Cosa 9610 User manual

INSTALLATION, OPERATION
AND
MAINTENANCE
MANUAL
COSA 9610™
GENERAL PURPOSE & EXPLOSION
PROOF
Version:
1.4.2
Revision date: June 7th 2019
CAL.01. D .9826

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™
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COSA INSTRUMENT CORPORATION
New York Texas Corporate Headquarters,
Manufacturing Offices: Sales & Service Offices:
84F Horseblock Rd. 4140 World Houston Parkway
Yaphank, NY 11980 Suite 180
Tel: [phone] Houston, TX 77032
Fax: [phone] Tel: [phone]
Fax: [phone]
E-mail:
[e-mail]
http://www.cosaxentaur.com
Copyright ©
2019
All rights reserve d.
The contents of this publication are presented for informational purposes only. While every effort has
been
made to ensure this document error-free, it should not be construed as warranties or guarantees,
expressed or implied, regarding the product or services described herein or its use or applicability.
COSA Instrument Corporation reserves the right to revise or to improve the design or specifications of
the
COSA 9610™ at any time and without
notice.

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Table of Contents
1. INTRODUCTION
................................................................. 5
1.1.
I NTRODUCTION ................................................................................ 5
1.1.1. Purpose of the anal yzer..........................................................................5
1.2. THE COSA 9610™ ANALYZER ............................................................ 5
1.2.1. Oven with oxygen sensor........................................................................6
1.2.2. The sample system (SCS) .......................................................................7
1.3. CALIBRATION P ROCEDURE ................................................................. 8
1.4. EXTENDED (DUAL) RANGE
O PTION .................................................... 10
1.4.1. Operation ...........................................................................................10
1.5. SPECIFICATIONS COSA 9610™ WOBBE INDEX ANALYZER ....................... 11
1.5.1. Analyzer performance..........................................................................11
1.5.2. Utilities................................................................................................. ..11
1.5.3. Installation..........................................................................................11
1.6 X-Purge option…………………………………………………………………… 12
2.
INSTALLATION................................................................. 16
2.1. GENERAL
................................................................................... 16
2.2. STORAGE
................................................................................... 16
2.3. PLACEMENT
................................................................................ 16
2.3.1. Ge n era l................................................................................................. 16
2.3.2. COSA 9610™ in general purpose execution (Type 01 &
02) .................... 17
2.3.3. COSA 9610™ in explosion proof execution (Type 01-Ex &
02-Ex) .............17
2.4. MECHANICAL CONNECTIONS .............................................................. 18
2.4.1. Ge n era l................................................................................................. ..18
2.4.2. Sample supply......................................................................................19
2.4.3. Calibration gasses ................................................................................19
2.5. ELECTRICAL CONNECTIONS..............................................................20
2.5.1. COSA 9610™ in general purpose execution............................................20
2.5.2. COSA 9610™ in explosion proof execut ion .............................................20
3. IN
OPERATION................................................................. 21
3.1. START-UP SAMPLE CONDITIONING SYSTEM
.......................................... 21
3.1.1. Inspection, visual and external connections ...........................................21
3.1.2. Air orifice se l ect ion ...............................................................................21
3.1.3. Opening of shut-off v al ves ..................................................................... 22
3.1.4. Setting of gas pressure reducer.............................................................22
3.1.5. Adjusting flow with flow meters ............................................................22
3.1.6. Adjusting booster relays ........................................................................ 22

