Cosa 9610 User manual

INSTALLATION, OPERATION
AND
MAINTENANCE MANUAL
COSA 9610™
GENERAL PURPOSE & EXPLOSION PROOF
Version: 1.3.3
Software version: 2.3.0.0
Revision date: August 17, 2009
Print date: 08/17/09

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™
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CAL.xx.x.xxxx
COSA INSTRUMENT CORPORATION
New Jersey Sales Office: Texas Sales & Service Offices:
55 Oak Street 7125 North Loop East
Norwood, NJ 07648 Houston, TX 77028
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
New York Corporate &
Manufacturing Offices: E-mail:
84G Horseblock Rd. [email protected]
Yaphank, NY 11980
Tel: [phone] http://www.cosa-instrument.com
Fax: [phone]
Copyright © 2009
All rights reserved.
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. INTRODUCTION ...............................................................................5
1.1.1. Purpose of the analyzer..........................................................................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 PROCEDURE..................................................................8
1.4. EXTENDED (DUAL)RANGE OPTION .....................................................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
2. INSTALLATION................................................................ 12
2.1. GENERAL.....................................................................................12
2.2. STORAGE.....................................................................................12
2.3. PLACEMENT..................................................................................12
2.3.1. General...............................................................................................12
2.3.2. COSA 9610™ in general purpose execution (Type 01 & 02).....................13
2.3.3. COSA 9610™ in explosion proof execution (Type 01-Ex & 02-Ex).............13
2.4. MECHANICAL CONNECTIONS..............................................................14
2.4.1. General...............................................................................................14
2.4.2. Sample supply .....................................................................................15
2.4.3. Calibration gasses................................................................................15
2.5. ELECTRICAL CONNECTIONS...............................................................16
2.5.1. COSA 9610™ in general purpose execution............................................16
2.5.2. COSA 9610™ in explosion proof execution .............................................16
3. IN OPERATION................................................................ 18
3.1. START-UP SAMPLE CONDITIONING SYSTEM...........................................18
3.1.1. Inspection, visual and external connections............................................18
3.1.2. Air orifice selection...............................................................................18
3.1.3. Opening of shut-off valves....................................................................19
3.1.4. Setting of gas pressure reducer.............................................................19
3.1.5. Adjusting flow with flow meters ............................................................19
3.1.6. Adjusting booster relays .......................................................................19
3.2. START-UP OF THE CONTROL UNIT ......................................................21
3.2.1. Description..........................................................................................21

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3.2.2. Programming the measurement parameters...........................................21
3.2.3. Main screen.........................................................................................21
3.3. PROGRAMMING MENUS....................................................................27
3.3.1. Calibration Menu..................................................................................27
3.3.2. Operation Menu...................................................................................28
3.3.3. Measurement Menu..............................................................................29
3.3.4. Output Menu .......................................................................................30
3.3.5. Communications Menu .........................................................................31
3.3.6. System Menu.......................................................................................32
3.3.7. Display Menu.......................................................................................33
3.3.8. Reset Alarms Menu ..............................................................................34
3.4. TEMPERATURE CONTROLLED OVEN......................................................35
3.4.1. Furnace temperature control unit ..........................................................35
3.4.2. Adjustment procedure temperature regulator.........................................36
4. PREVENTIVE MAINTENANCE ............................................ 37
4.1. WEEKLY /MONTHLY MAINTENANCE ....................................................37
4.1.1. Compressor (optional)............................. Error! Bookmark not defined.
4.1.2. Filters .................................................... Error! Bookmark not defined.
4.2. THTREE (3) MONTH MAINTENANCE......... ERROR!BOOKMARK NOT DEFINED.
4.2.1. Compressor (optional)............................. Error! Bookmark not defined.
4.3. ANNUAL MAINTENANCE....................................................................38
4.4. TROUBLESHOOTING........................................................................39
4.5. REPLACEMENT OF RESIDUAL OXYGEN SENSOR........................................40
5. INSTALLATION DRAWING................................................ 41
6. ORDERING OF SPARE PARTS............................................ 42

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA 9610™
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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 extended with a purge system.

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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 burning
spiral. The temperature is maintained with a temperature controller 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 ZrO2grating become mobile through
vacancies herein. By fixing porous Pt-electrodes at both sides of the ZrO2, O2, gas
molecules can through diffusion by an uptake of two electrons from the Pt electrode enter
the ZrO2as O2-ion, move to the other electrodes and be converted in gaseous O2again by
release of the two electrons.
Inlet
Air/Gas
Mixture
Oven
Heating Spiral Oxygen Sensor
Drain
Vent

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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 the high 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 range mixing 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 40 MJ/Nm3, an extended range
option is available which covers a Wobbe index of 0-95 MJ/Nm3. This is accomplished by
adding a second gas orifice tube and selection valve to make changeover possible. The
dilution ratios of each orifice tube 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.