IMR 5000 Operating Manual S/N: For information only! IMR Environmental Equipment Inc.
INTRODUCTION 3 SAFETY INSTRUCTIONS 3 SYSTEM DESCRIPTION - IMR 5000 GAS ANALYSIS SYSTEM 4 Function chart IMR 5000 - complete gas analysis system 5 PREPARATIONS FOR USE 7 1) Installation - Gas sampling probe 7 2) Installation - Gas conditioning unit 8 3) Installation - Gas controlling unit 9 Technical data: 10 1) Description of SDU5000 (IMR Sensor Display Unit) 12 LEDS and Buttons 15 2) Switching on the IMR 5000 and IMR 400 16 2.1.1 Warm-up cycle 17 2.1.2 Measurement mode 17 2.1.3 Reset mode 18 2.1.4 Calibration with test-gas 18 MAINTENANCE 20 SPARE PARTS 21 APPENDIX - CIRCUIT DIAGRAM- IMR 5000 22 APPENDIX - CIRCUIT DIAGRAM- IMR 400 23 APPENDIX - TERMINAL BLOCKS - IMR 5000 24 APPENDIX - TERMINAL BLOCKS - IMR 400 25 HEATED HOSE 26 FILTER-ELEMENT IMR 400 27 WARRANTY 28 2
INTRODUCTION Thank you for purchasing the IMR Combustion-Gas Analyzer System 5000 with integrated gas-conditioning system. Please read the following instructions before operating the unit for the first time. The IMR 5000 is 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 just 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. 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 inlet 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 and the instrument should be unplugged. Do not use this analyzer in water. Never spill water or any liquid on the analyzer. 3
SYSTEM DESCRIPTION - IMR 5000 GAS ANALYSIS SYSTEM System features: Gas-sampling probe with 750mm tube and mounting flange Heated hose 1.5m IMR 400 Gas conditioning system IMR 5000 O 2 4 20mA CO 4 20mA CO 2 4 20mA NO 4 20mA 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 unit. The gas-conditioning unit dries the flue-gas and removes moisture. The controller then analyzes the clean and dry gas. The gas analysis system consists of two wall-mounted housings: 1. Gas sampling and conditioning IMR 400 2. Gas analyzer IMR 5000 4
Function chart IMR 5000 - complete gas analysis system 5
Gas flow schematic MODBUS MODBUS Gas Out Temp SO2 24VDC Power Supply On/Off Pump L1N Gas measuring unit Valve#2/A Valve#1/A Valve#2/B Timedelay Relay Pushbutton Selector-Switch red green yellow Filter Valve#1/B Valve#3/A Relay#1 Valve #3 Gas In Gas Out Air In Cal Gas1 SO2 L1 N Purge Gas IN Gas Conditioning unit Flue-Gas Gas Dryer Controller Diaphragm Pump (Purging) green Condensation Out Thermocouple Electrical Connection Gas flow Enclosure heated hose Gas probe STACK 6
PREPARATIONS FOR USE 1) Installation - Gas sampling probe Install the flange at the sampling point and then mount the gas-sampling probe to the flange. Note: Connect the heated hose to the gas-sampling probe before mounting the probe to the flange. Technical data: Sampling tube length: Heated hose Flange dia Temp Probe Length: 750 mm 1500mm 100mm 250mm Note: Disconnect the AC power for any type of service. 7
2) Installation - Gas conditioning unit Choose a place for the gas-conditioning unit and then mount the gas-conditioner to the wall. The best place for the gas-conditioning unit is within 1m of the gas-sampling probe. Leave space around the housing. Note: Do not extend the hose between the probe and the gas conditioning unit with any kind of tubing, because condensed water will cause a problem. Connect the heated hose to the gas-conditioning unit and connect the plug of the heated hose with its socket on the enclosure. PVC hose (approx. 10m) has to be connected to the gas outlet of the gas conditioning unit and the gas inlet of the gas-controlling unit. The On/Off-switch for the conditioning unit is located on the outside of the enclosure. The unit is heating the hose when the green LED is on and it has reached its temperature when the LED is flashing. The unit has a power cord already installed. Connect the power cord to AC when the installation is complete. Technical data: Power supply: 120V / 50Hz Wall mounted housing: 350 x 300 x 200 mm Ready for operation: 20 min Ambient temperature: 5 C - 40 C Storage temperature: -25 C - +65 C Fuse: 4A / 120VAC Schematic: Connection 8
