New Cosmos Electric PS-7, Instruction Manual

Page 1: ...struction Manual Keep this manual for easy reference Carefully read this manual prior to use This manual describes the standard model If your unit has end user specific options this manual will be superseded by your delivery specifications Instruction Manual No GAE 018 02 Aug 2020 ...

Page 2: ... to 36 Base Unit installation Wiring 6 1 Installation and Wiring on pages 11 and 12 Operation 7 1 Operation on pages 15 to 24 Normal operation on page 24 点滅 Troubleshooting 10 Troubleshooting on pages 40 and 41 点滅 Trouble Alarm 7 3 Trouble Alarm Operation on pages 26 and 27 Gas Alarm 7 2 Gas Alarm Operation on page 25 Gas inlet Gas outlet Cable entry Flashing Flashing ...

Page 3: ...7 Operation 15 7 1 Operation Procedure 15 7 2 Gas Alarm Operation 25 7 3 Trouble Alarm Operation 26 7 4 Test Mode 28 7 5 Maintenance Mode 29 8 Maintenance 30 9 Consumable Replacement 33 9 1 Filter Element Replacement 33 9 2 Sensor Unit Installation Replacement 34 9 3 Sampling Unit Replacement 37 9 4 Activated Chacoal Filter Installation Replacement 39 10 Troubleshooting 40 11 Specifications 42 12 ...

Page 4: ...s detectors are divided into the following six models according to the sensor unit type and with without a pyrolyzer For sensor selection please contact New Cosmos or its authorized representative Sensor unit type With communication function Without communication function COMM less model Toxic gas sensor unit CDS 7 PS 7 01 PS 7 04 Combustible gas sensor unit CHS 7 Oxygen sensor unit COS 7 PS 7 02 ...

Page 5: ...s unit or its electrical circuits Doing so may compromise the performance of the product This product is not drip proof and thus should be kept away from water Only use this product in accordance with the applicable laws and regulations Set the main unit s power switch located on the front of the base unit to the OFF position before installing removing the main unit Installation removal while the ...

Page 6: ...R1 4 ø6 mm is shipped for unspecified orders 2 Normal blow type fuse is provided for COMM less model 3 Two pcs are provided per system 4 One pc is provided per system 5 One pc is provided with a PS 7 05 or PS 7 06 unit An activated charcoal filter s inner sleeve KF 6S Y1 is provided with a separately sold sensor unit and not included in standard contents Fittings will be provided as per the delive...

Page 7: ...t isolated from each other When using with external devices provide isolation to prevent noise from other power lines from interfering with the analog output of the detector When wiring place wires to avoid potential noise sources e g large power transformers motors and powers supply units Ensure cables between the gas detector and external devices are connected correctly Gas out Rc 1 4 LCD Mainte...

Page 8: ...d cables through the cable entry hole at the bottom of the base unit 3 Filter unit MF 50 Incorporates a filter element FE 1 that prevents dust from entering the gas inlet and the sensor 4 Inlet spacer Prevents the filter unit from being over tightened 5 Latch 2 places Secures the main unit to the base unit 6 White line 2 places Indicates that the latch is in the lock position 3 4 5 1 2 ...

Page 9: ... notification numeric gas concentration value gas concentration on a bar graph trouble status maintenance test mode and flow rate status 5 Operation buttons covered Include the setting adjustment buttons and the TEST switch 6 Front cover Gently pull out and slide it down to access the operation buttons 7 Front panel Incorporates a built in main board 8 Sampling unit Incorporates a built in pump un...

Page 10: ...rns the main unit on off If the base unit s power switch is off no power is supplied to the main unit 6 MNT switch maintenance switch Switches between the maintenance mode 1 MNT1 maintenance mode 2 MNT2 and normal operation mode center position 7 Pyrolyzer connector Supplies power to a connected pyrolyzer CDP 7 Not provided for COMM less models 8 Gas inlet Thread size Rc1 4 Filter unit MF 50 is at...

Page 11: ...COMM Imports data from a currently inserted sensor at the initial startup etc 5 UP and DOWN buttons UP DOWN Used to increase decrease the parameter value 6 Analog output check connector CP Dedicated connector to check the unit s 4 20 mA analog output 7 TEST switch recessed TEST Turns the test mode on off 8 Button for administrator use Administrator use 9 Communication connector CN Used for PDA com...

Page 12: ... gas Spinning quickly The flow rate is normal FL500 indicated on the sub display Spinning slowly The flow rate is reduced Possible filter tube clogging FL400 or less indicated on the sub display Stopped The flow rate is too low Low flow rate alarm FL300 or less indicated on the sub display 7 Gas concentration on the bar graph One bar represents 5 of the full scale value The bar graph value increas...

