Cosmos PS-7 User manual

New Cosmos PS-7
User Manual
Includes:
Product Manual
Administrator Manual
Pyrolyzer Manual

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PS-7 Manual
©DOD Technologies, INC
675 Industrial Drive Bldg. A.
Cary, IL 60013
Phone [phone] • Fax [phone]

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Table of Contents
Chapter 1 –Introduction ........................................................................................................................................ 5
1.1 Explanation of Symbols .................................................................................................................................................... 5
Chapter 2 –Safety Instructions ............................................................................................................................. 6
Chapter 3 –Contents of This Package .................................................................................................................. 7
3.1 End of Line Filter Use............................................................................................................................................................ 8
Chapter 4 –System Flow Diagram ........................................................................................................................ 9
Chapter 5 –Description ....................................................................................................................................... 10
5.1 Components on the Main Unit ........................................................................................................................................... 10
5.2 Details of the Key Switch Section...................................................................................................................................... 12
5.3 Details of the LCD Screen Display ..................................................................................................................................... 13
Chapter 6 –Installation and Wiring ..................................................................................................................... 14
6.1 Installing the Main Unit ...................................................................................................................................................... 15
6.2 Wiring Instructions ............................................................................................................................................................. 16
Chapter 7 –Operation .......................................................................................................................................... 18
7.1 Operation Procedures......................................................................................................................................................... 18
7.2 Gas Alarm Operating Instructions ..................................................................................................................................... 30
7.3 Trouble Alarm Operating Instructions............................................................................................................................... 32
7.4 Test Mode Settings and Operating Instructions .............................................................................................................. 33
7.5 Maintenance Mode Settings and Operating Instructions................................................................................................ 34
Chapter 8 –Maintenance and Inspection............................................................................................................ 35
Chapter 9 –replacing Consumables.................................................................................................................... 38
9.1 Replacing the Filter Element (FE-1)................................................................................................................................... 38
9.2 Attach/Replacing the Sensor Unit ..................................................................................................................................... 39
9.3 Replacing the Sampling Unit.............................................................................................................................................. 41
Chapter 10 –Troubleshooting ............................................................................................................................. 44
Chapter 11 –Specifications................................................................................................................................. 45
Chapter 12 –Warranty ......................................................................................................................................... 46
Chapter 13 –Detection Principles ....................................................................................................................... 46
13.1 Electrochemical Sensor ................................................................................................................................................... 46
13.2 Hot-wire Semiconductor Sensor..................................................................................................................................... 47
13.3 Galvanic Cell Sensor......................................................................................................................................................... 47
Chapter 14 –Glossary.......................................................................................................................................... 48
Administrator Manual........................................................................................................................................... 49
Chapter 1 –Passwords........................................................................................................................................ 50
1.1 Password Protected Settings ............................................................................................................................................ 50
1.2 Releasing the Password Lock............................................................................................................................................ 50
Chapter 2 –Changing Settings ............................................................................................................................ 51

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2.1 Span Adjustment ................................................................................................................................................................ 51
2.2 21Vol% Adjustment ............................................................................................................................................................ 52
2.3 Changing Setting Values.................................................................................................................................................... 53
2.4 Changing the Alarm Settings ............................................................................................................................................. 55
Pyrolyzer Manual.................................................................................................................................................. 57
Chapter 1 –Attach/Replacing the Pyrolyzer ....................................................................................................... 58

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PS-7 Manual
Chapter 1 –Introduction
Thank you for purchasing the extractive COSMOS Gas Detector Model PS-7.
This Gas Detector is designed to detect the leakage of toxic and combustible gases. It is designed to display
the concentration level of detected gases on the main unit and output that information externally as an
analog signal. When a preset warning level of gas is detected, the warning lamp (ALARM lamp) on the main
unit starts to blink, the external contact output is activated, and the amount of leaking gas is monitored.
The sensor unit and sampling unit used in the Gas Detector can be replaced without the use of tools. Regular
replacement of these components eliminates the need to perform calibration on-site. To ensure correct
operation, read this manual carefully before attempting to install or operate the Gas Detector.
1.1 Explanation of Symbols
This manual uses the following symbols. Their meanings must be understood and observed to ensure safe
operation of the unit.
Danger:
Indicates an impending hazardous situation that, if not avoided, will result in serious
injury or death.
Warning
Indicates a potentially hazardous situation that, if not avoided, could result in serious
injury or death.
Caution
Indicates a potentially hazardous situation that, if not avoided, could result in minor
injury or physical damage.
Note
Indicates operational advice and/or instructions.