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3.2. START-UP OF THE CONTROL
U NIT ..................................................... 25
3.2.1. Description ..........................................................................................25
3.2.2. Programming the measurement pa rameters ............................................ 25
3.2.3. Main screen .......................................................................................... 25
3.3. PROGRAMMING MENUS .................................................................. 30
3.3.1. Calibration Menu................................................................................... 30
3.3.2. Operation Menu .................................................................................... 31
3.3.3. Measurement M e nu ............................................................................... 32
3.3.4. Output M e nu......................................................................................... 33
3.3.5. Communications M e nu........................................................................... 34
3.3.6. System M e nu ........................................................................................ 36
3.3.7. Display Menu ........................................................................................ 37
3.3.8. Reset Alarms M e nu................................................................................ 38
3.4. TEMPERATURE CONTROLLED OVEN .................................................... 39
3.4.1. Furnace temperature control uni t ........................................................... 39
3.4.2. Adjustment procedure temperature re gula t o r .......................................... 40
4. PREVENTIVE MAINTENANCE .............................................
41
4.1. WEEKLY / MONTHLY MAINTENANCE
................................................... 41
4.1.1. Compressor (optional)........................................................................... 41
4.1.2.
Filters................................................................................................... 41
4.2. THREE (3) MONTH MAINTENANCE .....................................................41
4.2.1. Compressor (optional).......................................................................... 41
4.3. ANNUAL MAINTENANCE .................................................................. 42
4.4. TROUBLESHOOTING
...................................................................... 43
4.5. REPLACEMENT OF RESIDUAL OXYGEN SENSOR
....................................... 44
5. INSTALLATION DRAWING.................................................45
6. ORDERING OF SPARE PARTS ............................................
46
7. CERTIFICATIONS .............................................................
48

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1. INTRODUCTION
1.1. INTRODUCTION
1.1.1. Purpose of the analyzer
The continuous COSA 9610™ analyzer determines online the Wobbe-index of a gas. The
COSA 9610™ can be used both, as feed forward and feedback analyzer for gases mixing
or as a feed forward analyzer for burning control. In order to achieve an optimal
performance of the analyzer system it is necessary to read this manual thoroughly before
installation and start-up.
For the combustion of gas, air is required. When supplying the right quantity of air, the
gas will completely burn. This is the so-called stoichiometric air requirement of the gas.
Because of this, the Wobbe-index can also be seen as a value for the need of air in gas.
By burning the gas with a small excess of air, the flue gas will contain the remaining
oxygen from the air, which has not taken part in the combustion. When the Wobbe-
index of a gas changes, the stoichiometric air requirement and the percentage of the
remaining oxygen in the flue gas will change simultaneously. By measuring the
concentration of oxygen in the flue gas, after calibrating the instrument with two gasses
with known Wobbe-index, the Wobbe index can be calculated.
1.2. THE COSA 9610™ ANALYZER
The COSA 9610™ features fast response time and high accuracy. These features make it
unique over conventional Wobbe index analyzers. The oxygen concentration in the air is
considered as constant, namely 20.95%. Functionally we can divide the analyzer-unit in 3
major parts:
• Sample System
• Electronics compartment
• Oven compartment
Optionally the COSA 9610™ can be built in an explosion proof execution. In explosion
proof execution, the analyzer is protected with a purge system.
WARNING - Potential Electrostatic Charging Hazard.
Due to the materials construction of the viewing port, there is a potential to build up an
electrostatic charge across the surface. Suitable precautions should be taken to reduce
this risk.
Risque potentiel de charge électrostatiqueEn raison de la construction en matériaux du
port d'observation, il est possible que des charges électrostatiques se forment sur la
surface. Des précautions appropriées doivent être prises pour réduire ce risque.

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1.2.1. Oven with oxygen sensor
The gas/air mixture is burnt catalytically in an oven, which is kept at 812ºC with a heating
spiral. The temperature is maintained with temperature control using a K-type
thermocouple. The oxygen sensor in the oven is a zirconium oxide cell. This is mounted
such, that one side is in contact with the outside air and the other side with the flue
gasses. At high temperatures, (600ºC) O2-ions in the ZrO2 grating become mobile through
vacancies therein. By fixing porous Pt-electrodes at both sides of the ZrO2, O2, gas
molecules can, through diffusion by and uptake of two electrons from the Pt electrode,
enter the ZrO2 as O2-ion, move to the other electrodes and be converted in gaseous O2
again by release of the two electrons.
OvenVent
Inlet
Air/Gas
Mixture
Heating Spiral
Oxygen Sensor
Drain

