ANALOX COSAMS Generic User manual

Analox Military Systems Ltd
15 Ellerbeck Court, Stokesley Business Park,
North Yorkshire, TS9 5PT, UK
T: [phone] F: [phone]
W: www.analoxmilitarysystems.co.uk E: [e-mail]
Copyright © 2015 Analox Ltd. All Rights Reserved.
COSAMS Generic
User Manual
Commercial in Confidence

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 3 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
Revision history
Date
Rev
By
DCN
Comments
CHKD
CHKD
Date
Ext.
APP
D
Ext.
APPD
Ref
Ext.
APPD
Date
02/03/2020
03
PJO
2019-0087,
2020-0026
New catalyst MSDS added, Update to the
maintenance procedure for the IR source to show
new variant created during Venus Solo changes
DG
03/04/2020
-
-
-
16/12/2019
02
PJO
2019-0141
Update to the generic COSAMS manual to bring
it in line with latest version of manual, but
keeping generic parts of manual
DG
20/12/2019
-
-
-
15/03/2016
01
PJO
N/A
Temperature specification updated
PB
15/03/2016
-
-
-
29/10/2015
00
PJO
N?A
Original Issue - Derived from P0138-810-07
N/A
N/A
-
-
-
-
-
-
-
-
-
-
-
-
-

Table of Contents
1Introduction..................................................................................................................... 9
2Modification state control ........................................................................................... 10
3System checklist ............................................................................................................ 12
4Transport and storage considerations........................................................................ 13
5Installation details......................................................................................................... 14
5.1 Overview ......................................................................................................................................... 14
5.1.1 Tools/consumables required for installation .......................................................................................................14
5.2 Mechanical installation.................................................................................................................. 15
5.2.1 Mounting COSAMS ........................................................................................................................................................15
5.3 Electrical installation...................................................................................................................... 17
5.3.1 AC Cable identification .................................................................................................................................................18
5.3.2 DC Cable identification .................................................................................................................................................19
5.3.3 Signal output ....................................................................................................................................................................20
5.3.4 Equipotential bonding strap.......................................................................................................................................20
6Technical description .................................................................................................... 21
6.1 Gas sampling .................................................................................................................................. 21
6.2 Power supply .................................................................................................................................. 24
6.2.1 Power supply (AC variant) ...........................................................................................................................................24
6.2.2 Power supply (DC variant) ...........................................................................................................................................24
6.3 Power distribution ......................................................................................................................... 24
6.4 CO sensor ........................................................................................................................................ 24
6.5 5S3 control interface...................................................................................................................... 25
6.6 SDA operator console .................................................................................................................... 25
6.7 SDA output module ....................................................................................................................... 25
6.8 Electrical schematic (AC variant) .................................................................................................. 26
6.9 Electrical schematic (DC variant) .................................................................................................. 27
7Operating instructions.................................................................................................. 29
7.1 Controls........................................................................................................................................... 29
7.2 Start-up........................................................................................................................................... 29
7.3 Warm-up......................................................................................................................................... 30
7.4 Normal operation........................................................................................................................... 30
7.4.1 System status indicator.................................................................................................................................................30
7.5 Menu ............................................................................................................................................... 31
7.5.1 Adjusting the backlight.................................................................................................................................................32
7.5.2 Auto-zero function .........................................................................................................................................................33
7.5.3 Replacing catalyst ...........................................................................................................................................................33
7.5.4 Resetting the service interval timer .........................................................................................................................33
7.5.5 COSAMS information ....................................................................................................................................................33
7.5.6 Data logging .....................................................................................................................................................................34
8Calibration...................................................................................................................... 38
8.1 Zero and span calibration.............................................................................................................. 38
8.1.1 Performing a zero calibration.....................................................................................................................................38
8.1.2 Performing a span calibration....................................................................................................................................39
9Alarms............................................................................................................................. 40
9.1 Adjusting alarm set points ............................................................................................................ 40

