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

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 5 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
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

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 6 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
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

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 7 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
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.

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 8 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
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.

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 9 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
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.

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 10 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
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

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 11 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
The baseplate is fitted with a modification state label as shown below:
Figure 2 Baseplate modification state label
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 state ‘01’ after MOD State, 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/DCN
No
Details
0
First article delivery
1
2
3
Table 2 Baseplate modification state

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 12 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
3System checklist
Each system, suitable for fitting out one submarine, comprises the following items:
Item
Description
1.
COSAMS instrument
2.
Power input connector
3.
Signal output connector
4.
Enclosure locking key
5.
2m length of calibration sample tube
6.
USB lead
7.
COSAMS software CD
8.
User Manual
9.
Test Certificate/statement of Conformity
Table 3 System checklist

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 13 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
4Transport and storage considerations
To avoid equipment damage when storing or transporting a COSAMS unit it must always be packed in
suitable transport packaging.
CAUTION: WHEN STORING OR TRANSPORTING A COSAMS UNIT IT MUST ALWAYS BE
PACKED IN SUITABLE TRANSPORT PACKAGING.
CAUTION: PRIOR TO POWERING UP THE INSTRUMENT, IT SHOULD ALWAYS BE
ALLOWED TO RETURN TO ITS OPERATING TEMPERATURE RANGE AND ANY
CONDENSATE THAT MAY HAVE FORMED MUST BE ALLOWED TO EVAPORATE.
NOTE: DETAILS OF PERMISSIBLE STORAGE TEMPERATURE, HUMIDITY AND PRESSURE
RANGES CAN BE FOUND IN SECTION 15, ENVIRONMENTAL SPECIFICATIONS.
NOTE: THE COSAMS WILL REQUIRE CALIBRATION AFTER TRANSPORT OR STORAGE.

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 14 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
5Installation details
5.1 Overview
The COSAMS electronics are housed in a custom-made cabinet fabricated from 5000 series aluminium.
External surfaces are painted with RAL7001 (silver grey) epoxy paint to DTD5555A (MIL-22750F) with low-
profile spatter finish.
The cabinet has two lugs per side for direct-mounting to a bulkhead.
The enclosure achieves a minimum ingress protection of IP44.
Figure 3 COSAMS overview
Access is required from the left hand side for the electrical connections:
•power input (1)
•4-20mA signal output (2)
•earth stud for equipotential bonding to the submarine hull (4)
Two waterproof fuse holders are also accessed from the left hand side (3) (DC variant).
The fuse holders are located internally for the AC variant.
Gas sample is drawn through an inlet (5) in the cabinet’s base and exhausts out of the right hand side (6). A
water-proof breather port (7) is also mounted on the right hand side to ensure that cabinet internal pressure
tracks submarine compartment pressure.
Push-fit sinters are supplied with the COSAMS and one should be fitted in both the inlet and exhaust ports to
pre-filter the sample and guard against water entry in the event of splashing.
Access to the cabinet base and right-hand side will be required to maintain the pre-filters and also when
applying calibration gas to the COSAMS.
5.1.1 Tools/consumables required for installation
Installation of the hardware is possible using standard hand tools (i.e. spanners/socket set, screwdrivers, hex
keys, soldering iron, etc.); no special tools or consumables are required.

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 15 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
Upon installation, the system should be calibrated according to section 8.
5.2 Mechanical installation
5.2.1 Mounting COSAMS
Figure 4 Mounting arrangement
M8 hardware should be used to securely bolt the COSAMS using the two mounting lugs protruding
from either side; the relative positions of the rectangularly arranged mounting holes (330 x 369mm
centres) are indicated in Figure 5

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 16 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
Figure 5 Relative positions of COSAMS mounting holes

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 17 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
5.3 Electrical installation
Three external electrical connections are required to the COSAMS:
•power input
•signal output
•equipotential bonding strap
The COSAMS cabinet has a 3-way, male, chassis-mounted plug for connection to an 85-264Vac, 47-63Hz
supply; maximum power consumption is 90W, or a low voltage DC supply; maximum power consumption is
150W. A mating connector (3-way, female, cable-mounting socket) is supplied with COSAMS.
NOTE: THE DESIRED SUPPLY VOLTAGE IS FACTORY FIT ONLY AND SHOULD BE DECIDED
PRIOR TO ORDERING.
A 3-way, female, chassis-mounted socket provides connection to the 4-20mA output signal and a mating
connector (3-way, male, cable-mounting plug) is supplied with COSAMS.

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 18 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
5.3.1 AC Cable identification
AC version cables are to be terminated as follows:
Connector description
Manufacturer’s part number
VG95234/MIL-STD-5015C 3-
way cable female socket, 90°
ITT Cannon CB8U14S-7SS
VG95234/MIL-STD-5015C 3-
way cable male plug, 90°
ITT Cannon CB8U14S-7PS
Table 4 Connector details
Pin no.
Function
Cable core
1
L1
Installer to advise
2
L2
3 [refer to the
CAUTION below]
Earth
Not connected
Body
Earth
Screen
1
Signal +
Installer to advise
2
Signal -
3
Not connected
Not connected
Body
Earth
Screen
Table 5 Connector pin-out
CAUTION: NO CONNECTION IS TO BE MADE TO PIN 3 OF THE CABLE MOUNTED POWER
CONNECTOR. PIN 3 OF THE COSAMS CABINET-MOUNTED PLUG IS
CONNECTED TO THE CABINET BODY IN ORDER TO MAKE PROTECTIVE EARTH
CONNECTION DURING FACTORY SET UP AND TESTING.

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 19 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
5.3.2 DC Cable identification
DC version cables are to be terminated as follows:
Connector description
Manufacturer’s part number
Power input (24Vdc)
VG95234/MIL-STD-5015C 3-way
cable female socket, straight
ITT Cannon CB6U16-10SS
VG95234/MIL-STD-5015C 3-way
cable male plug, straight
ITT Cannon CB6UE14S-7PS
Table 6 Connector details
Pin no.
Function
Cable core
A
+VE
Installer to advise
B
-VE
C [refer to the
CAUTION below]
Earth
Not connected
Body
Earth
Screen
A
Signal +
Installer to advise
B
Signal -
C
Not connected
Not connected
Body
Earth
Screen
Table 7 Connector pin-out
CAUTION: NO CONNECTION IS TO BE MADE TO PIN 3 OF THE CABLE MOUNTED POWER
CONNECTOR. PIN 3 OF THE COSAMS CABINET-MOUNTED PLUG IS
CONNECTED TO THE CABINET BODY IN ORDER TO MAKE PROTECTIVE EARTH
CONNECTION DURING FACTORY SET UP AND TESTING.

COSAMS Generic
User Manual Int. Approved
Document ref: P0138-840-03 April 2020 Page 20 of 89
Copyright © 2015 Analox Ltd. All Rights Reserved.
Commercial in Confidence
5.3.3 Signal output
An Analox SDA output module controls a 4-20mA analogue signal proportional to the perceived CO
concentration over the range 0-200ppm. The module is configured to operate in active mode and
compliance is maintained for loop resistances up to 500Ω.
The analogue output is set to ~2mA during warm-up and in the case of a fault condition being detected.
During the course of an auto-zero operation the 4-20mA output is maintained at a value corresponding to
the CO measurement recorded immediately prior to initiating the auto-zero.
5.3.4 Equipotential bonding strap
A suitable flexible bonding strap must be attached to the COSAMS M8 earth bonding stud. This will be the
means of achieving HF bonding according to MIL STD 1310.