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1.2.2. The sample system (SCS)
In the sample conditioning system (SCS), gas and air are mixed in a constant proportion,
such that a small excess of air is present (± 2.5% oxygen) in the flue gas. The gas and air
pressure, are equalized by a dome-loaded pressure reducer (or booster relay), where the
gas pressure governs the air pressure.
The booster relay has a temperature reducing effect; the gas/air mixing proportion can
therefore vary as consequence of variations in viscosity. Therefore, the temperature of the
gas and the air are equalized in a heat exchanger. The gas and air temperature are still at
surrounding temperatures, however, as long as gas and air fluctuate to the same extent
this hardly influences the mixing proportion. In case of large surrounding temperature
fluctuations, the calibration sequence has to be performed more often. Hereafter gas and
air are mixed in the mixing chamber. The mixing chamber is equipped with orifices in the
inlet nozzles. The gas and airflow are determined by a critical expansion over the orifices.
The turbulence created provides a homogeneous mixture.
The diameter ratio of the orifices, together with the ratio between gas and air pressure,
determine the mixing proportion.
After the mixing chamber, the mixture flow is divided into an excess flow to vent and a
flow to oven. The flow to the burning oven will be approximately 30-50 Nl/hr. The vented
stream is approximately 500 Nl/hr with a maximum 1000 Nl/hr.

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1.3. CALIBRATION PROCEDURE
The analyzer can be calibrated in three different ways:
• Single point calibration
Only one calibration gas is used. The value of the gas is chosen middle of the
measuring range. This is only used to correct any offset error to the measurements.
• Two point calibration
Two calibration gases are used. The low calibration gas is set at ± 20% of the
measuring range. The high calibration gas is set at ± 80% of the measuring range.
The advantage over a single point calibration is the increased accuracy over the entire
span.
• Three point calibration
This method uses three calibration gases and is mandatory for a dual range analyzer.
The medium range calibration gas must be in the middle of the measuring range.
All three calibration methods can be performed both manually and automatically:
• Manually
The operator navigates the procedure via on-screen menu to open the correct gas
valves to the analyzer. The operator controls the timing.
• Automatically
The analyzer itself controls the timing of the valves switching. When the measured
values stay within the specified tolerances, the newly calculated calibration
parameters will be accepted. Otherwise, the analyzer will keep the old value and
generates a CAL ERROR on the display and switch the system fault contact and
calibration fault contact.
The automatic calibration can be started as followed:
• Programmable time schedule (Timed calibration)
• Initiated manually via on-screen menu (Semi-automatic calibration)
• External host activates the calibration request contact (Remote calibration)
The one-point calibration/validation procedure will be executed as followed:
1. Analyzer activates calibration/validation contact.
2. The procedure pauses for the specified “Calibration Start Delay” time for the
external host to prepare for calibration/validation.
3. Process gas is switched off and the calibration gas is switch on.
4. The analyzer waits for the readings to stabilize up to the “Switch Time”.
5. Calibration gas is switched off and the process gas is switched on.
6. Analyzer deactivates calibration/validation contact.

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The two-point calibration/validation procedure will be executed as followed:
1. Analyzer activates calibration/validation contact.
2. The procedure pauses for the specified “Calibration Start Delay” time for the
external host to prepare for calibration/validation.
3. Process gas is switched off and the low calibration gas is switch on.
4. The analyzer waits for the readings to stabilize up to the “Switch Time”.
5. Low calibration gas is switched off and thehigh calibration gas is switched on.
6. The analyzer waits for the readings to stabilize up to the “Switch Time”.
7. High calibration gas is switched off and the process gas is switched on.
8. Analyzer deactivates calibration/validation contact.
The three-point calibration/validation procedure will be executed as followed:
1. Analyzer activates calibration/validation contact.
2. The procedure pauses for the specified “Calibration Start Delay” time for the
external host to prepare for calibration/validation.
3. Process gas is switched off and the low calibration gas is switch on.
4. The analyzer waits for the readings to stabilize up to the “Switch Time”.
5. Low calibration gas is switched off and the medium calibration gas is switched on.
6. The analyzer waits for the readings to stabilize up to the “Switch Time”.
7. The analyzer switched the gas stream to the high rangemixing chamber.
8. The analyzer waits for the readings to stabilize up to the “Switch Time”.
9. Medium calibration gas is switched off and the high calibration gas is switched on.
10. The analyzer waits for the readings to stabilize up to the “Switch Time”.
11. High calibration gas is switched off and the process gas is switched on.
12. Analyzer deactivates calibration/validation contact.
Between each step of the calibration process a switch time is programmed enabling the
analyzer to stabilize. After the switch time the new value is used in the calibration
algorithm. The calibration gas switch time is user programmable. By default, it is set at
120 seconds. Depending on the distance to the calibration gases it may be necessary to
change to a longer or shorter delay.

