New Cosmos Electric KD-12 User manual

Diffusion type Gas Detector
Model KD-12
Instruction Manual
 Keep this instruction manual where it is readily accessible.
 Thoroughly read this instruction manual before using the equipment so it can be used
safely and correctly.
 This manual provides information concerning standard specifications. If the specifications
of your model are nonstandard, refer to the delivery specifications.
Instruction Manual No.
G E-048-00
September 2013
New
Cosmos Electric Co., td.

•
••
• Nomenclature
See pages 4 to 6.
•
••
• Replacement of Sensor Unit
See pages 29 and 30.
•
••
• Wiring and Connecting
Methods
See pages 11 to 15.
Ground terminals
24 V
power
supply
Indicator
E.g., External
alarm
Shield
•
••
• Display and Operation in
Each Mode
See page 18.
•
••
• Maintenance Check and
Operation Methods
See pages 20 to 28.
•
••
• Troubleshooting
See page 31.

Table of Contents
1. Introduction .................................................................................................................. 1
2. Precautions.................................................................................................................. 2
3. Contents of Package ................................................................................................... 3
4. External Dimensions and Nomenclature..................................................................... 4
4-1. Main Unit .................................................................................................................. 4
4-2. Display and Control Blocks...................................................................................... 5
4-3. Terminal Block.......................................................................................................... 6
5. Installation.................................................................................................................... 7
5-1. Installation Method................................................................................................... 7
5-2. Examples of Installation Positions ......................................................................... 10
5-3. Mounting of Optional items .....................................................................................11
6. Wiring Method............................................................................................................ 12
6-1. Wiring Work............................................................................................................ 12
6-2. Wiring and Connection........................................................................................... 13
7. Precautions before Use............................................................................................. 16
 In Case of Gas Leakage .................................................................................................. 16
8. Display at Start-up (Initial Delay)................................................................................ 17
9. Display and Operation in Each Mode ........................................................................ 18
10. Trouble larm............................................................................................................. 19
11. Maintenance Check and Operation Method .............................................................. 20
11-1. Daily Inspection and Periodical Inspection............................................................ 20
11-2. Preparing Calibration Gas ..................................................................................... 21
11-3. Calibration Method................................................................................................. 23
 Maintenance Mode........................................................................................................... 23
 Zero djustment ............................................................................................................... 24
 Span Rough djustment................................................................................................... 26
 Full-scale and larm Set Value Display ........................................................................... 27
 Test Mode......................................................................................................................... 28
11-4. Replacement of Sensor Unit................................................................................. 29
12. Troubleshooting ......................................................................................................... 31
13. Specifications............................................................................................................. 32
14. Markings of explosion-proof....................................................................................... 33
15. Warranty..................................................................................................................... 34
16. Life Expectancy.......................................................................................................... 34
17. Glossary ..................................................................................................................... 35

1
1. Introduction
• Thank you for purchasing the KD-12 Diffusion type Gas Detector.
• In order to ensure the correct and safe operation of this product, be sure to read this
manual before use.
• This product detects combustible gas, and CO2. The product detects gas leakage at an
early stage in industrial facilities (e.g., gas production plants and depots, chemical plants,
paint factories, and power plants), and outputs the gas concentration value in analog
signal form while displaying the gas concentration value.
If the gas concentration reaches a preset alarm level, the red L RM indicator will flash
and turn ON an external contact output, thus helping to prevent disasters such as
explosion accidents and fires.
• Maintenance and inspection are indispensable to the reliable performance of the Gas
Detection/ larm System. Be sure to perform the maintenance checks described in this
manual.
Explanation of Symbols
The following symbols are used to indicate and classify precautions in this manual.
DANGER
Indicates information that, if not heeded, is likely to result in death or
serious injury.
WARNING
Indicates information that, if not heeded, could possibly result in death or
serious injury.
CAUTION
Indicates information that, if not heeded, could result in minor injury, or
damage to the product.
MEMO
Indicates advice on handling the product.