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PS-7 Manual
Chapter 2 –Safety Instructions
Read and understand the following information to ensure that the Gas Detector is used correctly. The Gas
Detector must always be used in accordance with relevant laws and regulations, and all wiring, installation,
and other work associated with the Gas Detector must be performed by qualified personnel.
Warning
•When the Gas Detector detects a gas leak, carry out the procedures stipulated by
your company in response to gas leaks.
•The Gas Detector must be grounded to prevent electric shock.
•The Gas Detector is not explosion-proof. It must be installed in a safe location.
Caution
•Do not disassemble or modify the unit or change its construction or circuitry in
any way. Doing so may impair the unit's performance.
•The Gas Detector is not drip-proof and must be installed in a location free from
spattering water.
•The unit must be used in accordance with prescribed laws and regulations.
•Please turn the power switch located on the front of the base unit OFF when
attaching or removing the main unit. If this is done with the switch left ON, the unit
may become damaged, or give false alarms.

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PS-7 Manual
Chapter 3 –Contents of This Package
The following components are included with the standard Gas Detector unit. Ensure that all components are
present before attempting to use the unit. Every effort is made to ensure that the unit is packed correctly, but
if any components are damaged or missing, contact your local authorized distributor.
*1 2 sticks are provided with each system.
NOTE:
1. The sensor unit is not bundled with the Gas Detector and must be purchased separately.
2. When it is with DeviceNet unit, the contents are as described in the DeviceNet Unit Instruction manual
IMPORTANT NOTICE - If using the PS-7 for absorbent / corrosive gases such as HCl, HF, Cl2, HBr, etc. You
must remove the internal filter and install #2-800-013 OR #60009 Corrosive Filter at the end of the sample
line.
Teflon FEP sample tubing must be used in conjunction with the corrosive filter when monitoring for corrosive
/ absorbent gases. 1/4 OD x 3/16” ID
See Chart on next page
Description
Quantity
PS-7 Gas Detector
1
Male connector ¼” NPT
2
Filter elements (FE-1, 12 pcs.)
(For MF-50 Filter Unit)
1
Fuse (0.5 A)
1
Mounting screws (M4 8)
2
Stick for Test
2*1
Operation Manual
1*2
Operation Manual
1*2

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3.1 End of Line Filter Use
PN: 780248
PN: 60009
PN: 2-800-013
Use with
Use with:
Use with:
AsH3
BCl3
BCl3
COCl2
Bf3
Bf3
C4F8
Cl2
Cl2
C5F8
DCS
DCS
B2H6
HBr
HBr
H2S
HCl
HCl
H2Se
HF
HF
GeH4
SiCl4
SiCl4
CH4
SiF4
SiF4
IPA
WF6
WF6
CH2F2
POCl3
POCl3
CH4
Hydrazine
Hydrazine
CHF3
NH3
NH3
CO
O3
O3
H2
NF3
PH3
SiH4
O2

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PS-7 Manual
Chapter 4 –System Flow Diagram
Figure 1 System flow diagram
GAS OUT
Rc 1/4
LCD Display
Maintenance
switch
P
Pump
Sensor
Flow
sensor
MF-50(Dust filter)
GAS IN
Rc 1/4
GAS IN
Rc 1/4
Controller
F1
ZA1
ZA2
ZC
TA
TC
Power
DC 24V
TB
2
1st level warning
2nd level warning
Common
Trouble
warning
Warning contact capacity (ZA1orZA2-ZC)
(Rated load: 125 V AC or 30 V DC
0.5-A resistance load)
Trouble output (TA-TC)
(Rated load: 30 V DC 30-mA
resistance load)
Gas alarm contact output
(N/O)
PW
Jack
(4-conductor shielded cable)
+
-
+
-
TB
1
FS
Sampling Unit
P
N
G
H
E
SW
1
SW
2
TR
AL
Key
Sheet
Analog Output
4 to 20 mADC
Trouble warning output
(N/C)
CPU Board
Warning
Pay special attention to the polarity of the trouble warning output. As the circuit protection
diodes are internalized, if the polarity is reversed, the trouble warning 1 Pull back
not be output.
Caution
The analog output source is not insulated from the power source. In case it is used in
combination with other types of devices, the analog signal must be isolated from flowing into
the power sources of the other devices.

