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
BA_IMC-8_-4_e_2011-09-20.doc Page 3 of 24
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
ExTox IMC-8/-4
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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

Instruction Manual
ExTox IMC-8/-4
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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)

Instruction Manual
ExTox IMC-8/-4
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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.

Instruction Manual
ExTox IMC-8/-4
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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.

Instruction Manual
ExTox IMC-8/-4
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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.