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1.4. EXTENDED (DUAL) RANGE OPTION
1.4.1. Operation
When the measuring range of the analyzer is larger than 1150BTU/SCF, an extended range
option is available which covers a Wobbe index of 2850.BTU/SCF. This is accomplished by
adding a second gas-mixing orifice and selection valves to make changeover possible.
The dilution ratios of each mixing orifice are chosen such that the measuring ranges overlap.
Via the software it is possible to create a 4/20mA current loop signal that covers the whole range.
It is necessary to establish a switch over point that must be calibrated.
For this reason the calibration system is expanded with an extra solenoid valve.

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1.5. SPECIFICATIONS COSA 9610™ WOBBE INDEX ANALYZER
1.5.1. Analyzer performance
Make
Cosa Xentaur Corporation
Service
Natural gas, fuel-gas, biogas, etc.
Ranges
Wobbe index 0-2850 BTU/scf (0-95 MJ/Nm3), span
0-1150 BTU/scf (40 MJ/Nm3) (selectable
CARI 0-20, span 0-10)
Accuracy
± 0.4% of measuring value natural gas
Repeatability
±0.7 BTU/scf (±0.03 MJ/Nm3)
Drift
±0.4 BTU/scf (±0.01 MJ/Nm3), 24 hours
Response time
T90<5 seconds†
Output
2 isolated 4-20 mA outputs, 4 outputs total optional
Span and service selectable
Display & Optional Digital Output
8 User-programmable contact relays
Safety
General area or Explosion proof
† Wobbe w/o density cell or with streaming S.G. option
1.5.2. Utilities
Power supply
110 VAC, 50/60 Hz or 230 VAC/50 Hz
Power consumption
430 VA maximum
Instrument air
0.353 SCF/min (analyzer) at 3 barG (43psig)
0.706 SCF/min (purge system) at 5.5 barG (80psig)
Sample
0.035 SCF/min at 2 barG (29psig)
1.5.3. Installation
Mounting
Freestanding Frame.
Dimensions
39 x 39 x 16 inches (1000 x 1000 x 400 mm)
Weight
± 330 lbs (150 kg)
Ambient temperature
40-113º F (+5 to 45 °C)
Allow ambient temperature variation: ±45ºF (7 °C)
per 24 hours
Humidity
0-90%