3) Installation - Gas controlling unit Choose the best place to mount the gas analyzer and then mount it with the enclosed brackets to a wall. The place should be close to the gas-conditioning unit. Leave space around the housing for the different outlets and inlets. Connect the PVC hose of the conditioning unit with the controlling unit. A power cord is already installed. Connect the power cord to AC when the installation is complete. Schematic: Connection Exaust c Off On Fan Gas Out Heated Hose Connection Exaust Silicone Hose To IMR 5000 Heated Hose Gas Probe Filter 9
Technical data: Parameter Sensor Technology Accuracy Measuring range O 2 Electrochemical +/-1% 0 25% CO Electrochemical +/-1% 0 -- 4000ppm CO 2 NDIR +/-1% 0 20% NO Electrochemical +/-1% 0 100ppm Power supply: Housing: 120V/ 50Hz wall mounted 700 x 500 x 250 mm SDU5000 Display: Ready for operation: 40 min Ambient temperature: 5 C - 50 C Storage temperature: -25 C - +65 C Fuse: 2A / 120VAC 10
Internal panel IMR 5000 11
OPERATION Note: Before the first use The IMR 400 must be turned on for at least 40 minutes before the IMR 5000 can be turned on. O2 Sensor in % CO Sensor in ppm CO 2 Sensor in % NO Sensor in ppm Yellow-LED Red-LED Green-LED Reset Calibration- switch On/Off - Calibration-mode - Warm-up mode (Purge) - Measurement mode - Pushbutton to reset the unit into warm-up / zero-adjustment mode - Switch between Measurement and calibration - On/Off switch for the IMR 5000 (only measuring unit) 1) Description of SDU5000 (IMR Sensor Display Unit) The Sensor display unit will display the gas sensor in their actual ppm or % values. 12
Important: This is only for your information! Default configuration: Slot 1 AI183 input card Input 1: Configuration: 4 20mA input O2 sensor Input 2: Configuration: 0 5V input CO sensor Input 3: Configuration: 0 5V input CO2 sensor Slot 2 AI183 input card Input 1: Configuration: 0 5V input Slot 3 AO183 output card I Output 1: Configuration: 4 20mA O2 output Output 2: Configuration: 4 20mA CO output Output 3: Configuration: 4 20mA 13
Slot 4 AI183 input card Input 1: Configuration: 0 5V input NO output For more detailed information about these points check the specification SDU5000 Manual Included with this package. SDU5000 A1+ A1- A2+ A2- A3+ A3- R1 A1 B1 G1 OI183 SLOT4 OI183 X1 + - + - + - + - O2 CO CO2 NO 14
LEDS and Buttons Green LED Measurement mode Cal-mode Warm-up mode Red LED Measurement mode Cal-mode Warm-up mode Yellow LED Measurement mode Cal-mode Warm-up mode - on - off - off - off - off - on - off - on - off Pushbutton The pushbutton is resetting the internal timer. Rotary switch Use this switch to switch between the calibration mode and measurement mode. Calibrate each toxic-sensor with calibration gas. As soon as you switch the unit is drawing the gas from the specific "cal-gas inlet" fitting on the right hand side and does not draw combustion gas anymore. Measure Cal - Pos.1 Measurement - Pos.2 Calibration 15
2) Switching on the IMR 5000 and IMR 400 Please make sure that all the connections (electrical and tubing) are made on the - gas sampling probe - gas conditioning unit AC-connection - IMR 5000 / IMR 400 A power cord with a protective earth contact is needed to operate both units. A power cord is already installed, please check for the correct size plug. 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 DWG F1711H44) for terminal block configurations 16