2
2. Precautions
• Read this manual completely and be sure you understand the information provided herein
before attempting to use the product.
• bide by all applicable laws and regulations when using this product.
WARNING
WARNING
 Be sure to ground the product to prevent electric shocks.
 If there is a gas leak alarm, take the necessary measures in accordance with your
company's regulations.
 The cable entry device and blanking elements shall be of TEX certified in type of
explosion protection flameproof enclosure ‘’d’’, suitable for the condition of use and
correctly installed.
 Unused apertures shall be closed with suitable TEX certified blanking elements.
 Fastener type M5 x 16 shall have a yield stress factor of min. 450 N/mm2.
CAUTION
 ll necessary work for the product including wiring and installation should be carried out
by suitably trained personnel in accordance with applicable code of practice.
 Inspection, maintenance and repair of the equipment should be carried out by suitably
trained personnel in accordance with applicable code of practice.
 Do not disassemble the product or modify the construction or electric circuits of the
product. Otherwise, the explosion-proof construction of the product may be adversely
affected.
 Do not install the product in places or near places where silicone sealant or gas is used.
Otherwise, the performance of the product may be adversely affected.
 Be sure to provide a protective cover (optional) if the product is installed outdoors.
 Use the product in accordance with applicable laws and regulations.
 Hydrocarbon gas except the target gas might be detected, so consider the measurement
environment.
Special Condition for Safe Use
 Use in TEX hazardous area, TEX certified cable glands according to EN 60079-0:2012
and EN 60079-1:2007 shall be provided by end-user.
 Use in IECEx hazardous area, IECEx certified cable glands according to IEC
60079-0:2011 and IEC60079-1:2007 shall be provided by end-user.
 Fastener type M5 x 16 shall have a yield stress factor of min. 450 N/mm2.
 Requirement of cable entry:
Thread size of cable entry .G3/4 or PF3/4
Depth of engagement ....10.86mm
Threads engagement .6
 The dimensions of flameproof joint between casing and casing cover of KD-12
flameproof housing are exceeding the minimum requirements stated EN/IEC60079-1.
Please contact the manufacturer for inspection, repair and/or adjustments of this
flameproof.

3
3. Contents of Package
• The product is provided with the following items. Make sure that none of these items is
missing.
• lthough the product is packed and shipped with the utmost care, contact your New
Cosmos representative if there should be any damage or missing items.
ccessories Optional items
Detector head
ccessory set
Two M5 screws: 2 pcs
M4 x 4 hexagon socket head screw:1pc
Hexagon wrench (nominal dia. 4):
1 each (see note 1)
Instruction Manual (see note 1)
MJ-1 Magnetic Stick (see note 1)
Protective cover (see note 2)
Horizontal type: KW-41
Vertical type: KW-42
PB-1 2B Pole Mounting Bracket (see note 2)
SK-1 Sensor Replacement Jig (see note 2)
GCP-09 Calibration Cap (see note 2)
Z-001K Gas Calibration Kit
2 bulb hand pump
Capillary for 2 bulb hand pump
Note: 1. hexagon wrench, Instruction Manual, and MJ-1 Magnetic Stick are provided for each
order.
2. The optional items are for use only with KD-12.
WARNING
 Do not use the magnetic stick for any purposes other than the operation of this product.
 Keep any magnets away from the equipment except MJ-1 magnetic stick.
 Keep in mind that when the magnetic stick attracts magnetic objects, tools, iron pieces,
etc., your hands may become pinched and injured.
 Do not touch the magnet if you are allergic to metal, otherwise your skin may become
chapped or reddened.
 Generally speaking, magnets break easily and the corrosion of the magnet progresses
from the fracture location. Fragments of the magnet may also get in your eyes or injure
your skin.
 The components of the magnetic stick may melt into water. Do not drink water exposed to
the magnetic stick.
 Keep the magnetic stick away from electronic medical devices, such as cardiac
pacemakers, or the magnetic stick may obstruct the normal operation of the device.
CAUTION
 Keep the magnetic stick away from magnetic tapes, floppy disks, and prepaid cards.
Otherwise, they may become magnetized and the information that they hold may be lost.
 Keep the magnetic stick away from high-precision devices, such as personal computers
and watches. Otherwise, they may malfunction.