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1.6 X-Purge option.
The COSA 9610A™ Calorimeter is protected by a Pepperl & Fuchs X-purge unit:
The purge Type X, EEx ‘px’ purge pressurization system protects general-purpose equipment
mounted in a standard enclosure so that it can be located and operated in a hazardous area.
The hazardous area classification can be Class I and/or Class II, Division 1/Zone 1 and/or
Zone 21. The X-purge operates by controlling and monitoring compressed instrument air or
inert gas through the protected enclosure(s) to remove and prevent the accumulation of
flammable gas, vapors, or dust.
The X-Purge system features these main parts:
• Electronic processor (EPCU) housed in an explosion/flameproof enclosure
• Intrinsically safe electrical/pneumatic manifold assembly
• Input/output connections and controls for operation
• I.S. user interface for programming and monitoring the system
• 316L stainless steel type 4X enclosure for EPCU and connections
• Pressure relief vent with flow and pressure monitoring at the exhaust
The user interface allows programming of up to 4 switch inputs, temperature modules,
enclosure power contacts, 2 auxiliary outputs, and various operational functions. Also, the
user interface screen allows monitoring and easy setup of configurable variables. With the
user interface menus, configuration of the standard information for setup and operation of a
system such as purge time, flow rates, pressures, and enclosure size are easily
programmable.
Additional features allow Class I and Class II operation, inputs for system bypass, enclosure
power on/off, temperature overload and activation of Rapid Exchange flow for cooling or
auxiliary relay for separate cooling source, delay power shutdown, and much more. The two
auxiliary contact outputs can be configured to activate on most of the input switches or any
of the configured alarm states for pressure, flows, and temperature.
The power for the solenoid valve on the manifold unit, inputs, and EPV-6000 vent are
provided by the EPCU through the internal, galvanically isolated intrinsic barrier. No
additional intrinsic safety barriers are required for annunciation.
The X-Purge provides a complete system for purging and pressurizing enclosures for
hazardous location operation.
The X-Purge system can be set up for Class I/ Division 1 (Zone 1), Class II/Division 1 (Zone
21), or both Class I & Class II/Division 1(Zone 1 & Zone 21) applications in accordance with
the NEC-NFPA 70, NFPA496, ISA 12.4, IEC61241-4, and EN60079-2. This system also
complies with IEC61508, SIL 2 level of integrity with SIL 3 option available.
The X-Purge consists of the control unit and user interface mounted in a 316L stainless steel
Type 4X (IP66) enclosure with the pneumatic solenoid valve mounted on the unit. A
proportional valve can be ordered in place of the solenoid valve for continuous control of
flow and pressure to the enclosure.

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The EPV-X-Purge relief vent is separate and is mounted to the enclosure. The components
of the X-Purge control unit are listed below:
• EPCU mounted in an explosion/flameproof enclosure
• I.S. user-interface with display and cable
• I.S. termination board (does not come with ‘CK’ kit version)
• Manifold with I.S. solenoid valve (does not come with ‘CK’ kit version)
• Flush mount type 4X IP66 fitting for protective gas supply to enclosure with tube attached
• Type 4X cable glands for I.S. wiring to I.S. inputs, vents, and temperature modules
• 316L stainless steel pipe nipples for power wires
• 316L stainless steel type 4X enclosure for the X-Purge controller
The components of the EPV-6000 vent:
• EPV-6000 vent with spark arrestor screen
• 1½” sealing nut with gasket for attachment of vent to customer’s enclosure
• A 5 meter, quick disconnect cable; blue (denoting I.S.), for connection to I.S. termination
board inside X-Purge control unit
The X-Purge control unit and vent are mounted to the calorimeter enclosure. Bottom, right
side mounting can be completed with only one control unit and vent. One unit is used for
enclosure sizes up to 450 ft3 (12.7 m3).
Electronic Power Control Unit – EPCU
The EPCU houses the redundant microprocessors, enclosure power contacts, (2) auxiliary
contacts, power supply module, galvanically isolated barriers for the inputs, vent(s), and
temperature modules; all stackable and easy to remove and install into the explosion proof
enclosure that houses them.
The power supply module is available in 24 VDC or 100-240 VAC units. The enclosure power
contacts are forced-guided safety relays. The auxiliary contacts can be user configured for
different functions depending on user requirements.
User-Interface Controller - UIC
The X-Purge is user programmable for many of the configurable options available. This is
done with the intrinsically safe user-interface on the face of the unit, which can also be
remote mounted. The user-interface is a 2 x 20 LCD that is programmed through a set of
buttons on the menu driven unit. All configuration and options are programmed through
this unit. There are also (5) LEDs for easy visual indication of operation:
• Safe Pressure – This turns on (blue) when safe pressure is achieved inside the enclosure.
• Enclosure power – This is (red) when the enclosure power is off, and (green) when
enclosure power is on. The enclosure power can be on only after a successful purge and a
safe pressure is achieved. Bypass option allows power to remain on if safe pressure is lost.
• Rapid Exchange® – The Rapid Exchange or purging flow rate turns on (blue) when the
flow rate is measuring proper flow.
• System Bypass – This turns on (yellow) when the system bypass is active. This should be
used only when the area around the enclosure is known to be safe.