2.1.1 Warm-up cycle The warm-up cycle starts after the unit is turned on. The selector switch has to be in the measurement mode at this point. During this cycle the unit does a self-check and purges the sensors with fresh air. The warm-up cycle takes about 40 minutes. The warm-up cycle is automatically done every 8 hours. Press the pushbutton to manually start the warm-up cycle. Status of the different modules - CO sensor is doing a zero adjustment - IMR 5000 will not draw any combustion gas in the first 40 minutes, the measurement will begin after the warm-up cycle - Gas conditioning unit is working - Red-LED must be on Red GreenYellow Reset Measurement Cal-Gas Zero-adjustment of the sensors Please check the values of the electrochemical cell after 40 minutes. The values must show the zero point Sensor Value O 2 % CO ppm CO 2 ppm NO ppm If the controller is not showing the zero value, then the value needs to be adjusted manually. Please see 2.1.4 for the zero point adjustment. 2.1.2 Measurement mode The measurement mode starts immediately after the warm-up cycle. 17
The measurement mode takes 8 hours (Time interval can be set by user as well). During the measurement mode all the sensors receive cleaned and dried combustion gas from the gasconditioning unit. The measurement will end after 8 hours and the unit will start another warm-up mode to purge the sensors. Status of the different modules - CO sensor is showing the actual measurement value - Gas-conditioning unit is cleaning and drying the combustion gas - Green LED must be on Red GreenYellow Reset Measurement Cal-Gas 2.1.3 Reset mode By pressing the pushbutton the IMR 5000 starts with the warm-up cycle and the instrument gets purged with fresh air. Status of the different modules - CO sensor value is going back to zero - Gas-conditioning unit is cleaning and drying the combustion gas - Red-LED must be on Red GreenYellow Reset Measurement Cal-Gas 2.1.4 Calibration with test-gas Please see the schematic of the sensor and the instructions in the appendix! Certified calibration gas is needed to calibrate the electrochemical sensor. The calibration should be checked once a month to ensure the accuracy of the measurement. 18
Gas Formula Calibration Formula O 2 AI1*(20.95/0.0380) AI1*(20.95/1) CO 2 (AI3*0.02-0.14)*(8.882/9.698) (AI3*0.02-0)*(1/1) CO AI2*(400/19.5) (AI2-0)*(1/1) NO AI4*(206.1/78) (AI4-0)*(1/1) Press the reset button and the analyzer starts the warm-up cycle (selector switch on measurement) 1.) Wait for 25 minutes. 2.) Adjust the zero point: Using the provided software, connect to the IMR 5000. Once the connection is secured, find out the IP address of the instrument (if using Ethernet) or connect directly via RS232. Load up the calibration file: F1711H44_Calibration. 3.) 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. Wait 3 minutes then look at the instrument, make a note of all the values for O 2, CO 2, CO and NO. Write these values down. If any of the values are nonzero (except for O 2 ) change the digit in red in the formula until the values are zero. (AI3*0.02-0)*(1/1) for CO 2, (AI2-0)*(1/1) for CO, (AI4-0)*(1/1) for NO. Send the changes to the instrument and verify that all sensors aside from O 2 read zero. To update O 2, simply change the red number into the number found on the second data page for O 2 raw in the following formula: AI1*(20.95/1). 4.) Switch the selector switch to the specific cal-gas location and apply the calibration gas to the analyzer. The fittings for the calibration gases are located on the right side of the housing. Red GreenYellow Reset Measurement Cal-Gas 5.) Adjust the span: 19