4
4. External Dimensions and Nomenclature
4-1. Main Unit
Number Name Description
1 Casing cover
2 Casing
3 Sensor unit Incorporates a gas sensor.
4 Ground terminal Used when grounding the frame.
5 State display
indicator
Indicates the power supply state (green), alarm sta
te (red), and
trouble state (yellow).
6 Control block Insert the magnetic stick to control or set the product.
7 Display block Displays the gas concentration and set values.
8 Cable entry
PF3/4orG3/4, pitch=1.81mm, Insertion length: 10.86mm,
No. of insertion threads: 6. Certified cable glands*1
must be
provided by end user and used.
9 Hexagon socket
head cap screw
Used for securing the Casing cover
. Use a hexagon wrench with a
nominal diameter of 4 mm.
10 Hexagon socket
set screw
Used for securing the cable glands or sensor units
. Use a hexagon
wrench with a nominal diameter of 2 mm.
*1: Used in TEX hazardous, TEX certified cable glands according to EN60079-0:2012 and
EN60079-1:2007.Used in IECEx hazardous area, IECEx certified cable glands according to
IEC60079-0:2011 and IEC60079-1:2007.

5
4-2. Display and Control Blocks
Magnetic switches
(Insert the magnetic stick to operate the magnetic switches.)
Number Name Description
1 MODE switch
Makes adjustments and settings or cancels the operation of
the product.
2 ENTER switch Enters settings or completes the control of the product.
3 ▲switch
Makes adjustments and settings or increases set values and
other values.
4 ▼ switch Decreases set values and other values.
Number Name Description
5 Display block Displays the gas concentration and set values.
State display indicator
Number Name Description
6 POWER indicator green lamp to display the power supply state.
7 L RM indicator red lamp to display the alarm state.
8 TROUBLE indicator yellow lamp to display the trouble state.

6
4-3. Terminal Block
Signal
ZA
ZC
24V(+)
GND
1
2
3
5
4
4～20mA
POWER
＋
－
E
2
1
3
4
5
Number Name Description
1 24 V (+) Power supply voltage (positive)
2 GND Power supply voltage (-) and analog signal
(negative) common
3 Signal 4- to 20-m (+) analog signal
4 Z
5 ZC
External contact
Ground terminal Used to ground the frame.
Clamp
Ground
terminal
Sensor
connector
O-ring
Lever

7
5. Installation
5-1. Installation Method
WARNING
 The cable entry device and blanking elements shall be of TEX certified in type of
explosion protection flameproof enclosure ‘’d’’, suitable for the condition of use and
correctly installed.
 Use in TEX hazardous area, TEX certified cable glands according to EN
60079-0:2012 and EN 60079-1:2007 shall be provided by end-user.
 Use in IECEx hazardous area, IECEx certified cable glands according to IEC
60079-0:2011 and IEC60079-1:2007 shall be provided by end-user.
 Unused apertures shall be closed with suitable TEX certified blanking elements.
 Fastener type M5 x 16 shall have a yield stress factor of min. 450 N/mm2.
 The dimensions of flameproof joint between casing and casing cover of KD-12
flameproof housing are exceeding the minimum requirements stated
EN/IEC60079-1. Please contact the manufacturer for inspection, repair and/or
adjustments of this flameproof.
 Installation of cable gland and sensor:
-Casing to cable glands -Casing to sensor
Thread size : PF3/4 or G3/4 Thread size : M27
Pitch : 1.81mm Pitch : 1.5mm
Insertion length : 10.86mm Insertion length : 8.25mm
Number of insertion threads : 6 Number of insertion : 5.5
 Shall lock the sensor unit and cable gland by the stainless steel socket head screw
before use.
* Top of socket head screw shall not be over the casing surface.

8
• Installing Height
Type of gas Installing height Remarks
Gas heavier than air
(Example. LPG)
10 cm or less from the floor
(Height to the sensor guard tip)
Keep a distance of approx. 7cm
from the sensor guard tip for
easy maintenance and
inspection
Gas as heavy as air
(Example: carbon
monoxide )
75 to 150 cm from the floor
(Height to the sensor guard tip)
Decide the height by considering
the specific gravity of the target
gas and mounting environment.
Gas lighter than air
(Example: methane and
hydrogen)
Near the ceiling Decide the height by considering
scaffold, etc. for easy
maintenance.
CAUTION
 Be careful not to damage the gas detector when installing it. Otherwise, the
explosion-proof performance of the gas detector will be lost.
 Do not install the product in the following places.
- Places where the ambient temperature exceeds the operating temperature range
(−10°C to 50°C).
- Places where condensation occurs.
- Places where water is directly sprayed.
- Places subject to corrosive gas.
- Places near to devices generating high frequency and magnetism.
- Places where any hydrocarbon gases other than the target gas exist.
 Install the gas detector in places where can be maintained and inspected with ease.
 Install the gas detector in places free from vibration.
 Install the gas detector in places free from sudden temperature changes.
 Keep the gas detector free from impacts.
 When installing the gas detector outdoors, be sure to install the protective cover
(optional).
 The installing height of the gas detector has an important relation to the specific
gravity of the target gas to be detected. Install the gas detector in accordance with
required regulations.

