CEMS Operating Manual IMR USA S/N: Sample IMR 5000 IMR 400 IMR 400 IMR 5000 Measure MESURE PURGE Purge CALIBRATE Calibrate OFF OFF RESET Measure ON ON Calibrate RESET PUMP Gas Dryer Inside PUMP Sensors Inside IMR Environmental Equipment Inc.
INTRODUCTION 3 SAFETY INSTRUCTIONS 3 SYSTEM DESCRIPTION - IMR 5000 & IMR 400 GAS ANALYSIS SYSTEM 4 PREPARATIONS FOR USE: 4 1) Installation - Probes 4 2) Installation Gas Conditioning Unit IMR 400 5 3) Installation Gas Analyzer Unit IMR 5000 5 OPERATION 6 1) Description of SDU5020 (IMR Sensor Display Unit) 7 2) Switching on the IMR 5000 8 2.1 Warm-up cycle 9 2.2 Measurement mode 10 2.3 Reset mode 10 2.4 Calibration with Test-Gas 11 MAINTENANCE 13 CONSUMABLES Part No. 13 SPARE PARTS Part No. 13 IMR 5000 TIMER 14 Instrument Schematics 15 IMR 5000 15 Exterior Layout: Front 15 Exterior Layout: Sides 16 Exterior Layout: Top/Bottom 17 IMR 400 18 Exterior Layout: Front 18 Exterior Layout: Side Views 19 Exterior Layout: Top/Bottom 20 WARRANTY 21 Company Information 22 2
INTRODUCTION Thank you for purchasing the IMR Combustion-Gas Analyzer System 5000 and IMR Peltier Dryer System 400 Please read the following instructions before operating the unit for the first time. The IMR 5000 and IMR 400 are a state of the art combustion-gas analysis system. Proper handling is necessary to make full use of the outstanding performance and features of the system. IMPORTANT INFORMATION: Use the instrument within the recommended temperature range. Never measure without the filter. The filter must be cleaned / replaced when dirty. The manufacturer or an authorized service facility should check and readjust the unit every three months if needed. SAFETY INSTRUCTIONS Please make sure that you read this section carefully for use of your new combustion gas analyzer. Follow all warnings and instructions marked on the product or displayed on the screen. The AC plug should only be connected to a socket with a protective earth contact. Any adjustment or maintenance of the analyzer under voltage should be avoided. The maintenance of the analyzer should be done by qualified personal. Do not use this analyzer in water. Never spill water or any liquid on the analyzer. 3
SYSTEM DESCRIPTION - IMR 5000 & IMR 400 GAS ANALYSIS SYSTEM The gas analysis system consists of a two wall-mounted housing: 1. Gas analyzer IMR 5000 2. Gas Conditioning IMR 400 System features: IMR 5000 O2, NO(x), Temperature Ethernet, RS422/485 (configurable), and 4-20mA output Full color paperless recorder with touch screen Gas-sampling probe with 1500mm tube and 100mm mounting flange Heated hose 1.5m Peltier dryer The analyzer is equipped with a gas-sampling probe, which has to be permanently mounted to the exhaust point. The gas flows through a heated hose to the gas-conditioning system. The Peltier Dryer rapidly cools the flue-gas and removes moisture. The controller then analyzes the clean and dry gas. PREPARATIONS FOR USE: 1) Installation - Probes Install the flange at the sampling point. The Heated Sampling Line will need ~40 minutes to reach temperature before it can be mounted to the flange. Note: Connect the Heated Sampling Line to the Gas-Sampling Probe before mounting the probe to the flange. Install the Temperature probe to the stack near the sampling probe. Be sure that the instillation location of the Probe(s) leaves enough cord to reach the necessary port(s) on the 5000. Note: Disconnect the AC power before any type of service. 4
2) Installation Gas Conditioning Unit IMR 400 Choose a place for the gas conditioning unit and then mount the gas analyzer to the wall. The best place for the gas conditioning unit is within 1m of the gas sampling probe. Leave space around the housing for access to inputs. NOTE: Do not extend the heated hose between the probe and the gas conditioning unit with any kind of tubing, because condensed water will cause a problem. Connect the Heated Sampling Line to the gas conditioning unit and then connect the power plug for the Heated Sample Line. Mount the temperature probe to the stack and then connect it to the unit IMR 400. IMPORTANT!! The Heated Sampling Line needs to be powered for at least 40 minutes prior to connecting the probe to the stack. This time is needed for the heated hose to reach temperature, and prevent wet samples