Page 13: ... length should be less than 5 m Gas name Formula Gas name Formula Gas name Formula Fluorine F2 Trichlorosilane SiHCl3 Ammonia NH3 Hydrogen fluoride 1 HF Silicon tetrachlorid SiCl4 Hydrogen sulfide H2S Chlorine Cl2 Chlorine trifluoride ClF3 Dimethylamine 1 CH3 2NH Ozone O3 Carbon tetrachloride CCl4 Tetrakis dimethylamino titanium Ti N CH3 2 4 Bromine Br2 Hydrogen bromide HBr Arsenic trichloride AsC...

Page 14: ...area Avoid sudden temperature changes This product is not drip proof and should be kept away from water The pressure differential between the gas inlet outlet and the outside air pressure atmospheric pressure should be within 1kPa In addition the pressure differential between the gas inlet and the gas outlet should be within 1kPa with negative pressure applied to the gas inlet Using the detector u...

Page 15: ...s not possible if the latches are not fully locked The protective film is attached to protect the connectors and internal tubing of the base unit against possible damage while installing the base unit Once the main unit has been installed onto the base unit it is no longer necessary Dispose of the used film in accordance with your company s rule and procedure When installing multiple PS 7 units si...

Page 16: ...To prevent this install the outlet spacer provided to the gas outlet first and then connect the metal tube fitting over the spacer Note The inlet spacer is pre installed when shipped Use metal tube fittings Swagelock SS 6MO 1 4RT or equivalent for both the gas inlet and outlet Wrap sealing tape tautly around the threads of each metal tube fitting to prevent slack approx 2 5 wraps Tape size 13 mm w...

Page 17: ...r with external devices provide isolation to prevent noise from other power lines from interfering with the analog output of the detector When wiring place wires to avoid potential noise sources e g large power transformers motors and powers supply units Ensure cables between the gas detector and external devices are connected correctly TB2 s gas alarm contact output is intended to be used with re...

Page 18: ...tubing for looseness 9 10 Check the sampling gas for flow rate and airtightness Not normal Normal 11 Is this for low oxygen detection 11 Perform 21vol adjustment No Yes 2 Turn on the base unit Base unit startup is completed Initial startup 3 Check the analog output for base unit １ Low oxygen detection Check the power source Check the wiring to the terminal blocks No Yes Install the sensor unit Ins...

Page 19: ...icated loop checker LC 7 needs to be connected to the base unit for adjustment Refer to 2 for details 1 Lift the cover flap open Set the MNT switch to the MNT2 position WARNING When using the 24 VDC power supply ensure that the power is 24 VDC 10 Check that the target gas type and full scale value are correct before using a new sensor unit Also check that the sensor unit expiration date has not be...

Page 20: ...sensor unit type using the 17 4 mA 4 0mA switch Sensor unit type MNT2 analog level CDS 7 4 0 mA CHS 7 COS 7 FS 25vol 17 4 mA COS 7 FS 50vol c Set the main unit s power switch to the ON position d Set the MNT switch to the center position for normal operation mode Main unit s power switch To ON position Lift the cover flap open COMM less models Lift the cover flap open To center position normal ope...

Page 21: ...d H terminals with a multimeter etc If the output level is within the range below go to Step 4 If not adjust it using the trimmer Sensor unit type Adjustable range COS 7 FS 50 10 64 10 80mA For COMM less models no need to adjust with the trimmer and the output is fixed at 17 4 mA with the LC 7 loop checker Lift the cover flap open To center position normal operation mode Trimmer adjustment screw R...

Page 22: ...this product is used for the first time or a different gas type sensor unit setting is installed e g target gas or full scale value is different the TROUBLE LED will flash SENS will appear and Err will be shown at the bottom right corner After this open the front cover and press the COMM button for more than one second to clear the error When the same type setting of the sensor unit is installed e...

Page 23: ...ge against the full scale value with 1 increments zs 5 zs 2 H H Gas alarm mode High High limit H H L L L L Low Low limit H L High Low limit Con Broken pyrolyzer wire detection 0 Not detected 1 Detected Con 0 Con 0 CG Calibration gas concentration 1 CG 40 CG 84 nEt DeviceNet on or off 2 0 Off 1 On nEt 0 nEt 0 F F value 1 FL Flow rate The current flow rate is displayed mL min P Sensor unit output 1 ...

Page 24: ... value O2 COS 7 A2 76 76 of full scale value AL button UP DOWN button LCD E g 0 0 ppm Sub display Amber TROUBLE LED is off Flow rate icon quickly spinning Clogging notification Flow rate icon spins slowly Indicates a possible clogged tube filter or excessive negative pressure etc Gas detection and monitoring continue even when this notification is present Low flow rate alarm notification Flow rate...

