IMR 5000 Operating Manual
S/N: SAMPLE
For information only!
IMR Environmental Equipment Inc.

Environmental Equipment, Inc.
SAMPLE
OPERATING MANUAL IMR 5000-SYSTEM
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
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SAMPLE
OPERATING MANUAL IMR 5000-SYSTEM
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.
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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
O2
4 – 20mA
CO
4 – 20mA
CO2 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
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Function chart IMR 5000 - complete gas analysis system
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Gas
Out
MODBUS
MODBUS
24VDC
Power
Supply
SO2
On/Off
Temp
L1 N
Pump
red
Valve#2/B
green
yellow
Valve#1/B
Filter
Valve#3/A
Valve #3
Relay#1
Valve#1/A
Pushbutton
Selector-Switch
Timedelay
Relay
Valve#2/A
Gas measuring unit
SO2
Cal
Gas1
Air In
Gas Out
Gas In
Controller
Diaphragm
Pump
(Purging)
Condensation Out
Enclosure
Electrical Connection
Gas flow
Thermocouple
green
Gas Dryer
Gas Conditioning unit
Flue-Gas
Purge
L1 N Gas IN
hose
Gas
heated probe
STACK
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OPERATING MANUAL IMR 5000-SYSTEM
Gas flow schematic
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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.
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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:
Wall mounted housing:
Ready for operation:
Ambient temperature:
Storage temperature:
Fuse:
120V / 50Hz
350 x 300 x 200 mm
20 min
5°C - 40°C
-25°C - +65°C
4A / 120VAC
Schematic: Connection
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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
Exaust
Heated Hose
Connection
Heated Hose
Silicone Hose
To IMR 5000
Gas Probe
Filter
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Technical data:
Parameter
O2
CO
CO2
NO
Sensor Technology
Electrochemical
Electrochemical
NDIR
Electrochemical
Accuracy
+/-1%
+/-1%
+/-1%
+/-1%
Power supply:
Housing:
120V/ 50Hz
wall mounted
700 x 500 x 250 mm
Display:
SDU5000
Ready for operation: 40 min
Ambient temperature: 5°C - 50°C
Storage temperature: -25°C - +65°C
Fuse:
2A / 120VAC
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Measuring range
0 – 25%
0 -- 4000ppm
0 – 20%
0 – 100ppm
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Internal panel IMR 5000
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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
CO
CO2
NO
Sensor in %
Sensor in ppm
Sensor in %
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.
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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
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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
X1
OI183
A1+
+
A1-
-
A2+
+
A2-
-
A3+
+
A3-
-
O2
CO
CO2
SLOT4
OI183
R1
+
A1
-
NO
B1
G1
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LEDS and Buttons
Green LED
Measurement mode
Cal-mode
Warm-up mode
- on
- off
- off
Red LED
Measurement mode
Cal-mode
Warm-up mode
- off
- off
- on
Yellow LED
Measurement mode
Cal-mode
Warm-up mode
- 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
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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
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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
O2
CO
CO2
NO
%
ppm
ppm
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.
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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.
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Gas
O2
CO2
CO
NO
Formula
AI1*(20.95/0.0380)
(AI3*0.02-0.14)*(8.882/9.698)
AI2*(400/19.5)
AI4*(206.1/78)
Calibration Formula
AI1*(20.95/1)
(AI3*0.02-0)*(1/1)
(AI2-0)*(1/1)
(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 O2, CO2, CO and NO. Write these values down. If any of the
values are nonzero (except for O2) change the digit in red in the formula until the values are zero.
(AI3*0.02-0)*(1/1) for CO2, (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 O2 read zero. To update O2, simply change the red number
into the number found on the second data page for O2 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:
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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 CO2, (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.
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SPARE PARTS
Part No.
Pump ( Gas5000 Unit )
SP670 (24VDC)
Pump ( Gas400 Unit )
SP600 (6VDC)
Dust filter(s)
72200
Dust filter - probe
72560
Valves
VQD1151
Purge pump ( Gas 400 Unit )
SP 670 24VDC
Permeation Dryer
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.
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L1
N
S1
X2
Z1
3
5
2
12 13 14
1
A2
5
2
X5
X3
Signal Low
2
1
0V
3
4
X6
X7
24VDC
=
T1
~
Supply R
P1
P2
PE
Signal Hi
X8/5
X8/6
X8/4
TC -
TC +
X8/1
X8/2
X8/3
N
4
12 13 14
X4
L1
1
A1
F1
X1
2
4
1+ 3
S3
M1
0V
=
13
14
K1
M2
9 10
11 12
1 5 2 63 7 4 8
X8/1 A1 B(-)
A1 Processcontroller Temp.GasS1 On/Off Switch
X8/2 A1 A(+)
S2 Pushbutton
A2 Processcontroller SO2
X8/3 A1 COMM
S3 Selectorswitch
F1 Fuse 2A
T1 Powersupply 24VDC X8/4 A2 B(-)
H1 LED red (24VDC)
X8/5 A2 A(+)
X1 L1
H2 LED green (24VDC)
X8/6 A2 COMM
X
2
N
H3 LED yellow (24VDC)
X8/7
X3 PE
M1 Gas pump
X8/8
X4 L1 (Filter)
M2 24VDC Fan
X8/9
X5 N (Filter)
K-TD Timedelay Relay
X8/10
X6 +24VDC
K Relay 1-4 (4PDT)
X8/11
X7 0V
P1 Thermocouple-probe
X8/12
Z1 Inline Filter
P2 SO2-sensor
X8/13
RResistor 18K
X8/14
Y1-3 Solenoids
X8/15
X8/16
X8/17
X8/18
X8/19
X8/20
=
A1
16 18
A2
15
K-TD
S2
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
Y3
Y2
Y1
H3
H2
H1
0V
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APPENDIX - CIRCUIT DIAGRAM- IMR 5000
See system prints included with this package.
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APPENDIX - CIRCUIT DIAGRAM- IMR 400
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APPENDIX - TERMINAL BLOCKS - IMR 5000
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4
3
2
1
X4
Power In
Enclosure
PCB
X3 - PE
Power In
PCB
Fan
Supply Pump
X2 - N
Fuse
L1-PCB
Fan
Supply Pump
X1- L
AC-Input
3
2
1
X5
2
1
X6
1
2
3
4
5
6
7
8
X7
3
4
1 - L1 pump
2 - N pump
X6
Pump Supply
5
6
PE
2
1
X8 - Front
123 - PE
4 - N hose X8/1
5 - L1 hose X8/3
6 - PE
X5
Hose AC Out
X1/2/3 - Terminalblocks
6
5
4
12-N
34 - L1
X4
PCB-Supply
X8
1 - L1hose X5/5
2 - N hose X5/4
345 - Thermocouple + X7/5
6 - Thermocouple - X7/6
Middle - PE
X7
123 - LED +
4 - LED 5 - Thermocouple + X8/5
6 - Thermocouple - X8/6
78-
Hose ext.
Temp. control
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APPENDIX - TERMINAL BLOCKS - IMR 400
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HEATED HOSE
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FILTER-ELEMENT IMR 400
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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.
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Company Information
IMR
Environmental Equipment, Inc.
3634 Central Ave.
St. Petersburg, Fl 33711
USA
Tel: 727-328-2818
Fax: 727-328-2826
800-RING-IMR
E-mail: [email protected]
Web Site: www.imrusa.com
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