reaching the sensors. Connect the 400 to wall power, and power on the instrument. The Red LED on the Heated Sampling Line is off while heating. It turns on when it reaches its maximum temperature and starts to cool down. The LED starts flashing indicating it has reached operating temperature. Note: It may be desirable to attach tubing to the Dryer Out port on the 400 as condensate may drip from here. 3) Installation Gas Analyzer Unit IMR 5000 Choose a place for the gas analyzer unit and then mount the gas analyzer to the wall. Leave space around the housing for access to inputs. Install the data cable and tubing between the 400 and 5000. Connect the 5000 to wall power, and power on the instrument. NOTE: A power cord is already installed; please check for correct plug compatibility. If the power cord is not correct, then insert a correct power cord through the cable gland at the bottom of the unit and then connect the power cord to the terminal block L1, N1 and GND (See drawings at end of manual) for terminal block configurations. 5
OPERATION IMR 5000 Purge Calibration Measure OFF ON RESET Measure Calibrate RESET IMR Environmental Equipment, Inc. S/N: A####A## WWW.IMRUSA.COM email: info@imrusa.com Phone: 1-727-328-2818 230 VAC! WARNING Electrical Hazzard Turn off unit before servicing Calibration-LED - Calibration-mode Purge-LED - Warm-up mode (Purge) Measure-LED - Measurement mode Reset - Pushbutton to reset the unit into warm-up / zero-adjustment mode Calibration- switch - Switch between Measurement and calibration On/Off - On/Off switch for the IMR 5000 6
1) Description of SDU5020 (IMR Sensor Display Unit) The sensor display unit will display the gas sensor in ppm, %, or mg/nm3 values. Important: This is only for your information! Factory configuration: Slot 1 AI 206 input card Input 1: Configuration: 0 60mV input O2 sensor Input 2: Configuration: 0 5V input NO sensor Input 3: Configuration: 0 5V input NO2 sensor Input 4: Configuration: Type K input Temperature sensor Slot 2 AO 206 input card Output 1: Configuration: 4 20mV O2 sensor Output 2: Configuration: 4 20mV NO(x) sensor Output 3: Configuration: 4 20mV Temperature sensor Technical data: Parameter Sensor Technology Accuracy Measuring range O2 Electrochemical +/-1% 0 25 % NO Electrochemical +/-1% 0 1000 ppm NO2 Electrochemical +/-1% 0 1000 ppm Temperature Type K Thermocouple +/-1% 0 1200 C Power supply: 230 VAC / 50Hz Ambient temperature: 5 C - 40 C Gas temperature: 0-1200 C / 0-2192 F Storage temperature: -25 C - +65 C Circuit Breaker: 6A / 250VAC Display: Sampling probe length: Heated hose: Flange diameter: SDU5020 1500mm 1500mm 100mm 7
LEDS and Buttons Purge LED Measurement mode Cal-mode Warm-up mode - off - off - on Calibration LED Measurement mode Cal-mode Warm-up mode - off - on - off Measurement LED Measurement mode Cal-mode Warm-up mode - on - off - off Pushbutton The pushbutton resets the internal timer. Rotary switch Use this switch to change between the Calibration mode and Measurement mode. Calibrate the toxic-sensors with calibration gas one at a time. When the switch is set to Calibrate it will begin drawing gas from the Cal Gas In port on the right hand side, and stops drawing combustion gas. Measure Calibrate - Pos.1 Measurement - Pos.2 Calibration 2) Switching on the IMR 5000 Please make sure that all the connections (electrical and tubing) are made on the - Gas Sampling Probe - Temperature Probe - Data (RS485, Ethernet, 4-20mA) 8
2.1 Warm-up cycle After initial setup and when the unit is powered on set the selector switch to Calibration mode. During this cycle the unit purges the sensors with fresh air. The unit should be kept in this cycle for 40 minutes. Check the values of the sensors after the initial 40 minute warm up. If the values are showing near zero values then switch to Measurement mode. If the zero-points are not satisfactory, then the value(s) needs to be adjusted manually. Please see 2.4 for the zero point adjustment. The Purge mode starts immediately after the Measurement mode. The Purge mode is 15 minutes (Default, duration is user selectable). To manually start the Purge (warm-up) cycle; push the RESET button. Status of the different modules during a Purge cycle - ALL sensors are doing a zero adjustment - IMR 5000 will not draw any combustion gas; measurement will begin after the warm-up cycle - The Red LED will be illuminated MESURE Purge Calibrate PURGE CALIBRATE Measure 9