Apply the calibration gas to the instrument. The reading should be stabilized within three minutes. Change the formula in the following way, where red is the value of the calibration gas and green is the value on the instrument: (AI3*0.02-0)*(1/1) for CO 2, (AI2-0)*(1/1) for CO, (AI4-0)*(1/1) for NO. It is possible that the digit in light blue is a non-zero value (refer to step 3). Take the calibration gas off. Once these changes are made, export the data ( icon. ) to the unit using the export 6.) Wait for 5 minutes until the sensors reach their zero point and then apply the calibration gas again. Repeat step 5 until you are satisfied with the reading you are receiving. Close the file and do not save. 7.) When all the sensors are calibrated, then switch the selector switch back to "measurement" and close the calibration gas bottles. Information: If the sensor needs to be exchanged, then a new calibration point has to be set. MAINTENANCE - Check the calibration once every other week. - Check the dust filter for dirt and replace if necessary. - Check the gas outlets. - Check the condensation outlet of the gas-conditioning unit. - Check the desiccant filter in the gas-conditioning unit - Check the filters of the gas-conditioning unit and replace if necessary. - Check the filter element of the probe and replace if necessary. 20
SPARE PARTS Pump ( Gas5000 Unit ) Pump ( Gas400 Unit ) Part No. SP670 (24VDC) SP600 (6VDC) Dust filter(s) 72200 Dust filter - probe 72560 Valves Purge pump ( Gas 400 Unit ) Permeation Dryer VQD1151 SP 670 24VDC MD-110-4 Please inform IMR about the serial No. and model of the analyzer by ordering spare parts. Please specify the maximum range by ordering sensors. Please ask for special items. 21
APPENDIX - CIRCUIT DIAGRAM- IMR 5000 See system prints included with this package. L1 S1 N L1 N PE X1 X2 X3 F1 Z1 1 X4 X5 ~ A1 Processcontroller Temp.Gas S1 On/Off Switch X8/1 A1 B(-) A2 Processcontroller SO2 S2 Pushbutton X8/2 A1 A(+) F1 Fuse 2A S3 Selectorswitch X8/3 A1 COMM H1 LED red (24VDC) T1 Powersupply 24VDC X8/4 A2 B(-) H2 LED green (24VDC) X1 L1 X8/5 A2 A(+) H3 LED yellow (24VDC) X2 N X8/6 A2 COMM M1 Gas pump X3 PE X8/7 M2 24VDC Fan X4 L1 (Filter) X8/8 K-TD Timedelay Relay X5 N (Filter) X8/9 K Relay 1-4 (4PDT) X6 +24VDC X8/10 P1 Thermocouple-probe X7 0V X8/11 P2 SO2-sensor Z1 Inline Filter X8/12 R Resistor 18K X8/13 Y1-3 Solenoids X8/14 X8/15 X8/16 X8/17 X8/18 X8/19 X8/20 4 X7 0V M1 M2 = X6 A1 1 2 12 13 14 5 X8/1 X8/2 X8/3 4 TC + 2 P1 3 T1 1 + 3 2 13 24VDC S3 4 = 14 K1 1 52 6 3 7 4 9 10 11 12 8 TC - X8/4 A2 X8/5 X8/6 12 13 14 P2 1 3 Signal Hi Supply R 2 5 0V Signal Low Color code: L1 - black, 18AWG N - blue, 18AWG PE - yellow, 18AWG 24VDC (+) - red, 24AWG 0VDC (-) - gray, 24AWG Sensor (+) - blue, 26AWG Sensor (-) - green, 26AWG Modbus (B-) - purple, 24AWG Modbus (A+) - orange, 24AWG Modbus(COMM) - yellow, 24AWG S2 A1 K-TD 16 18 = 15 A2 0V H1 H2 H3 Y1 Y2 Y3 22
APPENDIX - CIRCUIT DIAGRAM- IMR 400 23
APPENDIX - TERMINAL BLOCKS - IMR 5000 24
APPENDIX - TERMINAL BLOCKS - IMR 400 AC-Input PCB-Supply X1- L Fuse L1-PCB Fan Supply Pump X2 - N Power In PCB Fan Supply Pump 1-2 - N 3-4 - L1 Hose AC Out Pump Supply X4 X5 X6 X7 1-1 - 2-3 - PE 4 - N hose X8/1 5 - L1 hose X8/3 6 - PE 1 - L1 pump 2 - N pump Temp. control Hose ext. 2-3 - LED + 4 - LED - 5 - Thermocouple + X8/5 6 - Thermocouple - X8/6 7-8 - X8 1 - L1hose X5/5 2 - N hose X5/4 3-4 - 5 - Thermocouple + X7/5 6 - Thermocouple - X7/6 Middle - PE X3 - PE Power In Enclosure PCB 1 2 3 4 X4 1 2 3 X5 4 5 6 1 2 X6 1 2 3 4 5 6 7 8 X7 X8 - Front 3 4 2 PE 5 6 1 X1/2/3 - Terminalblocks 25
HEATED HOSE 26
FILTER-ELEMENT IMR 400 27
WARRANTY The company IMR Environmental Equipment International, Inc., 3634 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. 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. 3. 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. 4. 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. 5. 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. 6. 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. 28
Company Information IMR 3634 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 29