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Chapter 5 –Description
5.1 Components on the Main Unit
No.
Description
Function
1
POWER lamp
(Green) Power lamp. Illuminates during regular monitoring
operations.
2
TROUBLE lamp
(Yellow) The lamp blinks when trouble occurs.
3
ALARM lamp
(Red) The lamp blinks when the concentration level of detected
gas exceeds that of the preset alarm level.
4
LCD display
Warning displays, detected gas levels, bar graphs of gas levels,
trouble states, maintenance modes, test mode, flow sign are all
shown on the LCD display.
5
Key switches (inside)
Switches to carry out the various settings.
6
Filter unit (MF-50)
Incorporates a filter element (FE-1) that prevents dust from
entering the gas inlet and tubes leading to the sensor.
7
Operation section cover
Lift up gently to use key switches.
8
Front panel
Contains the main board.
9
Sampling unit
The pump is contained inside the sampling unit.
10
Main body cover
The cover protecting the sensor unit.
11
Latches
Latches to attach the main unit onto the base unit.
12
Locked/unlocked line
A line (mark) to show the return position of the latch.

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No.
Description
Function
13
Fuse
125 V, 0.5 A
14
Base unit power switch
The power switch for the base unit.
15
Mounting holes
Screw holes (5.5) for wall mounting.
16
Terminal strip
Used to connect external wiring.
17
Main unit power switch
The power switch for the main unit.
18
Maintenance switch
A switch that is set to regular, maintenance mode 1 (MNT1) or
maintenance mode 2 (MNT2).
19
Connector for the pyrolyzer
A connector to provide power to the pyrolyzer when one is being
used. (CDP-7 type).
20
Gas inlet
Aspiration inlet for sampled gas. A filter unit (MF-50) is attached.
21
Gas outlet
Exhaust outlet for sampled gas.
22
Cable entry
A hole for incoming cables.

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5.2 Details of the Key Switch Section
No.
Description
Display
Function
1
Span adjustment
switch
SPAN
To carry out 21vol% adjustments.
(For the COS-7 oxygen sensor unit.)
2
Zeroing switch
ZERO
To carry out zeroing.
(For the CHS-7 flammable gas sensor unit or CDS-7 toxic gas
sensor unit.)
3
Alarm point set switch
AL
Used to check the values of various alarm settings.
4
Communications
switch
COMM.
Sends sensor unit information to the main unit after initial
start-up, etc.
5
Up/down switch
UP
DOWN
Used to change the values of the test output, etc.
6
Connector to check
analog output
CP
A connector employed specially to check the analog output
from the main unit (4- 20 mA).
7
Test switch
TEST
Used to set to test mode.
8
Special command
switch
(None)
Used to change the values of various settings.
(For administrative use.)

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5.3 Details of the LCD Screen Display
No.
Meaning
1
Shows the detected gas concentration (with units).
2
Lights when the flow rate is decreasing. (Also, see no. 6 below.)
3
These light when the detected gas concentration exceeds that of the preset alarm level.
4
Lights on when there is sensor trouble, or when a sensor is inserted incorrectly.
5
Lights on when the pyrolyzer is disconnected.
6
Shows the flow rate of the sampling gas.
Fast rotating display: When flowing at normal rate (0.5 L/min).
Slowly rotating display: (Showing that it is clogged) When the load on the pipe is high.
No rotation: (Warning that the flow rate is decreasing) When the flow rate has decreased.
7
Bar graph of gas concentration. One division is 5% of a full-scale value.
When the bar extends to the far right, it is at full scale.
8
Shows the values of various settings. (For administrative use.)
9
Lights while in test mode.
10
Lights while in either maintenance mode 1 (MNT1) or mode 2 (MNT2).

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Chapter 6 –Installation and Wiring
Warning
•The Gas Detector is not explosion-proof. It must be installed in a safe location.
•When detecting highly adsorbent gases remove the internal filter and install proper
end of line filter (see page 8)
•The sample distance on the PS-7 is 50 feet for non-absorbent gases and 30 feet for
absorbent gases. FEP TEFLON tubing must be used with absorbent gases.
Caution
•The Gas Detector should be installed in a location free from shock and vibration, and
away from sources of high frequencies or magnetism.
•Do not use the gas collector hood when detecting gas concentrations in narrow spaces
such as ducts.
•Do not install the Gas Detector in locations where the temperature may exceed 40°C or
dew condensation or sudden temperature fluctuations may occur.
•The Gas Detector is not drip-proof.
•The pressure difference between the gas inlet/exhaust ports and the ambient
atmosphere must be within 1 kPa. The pressure difference between the inlet port and
exhaust port must be such that the inlet port is a negative pressure of 1 kPa or less.
•Install the Gas Detector vertically. (Inlet port and exhaust port must be in downward
direction.)
•Locate the detector tip (the tip of the gas sampling pipe) to be appropriate for the
specific gravity of the gas to be detected. It must also be placed in a location where the
target gases are likely to accumulate.
Type of gas
Installation height
Heavier than air
Not more than 30 cm above floor level
Equivalent to air
75 to 150 cm above floor level
Lighter than air
Near the ceiling