2.2 Measurement mode The measurement mode starts immediately after the warm-up cycle. The measurement mode is 8 hours (Default, duration is user selectable). During the measurement mode all the sensors receive cleaned and dried combustion gas from the gasconditioning system. Status of the different modules - All sensors are showing the actual measurement value - Gas-conditioning unit is cleaning and drying the combustion gas - The Green LED will be illuminated MESURE Purge Calibrate PURGE CALIBRATE Measure 2.3 Reset mode By pressing the RESET pushbutton the IMR 5000 starts a Purge cycle and the instrument purges with fresh air. The Reset button has no effect if the instrument is in Calibration mode. Status of the different modules - Sensors value are going back to zero - The Red LED will be illuminated MESURE Purge Calibrate PURGE CALIBRATE Measure 10
2.4 Calibration with Test-Gas Please see the schematic of the sensor and the instructions in the Instrument Schematics section! Certified calibration gas is needed to calibrate the sensor(s). Only use single gas calibration tanks. Do not use calibration tanks with multiple test gases. The calibration should be checked once a month to ensure the accuracy of the measurement. Current configuration Gas Offset Formula Calibration Formula O2-0.07 AI1*(10.07/5.23) AI1*(1/1) NO 0.0000 AI2*(206.4/0.2745) AI2*(1/1) NO2-0.0010 AI3*(39.63/-0.1411) AI3*(1/1) Temperature 0.0 AI4 AI4*(1/1) NO(x) n/a (Math2*1.32)+(Math3*2.03) n/a Measure Calibrate To begin calibration set the selector switch to Calibrate. Wait for 15 minutes. 11
Adjusting the zero point: Using the Observer software; connect to the IMR 5000. Once the connection is secured; find the IP address of the instrument (if using Ethernet) or connect directly via RS485. With the selector switch set to Calibrate Enter the specified password (the default password is blank). Choose to get to the configuration of the instrument then choose to send the calibration data to the instrument. Look at the instrument; make a note of all the values. If any of the values are nonzero change the Offset on the AI (analog input) page for that sensor. The O2 zero point can be found by using any gas that does not have an O2 balance. Set the formulas on the math page for each sensor to the Calibration Formula seen on the previous page. Send the changes to the instrument and verify that all sensors read zero. The fitting for the Calibration Gas Port is located on the right side of the housing. MESURE Purge Calibrate PURGE CALIBRATE Measure Adjust the span: 1. Apply the calibration gas to the instrument. 2. The reading should be stabilized within three minutes. 3. Set the formula for the current sensor to be calibrated; where red is the concentration of the calibration gas and green is the value on the instrument Overview page for the sensor being calibrated. a. Example AI#*(395/0.265) 4. Once these changes are made, export the data ( ) to the unit using the export icon. Verify accuracy. 5. Take the calibration gas off. 6. Wait for 5 minutes until the sensors reach their zero point and then apply the calibration gas again. Repeat step 3 & 4 until you are satisfied with the reading you are receiving. 7. When all the sensors are calibrated, close the calibration gas bottles then put the selector switch back to "Measurement". Information: If the sensor needs to be exchanged, then a new calibration point needs to be set. 12
MAINTENANCE - Check the calibration once every other week. - Check the dust filter for dirt and replace as necessary. - Check the gas outlets/fittings for debris. - Check the condensation outlet of the gas-conditioning unit. - Check the filters of the gas-conditioning unit and replace as necessary. - Check the filter element of the probe and replace as necessary. CONSUMABLES Part No. Dust filter (Plastic Housing) 72200 Dust filter (Paper) Probe 72560 SPARE PARTS Silicon Tubing Valves (Solenoids) Pump (IMR 5000 & IMR 400) Stainless Filter Housing Part No. SL-1814 VQD1151 Pump 24V 05001-Filt Gas Probe 1500mm 94502 Mounting Flange Heated Sample Line 1.5m 220V MT-FL-5000-3 H226-1.5-220 Please send the Serial Number and model of the analyzer when ordering spare parts. Please specify the maximum range when ordering sensors. Please ask about special items. 13