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9.2 Acknowledging alarms .................................................................................................................. 40
9.3 Clearing alarms and hysteresis...................................................................................................... 41
10 Technical in-service support software..................................................................... 42
11 Troubleshooting......................................................................................................... 43
11.1 Fault announcement ...................................................................................................................... 43
11.2 Fault diagnosis ............................................................................................................................... 43
11.3 Fault logging .................................................................................................................................. 43
12 Maintenance ............................................................................................................... 46
12.1 Spare parts...................................................................................................................................... 46
12.2 Special maintenance equipment................................................................................................... 47
12.3 Periodic maintenance .................................................................................................................... 48
12.3.1 Filter check and replacement ................................................................................................................................51
12.3.2 Auto-zero catalyst replacement...........................................................................................................................52
12.3.3 Cabinet breather inspection/replacement .......................................................................................................52
12.3.4 Removal and replacement of the baseplate assembly ...............................................................................53
12.3.5 Sample pump replacement....................................................................................................................................55
12.3.6 Infra-red source replacement................................................................................................................................57
12.4 Non-periodic maintenance............................................................................................................ 60
12.4.1 Solenoid valve replacement...................................................................................................................................60
12.4.2 Flow switch replacement.........................................................................................................................................61
12.4.3 Replacing the power supply unit (AC variant)................................................................................................62
12.4.4 Replacing the power supply unit (DC variant)................................................................................................64
12.4.5 Replacing the SDA Output Module PCB...........................................................................................................65
12.4.6 Replacing SDA Operator Console membrane label .....................................................................................66
12.4.7 Replacing the SDA Operator Console ...............................................................................................................67
12.4.8 CO sensor calibration ...............................................................................................................................................68
13 Warranty ..................................................................................................................... 71
14 Fault reporting to Analox.......................................................................................... 72
15 Specifications.............................................................................................................. 73
15.1 Mechanical specifications.............................................................................................................. 73
15.2 Electrical specifications (AC variant) ............................................................................................ 73
15.3 Electrical specifications (DC variant) ............................................................................................ 73
15.4 Environmental specifications ........................................................................................................ 74
15.5 Performance specifications ........................................................................................................... 74
16 Disposal ....................................................................................................................... 75
16.1 WEEE statement ............................................................................................................................. 75
16.2 Catalyst disposal............................................................................................................................. 75
Appendix A PremiOx Gold safety datasheet.............................................................. 76
Appendix B Nanaucat safety data sheet ........................................................................ 81

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List of figures
Figure 1 Modification state label.............................................................................................................. 10
Figure 2 Baseplate modification state label ............................................................................................ 11
Figure 3 COSAMS overview....................................................................................................................... 14
Figure 4 Mounting arrangement .............................................................................................................. 15
Figure 5 Relative positions of COSAMS mounting holes ....................................................................... 16
Figure 6 COSAMS internal pneumatic arrangement............................................................................... 21
Figure 7 COSAMS internal electrical arrangement (AC variant) ............................................................ 22
Figure 8 COSAMS internal electrical arrangement (DC variant))........................................................... 23
Figure 9 Internal wiring schematic (AC variant)...................................................................................... 26
Figure 10 Internal Wiring Schematic (Cabinet) (DC variant).................................................................. 27
Figure 11 Internal Wiring Schematic (Baseplate) (DC variant) .............................................................. 28
Figure 12 COSAMS front panel ................................................................................................................. 29
Figure 13 Start-up splash screen .............................................................................................................. 29
Figure 14 Warm-up screen........................................................................................................................ 30
Figure 15 Main display overview .............................................................................................................. 30
Figure 16 The main menu.......................................................................................................................... 31
Figure 17 The backlight sub-menu........................................................................................................... 32
Figure 18 Zeroing sensor indication......................................................................................................... 33
Figure 19 COSAMS information screen.................................................................................................... 33
Figure 20 Example of data logged by system.......................................................................................... 34
Figure 21 Span adjustment ....................................................................................................................... 39
Figure 22 Example of alarm set-point adjustment.................................................................................. 40
Figure 23 Alarm hysteresis ........................................................................................................................ 41
Figure 24 Fault indication (example of a flow fault) .............................................................................. 43
Figure 25 COSAMS internal components (1) ........................................................................................... 49
Figure 26 COSAMS internal components (2) ........................................................................................... 50
List of tables
Table 1 Cabinet modification state .......................................................................................................... 10
Table 2 Baseplate modification state ....................................................................................................... 11
Table 3 System checklist............................................................................................................................ 12
Table 4 Connector details.......................................................................................................................... 18
Table 5 Connector pin-out ........................................................................................................................ 18
Table 6 Connector details.......................................................................................................................... 19
Table 7 Connector pin-out ........................................................................................................................ 19
Table 8 SDA operator console menu items.............................................................................................. 31
Table 9 Fault codes .................................................................................................................................... 45
Table 10 COSAMS spare parts list............................................................................................................. 47
Table 11 Special maintenance equipment ............................................................................................... 47
Table 12 On board maintenance tasks ..................................................................................................... 48