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6.1 Installing the Main Unit
1. Determine the installation point and
attach the base unit using two M4 8
screws.
`
2. Run a cable through the cable entry
(the cutout hole near the bottom of
the base unit) and connect to the
terminal board. (Refer to 6.2 Wiring
Instructions.)
3. To attach the sensor unit, refer to 9.2
Attach/Replacing the Sensor Unit. To
attach it after attachment of the base
unit, proceed to step 4.
4. Remove the protective seal before
attaching the main unit.
5. Pull back the latches on both the left
and rights sides of the bottom of the
base unit, and attach the main unit
inserting from the top side first.
6. Push both the latches on the left and
right-hand sides of the base unit
back in until the locked/unlocked line
can be seen
2 Attach in line with the rails
1 Pull the latches on both sides forward

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NOTE: The protection seal on the base unit is to protect the connector and internal piping when attaching the
base unit. This seal is not necessary after the main unit is attached. Please dispose of it properly in
accordance with company disposal regulations.
If multiple units are to be mounted in a row, ensure that there is enough space between each unit (at least 3
cm on either side is recommended) to allow the main unit to be removed and reattached.
6.2 Wiring Instructions
Terminal Board
Sign
Polarity
Function
TB1
P
+
Power supply (24 V DC)
N
-
G
+
Gas concentration output (4-20 mA DC)
H
-
E
Ground
TB2
ZA1
Gas alarm contact output (1st level)
(no voltage contact 1a)
Rated load: 125 V AC or 30 V DC, 0.5-A resistance load
ZA2
Gas alarm contact output (2nd level)
(no voltage contact 1a)
Rated load: 125 V AC or 30 V DC, 0.5-A resistance load
ZC
ZA1, ZA2 common
TA
+
Trouble alarm
(Open collector: N/C)
Rated load: 30 V DC, 30-mA resistance load
TC
-
Trouble alarm common
Warning
Be sure to push the latches back as far as they will go. If the latches are not back behind the
locked/ unlocked line, normal gas detection will not be performed.

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Warning
•Be especially careful regarding the polarity of the trouble alarm (TA: plus, TC:
minus.) as the circuit protection diodes are internalized, if the polarity is reversed,
the trouble warning signal will not be output.
•To avoid electric shock, always disconnect the power supply before performing
any wiring operations.
•Ensure that the unit is properly grounded.
Caution
•Do not lay cables near sources of electrical noise, such as high-capacity
transformers, motors or power supplies.
•Ensure that the cables on the external device side and the gas detector side are
correctly connected.

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Chapter 7 –Operation
7.1 Operation Procedures
Carry out operations in the following manner. Refer to the items inside each box for more detailed
instructions (listed from the next page)

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Proceed with operation in the following manner:
1. Verify that the power supply voltage (the voltage between the P and N of the terminal block) is 24 VDC
10%.
2. Switch the base unit power ON.
Warning
•Verify that the power supply voltage is 24 V DC 10%.
•Before operating the Gas Detector, verify that the sensor unit correctly displays the
type of gas to be detected and the full-scale value.
Warning
•Before Turning the power on, check that all connections are correct. Refer to 6.2
Wiring Instructions and the separate delivery specifications if available.

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3. Analog adjustment in maintenance mode 2
-The analog output of the main unit changes when the maintenance switch is set to 2.
-Adjustment should be carried out based on the following instructions as the analog output also
differs depending on the sensor unit being used. For details regarding maintenance modes, refer
to 7.5 Maintenance Mode Settings and Operating Instruction.
Toxic gas sensor unit: CDS-7
Combustible gas sensor unit: CHS-7
Oxygen sensor unit: COS-7
(Value when at full scale 25vol%)
Oxygen sensor unit: COS-7
(Value when at full scale 50vol%)
*MUST BE ADJUSTED
1. Pull back to open
2. Move knob to the right to set to maintenance
mode 2 (MTN2)
1. Pull back to open
2. Move knob to the right to set to maintenance
mode 2 (MTN2)
Analog adjustment volume for maintenance mode 2
Analog adjustment volume for maintenance mode 2
The tester tests the current range.
G=plus
H=minus
The tester tests the current range.
G=plus
H=minus