IMR 5000 TIMER Purge Dial Measure Dial The white dial above T on dial is used to set the purge time (15min) user selectable. The white dial above T off dial is used to set the measure time (8 hrs) user selectable. The white dial selects the operating intervals. The blue dial sets the specific operating duration for the selected range Example: White dial is set to 6-60 Blue dial is set to 4 Result: 24 seconds 14
Instrument Schematics IMR 5000 Exterior Layout: Front IMR 5000 Purge Calibration Measure OFF ON RESET Measure Calibrate RESET IMR Environmental Equipment, Inc. S/N: A####A## WWW.IMRUSA.COM email: info@imrusa.com Phone: 1-727-328-2818 230 VAC! WARNING Electrical Hazzard Turn off unit before servicing 15
Exterior Layout: Sides Ethernet CXA RS 422/485 I/O Analog Out Cal Gas In Air In IMR Environmental Equipment, Inc. WWW.IMRUSA.COM email: info@imrusa.com Phone: 1-727-328-2818 16
Exterior Layout: Top/Bottom Flue Gas In 230 VAC Purge Out 17
IMR 400 Exterior Layout: Front IMR 400 OFF ON IMR Environmental Equipment, Inc. S/N: A####A## WWW.IMRUSA.COM email: info@imrusa.com Phone: 1-727-328-2818 230 VAC! WARNING Electrical Hazzard Turn off unit before servicing 18
Exterior Layout: Side Views Temp I/O Flue Gas Out IMR Environmental Equipment, Inc. WWW.IMRUSA.COM email: info@imrusa.com Phone: 1-727-328-2818 19
Exterior Layout: Top/Bottom Flue Gas In Heated Hose Power Heated Hose 230 VAC Dryer Out 20
WARRANTY The company IMR Environmental Equipment International, Inc., 3632 Central Ave., St. Petersburg, FL 33711, USA states the following: IMR as manufacturer hereby grants the following worldwide IMR guarantee for an IMR unit purchased from an authorized dealer. 1. The IMR guarantee shall entitle every IMR customer to demand a free replacement or repair of the defect parts of the IMR unit from any IMR dealer authorized for the respective IMR unit. 2. The IMR guarantee shall be granted on the factory new unit and shall commence on the date of the delivery of the original IMR unit to the customer. It shall last for a period of six months regardless of the type and the intensity of use and regardless of any change of owner, which may occur during this guarantee period. 3. The IMR guarantee shall refer to absence of faults with respect to the state of the art nature of the sold unit in terms of material and finish. The guarantee for all parts fitted during the twelve month guarantee period shall end with the unit guarantee. 4. After the establishment of a material or production fault by IMR or the authorized IMR dealer, the faults will be eliminated by means of free repair or replacement. Replaced parts shall become the property of IMR. 5. No guarantee claims may be made for maintenance and setting work, cleaning or other utility materials required for the function of the unit and other wear parts unless they have a direct bearing on work performed under the guarantee. 6. The terms and conditions for the acknowledgement of this guarantee shall be the presentation of the fully completed guarantee card which must contain the confirmation from the authorized IMR dealer on its delivery and, if applicable, the prescribed maintenance work. 7. The IMR guarantee shall only be applicable if a. the IMR unit has been maintained in accordance with the instructions issued by the manufacturers and the operating instructions by an authorized IMR dealer; b. only original IMR spare parts have been used for any repairs; c. the unit has been used properly, the operating instructions observed and the unit has not been used for a purpose other than the one for which it has been designed; d. the IMR unit has been left in its original design and meets the original IMR specifications; e. the fault is not due to external influences or use for a purpose other than the one for which it has been designed; f. exclusively authorized IMR dealers have made repairs to the IMR unit; g. the IMR unit has been sent to an authorized IMR dealer immediately after the fault was discovered. 21
Company Information IMR 3632 Central Ave. St. Petersburg, FL 33711 USA Tel: 727-328-2818 Fax: 727-328-2826 800-RING-IMR E-mail: info@imrusa.com Web Site: www.imrusa.com 22