9
• Mount the main unit to the wall with the M5 screws that are provided with the product. Be
sure to install the protective cover (optional) when mounting the main unit outdoors.
Mount the main unit with a 2B pole mounting bracket (optional) when mounting the main
unit to a 2B pole. Refer to 5-3 Mounting of Options for details of optional products.
• The casing cover of the gas detector needs be opened at the time of wiring. Therefore,
when installing the gas detector, provide sufficient space to enable the casing cover to be
opened to at least 90°.
Mounting hole
Mounting hole
90°or more

10
5-2. Examples of Installation Positions
• Install the product in places where gas easily accumulates.
Example of Installation Position
Partition
wall
Pipe
Valve
Detector
Flange
Example of Outdoor Installation Position
Entrance
(Suction port)
Roof fan
(Exhaust port) Entrances and windows
(Suction and exhaust ports)
Gas detector
mounting
position
Places where gas easily accumulates.
Gas detector
Side view
Pla
n
view

11
5-3. Mounting of Optional items
• Protective Cover
Horizontal Type (KW-41) Vertical Type (KW-42)
• 2B Pole Mounting Bracket
CAUTION
 Secure the casing cover with M3 screws if strong winds are expected.

12
6. Wiring Method
6-1. Wiring Work
• Be sure to provide explosion-proof wiring if the product is to be used in a hazardous area.
Cable Work
• Use a shielded cable, such as CVV-S with a thickness of 1.25 to 2.00 mm2. Lay all cables
in protective tubes, such as metal conduits or carbon steel pipes, or other protective
structure, such as a concrete duct.
• When using the external contact function of the product, which requires a five-conductor
cable, make sure that the maximum diameter of the cable conductor is 1.25 mm2. When
using only the analog signal function, which requires a three-conductor cable, without the
external contact function, make sure that the diameter of the cable conductor is 12.5 mm2
or 2.00 mm2.
CAUTION
 ll necessary work for the product including wiring and installation should be carried out
by suitably trained personnel in accordance with applicable code of practice.
 Inspection, maintenance and repair of the equipment should be carried out by suitably
trained personnel in accordance with applicable code of practice.
WARNING
 The cable entry device and blanking elements shall be of TEX certified in type of
explosion protection flameproof enclosure ‘’d’’, suitable for the condition of use and
correctly installed.
 Unused apertures shall be closed with suitable TEX certified blanking elements.

13
6-2. Wiring and Connection
Connecting Power Supply and Signal Wires
• Provide dedicated breakers, if needed, to lines that are connected to peripheral devices,
such as indicator units and signal converters.
• Use a dedicated cable, such as CVV-S (with a thickness of 1.25 to 2.00 mm2).
• Make sure that the power supplied to the product is within the specified voltage range.
• Make sure that the load resistance of the signal line, including the resistance of the wire, is
300 ohm or less.
WARNING
 Before opening the casing cover of the gas detector, be sure to turn off the product and
all devices (e.g., indicator unit and signal converter) connected to the product.
 If the power is turned ON, the power supply may become a source of ignition.
 Be sure to ground the product to prevent electric shocks.
 Shall use a conductor which is at least M4 size by solderless, for external earthing.
 Shall place the stainless steel plain washer between casing and terminal.
CAUTION
 Wire the connecting terminals correctly.
 Separate connection cables from power lines as far as possible.
When closing the casing cover, make sure that the power supply cord, harness, and
O-ring are not caught by the casing cover.