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Warnings, cautions and notes
Warnings and Cautions are used in this Manual to highlight potential hazards and safety risks. Notes are
used to provide supplementary information that is not hazard-related.
WARNING: THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT, IF NOT
AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
CAUTION: THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT, IF NOT
AVOIDED, COULD RESULT IN EQUIPMENT DAMAGE OR LOSS OF DATA.
NOTE: THIS INDICATES INFORMATION THAT IS CONSIDERED IMPORTANT BUT IS
NOT HAZARD RELATED.

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Safety information
Please read this manual prior to installing and using the Analox COSAMS, paying particular attention to the
following safety information:
WARNING: DISCONNECT THE POWER SUPPLY BEFORE PERFORMING ANY MAINTENANCE
WITHIN THE CABINET.
WARNING: HIGH PRESSURE GAS SUPPLY MUST NOT BE APPLIED TO EITHER OF THE
COSAMS GAS PORTS. TO DO SO MAY RESULT IN DAMAGE TO THE COSAMS
SYSTEM AND THE POSSIBLE EMISSION OF PROJECTILES. GAS PRESSURE AT
THE INLET PORT MUST NOT EXCEED 500HPA (GAUGE PRESSURE). DO NOT
OBSTRUCT THE EXHAUST PORT.
WARNING: THE COSAMS CONTAINS A SMALL QUANTITY OF NANAUCAT CATALYST
WHICH MUST BE REPLACED DURING ROUTINE SERVICING. THIS MATERIAL
MAY CAUSE IRRITATION OF THE EYES, NOSE, THROAT AND SKIN BUT UNDER
NORMAL CIRCUMSTANCES AN OPERATOR/TECHNICIAN WILL NOT COME
INTO CONTACT WITH THIS MATERIAL. A MATERIAL SAFET DATASHEET
(MSDS) IS INCLUDED IN THE APPENDIX.
WARNING: SOME COMPONENTS OF THE GFC CO SENSOR, MOUNTED WITHIN THE
COSAMS CABINET, ARE CONTROLLED TO 50°C DURING NORMAL OPERATION
OF THE SENSOR. THE SENSOR SHOULD BE ALLOWED TO COOL A LITTLE
BEFORE HANDLING.

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1Introduction
This manual details installation, operation and maintenance of the Analox COSAMS carbon monoxide (CO)
sensor, developed for the submarine atmosphere monitoring system.
Each COSAMS indicates the local CO concentration on a colour LCD and transmits a corresponding 4-20mA
signal to the submarine’s Central Air Monitoring System.
The COSAMS user interface permits calibration of the sensor and may be used to provide a local visual alarm,
if desired.

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2Modification state control
Each instrument is fitted with a serial number plate, as shown below:
Figure 1 Modification state label
The first COSAMS delivered will initially have no modification numbers crossed out, this is interpreted as
“Modification State 0”.
As design changes are made that affect the form or function of the instrument, the Modification Record boxes
will be used to track changes made to individual units. For example, as an instrument receives the first
authorised modification it will have the ‘1’ box crossed out, signifying that it is now at modification state 1.
Design changes that are applied to ALL delivered instruments in a controlled and timely manner may be
done without updating the modification record; the purpose of the modification record is to signify the
differences between instruments.
Modification
state
Date authorised
Details
0
First article delivery
1
2
3
4
5
6
7
8
9
Table 1 Cabinet modification state