Page 25: ...l adjustment to increase accuracy Sensor unit type Timing for 1 st adjustment Timing for 2 nd adjustment Steps Toxic gas CDS 7 30 minutes after powering up 24 hours after powering up Set the MNT switch to MNT1 or MNT2 Press the ZERO button Oxygen gas COS 7 25 vol Set the MNT switch to MNT1 or MNT2 Press the SPAN button Combustible gas CHS 7 One day after powering up 7 days after powering up Set th...

Page 26: ... The green POWER LED will flash one time indicating the zero adjustment is completed Press the SPAN button for more than four seconds The green POWER LED will flash one time indicating the zero adjustment is completed POWER LED ZERO button SPAN button Gas concentration with unit of measurement LEL ppb or ppm Target gas label Flow rate icon quickly spinning Green POWER LED is on Amber TROUBLE LED i...

Page 27: ...ed flash LCD Gas alarm contact ZA1 OFF open position OFF open position ON closed position ON closed position Gas alarm contact ZA2 OFF open position OFF open position OFF open position ON closed position Trouble alarm open collector TA ON closed position OFF open position ON closed position ON closed position FLOW SENS CONV ALARM1 ALARM1 ALARM2 ...

Page 28: ...LARM 2 On Off Flashes Red ALARM LED flashing Both ALARM1 and ALARM2 are shown on screen A1 and A2 relation in each gas alarm mode H H mode High High limit alarm L L mode Low Low limit alarm H L mode High Low limit alarm H L モード 上限 下限 2nd stage gas alarm ALARM1 and ALARM2 are lit Gas alarm contacts ZA1 ZA2 activate Alarm set value shown as A1 1st stage gas alarm ALARM1 is lit Gas alarm contact ZA1 ...

Page 29: ...rs on the LCD in the following situations When the sensor s zero level output is extremely low When a broken sensor wire is detected This applies to a combustible gas sensor CHS 7 only 3 Incorrect sensor installed The data e g target gas type full scale value from the last installed sensor is recorded by the gas detector If a newly installed sensor unit does not match the gas detector will detect ...

Page 30: ...7 Memory read error nG On Flashing Off Error code shown at the bottom right corner CAUTION Oxygen sensor COS 7 The analog output from this product falls to 0 6 mA or less in the event of a trouble alarm as listed above When the host system e g control room is set to the low limit alarm gas alarm activates when the gas concentration falls to the alarm set value or less and if the product s analog o...

Page 31: ... UP or DOWN button Increase decrease the analog output value using UP DOWN button Turn on off the recessed TEST switch with test stick CAUTION While in the test mode alarm test using the TEST switch the gas alarm contacts activate If the gas alarm contacts are used to operate the interlocks etc of the external devices release the interlocks etc beforehand as needed to prevent a possible activation...

Page 32: ...ected gas concentration Flashes Detected gas concentration value MNT2 Disabled fixed at OFF Disabled 1 fixed at ON Fixed at 4 0 mA or 17 4 mA Flashes Detected gas concentration value WARNING During normal operation gas monitoring mode ensure the MNT switch is set to the center position Gas alarm contacts and trouble alarm open collector do not activate during MNT1 MNT2 When the MNT switch is set t...

Page 33: ... display 2 Sampling gas flow rate 3 Airtightness 4 Filter element replacement 5 Check the tubing 6 Sensor unit installation replacement 7 Sampling unit replacement 8 Loop check and alarm test using the TEST switch 1 Concentration display Check that the gas concentration value is shown on the LCD and the detector is running Important Maintenance Notice In order to ensure the reliability of the gas ...

Page 34: ... is not possible and an appropriate flow rate cannot be maintained 6 Sensor unit installation replacement Install a new sensor unit into the gas detector at startup and replace it with a new one every 6 months except for combustible gas sensor units CHS 7 Refer to 9 2 Sensor Unit Installation Replacement for the procedure 7 Sampling unit replacement Replace the sampling unit with a new one every 3...

Page 35: ...2 PS 7 SiH4 25 ppm 3 4 5 Item Location Zero level output Alarm set value Flow rate Alarm test using the TEST switch Airtight ness Filter element Tubing Replacement sensor No Replace sampling unit Before adj After adj 1st stage 2nd stage 1 Cabinet 0 0 50 100 H1021943 2 Device A 0 0 5 10 H1021944 3 4 5 ...

Page 36: ...The filter element is accessible now 2 Replace the filter element with a new one 3 Install the filter unit top into the inlet Rotate and tighten the nut to secure the filter unit Ensure the O ring is correctly seated Precautions when replacing the entire filter unit or separating reinstalling it from into the inlet spacer Completely remove the old sealing tape no residue Wrap new sealing tape arou...

Page 37: ...or unit replacement should be performed every 6 months except for combustible gas sensors CHS 7 Replace the expired sensor unit with a new one The expiration year month is written on each sensor unit s individual package Replace the old one with a new one before the expiration date Turn off the gas detector before sensor unit replacement Setting the main unit s power switch to the OFF position wil...