14
6-2. Wiring and Connection (Continued)
MEMO
• If the main unit is grounded on the power supply side, do not connect a shielded cable
to the ground terminal (E) in the gas detector, or otherwise two-point grounding will result.
Connection Example with Power Supply Side Grounded
System Configuration Example
For details, refer to the Instruction Manual of each device.
V2M
KD-12
Indicator unit
Detector
G S
VISION
S-500
Security
management system
Comprehensive gas
detection/alarm system
KD-12
KD-12
KD-12
KD-12
Detector
Single detector connected
to indicator unit
Multiple
detectors monitored
together
KD-12R
Ground
terminals
CVVS cable
24V
power
supply
Indicator
Shield
External alarm
Ground terminal on
power supply side
Not grounded
Grounded

15
6-2. Wiring and Connection (Continued)
Typical Connection Procedure
(1) Prepare a power supply that can provide 24 V.
(Do not turn on the power supply before wiring the main unit.)
(2) Loosen the hexagon socket bolts on the four corners of the main unit using the
provided hexagon wrench with a nominal diameter of 4 mm, and open the casing
cover of the main unit.
(3) Press the lever of the terminal block with a flat-blade screwdriver.
(4) The clamp will open. Insert the lead wire.
(5) Connect the positive side of the power supply to the 24 V+ terminal.
(6) Connect the negative side of the power supply to the GND terminal.
(7) The lead wire will be automatically secured when the screwdriver is lifted.
(8) Check that the power supply cords are securely connected to the terminals. This
completes the power supply preparations.
(9) Wire the analog signal and external contact terminals, if required.
(10) Tighten the hexagon socket bolts (tightening torque: 0.8-2.4 N⋅m) on the four corners
of the main unit and close the casing cover of the main unit.
CAUTION
 When lowering the lever of the terminal block, be careful not to allow the flat-blade
screwdriver to slip off of the lever. Otherwise, the flat-blade screwdriver may damage the
sensor unit code or circuit board.
 When closing the casing cover, make sure that the power supply cord, harness, and O-ring
are not caught by the casing cover.

16
7. Precautions before Use


 In Case of Gas eakage
WARNING
 If there is a gas leak alarm, take the necessary measures specified by your company.
 If a gas leak occurs indoors, open the windows and doors to ventilate the room.
 Check the gas leakage location and promptly take the necessary measures.
 Measure the gas concentration with a portable gas detector and confirm the safety
before entering the detection site.
DANGER
 Without panicking, check that there is no fire around the product. Do not touch any
electric switches under any conditions. Sparks from turning electric switches ON or OFF
may cause ignition.
CAUTION
 Before turning ON any of the devices (e.g., indicator unit, signal converter) connected to
the product, recheck that all of the connections are correct. Make sure that the gas
detector and indicator unit or signal converter, in particular, are connected properly.

17
8. Display at Start-up (Initial Delay)
(1) When the power supply is turned ON, all of the indicator lamps (green, red, and yellow
lamps) and the display block are lit.
(2) While the indicator lamps (green, red, and yellow lamps) are lit, the following items will
be lit for approximately 1 second each.
Software version number (of the main unit) ex) 【 】
↓
Full scale ex) 【 】
↓
larm set value ex) 【 】
(3) Then the POWER indicator (green lamp) will be flashed for approximately 1 minute.
(4) When the POWER indicator is lit, the start-up of the main unit is completed and the
main unit will be in gas monitor mode.
MEMO
• The operation with the magnet stick is not available during the initial delay.
• The initial delay lasts approximately one minute after the power is turned on.
• The indicated condensation value may change rapidly during the initial delay, but it is not a
failure.
• If the sensor unit has not been used (energized) for a long period after shipped from
factory, it may take some time for the sensor to stabilize. When the sensor unit is turned
on after a long unused period, an alarm may be generated even when no gas exists.
Therefore, deactivate the interlocks of the external devices before starting operation.
• More than one hour after turning on the detector, make the zero adjustment and span
adjustment.Refer to 11.3 Calibration Method for the adjustments.
CAUTION
 Check that there is no gas around the product before starting the product.
 If the sensor output is not stable, the external contact point may operate after the initial
delay. Release the interlock of the external equipment if necessary.
 During the initial delay, the analog signal fixed at 4 m will be output and the external
contact will not operate.