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• Alarm Fault – The (red) LED blinks when any alarm input is detected and is solid when
there is an internal system fault.
Pneumatic Manifold with I.S. Solenoid
• Manifold with I.S. solenoid valve: The manifold system is mounted on the 6000 control unit
providing a needle valve to set enclosure pressure and an I.S. solenoid valve that is used for
purging (Rapid Exchange). Power for the I.S. solenoid valve is provided by the EPCU and is
galvanically isolated. Regulated instrument-grade air is required.
• Proportional valve option: The I.S. proportional valve is separated on the 6000 control unit
and provides continuous flow and pressure to the enclosure for purging (Rapid Exchange)
and pressurization. Power for the I.S. solenoid valve is provided by the EPCU and is
galvanically isolated. No needle valve is required. Pressures can be controlled from a user
set-point.
Certifications allow the X-Purge to be used on enclosures in a gas hazardous atmosphere.
Gas atmospheres require the purging of the enclosure. Dust atmospheres require the
physical removal of all the dust that collects inside. Both gas and dust atmospheres require
the following:
1) removing the dust,
2) sealing the enclosure, and then
3) purging the enclosure.
After these sequences, the pressure within the enclosure is above the minimum level. The
equipment within the enclosure can be energized.
Purge Timing
When using the X-Purge in a gas or gas and dust location, the time for purging an enclosure
can be based either on a known purge rate and time (fixed purge time), or based on the
flow rate being measured from the vent (dynamic purge time). Both methods base the time
on the flow measurement at the vent, and complete the process in steps. The EPCU will take
the readings from the vent and use the appropriate reading (listed below) as the useable
flow rate. For example, if the flow rate measurement from the EPV-6000 vent is 7 SCFM, the
EPCU will use 5 SCFM as the flow rate for evaluation. The flow rate measurement steps and
corresponding enclosure pressures are as follows:
• 5 SCFM @ 1.3” w.c. , (141 l/min @ 33 mm w.c.)
• 12 SCFM @ 2.5” w.c., (340 l/min @ 64 mm w.c.)
• 20 SCFM @ 3.1” w.c., (565 l/min @ 77 mm w.c.)
• 30 SCFM @ 3.4” w.c., (850 l/min @ 86 mm w.c.)
The COSA 9610™ uses the first setting of 5 SCFM @ 1.3” w.c. to establish the purge within
the enclosures. This volume exchange and purge timing is factory set to 8mins, but can be
re-configured to a different value if required by the Area Authority having jurisdiction at the
installation site.

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Fixed Purge Time
If the purge time must be held to a specific time, then this time is based on the known
enclosure volume, number of volume exchanges, and flow rate through the vent. If the flow
rate is below the required minimum, then the purging cycle will reset and will not start until
the flow rate is above the selected rate. This set up does not allow purge flow to go below
the value required and will not recalculate the time for purging if it goes above the required
purge rate.
Dynamic Purge Time
Dynamic purge time allows the purge time to be updated to the purge flow through the
vent. This method is not dependent on a constant flow from the protective gas source. It
bases the purge time on the measured flow and not a set flow. This is very useful when the
protective gas supply pressure varies throughout the purging cycle or when it may vary from
one installation to another.
The following parameters must be entered for the dynamic purge time:
• Enclosure volume
• Number of exchanges
The purge time will be based on the measurement of the vent and evaluation of this
measurement from the EPCU. This allows recalculation of the time based on this
measurement. During the dynamic purge time, the user-interface will display the purge time
in a percentage starting with 0% and ending with 100% (purge time complete).
Purging Modes
Purging start-up can be set up in 4 different modes, which are explained below:
• STD – Standard mode requires the operator to engage the manifold solenoid valve
manually when purging and manually disengage when a successful purging is complete.
• SA – Semiautomatic mode requires the operator to engage the manifold solenoid valve
manually when purging. The EPCU will automatically disengage when a successful purging is
complete.
• FA – Fully-automatic mode will automatically engage the manifold solenoid valve when
safe pressure is detected and will automatically disengage when a successful purging is
complete.
• PV –The proportional mode will continuously control the flow rate during and after
purging. This allows maximum efficiency of the protective gas supply. This is very useful for
areas where there is a limited amount of the protective gas supply available.
Inputs
There are (4) intrinsic safety inputs for activation of various outputs and actions by the
EPCU. These inputs accept only a dry contact for activation and are supplied by the EPCU’s
galvanically isolated barrier. The assignments of the inputs for various actions are achieved
through the user-interface controller. Only one function can operate an input. These inputs
can bypass the system for live maintenance on the enclosure.