Page 38: ...rward Hold the sensor unit by its sides and then pull it out of the main unit 5 Insert a new sensor unit and place the rear cover back on WARNING If the sensor unit is not completely inserted an airtight seal will not be created and correct gas detection will not be possible Press here then pull back the rear cover Push with palm to insert the sensor unit completely Insert a finger so that the sen...

Page 39: ... white lines are visible indicating that the latches have been locked WARNING Ensure that the latches are in the fully locked position white lines visible Normal detection is not possible if the latches are not fully locked Push the latch lock position White line Latch Rail 2 Align with the rail and slide on 1 Pull forward and hold the latches at both sides unlock position ...

Page 40: ...s with thumbs Press here 2 places CAUTION Turn off the gas detector before sampling unit replacement Setting the main unit s power switch to the OFF position will generate a trouble alarm output open collector is opened OFF If the trouble alarm output is used to operate the interlocks etc of the external devices release the interlocks etc beforehand as needed to prevent a possible activation of th...

Page 41: ...lation Replacement WARNING If the sensor unit is not completely inserted an airtight seal will not be created and correct gas detection will not be possible Take care that the cables are not caught between the front panel and sampling unit Dispose of used sensor sampling units in accordance with the applicable local laws and regulations NOTE Rear cover Front panel Ensure that cables are not caught...

Page 42: ...efer to 9 of 7 1 Operation Procedure CAUTION Replace the activated charcoal filter s inner sleeve KF 6S Y1 at the time of replacing the sensor unit Turn off the gas detector before filter installation replacement Setting the main unit s power switch to the OFF position will generate a trouble alarm output open collector is opened OFF If the trouble alarm output is used to operate the interlocks et...

Page 43: ...pling Unit Replacement Blown fuse Replace the fuse Turn off the detector before replacement 5 3 Base Unit Amber TROUBLE LED flashes Low flow rate due to clogged filter element Replace the filter element 9 1 Filter Element Replacement Low flow rate due to pump failure Replace the sampling unit 9 3 Sampling Unit Replacement Low flow rate due to clogged tubing Remove clog from the tubing Connector to...

Page 44: ...rmal operation mode 7 5 Maintenance Mode Cannot change the test mode value fixed at 0 Test mode value is set within the zero suppression range 1 Set the test mode value to the one greater than the zero suppression set value or 2 Change the zero suppression set value 1 7 4 Test Mode 2 PS 7 gas detector s operation manual for administrators Flow rate icon slowly spins Low flow rate due to clogged fi...

Page 45: ...s alarm 2 stages Red LED flashes ALARM1 and or ALARM2 shown on display Low flow rate alarm with a 10 second delay time Amber LED flashes FLOW shown on display Flow rate icon stops Sensor fault or incorrect sensor installed Amber LED flashes SENS shown on display Broken pyrolyzer wire Amber LED flashes CONV shown on display 3 External output Gas concentration analog output 4 20mADC common negative ...

Page 46: ...orptive gas consult New Cosmos or its authorized representative for the recommended material 2 Specify 1 4 in and 11 64 in for outside and inside diameter respectively during order placement if the standard 6 mm outside and 4 mm inside diameter tubing is not used 3 Not provided for COMM less models 4 COMM less models do not comply with the EMC directive The above specifications are subject to chan...

Page 47: ...ty Exclusions The following will be repaired at the cost of customer even during the warranty period 1 Failures and damages incurred by incorrect use deliberate acts or negligence of the user 2 Failures and damages caused by disaster earthquake storm and flood lightning extreme climate abnormal power supply voltage excessive electromagnetic interferences or other acts of God 3 Failures and damages...

Page 48: ...able The sensor element semiconductor on the platinum coil can be understood as two resistances in parallel being part of a bridge circuit The resistance change of the semiconductor is read as differential voltage using a bridge circuit This type of sensor is very sensitive and can detect combustible or toxic gases at a low ppm or even a ppb level 13 3 Galvanic Cell Sensor for Oxygen Detection The...

Page 49: ...ng a flash fire or explosion in the presence of an ignition source like arc flame or heat LEL Concentrations of combustible gas given in terms of percent of the lower explosion limit vol Gas concentrations given in terms of percent of cubic volume ppm Gas concentrations given in terms of millionth part of cubic volume Maintenance and inspection Tasks performed to ensure that equipment operates nor...

Page 50: ...9 01 GAE 018 02 Aug 2020 02 Additional copies of this instruction manual may be purchased Contact New Cosmos or its authorized representative for ordering Authorized representative Manufacturer NEW COSMOS ELECTRIC CO LTD 2 5 4 Mitsuya naka Yodogawa ku Osaka 532 0036 Japan www newcosmos global com ...