and ET-8D).
4Configuration
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 meas-
uring functions may otherwise lead to loss of safety functions.
Software extensions and settings of inputs and outputs depend on the different operation mo-
des.

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5Description
The following indications are valid for the standard types mentioned in paragraph 1. For special
types, generally with Article Number 7xxxxx, further amendments can be necessary. These will
then be part of an amendment to this Instruction Manual.
Documentation supplied with each IMC contains individually generated indications of the gas
flow, electrical circuit scheme, terminal assignment and construction of mounting plate.
5.1 Type IMC
5.1.1 Functions
▪Course of Measurement
The transmitters build in the IMC also measure continuously. The channels of the IMC are acti-
vated in the menu Channel Configuration by setting the Mode ON.
▪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 version:
rotary speed monitoring of both fans
flow rate monitoring: message for under-scale of nominal range
temperature monitoring of the measured gas cooler (if installed)
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 dur-
ing 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 / flush-
ing air by means of the magnetic valve. For that purpose you have to select the menu Mainte-
nance. By means of the keys SHIFT + F4 it can be switched between both gas inlets.

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5.1.2 Parameter Settings
▪System Parameters
In the menu System Parameter the operation mode "IMC" instead of "ET-8" and "ET-4" is fac-
tory-sided activated.
Attention: Changing of these settings should in no way be done by the user. Changed meas-
uring functions may otherwise lead to loss of safety functions.
The menu point OPTIONS comprises now also the possibilities of setting for flow rate monitor-
ing (see 6.1) and change-over of measuring points.
Access Level to perform changes within this Menu: 3
Menu Text Selection Function
FLOW-MIN 0 to 300 l/h 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 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 E3 Status signal housing fans (only for systems with DDL-Module 2.0, see
6.1)
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 ade-
quate test gas volume stream is provided, that means an application of test gas has to be set
which corresponds to the one in measuring operation1. 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.
1Depending on type the necessary test gas volume stream may be considerably above the in-
dicated 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
measured 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". Latch-
ing alarms can only be reset during measuring phase. Attention: This means that reset will be
possible 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 version:
rotary speed monitoring of both fans
flow rate monitoring: message for over- and under-scale of nominal range
temperature monitoring of the measured gas cooler (if installed)
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 dur-
ing 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 fac-
tory-sided activated.
Attention: Changing of these settings should in no way be done by the user. Changed meas-
uring functions may otherwise lead to loss of safety functions.
In the submenu BIO the following changes can be performed.
Access Level to perform changes within the Menu Timer: 3

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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 Measurement in minutes
Flow ON, OFF For IMC-Biogas 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 col-
umn -
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 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 Upper limit for flow rate monitoring in l/h. Over-scale leads
to system fault.
(Standard setting: 60 l/h)
MAX-
CHANNEL
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
measuring points with this setting are integrated in the discontinuous course of biogas meas-
urement.
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 E3 Status signal housing fan (only for systems with DDL-Module 2.0, see
6.1

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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 Pa-
rameter/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 nor-
mally 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 calibration of the O2-Measuring Channel you have to apply a test gas which does not con-
tain 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 inter-
nal magnetic 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 outputs keep the measured values of the last measurement.
Calibration is done in five phases:
Phase Indication in 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
operation2. This is to avoid that air is additionally sucked
in and dilution of the test gas resulting from this falsifies
calibration / adjustment.
4 READING SENSITIVITY/
READ SEN
The measured gas pump is switched off and batch meas-
urement is done within two minutes.
2Depending on type the necessary test gas volume stream may be considerably above the in-
dicated volume stream.

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Phase Indication in 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. Off-
set 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 message "ERROR" is issued after completed
calibration and the previous settings are kept.
Attention: The message "ERROR" for channels with
measuring 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 adapta-
tions take place you have to pay attention to system specific deviations in the documentation.
Switching between measuring points is configured in the menu SETUP>SYSTEMPARAME-
TER>OPTIONS. The drawing shows an example for a system with switching between 4 measur-
ing points.
OPTIONEN M1: ON 1 H
RS232 : 1 M2: ON 1 H
FLOW-MIN : 15 l/h M3: ON 1 H
FLOW-MAX : 60 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
measuring 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 indicate 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 an activated carbon filter(ACF).
This type is always coupled with switching between measuring points (see 5.2.5). The measur-
ing points can be configured that way that the gas composition is determined alternately before
and after the ACF. Depending on the configuration the H2S-Transmitter with corresponding
measuring range is activated automatically.
The relays described below cannot be configured freely.
IMC-8D (IMC-4D) Application
Relay K21 (K9) Switching of magnetic valves for high (before ACF) and low H2S-
Measuring Range (after ACF)
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 measur-
ing 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
measuring 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 ACF (Raw gas, Measuring range ≥1000 ppm)
L (Low) = Measurement after ACF (Measuring range 100 ppm)
ATTENTION:on wrong definition of measuring range (H/L) the H2S-Sensor can be damaged
due to overload.

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ExTox IMC-8/-4
Page 18 of 24 BA_IMC-8_-4_e_2011-09-20.doc
5.3.2 Calibration and Adjustment
Calibration shows the following specific features: In case there is no H2S-Transmitter for meas-
urement after ACF 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.

Instruction Manual
ExTox IMC-8/-4
BA_IMC-8_-4_e_2011-09-20.doc Page 19 of 24
6Operation of the Integral Measuring Concept
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,
whichare 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
housing fans. The normal flow through is appr. 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 flow rate monitoring 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 flow rate monitoring 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 flow rate monitoring
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 vol-
ume stream is indicated in litre per hour (l/h) during normal measuring mode.3The flow rate
monitoring is equipped with an upper (MAX) and lower (MIN) alarm level; the nominal range
which should be kept is in between.
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 effec-
tive.
3For this type the indication of the volume stream in the display of the control unit is not ap-
plied.

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ExTox IMC-8/-4
Page 20 of 24 BA_IMC-8_-4_e_2011-09-20.doc
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.
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 neces-
sary to disconnect hose lines. After connecting everything again please check tightness of sam-
ple 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 Condensate Trap
Draining of the condensate trap (standard for IMC-Types) has regularly to be done manuall and
the trap has to be cleaned on demand. For this purpose you have to loosen the screwed ele-
ment and drain the condensate. After connecting everything again please check tightness of
sample line.
Please make sure that the condensate is disposed safely depending on composition.
6.5 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
composes 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.