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The intrinsic safety inputs activate the auxiliary relays, energize the Rapid Exchange valve,
de-energize the enclosure contacts, and shut the system down, in addition to many more
actions and outputs.
Outputs
There are (2) normally open dry contacts for the enclosure power that can be energized only
after a successful purging and a minimum enclosure pressure is maintained. Loss of
pressure will cause the contacts to de-energize unless the shutdown timer is active or
bypass mode is implemented.
Also available are the Auxiliary 1 and Auxiliary 2, SPDT dry contact outputs. The auxiliary
outputs can be user configured using the user-interface controller and are controlled by
various inputs or various conditions such as low pressure, loss of pressure, bypass
implemented, Rapid Exchange valve on, enclosure above maximum pressure setting, and
many more. Both enclosure contacts and auxiliary contacts are forced-guided safety relays
for functional safety.
EPV-6000 I.S. Relief Vent
The EPV-6000 vent exhausts excess pressure from the enclosure if the pressure within the
enclosure is above 1.0” w.c. and measures flow and pressure during operation. The X-Purge
vent has a pressure transducer and thermal flow sensor that is connected to the 6000 EPCU
and is intrinsically safe through the galvanic isolation barrier within the EPCU. Because
measurement of the flow is always at the exhaust of the pressurized enclosure, the vent is
located on the enclosure(s) such that it is venting to the atmosphere. The vent is connected
to the I.S. termination board using theV1 connector and cable that comes with the vent. The
EPV-6000 vent can be mounted vertically or horizontally and is not gravity dependent. For
corrosive environments, the EPV-6000 has an optional stainless steel cap so that the body of
the vent is mounted in the enclosure with just the stainless steel cap exposed to the outside
environment.
The I.S. termination board is mounted inside the Type 4X (IP66) stainless steel enclosure
and does not require any lead seals to the EPCU enclosure. Wiring from the EPCU to this I.S.
termination board is provided. The power connection for enclosure power, auxiliary outputs
and power to the EPCU is completed within the explosion proof enclosure that houses the
EPCU. A stainless steel ¾” conduit extends to the outside of the Type 4X, IP66 stainless
steel enclosure for easy connection of the lead seals. Lead seals or Ex de cable glands are
not provided. Any certified lead seal or Ex de cable glands can be used. No special seals are
required. See X-purge manual for electrical connections.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™
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2. INSTALLATION
2.1. GENERAL
Upon receipt and unpacking of the COSA 9610™ a visual inspection must be carried out
to check for any visual damage, caused by transport. Any damage must be reported
immediately to:
COSA INSTRUMENT CORPORATION
Texas Office:
4140 World Houston Parkway suite 180
Houston, TX 77032
Tel: [phone]
Fax: [phone]
New York Office: E-mail:
84G Horseblock Rd. [e-mail]
Yaphank, NY 11980
Tel: [phone]
Fax: [phone]
We kindly ask you to submit photographs of the damage.
If the COSA 9610™ is supplied by the COSA XENTAUR CORPORATION, as part of a
complete package and built into a shelter or house, installation may differ from
hereunder described.
2.2. STORAGE
The COSA 9610™ must be stored frost-free and at a maximum temperature of 122ºF
(50°C), preferably in it’s original packing, and protected against direct sunlight and (rain)
water.
2.3. PLACEMENT
2.3.1. General
The COSA 9610™ can operate under ambient conditions between +41º F (5°C) and
+113ºF (45°C) and a maximum humidity of 90%.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™
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2.3.2. COSA 9610™ in general purpose execution (Type 01 & 02)
The COSA 9610™ is mounted to a freestanding stainless steel frame. Fixing lugs are
located on each corner of the cabinet. Fixings used must be suitable for the weight of
the COSA 9610™ (±331 lbs/150kg).
The COSA 9610™ must be mounted on such a level above the floor or underneath
located obstacles that the oven drain can be connected to a drain header or a condense
bottle.
The COSA 9610™ is supplied on a 304SS freestanding frame. This frame is to
be placed on a flat surface (i.e. concrete slab). Two holes
in the base of the frame enable the COSA 9610™ to be fixed to the floor .
2.3.3. COSA 9610™ in explosion proof execution (Type 01-Ex & 02-Ex)
The COSA 9610™ is supplied on a 304SS freestanding frame. This frame
is to be placed on a flat surface (i.e. concrete slab). Two holes in the base of the
frame enable the COSA 9610™ to be fixed to the floor.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™
Page 19 of 48
2.4. MECHANICAL CONNECTIONS
2.4.1. General
• Location and amount of connections may vary depending on type and execution of
the analyzer. See the project specific drawings of your order.
• Tubing connections on the COSA 9610™ are Swagelok double ferrule compression
type fittings for imperial sizes. (Reducers to metric fittings or NPT thread are
available)
• Only seamless and annealed imperial size instrument tubing according ASTM A-249 at
a maximum permissible hardness of Rockwell B-90 may be used.
• Tubing must be cut off straight and de-burred thoroughly. (Inside and outside of
tubing cutting edge)
• The outside surface of the tube ends entering the fittings must be clean and free from
scratches.
• Nuts and ferrules do not have to and must not be removed to avoid mixing up of the
nuts and or ferrules
• Tubing must be pushed into the fitting onto the seat
• Hand-tighten the nut and mark the nut against the fitting
• Use a correct size wrench to lock the body of the fitting and tighten the nut with another
correct size wrench for 1- 1/4 turn for 1/4" fittings, 3/4 turn for 1/8" fittings. (Watch the marks)
• Before connecting the tubing to the analyzer they must be blown through with dry
nitrogen or instrument air to remove all particles.
• All connections must be checked against leakage prior to putting the analyzer in
operation or installing the tubing.
• Pressurize the lines with nitrogen or instrument air at 7bar maximum to perform leak
test. Check each connection with soap. (e.g. snoop)
• Make sure before pressurizing for leak-test that the power to the analyzer is off
(sample and calibration selection valves closed) and that the instrument air supply
isolation valve in the analyzer is closed.
• Vent connections must not be pressure tested while connected to the analyzer.
Disconnect and cap these tubes if leak test is required.
• Re-connection of the fittings is done by hand tightening the nut followed by wrench
tightening for 1/4 turn.
• If a leak is detected, it might be fixed by tightening the fitting step by step a little
more (up to a 1/4 turn) until it is tight. Then the fitting has to be inspected if it has
not been over-tightened. This is done by disconnecting the fitting and to check if the
ferrules can still be rotated in relation to each other and the pipe. (If the ferrules can
also be moved in an axial direction the fitting is too loose) If the ferrules are stuck, the
pipe has to be cut just after the nut and newly installed according above instructions
using new ferrules. (The nut can be re-used)
• If this does not solve the problem, remove the fitting and inspect the fitting body for
damage. If it is damaged the complete fitting must be replaced.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™
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• If the body is not damaged the pipe has to be cut just after the nut and newly
installed according above instructions using new ferrules. (The nut can be re-used)
• Disconnected fittings can be re-installed by hand tightening the nut followed by
wrench tightening for 1/4 turn. It is recommended to perform a leak test after re-
installation.
2.4.2. Sample supply
The sample supply line must be heat-traced and/or insulated to keep the gas above dew
point. Check your sample data for required temperature.
Sample inlet connection on the analyzer is identified with a tag-plate.
The sample connection on the analyzer is for 1/8”OD tubing. Tubing size to the process
may require a different tube size, this should be determined taking into account process
pressure, sample line length and acceptable lag time.
2.4.3. Calibration gasses
Calibration gas composition is depending on range and process gas. COSA INSTRUMENT
can advise suitable compositions.
For a single range analyzer, 2 calibration gasses (low and high value) are recommended.
For a dual range analyzer, 3 calibration gasses (low/medium and high value) are
mandatory.